Abstract:
Improved, aesthetically appealing enclosure assemblies, such as dry saunas ( 20 ), are provided which eliminate unsightly threaded fasteners and other external connection hardware, while also affording an easy method of construction. The saunas ( 20 ) include a base panel ( 22 ), upright panels ( 24 ) and a top panel ( 26 ) cooperatively defining the sauna enclosure ( 28 ). The interconnection between the upright panels ( 24 ) is achieved through the use of complemental, magnetic coupler bodies ( 70,72,92,94,108,110 ) which are sized and located for direct, face-to-face contact and consequent strong magnetic attraction. The saunas ( 20 ) are equipped with internal far infrared heaters ( 30,32 ) which are likewise magnetically mounted through the use of coupler bodies ( 96 - 100  and  152 - 156 ).

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention is broadly concerned with saunas and other enclosure assemblies preferably used for personal care. More particularly, the invention pertains to such enclosures having at least certain panels connected using structure including magnetic coupler bodies operable to interconnect the panels by means of magnetic attraction. In this fashion, the enclosures can be rapidly and easily constructed, and not exhibit threaded fasteners or other unsightly external connection hardware. Additionally, internal infrared heaters can be connected to the enclosure panels using magnetic coupler bodies.  
         [0003]     2. Description of the Prior Art  
         [0004]     Dry saunas are becoming increasingly popular as personal accessories in modern homes. These saunas are typically relatively small in size (housing from 1-6 individuals), and are designed to deliver on-demand healthful dry heat therapy. In order to lessen the cost of such saunas, some manufacturers provide kits which can be assembled on-site by a homeowner. Generally, these sauna kits make use of threaded fasteners, brackets, or other conventional connection hardware in order to interconnect the sauna components, and especially the upright side panels thereof.  
         [0005]     While these constructions are accepted and of long standing, they are deficient in that the connection structure employed is visible, either from the exterior of the sauna or its interior, or both. This detracts from the appearance of the finished saunas which are made of high-quality wood such as cedar.  
         [0006]     In order to increase the salability of homeowner-constructed saunas and other personal care enclosures, it is important that they be relatively simple to construct and install, and aesthetically pleasing. While some prior sauna kits using conventional connection hardware meet these goals to a limited extent, there remains a need in the art for improved personal enclosure designs which more adequately address consumer demand.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention overcomes the problems outlined above and provides personal enclosures such as saunas which essentially eliminate the use of visible connection hardware, while also being simple to construct.  
         [0008]     Broadly speaking, a first aspect of the present invention concerns an enclosure assembly comprising a base panel, a plurality of upright panels extending upwardly from the base panel, and a top panel positioned atop the upright panels. The panels cooperatively define a personal care enclosure sized to simultaneously house no more than about six persons. The enclosure assembly further includes connection structure between at least certain of the panels and including complemental magnetic coupler bodies operable to magnetically interconnect the certain panels. In preferred forms, the couplers are embedded in the ends of the upright panels and oriented for direct, face-to-face contact.  
         [0009]     In another aspect of the present invention, a sauna comprises a base panel, a plurality of upright panels extending upwardly from the base panel, and a top panel surmounting the upright panels. The panels cooperatively define a sauna enclosure. The sauna also includes at least one sauna heater operable to heat the sauna enclosure. Yet further, the sauna includes connection structure between at least certain of the panels and including complemental magnetic coupler bodies operable to magnetically interconnect the certain panels.  
         [0010]     Another aspect of the present invention concerns a sauna comprising a base panel, a plurality of upright panels extending upwardly from the base panel, and a top panel surmounting the upright panels. The panels cooperatively define a sauna enclosure. The sauna also includes a sauna heater operable to heat the sauna enclosure. Additionally, the sauna includes mounting structure securing the sauna heater to at least one of the panels. The mounting structure comprises a magnetic coupling structure magnetically mounting the sauna heater to the at least one of the panels.  
         [0011]     Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0012]     A preferred embodiment of the present invention is described in detail below with reference to the attached drawing Figures, wherein:  
         [0013]      FIG. 1  is a perspective view of an assembled modular sauna in accordance with a preferred embodiment of the present invention;  
         [0014]      FIG. 2  is a perspective view of the base panel of the sauna;  
         [0015]      FIG. 3  is an exploded perspective view illustrating initial steps in the construction of the sauna shown with the front panel positioned in the base panel and with the left hand and rear panels ready for installation;  
         [0016]      FIG. 4  is an exploded perspective view similar to that of  FIG. 3 , but showing installation of the right hand panel of the sauna;  
         [0017]      FIG. 5  is a perspective view similar to that of  FIG. 4 , and depicting installation of the top panel of the sauna;  
         [0018]      FIG. 6  is an enlarged fragmentary view from  FIG. 3 , and depicting the installation of the front panel into the base panel of the sauna;  
         [0019]      FIG. 7  is a view of the underside of the top panel of the sauna;  
         [0020]      FIG. 8  is a horizontal sectional view of the completed sauna;  
         [0021]      FIG. 9  is an enlarged fragmentary view from  FIG. 8 , and illustrating the magnetic coupling of the upright sauna panels and the magnetic coupling of the infrared heater panels to the inner faces of the upright sauna panels;  
         [0022]      FIG. 10  is an enlarged perspective view illustrating one of the magnetic coupler bodies used in constructing the sauna;  
         [0023]      FIG. 11  is a fragmentary exploded perspective view of a side panel of the sauna, and showing the attachment of an infrared heater panel to the side panel;  
         [0024]      FIG. 12  is a rear view of one of the infrared heater panels; and  
         [0025]      FIG. 13  is an enlarged fragmentary view from  FIG. 4  and depicting the installation of a clip fastener between the front panel and left hand panel of the sauna. 
