1. Field of the Invention
The present invention relates generally to sliding shower doors, and, more particularly, to a headerless sliding shower door assembly.
2. Background of the Invention
Most conventional sliding shower door panels are comprised of fully framed translucent panels, where the frames are made from aluminum or other non-rusting metallic material. Fully framed shower door panels, though functional, are undesirable from a manufacturing, as well as an aesthetic point of view. Fully framed shower door panels are undesirable from a manufacturing viewpoint because of the material and labor costs incurred in fabricating and installing the metal frames about the translucent panels. Fully framed shower doors are also undesirable from an aesthetic point of view because unsightly oxidation typically develops on the framing members within a short period of time.
The aesthetic functionality of a shower door may be improved if a method may be devised to eliminate the door frames. Likewise, elimination of the door frames would improve manufacturing efficiency by eliminating material costs and reducing manufacturing operations. Some efforts towards frameless shower doors have been attempted in the art. In particular, shower doors in which the vertical framing members are eliminated have been developed. Such doors, while a step forward in the art, nevertheless typically still retain horizontal framing members such as a lower horizontal rail member and an upper horizontal header member and therefore suffer from all of the drawbacks of fully framed shower doors, albeit to a somewhat lesser degree. Thus, there remains room for improvement in the art.
It is the purpose of the present invention to provide a completely frameless sliding shower door assembly, i.e. an assembly that eliminates not only the vertical framing members of prior art doors, but also the vertical header and rail members as well.
An exemplary embodiment of the present invention presents a fully frameless sliding shower door assembly. The assembly dispenses with the need for vertical framing members by using door panels of sufficient strength and rigidity to be fully self-supporting. The need for an upper horizontal header member is eliminated by using a unique upper guide assembly where the guide is fixed to a movable shower door panel and configured to slide about a top edge of a stationary or fixed shower door panel. The upper guide assembly, being fixed to the moveable shower door panel and sliding about a top portion of the fixed door panel, therein uses the fixed door panel to provide lateral support for the movable door panel.
The need for a lower horizontal rail member is eliminated by the use of a unique roller assembly that is attachable to the movable door panel without the need for a rail member. One or more of the roller assemblies may be used in the shower door assembly as may be desired depending upon the size of the rollers, weight of the door to be supported, and aesthetic considerations. The roller assembly features an inverted generally U-shaped profile on the roller which engages with a matching, non-inverted generally U-shaped profile on the track. The mating inverted and non-inverted U-shaped profiles on the roller and track, respectively, make the roller self-centering upon the track, and therefore eliminates the need for guide channels formed into the track as is typical of prior art designs. The use of inverted and non-inverted U-shaped surfaces on the roller and track, respectively, also substantially increases the load bearing area of the roller in comparison to prior art designs which typically utilize a semicircular profile on the roller which engages a flat track. The rollers of the roller assemblies are the primary vertical load carrying members of the sliding shower door assembly, i.e. the rollers support the weight of the movable door panel.
The shower door assembly of the present invention also features a first or Inboard finger guard with an L-shaped cross-section having a vertical flange and a horizontal flange, the inboard finger guard being attached to an inboard side of the roller assembly. (For the purposes of this application, the term “outboard” is defined as facing outwardly from the shower enclosure or on the outside of the movable shower door. Similarly, the term “inboard” is defined to mean facing inwardly of the shower enclosure or on the inside of the movable shower door.) The horizontal flange of the inboard finger guard faces inwardly with respect to the track and is disposed underneath an elevated horizontal flange of the track. The elevated horizontal flange of the track faces outwardly with respect to the vertical flange of the inboard finger guard. This arrangement of an inwardly facing flange on the finger guard which overlaps with an outwardly facing flange on the track fully closes out the roller on its inboard side and therein prevents any possibility of fingers or toes from inadvertently being caught between the roller and the track on the inboard side of the roller.
