Method and device for producing a toilet seat set

Abstract

Toilet seat manufacturing process with the steps: - digital recording of a body contour and / or other physical parameters of a user (24), - Converting the acquired data into at least one CAD data set, - Saving the CAD data set in a data storage, - Controlling a production unit for producing a toilet seat (2) or a toilet lid (4) depending on the CAD data set or selecting a toilet seat (2) or toilet lid (4) from a group of toilet seats (2) / toilet lids (4) depending on the CAD data set.

Description

The invention relates to a device and a method for producing a toilet seat assembly, in particular a toilet seat.Different WC seat trim models are usually provided by the manufacturers, which differ in terms of design and also in terms of technology, for example with or without a take-off function. The basic design of such toilet seat sets is explained, for example, in the applicant's basic patent EP 1 199 020 B1. Accordingly, the toilet seat assemblies have a toilet seat and a toilet lid which are connected together by means of a toilet seat hinge arrangement and are fastened to a ceramic. This seat hinge arrangement can be designed with a damping function, by means of which the lowering of the toilet seat and the toilet cover from the open position to the ceramic is damped. Solutions are also known in which the opening and closing are assisted by a motor.DE 10 2008 052 206 A1, which is likewise based on the applicant, describes a method which makes it possible to select a WC seat assembly from a multiplicity of available WC seat assemblies by image acquisition of the ceramic, said WC seat assembly being optimally matched to the design of the ceramic, with the result that, after following this specification, a unit which is optimized with regard to the design and the function and consists of the ceramic and the suitable WC seat assembly is available.Further prior art is WO 2008 / 002 397 A2 and CN 1 712 198 A.However, it remains problematic that due to the different physical contours that come into contact with the toilet seat during use, optimal seating comfort for different users is not always ensured.In contrast, the object of the invention is to provide a toilet seat production method and an apparatus for carrying out the method, which enable the production of a toilet seat with improved seating comfort.This object is achieved with respect to the production method by the combination of features of claim 1, with respect to the apparatus by the combination of features of the subordinate claim 9.Advantageous further developments of the invention are the subject matter of the dependent claims.The inventive toilet seat assembly production method, hereinafter referred to merely as production method, proposes first digitally detecting the body contour coming into contact with the toilet seat, in particular the buttocks contour, and optionally also inputting or additionally detecting other parameters relevant to the seat comfort, such as the weight of the user, and converting the corresponding data into CAD data via an evaluation unit and storing them. The production of the actual toilet seat assembly, in particular the toilet seat, then takes place as a function of the present CAD data. By using these individual CAD data, the WC seat can then be optimally adapted to the user, so that the seating comfort is significantly improved compared to conventional solutions.In the case that the toilet seat assembly is used by a plurality of users, the corresponding data of these users can be recorded / stored and a CAD data record can be determined therefrom, which is adapted to the user group with regard to the seating comfort.Alternatively, it is also possible to select suitable WC seat sets from a group of available WC seat sets as a function of these data.Such a procedure differs in principle from the usual procedure in which the selection of the toilet seat assembly was effected substantially according to design considerations and according to the available ceramic. An adaptation to individual data of the user is without a preview.In a preferred exemplary embodiment of the invention, the production of the toilet seat assembly, preferably of the toilet seat, takes place as a function of the CAD data provided by a primary forming method, a forming method or a subtractive manufacturing method. Accordingly, the production can be effected, for example, by a generative method, such as, for example, 3D printing, or by pressing, injection molding or by a chip-removing production method.The production and the data processing are particularly simple if CAD data of a blank of the WC seat or of the WC seat assembly are provided, which blank is superimposed with the acquired / entered CAD data in order to modify the blank in accordance with the individual CAD data. In this procedure, certain basic data are thus present, which are then overlaid with the CAD data, so that the computing power of the evaluation unit and the manufacturing effort are reduced compared to solutions in which the entire seat contour is always calculated and formed individually.Of course, the WC cover can also be designed individually in a corresponding manner. In principle, however, the treatment of the toilet seat should be of primary importance.During the specific production of the toilet seat assembly or the blank to be machined, other functional elements, such as a seat heater, sensors, etc., can also be positioned as a function of the CAD data. In principle, such functional elements can already be integrated into the blank, wherein the CAD data are then adapted with regard to the positioning of the seat heater and / or sensors or other functional elements, such as a mechanical drive.The method is particularly simple to carry out if the digital capture is carried out by a 3D scanner. Since the measurement tolerances for detecting the body contour are at most in the tenth millimeter range, comparatively