Method of molding a toilet seat assembly

Abstract

A toilet seat assembly 10 includes a toilet seat 12 having a seat skin 14 defining the exterior surfaces thereof and a seat core 16 disposed within and surrounded by the seat skin 14 and a cover 18 having a cover skin 20 defining the exterior surfaces thereof and a cover core 22 disposed within and surrounded by the cover skin 20. The assembly is characterized by the cores 16, 22 each comprising a waste material. The waste material may be a single polymer wasted in the process of making other products. Alternatively or in combination therewith, combining a plurality of different materials (including different polymers) from different sources may be employed to formulate the waste material.

What is claimed is:  
     
         1 . A method of fabricating a toilet seat ( 12 ) and cover ( 18 ) comprising the steps of; 
 forming a seat ( 12 ) having a seat core ( 16 ) surrounded by a seat skin ( 14 ),    forming a cover ( 18 ) having a cover core ( 22 ) surrounded by a cover skin ( 20 ),    said method characterized by forming said cores ( 16 ,  22 ) of a waste material.    
     
     
         2 . A method as set forth in  claim 1  further defined as combining a plurality of different materials from different sources to formulate the waste material.  
     
     
         3 . A method of molding a toilet seat ( 12 ) and cover ( 18 ) comprising the steps of; 
 injecting a skin polymer into a seat mold cavity ( 24 ) and into a cover mold cavity ( 26 ), and    injecting a waste material into the seat mold cavity ( 24 ) and into the cover mold cavity ( 26 ) to fill the skin polymer.    
     
     
         4 . A method as set forth in  claim 1  further defined as injecting a waste material including a mixture of waste polymers from different sources.  
     
     
         5 . A method as set forth in  claim 1  further defined as injecting a waste material including particles of wood.  
     
     
         6 . A method as set forth in  claim 1  further defined as collecting solidified polymers from molding processes for products other than toilet seat assemblies, dividing the solidified polymers into a granular mix, heating the granular mix into a flowable mix, and injecting a waste material including the flowable mix.  
     
     
         7 . A method as set forth in  claim 4  including the step of molding the seat ( 12 ) and cover ( 18 ) in the same mold having a gate ( 32 ,  34 ) interconnecting the seat and cover mold cavities.  
     
     
         8 . A toilet seat assembly comprising; 
 a toilet seat ( 12 ) including a skin defining the exterior surfaces and a core disposed within and surrounded by said seat skin ( 14 ),    a cover ( 18 ) including a cover skin ( 20 ) defining the exterior surfaces thereof and a cover core ( 22 ) disposed within and surrounded by said cover skin ( 20 ),    said assembly characterized by said cores ( 16 ,  22 ) each comprising a waste material.    
     
     
         9 . An assembly as set forth in  claim 10  wherein said skins comprise a polymer and said waste material includes a mixture of different waste polymers.  
     
     
         10 . An assembly as set forth in  claim 10  wherein said waste material includes particles of wood.