This disclosure is generally directed to toilets and more particularly to a toilet lid and seat that are formed of at least one metallic material.
Toilet seats and lids have existed in various forms for many decades. A toilet seat provides a surface for an occupant to comfortably sit and a toilet lid provides a protective cover for the toilet facility. Generally, toilet seats and lids are made of wood or plastic materials. These materials can degrade, discolor, and/or become damaged over time. Thus, many toilet seats and lids may become unattractive, structurally unsound, or both. Some toilet seats have decorations and designs in various forms. However, these decorations are often not chemically resistant, scratch resistant, and durable, and do not exhibit long-lasting color fastness.
According to an embodiment of the present disclosure, an apparatus for use with a toilet includes first and second metallic layers bonded together along an edge to form a shell having a shape and size associated with the toilet apparatus, the shell having an interior volume. The apparatus also includes a core structural layer disposed within the interior volume of the shell. The apparatus further includes a plurality of exterior layers disposed on exterior surfaces of the shell, the exterior layers configured to envelop the toilet apparatus.
In another embodiment, a method of manufacturing a toilet apparatus includes bonding first and second metallic layers along an edge to form a shell having a shape and size associated with the toilet apparatus, the shell having an interior volume. The method also includes applying a plurality of exterior layers on exterior surfaces of the shell, the exterior layers configured to envelop the toilet apparatus. The method further includes injecting a core structural material into the interior volume of the shell.
In still another embodiment, a toilet includes a toilet bowl and a toilet seat and toilet lid secured to the toilet bowl. At least one of the toilet seat and toilet lid includes first and second metallic layers bonded together along an edge to form a shell having a shape and size associated with the toilet seat or lid, the shell having an interior volume. The at least one of the toilet seat and toilet lid also includes a core structural layer disposed within the interior volume of the shell, and a plurality of exterior layers disposed on exterior surfaces of the shell, the exterior layers configured to envelop the toilet seat or lid.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions and claims.
For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
The present disclosure provides a metallic toilet lid and seat for use with a toilet bowl. The metallic toilet lid and seat according to this disclosure provide many advantages, including a smooth surface and resistance to abrasion and scratching. The metallic toilet lid and seat may be customized with one or more images to convey a message or impression that may be of interest to a user. In addition, the metallic toilet lid and seat according to this disclosure are constructed to be more durable and retain their original appearance for a longer period than conventional toilet lids and seats.
Many toilet lids and seats are constructed using materials such as wood, processed wood fiber, medium density fiberboard, urea molding compound, polyurethane resins, and thermoplastic polymers. Each of these materials results in a product that is subject to wear, scratching, abrasion, and staining. In contrast, the metallic toilet lid and seat disclosed herein provide a durable, abrasion resistant, scratch resistant, smooth surface.
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In an embodiment, the top shell 202 and the bottom shell 204 are formed of carbon steel or stainless steel sheets. Each sheet may have any suitable thickness. In one embodiment, the top shell 202 and the bottom shell 204 have a thickness of approximately 1 mm. The top shell 202 and the bottom shell 204 may be formed of materials other than carbon steel or stainless steel. For example, the shells 202, 204 could be formed of aluminum, chrome, cast iron, copper, or any other suitable material.
After being formed, the top shell 202 and the bottom shell 204 are permanently bonded together to form a whole toilet lid shell, as described in greater detail below. The cavity within the whole toilet lid shell is filled with a material, such as rigid polyurethane foam. The top shell 202 and bottom shell 204 may be finished with one or more coatings or finish layers, such as a vitreous or porcelain enamel layer. This is described in greater detail below. In an embodiment, the coatings are applied prior to filling the cavity with foam.
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The top shell 302 and the bottom shell 304 are bonded together through a metal bonding process, such as welding, chemical bonding, adhesive, or any other suitable bonding method. After bonding, any sharp or rough surfaces may be removed by polishing.
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In accordance with the present disclosure, each of the metallic layers 404, 408 shown in
The exterior finish layers 402, 410 are applied to the exterior surfaces of the metallic layers 404, 408, as shown in
The exterior finish layers 402, 410 may be formed of ceramic or vitreous enamel that is sprayed or otherwise applied to the metallic layers 404, 408, and then cured or fired at a hot temperature (e.g., 1400°-1600° F.). The enamel finish layers 402, 410 provide a durable, scratch-resistant, colorfast surface for the metallic toilet lid or seat. The enamel coating could have a lower heat transfer coefficient than the metal used in the metallic layers 404, 408. The lower heat transfer coefficient reduces the heat transfer from the skin of the occupant to the seat, thus making the seat feel less cold and more comfortable.
While the exterior finish layers 402, 410 are described as enamel, the layers 402, 410 may be formed of any other suitable material that exhibits the advantageous properties of enamel. For example, the exterior finish layers 402, 410 may include one or more synthetic ceramic coatings, silicone, ultraviolet curable paint systems, crystallized varnish, or automotive grade coatings and paints.
