Patent Application
20220348769
The present application claims priority of DE 10 2021 110 977.9, filed Apr. 29, 2021, the priority of this application is hereby claimed, and this application is incorporated herein by reference.
The invention relates to a toilet seat assembly comprising a seat or a seat and a lid, where the seat or the seat and the lid are made of a polymer material.
A toilet seat assembly of this kind is generally secured by suitable fastening means to a toilet, and has at least one seat, which may have a ring-shaped or U-shaped configuration, and can be pivoted relative to the toilet, meaning that it can be swiveled from a folded-up position into a position lowered onto the toilet, and vice versa. The seat assembly frequently also comprises a lid, which is mounted pivotably in combination with the seat and can be pivoted separately from the seat from a folded-open into a folded-closed position. As well as the production of a seat assembly of this kind, of the seat and the lid, respectively, from wood or a woodbase material, in conjunction with a suitable surface-coating system or coating, seat assemblies of these kinds are commonly made of a polymer material, in other words of plastic. In this case it is usual to employ the plastics families of the thermosets, the thermoplastics, and the polyresins. In the case of the thermosets, the seat, or the seat and the lid, is or are frequently made of a urea resin, e.g., urea-formaldehyde (UF) or of a melamine-formaldehyde resin (MF/MPF). These materials are introduced in pellet form, in appropriate amount, into a compression mold, where they are liquefied at elevated temperature of around 140° C.-160° C. and brought under pressure into the desired shape. After the polymer matrix has cooled, the compression-molded parts can then be demolded. A thermoplastic commonly used is polypropylene (PP), which, in contrast to the thermosets, for example, can be processed to the seat or lid in an injection-molding process.
The polymer materials used are generally based on a petrochemical or fossil starting material, in other words a nonrenewable resource. The production of the respective polymer material from such a starting material is accompanied by release of CO2, which either enters the environment or requires costly and inconvenient abatement. Moreover, the use of certain polymer materials, such as urea-formaldehyde, for example, is classed as hazardous to health.
The problem addressed by the invention, therefore, is that of specifying a toilet seat assembly which is improved in these respects.
To solve this problem, the invention provides a toilet seat assembly comprising a seat or a seat and a lid, where the seat or the seat and the lid are made of a polymer material, which is distinguished by the fact that the polymer material consists to an extent of 40-99.5 wt % of at least one biopolymer, the polymer material comprising fibers and/or at least one organic or inorganic particulate filler, the fraction of the fibers and/or of the filler being between 0.5-60.0 wt %.
A feature of the toilet seat assembly of the invention is that the polymer material used consists to a great extent, or almost completely, of a biopolymer. A biopolymer of this kind is a material which consists of biogenic, i.e., renewable, raw materials, and which, furthermore, may also be biodegradable. The term therefore embraces, in particular, biobased biopolymers, which can be obtained from organic raw materials. Likewise identified as biopolymers, furthermore, are natural polymers, based for example on cellulose or cellulose derivatives, and also biobased plastics which can be produced by chemical modification of the biogenic starting materials, examples being polylactides, these biopolymers being suitable in principle for forming the polymer material or a part of the polymer material from which the seat or the lid is made. The use of such biopolymers therefore makes it possible to forgo the use of polymer materials based on fossil or nonrenewable raw materials to a considerable extent or almost completely. Referring to the seat assembly or to the individual seat or lid, this results in a markedly improved environmental or climatological balance, particularly in light of the fact that no additional greenhouse gases are produced in the course of production and, in particular, usage. It is also possible at least partly or completely to forgo the use of polymer materials which pose a health hazard.
Through use of fibers and/or at least one particulate filler, either organic or inorganic in nature, desired product qualities, more particularly mechanical properties, can be imparted to the seat assembly or to the seat or the lid produced from biopolymer material. The fibers embedded into the polymer matrix serve to reinforce the polymer matrix. Alternatively or additionally, at least one particulate filler may also be introduced or, respectively, embedded into the polymer matrix. A filler of this kind may serve in is particular for adjusting the density of material and also for adjusting the scratch resistance, the impact strength, and also the tensile strength and/or breaking strength.
