Patent Publication Number: US-2010123307-A1

Title: Extendable Flange Apparatus and Methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional. App. Ser. No. 61/104,221 filed on Oct. 9, 2008, which is hereby incorporated by reference in its entirety for all purposes. 
    
    
     TECHNICAL FIELD 
     The present disclosure generally relates to flanges for use in plumbing applications, and more particularly to flanges having extendable members. 
     BACKGROUND 
     Various flanges have been used to connect the discharge of a plumbing fixture to the waste drain pipe of a plumbing system. In some instances, the connection to the waste drain pipe is often found in the floor of a building, but the height of a finished floor sometimes makes the connection to the waste drain pipe inaccessible.  FIG. 1  is an exploded view of the installation of a plumbing fixture  100  with a conventional, non-extendable flange apparatus  102 . Due to the height of the finished floor  104 , the flange apparatus  102  is seated in a recessed area below the finished floor level. As such, when the plumbing fixture  100  is disposed on top of the finish floor  104 , the discrepancy between the seating level of the flange  102  and the finished floor level creates a gap between the discharge  106  of the plumbing fixture  100  and the top opening  108  of the flange  102 . To accommodate for the gap, a wax ring  110  of suitable thickness is disposed between the discharge  106  and the top opening  108  of the flange  102 . Adding a wax ring  110 , however, introduces an additional source of leakage and increases the difficulty of installation. 
     BRIEF SUMMARY 
     The present disclosure generally relates to extendable water closet flanges and methods for installing such water closet flanges. In one embodiment, the extendable flange apparatus includes an outer member comprising an outer tubular body and a first flange portion extending outwardly from an upper end portion of the outer tubular body, the first flange portion defining a first plane. The extendable flange further includes an inner member slidably coupled to the outer member, the inner member comprising an inner tubular body and a second flange portion extending outwardly from an upper end of the inner tubular body, the second flange portion defining a second plane. The outer tubular body has a central opening defined therethrough, and the inner tubular body is at least partially disposed within the central opening of the outer tubular body, the inner tubular body being operable to slide longitudinally, from a leveled position to an extended position. The first and second planes of the first and second flange portions, respectively, are substantially coplanar when the inner tubular body is in the leveled position, and the first plane is in a spaced relation with the second plane when the inner tubular body is in the extended position. 
     Another embodiment of the extendable flange apparatus of the present disclosure comprises an outer member comprising an outer tubular body and a first flange portion extending outwardly from an upper end portion of the outer tubular body, the first flange portion defining a first plane. The extendable flange also includes an inner member slidably coupled to the outer member, the inner member comprising an inner tubular body, a second flange portion extending outwardly from an upper end of the inner tubular body, the second flange portion defining a second plane, and a sealing member disposed at the upper end of the inner tubular body, the sealing member operable to provide a substantially sealed connection to a discharge of a plumbing fixture. The outer tubular body has a central opening defined therethrough, and the inner tubular body is at least partially disposed within the central opening of the outer tubular body, the inner tubular body being operable to slide longitudinally, from a leveled position to an extended position. The first and second planes of the first and second flange portions, respectively, are substantially coplanar when the inner tubular body is in the leveled position, and the first plane is in a spaced relation with the second plane when the inner tubular body is in the extended position. 
     Related methods for assembling and installing the disclosed flange apparatus between plumbing fixture discharges and drainage outlets are also described. For example, the ability to extend the inner member of the flange allows for a connection to the plumbing fixture discharge at the finished floor level regardless of whether the flange is seated at the finished floor level or below the floor level. Thus, the flange according to the present disclosure can be used in varying plumbing applications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference is now made to the following descriptions taken in conjunction with the accompanying drawings. 
