U.S. patent application number 11/986475 was filed with the patent office on 2009-05-21 for gel infused toilet seat.
Invention is credited to Liang Chou Chen.
Application Number | 20090126090 11/986475 |
Document ID | / |
Family ID | 40640416 |
Filed Date | 2009-05-21 |
United States Patent
Application |
20090126090 |
Kind Code |
A1 |
Chen; Liang Chou |
May 21, 2009 |
Gel infused toilet seat
Abstract
A gel-infused seat for a toilet bowl is provided comprising an
exposed base section for directly contacting a top rim of the bowl
while supporting a user's weight, the base section having a top
surface opposite to the bottom surfaces of the seat and at least
two edges including an inner circumferential edge and an outer
circumferential edge; a foam core layer covering the top surface of
the base section and extending to parts of the bottom surfaces of
the seat at its inner and outer circumferential edges; a gelatinous
overlay for defining a top contour of the seat that yields easily
to a pressure applied to give a comfortable softness to the user;
and an outer layer for covering the gelatinous overlay and foam
core layer leaving the base section exposed with substantially
constant space from the base section.
Inventors: |
Chen; Liang Chou; (East
Hanover, NJ) |
Correspondence
Address: |
Law Office of Christine Yang
17220 Newhope Street #102
Fountain Valley
CA
92708
US
|
Family ID: |
40640416 |
Appl. No.: |
11/986475 |
Filed: |
November 21, 2007 |
Current U.S.
Class: |
4/237 |
Current CPC
Class: |
A47K 13/02 20130101 |
Class at
Publication: |
4/237 |
International
Class: |
A47K 13/00 20060101
A47K013/00 |
Claims
1. A gel-infused seat for mounting on a toilet bowl comprising: a
sturdy base section extending along a top rim of the bowl for
supporting a user's weight while defining bottom surfaces of the
seat, the base section having a top surface opposite to the bottom
surfaces of the seat and at least two edges including an inner
circumferential edge and an outer circumferential edge; a foam core
layer covering the top surface of the base section and extending to
parts of the bottom surfaces of the seat at its inner and outer
circumferential edges; a gelatinous overlay for defining a top
contour of the seat that yields easily to a pressure applied to
give a comfortable softness to the user; and an outer layer for
covering the gelatinous overlay and foam core layer leaving the
base section exposed with substantially constant space from the
base section.
2. The gel-infused seat of claim 1, wherein the core layer is made
of polyurethane into a molding foam.
3. The gel-infused seat of claim 1, wherein the base section is
made of polypropylene.
4. The gel-infused seat of claim 1, wherein the gelatinous overlay
is made of polyurethane elastomers.
5. The gel-infused seat of claim 1, wherein, the outer layer is
made of a flexible elastomeric sheet with an appropriate friction
against the user's flesh.
6. A gel-infused seat for mounting on a toilet bowl comprising: a
base extending along a top rim of the bowl for supporting a user's
weight, wherein the base has a bottom surface, wherein the base
section has a top surface opposite to the bottom surface of the
seat and at least two edges including an inner circumferential edge
and an outer circumferential edge; a foam layer covering the top
surface of the base section and extending to parts of the bottom
surfaces of the seat at a foam inner circumferential edge and foam
core outer circumferential edge, wherein the foam layer is an
intermediate density polymer; a gel layer defining a top contour of
the seat that yields easily to a pressure applied to give a
comfortable softness to the user, wherein the gel layer is bonded
to the top surface of the foam layer; and an outer layer for
covering the gelatinous overlay and foam core layer leaving the
base section exposed with substantially constant space from the
base section.
7. The gel-infused seat of claim 6, wherein the foam layer is made
of foam polyurethane.
8. The gel-infused seat of claim 6, wherein the base section is
made of polypropylene.
9. The gel-infused seat of claim 6, wherein the gel layer is made
of polyurethane elastomers.
