JPH08289858A - Two-layer molded toilet seat and manufacture of the same - Google Patents

Abstract

PURPOSE: To hold the large part of a heater in the state of being fitted to a groove fitting part, to hold the part of the heater which can not be housed in the groove fitting part in a groove extension part and to hold the heater at a prescribed position by forming a groove for attaching the heater for housing the heater by the groove fitting part and the groove extension part. CONSTITUTION: A heating toilet seat is provided with a toilet seat main body as an upper layer part and a supporting base material 60 formed inside the toilet seat main body. Also, between the upper surface 61 of the supporting base material 60 and the toilet seat main body, a heater unit 70 provided with a linear heater 72 to be inserted inside the groove 64 for attaching the heater formed at the front end part of the supporting base material 60 and a sheet material 74 composed of aluminium foil is provided. The groove 64 for attaching the heater is formed by the groove fitting part 64a formed into one string-like groove over the approximately entire surface of the supporting base material 60 and the groove extension part 64b. Then, the large part of the heater 72 is surely held while being fitted to the groove fitting part 64a and the part of the heater 42 which can not be housed in the groove fitting part 64a is held by the groove extension part 64b.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a two-layer molded toilet seat in which an electric functional component such as a heater is built into the toilet seat by insert molding, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as shown in the plan view of FIG. 16 and the sectional view of FIG. 17 taken along the line AA of FIG. 16, a heated toilet seat 600 includes a horseshoe-shaped toilet seat main body 602 and a main body 602. The heater 606 attached to the back surface 604 of the toilet seat body 602 via the adhesive sheet 609, and the toilet seat body 60.
2 and a bottom plate 608 that seals the lower opening,
By energizing the heater 606, the toilet seat body 602 is heated. To manufacture the heated toilet seat 600, a heater 606 is adhered to the back surface 604 of the toilet seat body 602 by using an adhesive sheet 609 or the like, and then a bottom plate 608 is ultrasonically welded to the lower opening of the toilet seat body 602 or a hot plate. It is performed by joining by a welding method.

In such a heated toilet seat 600, the lower opening of the toilet seat body 602 and the bottom plate 60 are taken into consideration due to the resin shrinkage and the assembling property.
Since a narrow gap S with 8 cannot be avoided, dirt adheres to the gap. Dirt adhering to such a narrow gap cannot be easily removed even by wiping with a dust cloth or the like. Further, although the ultrasonic horn and the bottom plate 608 are formed into a flat plate in order to uniformly transmit the energy, such a plane shape not only has poor design, but also affects the shape of the toilet seat body 602. There is also a problem that it is difficult to form a curved surface that is comfortable to sit on and ergonomically excellent.

As a technique for solving such a problem, as disclosed in Japanese Utility Model Laid-Open No. 61-13685, there is known a technique in which a heater is insert-molded in a toilet seat. That is, as shown in FIG. 18, the heating toilet seat has a supporting base 620.
A groove 624 is formed on the upper surface 622 of the substrate, a heater 626 is manually inserted and supported in the groove 624, the heater 626 is set in the lower mold 631 of an injection molding mold 630, and a resin is filled in the cavity 632 to support the supporting substrate 620. By stacking a toilet seat body (not shown) on the heater 626, the heater 626 is attached to the support base 62.
0 and the toilet seat body. But,
In this heated toilet seat, the work of inserting the heater 626 into the groove 624 is troublesome, and the heater 626 may come off the groove 624 due to the injection pressure of the resin and ride on the upper surface 622. There is also a problem that it becomes thinner and the strength is lowered.

Another conventional heating toilet seat is disclosed in Japanese Patent Application Laid-Open No. 61-247426. In this heating toilet seat manufacturing method, a sheet heating element having a through hole is set in an injection molding die and injection molding is performed to form a preforming body in which the sheet heating element and a substrate are integrally formed. The body is set in another injection molding die, and the toilet seat body is laminated on the sheet heating element. However, it is difficult to manufacture a thin sheet such as a sheet heating element having a large area such as a toilet seat with uniform heating characteristics over the entire toilet seat. For this reason, when the sheet heating element is used, there is a problem that the toilet seat surface of the heating toilet seat cannot be heated to a uniform temperature.