         FIG. 1  illustrates an exploded view of a plumbing fixture installed with a conventional flange apparatus; 
         FIG. 2A  illustrates a perspective view of an embodiment of an extendable flange apparatus in accordance with the present disclosure; 
         FIG. 2B  illustrates a perspective view of the extendable flange apparatus shown in  FIG. 2A  in an extended position; 
         FIG. 3A  is a cross-sectional view of the extendable flange apparatus shown in  FIG. 2A ; 
         FIG. 3B  is a cut-away, perspective view of the extendable flange apparatus shown in  FIG. 2A ; 
         FIG. 4A  is a perspective view of another embodiment of an extendable flange apparatus installed below a finished floor level; 
         FIG. 4B  is a perspective view of the extendable flange apparatus shown in  FIG. 4A  in an extended position; 
         FIG. 5  is a perspective view of the extendable flange apparatus shown in  FIGS. 4A and 4B  in an extended position connecting a plumbing fixture to a waste drain pipe; 
         FIG. 6A  is a cut-away, perspective view of an exemplary embodiment of an extendable flange apparatus in accordance with the present disclosure; 
         FIG. 6B  is a cut-away, perspective view of the extendable flange apparatus shown in  FIG. 6A ; 
         FIG. 7  is a perspective view of an embodiment of an inner member of an extendable flange apparatus according to the present disclosure; 
         FIG. 8A  illustrates a perspective view of another exemplary embodiment of an extendable flange apparatus in accordance with the present disclosure; 
         FIG. 8B  illustrates a perspective view the extendable flange apparatus shown in  FIG. 8A  after a central detachable portion of a sealing member is removed; and 
         FIG. 8C  illustrates an elevational, cut-away view of an extendable flange apparatus in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various aspects of an extendable flange apparatus and related methods for installing the extendable flange between varying plumbing fixture discharges and waste drainpipe outlets according to the present disclosure are described. It is to be understood, however, that the following explanation is merely exemplary in describing the devices and methods of the present disclosure. Accordingly, several modifications, changes and substitutions are contemplated. 
       FIG. 2A  is a perspective view of an extendable flange apparatus  210  in accordance with the principles of the present disclosure. The extendable flange  210  comprises an outer member  220  and an inner member  230  that are slidably coupled, thereby allowing the inner member  230  to extend upwardly from a level position to an extended position relative to the outer member  220 .  FIG. 2B  is a perspective view of the extendable flange apparatus  210  in an extended position. As such, the extendable flange apparatus  210  is operable to accommodate a potential gap between the seating level of the flange apparatus  210  and the finished floor level without the use of a wax ring or other substitutes for a wax ring. 
       FIGS. 3A and 3B  provide a cross-sectional view and a perspective, cut-away view of the extendable flange apparatus  210 , respectively. As illustrated, the outer member  220  includes an outer tubular body  224  and a first flange portion  222  extending outwardly from an upper end portion  225  of the outer tubular body  224 . The outer tubular body  224  also includes a lower end portion  226 . The first flange portion  222  includes bores  228  defined therethrough, and fasteners (not shown), such as threaded screws, can be inserted through the bores  228  to secure the first flange portion  222  against a floor surface. The inner member  230  includes an inner tubular body  234  and a second flange portion  232  extending outwardly from an upper end portion  235  of the inner tubular body  234 . 
     The outer tubular body  224  includes a central opening defined therethrough, and the inner tubular body  234  is at least partially disposed within the central opening of the outer tubular body  224 . As illustrated in  FIGS. 2A-B  and  3 A-B, the inner tubular body  234  is operable to slide longitudinally from a leveled position to an extended position. In an embodiment, the first and second flange portions  222  and  232  define first and second planes, respectively, and in the leveled position, the first and second flange portions  222  and  232  are coplanar and level with each other. In the extended position, the first and second planes defined by the first and second flange portions  222  and  232  are in a spaced relation. The second flange portion  232  has openings  236  defined therethrough, and fasteners (not shown) can be inserted through the openings  236  to secure the second flange portion  232  to a plumbing fixture (not shown). 
     The extendibility of the inner tubular body  234  relative to the outer tubular body  224  permits the use of the extendable flange  210  in varying plumbing applications. The extendable flange  210  is operable to provide a connection to the plumbing fixture discharge at the finished floor level regardless of whether the first flange portion  222  is seated at the finished floor level or below the finished floor level. 
