Manufacturing method for toilet seat

Abstract

The invention relates to the manufacture of a toilet seat by introducing a seat heating part (2) into a first mould formed by two mould parts (1 and 3), filling the mould with a flowable material and hardening the material in order to manufacture the seat heating part and a composite of the material in the mould.

Description

TECHNICAL FIELD

[0001] The invention relates to the manufacture of a toilet seat and, in addition thereto, also to the manufacture of a toilet seat set with a toilet lid and a toilet equipped with the toilet lid. BACKGROUND

[0002] A flush toilet (WC) usually has a toilet body with a bowl and a device for its flushing and a toilet seat fitted on the toilet body. One end of the toilet seat is usually hinged and thus fitted on the toilet body in a way that it can be turned over, and is usually also additionally provided with a toilet lid. The toilet seat serves for the user to sit on the bowl during use, and accordingly there is an opening above the bowl (where the opening does not necessarily have to be closed around it), while the toilet lid is supposed to cover the top of the bowl and thus usually lies above the toilet seat and is usually also provided in a way that it can be turned over. The set consisting of the toilet lid and the toilet seat fixed to each other, which is provided for fitting on the toilet body, is also called a toilet set.

[0003] In recent years, toilets with further technical functions have increasingly appeared, for example for cleaning the bowl cavity after use or for deodorization, and secondly also for heating the toilet seat. They work by means of electric resistance heating, or, less commonly, by means of heating a heating layer in the toilet seat by induction. In both cases the seat heating is integrated in the toilet seat, i.e. an electric heating resistor or an inductive heating layer, wherein outside the toilet seat further functional elements for the supply, control, in particular regulation, or as an inductive source can of course be provided.

[0004] In practice, the problem is raised in particular how to integrate the seat heating, i.e. the mentioned heating resistor or inductive heating layer, in the toilet seat during the manufacture of the toilet seat. If the toilet seat is usually composed of several housing parts, for example a lower half-shell and an upper half-shell and a filling between them, the seat heating can be placed between these housing parts. SUMMARY

[0005] The problem addressed by the invention is to provide a manufacturing method for a heatable toilet seat.

[0006] The problem is solved according to the invention by the manufacturing method according to claim 1. However, the invention secondly also relates to the corresponding manufacture of a toilet seat set according to claim 10 and a toilet according to claim 11.

[0007] According to the invention, the seat heating element is introduced into a mold ("first" mold) provided for manufacturing at least a portion of the toilet seat before the material for manufacturing is introduced into the mold. The material is introduced into at least one side of the seat heating element in a flowable state and is hardened in the mold. In the mold, contact is initially made between the still flowable material and the seat heating element, so that an adhesive bond with good adhesion can be formed therebetween. It is particularly preferred that the flowable material wet the seat heating element over a large area, for example, substantially over the entire side (both sides of the seat heating element in total). This is particularly true when the seat heating element has a planar shape.

[0008] Of course, other method steps can also be carried out, but these are not absolutely necessary. This will also be discussed in more detail later.

[0009] The seat heating element to be introduced into the mold has a preferably planar design, at least to the extent that it can be held on a carrier film (in this respect, the carrier film is therefore approximately considered to be part of the seat heating element). For example, it can be a wire structure (Drahtstrukturen) or conductor track (Leiterbahnen) which is adhesively, printed or otherwise fixed on a plastic film. The seat heating element can be defined and etched on the carrier film, for example, also in a photolithographic manner.

[0010] Furthermore, the seat heating element itself can have a more planar layer structure than the conductor tracks or wire structures, since it consists of an electrically conductive polymer, an electrically conductive carbon layer or similar. However, a metal wire or conductor track structure on a plastic film, in particular an ABS film, is preferred.

[0011] Preferably, the carrier film remains in the first mold and thus becomes part of the composite. The carrier film can thus contribute to the flowable material being applied planarly to one side of the seat heating element, but for example not to the other side. Furthermore, the carrier film simplifies handling of the seat heating element before and during insertion into the mold.