cost-effective scanners can be used.In a variant of the invention, it is proposed to also include the soft mass portion of the user in the CAD data.According to the invention, it is preferred if the toilet seat assembly, in particular the toilet seat and / or the toilet cover, is made of urea.Accordingly, the device according to the invention for carrying out the method has a device for detecting and / or inputting physical parameters of a user and an evaluation unit for converting these parameters into CAD data. The apparatus further has a storage means for this CAD data. These are available to a control unit, via which a production unit can be controlled in order to produce the components of the toilet seat assembly as a function of the stored CAD data of the user.As mentioned at the beginning, it is particularly preferred if the means for detecting is a 3D scanner.The production unit can be a 3D printer, a pressing machine, an injection molding machine or a machine tool for machining. Mixed forms of such machining units are also possible. It is thus conceivable, for example, to produce the blank (basic shape) by pressing and then to carry out the individual machining by machining or by a generative method.As explained at the beginning, the production method and the device according to the invention provide a toilet seat assembly which is individually matched to a user or a user group.In principle, it is also possible to take ceramic-side parameters into account when generating the CAD data, so that the individual WC seat assembly is optimized both on the user side and on the ceramic side.The individual physical parameters can be recorded, for example, in service centers or at dealers who have such 3D scanners. On site, the corresponding CAD data are then generated and then forwarded to a central manufacturing facility, which takes over the individual manufacturing of the toilet seat assembly and then delivers it to the customer after completion.Preferred exemplary embodiments of the invention are explained in more detail below with reference to schematic drawings. The following are shown: FIG. 1 is a three-dimensional view of a toilet seat assembly manufactured according to the invention; FIG. 2 is a block diagram illustrating a method sequence according to the invention; FIGS. 3, 4 are schematic diagrams of a scanning process according to the block diagram in FIG. 2; and FIGS. 5, 6 are sectional views along the section line A-A in FIG. 1 to illustrate the processing of a blank according to the block diagram in FIG. 2.FIG. 1 shows a three-dimensional representation of a toilet seat assembly 1 produced according to the invention, which is designed in a manner known per se with a toilet seat 2 and a toilet cover 4-hereinafter simply referred to as seat, cover. These are pivotably connected to one another via seat joints 6, 8, indicated by dot-dash lines, and can be fixed on pins, not shown, fastened to a ceramic 12. The connection to these pins is preferably designed such that the toilet seat assembly 1 with a take-off function can be easily placed on and removed without using special tools or the like.In the exemplary embodiment shown, the user-side surface of the seat 2 is designed in accordance with the body contour of the user. This is effected, for example, in such a way that a slightly rounded seat surface 14 and adjoining rounded side walls 16, 18 are formed at least in those regions which come into direct contact with the user, corresponding to the body contour, preferably the buttocks / thigh contour of the user. Additionally, the width b of the seat bottom 14 or the width B or the entire geometry of the seat ring may be adjusted depending on the individual data to improve seat comfort. In principle, it is also possible to adapt the geometry of the seat ring along the circumference, so that the aforementioned dimensions, for example the width b, B, vary depending on the individual data. Profiling of the seat 2 in the circumferential direction of the seat ring (see dot-dash line 20) for adaptation to the buttocks / thigh contour is also possible. In simplified terms, the entire geometry of the seat 2 can be shaped individually depending on the physical parameters of the user. This will be explained below with reference to FIGS. 2 to 6.In a simple embodiment, a standard cover is assigned to this individual seat contour. Of course, the geometry of the cover 4 can also be individually adapted depending on the user data, in order to also form an optimum fit with respect to the seat 2.The production method according to the invention is explained with reference to the block diagram according to FIG. 2.In a first method step, for example, physical, person-related parameters are input, which on the one hand facilitate the assignment and on the other hand relate, for example, to parameters that cannot be detected via a scanning process, such as the user weight, the user age, etc. In this case, for example, the soft mass content of the user can also be detected in the body regions coming into contact with the toilet seat. This soft mass can contain the body fat content and optionally also the muscle mass in this region. As indicated in FIG. 2, this is an optional possibility.However, part of the method according to the invention is to record the relevant body contour, i.e. the buttocks and / or thigh contour, by means of a suitable method. This is preferably effected by a scanning process by means of a 3D scanner 22, as is indicated in FIGS. 3 and 4. These are conventional scanners 22, which are comparatively inexpensive and allow body contours to be detected with an accuracy of one tenth of a millimeter. Such 3D scanners 22 operate, for example, according to the runtime or triangulation principle and frequently use a laser as the light source. So-called 3D strip light scanners are also known, in which one or more parallel lines are projected onto the object and the line profile is then evaluated accordingly. In low