The shower door assembly of the present invention also features a second or outboard finger guard comprised of an upwardly raised surface on the track which inhibits finger or toe access to the roller on the outboard side of the roller. The finger guards of the present invention serve to prevent fingers and toes from getting caught between the roller and the track and represent an improvement the art because such features appear to be lacking in prior art designs.
Another feature of the present invention is a track leveling feature or device which improves ease of installation. For the movable shower door to move freely, it is important that the track be level. A level track ensures even contact of the roller assembly or assemblies attached to the door and likewise ensures good alignment with abutting walls or door jambs of the shower enclosure. In the exemplary embodiment, the leveling feature comprises a threaded hole for the receipt of a set screw at one end of the track. The set screw is threaded into the hole from an upper surface of the track until the screw bears against the shower enclosure floor surface, or in the case of tub installations, the tub rail surface. Additional tightening of the set screw causes the track to rise at an angle to the floor or tub rail surface and in this manner, the track may be brought to horizontal level with respect the floor or tub rail surface, thereby substantially easing installation of the shower door assembly.
The above and other features of the invention will become more apparent from the following detailed description.
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The invention may, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled hi the art. Like numbers refer to like elements throughout.
With reference to
With reference to
The roller 26 features an inverted U-shaped groove or rolling surface 32 which mates with a U-shaped rolling surface 34 formed on the track 22. The rolling surface 32 of the roller 26 and the rolling surface 34 of the track 22 are of generally the same radius of curvature to facilitate smooth rolling contact between the two rolling surfaces 32 and 34. The U-shaped rolling surface 34 of the track 22 and the mating inverted U-shaped rolling surface 32 of the roller 26 function to keep the roller 26 centered on the track 22 during opening and closing movement of the movable door panel 12 without the need for guide channels or other guiding or roller capturing features in the track. The radius of curvature of the rolling surfaces 32 and 34 may vary but should be sufficiently deep to self-center the roller 26 on the track 22. Experimentation has shown that a radius of curvature within the range of about ½″ to about ⅝″ to be suitable for most typical applications. The roller further includes a bore 36 for slip-fit receipt of an axle 38.
In typical installations, the roller 26 will be generally centered with respect to a thickness 40 of the movable door panel 12, as illustrated in
With reference to
The inboard and outboard roller clamping plates 42 and 44 are shown in the exemplary embodiment as having a generally semicircular shape with a beveled surface. This configuration was chosen for its pleasing aesthetic appearance. Other shapes having the utilitarian features discussed herein are also suitable.
With continued reference to
With reference to
The inboard 58 and outboard 68 finger guards of the present invention serve to prevent fingers and toes from getting caught between the roller 26 and the track 22 and represent an improvement in the art as such features are often lacking in prior art designs.
With reference to
In the exemplary embodiment, the track leveling feature 78 comprises a hole 82 which is threaded for the receipt of a set screw 80. Typically, each track 22 will include a single leveling feature 78, i.e. threaded hole 82 and set screw 80, located at one end of the track. During installation, the set screw 80 is threaded into the hole 82 from the U-shaped rolling surface 34 of the track 22 until the screw bears against the track mounting surface 24. Additional tightening of the set screw 80 causes the track 22 to rise at an angle to the mounting surface 24 and in this manner, the track 22 may be brought to horizontal level with respect the mounting surface 24, thereby substantially easing installation of the shower door assembly 10.
With reference to
With reference to
The upper guide assembly 16 includes a guide block 90. The guide block 90 includes on its outboard side a channel 104. The channel 104 is configured to be slidable along a horizontal length 106 (see
With reference to
In the reverse configuration shown in
Both of the upper guide assembly 16 configurations described above will provide sufficient lateral support to the movable door panel 12, however the configuration of
The sliding shower door assembly 10 of the present invention is not limited to any particular choice of materials. A number of materials for each component of the assembly 10 are suitable and are known in the art. For example, the movable and fixed door panels 12 and 14 will typically be made of a relatively lightweight material that is sufficiently strong to be fully self-supporting for the purpose of eliminating any need to frame the door panels. Presently, translucent or transparent materials are preferred for shower doors in residential home installations. A variety of rigid translucent polycarbonate and acrylic materials including Lucite and Plexiglass are suitable. Opaque plastic and metallic materials are also suitable. Treated wood materials may also be suitable.
