Abstract:
A composite water closet flange includes a hub member having a hub member axis and including a connecting portion and a through-passage extending through the connecting portion. The connecting portion includes a shoulder extending radially outwardly. A plurality of locking tabs extend radially outwardly and are axially spaced apart from the shoulder. A ring member is mounted on the hub member and includes an inner peripheral portion surrounding the connecting portion and defining an opening. The inner peripheral portion includes a plurality of engagement portions interposed between the shoulder and respective ones of the locking tabs. A key slot is defined in the inner peripheral portion and communicates with the opening. The key slot is sized and configured to receive at least one of the plurality of locking tabs therethrough.

Description:
FIELD OF THE INVENTION 
     The present invention relates to water closet flanges and, more particularly, to water closet flanges including multiple, coupled components. 
     BACKGROUND OF THE INVENTION 
     Water closet flanges are used to join water closets or toilet bowls to the open ends of sewer pipes, for example, in residential or commercial structures. It is known to form multiple component or composite water closet flanges. An exemplary composite water closet flange  10  is shown in FIG. 11, which is a bottom plan view thereof. The water closet flange  10  includes a hub member  20  including a tubular portion  22  and a radially outwardly extending flange portion  24  on the upper end of the hub member  20 . A plurality of spaced apart locking tabs  26  also extend radially outwardly from the hub member  20  and are positioned axially below the flange portion  24 . A ring member  50  surrounds the upper portion of the hub member  20 . The ring member  50  has an inner peripheral edge  52  defining an opening and having an inner diameter selected such that portions of the ring member  50  are interposed between the flange  24  and each of the locking tabs  26 . In this manner, the flange  24  and the locking tabs  26  cooperate to secure the ring member  50  on the upper end of the hub member  20 . The tubular portion  22  may be adapted to fit tightly over the sewer pipe. The ring member  50  includes bolt holes  54  for receiving bolts to secure the water closet to the ring member  50 . 
     The hub member  20  may be formed of polyvinylchloride (PVC) or other suitable polymeric material with the ring member  50  being formed of metal. Typically, the water closet flange  10  is assembled by forcing the ring member  50  over the locking tabs  26  such that the locking tabs  26  are temporarily deflected, allowing the ring member to seat between the flange portion  24  and the locking tabs  26 . Generally, it is preferable to provide at least four locking tabs  26 , allowing the ring member to seat between the flange portion  24  and the locking tabs  26  to provide a secure and stable joinder between the hub member  20  and the ring member  50 . As a result, it is typically necessary to deflect two or more of the locking tabs  26 , requiring substantial amounts of force (e, using a mallet). The locking tabs  26  may be frequently broken, in which case the hub member  20  typically must be discarded. 
     SUMMARY OF THE INVENTION 
     According to embodiments of the present invention, a composite water closet flange includes a hub member having a hub member axis and including a connecting portion and a through-passage extending through the connecting portion. The connecting portion includes a shoulder extending radially outwardly. A plurality of locking tabs extend radially outwardly and are axially spaced apart from the shoulder. A ring member is mounted on the hub member and includes an inner peripheral portion surrounding the connecting portion and defining an opening. The inner peripheral portion includes a plurality of engagement portions interposed between the shoulder and respective ones of the locking tabs. A key slot is defined in the inner peripheral portion and communicates with the opening. The key slot is sized and configured to receive at least one of the plurality of locking tabs therethrough. 
     According to further embodiments of the present invention, a composite water closet flange includes a hub member having a hub member axis and including a connecting portion and a through-passage extending through the connecting portion. The connecting portion includes a radially extending shoulder. A plurality of radially extending locking tabs are axially spaced apart from the shoulder. A ring member is mounted on the hub member and includes a plurality of engagement portions interposed between the shoulder and respective ones of the locking tabs. A key slot is defined in the ring member. The key slot is sized and configured to receive at least one of the plurality of locking tabs therethrough. 
     According to further embodiments of the present invention, a hub member for use with a ring member having a key slot to form a composite water closet flange is provided. The hub member has a hub member axis and includes a connecting portion and a through-passage extending through the connecting portion. The connecting portion includes a shoulder extending radially outwardly. A primary locking tab extends radially outwardly and is axially spaced apart from the shoulder. The primary locking tab is sized and configured to allow the primary locking tab to pass through the key slot. A secondary locking tab extends radially outwardly and is axially spaced apart from the shoulder. The secondary locking tab is sized and configured to prevent the secondary locking tab from passing through the key slot. 
     According to further embodiments of the present invention, a ring member for use with a hub member including a plurality of locking tabs to form a composite water closet flange is provided. The ring member includes an inner peripheral portion adapted to surround the hub member and defines an opening. A key slot is defined in the inner peripheral portion and communicates with the opening. The key slot is sized and configured to receive at least one of the plurality of locking tabs therethrough. 
