JP5976306B2 - Toilet seat and its manufacturing method - Google Patents

Description

  The present invention relates to a toilet seat sheet that is detachably mounted on the upper surface of a toilet seat of a Western-style toilet and a method for manufacturing the toilet seat.

  From the standpoint of improving seating comfort and heat retention as well as hygiene considerations, it is often done with a toilet seat cover made of fabric (woven fabric, knitted fabric, non-woven fabric). Things are commercially available.

  In general, the upper surface of the toilet seat is mostly O-shaped or U-shaped. In addition, it is also popular to wear an inverted U-shaped cleaning / heating device. As a toilet seat cover that can be mounted on any of these shapes, a toilet seat cover is known that is composed of a pair of seats formed in a substantially crescent shape that is long and symmetrical in the front-rear direction so as to substantially follow the planar shape of the toilet seat. Yes. The sheet body is composed of a pressure-sensitive adhesive layer made of a resin having adhesiveness formed by laminating on the surface fiber layer and the back surface thereof (for example, Patent Document 1).

  A polyester fabric that is easy to process is often used as the surface fiber layer of the sheet body. However, even if an antibacterial agent or deodorant is used to impart antibacterial / deodorant performance to the polyester fabric, these only remain on the fabric surface and can be easily removed by washing.

  Then, this inventor considered using the cloth | dye by the acrylic thread which can mix | blend an antibacterial agent and a deodorizing agent with raw material fiber. At that time, the problem was edge processing.

  In order to manufacture such a toilet seat sheet, generally, a large sheet material is cut into a crescent shape by punching. At that time, foamed resin and non-woven fabric are not a problem, but those made of woven fabric and knitted fabric including acrylic fiber will unwind and fall out of the edge if the edge is not treated in any way. . For this edge treatment, a product in which the edge portion is taped and sewn with tape is also known, but it has been found that when washing, the end gradually warps and looks worse.

Therefore, the present inventor considered ultrasonic cutting welding instead of punching, but for example, acrylic fibers are difficult to melt, and acrylic fibers and other materials (polyester, etc.) have different melting points. and Tsu or such can be sufficiently melted fix the edge portion. The present inventor has repeated trial and error and found that the edge portion can be melted and fixed only when various conditions are met.

  Accordingly, an object of the present invention is to provide a toilet seat sheet having an acrylic fiber surface, which is cut by an ultrasonic cutting machine, that does not collapse the outline without special edge treatment, and a manufacturing method therefor Is to provide a method.

The toilet seat sheet of the present invention, in a first aspect, is a pair of crescent-shaped sheets that are detachably mounted on the toilet seat of a Western-style toilet bowl or the toilet seat of its washing / heating device, The sheet 2 has four layers of a knitted fabric layer composed of at least a front yarn 21 and a back yarn 22, a core material layer 23, a cushion layer 24, and an adhesive layer 25. The front yarn 21 is kneaded with an antibacterial agent or deodorant. The back yarn 22 is a polyester yarn, and the core layer 23 is any one of a polyester spunbond nonwoven fabric, a polyester canvas, and a polyester hot melt sheet ( Claim 1).

  In a second aspect, the present invention is a pair of sheets formed in a crescent shape that is detachably attached to the upper surface of a toilet seat of a Western-style toilet bowl or a cleaning / heating apparatus thereof, wherein each of the sheets is It consists of at least four layers: a surface yarn layer, a core material layer, a cushion layer, and an adhesive layer. The surface yarn layer is an acrylic yarn, and the core material layer is made of a polyester spunbond nonwoven fabric, a polyester canvas, and a polyester layer. It is one of hot melt sheets, and the core material layer and the cushion layer are tufted with acrylic yarn of the surface yarn layer (Claim 2).

Preferably, the basis weight of the core material layer is 10 to 300 g / m ² , more preferably 30 to 200 g / m ² (Claim 3).

Preferably, the cushion layer is a thick nonwoven fabric or polyurethane, and the weight per unit area is 50 to 300 g / m ² , more preferably 70 to 250 g / m ² (Claim 4).

Preferably, the basis weight of the knitted fabric layer composed of the front yarn and the back yarn is 200 to 700 g / m ² , more preferably 400 to 600 g / m ² (Claim 5).

  At the time of sale, the pressure-sensitive adhesive layer is covered with a release sheet (Claim 6).

The method of the present invention, in a first aspect, is a method for producing a pair of sheets formed in a crescent shape that is detachably mounted on the toilet seat of a Western-style toilet or the toilet seat of its washing and heating device, Each sheet 2 has at least four layers of a knitted fabric layer composed of a front yarn 21 and a back yarn 22, a core material layer 23, a cushion layer 24, and an adhesive layer 25. The front yarn 21 contains an antibacterial agent or deodorant. Acrylic yarn kneaded , the back yarn 22 is a polyester yarn, and the core material layer 23 is ultrasonically cut and welded with a toilet seat sheet, which is one of a polyester spunbond nonwoven fabric, a polyester canvas, or a polyester hot melt sheet. Cutting and welding with a machine (Claim 7).