The roller assembly or assemblies 18 will typically be made from metallic materials, with stainless steel and aluminum often being preferred for aesthetic reasons. Structural plastic materials however, are also suitable. The track 22 will typically be a metallic or plastic extrusion. The upper guide assembly 16 will typically be made from plastic materials. Metallic materials are also suitable.
With reference to
After the track 22 has been leveled, the roller assemblies 18 may be installed. To install each roller assembly 18 in the movable door panel 12, first the axle 38 will be fitted into the roller 26. The roller 26 containing the axle 38 is then fitted into an opening for receipt of the roller 26 in the movable door panel 12. The inboard and outboard roller clamping plates 42 and 44 are then placed on inboard and outboard faces of the movable door panel 12 and positioned such that ends of the axle 38 are located within the blind-bores 50 of the roller clamping plates 42 and 44, and the through-bores 54 of the inboard roller clamping plate 42 are aligned with the blind-bores 56 of the outboard roller clamping plate 44.
Thereafter, inboard finger guard 58 is positioned on the inboard roller clamping plate 42 and the through-bores 55 of the inboard finger guard 58 are aligned with the through-bores 54 of the inboard roller clamping plate 42. Subsequently, the fasteners 52 are installed to thereby secure the roller clamping plates 42 and 44, and consequently the roller assembly 18, to the movable door panel 12. In a typical installation, the movable door panel 12 will include two roller assemblies 18.
Upon attachment of the roller assemblies 8 to the movable door panel 12, the movable door panel is engaged with the track 22 by sliding an outboard side of the movable door panel 12 about the track 22 such that the inverted U-shaped rolling surfaces 32 of the rollers 26 engages with the U-shaped rolling surface 34 of the track 22.
Upon engagement of the roller assemblies 18 of the movable door panel 12 to the track 22, the upper guide assembly 16 is installed to provide lateral support to the movable door panel 12. The upper guide assembly 18 is installed by first positioning the channel 104 of the guide block 90 about the upper portion 108 of the fixed door panel 14. Thereafter, an upper portion 116 of the movable door panel 12 is set against the vertical wall 112 of the guide block 90. The bushings 96 are then placed in holes 118, (see
If used, the optional inner guide liner 100 will be installed in the channel 104 of the guide block 90 prior to positioning the channel 104 of the guide block 90 about the upper portion 108 of the fixed door panel 14. Similarly, if used, the optional compression gaskets 102 will be installed on the vertical wall 112 and the horizontal wall 114 of the guide block 90 prior to installation of the movable door panel 12 to the guide block 90. Upon installation of the upper guide assembly 16, the sliding shower door assembly 10 of the present invention is completed.
The foregoing detailed description and appended drawings are intended as a description of the presently preferred embodiment of the invention and are not intended to represent the only forms in which the present invention may be constructed and/or utilized. Those skilled in the art will understand that modifications and alternative embodiments of the present invention which do not depart from the spirit and scope of the foregoing specification and drawings, and of the claims appended below are possible and practical. It is intended that the claims cover all such modifications and alternative embodiments.
This application claims priority to U.S. Utility application Ser. No. 13/659,810, filed on Oct. 24, 2012, now abandoned which in turn claims priority to U.S. Provisional Application Ser. No. 61/550,808, filed Oct. 24, 2011—the contents of both applications are expressly incorporated herein by reference in their entirety.
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Number | Date | Country | |
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20150164284 A1 | Jun 2015 | US |
Number | Date | Country | |
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61550808 | Oct 2011 | US |
Number | Date | Country | |
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Parent | 13659810 | Oct 2012 | US |
Child | 14631672 | US |