Patent Publication Number: US-2020284017-A1

Title: Seal Cup and Mounting Caps for Toilet Installation

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This utility application claims the benefit of and priority date of U.S. application 62/821,040 filed on Mar. 20, 2019, the contents of which are incorporated herein by reference. 
    
    
     COPYRIGHT AND TRADEMARK NOTICE 
     This application includes material which is subject or may be subject to copyright and/or trademark protection. The copyright and trademark owner(s) has no objection to the facsimile reproduction by any of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright and trademark rights whatsoever. 
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The invention generally relates to plumbing installation systems. More particularly, the invention relates to means and methods of testing a toilet waste and drain systems, storage of fasteners, new fasteners and wax free toilet installation. 
     (2) Description of the Related Art 
     The known related art fails to anticipate or disclose the principles of the present invention. 
     In the related art, general wax free toilet installation systems are known. For example, wax free systems by Scott Duncan include U.S. Pat. No. 9,512,605—Wax free systems with springs for new and existing toilets—U.S. Pat. No. 9,663,934—Floating Nipple Assemblies for Wax Free Installation of New and Existing Toilets and U.S. Pat. No. 9,062,445—Wax Free Kit for New and Existing Construction. These products are innovative and commercially successful. But, the prior art fails to disclose, suggest or anticipate efficient means of testing waste and drain pipe and fastening wax free systems in a manner integral with the wax free installation systems, thus, there is a need in the art for the disclosed embodiments. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention overcomes shortfalls in the related art by presenting an unobvious and unique combination and configuration of methods and components to provide a seal cap used for testing waste and drain pipes prior to the wax free installation of a toilet. The disclosed seal cap artfully fits over a toilet flange without interfering with the subsequent configuration and wax free installation of a toilet. The disclosed seal cup system also stores new caps that are uniquely threaded to avoid dangerous and unsightly screws or protruding traditional screw caps. The disclosed screw cap systems provide a first or inner cap having centrally disposed inner threads to secure a toilet to a flange. The first or inner caps also have outwardly facing threads at the outer circumference, enabling the attachment of outer caps that are more bulbous than the caps of the prior art, with the disclosed outer caps being safer, have a less pointed protrusion. 
     Disclosed embodiments include clever caps or caps with thermally applied inserts that overcome shortfalls in the related art by providing an economic lower threaded portion in the cap and providing an upper void, allowing for bolts or studs to be used in an uncut condition. 
     These and other objects and advantages will be made apparent when considering the following detailed specification when taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  exploded view of disclosed components 
         FIG. 2  compact view of disclosed components in market condition or configured for packaging 
         FIG. 3  separate components of the prior art 
         FIG. 4  perspective view of test seal in place 
         FIG. 5  perspective view of components and toilet aligned for installation 
         FIG. 6  perspective view of components and toilet fastened together 
         FIG. 7  perspective view of inner nut installed and outer cap in background 
         FIG. 8  perspective view of inner nut and outer cap secured to installation bolt and closet flange 
         FIG. 9  depicts top perspective view of a clever cap or thermal cap 
         FIG. 10  depicts a bottom perspective view of a clever cap or thermal cap 
         FIG. 11  depicts a clever cap or thermal cap and an insertion piece 
         FIG. 12  depicts a sectional view of a clever cap or thermal cap 
     
    
    
