US 3060453 A
Abstract available in
Claims available in
Description (OCR text may contain errors)
Oct. 30, 1962 G. D. SWAN 3,060,453
I STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 1 F/6./ FIG. 3 I
// 20 4,5 l INVENTOR.
F/@ 2 /2 650/?65 DEV/E) SWAN Oct. 30, 1962 e. D. SWAN 3,060,453
STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 2 ATTORNEY 1962 G. D. SWAN 3,060,453
STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 3 FIG. 8
i: f 1; v F/6., 9 34/ ll INVENTbR.
United States This invention relates to a structurally and functionally improved stall enclosure, and in its preferred aspects aims to provide such an enclosure for use as a shower stall.
It is a primary object of the invention to furnish a unit of this character which will not require any door or curtain at its portal or entrance, and in which no splash or spray generated by the shower head will cause water to flow outwardly through that portal.
A further object is that of designing a unit of this type which may be economically manufactured, either directly at the locale of installation or otherwise. Where manufactured at a relatively distant location, the several parts providing the enclosure may be produced in quantity and readily stored in compact organizations for ship ping or other purposes.
In any event, by means of the present teachings, an assembly is provided which will include only a few parts, capable of being readily coupled to each other to furnish a leakproof stall functioning with freedom from all difiiculties for indefinite periods of time. Moreover, the parts may be combined in various manners by relatively unskilled labor to furnish desired layouts compatible with the design of any given building and space capable of accommodating the stall.
A still further object is that of teaching an improved method of manufacture whereby one or more of the components of the stall enclosure may be provided. However, those units may be otherwise manufactured. Also, the herein-described method may be advantageously employed to furnish desired sheets of material for other units.
With these and other objects in mind, reference is bad to the attached sheets of drawings illustrating one practical embodiment of the invention, and in which:
FIG. 1 is a fragmentary front elevation of the entrance or portal portion of the enclosure;
FIG. 2 is a sectional plan view thereof;
FIG. 3 is a transverse sectional view taken along the line 3-3 in the direction of the arrows, as indicated in FIG. 2;
FIGS. 4 and 5 are sectional side views taken along the line 4--4 and 5-5 in the direction of the arrows, as indicated in FIG. 2, 'and showing the preferred roof and base sections of the stall;
FIG. 6 is an exploded perspective view of the preferred components which provide the enclosure;
FIG. 7 is a fragmentary enlarged sectional View of a detail of the assembly involving the side wall and pan portions thereof; and 1 FIGS. 8 and 9 are fragmentary sectional views, inenlarged scale, illustrative of the procedure to be followed in conforming to the improved method.
It is to be understood that an enclosure embodying the present teachings is primarily intended to be in cluded within a housing structure which will ordinarily embrace an adjoining room. It may, of course, form a separate unit. In any event, vertically extending supporting members 10 are included in thestructure, and certain of these are spaced a distance equal to that which is to define the width of the portal or entrance portion of the stall. A facing sheet or wall structure 11 may intervene these members and may also mount a frame 12 of suitable outline to define the entrance. Additionally, there will normally be included in the structure a floor 13 of any desired material mounted upon supporting beams 14. The stall itself will include a side wall supported upon a pan base and preferably covered by a ceiling part, as hereinafter described in detail. These units will extend adjacent and be braced in any suitable manner by the supporting structure of the housing, and especially vertical members such as 10, the wall section 11 and where otherwise necessary. Such bracing has not been shown in detail in the present illustrations. As has been shown, however, the pan will rest upon the floor section 13 or its equivalent.
Considering the side wall of the stall, it will include a Sheet of material having an outer end portion 15 which is continued in the form of a spiral or volute shape, as indicated at 16, throughout the greater part of a circle. The sheet is continued in the form of a fitting-mounting face 17, in turn continued in a reversely curved surface 18 terminating in a face 19 extending substantially parallel to and spaced from surface 15. The outer edge zones of surfaces 15 and 19 terminate in a jamb embracing angularly extending flange portions 2t). The spacing between surfaces 15 and 19 is adequate to furnish a portal or entrance portion. Surface 17 has an area such that it may support without difiiculty fittings such as valve handles 21 and 'a shower head 22. Other fittings may also, if desired, be thus supported.
In the latter connection it will be observed, as indicated by the dotted lines 23, a further and relatively low wall may intervene spaced zones of the sheet providing surfaces 15 and 19, to define a tub. By having this wall extend at elected angles, the area of the tub may be increased or diminished at will. Of course, a separate tub may be positioned within the stall; the side wall of the latter being contiguous and suitably joined to the faces of the tub in any acceptable manner Normally, however, the stall will include merely a shower head fitting and the valves controlling the flow of water. As illustrated especially in FIG. 2, face or baflle surface 17 extends outwardly from the axis defined by surfaces 18 and 19 at an angle of approximately 45". In any event, the sheet furnishing the side wall extends throughout substantially one convolution.