  In a second aspect, the method of the present invention is a method for producing a pair of sheets formed in a crescent shape, which is detachably mounted on the toilet seat of a Western-style toilet or the toilet seat of its washing / heating device, Each of the sheets is composed of at least four layers of a surface yarn layer, a core material layer, a cushion layer, and an adhesive layer, the surface yarn layer is an acrylic yarn, and the core material layer is a polyester spunbond nonwoven fabric or a polyester canvas. The toilet seat sheet is a polyester hot melt sheet, and the core material layer and the cushion layer are tufted with acrylic yarn of the surface yarn layer, and is cut and welded by an ultrasonic cutting welding machine. And

  According to invention of Claim 1 and 2, the toilet seat sheet | seat which has the surface of acrylic yarn cut | disconnected with the ultrasonic cutting | disconnection welding machine, Comprising: Even if it does not carry out a special edge process, what does not collapse an outline is obtained.

  According to invention of Claims 3-5, the preferable aspect of the toilet seat sheet | seat of Claim 1 is shown.

  According to the invention of claim 6, the pressure-sensitive adhesive layer is protected until use.

  According to the method invention of Claims 7 and 8, by using an ultrasonic cutting and welding machine, edge processing of a toilet seat sheet having an acrylic fiber surface, which cannot be achieved by a conventional punching machine, can be performed. In addition, since an ultrasonic cutting and welding machine is used, not only straight portions but also curved portions can be freely processed and endless processing can be performed.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

It is a perspective view of a western style toilet equipped with the toilet seat sheet of the present invention. It is (a) front view and (b) side view of a toilet seat. It is a cross-sectional view which concerns on 1st Example of the arrow part of FIG. (A)-(c) is sectional drawing which shows the three-step manufacturing process of the toilet seat sheet which concerns on 1st Example. It is a cross-sectional view which concerns on 2nd Example of the arrow part of FIG. (A)-(c) is sectional drawing which shows the three-stage manufacturing process of the toilet seat sheet which concerns on 2nd Example.

  As shown in FIG. 1, the toilet seat sheet of the first embodiment is detachably mounted on the upper surface of the toilet seat 11 of the western toilet 1. The toilet seat 2 is composed of a pair of seats formed in a substantially crescent shape that is long in the front-rear direction and symmetrical to be substantially in line with the planar shape of the toilet seat.

  As shown in FIG. 3, the toilet seat 2 is composed of four layers when in use. A knitted fabric layer comprising a front yarn 21 and a back yarn 22, a core material layer 23, a cushion layer 24, and an adhesive layer 25 in this order from the top. At the time of sale, the pressure-sensitive adhesive layer 25 is covered with the release sheet 26, and thus has five layers.

The front yarn 21 is 100% acrylic yarn having a height of about 5 to 10 mm. The back yarn 22 is composed of 2 to 5 100% polyester yarns. The front yarn 21 and the back yarn 22 are knitted at the base portion, and the front yarn is exposed on the surface. The basis weight of these two layers is preferably 200 to 700 g / m ² , more preferably 400 to 600 g / m ² .

For the core material layer 23, a polyester spunbond nonwoven fabric, a canvas, a hot melt sheet, or the like can be used. The basis weight of the core material layer 23 is 10 to 300 g / m ² , more preferably 30 to 200 g / m ² . For example, in the case of “Marix” (trademark of Toray Industries, Inc.) which is a spunbond nonwoven fabric, it is 30 to 60 g / m ² , and in the case of other nonwoven fabrics, it is 160 to 200 g / m ² .

The cushion layer 24 is made of a thick nonwoven fabric or polyurethane, and has a basis weight of 50 to 300 g / m ² , more preferably 70 to 250 g / m ² .

The pressure-sensitive adhesive (including the adhesive) that constitutes the pressure-sensitive adhesive layer 25 is required to be sticky enough that it does not shift or fall off during use, but can be easily peeled off from the toilet seat during replacement. Therefore, it must have an appropriate adhesion or adhesive strength. As long as these conditions are satisfied, any known pressure-sensitive adhesive (or adhesive) may be used. Preference is given to pressure-sensitive acrylic and polyurethane pressure-sensitive adhesives (or adhesives). It may contain a foaming agent.

  The release sheet 26 is not particularly limited as long as it can protect the pressure-sensitive adhesive layer 25, but PET is particularly preferable.

A method for forming the edge of the toilet seat 2 will be described.

First, it is preferable to integrate the core material layer 23 and the cushion layer 24 by a method such as needle punching because it facilitates the subsequent work, but this integration step can also be omitted. A knitted fabric layer made of the front yarn 21 and the back yarn 22 is bonded to the core material layer 23 and the cushion layer 24 with an adhesive. Subsequently, the pressure-sensitive adhesive layer 25 and the release sheet 26 are adhered.