     In one embodiment, the first flange portion  322  is seated below the finished floor level to anchor the flange  310 , and the second flange portion  332  is initially level with the first flange portion  322  as shown in  FIG. 4A . To complete the installation of the flange  310 , screws (not shown) are inserted through the openings  336  of the second flange portion  332  and then through openings (not shown) of a plumbing fixture  340  seated at the finished floor level as shown in  FIG. 5 . Nuts (not shown) are used to engage the screws and secure the second flange portion  332  to the plumbing fixture  340 . As the nuts are tightened, the screws pull the second flange portion  332  upwardly to allow the inner tubular body  334  to reach the extended position as illustrated in  FIGS. 4B and 5 . 
     It is to be appreciated that the extendable flange apparatus disclosed herein may be modified to provide a variety of desired functionalities. In some embodiments, the extendable flanges of the present disclosure may include a mechanism for limiting the extension of the flanges and preventing the disassembly of the inner and outer members.  FIGS. 6A and 6B  are cut-away, perspective views of an exemplary embodiment of an extendable flange  410 . The flange  410  may be configured to include at least one latch  440  disposed at a lower end portion  450  of the inner tubular body  434 . In the illustrated embodiment, a plurality of latches  440  are provided. The latches  440  are operable to limit the extent which the inner tubular body  434  can be pulled up relative to the outer tubular body  424  by functioning as a mechanical latch against the lower end portion  426  of the outer member  420 . As such, the latches  440  are operable to cooperate with the lower end portion  426  of the outer tubular body  424  to prevent the inner and outer members  430  and  420  from being completely disassembled. It is to be appreciated that the latches  440  can be configured to have a variety of shape and profile. In the illustrated embodiment, the latches  440  each comprise a proximal edge portion  442  that is substantially orthogonal to the surface of the inner tubular body and a tapering distal edge portion  444 . The tapering distal edge portion  444  allows for easy insertion of the inner member  430  inside the outer member  420 , thereby improving the ease of assembly for the flange  410 . 
     In some embodiments, the extendable flanges of the present disclosure may include a mechanism for limiting the rotational movement of the inner and outer members relative to each other. For example, in the embodiment illustrated in  FIGS. 6A and 6B , the inner member  430  comprises a longitudinal channel  460  defined in an outer surface of the inner member  430 , and the outer member  420  comprises a guide element  462  extending from an inner surface of the outer member  420 . The inner and outer members  430  and  420  are aligned such that the guide element  462  extends into the longitudinal channel  460 . As such, the guide element  462  and the longitudinal channel  460  are operable to cooperate to substantially limit the rotational movement of inner and outer members  430  and  420  relative to each other. Nonetheless, the guide element  462  is still operable to move along the longitudinal channel  460  to allow for longitudinal movements of the inner and outer members  430  and  420 . It is to be appreciated that in some embodiments, depending on the ease of manufacturing, the guide element  462  may be disposed on an outer surface of the inner member  430  instead, and the longitudinal channel  460  may be defined in an inner surface of the outer member  420  instead. 
     Some embodiments of the extendable flanges of the present disclosure may include a sealing member for providing a seal between the inner and outer members of the flanges. For example, in the embodiment illustrated in  FIGS. 6A and 6B , a circumferential groove  470  is defined in an outer surface of the inner member  430 , and an o-ring  472  is substantially seated in the groove  472 . Disposed in between the inner and outer members  430  and  420 , the o-ring  472  is operable to seal any gap that may be present between the inner and outer members  430  and  420 . It is to be appreciated that the embodiments provided in  FIGS. 6A and 6B  are merely exemplary, and other kinds of sealing member may be used in place of the illustrated o-ring  472 . It is to be further appreciated that in some embodiments, depending on the ease of manufacturing, the circumferential groove  470  may be defined in an inner surface of the outer member  420  instead. 