The present invention solves the above-mentioned problems of the prior art, and provides a two-layer molded toilet seat and a manufacturing method thereof, in which the heater can be easily attached and the heater can be easily insert-molded at a predetermined position. The purpose is to do.

[0007]

The invention according to claim 1 made in order to solve the above-mentioned problems, in a two-layer molded toilet seat having a built-in heater, has a supporting base material having a surface part, and a surface part of the supporting base material. The heater mounting groove, the linear heater housed in the heater mounting groove, and the upper layer portion that is laminated on the supporting base material and covers the heater. Is provided with a groove fitting portion that substantially fits the heater, and a groove expansion portion having a cross-sectional area wider than the wire diameter of the heater.

According to a second aspect of the present invention, in a method for manufacturing a double-layer molded toilet seat in which a heater is built in between a supporting base material and an upper layer portion, a step of forming a linear heater and a groove fitting for substantially fitting the heater. Forming a support base having a heater mounting groove having a joint portion and a groove expansion portion continuous with the groove fitting portion and wider than the cross section of the heater; and fitting the heater to the heater mounting groove. The steps of storing the heater in the groove for mounting the heater in the cavity of the molding die, and the step of housing the heater in the groove for mounting the heater in the cavity of the molding die. A step of forming an upper layer portion on the base material and covering the heater.

According to a third aspect of the present invention, the groove for extending the heater mounting groove is formed at a position apart from the gate of the molding die.

According to a fourth aspect of the present invention, in a two-layer molded toilet seat incorporating a heater, a supporting base material having a front surface portion and a rear surface portion, a heater mounting groove formed on the front surface portion of the supporting base material, and a heater mounting groove. The linear heater housed inside is stacked on the supporting base material, is provided on the upper layer portion covering the heater, and is provided on the back surface side of the supporting base material, is connected in series to the heater, and is predetermined by the heater. A temperature fuse that cuts off the power supply to the heater when the temperature reaches the above temperature, and the heater mounting groove is arranged so as to be closer to the temperature fuse, and is closer to the temperature fuse than the depth of other portions. It is characterized in that it has a deep groove portion deeply formed.

According to a fifth aspect of the present invention, in a two-layer molded toilet seat incorporating an electric element, a supporting base material, an electric element mounted on the supporting base material, and a socket provided on the supporting base material for supplying power from the outside. And an upper layer part that is laminated on the supporting base material and covers the electric element, and the socket has a socket mounting hole formed in the supporting base material and a socket base part that is fitted into the socket mounting hole. However, the outer peripheral portion of the socket base portion and the inner peripheral portion of the socket mounting hole are in close contact with each other at a joint portion joined by ultrasonic welding.

According to a sixth aspect of the present invention, the socket base portion is made of a resin material that melts with the supporting base material and has a high melting point or a high thermal deformation temperature with respect to the supporting base material.

[0013]

In the double-layer molded toilet seat according to the first aspect of the present invention, the heater is built in between the supporting base material and the upper layer portion. The heater is held in a heater mounting groove formed on the surface of the supporting base material. In other words, most of the heater is held securely in the groove fitting part of the heater mounting groove, and the part of the heater that could not be stored in the groove fitting part is held in the groove expansion part. To be done. Therefore, all the heaters are housed in the heater mounting groove, and a part of the heater does not float above the surface of the supporting base material, and the heater can be held at a predetermined position.

A second aspect of the present invention is a method for suitably manufacturing the double-layer molded toilet seat of the first aspect. The manufacturing process is in the following order. A supporting base material having a heater mounting groove is formed. The heater mounting groove is composed of a groove fitting portion and a groove expansion portion. To store the heater in the heater mounting groove, the heater is stored from the groove fitting portion and finally stored in the groove expansion portion. Since the portion of the heater not accommodated in the groove fitting portion is accommodated in the groove expansion portion, the heater does not float above the upper surface of the supporting base material. Therefore, when manufacturing the upper layer portion by injection molding, the heater is not subjected to the high resin pressure of the molten resin.

According to the third aspect of the present invention, by forming the groove expansion portion at a position away from the gate, even if the heater is accommodated in the groove expansion portion in a loose state, a high injection pressure from the gate is not received. Therefore, the heater is not displaced in the groove expansion portion.