10. The gel-infused seat of claim 6, wherein, the outer layer is
made of a flexible elastomeric sheet with an appropriate friction
against the user's flesh.
11. A gel-infused seat for mounting on a toilet bowl comprising: a
base extending along a top rim of the bowl for supporting a user's
weight, wherein the base has a bottom surface, wherein the base
section has a top surface opposite to the bottom surface of the
seat and at least two edges including an inner circumferential edge
and an outer circumferential edge; a foam layer covering the top
surface of the base section and extending to parts of the bottom
surfaces of the seat at a foam inner circumferential edge and foam
core outer circumferential edge, wherein the foam layer is an
intermediate density polymer; a gel layer defining a top contour of
the seat that yields easily to a pressure applied to give a
comfortable softness to the user, wherein the gel layer is bonded
to the top surface of the foam layer; and an outer layer for
covering the gelatinous overlay, wherein the outer layer receives
an embossed texture pattern.
12. The gel-infused seat of claim 11, wherein the foam layer is
made of foam polyurethane.
13. The gel-infused seat of claim 11, wherein the base section is
made of polypropylene.
14. The gel-infused seat of claim 11, wherein the gel layer is made
of polyurethane elastomers.
15. The gel-infused seat of claim 11, wherein the foam layer is
made of foam polyurethane, wherein the gel layer is made of
polyurethane elastomers, wherein the base section is made of
polypropylene.
Description
BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] The present invention relates to a toilet seat. More
particularly, the present invention relates to a cushioned toilet
seat with an additional infusion of gelatinous elastomers to a seat
frame that does not require a complex or series of injection
moldings.
[0003] B. Description of the Prior Art
[0004] There has been a problem recognized in relation to the
inconvenient hard feeling when sitting on the conventional toilet
seats made simply of a molded plastic, a carved wood or even a
composite of different thermoplastic materials.
[0005] A soft layer to envelope a harder seat ring core in making
more comforting seating surface for toilet users has been the
subject of many patents including U.S. Pat. No. 7,111,331 to
Cecchin that describes a skin polymer filled with a core material
thru concentric co-injection; U.S. Pat. No. 6,640,349 to Toldo et
al. describing encapsulation of a toilet seat ring with a plastic
overlay covering thru consecutive injections of polymeric overlay
and then a core material; U.S. Pat. No. 6,154,892 to Hogue; and
many others.
[0006] Of these known technologies, U.S. Pat. No. 6,154,892
suggests a toilet seat comprising a rigid injection molded seat
insert of a reinforced thermoplastic material and an injection
over-mold layer of a soft thermoplastic material. The entire
exterior surface of seat insert of the '892 patent is generally
buried in the even thickness of the over-mold layer except some
exposures of the insert as bumpers or stand-offs. However, it
requires two separate molding processes involving a molding of the
rigid insert and an over-molding of top layer for non-slip seating
surface.
[0007] It will be clearly advantageous to provide a new toilet seat
with an enhanced cushion that requires one less injection process
on the contrary to conventional seat constructions.
[0008] Therefore, apart from conventional thoughts of constructing
a cushioned toilet seat, an object of the present invention is to
provide an original toilet seat that is significantly easy on
manufacturing while adding an infusion of gel for a heightened
seating comfort.
[0009] Another object of the invention is to provide a toilet seat
component that can be made perfectly compatible with a wide variety
of toilet fixture designs requiring no extra investment in existing
manufacturing systems.
[0010] Yet another object of the present invention of the present
invention is to provide the comfort of jellified seating face of a
toilet seat combined with improved outer skin layers for sanitation
and pleasant sensation.
SUMMARY OF THE INVENTION
[0011] The gel-infused seat for a toilet bowl according to the
present invention comprises a downwardly exposed base section for
directly contacting a top rim of the bowl while supporting a user's
weight and multiple overlays joined securely to the base section in
a unique structure to facilitate the manufacturing of the seat,
which provides a substantially improved seating comfort. The base
section has a top surface opposite to the bottom surfaces of the
seat and at least two edges including an inner circumferential edge
and an outer circumferential edge. To give a firm bond between
overlays as well as a softer volume, a foam core layer covers the
top surface of the base section and extends to parts of the bottom
surfaces of the seat at its inner and outer circumferential edges.