The overall amount of these adjuvants, whether they be only fibers, only the filler, or fibers and filler, is in the range of 0.5-60 wt %. This means that this fraction, depending on the amount of polymer material, may be relatively low to considerable, according to which properties, more particularly which mechanical properties, the finished seat or lid is to have, and which properties are delivered by the polymer matrix itself, these properties being amenable to further adjustment/enhancement by means of corresponding additions.
As stated, different kinds of biopolymers can be used. It is possible to use a biopolymer of lignin, polylactides, polycaprolactone, natural resins, bio-polyethylene, natural rubber, shellac, gutta percha, cellulose, mastic, starch, proteins, natural fatty acids, or a mixture thereof, and also copolymers of the aforementioned substances. It is therefore possible to use different types of biopolymer, and so there is also a corresponding possibility for selection in relation to the requisite properties of the seat or lid.
In this case only one biopolymer may be used to form the polymer material or a part of the polymer material. Alternatively, however, a mixture of two or more different biopolymers may also form the polymer material or be present therein. This means that it is also possible to use two or more different biopolymers, more particularly of the is polymer types identified above, and this further enlarges the variation spectrum.
As described, according to a first alternative, fibers are embedded into the polymer material or into the cured polymer matrix. These fibers may be, for example, natural fibers, which in conjunction with the biopolymer or biopolymers used reinforces still further the eco-based character. Natural fibers which can be used are, in particular, plant fibers such as bamboo, sisal, flax, coir or corn fibers, which are readily available in sufficient quantity and are sometimes obtained as waste products in the processing of the plants in question. The stated kinds of fiber are, in particular, fast-growing plant materials. In addition it is of course also possible to use wood fibers, in other words likewise natural fibers, which are obtained in large quantity in the processing of wood as well. This means that natural fibers or plant fibers may be used fundamentally.
Additionally or alternatively to this, it is also conceivable for the fibers to be glass fibers, carbon fibers or polymer-based textile fibers. These fibers too are outstandingly suitable as reinforcing fibers and can be embedded without problems into the polymer matrix.
It is conceivable to introduce only one type of fiber—that is, for example, only wood fibers or only glass fibers, or the like. Besides this, however, it is of course also conceivable to embed a mixture of different fibers into the polymer material. This too in turn allows considerable variation in the matrix reinforcement that is achievable in this way.
The length of the fibers used ought to be in the range between 1-10 mm, for a fiber thickness between 0.1-1 mm. If glass fiber is used, preference is given to using fibers 2-5 mm in length.
As fillers too it is possible to use different kinds of filler. It is conceivable for the particulate filler introduced to comprise glass, more particularly spherical glass. This glass, which is incorporated in the form of glass flour, also serves for improving the flow properties in the production context, in other words in the shaping operation.
Alternatively or additionally it is also possible to use a particulate filler in the form of lime, quartz, dolomite, feldspar, silicon carbide, aluminum oxide, aluminum hydroxide, calcium silicate, magnesium silicate, zirconium oxide or titanium oxide. These fillers improve the scratch resistance in particular.
As a particulate filler for improving the flame retardancy it is additionally possible to io introduce aluminum trihydrate or perlite.
A further possibility is to introduce, as a particulate filler, hollow glass spheres or hollow glass beads as well, these being small or ultrasmall hollow bodies which serve in particular to reduce the density and hence the weight of the seat or lid produced.
And, lastly, carbon black as well, for example, in the form of carbon black particles, can be introduced for the purpose of improving the UV resistance or for adjusting the electrical conductivity.
It is of course possible to introduce not only a single type of particulate filler. Instead it is also conceivable to introduce a mixture of two or more different fillers.
The average particle size ought to be in the range between 0.01-2.0 mm, more particularly between 0.05-1 mm.
Frequently it is also desired for the seat or the lid to have a particular color. As well as the possibility of achieving the coloration by means of an applied varnish, it is also conceivable to introduce at least one organic or inorganic pigment at 0.55.0 wt % into the polymer material. This means that a targeted coloring of the material is achieved by way of this pigment, with the article produced accordingly being colored right through.