[0012] According to a further design, the electric heating conductor of the seat heating element is arranged on the lower side of the carrier film with respect to the final assembly position of the toilet seat. "Lower side" here thus does not refer to the situation during manufacture, but rather to the situation when the toilet seat is assembled to the toilet body (in the downwardly turned state). The carrier film can thus be used for electrical insulation, for example. For example, the carrier film can form the final seat surface, or it is subsequently only covered with a layer which is not sufficient for electrical insulation.

[0013] Alternatively, or otherwise, the carrier film can prevent the structure of the heating conductor from being exposed on the final seat surface, for example, because they cannot be sufficiently flattened or embedded in subsequent coating processes. However, during the aforementioned manufacturing process, flowable material that can be introduced into the first mold can flow around the structure of the electrically heated conductor with a certain thickness and integrate these structures into itself.

[0014] The flowable material introduced into the first mold is deformed by pressure, for example, in injection molding, which can cause the seat heating element (particularly including the carrier film) to be slightly or completely pressed against the tool wall. Here, for example, a generally flat and flat shape can be transformed into a curved shape, and / or the seat heating element can be deformed to approach the mold wall and / or approach the future upper surface of the toilet seat. If heat is applied in this case, for example in injection molding, this can certainly simplify the deformation of the seat heating element, especially the carrier film. In such applications, the seat heating element does not need to be pre-fixed in the final desired position, but can be pre-fixed in a temporary position, and then moved from that temporary position to the final position as described above, particularly in areas not directly affected by pre-fixation, see the embodiments.

[0015] For example, a portion of the seat ring heating element or carrier film can be secured by clamping between two parts of the first mold, for example by contacting contact points on the seat ring heating element with pins, thus ensuring subsequent contact with these contact points. Alternatively or additionally, the seat ring heating element or carrier film can also be pre-secured by a vacuum device, preferably located on the side where the seat ring heating element subsequently deforms. In a preferred design (see below), this side is later coated so that any trace of the vacuum channel is inconspicuous.

[0016] The location closer to the upper surface improves the energy efficiency of the seat heating unit in terms of desired surface temperature and energy consumption, and also improves the response behavior after activation.

[0017] It is not necessarily necessary to traverse a large distance here; advantageously, for example, the seat heating part with a carrier film is pressed and thus adheres to the desired outer surface of the first mold in a defined manner, which cannot be reliably ensured by simply inserting it into the mold (positioned in two other spatial directions if necessary).

[0018] The generally accepted description to date is that filling the first mold with a flowable material and the hardened material can correspond to different techniques, particularly injection molding, which is currently preferred and involves the introduction of thermoplastic materials and materials that liquefy by heating. However, methods using thermosetting materials, such as those called pressing or casting, can also be considered.

[0019] For example, compared to compression molding, injection molding with thermoplastic materials can produce more precise and refined molds, and the manufacturing process is faster. In particular, it requires little or no finishing (e.g., at the parting line), where finishing is disadvantageous, not only labor-intensive but also inevitably causing surface damage. However, injection molding requires relatively expensive tools and machinery.

[0020] The preferred thermoplastic material is ASA. This material has a particularly significant chemical similarity to the aforementioned preferred carrier film material, ABS, thus achieving excellent adhesion and stable bonding between the two materials. If the seat heating element itself (whether it is in the form of a conductor circuit, wire, or sheet) does not impede this contact (whether through its penetration or by its arrangement on the other side), the adhesion between the material of the heating conductor itself (or the sensing layer) and the introduced flowable material may be less important or not important at all in this case.

[0021] If the carrier film is located outside the seat heating element relative to the manufactured toilet seat, in a particularly simple design, the carrier film can form the surface of the manufactured toilet seat. However, it is preferable to subsequently coat it, more precisely, preferably by applying another flowable material in a "second" mold. The second mold discussed here is conceptually different from the molds mentioned so far (hence the term "first mold"). This second mold is preferably attached to the seat heating element or carrier film on the opposite side relative to the material introduced in the first mold, wherein this need not be performed simultaneously with the process in the first mold, and the second mold, especially generally, can only be formed after the material introduced into the first mold has hardened.

[0022] The second mold is preferably (also) closed, but an open mold can also be used in principle, for example, for pouring flowable materials. The second mold can also represent a second injection molding step. However, it is preferred not to use thermoplastic materials here, but rather to use materials that have been hardened by a chemical process to pour the seat heating part in the second mold.