For allowing a functional contour as well as sensible softness, a
gelatinous overlay is provided defining a top contour of the seat
that yields easily to a pressure applied to give a comfortable
softness to the user. An outer layer covers the gelatinous overlay
and foam core layer leaving the base section exposed with
substantially constant space from the base section.
[0012] As a way to ensure a permanent unity between the multiple
layers of seat that involves no encapsulation but open overlays,
several structural features are embedded in the skin as well as
base section: First, two opposite overhangs are made of the core
layer at its inner end near opening and outer end near outer edge;
second, two opposite notches are formed on base section along the
inner and outer peripheral edges of bottom respectively and then
buried under solidified overhangs, respectively and finally, a
number of intermittent eyes are formed through notch of base
section. Such a partial wrapping over base section permits
manufacturing of layered seat in most simplified way because
pouring and curing of molten materials can be done just with a
lower mold utilizing base section itself as an upper mold
eliminating the need for two consecutive injection processes or a
sophisticated combination of the two.
[0013] Embodiments of the invention will now be described by way of
example with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a gel-infused seat according
to the present invention installed on a conventional toilet
bowl.
[0015] FIG. 2 is a bottom perspective view of the toilet seat of
FIG. 1 raised in a mode of operation. FIG. 3 is a cross sectional
view taken along line 3-3 of FIG. 2 showing the component layers of
the seat of the invention.
[0016] Similar reference numbers denote corresponding features
throughout the attached drawings. [0017] 1 Toilet Bowl [0018] 2
Tank [0019] 4 Front Seat In Portion [0020] 6 Wooden Lid [0021] 8
Seat [0022] 10 Hinge Sections [0023] 12 Base Section [0024] 16
Support Strips [0025] 18 End Surfaces [0026] 20 Outer Edge [0027]
21 Bottom [0028] 22 Top Surface [0029] 24 Flexible Elastomeric Skin
[0030] 26 Inner Side [0031] 28 Outside [0032] 30 Gel Layer [0033]
32 Smooth Mound Profile [0034] 34 Core Layer [0035] 36 First
Overhang [0036] 38 Second Overhang [0037] 40 First Opposite Notch
[0038] 42 Second Opposite Notch [0039] 46 Intermittent Eyes
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] With reference to FIG. 1, a typical toilet bowl 1 has a
pluming portion of a tank 2 in the back and a front seating portion
4 that comprises a hinged assembly of a plastic or wooden lid 6 and
a seat 8 made in accordance with the present invention. Two hinge
sections 10 may be of any known types that mount the lid 6 and seat
8 to pivot independently of each other on a rear portion of bowl
1.
[0041] In FIG. 2, seat 8 of the present invention is raised to show
a firm base section 12 exposed at the bottom of seat 8. Base
section 12 is shaped generally in an oval ring although it may be
made into a C-shape or so called open front less cover type. An
elliptical central opening 14 of seat 8 is arranged to overlie the
bowl 1. Three or more support strips 16 may be formed integral to
base section 12, which may be made of polypropylene (PP) by an
injection molding and then it is joined by multiple top layers to
give unique characteristics to the seat 1 of the present
invention.
[0042] Referring also to FIG. 3 wherein seat 1 is positioned upside
down and shown in cross section toward the front end thereof, end
surfaces 18 of strips 16 extend in a common plane allowing seat 8
to contact a flat top surface (not shown) of bowl 1 locally. Except
the local protrusions of strips 16, seat 8 is generally deflected
so that the inner edge at opening 14 lies lowest near the common
plane of strips 16 while an outer edge 20 of oval seat 8 defines
the highest area elevated from the bottom end surface 18 to form a
converging bottom 21. So, outer edge 20 of seat 8 provides a good
clearance between bowl 1 to insert a hand for raising the seat 8 in
use or cleaning. A top surface 22 of seat 8 may be made of a
pattern cut of a flexible elastomeric skin 24 with a good bacterial
repellence as well as an appropriate grip against the user's flesh.