According to a fourth aspect of the present invention, the heater mounting groove formed in the surface portion of the supporting base material is provided with a groove deep portion which is arranged closer to the thermal fuse and deeper than the other portions. The heater disposed at is close to the thermal fuse provided on the back surface of the supporting base material. Therefore, the thermal fuse can quickly detect the abnormal temperature of the heater.

In the fifth aspect, the electric element mounted on the supporting base is supplied with electric power from the outside through the socket. The socket is configured by inserting a socket base into a socket mounting hole formed in a supporting base material. The outer peripheral portion of the socket base portion and the inner peripheral portion of the socket mounting hole are joined via a joint portion. Since the joint portion is joined by ultrasonic welding, the sealing property is high, and resin leakage does not occur during injection molding for forming the upper layer portion.

According to the present invention, as the resin material of the socket base portion, a resin material that melts with the supporting base material and has a high melting point or a high heat deformation temperature is used.
When the molten resin for forming the upper layer portion is injected, the molten resin is welded by the heat, but the socket base portion does not lose its shape.

[0019]

Preferred embodiments of the present invention will be described below in order to further clarify the structure and operation of the present invention described above.

FIG. 1 is a perspective view showing a Western-style toilet 20 equipped with a heated toilet seat according to an embodiment of the present invention. As shown in FIG. 1, the western-style toilet 20 includes a toilet body 22 and a toilet body 2.
2, a heating toilet seat 40 and a toilet lid 26 pivotally supported at one end, a sanitary washing device 30 equipped with a washing nozzle, and a washing water tank 28.

The heated toilet seat 40 has a horseshoe-shaped toilet seat body 50 as an upper layer portion shown in FIGS. 2 and 3, and a supporting base material 60 shown in FIG. 4 insert-molded in the toilet seat body 50.
And 2 is a partially cutaway plan view of the heating toilet seat 40, FIG. 3 is a side view of the heating toilet seat 40, FIG. 4 is a plan view of the supporting base material 60, and FIG. 5 is a cross-sectional view taken along line BB of FIG. Is.

As shown in FIG. 4, the supporting base material 60 is inserted into the toilet seat body 50 and has a similar shape in which the outer shape of the heated toilet seat 40 is slightly reduced. Upper surface 61 of supporting base material 60
The heater mounting groove 64 is formed in the shape along the broken line.

A heater unit 70 is provided between the upper surface 61 of the support base 60 and the toilet seat body 50, as shown in FIG. 5 and FIG. . The heater unit 70 includes a linear heater 72 inserted into the heater mounting groove 64, and a sheet material 74 made of aluminum foil and having an adhesive material on one surface thereof.

Further, the heated toilet seat 40 shown in FIG. 2 is provided with a hinge portion 90 at a rear end thereof for rotatably supporting the toilet bowl main body 22, and a heating toilet seat 40 has a lower surface portion with a toilet bowl main body 22. There are formed four cushion parts 120 that contact the upper surface of the. In the cushion portion 120A of the cushion portion 120, a thermal fuse 140 is stored to prevent the heater 72 from exceeding a predetermined temperature due to an overcurrent. Further, the heating toilet seat 40 has a socket 150 for supplying power to the heater 72 from the outside, and a seating surface 50.
A thermistor 170 for detecting the temperature of a is mounted.

The toilet seat body 50 has a temperature of 200 ° C to 240 ° C.
It is formed by injection molding of the ABS resin melted at a position or a PP resin melted at a lower temperature than the ABS resin, and the supporting base material 60 is also formed of the same resin. In addition, in order to obtain heat resistance as the heating toilet seat 40, Sb and Br are added to these resin materials as flame retardants. In addition, the content of these, considering its properties,
It is preferable to adjust Sb: 1 to 10% by weight and Br: 5 to 6% by weight. Further, as a colorant, titanium dioxide is contained in an amount of 1.7 to 4% by weight.