cost systems, the scanner 22 is manually guided to allow full scanning. With higher requirements, the scanners 22 are guided over NC axes or by a robot in order to ensure an exact 3D measurement.In principle, 3D scanners 22 can also be used in which the contour is traversed by direct contact via a mechanical sensor.As indicated in FIG. 3, the region of a standing user 24 coming into contact with the seat 2 can be scanned and measured by a suitable scanner 22. According to FIG. 4, however, the user 24 can also be seated, so that a more accurate measurement of the body contour contacted with the seat 2 is made possible. Of course, a 3D measurement is also possible with a person lying in an abolescent fashion. In principle, the scanner 22 can be integrated into a corresponding light-transmissive seat contour that simulates a seat 2, so that measurement in the proper use is made possible. It is entirely sufficient if the user 24 only wears thin clothing that is as close as possible to the body.The point cloud resulting from such a measurement is then converted via a suitable evaluation unit into CAD data which are used in the shaping of an individual seat 2 or cover 4 described below. These CAD data sets, which make CAM production possible, can of course also include the other physical parameters mentioned above, such as the weight or the age of the user 24.It is also possible to record the physical parameters of a plurality of users and then convert them via the evaluation unit into a CAD data record which enables the production of a seat 2 / cover 4 which has a fit matching the group of people. These CAD data sets are transferred via suitable interfaces, for example an STL interface or the like. In order to be able to process further information in addition to the geometry, data formats such as, for example, the VRML, OBJ or AMF format can be used in such 3D shaping methods. Of course, other file formats can also be used.In principle, the geometry data of the blank 26 can also be stored as CAD blank data in the evaluation unit, so that, starting from these predefined blank data, only the individual geometry data for creating the CAD data sets have to be calculated-in this way the computational effort can be significantly reduced compared to conventional solutions.In particular, the data recorded via inexpensive scanners 22 can be evaluated using conventional tablets or laptops, so that the outlay on apparatus for an evaluation unit of this type is minimal.The CAD data sets resulting from the evaluation of the point clouds are then stored and can be loaded for processing via a control unit of a production unit in order to actuate the latter.As explained at the beginning, the production can be carried out by a primary forming, forming or subtractive method; machining is particularly preferred by a generative method (3D printing), by pressing, injection molding and / or by a machining method.The method is particularly effective if, according to FIG. 5, a blank 26 is provided which has a larger volume than the individually manufactured seat 2, so that, for example, by machining, the individual shaping of the seat 2 can take place as a function of the CAD data. This blank 26 is indicated in dash-dot lines in FIG. 5. Reference numeral 28 denotes a buffer with which the finished seat 2 rests on the ceramic 12. This buffer 28 is naturally applied to the underside of the seat 2 only after shaping. As indicated by dot-dash lines in FIG. 5, the ceramic-side region and thus the entire profile of the seat 2 can also be shaped as a function of the individual data of the user 24, so that, for example, a greater wall thickness is realized in persons of heavy weight than in persons of lower weight, wherein the respective wall thicknesses transverse to the support surface can then also be adapted to the respective individual requirements.FIG. 6 shows an exemplary embodiment in which the blank 26 merely forms a core, onto which material is then applied for forming the individual geometry, for example by pressing, injection molding or by 3D pressure (generative method). Such a solution makes it possible, for example, to apply an indicated heater 30 (and / or sensors) to the core 26 (blank) and then to cover it with the material by injection molding, pressing or 3D printing. The material of the blank 26 can be selected with regard to optimizing the strength and the outer material can be selected with regard to seating comfort, wear resistance and / or the appearance.The seat 2 and the associated cover 4 configured in this way are then provided with the seat joints 6, 8 mentioned at the beginning in a finished assembly and optionally polished again and can then be associated with the provided user 24 via the stored data. This assignment can be facilitated by an identifier provided on the seat assembly 1, which, for example, makes it possible to request a replacement part at the manufacturer in the event of damage to the seat 2.As explained at the beginning, it is in principle also possible to provide a plurality of individually modified variants of a model of a toilet seat assembly 1, so that the most appropriate one can then be selected from the plurality of variants by means of the 3D acquisition of the user contour(s). Accordingly, it is also possible to keep a plurality of blanks 26 ready for each model, wherein the blank 26 on which the production is based is then selected from the multiplicity of variants.Disclosed are a method and a device for producing a toilet seat assembly 1, in particular a toilet seat 2, the geometry of which is formed as a function of individually acquired user data. Furthermore, a WC seat 2 produced by such a method or by such a device is disclosed.List of reference numbers:1 WC seat assembly 2 WC seat 4 WC cover 6 seat joint 8 seat joint 12 ceramic 14 seat surface 16 side wall 18 side wall 20 profiling in the longitudinal / circumferential direction 22 scanner 24 user 26 blank 28 buffer 30 heating / sensor

