EXPANDABLE ANCHOR BOLT SYSTEM AND TOILET INSTALLATION METHOD

The present invention provides an expandable anchor bolt system for securing a toilet to a closet flange. The system includes an anchor bolt with an expandable lower end designed to securely engage with a groove of the closet flange, and an upper end configured to accommodate fastening means. The expansion mechanism is activated by inserting an expansion pin that does not require tools and can lock to maintain the expanded state of the anchor bolt. The system further comprises a bolt cap for covering the upper end of the assembled components, offering an aesthetically pleasing finish and protection. The system is adaptable to various flange conditions, particularly suitable for installations involving damaged or compromised closet flanges. This invention simplifies the installation process while ensuring the stability and safety of the toilet installation, providing an improved method for toilet installation in both new construction and repair scenarios.

FIELD OF THE DISCLOSURE

The present invention generally relates to plumbing installation hardware, specifically an expandable anchor bolt system for securing a toilet to a closet flange.

BACKGROUND OF THE INVENTION

Toilets are typically secured to bathroom floors using a closet flange, which provides a connection point for the toilet and a seal to the floor. Conventionally, toilet bolts are used in conjunction with wax rings to secure the toilet to the flange and create a watertight seal. However, traditional toilet bolts and their installation methods have several drawbacks.

A common issue with conventional bolts is that they tend to loosen over time, which can cause the toilet to wobble, potentially compromising the seal and leading to leaks. Additionally, the installation of traditional bolts usually requires tools and can be particularly cumbersome in confined spaces. When dealing with damaged flanges, the problem becomes more complex as the integrity of the bolt's grip may be compromised.

Moreover, existing devices do not always meet the need for a simple, tool-free installation process, nor do they provide solutions for enhancing the stability of toilet installations when the original flange is damaged or compromised.

Therefore, there is a need to improve an expandable anchor bolt system that can adapt to various conditions of closet flanges, ensure high stability and safety, and facilitate a simple and tool-free installation process. Such a system should also provide an aesthetically pleasing finish for the installed toilet and maintain consistent performance in both new installations and repairs.

SUMMARY OF THE INVENTION

The present invention provides an expandable anchor bolt system designed to facilitate the secure and stable installation of a toilet to a closet flange, enhancing the convenience and efficiency of the installation process. This invention addresses various limitations associated with traditional toilet bolt systems, offering a solution suitable for both standard installation scenarios and situations involving damaged or compromised closet flanges.

On one aspect, the invention includes an anchor bolt with an upper end and a lower end. The lower end of the anchor bolt is uniquely designed to expand within the groove of the closet flange during installation. This expansion is achieved through an expansion pin; when the expansion pin is inserted into the anchor bolt, it causes the lower end to widen outwardly. This outward movement secures the anchor bolt within the closet flange, preventing movement and providing a stable foundation for the toilet installation.

The upper end of the anchor bolt features threading to receive various fastening means, such as a nut. The choice of fastening means can be based on the specific requirements of the installation environment, providing versatility and adaptability. When a nut is used, it engages with the threaded portion of the anchor bolt and is secured against the upper surface of the closet flange.

Additionally, the invention includes a bolt cap designed to snugly fit over the upper end of the anchor bolt assembly. The bolt cap not only provides an aesthetically pleasing finish to the installation but also helps protect the bolt from environmental factors and prevents the accumulation of dust and debris.

Another notable feature of the invention is the tool-free installation of the expansion pin, which simplifies the installation process. The expansion pin is designed for easy manual insertion and locks within the anchor bolt to prevent the contracted state of the expanded lower end from retracting. This feature eliminates the need for additional tools during installation, making the process more straightforward and user-friendly.

Furthermore, the expandable anchor bolt system is designed to be compatible with various types of flanges, including repair flanges used to fix or reinforce damaged closet flanges. Compatibility with repair flanges ensures that the invention can be used in a wide range of repair scenarios, providing a reliable solution when the original flange is unusable.

In addition to the components and their configurations, the invention also encompasses a method for securing a toilet to a closet flange using the expandable anchor bolt system. The method includes positioning the anchor bolt, inserting the expansion pin, engaging the fastening means, and securing the toilet to the bolt. This process represents a significant improvement over existing methods, emphasizing ease of installation and the robustness of the final assembly.

Overall, the invention provides a novel and advantageous expandable anchor bolt system that significantly enhances the reliability and simplicity of toilet installations. Its innovative features address common issues associated with traditional installation hardware, offering benefits highly valued in both residential and commercial environments.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring simultaneously to FIG. 1 and FIG. 3A, FIG. 1 illustrates an embodiment of the present invention, which relates to an expandable anchor bolt system specifically designed for securely and safely mounting a toilet to a closet flange. FIG. 3A shows a partial view of the expandable anchor bolt system of FIG. 1 after installation. This expandable anchor bolt system addresses common challenges and limitations found in conventional toilet installation methods, with particular emphasis on ease of installation, adaptability to various flange conditions, and long-term stability and safety of the installation.