       FIG. 7  is a perspective view of an inner member  530 , which may be the inner member of any extendable flange apparatus described in the present disclosure. The inner member  530  includes an inner tubular body  534  and a flange portion  532  extending outwardly from an upper end portion  535  of the inner tubular body  534 . The inner member  530  further comprises at least one fitting member  580  disposed on an outer surface of the inner member  530 . The inner member  530  is operable to be at least partially disposed within a central opening defined through an outer member (not shown) of an extendable flange such that the inner member  530  and the outer member are slidably coupled. The fitting member  580  is dimensioned to span any gap between the outer surface of the inner member  530  and the inner surface of the outer member, thereby limiting lateral (diametric) movements of the inner member  530  relative to the outer member. For example, wobbling movements would be substantially reduced with the use of the fitting member  580 . After a plumbing fixture is installed with an extendable flange comprising the inner member  530 , the limitation on the lateral movements of the inner member  530  relative to the outer member is operable to limit external movements of the plumbing fixture due to outside forces exerted on the plumbing fixture, thereby imparting stability to the installation of the plumbing fixture. 
     In an embodiment, the fitting member  580  may comprise a plurality of protrusions  580  disposed on the outer surface of the inner member as illustrated in  FIG. 7 . A plurality of protrusions  580  may be particularly advantageous because the voids between the plurality of protrusions  580  provide space to accommodate for debris that may fall in between the inner member  530  and the outer member of the extendable flange during installation. Without the voids, debris that fell in between the inner member  530  and the outer member would jam the inner member  530  and the outer member, rendering the extendable flange unextendable. In another embodiment, other suitable fitting member  580  may include at least one rib member extending laterally or longitudinally along the outer surface of the inner member  530 . 
       FIG. 8A  is a perspective view of an extendable flange apparatus  610  comprising an inner member  630  slidably coupled to an outer member  620 . The inner member  630  further includes a sealing member  690  disposed at an upper end of the inner tubular body  634  of the inner member  630 . The sealing member  690  is operable to provide a seal between the flange  610  and the discharge of a plumbing fixture. In an embodiment, the sealing element  690  may be integrally formed with the inner member  630 . In another embodiment, the sealing member  690  may be laminated or spin-welded to the inner member  630 . In some embodiments, a top surface of the upper end portion  635  of the inner member  630  comprises an upwardly extending ring member  696  as shown in  FIG. 8C , and the sealing member  690  is welded over the ring member  696  onto the top surface of the upper end portion  635  of the inner member  630 . 
     One embodiment of the inner member  630  comprises one or more o-rings used as the sealing member  690 . In some embodiments, the sealing member  690  comprises a flexible membrane  690  that may include a central detachable portion  692  and a circumferential, inwardly-extending lip portion  694 . Such a membrane is operable to prevent the gases from the plumbing system to escape into the building before the plumbing fixture is install. If the plumbing code requires it, the flexible membrane  690  also allows for a leak test of the plumbing system to be conducted without the use of an additional part to plug or cap the flange connection to the waste drain pipe. When the central detachable portion  692  is removed during installation, the remaining circumferential lip portion  694  is operable to be bent downwardly when engaged by the discharge of the plumbing fixture.  FIG. 8B  is a perspective view of the inner member  630  after the detachable portion  692  has been removed. As such, the flexible inwardly extending lip  694  is operable to provide a sealed connection to the discharge of a plumbing fixture as the flange portion  632  of the inner member  630  is coupled to the plumbing fixture and pulled upwardly. 
     In some embodiments, the circumferential lip  694  of the membrane  690  may extend both inwardly and upwardly and have a raised profile. The raised profile of the circumferential lip  694  allows for additional accommodation for the potential gap between the seating level of a flange apparatus and the finished floor level. The raised circumferential lip  694  is particularly advantageous in embodiments in which the gap between the seating level of a flange apparatus and the finished floor level is longer than the length of the inner member of an extendable flange of the present disclosure. In some embodiments, the flexible membrane  690  includes only the circumferential lip  694  but not the central detachable portion  692 , in which case, the circumferential lip  694  defines a central opening in the flexible membrane  690 . 
     It should be appreciated that the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. Moreover, the above advantages and features are provided in described embodiments, but shall not limit the application of the claims to processes and structures accomplishing any or all of the above advantages. 
     Additionally, the section headings herein are provided for consistency with the suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” the claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in the claims found herein. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty claimed in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims associated with this disclosure, and the claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of the specification, but should not be constrained by the headings set forth herein.