Where a tub is present the rim of the same will act as a splash guard, such that the angle of mounting face 17 may be decreased. This angularity may be diminished to a point where it is just slightly in excess of Where no tub or other splash guard is present, the angularity of face 17 should not be less than substantially In all events, the fitting-mounting face or baffle 17 should be located at a point approximately midway between face 15 and the opposite inner end wall of the stall. If the tub rim extends as shown in FIG. 2, a second drain opening may be provided between the rim and the sill or curb of the pan base.
Considering the pan base, it will preferably include a deck or lower surface 24-. The outline of the latter will conform to the normal outline of the side wall. However, the area of that base will be slightly less than that defined by the side wall. This will be true when the latter is unrestrained and simply placed on a horizontal supporting surface. Otherwise, the normal outline f the side wall and base are in their main parts identical. Extending upwardly from the deck 24- and integral therewith is a side wall 25. Intermediate its upper and lower edges, this wall is flanged outwardly, as at 26', to provide a sheet supporting or ledge surface. The end zones of this wall extend parallel to each other and are joined by a sill or curb 26 providing a connecting structure formed with shoulders 27 in line with the ledge 26. As shown especially in 'FIG. 7, a grid pattern. may extend outwardly from the lower face of deck 24; a portion of that pattern having been indicated at 28. By such an expedient, the base pan is suitably rigidified.
The ceiling of the stall may be furnished by a nit generally indicated at 29, the parts of which are ge erally a mere reversal of those providing the base pan- Flange portions 20 are preferably continued, as indicated at 30 and 31, to furnish contact portions or face plates bearing against the shoulders of surfaces 27. As will be noted, the inner vertical walls of those shoulders are spaced from the corresponding faces of wall 25 to furnish openings such that the adjacent edge zones of the main side wall may pass therethrough to accordingly furnish an interlocking structure. Conveniently after manufacture, deck surface 24 may be formed with an opening 32 accommodating a drain pipe 33. Similarly, the ceiling section 29 may be formed with such an opening, which in that instance conveniently serves to accommodate a lighting fixture (not shown). Shoulder 27 forms a face plate to receive horizontal flanges 31. Wall section 25 terminates at sill 26, so that when the parts are in posit-ion, a locked joint is provided.
As particularly hown in FIGS. 4 and 5, the main housing structure may include horizontally extending structural parts 33. These will extend respectively into the sections 26 of the ceiling part and the base pan, to suitably rigidify them. The sheet forming the main side wall, in addition to being supported by joists or similar units, will be rigidifled by the frame 12. To achive this, and as shown in FIG. 2, flange portions 20 may be interposed between that frame and the adjacent surface of wall 11.
The materials providing the units of the stall or enclosure are formed of sprayed resins reinforced by Fiberglas. These resins, according to the preferred concept of this invention, will be of the type which will set at room temperatures. Inexpensive forms or patterns for the production of theparts may be made of any number of materials, such as ordinary wood, plywood, composition materials, etc. Styrene is especially useful in the providing of patterns, in that its surface is free of pits and irregularities.
ere the assembly is produced at a manufacturing plant, pressure molding will preferably be used. Otherwise, a spray gun will be used for the distribution of the desired resin material, and will shred the ropelike fibers of Fiberglas. These resins are mixed with any desired colors and the required catalyst in One continuous operation. The wall casting produced according to any procedure will be designed to sweep in a wider are than that of the base or ceiling. This will create a springlike action when the Wall unit is fitted onto the adjacent base and ceiling parts, if the latter is used.
In thi connection, it will be understood that the ceiling may, of course, be separately formed to include a decorative surface, a transparent or translucent member, or otherwise. In any event, the spring action due to the inherent memory of the plastic employed exerts sufficient pressure along the curved flange or ledge of the base casting to hold the wall in place. This may be achieved without the use of fasteners or adhesives, although desired materials may, of course, be employed. The open form of the wall casting permits nesting of a number of these units, thus minimizing problems ordinarily arising in storage or shipment. Also, it facilitates handling at a job site, where building equipment must necessarily pass through normal openings. The base and ceiling units being identical except for reversal of pattern, provide, in conjunction with the side wall, a monolithic structure. The overlapping of the base and side wall unit forms a locked joint. Similar joining of the ceiling casting assures structural solidity and stability. The amalgamated whole is comparable to a capsule including top and bottom caps. By upending the assembly, a reversal of the unit is feasible, so that flexibility of the finished plan is possible without resorting to separate and special castings.
As afore brought cut, surface 17 extends at a 45 angle with the axis of the opening or portal. By having the parts thus disposed, it becomes practically impossible to splash water through that opening. When the jamb is fastened as described, its hooklike edge zones form an anchor for the main spring action of the wall section. With a ceiling unit being employed, both the upper and lower ends of the portal surfaces are anchored to maintain stability and proper configuration of the entrance.
A preferred method of forming parts of the enclosure has been diagrammatically illustrated in FIGS. 8 and 9. That method may, however, be employed to advantage in the manufacture of articles other than one or more of the components providing the stall.