The toilet seat sheet composed of the above five layers is melted and cut by an ultrasonic cutting and welding machine. The ultrasonic cutting and welding machine used is “LWU-3016” manufactured by Quinlight Electronic Seiko Co., Ltd. (Wakayama Prefecture). This ultrasonic cutting and welding machine performs cutting and welding between the horn 3 and the lower anvil 4.

From the state of FIG. 4 (a), the horn 3 is pressed against the toilet seat sheet, (b) is cut and the periphery is welded (c).

  Table 1 is an effect confirmation test result table which was performed while fixing the conditions of acrylic as the front yarn 21 and polyester as the back yarn 22 and changing other conditions. According to this, in order to melt and fix the edge portion, the following conditions are considered necessary.

At least four layers of a knitted fabric layer comprising a front yarn 21 and a back yarn 22, a core material layer 23, a cushion layer 24, and an adhesive layer 25 are required. Among them, it is important to appropriately select the core material layer and the cushion layer.

As the core material layer 23, “Marix” (weight per unit area: 30 to 60 g / m ² ), which is a polyester spunbond nonwoven fabric, and polyester canvas (weight per unit area: 160 to 200 g / m ² ) are preferable.

Preferred as the cushion layer 24 is a polyester non-woven fabric (weight per unit area 70 to 250 g / m ² ).

  5 and 6 show a second embodiment of the present invention.

  As shown in FIG. 5, the toilet seat 2A is composed of four layers when in use. The top yarn layer 21A, the core material layer 23A, the cushion layer 24A, and the pressure-sensitive adhesive layer 25A are arranged in this order from the top. At the time of sale, since the pressure-sensitive adhesive layer 25A is covered with the release sheet 26A, it has five layers.

Compared with Example 1, the back yarn 22 does not exist. Further, unlike the first embodiment, the core material layer 23A and the cushion layer 24A are tufted by the acrylic yarn constituting the surface yarn layer 21A.

The material and basis weight of the surface yarn layer 21A, the core material layer 23A, the cushion layer 24A, the pressure-sensitive adhesive layer 25A, and the release sheet 26A are the same as in Example 1.

A method for forming the edge of the toilet seat 2A will be described.

First, the acrylic yarn constituting the surface yarn layer 21A integrates the core material layer 23A and the cushion layer 24A by tufting. Subsequently, the pressure-sensitive adhesive layer 25A and the release sheet 26A are adhered.

The toilet seat sheet composed of the above five layers is melted and cut by an ultrasonic cutting and welding machine. The ultrasonic cutting and welding machine used is “LWU-3016” manufactured by Quinlight Electronic Seiko Co., Ltd. (Wakayama Prefecture). In this ultrasonic cutting and welding machine, cutting and welding is performed between the horn 3 and the lower anvil 4.

From the state of FIG. 6A, the horn 3 is pressed against the toilet seat sheet (b) is cut and the periphery is welded (c).

Japanese Utility Model Publication No. 2-19298

1 Western-style toilet 11 Toilet seat 2,2A Toilet seat sheet 21,21A Front thread (layer)
22 Back thread 23, 23A Core material layer 24, 24A Cushion layer 25, 25A Adhesive layer 26, 26A Release sheet 3 Horn 4 Anvil

Claims (5)

A pair of seats formed in a crescent shape, detachably attached to the upper surface of a toilet seat of a Western-style toilet bowl or a cleaning / heating device thereof,
Each of the sheets (2A) has at least four layers of a surface yarn layer (21A), a core material layer (23A), a cushion layer (24A), and an adhesive layer (25A),
The front yarn (21A) is an acrylic yarn,
The core material (23A) is any one of a polyester spunbond nonwoven fabric, a polyester canvas, and a polyester hot melt sheet,
The toilet seat sheet, wherein the core material layer (23A) and the cushion layer (24A) are tufted with acrylic yarn of the front yarn (21A). Claim 1 Symbol mounting of toilet seat basis weight is 10 to 300 g / m ² of the core layer (2 3A). Toilet seat according to claim 1 or 2 in serial placement basis weight is 50 to 300 g / m ² of the cushion layer (2 4A). The toilet seat sheet according to any one of claims 1 to 3 , wherein the pressure-sensitive adhesive layer ( 25A) is covered with a release sheet ( 26A). A method for producing a pair of seats formed in a crescent shape, which is detachably attached to the upper surface of a toilet seat of a Western-style toilet bowl or a cleaning / heating device thereof,
Each sheet (2A) has at least four layers of a surface yarn layer (21A), a core material layer (23A), a cushion layer (24A), and an adhesive layer (25A),
The surface yarn layer (21A) is an acrylic yarn,
The core layer (23A) is any one of a polyester spunbond nonwoven fabric, a polyester canvas, and a polyester hot melt sheet.
The toilet seat is characterized in that the core layer (23A) and the cushion layer (24A) are tufted with acrylic yarn of the surface yarn layer (21A). The toilet seat is cut and welded by an ultrasonic cutting welding machine. Sheet manufacturing method.

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