     According to method embodiments of the present invention, a method of assembling a water closet flange includes providing a hub member having a hub member axis and including a connecting portion and a through-passage extending through the connecting portion. The connecting portion includes a shoulder extending radially outwardly. First and second locking tabs extend radially outwardly and are axially spaced apart from the shoulder. A ring member is provided including an inner peripheral portion defining an opening and a key slot defined in the inner peripheral portion and communicating with the opening. The key slot is sized and configured to receive at least one of the first and second locking tabs therethrough. The connecting portion of the hub member is positioned in the opening of the ring member such that the inner peripheral portion is interposed between the second locking tab and the shoulder. The connecting portion of the hub member is positioned in the opening of the ring member such that the first locking tab is axially aligned with the key slot. The first locking tab is axially displaced through the key slot. 
     Objects of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments which follow, such description being merely illustrative of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a bottom, perspective view of a composite water closet flange according to embodiments of the present invention; 
     FIG. 2 is a top plan view of the water closet flange of FIG. 1; 
     FIG. 3 is a bottom plan view of the water closet flange of FIG. 1; 
     FIG. 4 is a cross-sectional view of the water closet flange of FIG. 1 taken along the line  4 — 4  of FIG. 3; 
     FIG. 5 is a bottom plan view of a hub member forming a part of the water closet flange of FIG. 1; 
     FIG. 6 is a top plan view of a ring member forming a part of the water closet flange of FIG. 1; 
     FIG. 7 is a cross-sectional view of the ring member of FIG. 6 taken along the line  7 — 7  of FIG. 6; 
     FIG. 8 is a fragmentary, enlarged cross-sectional view of the ring member of FIG. 6; 
     FIG. 9 is a bottom plan view of the water closet flange of FIG. 1 in a first partially assembled position; 
     FIG. 10 is a bottom plan view of the water closet flange of FIG. 1 in a second partially assembled position; and 
     FIG. 11 is a bottom plan view of a composite water closet flange of the prior art. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     With reference to FIGS. 1-4, a multi-component or composite water closet flange  100  according to embodiments of the present invention is shown therein. The water closet flange  100  includes a hub member  120  and a ring member  150  mounted on the hub member  120 . The hub member  120  and the ring member  150  are relatively configured to facilitate assembly of the water closet flange  100  using methods in accordance with the present invention. 
     The water closet flange  100  may be adapted to join a water closet of conventional or other design to a sewer pipe end. The hub member  120  and the ring member  150  may be formed of different materials to reduce cost and/or improve performance characteristics of the water closet flange. 
     Turning to the hub member  120  in more detail and with additional reference to FIG. 5, the hub member  120  has a hub member axis A—A (FIG.  4 ). The hub member  120  includes a tubular body portion  122  and a connecting portion  132 . The body portion  122  and the connecting portion  132  are preferably integrally formed as illustrated. A through-passage  121  extends through the hub member  120  from a top opening  121 A to a bottom opening  121 B. Preferably, the through-passage  121  is cylindrical as shown and the hub member axis A—A extends along the center axis of the through-passage  121 . Preferably, the through-passage  121  has a length L (FIG. 4) of between about 2.000 and 2.750 inches and a diameter B (FIG. 4) of between about 3.000 and 4.500 inches. 
     The connecting portion  132  includes a flange  133  located adjacent the upper end of the hub member  120 . The flange  133  extends radially outwardly (with respect to the hub member axis A—A) from the body portion  122 . A circular shoulder  124  extends radially outwardly from the flange  133 . A plurality of circumferentially spaced apart locking tabs  126 A,  126 B,  126 C,  128  extend radially outwardly from the flange  133  as well. The locking tabs  126 A,  126 B,  126 C,  128  are axially spaced apart (with respect to the hub member axis A—A) from the shoulder  124  so as to define a circumferential channel  134  (FIG. 4) therebetween. Preferably, four locking tabs  126 A,  126 B,  126 C,  128  are provided. However, more or fewer locking tabs may be used. Preferably, the locking tabs  126 A,  126 B,  126 C,  128  are spaced apart equidistantly about the periphery of the connecting portion  132 . 
     Turning to the ring member  150  in more detail and with additional reference to FIGS. 6-8, the ring member  150  includes a circular ring body  160 . A circular, inner peripheral portion  162  extends radially inwardly (with respect to the axis A—A) to an inner peripheral edge  152 . The inner peripheral edge  152  defines an opening  151 . The inner peripheral edge  152  further defines a radially outwardly (with respect to the axis A—A) extending key slot  158  communicating with the opening  151 . A plurality of mounting holes  154 ,  156  are formed in the ring body  160 . Preferably, at least some of the mounting holes  154 ,  156  are centered along a bolt circle having a diameter of between about 6.130 and 6.140 inches. 
