MODULAR PANEL TOILET
A method of manufacturing a toilet includes lowering a toilet engine guide in a manufacturing support, aligning a plurality of frame members with the manufacturing support, installing at least one toilet engine component in the toilet engine guide, coupling a toilet seat assembly to the toilet, and coupling a plurality of panels to the plurality of frame members.
This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/452,225, filed Mar. 15, 2023, which is incorporated herein by reference.
FIELDThe present disclosure relates generally to toilets. More specifically, the present disclosure relates to a toilet having modular features and/or features that improve manufacturing of the toilet.
BACKGROUNDConventional toilets may be formed nearly entirely from porcelain or other ceramic materials. The porcelain may be treated or coated with vitreous china. As part of the manufacturing process, the toilet is fired at a high temperature until it is hardened.
One challenge relates to the fact that each time a new toilet design is created (e.g., a new design for the base), the entire flush engine for the toilet (i.e., the bowl, sump, and trapway) must be re-engineered and validated to ensure that it provides desired flow and other performance characteristics. One consequence of this is that it may take a relatively significant amount of time and cost to bring a new toilet design to final state because of the engineering time and effort involved. This may also result in toilets of various aesthetic designs having different performance characteristics.
It would be advantageous to reduce the amount of time and effort required to design and manufacture a new toilet design. It would also be advantageous to provide an improved toilet design that may be produced in a more energy efficient manner than conventional toilets.
Exemplary embodiments are described herein with reference to the following drawings, according to an exemplary embodiment.
As shown in the exemplary embodiment of
Generally, tankless toilets are illustrated. The flush is powered by line pressure of the water source (e.g., municipal water line) or an auxiliary pump. However, certain aspects may be applied to a toilet with a tank formed separately from a pedestal and later coupled to the pedestal, or applied to a toilet in which the tank may be integrally formed with the pedestal as a one-piece design. In other words, the toilet may be a one-piece design, a two-piece design, or have any suitable configuration. The toilet disclosed herein may have a wide variety of skirted toilet configurations, and all such configurations are intended to be encompassed herein. The following description of various toilet features is therefore intended as illustration only of one possible embodiment, and it should be understood by those reviewing the present description that similar concepts or features may be included in various other embodiments.
It should be noted that the shapes and configurations of the tank, pedestal, seat assembly, and the internal components (including the trapway and other features) may vary from the embodiments shown and described herein, and that the embodiments disclosed herein are not intended as limitations. It should be noted that various components of the toilet may be made of vitreous china. It should be noted that various components of the toilet may be polymeric and/or over molded or otherwise fixed to the toilet.
At act S101, the robot 80 lowers a toilet engine guide 72 into a manufacturing support 70. As shown in
At act S103, the robot 80 aligns the frame members 103 with the manufacturing support 70. The frame members 103 may be rotatably connected to the toilet engine guide 72 such that the frame members 103 rotate with the frame members 103 contact the manufacturing support 70. As shown in
At act S105, the robot 80 installs at least one toilet engine component in the toilet engine guide 72. The toilet engine component may include a valve assembly including at least one valve for providing water to a rim channel and/or at least one valve for providing water to a sump jet.
As shown in
At act S107, the robot 80 installs at least one toilet engine component in the toilet engine guide 72. As shown in
At act S109, the robot 80 attaches a rim channel assembly 14 to at least one of the toilet bowl 16 or the frame members 103. As shown in
At act S111, the robot 80 attaches a toilet seat assembly 13 to at least one of the toilet bowl 16 or the frame members 103. As shown in
At act S113, the robot 80 removes the toilet 100 from the manufacturing support 70. The robot 80 may trip a mechanism to release the toilet 100 from the manufacturing support 70. In one example, the trip mechanism may be triggered by gravity such that lifting the toilet 100 causes the manufacturing support 70 to release the toilet 100.