It is possible, for example, to use inorganic pigments based on oxides, oxyhydroxides, sulfides, silicates, sulfates or carbonates, with examples that may be mentioned including titanium dioxide, via which the customary white color is imparted. A white coloration may also be achieved using aluminum trihydrate, which additionally serves as a flame retardant, zirconium silicate, aluminum oxide, calcium carbonate, barium carbonate, kaolin chamotte, tin oxide or zinc oxide. Iron oxide, silicon carbide, carbon nanotubes or carbon black may be introduced, for example, as pigments for producing darker articles or gray or black articles, and other colors may also be formed by means of corresponding spinels, in which case as well there is a large possibility for color variation.
Alternatively it is also possible to use organic pigments such as, for example, indigo, chlorophyll, and synthetically produced organic colors to achieve coloration.
As well as the possibility of using only one kind of pigment, it is of course conceivable here as well to introduce a mixture of different organic or different inorganic pigments. This means that, ultimately, different color pigments having different colors are mixed, in order to obtain a mixed color and so to extend the color palette further. It is likewise conceivable to introduce a mixture of organic and inorganic pigments.
According to one particularly advantageous development, provision may be made for at least one adjuvant with antibacterial quality to be present at 0.1- 5.0 wt %. By way of io such an adjuvant, the seat assembly or the seat and optionally the lid are given an inherent, quasi-intrinsic antibacterial quality. The reason is that, on the basis of this incorporated antibacterial adjuvant, the seat or lid material inherently has an antibacterial activity to a certain extent, thus being capable of killing bacteria which regularly form colonies on the surface, or at least preventing or limiting their propagation. From a is hygiene standpoint this is a particular advantage, since soiling and hence bacteria may sometimes adhere to a toilet seat assembly. Through incorporation of this adjuvant it is possible, advantageously, to inhibit the propagation of the bacteria or to kill the bacteria.
Such adjuvants present are preferably metal ions, more particularly silver, copper, zinc, lead or tin ions. The inhibition of propagation or the killing is based on an oligodynamic effect. The adjuvant supplying the metal ions is introduced in a simple way in particulate form.
It is conceivable, furthermore, for the seat or the lid to have a coating. Where, for example, no pigments are introduced, coloration would be conceivable via a coating of this kind in the form of a varnish. Preferably, however, the coatings which can be used also have an antibacterial quality, meaning that a surface with antibacterial quality can be applied by way of such coatings—alternatively or additionally to the aforementioned antibacterial adjuvants. A coating of this kind used may be a varnish, a powder coating, a gel coat, a topcoat or a foil. A varnish used may be, for example, a waterborne, solvent borne or oil-based varnish, or ultra-high-solids (UHS) varnishes, which possess a very low solvent fraction and a very low fraction of volatile organic compounds. A gel coat is a coating which is applied as a protective layer and which seals the underlying polymer matrix and at the same time protects it from UV radiation as well. A topcoat also acts similarly. Since both the gel coat and the topcoat are applied in fluid form, it is readily possible to admix such systems, and also the varnish, of course, with corresponding adjuvants, containing, for example, the aforementioned metal ions, pigments or fillers. In the case of powder coating, the abovementioned adjuvants can be added in powder form.
An alternative possibility is the laminating application of a foil, this being a polymeric foil, which is joined firmly to the underlying polymer matrix. This foil as well may be equipped antibacterially by the introduction of corresponding adjuvants in the course of its production.
The invention additionally relates to a sanitary installation comprising a toilet and also a toilet seat assembly of the type described above. This installation may be a floor-mounted toilet or a wall-mounted toilet.
Further advantages and particulars of the present invention arise out of the exemplary embodiment described in the following and also from the associated drawings.
In the drawings:
Indicated below in tables 1 and 2, to start with, are various compositional variants of the material forming the seat or the lid, comprising either just the polymer material or else additional constituents.
0-40
0-40
Table 1 indicates the components forming the seat or lid material. Indicated in addition are four variants 1-4, each having different constituents. The respective amounts are in wt %.
As components forming the material, firstly the biopolymer is indicated, which may be either only one biopolymer, or a mixture of two or more biopolymers.
