Abstract:
An improved water closet flange for connection to a plumbing fixture is described. The improved flange comprises an anchoring element or outer flange, connected to a flexible conduit tube or flexible sleeve, in which is attached an O-ring type of gasket. The improved flange connects a toilet bowl outlet to a waste drainpipe outlet without any flow reduction in between both connecting elements. The improved flange allows the connection between a toilet bowl discharge and a well placed vertical waste drainpipe. The improved flange also allows the connection between a toilet bowl discharge and a waste drainpipe outlet that is offset, horizontally oriented, or diagonally placed. The improved flange may further comprise an O-ring type of gasket disposed on the exterior of the flexible sleeve to provide a tight seal between the outer surface of the flexible sleeve and the inner surface of a waste drainpipe. The flexible sleeve can be implemented in a variety of sizes or diameters, including, for example, 3 inch (7.5 cm) and 4 inch (10 cm) diameters. An alternative embodiment of the flexible sleeve can fit either 3 inch or 4 inch drainpipes with the help of an appropriate O-ring seal of the appropriate dimensions.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of U.S. application Ser. No. 10/370,747 filed Feb. 20, 2003, entitled “Improved Flexible Sleeve for Connection to a Plumbing Fixture,” which is incorporated by reference herein in its entirety for all purposes. 

   FIELD OF THE INVENTION 
   This application relates generally to devices for connecting plumbing fixtures to waste drain conduits, and more particularly to the combination of a specially configured flexible sleeve and a closet flange, which mounts a water closet (toilet) on a supporting floor surface and also provides a tight sealed interconnection between the water closet (toilet) and the water waste drain pipe, allowing a good connection even between uneven outlets. 
   BACKGROUND 
   Water closets, also called toilets, are waste disposal devices commonly installed in most bathrooms. These kinds of plumbing appliances generally have a water storing receptacle called a water tank that is attached to a siphon seat-shaped bowl called toilet bowl. Periodically, waste is removed from the toilet bowl by flushing, thereby allowing water to drain from the water tank through the toilet bowl and into a waste drainpipe. In order to work, however, the toilet bowl must be connected to the waste drainpipe by fluid carrying conduits. Typically, the toilet bowl will sit flat on a floor and connect with a water closet outer flange. The water closet outer flange in turn connects with conduits leading to a waste drainpipe. 
   Existing toilet flanges often include a conduit portion for passing the waste fluids through the floor (upon which the toilet sits), a number of openings to fasten the flange to the floor, and other openings to attach the toilet bowl to the flange itself. Additionally, there may be an appropriate seat for a toilet seal, which typically may be made either from wax or by a relatively high-density foam or rubber. 
   Toilets are installed and located in accordance with interior decorating aesthetics of the bathroom. The location of the toilet is determined by the location of the waste drainpipe in the floor, and logically, this will determine the location of the toilet bowl discharge and hence the location of the outlet flange. However, in making openings through floors and in making the connection between the toilet bowl discharge and the waste drainpipe, there is some likelihood that the toilet bowl opening will be in an awkward or inconvenient place. An example would be where the toilet discharge opening has to be directly above a floor beam or too close to a wall. To overcome such problems there have been provided, in the past, offset flanges for toilet bowls. Examples of such offset flanges include the flanges depicted in U.S. Pat. Nos. 3,967,836 and 6,052,839. These prior offset flanges attempt to overcome the problems associated with positioning of the toilet bowl outlet pipe by positioning the conduit at one end of the flange adjacent to one lateral edge of the flange. In this way, the toilet bowl outlet pipe can be positioned adjacent to a beam or tight against a wall or other obstacle without much inconvenience. 
   A problem associated with the previously described apparatuses is that even though they provide some flexibility, both are comprised of rigid connecting conduits, and therefore provide limited flexibility and depth connection distances. For example, U.S. Pat. No. 3,967,836 has a maximum offset of 1¾″ (one and three quarter inches), which cannot be exceeded; and U.S. Pat. No. 6,052,839 requires a larger maximum offset. But the problem with the apparatus described in U.S. Pat. No. 6,052,839 is its minimum offset. More specifically, because it has a connecting rigid conduit in the shape of an elbow, its use is limited to angled connections. Moreover, this shape requires that the vertical distance between the toilet bowl discharge and the waste drain pipe outlet should be at least about 5–6 inches deep. 