[0023] Compared to using a carrier film as the seat surface or injection molding, Überfluten offers several potential advantages. For example, certain materials that are less suitable for use as films but particularly well-suited for toilet seat surfaces can be used for Überfluten. According to the invention, polyurea is preferred due to its long-term stability and resistance to discoloration (e.g., due to textile dyes, stains, etc.). However, polyurethane is also a good option and is equally preferred. In principle, compared to using a carrier film as the surface, Überfluten can significantly improve the transition of the Überfluten material to other materials (especially injection-molded materials) and avoid problems caused by film edges. The aforementioned materials are two-component materials (possibly also containing dyes), which can be hardened in a second mold.

[0024] The thickness of the infusion material (i.e., perpendicular to the surface) is preferably no more than 2 mm, particularly preferably no more than 1.8 mm, 1.6 mm, 1.4 mm, 1.2 mm, or even no more than 1 mm. On the other hand, the lower limit of the material thickness is preferably 0.2 mm, 0.3 mm, 0.4 mm, and finally 0.5 mm.

[0025] To feed material into the second mold, flowable material can be guided through an inflow channel located laterally relative to the manufactured toilet seat in its flipped-down assembled state and relative to the cross-section passing through the seat ring (here transverse to the direction of extension of the toilet seat, i.e., the smallest cross-section), preferably at one end of the filling area, such as the lower edge. This location is particularly preferred to be at the front or rear, i.e., at the front or rear relative to the toilet seat's usual central plane of symmetry in that plane. In embodiments, this applies to the rearmost portion of the seat ring. At this location, any marks are particularly inconspicuous. The same applies to advantageous overflow channels during filling; see embodiments.

[0026] The inflow channel for the first mold can be implemented on the lower side (at a position that is flipped downwards relative to the assembly of the toilet seat). This position is not very conspicuous.

[0027] In principle, the first and second molds can be completely different, in which case the composite material removed from the first mold must be placed into the second mold. However, it is preferable that the two molds share a single mold component, more specifically, a mold component adjacent to the material filled in the first mold. The mold component on the other side is then moved or replaced, thereby creating a cavity for injection that was not previously present.

[0028] According to the present invention, a toilet seat manufactured in the described manner can be connected to a toilet lid. The toilet lid can also be manufactured, for example, by injection molding. Typically, the two components are hinged together, in which a rotational damper can be used. This constitutes a toilet seat kit.

[0029] In addition, toilets can be manufactured using the toilet seat ring according to the invention, either by mounting the toilet seat ring itself onto the toilet body (the toilet seat can also be mounted on the toilet body independently of the toilet seat ring), or by placing the aforementioned toilet seat ring kit onto the toilet body.

[0030] Of course, the seat heating element can be controlled and / or powered by the toilet body or a housing structure mounted on the toilet body, wherein wire connections (conventional electrical contact) are acceptable, as are "wireless" technologies, such as inductive "wireless" technologies. The control element can also be partially housed within the toilet seat, and partially housed in the manner described. Furthermore, the toilet seat can of course also have a battery, particularly a rechargeable battery, a capacitor, or a similar device to store electrical energy. Attached Figure Description

[0031] The present invention will now be described in more detail with the aid of embodiments, wherein the various features within the scope of the claims may also be necessary for the present invention in other combinations, and there is no detailed distinction between different categories of claims.

[0032] Figures 1 to 7 The manufacture of the toilet seat according to the invention is illustrated in schematic cross-sectional views, and more precisely, the manufacture of the toilet seat according to the invention is illustrated in chronological order.

[0033] Figure 8 A top view of a toilet seat produced as a result of this manufacturing method is shown. Detailed Implementation

[0034] exist Figure 1 In the diagram, 1 represents the mold component of the injection molding machine, wherein the seat ring heating unit 2 is inserted into the mold component, and more specifically, into the hollow mold constructed within the mold component. This insertion can be done manually, but it can also be done mechanically, for example, using a vacuum device on a robotic arm.