     REFERENCE NUMERALS IN THE DRAWINGS 
       100  seal cup 
       110  lower cavity of seal cup  100   
       130  upper lip of seal cup  100   
       140  feet of seal cup  100   
       200  cap assembly 
       220  inner cap of cap assembly  200   
       230  outer threads of inner cap  220   
       260  outer cap of cap assembly  200   
       270  inner threads of outer cap  260   
       300  attachment bolts 
       400  wax free spring seal 
       500  closet flange 
       520  bolt voids defined within closet flange  500   
       600  toilet 
       620  toilet horn 
       700  prior art 
       800  thermal cap 
       810  outer curved surface of thermal cap  800   
       815  bottom surface of thermal cap  800   
       820  outer flat surface of thermal cap  800   
       830  lateral support structure between outer cap surface and cap sleeve  840   
       840  cap sleeve, sometimes found in the center portion of a thermal cap  800   
       850  superior void of cap sleeve, defined by the inner walls of the cap sleeve and inner wall of the thermal cap 
       900  threaded insert 
       910  outer friction ridges 
       920  inner threads 
       930  cylinder 
       940  exterior lip 
       950  superior smooth section 
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims and their equivalents. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. 
     Unless otherwise noted in this specification or in the claims, all of the terms used in the specification and the claims will have the meanings normally ascribed to these terms by workers in the art. 
     Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in a sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number, respectively. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. 
     The above detailed description of embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. For example, while steps are presented in a given order, alternative embodiments may perform routines having steps in a different order. The teachings of the invention provided herein can be applied to other systems, not only the systems described herein. The various embodiments described herein can be combined to provide further embodiments. These and other changes can be made to the invention in light of the detailed description. 
     Any and all the above references and U.S. patents and applications are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions and concepts of the various patents and applications described above to provide yet further embodiments of the invention. 
       FIG. 1  depicts an exploded view of disclosed components that may take kit form and may include a seal cup  100  with the seal cup comprising a lower cavity  110 , an upper lip  130  and a plurality of feet  140  attached to a lower surface of the upper lip. The feet  140  of the seal cup may mate into or fit into bolt voids  520  with the bolt voids defined within a closet flange  500 . When the feet  140  of the seal cup are inserted into the voids of the closet flange, a pressure test may be performed to test the integrity of the related waste and drain system. This pre-installation test is typical in modern day construction practices. Moreover, a lower portion of the upper lip may have concentric walls to comport with and seal with an upwardly urged top seal, with the top seal sometimes urged upwardly by use of a threads or springs or other means. Moreover, a rib seal system may be employed to seal a seal cup to the closet flange. Sometimes the downward force of attachment of a cup seal may be used to seal with a closet flange. 
     For toilet installation, attachment bolts  300  may be fitted into the bolt voids of the closet flange to secure a wax free spring seal  400  or analogous sealing component between the closet flange and toilet. The attachment bolts will protrude past the toilet and be secured by the cap assembly  200 . The cap assembly may comprise an inner cap  220  with the inner cap comprising inner threads to comport with the attachment bolts and outer threads  230  to mate with the inner threads  270  of the outer cap  260 . The disclosed cap assembly system provides advantages over the prior art in that the inner cap  200  is made of a flexible material and takes on a wide profile so as to not crack or otherwise damage the toilet that is held in tension by the inner cap. The outer cap  260  provides advantages over the prior art in that the inner cap and attachment bolt are well covered in a wide profile such that children will not hurt themselves on the inner cap and will not easily remove the outer cap. 
     As shown and discussed further below, the seal cup  100  provides multiple uses in a compact form factor. The seal cup provides convenient means of sealing the closet flange for pressure testing and provides means of packaging, marketing and storing related components such as the cap assembly components and attachment bolts. For further all in one packaging, the seal cup may fit into a wax free spring seal  400  and a closet flange may fit over the wax free spring seal. Thus a plumber or DIY homeowner may conveniently purchase all parts needed to effortlessly and quickly set a toilet. 
       FIG. 2  depicts a kit ready for sale or marketing. Not shown is a clear plastic seal that may be used to contain the contents of the seal cup  100 . A disclosed kit may contain or include a seal cup filled with attachment bolts, two inner caps and two outer caps. A wax free spring seal or similar seal system may hold the seal cup. A closet flange may be disposed around the wax free spring seal. 