The expandable anchor bolt system 100 comprises an anchor bolt 110 having an upper end 112 and a lower end 114. The lower end 114 of anchor bolt 100 is ingeniously designed to expand within the groove 12 of a closet flange 10 during installation (see FIG. 3A). The aforementioned expansion is facilitated by inserting an expansion pin 120 into a channel 116 of anchor bolt 110, which causes the lower end 114 to outwardly expand, thereby securing anchor bolt 110 within the groove 12 of the closet flange 10. This outward expansion action creates a firm grip within the groove 12 of the closet flange 10, ensuring that anchor bolt 110 remains securely in place. This expansion mechanism represents a significant advancement over traditional methods, providing a robust and reliable means of securing the toilet to the flange without loosening over time.

The expanded portion of the lower end 114 of anchor bolt 110 includes split segments 114a. These split segments 114a are critical to the expansion action, as they are designed to move outward upon insertion of expansion pin 120. The design and material of split segments 114a are optimized to ensure a smooth yet firm expansion, providing a balance between ease of insertion and secure fixation once in place. This unique expansion mechanism ensures a tight and secure fit, preventing the toilet from wobbling or loosening over time, which is a common issue with traditional toilet installation systems.

The aforementioned expansion pin 120 is an elongated component designed for easy insertion into the channel 116 of anchor bolt 110. The size and shape of expansion pin 120 are specifically designed to snugly fit the internal channel 116 of anchor bolt 110. Upon insertion, expansion pin 120 moves downward along the channel 116, interacting with the split segments 114a located at the lower end 114 of bolt 110. This interaction is critical, as expansion pin 120 pushes the split segments 114a outward, causing them to expand. The outward expansion of these split segments 114a is key to firmly locking anchor bolt 110 within the groove 12 of the closet flange 10, thereby providing a robust and reliable foundation for toilet installation.

One of the most notable features of expansion pin 120 is its operation without the need for additional tools. This design aspect is particularly innovative, as it allows for manual insertion of expansion pin 120 without requiring any extra tools or equipment. This not only simplifies the installation process but also makes it more accessible, especially in situations where the use of tools is impractical or inconvenient. The tool-free characteristic represents a significant advancement over conventional installation methods, which typically require specialized tools or equipment.

Furthermore, the design of expansion pin 120 includes a locking mechanism, which in this embodiment is the locking head 122 of expansion pin 120. Through this locking head 122, once expansion pin 120 is fully inserted into anchor bolt 110, the interference between locking head 122 and anchor bolt 110 prevents further insertion of expansion pin 120.

In this embodiment, the upper end 112 of anchor bolt 110 is provided with a threaded portion 112a for engaging with various fastening means. These fastening means may include a nut 130. When using nut 130, it engages with the threaded portion 112a of anchor bolt 110 and firmly presses against the upper surface of the closet flange 10 to ensure that anchor bolt 110 is securely fixed in place. Specifically, in this embodiment, nut 130 is specially designed to be used in conjunction with the threaded portion 112a of the upper end 112 of anchor bolt 110. After positioning anchor bolt 110 within the closet flange 10 and activating the expansion mechanism at the lower end, nut 130 is threaded onto the threaded portion 112a of the upper end 112. As nut 130 is tightened, it firmly presses against the upper surface of the closet flange 10. This action secures anchor bolt 110 in place, preventing any movement and ensuring a stable and secure connection between the toilet and the closet flange 10. The design of nut 130 facilitates ease of use, allowing for manual tightening while providing strong and reliable fastening force.

Furthermore, referring simultaneously to FIG. 2 and FIG. 3B, FIG. 2 illustrates another embodiment of the present invention, which relates to an expandable anchor bolt system specifically designed for securely and safely mounting a toilet to a closet flange. FIG. 3B depicts a view of the anchor bolt equipped with an external flange installed on the upper surface of the closet flange. In this embodiment, expandable anchor bolt system 200 differs from expandable anchor bolt system 100 primarily in the design of the anchor bolt. In this embodiment, the threaded portion 212a of the upper end 212 of anchor bolt 210 is shorter, and the lower end 214 includes an integrally formed external flange 218. The external flange 218 serves as the fastening means of this embodiment, acting as a built-in stop device. That is, after installation, the external flange 218 of expandable anchor bolt system 200 is firmly pressed against the upper surface of the closet flange 10 (see FIG. 3B), enhancing the stability and safety of anchor bolt 210's installation on the flange. When anchor bolt 210 is inserted into the groove 12 of the closet flange 10, the external flange 218 rests against the upper surface of the closet flange 10, thereby preventing bolt 210 from further penetrating or passing through the groove 12 of the closet flange 10. This design is particularly beneficial in situations requiring simpler installation. Additionally, in this embodiment, the lower end 214 also includes split segments 214a, which function similarly to split segments 114a in the corresponding embodiment of FIG. 1.