[0035] The seat heating element 2 is specifically composed of a plastic film, i.e., ABS. This plastic film... Figure 1 The right side of the image has a resistance heating element made of copper wire, which can be glued on, or it can be constructed by photolithography, for example, from a layer pre-deposited planarly on an ABS film.

[0036] Seat ring heating part 2 is shown in the diagram Figure 1 The invisible part protrudes slightly from the hollow mold below, so as to... Figure 2 In the next step shown, clamp it there. Figure 2 As can be seen, the second mold component 3 is placed from the right side.Figure 1 The first injection mold 1 and 3 are defined on the mold component 1, which is already visible in the mold. The second mold component 3 is included in the mold component 3. Figure 2 The visible inflow channel is for the heated thermoplastic material, i.e., ASA, to allow injection molding of the rear of the seat ring heating section 2. This is achieved by joining the two mold components 1 and 3. Figure 1 The seat heating element 2, whose lower edge has been slightly pre-fixed, is clamped between and held between the two mold components 1 and 3 in a manner not shown. Furthermore, the seat heating element 2 has a shape that roughly matches the inner wall of the mold component 1, but is not completely positionally defined.

[0037] Alternatively, the seat heating element 2 can, for example, be in Figure 1 and 2 The lower region of the ring or other locations on its left side are pre-fixed by a vacuum device. If the outlet of the vacuum channel is not too large, the presence of the carrier film of the seat ring heating part 2 will not interfere with the injection molding process.

[0038] By introducing flowable ASA into the first injection molds 1 and 3 (shown as components in Figure 2), the heated ASA is applied from the right side to the seat heating element 2 located on the left side of the first mold, gradually pressing the seat heating element 2 against the left outer wall of the first molds 1 and 3. Combined with the aforementioned clamping, this achieves positional fixation, where the injection material ensures that the seat heating element 2 is well-grounded against the outer wall of the first mold, thereby improving and ensuring positioning. Furthermore, the heated flowable ASA wraps around the copper conductors on the ABS carrier film of the seat heating element 2 and embeds them together with the carrier film. Finally, the injection material covers the entire right side of the seat heating element 2 (or the upper side for the lower part of the seat heating element 2), where the uppermost region of the approximately U-shaped first mold in the shown cross-section is not covered by the seat heating element 2.

[0039] Figure 3 The image shows the state of the first molds 1 and 3, which remain closed even when fully filled.

[0040] Figure 4 The diagram shows the state after the first mold is opened by moving mold component 1 away from mold component 3. In this state, the seat heating element 2 and the lower shell 5, which will be produced after the ASA curing of the future toilet seat, remain in their positions on the mold component 3. Subsequently, according to... Figure 5 The third mold component 6 is moved in from the left. This third mold component, together with the seat ring heating part 2 (if the lower shell 5 is no longer present), forms a cavity for injection. Hereinafter, the combination of the two mold components 3 and 6 will be referred to as the second mold, in which the previously formed lower shell 5 and its seat ring heating part 2 reduce and restrict the actual cavity for injection. This is achieved through...Figure 5 The inlet channel 7, symbolically shown at the bottom, introduces the polyurea (or polyurethane) into a flowable state until the second molds 3 and 6 are fully filled and the polyurea material flows out through the overflow channel (not shown) in the upper region.

[0041] exist Figure 6 In the middle, the second molds 3 and 6 were filled accordingly, and... Figure 5 The cavity is not yet filled. In contrast, we can also see that the cavity to be filled is relatively small, as it is formed with a small material thickness ranging from 0.5 to 1 mm.

[0042] After the polyurea material has cured due to the chemical reaction therein (i.e., after chemical hardening), the second molds 3 and 6 can be opened and the now-formed assembly can be removed. This assembly is a layered composite of the lower shell 5, the seat ring heating part 2 (i.e., the copper resistance heating part on the carrier film), and the polyurea infusion layer 8 on its top or left side.

[0043] Figure 8 A more realistic top-down view shows the finished product, where the inlet channel is indicated by the previously used reference numeral 7, but here it is located at the very back and rear of the toilet seat relative to the toilet user's position. 9 indicates three overflow channels located on the lower edge of the toilet seat at the user's position. 2 indicates the seat heating element. Undoubtedly, Figures 1 to 7 The U-shaped cross-sectional profile shown corresponds to the cross-section of a toilet seat, which is perpendicular to... Figure 8 The cross-sectional plane, and the positions of inlet channel 7 and overflow channel 9 are in Figures 1 to 7 It is a symbolic representation.