Next, a method of manufacturing the heated toilet seat 40 will be outlined. First, the support base material 60 shown in FIG. 4 is manufactured by injection molding. On the other hand, a sheet material 74 having a predetermined shape is formed by cutting out an aluminum foil. Next, the socket 150 is attached to the support base 60, and then the support base 6
The heater 72 is housed in the heater mounting groove 64 above 0, the thermistor 170 is further mounted, the heater 72 and the thermistor 170 are connected to the terminals of the socket 150, and then the thermistor 170 or the like is taped 180 (180a, 180b).
Then, the sheet material 74 is attached to the support base material 60 so as to cover them with the sheet material 74.

After that, as shown in FIG. 7, the heater unit 70 and the like are placed between the upper mold 202 and the lower mold 204 constituting the molding mold 200 of the injection molding machine while being placed on the lower mold 204. The supporting base material 60 on which is mounted is set. At this time, the cavity 206 is formed between the sheet material 74 and the wall surface of the upper mold 202. Then, the molten resin R is filled into the cavity 206 through the gate 208. Then, after cooling and solidifying, the mold is released and the resin molded body is taken out,
Heating toilet seat 4 by connecting the thermal fuse 140, etc.
0 is completed.

The toilet seat body 50 is firmly fixed to the supporting base material 60 by melting the molten resin at the time of injection molding with the surface portion of the supporting base material 60. The molten resin comes into contact with the supporting base material 60 to melt the surface of the supporting base material 60, but the temperature of the molten resin is lowered by the contact, so that the inside of the supporting base material 60 is also melted. There is no. Further, by using the ABS resin or the PP resin, it is possible to manufacture it with a good appearance and at low cost.

In the above embodiment, the heater 72 is inserted into the heater mounting groove 64 of the support base 60 and covered with the sheet material 74 from above, so that the sheet material 74 has a smooth surface. And the upper surface 61 of the supporting substrate 60.
Firmly adhere to. Therefore, during injection molding, the molten resin R does not cause the heater 72 to shift or deviate.
As a result, there is no partial thin-walled portion of the toilet seat body 50 due to the deviation of the heater 72, and the reduction in strength due to the thin-walled portion does not occur.

Since the sheet material 74 for holding the heater 72 is made of aluminum foil,
The heat of the heater 72 can be efficiently transferred to the seating surface 50a with little heat loss, and the heat can be evenly transferred to the wide seating surface 50a, and the temperature unevenness of the seating surface 50a can be reduced.

Further, the toilet seat body 50 is realized by insert molding to be integrated with the support base material 60, and since there is no gap at the joint, cleaning is easy and the shape of the heating toilet seat 40 itself is also. The shape of the supporting base material 60 can be varied without being restricted, and the supporting base material 60 can be easily manufactured into a shape excellent in sitting comfort and design.

Next, the structure of the characteristic portion of the heated toilet seat 40 will be described.

First, referring to FIGS. 4 and 8 to 10,
Heater mounting groove 64 formed in the upper surface of the supporting base material 60
Will be described. The heater mounting groove 64 (indicated by a chain line in FIG. 4) is provided in the socket 15 for receiving power from the outside.
A groove fitting portion 64a is formed in one streak groove over almost the entire surface of the supporting base material 60 with 0 as the starting point and the ending point. The groove fitting portion 64a is slightly smaller than the cross-sectional shape of the heater 72, and the heater 72 is lightly press-fitted by hand to prevent the heater 7 from coming off due to injection pressure.
It is a shape that can fit and hold 2.

As shown in FIG. 8, a part of the heater mounting groove 64 formed at the front end portion of the supporting base material 60 serves as a groove expansion portion 64b. 9 is a sectional view taken along line CC of FIG. 8, and FIG. 10 is a sectional view taken along line DD of FIG. The groove expansion portion 64b is formed in the lower step portion wider than the cross-sectional diameter of the heater 72, and the depth thereof is the groove fitting portion 64a.
And the front end and the rear end thereof are each R-shaped in plan view.

Next, the heater mounting groove 64 of the supporting substrate 60.
The operation of inserting the heater 72 into the inside will be described. The heater 72 is stored in the groove fitting portion 64a starting from the socket 150, and is finally stored in the groove expanding portion 64b in FIG. At this time, the heater 72 is housed in a loop shape in the groove expansion portion 64b.