In one option, the robot 80 installs the front lift plate 19 and the side lift plate 18 after removing the support structure 70. The robot 80 may turn the toilet 100 over (e.g., facing downward) then secure the front lift plate 19 and the side lift plate 18 using one or more fasteners. The front lift plate 19 and the side lift plate 18 may have various sizes (e.g., short, medium, or tall) in order to place the toilet 100 (e.g., seat 12) at a specific height. Various users may be comfortable at different sitting heights.
The robot 80 may also attach a foot lever (e.g., foot pedal 29) to the toilet 100. The foot lever may include protrusion that are aligned with opening on the frame 103. The foot lever may be held in place by tension.
The panels may couple to the toilet 100 in a variety of techniques. The panels may snap fit to the frame members 103. For example, the panels may each include one or more tapered beams that mate with an opening of the frame members 103. The panels may each include a cavity with a pull perimeter snap ridge that mates with a protrusion or snap-in mound of the frame members 103. The panels may be fastened to the frame members 103 using a screw or bolt. The panels may be secured to the frame using magnets (i.e., each panel may include one or more magnets that align with one or more magnets of the frame members 103). The robot 80 may press the panels into the toilet 100 in order to connect the panels to the frame members 103.
Alternatively, the panels may be attached and removed by the user. The user may press the panels to the toilet 100 in order to connect the panels to the frame members 103. The user may thread a fastener from the panels to the frame members 103.
The panels may be swapped out by the user. That is, the user may remove one set of panels and install another set of panels. The panels may be formed of plastic or metal. An example plastic may be acrylonitrile butadiene styrene. An example metal may be aluminum. The panels may be formed using a 3D printer. The panels may include decals or stickers. The panels may be printed on using ink, paint, toner, or another substance that is applied on the panels from a nozzle.
As shown in
The controller 301 may include various inputs or interfaces for receiving electrical signals. A first interface may be connected to a foot input (e.g., kick panel 20). A second interface may be connected to a manual input (e.g., local control 110). A third interface (e.g., communication interface 353) may be connected to a wireless input (e.g., Bluetooth or Wifi). The controller 301 is configured to generate a valve command in response to the foot input, the manual input, or the wireless input. In addition, a fourth interface may be connected to a sensor configured to detect presence of a user or motion of the user.
The components of the control system may communicate using bus 348. The control system may be connected to a workstation or another external device (e.g., control panel) and/or a database for receiving user inputs, system characteristics, and any of the values described herein.
Optionally, the control system may include an input device 355 and/or a sensing circuit 356 in communication with any of the sensors. The sensing circuit receives sensor measurements from sensors as described above. The sensors may detect the presence of the user) the identity of the user) or gestures from the user. The input device may include any of the user inputs such as buttons, touchscreen, a keyboard, a microphone for voice inputs, a camera for gesture inputs, and/or another mechanism.
Optionally, the control system may include a drive unit 340 for receiving and reading non-transitory computer media 341 having instructions 342. Additional, different, or fewer components may be included. The processor 300 is configured to perform instructions 342 stored in memory 352 for executing the algorithms described herein. A display 350 may be an indicator or other screen output device. The display 350 may be combined with the user input device 355.
At act S201, the controller 301 (e.g., processor 300) identifies a presence or absence of a command signal from a remote control 120. The remote control 120 may send a wireless signal to the controller 301. The wireless signal may be in response to a button depressed or voice command announced by the user. The wireless signal may be in response to a sensor included on the remote control 120. Other sensors may be used. The sensor may include any type of sensor configured to detect certain conditions and/or to provide functionality. Odor sensors, proximity sensors, and motion sensors are non-limiting examples of sensors that may be employed with the systems of this application. Proximity sensors may be employed to detect the presence of an object within a zone of detection without physical contact between the object and the sensor. Electric potential sensors, capacitance sensors, projected capacitance sensors, and infrared sensors (e.g., projected infrared sensors, passive infrared sensors) are non-limiting examples of proximity sensors that may be employed with the systems of this application. Motion sensors may be employed to detect motion (e.g., a change in position of an object relative to the objects surroundings).