In addition to the aforementioned core components, expandable anchor bolt systems 100 and 200 also include a bolt cap 140, designed to securely lock onto the assembled upper ends 112, 212 of anchor bolts 110, 210. In other words, bolt cap 140 is suitable for locking onto the threaded portions 112a, 212a of the upper ends 112, 212. Bolt cap 140 serves a dual purpose—it not only provides a clean and aesthetically pleasing appearance after installation but also protects the components of expandable anchor bolt systems 100 and 200 from environmental factors and prevents the accumulation of dust and debris.

Furthermore, it is noteworthy that the expandable anchor bolt system 100 offers significant advantages in adapting to various flange conditions. It is compatible not only with standard closet flanges but also with repair flanges used to repair or reinforce damaged closet flanges. More specifically, repair flanges are typically employed as a means to fix a damaged closet flange 10 without the need for complete replacement. These repair flanges are designed to cover or surround the damaged area of the closet flange 10, providing a new and sturdy mounting surface for the toilet. However, the introduction of a repair flange increases the overall thickness of the flange, that is, the combined thickness of the damaged closet flange 10 and the repair flange. This makes the adaptability of the expandable anchor bolt system 100 particularly important. This is because the nut 130 on the upper end 112 of anchor bolt 110 of the expandable anchor bolt system 100 allows for adjustable compression to accommodate different flanges, which is crucial in achieving a secure fit on the repair flange.

Referring simultaneously to FIG. 4, which illustrates a flowchart of the installation process for the expandable anchor bolt system, the steps for securing a toilet to a closet flange are described. This step-by-step process ensures the safe and stable installation of the toilet, addressing the challenges commonly encountered with traditional installation methods.

First, refer to step S110, which involves preparing the anchor bolt and flange. Specifically, prepare anchor bolt 110 equipped with expansion pin 120. Concurrently, ensure that the closet flange 10 is properly positioned and secured to the floor of the bathroom or restroom, positioned above the drain pipe.

Next, refer to step S120, which involves inserting the anchor bolt into the flange's groove. Specifically, insert anchor bolt 110 into the groove 12 of the closet flange 10. If using anchor bolt 210 with external flange 218 as shown in FIG. 2, ensure that the external flange 218 is pressed against the upper surface of the closet flange 10.

Then, refer to step S130, which involves activating the expansion mechanism. Specifically, insert expansion pin 120 into the channel 116 of the upper end 112 of anchor bolt 110. Subsequently, push expansion pin 120 downward until it locks into place, causing the lower end 114 of anchor bolt 110 to expand and firmly grip the groove 12 of the closet flange 10.

Next, refer to step S140, which involves securing the anchor bolt. Specifically, if using nut 130 as the fastening means, thread nut 130 onto the threaded portion 112a of the upper end 112 of anchor bolt 110 until it is tightly pressed against the upper surface of the closet flange 10. If using anchor bolt 210 with external flange 218 as shown in FIG. 2, this step is not necessary.

Next, refer to step S150, which involves positioning and securing the toilet. Align the mounting holes of the toilet with the upper ends of anchor bolts 110 protruding from the closet flange 10. Gently place the toilet onto the closet flange 10, ensuring that anchor bolts 110 are correctly aligned with the mounting holes. Once the toilet is in place, use bolt cap 140 to secure the toilet to anchor bolts 110. Tighten these fasteners to ensure the toilet is firmly attached to the closet flange 10.

Then, following step S160, install the bolt caps 140. Specifically, once the toilet installation is complete and secured, place bolt cap 140 over the upper ends 112 of each anchor bolt 110. In certain embodiments, bolt cap 140 should closely fit the upper ends 112 of anchor bolts 110, thereby covering the upper ends 112 and providing a clean and finished appearance to the installed toilet. In this embodiment, since the toilet and its mounting holes are considered to be common knowledge in the art, further description is omitted. Interested parties may refer to U.S. Pat. No. 6,254,141 for understanding the positional relationship between toilet mounting holes and the closet flange 10.

Overall, the expandable anchor bolt system proposed by the present invention is a novel and effective toilet installation solution, offering significant improvements over existing systems in terms of installation convenience, adaptability, and long-term reliability. Its unique features and thoughtful design address the specific needs and challenges in the plumbing installation field, providing a system that is both user-friendly and efficient.