Abstract A toilet seat, exclusive of the hinge assembly, has only a resilient expanded-foam interior and a plastic film sheet cover. The toilet seat is made by pre-forming the film sheet cover in a mold and heat sealing it to form a tubular ring-like structure or annulus into the interior of which expandable foam material is injected to expand and fill the annulus. As an alternate method of manufacture, the resilient foam interior is pre-formed in a mold and then covered with plastic film which is heat sealed. The toilet seat has no rigid base of wood, or other material. A small rigid bar of metal or other material is cemented to the interior of the seat. The bar has tapped holes therein for receiving screws of the hinge assembly.
The method of making a toilet seat comprising the steps of: a. mold-forming an annular recess in a first sheet of plastic film to form the upper portion of a tubular annular cover member; b. fastening a bar of rigid material to an inner surface of a second sheet, said bar having tapped holes therein for receiving hinge screws; c. placing said second sheet of plastic film in contiguous relation to the annular recess of the mold-formed first sheet; d. heat sealing the first and second sheets together along the inner and outer edges of the annular recess; e. injecting expandible resilient plastic foam material through one of said tapped holes in said rigid bar into the interior of the sealed annulus to fill the same upon expansion of said foam material and allowing trapped air to escape through another of said tapped holes; and f. removing the excess film sheet material inside and outside the annular seals.
Claim 2
Independent Claim
158 words
The method of making a toilet seat comprising the steps of: a. mold-forming an annular recess in a first sheet of plastic film to form the upper portion of a tubular annular cover member; b. fastening a bar of rigid material to an inner surface of a second sheet, said bar having tapped holes therein for receiving hinge screws; c. placing said second sheet of plastic film in contiguous relation to the annular recess of the mold-formed first sheet; d. heat sealing the first and second sheets together along the inner and outer edges of the annular recess; e. injecting expandible resilient plastic foam material through one of said tapped holes in said rigid bar into the interior of the sealed annulus to fill the same upon expansion of said foam material and allowing trapped air to escape through another of said tapped holes; and f. removing the excess film sheet material inside and outside the annular seals.