Thus, as shown in these figures, the numeral 34 indicates the mold, conveniently formed of plywood, styrene, Fiberglas, metal or other suitable materials, and the surface of which should have a fine or polished finish. If necessary, that surface may be coated with a resin-base lacquer 35 and a superimposed layer 36 of mold-release material. The latter may be wax, Teflon, silicone, etc. T hereupon, a layer 37 of a resin which sets at room temperature is applied. That resin may be a suitable epoxy, polyester or vinyl. While this layer is still somewhat adhesive, fine particles 38 are embedded therein. These particles may be glass or stainless steel beads, marble, Carborundum, granite, etc. A flock gun may be employed to distribute them. In the case of glass beads, they may be approximately .003" in diameter. In any event, they should be disposed with their edges touching each other. A mat 49 of woven Fiberglas may be applied to the outer faces of pellets 38, and a further resin layer may be sprayed thereover and through its interstices to thus form a completed panel. Otherwise, if required, a further layer 39 may cover the particles 38, and in this layer there may be incorporated reinforcing in the form of shredded flakes of suitable material, particles of Piberglas and a proper catalyst such as triethylenetetranium, commonly known as Teta. Layer 39 will conveniently be of the same material as layer 37. Further pellets or beads may be added. The material is now allowed to cure to a consistency such that it may be removed, without damage, from the mold.
With the assembly sufliciently cured, it is stripped off mold 34. If a relatively rough texture is desired, the unit may now be used. Usually, the procedure is continued by grinding and polishing the surface which has been in contact with the mold down to the line XX in FIG. 9. This will approximate half the thickness of particles 38. These being in substantial contact with each other, a flat, non-abrasive and impervious surface results. This surface may be cleaned by scouring. By forming a grooved or embossed design in the mold surface, that design will be embodied in the finished article.
That article may be flexed without separation of the minute beads, which are homogeneous with the cast sheet. The widest diameter of those beads being exposed after the grinding operation, only a minimum of plastic is exposed to surface abrasion. By silvering those beads prior to including them in the unit, a highly reflective and desirable surface results. Thus a surface is provided that may be used to advantage in the present stall, and will also be useful in counters, screens, wallboard, etc.
Thus, among others, the several objects of the invention as specifically aforenoted are achieved. Obviously, numerous changes in construction and rearrangement of the parts might be resorted to, and the steps of the method might be varied, without departing from the spirit of the invention as defined by the claims.
1. A shower stall including in combination a spirally curved sheet embodying resiliency such that it tends to expand, said sheet providing a vertical wall of substantially one convolution, outwardly extending parts at the ends of said sheet and disposed in parallel and spaced relationship to thus provide a portal, a fitting-mounting face forming a part of said sheet and extending away from the portal entrance at an angle to the axis of that entrance, a pan base for mounting said sheet, said base having an spe r53 outline substantially conforming to the outline defined by said sheet and a surface of said pan extending exteriorly of said sheet and providing a recess to receive and retain the lower edge zone thereof to retain its ends against separative movements.
2. In a stall as defined in claim 1, said sheet being relatively thin and flexible, the area defined by the normal outline of the lower edge of the sheet being slightly difierent from that of the sheet-receiving surface of the base, an outer wall forming a part of said base and including said recess and surfaces of said wall and sheet overlapping and being maintained in contact; due to the expansive tendency of said sheet.
3. In a stall as defined in claim 1, a curbing forming a part of said base and extending above the face of the latter between the outwardly extending parts of said sheet and shoulders at the ends of said curving and the edge zones of said sheet being supported upon said shoulders.
4. A stall including in combination a spirally disposed sheet of material having its ends separated to define a portal therebetween and embodying resiliency such that those ends tend to separate, a pan including a deck and an upwardly extending side wall defining a space less than the outline which said sheet tends to assume, the lower edge zone of the outer sheet face bearing against the inner face of said side wall to restrain separation of its ends beyond a certain distance, a connecting structure forming a part of said base and intervening the ends of said sheet and said structure providing surfaces to receive and sup port the end zones of said sheet.
5. In a stall as defined in claim 4, one end zone of said sheet including a face extending substantially parallel to the zone at the opposite end of said sheet, said connecting structure being in the form of a sill extending upwardly from said base and of a length substantially equal to the distance between the sheet ends and parallel surfaces forming parts of said sill to engage with the end zones of said sheet.
6. In a stall as defined in claim 5, the parallel surfaces of said sill comprising shoulders extending outwardly thereof, an outwardly extending ledge in the side Wall of said base and substantially in line with said shoulders and the lower edge of said sheet resting upon said ledge and shoulders.
References Cited in the file of this patent UNITED STATES PATENTS 1,215,681 Maury et al Feb. 13, 1917 1,235,091 Anderson July 31, 1917 2,204,929 Fairhurst June 18, 1940 2,757,385 Whittick Aug. 7, 1956 2,805,974 Brucker Sept. 10, 1957 2,845,379 Bey July 29, 1958 FOREIGN PATENTS 791,268 France Sept. 23, 1935