At act S203, the controller 301 (e.g., processor 300) identifies a presence or absence of a command signal from a local hand control 110. The user may press in the hand control 110 to cause generation and transmission of the command signal to the controller 301. Alternatively, the local hand control 110 may include a touchscreen, touch sensor, capacitive sensor, electric potential sensors, optic sensors, radio-frequency (RF) sensors, sound sensors, magnetic sensors (e.g., magnetometers), vibration sensors, and/or infrared sensors (e.g., projected infrared sensors, passive infrared sensors).
At act S205, the controller 301 (e.g., processor 300) identifies a presence or absence of a command signal from a local foot control 29. The food pedal 29 may be connected to a pressure sensor that generates the command signal for the controller 301.
The controller 301 may process the command signal from the remote control 120, the command signal from the local hand control 110, and/or the command signal from the local foot control 29. For example, when signals are received from any two devices, the controller 301 selects one command signal to override the second and/or third other command signals. The controller 301 may rank the foot control 29 to override the remote controller 120. The controller 301 may rank the local hand control 110 to override the remote controller 120 and the foot control 29. Other ranking techniques may be used.
At act S207, the controller 301 (e.g., processor 300) determines a motor command for a motor coupled to the lid 10 in response to one or more of the command signals. The motor command for the motor may indicate a preset level for lifting the lid 10. The lid 10 may be lifted the command signal from the remote control 120, the command signal from the local hand control 110, or the command signal from the local foot control 29. In other words, any user inputs or detection may cause the lid 10 to open.
At act S209, the controller 301 (e.g., processor 300) determines a motor command for a motor coupled to the seat 12 in response to one or more of the command signals. The controller 301 may cause the seat 12 to be opened when a user input, rather than sensor data alone, is received at the controller 301. The user input may be a keypress at the remote control 120, a touch at the local hand control 110, or a kick at the local foot control 29. The motor command for the motor may indicate a preset level for lifting the seat 12.
Processor 300 may be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more programmable logic controllers (PLCs), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Processor 300 is configured to execute computer code or instructions stored in memory 352 or received from other computer readable media (e.g.) embedded flash memory) local hard disk storage) local ROM, network storage, a remote server, etc.). The processor 300 may be a single device or combinations of devices, such as associated with a network, distributed processing, or cloud computing.
Memory 352 may include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data and/or computer code for completing and/or facilitating the various processes described in the present disclosure. Memory 352 may include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects and/or computer instructions. Memory 352 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Memory 352 may be communicably connected to processor 300 via a processing circuit and may include computer code for executing (e.g., by processor 300) one or more processes described herein. For example, memory 298 may include graphics, web pages, HTML files, XML files, script code, shower configuration files, or other resources for use in generating graphical user interfaces for display and/or for use in interpreting user interface inputs to make command, control, or communication decisions.
In addition to ingress ports and egress ports, the communication interface 353 may include any operable connection. An operable connection may be one in which signals) physical communications) and/or logical communications may be sent and/or received. An operable connection may include a physical interface, an electrical interface, and/or a data interface. The communication interface 353 may be connected to a network. The network may include wired networks (e.g., Ethernet), wireless networks, or combinations thereof. The wireless network may be a cellular telephone network, an 802.11, 802.16, 802.20, or WiMax network, a Bluetooth pairing of devices, or a Bluetooth mesh network. Further, the network may be a public network, such as the Internet, a private network, such as an intranet, or combinations thereof, and may utilize a variety of networking protocols now available or later developed including, but not limited to TCP/IP based networking protocols.
While the computer-readable medium (e.g., memory 352) is shown to be a single medium, the term “computer-readable medium” includes a single medium or multiple media, such as a centralized or distributed database, and/or associated caches and servers that store one or more sets of instructions. The term “computer-readable medium” shall also include any medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a computer system to perform any one or more of the methods or operations disclosed herein.
In a particular non-limiting, exemplary embodiment, the computer-readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer-readable medium can be a random access memory or other volatile re-writable memory. Additionally) the computer-readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device to capture carrier wave signals such as a signal communicated over a transmission medium. A digital file attachment to an e-mail or other self-contained information archive or set of archives may be considered a distribution medium that is a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a computer-readable medium or a distribution medium and other equivalents and successor media, in which data or instructions may be stored. The computer-readable medium may be non-transitory, which includes all tangible computer-readable media.