As a further, optional polymer component, a conventional polymer, i.e., a petroleum-based polymer, is indicated, which, however, need also not be present, if the polymer material is formed exclusively by the biopolymer.
Listed furthermore as an option is an inorganic filler and also an organic filler as components. The fillers are optional as well.
The same is also true of the fibers, which may be introduced for reinforcement.
Also indicated are optional adjuvants in the form of color pigments, and also an optional adjuvant with antibacterial effect.
In the case of variant 1 from table 1, only the polymer material is present, and it may consist either just of 100% biopolymer, or else, additionally, of conventional polymer, in other words of a polymer mixture of biopolymer and conventional polymer. The fraction of conventional polymer here is not more than 40 wt % and the fraction of biopolymer here is not less than 60 wt %. No further components are present.
Variant 2 is distinguished by the fact that, in addition to the biopolymer and the optional conventional polymer, a pigment is present, and the pigment fraction may be 1-5 wt %.
According to variant 3, again, either only biopolymer or additionally conventional polymer as well are present for forming the polymer material, and also present, as already known from variant 2, is a pigment. Additionally indicated are three different filling agents, these being inorganic filler, organic filler, and fibers; in the exemplary embodiment shown, all three are present, but they are correspondingly highly variable in terms of the amount in which they are added. In the example shown, all three are present at not less than 0.5 wt %. This, however, is not absolutely mandatory, but is only the case in the example. It is of course conceivable, for example, also to introduce only inorganic fillers and no organic fillers, and additionally any fibers or the like.
According to variant 4, lastly, which builds on variant 3, there is additionally an adjuvant with antibacterial effect present, specifically at 0.1-2 wt %, in order to endow the seat or lid material overall with an antibacterial quality.
According to table 2, which is constructed like table 1, likewise four different variants of different component compositions are indicated in wt %. These variants 1-4 correspond ultimately to the variants 1-4 from table 1. Here, however, there is additionally indicated a coating as a further component, which covers the base material on the completed seat or lid. The coating, as observed, may be a varnish, a power coating, a topcoat, a gel coat, or a foil applied by lamination. In all variants 1-4 such a coating is provided here, by way of example. Given that this coating as well of course accounts for a certain wt % fraction, there is necessarily a slight variation in the fractions of the other components, since in each variant from tables 1 and 2, of course, the sum total of the respective component fractions is 100 wt %.
According to
In the exemplary embodiment of
In the case of the exemplary embodiment of
In the example shown, there are additionally one or more fillers 4 introduced, which may be the organic or inorganic fillers described, examples being quartz particles, dolomite particles, etc., or else may be hollow glass beads or the like—reference is made to the introductory observations regarding the organic/inorganic fillers which can be used and their function. Although in the example of
In the case of the exemplary embodiment of
In the case of the exemplary embodiment of
In line with the examples of
In the case of the exemplary embodiment of
The exemplary embodiment of
According to the components used, and/or to the nature of the starting materials, different production processes are conceivable. It is possible, for instance, to produce the seat or lid using particulate starting materials, hence in the form of corresponding pellets or the like, in a compression molding process with metal molds made, for example, of stainless steel, nickel or aluminum, in which case the particulate components are first melted by heating and then shaped.
As an alternative to this, it is also conceivable to produce the seat or lid using corresponding particulate components in an injection-molding process, in which case, of course, the polymer material or its starting components are first melted, to form an injectable composition comprising the other particulate components in bound form.
A further possibility is to produce the seat or the lid from a prefabricated semifinished product, such as a sheet or a plate, by thermoforming. This prefabricated semifinished product consists of all the necessary components forming the base material. The thermoforming process merely gives this semifinished product the appropriate final shape.
It is conceivable, furthermore, to produce the seat or lid from a suitable molding compound, produced on the basis of the particulate components, in a sheet molding compound (SMC) process using compression molds.
After the corresponding molding has been produced, it may either be already complete, or else an additional coating may be applied, which either has visual qualities only, or may additionally have been furnished antibacterially as well.
While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 110 977.9 | Apr 2021 | DE | national |
