Gruber Systems, Inc.

Ronald F Hayes

Louis A Garasi

A toilet base containing substantially no ceramic material includes a one-piece plastic bowl with a smooth interior surface and a plastic trap that are mounted within a cast thermoset plastic containing a major amount by weight of one or more fillers such as calcium carbonate, alumina, glass frit and mixtures thereof.

Cast toilet base structure

A toilet base containing substantially no ceramic material includes a one-piece plastic bowl with a smooth interior surface and a plastic trap that are mounted within a cast theromset plastic containing a major amount by weight of one or more fillers such as calcium carbonate, alumina, glass frit and mixtures thereof.

Method for making a cast toilet base of plastics material

The invention is a molding process adapted for the production of plumbing fixtures, such as a toilet whose functional surfaces are resistant to erosion by moving water wherein a ceramic shell forms a liner having external surfaces and the functional surfaces of the plumbing fixture. In the case of the toilet the ceramic shell includes a bowl, a siphon trap and a water flush ring. The molding process includes the steps of coating the external surfaces of the ceramic shell with a layer of resilient material and then suspending the ceramic shell upside down within a female mold member having internal surfaces so that the internal surfaces of the female mold member are slightly spaced from the external surfaces of the ceramic shell thereby leaving a gap between the internal surfaces of the female mold member and the external surfaces of the ceramic shell. The molding process also includes the steps of filling the gap with a catalyzed polyester resin matrix mixed with a filler and pigments and permitting the matrix to bond and to cure to the coated external surfaces of the ceramic shell. The molding process further includes the step of removing the female mold member thereby producing a plumbing fixture, such as a toilet, that has an attractive exterior appearance which matches other plumbing fixtures to be used in the same room in both their color texture and their design.

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Northridge, CA, United States of America

Ronald F Hayes