Polyurethane Toilet Seat One-Time Molding for Strong Bonding
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Solution Overview
Problem
Traditional polyurethane toilet seats face issues such as poor bonding between the seat support and the foaming seat, leading to delamination and increased manufacturing costs due to complex processes, and they are uncomfortable and prone to yellowing, which affects their performance and longevity.
Innovation Solution
A compound type polyurethane toilet seat with a surface coating layer and positioning structure that seamlessly covers the seat support through a one-time molding process, using a polyurethane raw material composition of polyether polyol and isocyanate, which reacts to form a strong bond and enhance comfort and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the polyurethane foaming seat and seat support are processed separately and bonded together, then the manufacturing process becomes more complex, but the bonding intensity between them deteriorates, leading to delamination and cracking
Solution Approach 1:
The patent merges the processing of the polyurethane foaming seat and seat support into a single integrated molding operation. The seat support is placed within the polyurethane material during the foaming process itself, allowing both components to be formed simultaneously as one unified structure. This eliminates the separate bonding step that causes delamination while maintaining manufacturing feasibility through one-time molding.
2Reliability
If the polyurethane foaming seat and seat support are molded in one body with the seat support covered in the polyurethane seat, then the processing cost increases due to complicated process, but the bonding intensity improves
Solution Approach 1:
The patent combines multiple operations into a single molding process where the seat support is positioned within the polyurethane material before foaming occurs. This integrated approach forms both the seat support and polyurethane seat as one unified structure in a single operation, eliminating the need for separate bonding processes and reducing overall process complexity while ensuring strong bonding intensity.
3Ease of manufacture
If traditional plastic material is used for the toilet seat, then the manufacturing process is simple, but the comfort level and appearance deteriorate due to coldness, hardness, and yellowing
Solution Approach 1:
The patent employs composite materials by combining the seat support structure with polyurethane foaming material. The polyurethane material provides superior comfort characteristics including warmth, softness, and resistance to yellowing, while the integrated molding process maintains manufacturing efficiency. This composite approach eliminates the drawbacks of traditional plastic seats while preserving process simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces manufacturing costs, improves bonding strength, and enhances user comfort by eliminating delamination and providing a higher-quality product that withstands temperature variations, thus improving the overall quality and market value.
Implementation Method 1
using a polyurethane raw material composition of polyether polyol and isocyanate, which reacts to form a strong bond
Data Source
AI summary
A compound type polyurethane toilet seat, comprising a surface coating layer, a positioning structure and a seat support; the surface coating layer is made from polyurethane and seamlessly covers the outer surface of the seat support by means of the positioning structure; the preparation process comprises: step 1, spraying a release agent and an in-mold paint in a cavity of a mold; step 2, cleaning the surface of the seat support; step 3, polishing or abrasive blasting; step 4, thermally treating the seat support; step 5, spraying the release agent in the cavity of the mold, and installing the seat support in the cavity of the mold; step 6, injecting a polyurethane raw material into the cavity of the mold, and shaking the mold; step 7, foaming the polyurethane raw material.