     As best seen in FIGS. 1-4, when the water closet flange  100  is fully assembled, the ring member  150  is mounted on the hub member  120  such that at least engagement portions  162 A (FIG. 4) of the inner peripheral portion  162  are captured in the channel  134  between the shoulder  124  and the locking tabs  126 ,  128 . The ring member  150  and the hub member  120  are relatively positioned such that the key slot  158  is offset from each of the locking tabs  126 ,  128 . In this manner, the locking tabs  126 ,  128  in cooperation with the shoulder  124  serve to prevent or resist deliberate or inadvertent separation of the ring member  150  from the hub member  120 . The ring member  150  may be secured to a water closet using suitable fasteners inserted through one or more of the holes  156  and such that the opening  121 A is positioned adjacent the drain opening of the water closet. The hub member body  122  may be inserted into a drain pipe or placed over a drain pipe such that the drain pipe is received in the through-passage  121 . Preferably, the hub member body  122  is adapted to fit snugly on or in the drain pipe to secure the water closet flange  100  to the drain pipe. 
     Preferably, the shoulder  124  overlaps the ring member  150  an overlap distance K (FIG. 4) of at least 0.114 inch and, more preferably, of between about 0. 119 and 0. 125 inch. Preferably, each of the locking tabs  126 A,  126 B,  126 C,  128  overlaps the ring member  150  a distance I of at least 0.035 inch and, more preferably, of between about 0.038 and 0.041 inch. Preferably, the height J of the channel  134  is between about 0.25 and 0.35 inch greater than the received thickness of the inner peripheral portion  162 . 
     Preferably, the top end surface  135  of the flange  133  is substantially coplanar with the top end  101 A of the water closet flange  100 . While the shoulder  124  as shown in the figures extends continuously and endlessly, the shoulder may be discontinuous. The shoulder  124  may be replaced with a plurality of shoulder portions spaced apart about the periphery of the flange  133 . 
     The hub member  120  and the ring member  150  may be formed of different materials. Preferably, the hub member  120  is formed of a non-metallic material and the ring member  150  is formed of metal. Preferably, the hub member  120  is formed of a polymeric material, more preferably from PVC and/or ABS. Most preferably, the hub member  120  is formed of PVC. 
     The water closet flange  100  may be assembled using the following method according to method embodiments of the present invention. The hub member  120  is placed on a firm surface such as a work table such that the top end face  135  (FIG. 4) of the hub member  120  engages the work surface. The ring member  150  is placed top face down over the hub member  120  such that the hub member body  122  is received in the opening  151 . The inner peripheral portion  162  of the ring member  150  is slid beneath the adjacent locking tabs  126 A,  126 B and into the channel  134  on the associated side of the hub member  120  as shown in FIG.  9 . Notably, the locking tabs  126 C and  128  remain disposed beneath the inner peripheral portion  162 . 
     Before or following the step of sliding the ring member  150  beneath the locking tabs  126 A,  126 B, the locking tab  128  is radially aligned with the key slot  158  as shown in FIG.  9 . The locking tab  128  is sized and shaped such that the locking tab  128  can pass axially through the key slot  158  without significant interference. Preferably, the length G (FIG. 6) and width H of the key slot  158  are selected to provide clearances of between about 0.032 and 0.063 inch on each of the three edges of the locking tab  128 . 
     Thereafter, the ring member  150  is forced axially downwardly onto the remaining locking tab  126 C. The locking tab  126 C is thereby deflected such that the inner peripheral portion  162  passes over the locking tab  126 C and into the channel  134  as shown in FIG.  10 . At the same time, the locking tab  128  passes through the key slot  158  uninhibited. Accordingly, a substantially reduced amount of force is required to mount the ring member  150  onto the hub member  120  as compared to methods of the prior art. The locking tab  126 C is formed of a material and in a configuration such that it resiliently returns to its original orientation to seat in the channel  134 . 
     Finally, the hub member  120  is rotated relative to the ring member  150 , for example, in a direction R (FIG.  10 ), to place the locking tab  128  in an offset position with respect to the key slot  158  as shown in FIG.  3 . 
     Because the key slot  158  reduces the force required to fully mount the ring member  150  on the hub member  120 , the ring member  150  may be installed using modest force and without use of a mallet or the like. As a result, the rate of assembly of composite water closet flanges  100  may be substantially increased as compared to the rates of assembly of composite water closet flanges of the prior art. Moreover, the assembly methods of the present invention may provide reduced stresses to the locking tabs, thereby reducing the incidence of damage to the locking tabs. 
     Preferably, the locking tab  128  is sized and/or shaped differently than the other locking tabs  126 A,  126 B,  126 C and the key slot  158  is sized or shaped to allow the locking tab  128 , but not the locking tabs  126 A,  126 B,  126 C, to pass through the key slot  158 . In this manner, the consistency and uniformity of the strength of the coupling is improved. 
     Preferably, the circumferentially extending length C (FIG. 5) of the locking tab  128  is between about 0.230 and 0.200 inch less than the length E of the locking tabs  126 A,  126 B,  126 C. Preferably, the length C is between about 0.620and 0.630 inch. Preferably, the radially extending widths D and F of the locking tabs  126 A,  126 B,  126 C,  128  are substantially the same and between about 0.045 and 0.055 inch. 
     The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.