   Because of the rigidity of the conduit portions of the closet flanges that are currently available, there are several problems related with offset, angled and uneven installations. Most professionals who deal with these kinds of problems turn to modifying the waste drain line or change the toilet for a bigger or smaller one, depending on the case. Those solutions are expensive and can cause delays in the installation process. 
   To address these problems, an improved water closet flange is hereby disclosed. The improved flange has a flexible conduit (i.e. sleeve) portion for carrying fluids and connecting to the waste drain pipe outlet, and such a flexible sleeve will facilitate its installation even between offset, uneven or angular outlets. 
   BRIEF SUMMARY 
   Disclosed herein is an improved flange apparatus for connection to a plumbing fixture, such as a toilet, wherein the improved flange may comprise an anchoring element or outer flange that is connected to a flexible conduit tube or flexible sleeve, to which is attached an O-ring type of gasket. The improved flange can connect a toilet bowl outlet to a waste drainpipe outlet without any flow reduction between both connecting elements. A further aspect of the improved flange allows the connection between a toilet bowl discharge and a waste drainpipe outlet that are not aligned with each other. Another aspect of the improved flexible sleeve allows the connection between a toilet bowl discharge and a horizontal waste drainpipe outlet. A further aspect of the flexible sleeve prevents any type of leakage or dripping between the toilet bowl discharge and the waste drainpipe outlet. Another aspect of the flexible sleeve is an outer flange element able to firmly anchor a plumbing fixture to a surface. Yet another aspect of the improved flange eliminates the need for using a wax seal or a rubber foam seal in the installation of a toilet, because of the seal provided by the joint between the toilet outlet and the flexible sleeve. A further aspect of the improved flange is an O-ring type of gasket mounted on the flexible sleeve that provides a tight seal between the outer surface of the flexible sleeve and the inner surface of the waste drainpipe in which is connected. Another aspect of the improved flange is the connection between the flexible sleeve and the inner surface of the waste drainpipe, which does not need any kind of gluing or cementing to provide a hermetic seal. The flexible sleeve can be implemented in a variety of sizes or diameters, including, for example, 3 inch (7.5 cm) and 4 inch (10 cm) diameters. An alternative embodiment of the flexible sleeve can fit either 3 inch or 4 inch drainpipes with the help of an appropriate O-ring seal with the appropriate dimensions. 
   These aspects of the improved flange are described only for the purpose of clarifying the nature of the present invention. Furthermore, several exemplary embodiments of the invention are illustrated in the below-described figures of the accompanying drawings and are described in detail hereinafter. These embodiments are to be taken as representative of the multiple embodiments of the invention that lie within the scope of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is a schematic isometric perspective view of one embodiment of an improved flange apparatus. 
       FIG. 1B  is a schematic isometric perspective view of one embodiment of an improved flange in which the flexible sleeve comprises a corrugated material. 
       FIG. 2A  is a schematic isometric cross-sectional view of an improved flange apparatus taken from line  2 — 2  of  FIG. 1A . 
       FIG. 2B  is a schematic isometric cross-sectional view of an improved flange apparatus taken from line  2 — 2  of  FIG. 1A  that also depicts an internal structure. 
       FIG. 2C  is a schematic isometric cross-sectional view of an improved flange apparatus taken from line  2 — 2  of  FIG. 1B . 
       FIG. 3  is an alternative schematic isometric cross-sectional view of an outer flange taken from line  2 — 2  of  FIG. 1 . 
       FIG. 4A  is a schematic isometric cross-sectional view of one embodiment of an improved flexible sleeve taken from line  2 — 2  of  FIG. 1A . 
       FIG. 4B  is a schematic isometric cross-sectional view of one embodiment of an improved flexible sleeve taken from line  2 — 2  of  FIG. 1A  that also depicts an internal structure. 
       FIG. 4C  is a schematic isometric cross-sectional view of one embodiment of an improved flexible sleeve taken from line  2 — 2  of  FIG. 1B . 
       FIG. 5  is a cross-sectional view of an improved flange apparatus in its operative position between a toilet bowl and a waste drainpipe. 
       FIG. 5A  is an enlarged partial sectional view of the embodiment shown in  FIG. 5 . 
       FIG. 6  is a cross-sectional side view of an improved flexible sleeve installed in a vertically oriented waste drainpipe. 