In an alternative embodiment, dedicated hardware implementations, such as application specific integrated circuits, programmable logic arrays and other hardware devices, can be constructed to implement one or more of the methods described herein. Applications that may include the apparatus and systems of various embodiments can broadly include a variety of electronic and computer systems. One or more embodiments described herein may implement functions using two or more specific interconnected hardware modules or devices with related control and data signals that can be communicated between and through the modules, or as portions of an application-specific integrated circuit. Accordingly, the present system encompasses software, firmware, and hardware implementations.
The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
One or more embodiments of the disclosure may be referred to herein, individually and/or collectively) by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.
It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
Claims
1. A method of manufacturing a toilet, the method comprising:
- lowering a toilet engine guide in a manufacturing support;
- aligning a plurality of frame members with the manufacturing support;
- installing at least one toilet engine component in the toilet engine guide;
- coupling a toilet seat assembly to the toilet; and
- coupling a plurality of panels to the plurality of frame members.
2. The method of claim 1, wherein installing at least one toilet engine component in the toilet engine guide further comprises:
- installing a trapway in the toilet engine guide; and
- installing a toilet bowl in the toilet engine guide.
3. The method of claim 1, further comprising:
- mounting a rim channel assembly on the toilet.
4. The method of claim 1, further comprising:
- removing the toilet from the manufacturing support.
5. The method of claim 1, further comprising:
- coupling a lid panel to toilet seat assembly.
6. The method of claim 1, further comprising:
- attaching a foot lever to the toilet.
7. The method of claim 1, wherein the toilet seat assembly includes a push button.
8. The method of claim 7, wherein the push button is configured to move in a path along a line of an axis of a lid or a seat of the toilet seat assembly.
9. The method of claim 7, wherein the push button includes a partial flush position and a full flush position.
10. The method of claim 1, wherein the toilet seat assembly is operable to open at a first angle based on a first lock position and a second angle based on a second lock position.
11. The method of claim 2, wherein at least one of the plurality of frame members is rotatably coupled to the toilet engine guided and rotates in response aligning the plurality of frame members with the manufacturing support.
12. An apparatus for raising and lowering a toilet seat and a toilet lid, the apparatus comprising:
- a hooking member coupled to the toilet lid and configured to rotate with the toilet lid;
- a release mechanism coupled to the toilet seat and configured to rotate with the toilet seat; and
- a lock configured to actuate in response to the hooking member of the toilet lid to engage or disengage the release mechanism of the toilet seat.
13. The apparatus of claim 12, wherein the hooking member includes a park engageable with the lock.
14. The apparatus of claim 12, wherein a guide surface of the lock corresponds to a first angle of the toilet lid at a first position of the lock and a second angle of the toilet lid at a second position of the lock.
15. The apparatus of claim 12, wherein the lock is disengaged in response to opening the toilet seat.
16. The apparatus of claim 12, wherein closing the toilet seat resets the lock.
17. A controller for a toilet, the controller comprising:
- a first interface connected to a foot input;
- a second interface connect to a manual input;
- a third interface connected to a wireless input; and
- a controller configured to generate a valve command in response to the foot input, the manual input, or the wireless input.
18. The controller of claim 17, further comprising:
- a fourth interface connected to a sensor configured to detect presence of a user or motion of the user.
19. The controller of claim 17, wherein the foot input, the manual input, or the wireless input indicates a volume of water.
20. The controller of claim 17, wherein the foot input, the manual input, or the wireless input indicates a partial flush.
Type: Application
Filed: Mar 6, 2024
Publication Date: Sep 19, 2024
Inventors: Karger David Kohler (Kohler, WI), Hiroyuki Muraoka (Milwaukee, WI), Tony L. Lambert (Sheboygan, WI), Ryan Grotegut (Sheboygan, WI)
Application Number: 18/597,663