[0044] The polyurea material (or polyurethane) used for the actual surface application exhibits excellent properties in terms of appearance, durability, color fastness, and resistance to light, detergents, skin contact, and cosmetic chemicals. Meanwhile, the lower shell 5, made of injection-molded ASA, possesses excellent morphological stability and requires minimal or no post-processing. The seat heating element 2 is positioned at the top of the toilet seat, very close to the surface, thus facilitating energy-efficient and responsive operation with precise control or regulation. For example, energy savings are particularly advantageous when the seat heating element utilizes wireless power transmission. Furthermore, relatively low voltage can be used, which enhances safety or reduces or eliminates the need for safety measures.

[0045] Of course, during manufacturing, especially in the lower shell 5, other components, particularly electrical or electronic components, can be integrated, and the U-shaped cross-sectional shape can be consistent with... Figure 8 The shapes change in the same way in the top view.

[0046] This embodiment illustrates an advantageous combination of two manufacturing methods. Injection molding, performed in the first mold, is relatively fast and cost-effective for mass production. On the other hand, infusion molding in the second mold allows for the use of highly advantageous materials that, as a second component (with dyes added if necessary), cannot be injection molded but instead undergo chemical hardening on their own. Combined with injection molding, this results in superior surface quality and avoids adhesive or welded joints or other separation edges (e.g., when separately manufactured housings are joined). Infusion molding also avoids noticeable film edges on the edges of the seat heating element.

Claims

1. A method for manufacturing a toilet seat, comprising the following steps: - Provides seat ring heating element (2). - The seat ring heating part (2) is introduced into the first mold (1, 3). - Fill the first side of the seat ring heating part (2) in the first mold (1, 3) with a flowable material. - Harden the material to manufacture the composite of the seat heating part (2) and the hardened material in the first mold (1, 3).

2. The method according to claim 1, wherein, The seat heating part (2) on the carrier film is introduced into the first mold (1, 3), the carrier film is preferably made of ABS, and preferably the carrier film is then retained in the first mold (1, 3) and in the composite produced.

3. The method according to claim 2, wherein, The electric heating conductor of the seat ring heating part (2) is disposed on the lower side of the carrier film.

4. The method according to any one of the preceding claims, wherein, When the first mold (1, 3) is filled, the seat ring heating part (2) deforms due to the flowable material.

5. The method according to any one of the preceding claims, wherein, The material used to fill the first mold (1, 3) and harden the first mold (1, 3) corresponds to the injection molding process and the material is thermoplastic, preferably ASA.

6. The method according to claim 5, wherein the method comprises the following additional step: - After the material has hardened, the composite is poured into the second side of the seat ring heating part (2) in the second mold (3, 6), wherein, The second mold (3, 6) is preferably closed, in which a pouring material in a flowable state is used, and then hardened in the second mold (3, 6).

7. The method according to claim 6, wherein, An inflow channel (7) leading to the second mold (3, 6) and an overflow channel (9) of the second mold are used for the injection material. The channels (7, 9) are laterally inserted into the cavity of the second mold (3, 6) relative to the cross-section through the toilet seat, preferably located at one end of the injection area.

8. The method according to claim 6 or 7, wherein, A portion (3) of the second mold (3, 6) has been used as a part of the first mold (1, 3).

9. The method according to claim 5, optionally in combination with another claim from the preceding claims, wherein, The inflow channel (4) leading to the first mold (1, 3) is used for the inflow of thermoplastic material, and the inflow channel enters the cavity of the first mold (1, 3) on the lower side.

10. A method for manufacturing a toilet seat assembly, wherein, The toilet seat ring is manufactured and connected to the toilet lid according to any one of claims 1-9.

11. A method for manufacturing a toilet, wherein, A toilet seat is manufactured according to any one of claims 1-9, and the toilet seat is connected to a toilet body, wherein preferably a toilet kit is first manufactured according to claim 10, and then the toilet kit is connected to the toilet body.

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