       FIG. 7  is a side view of an improved flexible sleeve installed in diagonally oriented waste drainpipe. 
       FIG. 8  is a side view of an improved flange apparatus installed in a horizontally offset waste drainpipe. 
       FIG. 9  is a side view of an improved flange apparatus installed in a horizontally oriented waste drainpipe. 
       FIG. 10A  is a side view of an improved flange apparatus having a 3 inch external diameter that is installed in a vertically oriented 3 inch waste drainpipe. 
       FIG. 10B  is a side view of an improved flange apparatus having a 3 inch external diameter that is installed in a vertically oriented 4 inch waste drainpipe. 
   

   DETAILED DESCRIPTION 
     FIGS. 1A–2C  depict several alternative embodiments of the improved flange. In particular,  FIGS. 1A–1B  depict schematic isometric perspective views of the improved flange. Cross-sectional views of the flanges depicted in  FIGS. 1A–1B  are also depicted in  FIGS. 2A–2C . In each of these figures, the improved flange  5  comprises an outer flange  10  attached to a flexible sleeve  12  with an attaching lip  32 , which is part of the upper portion of the sleeve  16 . The attaching lip  32  is seated in the radial groove  22  and forms a seal between the attaching lip  32  and the outer flange  10 . In addition, the flexible sleeve  12  has an O-ring type seal  30  that is mounted around the flexible conduit portion  14 . The O-ring seal  30  can comprise a plurality of O-rings, such as ten O-rings, one to four O-rings, or only one O-ring. 
   As clearly shown in  FIGS. 1A ,  2 B, and  3 , the outer flange  10  is substantially cylindrical in shape, having a linear longitudinal axis  19  (shown explicitly in  FIG. 3 ) extending along the centerline of the outer flange  10  from its first end  51  to its second end  52 . The flexible sleeve  12  is attached to the outer flange  10  and connects the plumbing fixture discharge (as from a toilet, for example), attached via the outer flange, to the waste drain pipe outlet, with the sleeve&#39;s proximal end  55  corresponding to the plumbing fixture discharge and its distal end  56  corresponding to the waste drain pipe outlet. The proximal and distal ends of the sleeve each have a longitudinal axis ( 21  and  31  respectively) that is colinear with the longitudinal axis  19  of the outer flange (and in  FIG. 2B , the longitudinal axis  21  of the proximal end of the sleeve coincides with the linear longitudinal axis  19  of the outer flange) when the sleeve  12  is in an unflexed state, as shown in  FIGS. 1A and 2B . 
   The flexible sleeve could be made in two different outside diameter sizes in order to fit into the two most commonly used types of waste drainpipes. For 4 inch drainpipes, the outside diameter of the flexible sleeve  12  can be between 3.125 to 4.250 inches, 3.750 to 4.125 inches, or 4.125 inches. For 3 inch drainpipes, the outside diameter of the flexible sleeve can be between 2.250 to 3.750 inches, or about 3.000 inches. 
   The O-rings used for connecting a flexible sleeve  12  having a 4 inch nominal external diameter with a waste drainpipe having a 4 inch diameter can have an internal diameter between 1 to 5 inches, or between 3 inches and 4.250 inches, or about 3.250 inches. The O-rings used for connecting a flexible sleeve  12  having a 4 inch nominal external diameter with a 4 inch waste drainpipe can have an external diameter between 2 and 6 inches, between 3 and 4.750 inches, or about 4.4 inches. The O-rings used for connecting a flexible sleeve having a 3 inch external diameter with a regular 3 inch waste drainpipe, can have an internal diameter between 0.75 and 4 inches, or an internal diameter between 1.5 and 3.5 inches, or an internal diameter of about 2.4 inches. By using bigger O-rings, flexible sleeves having a 3 inch external diameter can be connected to a regular 4 inch waste drainpipe, resulting in a product that fits most drain pipes. 
   The O-rings used for connecting a flexible sleeve having a 3 inch external diameter with a 4 inch diameter waste drainpipe can have an internal diameter between 0.75 inches and 4 inches, or a internal diameter between 1.5 inches and 3.5 inches, or an internal diameter of about 2.4 inches. The O-rings used for connecting a flexible sleeve having a 3 inch external diameter with a 4 inch diameter waste drainpipe can also have an external diameter between 2 and 6 inches, or an external diameter between 3 and 4.75 inches, or an external diameter of about 4.4 inches. 
