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US 11,603,650 B2Granted
Plumbing fixtures with insert-molded components
AssigneeKohler Co.
InventorsMark Schibur, Jeremiah Rauwerdink
Life of this patent
Estimating the term…
Abstract
A plumbing fixture includes an electrical component insert-molded within a portion of the plumbing fixture, the portion formed from an epoxy. The electrical component is offset from and disposed below an outer surface of the plumbing fixture.
Claims20
A toilet comprising:
- a base structure comprising:
- a bowl;
- a sump at a lower portion of the bowl;
- and
- a trapway extending from the sump;
- a toilet shell having an inner surface and an outer surface configured to conceal at least a portion of the base structure;
- and
- at least one electrical component insert-molded within a portion of the toilet shell, the portion formed from an epoxy, wherein the electrical component is offset from and disposed below the outer surface of the toilet shell, wherein the at least one electrical component includes a sensor for the toilet insert-molded within the portion of the toilet shell.
5 more elements
A method of manufacturing a toilet, the method comprising:
- attaching an electric component to a base structure of the toilet, the base structure having a bowl, a sump at a lower portion of the bowl, and a trapway extending from the sump;
- placing the base structure into a first mold, the first mold defining a first shape for the desired outer shape of a toilet shell;
- injecting a first polymeric material into the first mold, the first polymeric material surrounding the base structure and the electric component;
- removing the base structure from the first mold;
- placing the base structure into a second mold, the second mold defining a second shape that is the same as the desired outer shape of the toilet;
- and
- injecting a second polymeric material into the second mold forming a second polymeric layer.
4 more elements
A method of manufacturing a toilet, the method comprising:
- placing a base structure into a first mold, the first mold defining a first shape for a toilet shell, the first mold having a portion extending toward the base structure, the portion creating a void during injection molding, and the base structure having a bowl, a sump at a lower portion of the bowl, and a trapway extending from the sump;
- injecting a first polymeric material into the first mold, the first polymeric material surrounding the base structure and the portion of the first mold forming a first polymeric layer;
- removing the base structure from the first mold;
- inserting an electrical component in the void formed in the first polymeric layer by a male portion of the first mold;
- placing the base structure into a second mold, the second mold defining a second shape that is the same as the desired outer shape of the shell;
- and
- injecting a second polymeric material into the second mold, forming a second polymeric layer.
4 more elements
Dependencies are inferred from the claim text.