Claims

WC seat assembly production method with the steps: - digital acquisition of a body contour and / or other physical parameters of a user (24), - conversion of the acquired data into at least one CAD data record, - storage of the CAD data record in a data memory, - control of a production unit for producing a WC seat (2) or a WC cover (4) depending on the CAD data record or selection of a WC seat (2) or WC cover (4) from a group of WC seats (2) / WC covers (4) depending on the CAD data record.Production method according to claim 1, wherein machining of the WC seat (2) or the WC cover (4) corresponding to the body contour takes place as a function of the CAD data set by a primary forming method, a forming method and / or a machining method.Production method according to claim 1 or 2, comprising a blank (26), the blank data of which are overlaid with the acquired data.Production method according to one of the preceding patent claims, wherein during production a seat heater (30) and / or sensors are positioned, the position of which is taken into account in the creation of the CAD data set.Production method according to one of the preceding patent claims, wherein the digital detection is carried out by 3D scanning.Production method according to one of the preceding patent claims, wherein the toilet seat assembly (1) is produced substantially from urea.Production method according to one of the preceding patent claims, wherein ceramic-side data are also taken into account in the generation of the CAD data set.Production method according to one of the preceding patent claims, wherein the CAD data record also includes the soft mass of the user (24).Device for carrying out the method according to one of the preceding patent claims, having a device for detecting physical parameters of a user (24), an evaluation unit for converting the detected data into at least one CAD data record, a data memory for the CAD data record, a control unit for controlling a production unit as a function of the CAD data record and a production unit for producing a WC seat (2) and / or a WC cover (4) as a function of the CAD data record.The apparatus of claim 9, wherein the means for detecting the physical parameters is a 3D scanner (22).The apparatus of claim 9 or 10, wherein the manufacturing unit is a 3D printer, a press machine, an injection molding machine, or a machine for machining.

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