   The flexible sleeve should be flexible enough to support the installation between a plumbing fixture and an offset, angled, or misaligned waste drain pipe. Accordingly, the hardness of its materials can range from 35 shore A to 90 shore A, or from 35 shore A to 55 shore A, or more specifically about 40 shore A. The length of the flexible sleeve  12  can be between 2 and 30 inches, or between 6 and 15 inches, or more specifically about 12 inches. The thickness of the flexible sleeve may also be between about 0.040 to about 0.400 inches, or between about 0.100 and about 0.350 inches, or more specifically about 0.200 inches. 
     FIG. 1B  depicts a schematic isometric perspective view of an improved flange  5  comprising a corrugated portion  36  on the upper portion of the flexible sleeve  12 . The corrugated portion  36  helps to avoid any kinking of the flexible sleeve  12  when it is installed in an offset, diagonal, horizontal, or angular arrangement. The corrugated portion  36  of flexible sleeve  12  can comprise as little as ⅙ of the sleeve&#39;s length or it can comprise the entire length of the flexible sleeve. The corrugated portion  36 , however, preferably comprises ¼ to ½ of the total length of the flexible sleeve  12 , and more preferably ⅓ of the total length of the flexible sleeve  12 . 
     FIG. 2B  depicts a schematic isometric cross-section view of an improved flexible closet flange, taken from the line  2 — 2  in  FIG. 1A . In  FIG. 2B , an internal structure  38  is depicted that can comprise a longitudinally coiled wire or a set of rings. This embodiment can be utilized whenever the positioning of the flexible closet flange inside the drainpipe could result in shrinkage of the inside diameter of the flexible sleeve  12  as a result of kinking or other deformations. This shrinkage can result in the accumulation of waste products inside the sleeve, eventually leading to an undesirable drainage jam. 
     FIG. 2C  depicts a schematic isometric cross-sectional view of an improved flange  5 , taken from line  2 — 2  in  FIG. 1B  wherein the flexible sleeve  12  comprises a corrugated portion  36 . The corrugated potion  36  allows the flexible sleeve  12  be mounted to offset, angled, or diagonally positioned drain pipes while minimizing kinking or other deformations. 
     FIG. 3  depicts a cross-sectional perspective view of an outer flange piece  10 . The outer flange  10  can include one or more apertures  18  for fasteners that secure the outer flange  10  to a surface, such as a floor, as well as one or more other apertures  20  for fasteners that secure the outer flange  10  to a plumbing fixture, such as a toilet bowl. The outer flange can also comprise a radial groove  22  in which the attaching lip  32  (shown on  FIG. 4 ) of the flexible sleeve  12  (also shown on  FIG. 4 ) will sit. 
     FIG. 4A  depicts an isometric cross-sectional view of the flexible sleeve  12  with an O-ring  30  attached around the flexible conduit portion  14 . Also shown in  FIG. 4  is the upper portion of the sleeve  16 , which is comprised of the attaching lip  32  and a sealing surface  34 . The flexible sleeve  12  can be comprised of any thermoplastic rubber, any engineering polymer, or any chemical treated materials capable of resisting chemicals such as chlorides and acids such as a PVC compound. The flexible sleeve  12  should also be able to resist organic gases and fungus attacks. The flexible sleeve  12  can be made of flexible materials, corrugated materials, or a combination of both, and it can be extruded, vulcanized, or molded. The flexible sleeve  12  should be flexible enough to support the installation between a toilet and an offset, or unfair, or angled installed waste drain pipe, the hardness of its materials can range from 35 shore A to 90 shore A, from 35 shore A to 55 shore A, or more specifically about 40 shore A. The length of the flexible sleeve  12  can be between 2 to 30 inches, or between 6 and 15 inches, and more specifically about 12 inches. Depending upon the type of installation, the flexible sleeve  12  can be used without the outer flange  10 . The O-rings  30  can be molded as a part of the conduit portion of the flexible sleeve  12 , or they may be fused, sonic welded, glued, or can be independent from the sleeve with free displacement movement along the external face of the flexible sleeve  12 . 