Skin 24 may be comprised of a fabric backing and a predetermined
thickness of a polymer topcoat. Then, in the main process of
forming the seat 8, skin 24 may be placed in an open mold bottom
(not shown) first and aligned with the mold interior, which is the
final shape of seat top 22.
[0043] In order to ensure a permanent bond between multiple layers
of seat 8, skin 24 is adapted to wrap the base section 12 to its
inner side 26 and outer side 28 with small spaces between them. In
case the entire layers of seat 8 are opted to be manufactured by an
injection molding, these spaces may communicate with gates of the
mold for supplying layer materials to fill the void formed between
skin 24 and base 12. In the simplest embodiment, the layers except
the base section 12 may be made free of an injection molding
process. Instead, the skin 24 held in the open mold will receive a
measured amount of a top GEL 30, which may be one of gel-like
viscoelastic materials like polyurethane elastomers, or any
suitable material that has a rate of deformation being proportional
to the applied pressure.
[0044] A designed smooth mound 32 raised at the front center of
seat 8 is the result of top GEL 30 flowing in a concave area of the
mold. The mound 32 may work as a decency guard. In addition, due to
the fluidity of GEL 30 material before curing, different
topographic surfaces of toilet seat 8 may be formed according to
the present invention for an enhanced seating comfort of toilet
users while taking advantage of the superior softness of GEL 30.
Upon leveling of top GEL 30 material, a polyurethane (PU) core
layer 34 is introduced in a molten state to fill the gap between
top GEL layer 30 and the base section 12 now temporarily held over
top GEL layer 30. Alternatively, this final sequence of molding may
be reversed so that a controlled amount of the core layer 34 is
evenly poured first along the groove formed jointly by top GEL 30
and the remaining interior surface of skin 24 and then base section
12 is lowered onto the fluid core layer 34 and maintained at its
predetermined position with respect to skin 24 until the layers 30
and 34 are set.
[0045] As a way to ensure a permanent unity between the multiple
layers of seat 8 that involves no encapsulation but open overlays
according to the present invention, several structural features are
embedded in the skin 24 as well as base section 12: First, two
opposite overhangs 36, 38 are made of the core layer 34 at its
inner end near opening 14 and outer end near outer edge 20; second,
two opposite notches 40, 42 are formed on base section 12 along the
inner and outer peripheral edges of bottom 21 respectively and then
buried under solidified overhangs 36 and 38, respectively and
finally, a number of intermittent eyes 46 are formed through notch
40 of base section 12.
[0046] Therefore, the improved gel-infused toilet seat 8 can be
provided according to the present invention through a single
extrusion production process of PP base 12 with the three
additional layers of PU form core layer 34, top GEL 30 and
elastomeric skin 24 chemically as well as structurally bound all
together.
[0047] Such a partial wrapping over base section 12 permits
manufacturing of layered seat 8 in most simplified way because
pouring and curing of molten materials can be done just with a
lower mold utilizing base section 12 itself as an upper mold
eliminating the need for two consecutive injection processes or a
sophisticated combination of the two.
[0048] While the presently preferred form of the gel-infused toilet
seat has been shown and described, and several modifications
thereof discussed, persons skilled in this art will readily
appreciate that various additional changes and modifications may be
made without departing from the spirit of the invention, as defined
and differentiated by the following claims.
[0049] Although the base section 12 is described as an
injection-molded component, different blocks of solid material such
as wood may be shaped with the similar features to make the
inventive seat 8.
[0050] Optionally, the outer surface elastomeric skin 24 can be
imprinted with a variety of graphics and designs. The outer surface
elastomeric skin 24 can also be embossed with a textured
pattern.
* * * * *