Therefore, most of the linear heater 72 is securely held in the groove fitting portion 64a of the heater mounting groove 64, and cannot be stored in the groove fitting portion 64a. The portion of the heater 72 is held by the groove expansion portion 64b. As a result, even with the long heater 72,
All are housed in the heater mounting groove 64, and a part thereof does not float from the upper surface 61 of the support base 60,
The heater 72 can be held at a predetermined position.

Further, when the heater 72 is housed in the heater mounting groove 64, it is not necessary to house all the heater 72 in the groove fitting portion 64a, and the remaining portion may be housed in the groove expanding portion 64b. , Its work is also easy.

Further, the groove expansion portion 6 of the heater mounting groove 64 is provided.
4b is formed at a position away from the gate 208, and does not receive a high injection pressure from the gate 208 even if the heater 72 is accommodated in the groove expansion portion 64b in a loose state.
Therefore, the heater 72 is not displaced or floated up in the groove expansion portion 64b, and there is no partial thin portion of the toilet seat body 50 due to the displacement of the heater 72 or the like, and the reduction in strength due to the thin portion does not occur.

In addition, since the heater 72 in the groove expansion portion 64b is arranged so as to spread in a plane in the groove expansion portion 64b, the temperature distribution on the seating surface 50a of the toilet seat body 50 can be made uniform. .

In addition, the groove expansion portion 64b is finally provided with the heater 7.
The heater mounting groove 6 of the heater 72 is provided in the groove fitting portion 64a in the middle of the groove fitting portion 64a.
You may fine-tune the state that fits in 4. Also in this case, the position far from the gate 208 or the position where the injection pressure is not large is preferable.

Further, although the groove expansion portion 64b of the above-described embodiment is configured to be wider than the groove fitting portion 64a of the heater mounting groove 64, the present invention is not limited to this, and the groove fitting portion 64a is not limited to this.
Any structure may be used as long as it can absorb the portion of the heater 72 that has not been housed therein. For example, the depth may be changed.

Next, the socket 150 will be described.
11 is an enlarged view of a main part of FIG. 2, and FIG. 12 is an E of FIG.
It is sectional drawing along the -E line. A socket mounting hole 152 is formed in an end portion of the support base 60, and a socket base 160 is mounted in the socket mounting hole 152. The socket mounting hole 152 has an upper expansion recess 154.
And a lower through hole 156. Socket base 1
A socket terminal 162 is inserted into the socket 60, and a plug (not shown) connected to a commercial power supply via the socket terminal 162 is removable.

The socket base portion 160 is made of the same ABS resin as the supporting base material 60. However, the socket base portion 160 has a glass melting point to increase its strength and a melting point higher than that of the supporting base material 60.

Further, the socket base 160 has a collar 164.
And an annular leg 166. Collar 164
The lower part of the is attached to the wall surface of the socket mounting hole 152 by ultrasonic welding. That is, in order to perform ultrasonic welding, as shown in FIG.
As shown in FIG.
Insert the socket base 160 into 52 and insert the upper expansion recess 15
The acute angle portion 164a of the flange portion 164 of the socket base portion 160 is brought into contact with the tapered surface 158 formed between the lower portion of No. 4 and the upper portion of the lower through hole 156. In this state, the supporting base material 60
Installed on the support base US, on the upper surface of the socket base 160,
The ultrasonic welding is performed by applying a horn H and applying vibration energy to the horn H. As a result, the acute angle portion 164a of the flange portion 164 of the socket base portion 160 has the tapered surface 158.
Weld to.

Therefore, the socket base 160 is adhered to the tapered surface 158 over the entire circumference of the flange 164 with a high sealing property, and no gap is formed therebetween. Therefore, at the time of injection molding, the molten resin flows from the gap into the socket mounting hole 152.
It does not enter the inside and go around to the lower part of the supporting base material 60, and the molding surface is also beautiful. In addition, since there is no gap, urine, water, detergent, etc., will enter between them and the heater 72
Does not cause poor continuity.

Further, the flange 164 of the socket base 160
Is received by the upper expansion recess 154 of the socket mounting hole 152, so that it is firmly supported against the injection pressure applied from the upper surface of the socket base 160, and the injection pressure is applied in the direction that provides high sealing performance. In addition, it is possible to further prevent resin leakage.