       FIG. 3  depicts the current state of disorganization and potential for mismatched parts of the prior art. In the prior art, toilet components are sold separately and often in different areas of a home improvement store. The shown pressure test cap has no use in storing components. The wax ring is now obsolete by use of a wax free spring seal or similar system. The bolt caps of the prior art often fail to total enclose attachment bolts and sometimes leave the ends of the attachment bolts exposed. The caps of the prior art are often a choking hazard as young children may remove the caps and swallow them. 
       FIG. 4  depicts the disclosed seal cup  100  used as a test seal such that the waste and drain lines may be pressure tested prior to installation of the toilet. The feet  140  of the seal cup  100  provide a toolless solution to pressure testing while providing convenient means of storing hardware needed after the pressure test. The lower cavity of the seal cup is well positioned to store the cap and bolt components such that they are unlikely to be lost during the construction process. 
       FIG. 5  depicts the beginning of the toilet installation process wherein the attachment bolts  300  are secured into the voids  520  of the closet flange  500 . The wax free spring seal  400  is centrally disposed within the closet flange. The horn  620  of the toilet  600  may be disposed within the top portion of the wax free spring seal  400 . The upper or superior ends of the attachment bolts  300  may be inserted through voids of the toilet as shown in  FIG. 6 . 
       FIG. 6  depicts a further progression of toilet installation wherein the horn of the toilet has been inserted into the top void of the wax free spring seal. 
       FIG. 7  depicts an attachment bolt  300  passed through the toilet and now secured to the toilet by use of an inner cap  220 . The inner cap may comprise outer threads  230  used to secure the outer cap  260  by use on the inner threads  270  of the outer cap. 
       FIG. 8  shows a finished or near finished assembly of a toilet using the disclosed components and methods. 
       FIG. 9  depicts a thermal cap  800 , with the thermal cap comprising one or more outer flat surfaces  820  and one or more outer curved surfaces  810 . The combination of the flat and curved surfaces provide an advantage of allowing the cap to be turned by hand. 
       FIG. 10  depicts a bottom perspective view of a thermal cap  800 . A threaded insert  900  is shown as disposed within a cap sleeve  840  of the thermal cap. A threaded insert may be heated and then inserted into a cap sleeve, with the heat of the threaded insert causing material of the cap sleeve to melt or deform. Upon cooling, the threaded insert may be rigidly or securely disposed within the cap sleeve or thermal cap. 
     A thermal cap may comprise a plurality of lateral support structures  830 , that provide an advantage over the prior art in allowing air gaps between the exterior walls of the thermal cap and the cap sleeve. The air caps reduce weight and the cost and materials used in constructing the thermal cap. 
       FIG. 11  depicts a thermal cap having a bottom surface  815  and a cap sleeve  840  with the thermal cap ready to accept a heated threaded insert  900 . A threaded insert may comprise a general cylinder body having an exterior surface comprising one or more rings of outer friction ridges  910 . The outer friction ridges overcome shortfalls in the prior art by sometimes melting into a cap sleeve and thus quickly and securing attaching with in the cap sleeve. A threaded insert may comprise interior threads, that may comport with attachment bolts or other fasteners. 
     A threaded insert  900  may comprise an exterior lip  940  with the exterior lip providing advantages over the prior art as being a continuous anchor point that may be embedded into the cap sleeve or thermal cap. A threaded insert may comprise a smooth section  950  that may be above or superior to the exterior lip. The smooth section or superior smooth section overcomes shortfalls in the art by providing a contrast or different elevation from the exterior lip, to help the exterior lip not set too deeply into the thermal cap. 
       FIG. 12  depicts a superior or upper void  950  of the cap sleeve  840 . The upper void provides advantages over the prior art by allowing fasteners such as attachment bolts to be untrimmed or uncut as excess fastener length may be disposed within the upper void  950 . 
     The disclosed embodiments may include the following items: 
     A toilet installation and pressure testing kit, the kit comprising: 
     a seal cup ( 100 ) with the seal cup comprising a lower cavity ( 110 ), an upper lip ( 130 ) and a plurality of feet ( 140 ) with the plurality of feet attached to a lower surface of the upper lip. 
     The seal cup of item  1  wherein the lower surface of the upper lip comprises a concentric wall that comports with a wax free spring seal ( 400 ). 
     The seal cup of item  1  wherein the upper lip comprises a planar surface, not defining a lower cavity. 
     The kit of item  1  further comprising a plurality of attachment bolts ( 300 ); 
     The kit of item  4  further comprising a plurality of cap assemblies ( 200 ), with each cap assembly comprising: 
     an outer cap ( 260 ) with the outer cap having an inside surface comprising inner threads ( 270 ); 
     an inner cap ( 220 ) with the inner cap comprising outwardly disposed outer threads ( 230 ). 
     The kit of item  5  further comprising a wax free spring seal. 
     The seal cup of item  1  further comprising a transparent member covering a top void of the seal cup. 
     The seal cup of item  1  further comprising a plurality of thermal caps ( 800 ) with each thermal cap comprising an outer curved surface ( 810 ), an outer flat surface ( 820 ), a bottom surface ( 815 ) and a cap sleeve ( 840 ). 
     The seal cup further comprising a threaded insert disposed within the cap sleeve.