In some embodiments, each exterior finish layer 402, 410 is opaque white. However, the exterior finish layers 402, 410 are not limited thereto. For example, either one or both of the exterior finish layers 402, 410 may be colored, tinted, mirrored, or clear and colorless. Either one or both of the exterior finish layers 402, 410 may be smooth or textured, and have a glossy or matte finish. Either one or both of the exterior finish layers 402, 410 may be plain, patterned, or include decorative pictures. Either one or both of the exterior finish layers 402, 410 may be embossed, stamped, or engraved with an image or decoration. In an embodiment, either or both exterior finish layers 402, 410 could be eliminated. That is, the metallic layers 404, 408 could have no exterior finish coating.
The core layer 406 may be formed of rigid polyurethane foam. The core layer 406 accounts for the majority of the thickness of the toilet lid 200 and provides most of the rigidity of the toilet lid 200. In one embodiment, the thickness of the core layer 406 is approximately fifteen millimeters (15 mm). The content and thickness of the core layer 406 may vary based on application requirements. For example, the foam in the core layer 406 can be more or less rigid, and more or less dense, depending on requirements.
In an embodiment, the cavity within the toilet lid shell or toilet seat shell is filled with rigid polyurethane foam, thereby forming core layer 406. The rigid polyurethane foam adds rigidity and structural strength to the shape of the toilet lid or seat. The rigid polyurethane foam also provides insulation to reduce heat transfer from the skin of the occupant.
Rigid polyurethane is produced by mixing two components in liquid form that chemically react with each other. The chemical reaction causes the urethane to expand throughout the cavity and crosslink, thereby forming a rigid aerated solid. The rigid urethane is injected in liquid form into the cavity through holes in the shell of the toilet lid or seat. In an embodiment, the holes may coincide with the fastener holes used for fasteners to mount hinges in the finished toilet lid or seat. The injection holes may also coincide with the holes for mounting the bumpers to the lid or seat. The foam is injected into the cavity after vitreous enameling or any other process step at hot temperature.
Although the core layer 406 is described as being formed of rigid polyurethane foam, other materials may be used. For example, the core layer 406 may be formed of other types of expandable foam, or any other suitable material.
In an embodiment, the exterior surface of the metallic toilet lid 200 (or a similarly formed metallic toilet seat) includes one or more decorative graphics. Each decorative graphic may represent any picture, graphic, text, or other image, and is customizable to appeal to a user of a toilet where the toilet lid 200 is installed. In certain embodiments, the decorative graphics may be chosen to match or coordinate with a particular decorative scheme of a bathroom or restroom where the toilet is installed. In other embodiments, the decorative graphics may be chosen to display or feature a logo or trademark of a business. In still other embodiments, the decorative graphics may be chosen to display or feature a picture or design that reflects an interest or hobby of a homeowner.
In one embodiment, the top or bottom shell of the toilet lid 200 can be formed with a flat recess. In the recess, artistic glass (e.g., Murano glass) can be inlayed and fired with the metal at high temperature, thereby seamlessly bonding the glass to the metal surface of the toilet lid. This allows the toilet lid to include countless artistic and beautiful designs incorporated into glass.
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The holes 502, 503 additionally provide an opening into the interior space of the toilet lid 500. Liquid or aerosol material, such as expanding polyurethane foam, may be injected through one or more of the holes 502, 503 to form a core layer, such as the core layer 406 of
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Initially, in step 601, sheet metal (e.g., carbon steel sheet metal) is shaped into top and bottom shells for a toilet seat or toilet lid (e.g., top shell 202 and bottom shell 204). The top and bottom shells may have any suitable shape and dimensions. Next, in step 603, the top and bottom shells are permanently bonded together to form a whole shell for the toilet seat or toilet lid. The whole shell is initially hollow, with an interior cavity that is accessible via one or more holes in the shell (e.g., fastener holes 502 or bumper holes 503).
Next, in step 605, the exterior surfaces of the shell are finished with one or more coatings or finish layers (e.g., layers 402, 410). The finish layers may include a vitreous or porcelain enamel layer. The finish layers may also include one or more decorative layers, such as decorative glass that is installed in a recess on a surface of the shell. Next, in step 607, the cavity within the shell is filled by injecting material through one or more of the holes in the shell. The material may be a liquid or aerosol that expands throughout the cavity and cures into rigid polyurethane foam. Once cured, the foam provides rigidity and insulation to the finished toilet lid or toilet seat.
Next, in step 609, any foam that may have escaped from the cavity during expansion is removed from the exterior surface of the toilet lid or toilet seat. Then, in step 611, one or more hinges, bumpers, or other hardware are installed on the toilet lid or toilet seat.
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It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.