Further, the supporting base 60 and the socket base 16
Since the same material is used as the ABS resin, a part of the bonded portion between the socket base 160 and the supporting base material 60 is melted during injection molding to improve the integrity and the socket base 16
Since the melting point of the resin of 0 is higher than that of the supporting base material 60, the shape of the socket base 160 does not collapse because the socket base 160 is not partially melted by the heat of injection.

In the above-mentioned embodiment, the socket mounting hole 152 and the socket base 160 are adhered by ultrasonic welding. However, the present invention is not limited to this, and another method can be used as long as the both can be surely sealed. Alternatively, for example, an adhesive or a so-called snap fit structure may be used.

Next, the mounting structure of the thermal fuse 140 mounted on the heated toilet seat 40 will be described. FIG. 14 is a cross-sectional view taken along the line FF of FIG. Toilet body 22
The thermal fuse 140 is housed in the cushion portion 120A at the rear portion, which is the upper surface of the thermal fuse 140. That is, the cushion portion 120 </ b> A has the protruding portion 124 that has the storage chamber 122 integrally protruding from the lower portion of the support base material 60 and having an oval cross section.
And the locking portion 130a press-fitted into the opening of the storage chamber 122.
And a cushion member 130 that is attached via the.

At the upper part of the cushion portion 120A, mounting through holes 126, 126 penetrating from the storage chamber 122 to the upper surface 61 of the supporting base material 60 are formed. Mounting hole 12
Fuse terminals 127 and 127 are press-fitted into 6 and 126. The fuse terminals 127 and 127 are connected to the heater 72.
Connected to each of the leader lines. Also, the heater 72
Upper surface 6 with lead wire and fuse terminals 127, 127
A tape 180b is attached to a predetermined portion of No. 1 (FIG. 11). The tape 180b is affixed to the cutout hole portion of the sheet material 74 and strengthens the connection between the fuse terminal 127 and the lead wire of the heater 72, and the heater 7
The second lead wire and the sheet material 74 are prevented from coming into contact with each other, and the molten resin at the time of injection molding is prevented from entering the mounting through hole 126.

Between the fuse terminals 127 and 127,
A thermal fuse 140 is connected to prevent overcurrent of the heater 72. The thermal fuse 140 is molded with a resin filler 129 made of silicon rubber, urethane or the like and insulated from moisture or the like from the outside.

The heater mounting groove 64 is also guided above the thermal fuse 140, and the heater mounting groove 64 in this portion is a groove deep portion 64c formed deeper than the groove fitting portion 64a. There is. As a result, since the portion of the heater 72 housed in the groove deep portion 64c is arranged close to the thermal fuse 140, the thermal fuse 140 quickly senses the heat of the heater 72, and when an abnormal temperature occurs, It is possible to quickly stop the energization of the heater 72.

Next, the heater 72 and the heater terminal 73 will be described. 15A shows a state before the heater terminal 73 is attached to the heater 72, and FIG. 15B shows a state after the attachment. The heater 72 includes a core wire formed of an aromatic polyamide fiber, a coiled heater wire 72a made of copper nickel wound around the core wire, and a coating portion 72b covering the heater wire 72a. The coating portion 72b has a temperature (200 to 25
Since it has heat resistance to 0 ° C., it is made of silicon. Covering part 72b made of silicon
Has heat resistance as described above, but is weak in strength, and when a notch is formed, it is easy to tear from the notch. Therefore, the heater terminal 73 is attached to the heater 72 so that the covering portion 72b is not damaged by the heater terminal 73 attached to the heater 72.
The following configurations are adopted.

The heater terminal 73 has a rod-shaped terminal contact portion 73a fixed to a socket (see FIG. 2) and the like, and a terminal grip portion 73b for gripping the end portion of the heater 72. The terminal gripping portion 73b of the heater terminal 73 includes a tip gripping portion 73b1, a connecting portion 73b2, and a root gripping portion 73b.
3 and 3 are integrally formed. The tip gripping portion 73b1 makes electrical contact by gripping the outer circumference of the heater wire 72a, and both end portions thereof are formed in a corrugated shape, and substantially imitates when gripping the outer circumference of the heater wire 72a. It becomes a shape. On the other hand, the base grip portion 73b3 includes the heater 72.
The cover 72b holds the end of the cover 72b, has a parallelogram in a developed state, and becomes thinner toward the tip. When the end portion of the heater 72 is gripped by the heater terminal 73, the base grip portion 73b3 causes the covering portion 7 of the heater 72 to be covered.
Since the length in the circumferential direction for gripping 2b is large, the gripping force is large. Moreover, the base grip portion 73b3 is connected to the heater 72.
Since it does not bite into the covering portion 72b of the above, the above-mentioned notch that causes a crack does not occur.