   An alternative embodiment of a flexible sleeve  12  is depicted in  FIG. 4B . In  FIG. 4B , an internal structure  38  comprising a longitudinally coiled wire or a set of rings is disposed within the wall of the flexible sleeve  12 . This embodiment can be utilized whenever the positioning of the flexible closet flange inside the drainpipe could result in a shrinkage of the inside diameter of the sleeve due to kinking or other deformation. This shrinkage can result in the accumulation of waste products inside the sleeve, eventually leading to a drainage jam. 
   Another alternative embodiment of the flexible sleeve  12  is depicted in  FIG. 4C . In  FIG. 4C , the flexible sleeve  12  further comprises a corrugated portion  36  that facilitates the installation of the flexible sleeve into an offset, diagonal, or horizontal arrangement. The corrugated portion  36  allows the flexible sleeve  12  to be mounted in such arrangements while minimizing the effects of kinking and shrinkage of the inside diameter of the sleeve. 
     FIG. 5  is a cross-sectional side view of the improved flange in its operative position between a toilet bowl  24  and a waste drain pipe  26 . The outer flange  10  anchors the toilet bowl  24  to a floor, and firmly grips the flexible sleeve  12 , which fits inside the waste drain pipe  26 . In addition, the O-ring  30  creates a seal against the inner surface of said waste drain pipe  26 . The materials for the outer flange  10  can be any ferrous or non-ferrous metals, ABS, PVC or any other type of hard synthetic plastic. The outer flange may have or may not have a radial groove on it, all depending in the type of application or use that the flexible closet flange is going to be put through. 
     FIG. 5A  is an enlarged partial view of the embodiment shown in  FIG. 5 . In  FIG. 5A , the seal between the toilet discharge outlet  28  and the sealing surface  34  on the upper portion  16  of the flexible sleeve  12  eliminates the need for regular wax seals or foam rubber gaskets. When the toilet  24  is fastened to the outer flange  10 , the toilet discharge outlet  28  will be pushed against the sealing surface  34  on the upper portion of the sleeve  16 , thereby creating a firm and tight seal that will prevent gas and fluids from leaking from the drain pipe to the floor in which the toilet bowl  24  is seated. 
     FIGS. 6–10B  show different installments and embodiments in which the improved flange can be used.  FIG. 6  is a cross-sectional side view of one kind of installation between the flexible sleeve  12  and a vertically installed waste drainpipe  26 . Although this kind of installation is preferred, the conditions permitting this kind of installation are not always available. This is problematic because most water closet flanges are designed to be installed under these conditions (with a vertically aligned waste drainpipe), and do not allow any misalignment between the toilets and waste drainpipes outlets. 
     FIG. 7  is a cross-sectional side view of an installation between the flexible sleeve  12  and a diagonally installed waste drainpipe  26 . The flexible sleeve is advantageous because it can be readily adapted to connect to a drainpipe  26  that is disposed at a non-vertical angle without any additional equipment or materials. 
     FIG. 8  is a cross-sectional side view of an installation between the flexible sleeve  12  and an offset waste drainpipe  26 . As stated previously, the flexible sleeve  26  can be readily adapted to connect an offset waste drainpipe  26  without any additional equipment or materials. 
     FIG. 9  is a cross-sectional side view of an installation between the flexible sleeve  12  and a horizontally-installed waste drainpipe  26 . Again, the flexible sleeve  26  can be readily adapted for the situation where the drainpipe  26  is horizontally disposed without any additional equipment or materials. 
     FIG. 10A  is a cross-sectional side view of an installation between a 3 inch flexible sleeve  12  and a vertically-installed 3 inch waste drainpipe. In  FIG. 10A , an O-ring  30  creates a seal against the inner surface of the 3 inch waste drain pipe  26 .  FIG. 10B  is a cross-sectional side view of an installation between a 3 inch flexible sleeve  12  and a vertically-installed 4 inch waste drainpipe. Much like  FIG. 10A , an O-ring  30  creates a seal against the inner surface of the 4 inch waste drain pipe  26 . It is contemplated that one kind of O-ring  30  may be utilized to form an effective seal for both 3 inch and 4 inch drain pipes, thereby eliminating the need for additional adapters or parts. 
   Although preferred embodiments of the present inventions have illustrated in the accompanying drawings and described in the foregoing detailed description, it will be understood that the inventions are not limited to the embodiments disclosed, but are capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims and equivalents thereof. Applicant intends that the claims shall not invoke the application of 35 U.S.C. § 112, 6 unless the claim is explicitly written in means-plus-function or step-plus-function format.