The present invention is not limited to the above-described embodiments, but can be implemented in various modes without departing from the scope of the invention.

[0056]

As described above, according to the first aspect of the present invention.
According to the two-layer molded toilet seat of the present invention, by forming the heater mounting groove for accommodating the heater from the groove fitting portion and the groove expanding portion, most of the heater is the groove fitting portion of the heater mounting groove. The heater is securely held in a substantially fitted state, and the portion of the heater that cannot be accommodated in the groove fitting portion is held in the groove expansion portion. Therefore, the heater is entirely housed in the heater mounting groove, and a part of the heater does not float above the upper surface of the supporting base material, so that the heater can be held at a predetermined position.

Further, according to the manufacturing method of the second aspect, when the heater is housed in the heater mounting groove, the heater is housed in order from the groove fitting portion to the groove expanding portion, so that the groove fitting portion is fitted in the groove expanding portion. It is possible to store the portion of the heater that was not stored in the joint portion, and thus the work of storing the heater without floating in the heater mounting groove becomes easy.

According to the third aspect of the present invention, by forming the groove expansion portion of the heater mounting groove at a position distant from the gate, even if the heater is accommodated in the groove expansion portion in a loose state, high ejection from the gate is achieved. Do not receive pressure. Therefore, the heater is not displaced at the groove expansion portion.

According to the fourth aspect of the present invention, the heater mounting groove is formed so as to be close to the thermal fuse and deeper than the other portions, so that the heater disposed in the deep groove can be used as the thermal fuse. Since they are close to each other, the thermal fuse can quickly detect the abnormal temperature of the heater.

According to the fifth aspect, by ultrasonically welding the socket base portion to the socket mounting hole, the sealing performance is high, and resin leakage does not occur during injection molding for forming the upper layer portion.

According to the sixth aspect, as the resin material of the socket base portion, a resin material that melts with the supporting base material and has a high melting point or a high heat distortion temperature is used. When injecting resin,
The heat welds them together, but the socket base does not lose its shape.

[Brief description of drawings]

FIG. 1 is a perspective view showing a Western style toilet 20 equipped with a heated toilet seat 40 according to an embodiment of the present invention.

FIG. 2 is a plan view showing a heating toilet seat 40 partially broken away.

FIG. 3 is a side view showing a heated toilet seat 40.

FIG. 4 is a supporting base material 60 inserted into the heating toilet seat 40.
FIG.

5 is a cross-sectional view taken along the line BB of FIG.

6 is an enlarged cross-sectional view of the main part of FIG.

FIG. 7 is an explanatory view illustrating a resin molding process of the heated toilet seat 40.

FIG. 8 is an enlarged plan view showing the periphery of a groove expansion portion 64b of the heater mounting groove 64.

9 is a sectional view taken along the line CC of FIG.

10 is a cross-sectional view taken along the line DD of FIG.

FIG. 11 is a plan view showing a part of FIG. 2 in an enlarged manner.

12 is a cross-sectional view taken along the line EE of FIG.

FIG. 13 is an explanatory diagram illustrating an ultrasonic welding process of the socket base portion 160.

14 is a cross-sectional view taken along the line FF of FIG.

FIG. 15 is an explanatory diagram illustrating a heater 72 and a heater terminal 73.

FIG. 16 is a plan view showing a conventional heated toilet seat.

FIG. 17 is a cross-sectional view taken along the line AA of FIG.

FIG. 18 is an explanatory view illustrating a manufacturing process of a conventional heated toilet seat.

[Explanation of symbols]

 20 ... Western-style toilet 22 ... Toilet body 26 ... Toilet lid 28 ... Wash water tank 30 ... Sanitary washing device 40 ... Heating toilet seat 50 ... Toilet seat body 50a ... Seating surface 60 ... Support base material 61 ... Top surface 64 ... Heater mounting groove 64a ... Groove fitting portion 64b ... Groove expansion portion 64c ... Groove deep portion 70 ... Heater unit 72 ... Heater 72b ... Covering portion 73 ... Heater terminal 74 ... Sheet material 90 ... Hinge portion 120 ... Cushion portion 120A ... Cushion portion 122 ... Storage chamber 124 ... Projection portion 126 ... Mounting through hole 127, 127 ... Fuse terminal 129 ... Resin filling material 130 ... Cushion member 130a ... Locking portion 140 ... Thermal fuse 150 ... Socket 152 ... Socket mounting hole 154 ... Upper expansion recess 156 ... Lower penetration Hole 158 ... Tapered surface 160 ... Socket base 162 ... Socket terminal 164 ... Collar 164a Acute angle portions 166 ... annular leg 170 ... thermistor 180 ... Tape 180b ... tape 200 ... mold 202 ... upper mold 204 ... lower mold 206 ... cavity 208 ... Gate H ... horn R ... molten resin S ... gap US ... supporting table

 ─────────────────────────────────────────────────── ─── Continued front page (72) Inventor Seiichiro Inoue 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture Totoki Kikai Co., Ltd. (72) Inventor Fumio Uemura Yukicho, Kanda-cho, Kyoto-gun, Fukuoka Prefecture 11 Fukuoka No. 7 Toko Co., Ltd.

Claims (6)

[Claims] 1. A double-layer molded toilet seat with a built-in heater, a supporting base material having a surface portion, a heater mounting groove formed on the surface portion of the supporting base material, and a wire accommodated in the heater mounting groove. A heater, and an upper layer portion that is laminated on the supporting base material and covers the heater. The heater mounting groove has a groove fitting portion that substantially fits the heater and a wire diameter larger than the wire diameter of the heater. A two-layer molded toilet seat, comprising: a groove expansion portion having a cross-sectional area; 2. A method for manufacturing a two-layer molded toilet seat, in which a heater is incorporated between a supporting base material and an upper layer portion, a step of forming a linear heater, and a groove fitting portion for substantially fitting the heater. A step of forming a supporting base material provided with a heater mounting groove having a groove expansion portion continuous to the groove fitting portion and wider than the cross section of the heater; and a heater from the groove fitting portion of the heater mounting groove. The steps of housing the groove expansion part in this order, placing the heater in the groove for mounting the heater in the cavity of the molding die, and injecting molten resin from the gate of the molding die And a step of forming an upper layer portion that covers the heater, and a method for manufacturing a double-layer molded toilet seat. 3. The method for manufacturing a double-layer molded toilet seat according to claim 2, wherein the groove expansion portion of the heater mounting groove is formed at a position apart from the position of the gate of the molding die. 4. A two-layer molded toilet seat with a built-in heater, a supporting base material having a front surface portion and a back surface portion, a heater mounting groove formed on the front surface portion of the supporting base material, and a heater mounting groove. The linear heater is laminated on the supporting base material, and the upper layer part covering the heater is provided on the back surface side of the supporting base material. The heater is connected in series to the heater and the temperature of the heater exceeds a predetermined temperature. The heater mounting groove is arranged so as to be close to the thermal fuse and is deeper so as to be closer to the thermal fuse than the depth of other parts. A double-layer molded toilet seat having a formed groove deep portion. 5. A double-layer molded toilet seat having a built-in electric element, a supporting base material, an electric element mounted on the supporting base material, a socket provided on the supporting base material for supplying electric power from the outside, and a supporting base. An upper layer part that is laminated on the material and covers the electric element; and the socket has a socket mounting hole formed in the supporting base material and a socket base part that is fitted into the socket mounting hole. A two-layer molded toilet seat, wherein the outer peripheral portion of the base portion and the inner peripheral portion of the socket mounting hole are in close contact with each other at a joint portion joined by ultrasonic welding. 6. The double-layer molded toilet seat according to claim 5, wherein the socket base is made of a resin material that melts with the supporting base material and has a high melting point or a high heat distortion temperature with respect to the supporting base material.