     
    
       [0026]     The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0027]     Turning now to the drawings, a sauna  20  is illustrated in  FIG. 1  and generally includes a base panel  22 , upright side panels  24  extending upwardly from base panel  22 , a top panel  26  surmounting the side panels  24  so as to define a sauna enclosure  28  (e.g., see  FIG. 5 ). Additionally, the sauna  20  is equipped with a floor-mounted heater  30  as well as three upright heaters  32 , 34 , 36  which are operable to heat the enclosure  28 . Although the illustrated sauna has a generally rectangular configuration, it is entirely within the ambit of the present invention to provide other sauna configurations (e.g., saunas having more or less upright panels to present different polygonal shapes or a circular shaped modular sauna with interconnected panels). The principles of the present invention are equally applicable to saunas using more or less heaters than those shown.  
         [0028]     It is noted that the heaters  32 , 34 , 36  (and others as identified below) are preferably configured to emit far infrared radiation (“FIR”) within the sauna  20  so as to provide both heating and desirable radiation treatment. More preferably, the heaters include carbon-black-containing planar heating elements. Those ordinarily skilled in the art will appreciate that such arrangement provides a dry sauna with FIR treatment. However, it is initially noted that certain aspects of the present invention are not limited to such a sauna (e.g., certain principles apply to other types of saunas, such as steam saunas) or heaters (e.g., traditional coil heaters, etc.).  
         [0029]     Returning to the illustrated embodiment, the base panel  22  is preferably fabricated from wood (e.g., cedar) and has a slatted floor  38  as well as an outermost decorative footed perimeter  40  (e.g., formed of synthetic resin material). The base  22  is designed to present a continuous peripheral groove  42  between floor  38  and perimeter  40 . Also, the base  22  has a laterally extending recess  44  which houses a drop-in FIR heater  46 . A wooden grating  48  is located within the recess  44  and covers the heater  46 .  
         [0030]     The upright panels  24  in this embodiment include a front panel  50 , left hand panel  52 , rear panel  54 , and right hand panel  56 . The resulting enclosure  28  is substantially square in plan. As previously noted, however, other upright wall assemblies could employed, giving a variety of different enclosure footprints and shapes.  
         [0031]     Front panel  50  preferably is fabricated largely from wood and includes a lapped fascia wall  58  and a similarly slatted interior wall  60 . A central doorway  62  is provided in the front panel and a hingedly mounted door  64  (preferably glass) is mounted within the doorway. The butt ends of the front panel  50  are defined by vertical, solid wood risers  66 , 68 , each of the latter carrying a pair of vertically spaced apart magnetic coupler bodies  70 , 72 . Finally, external sauna control panel  74  is housed within front panel  50  to allow the user to control the operation of sauna  20 .  
         [0032]     The left and right hand panels  52 , 56  are essentially mirror images of each other and each preferably is fabricated from wood to present lapped exterior wall  76  and a similar lapped interior wall  78 . The ends of the panels  52 , 56  are defined by vertical risers  80  and outboard L-shaped vertical trim pieces  82 , and an uppermost horizontal top board  83  extends between the risers. As best seen in  FIG. 11 , each of the panels  52 , 56  has a vertical, essentially rectangular recess  84  formed therein. The recess  84  is bounded by baseboard  86 , internal risers  88 , 90  (see  FIG. 9 ) and a top board (not shown).  
         [0033]     Each of the panels  52 , 56  has a pair of vertically spaced apart magnetic coupler bodies  92 , 94  located just inboard of each of the trim pieces  82 . Additionally, the internal risers  90  each have a total of three embedded vertically spaced apart magnetic coupler bodies  96 , 98 , 100 . Finally, each panel  52 , 56  has electrical power cableway openings  101  in the top and bottom thereof which are important for purposes to be made clear.  
         [0034]     Rear panel  54  preferably is formed of wood and has a lapped exterior wall  102 , a lapped interior wall  104  and endmost vertical risers  106 . The risers  106  each have a pair of vertically spaced apart magnetic coupler bodies  108 , 110  embedded therein. The rear panel  54  also has a vertical, substantially rectangular recess  112  defined by internal risers  114 , 116  as well as baseboard  118  and a top board (not shown). The risers  116  have magnetic coupler bodies  96 , 98 , 100  embedded therein, in exactly the same fashion as the previously described risers  90  forming a part of the left and right hand panel recesses  84 . Upper and lower electrical cableway openings  120  are also provided.  
         [0035]     Top panel  24  includes an uppermost roof  122  and a peripheral skirt  124 . Referring to  FIG. 7 , it will be seen that the preferred top panel  24  presents a lapped interior wall  126  with a number of optional accessories mounted thereon, e.g., speakers  128 , accent lights  130 , main light  132 , housing  134  designed to accommodate stereo equipment such as a CD player and amplifier, and an adjustable vent assembly  135 . Further, the interior of top panel  24  presents a peripheral groove  136  between skirt  124  and wall  126 , as well as a forward overhang  138 . As with the other panels, the top panel  24  is preferably formed primarily of wood (e.g., cedar).  
         [0036]     As noted, the panels  52 , 54 , 56  each support a respective heater  32 ,  34 , 36  within the corresponding recesses  84  and  112 , namely side panel FIR heaters  140  and rear panel FIR heater  142 . These FIR heaters are identical except for the size difference, and each includes an appropriately dimensioned frame  144  made up of vertical members  146  and spaced apart crosspieces  148 . The frames  144  are preferably formed of wood (e.g., cedar). Moreover, each frame  144  supports a thin, planar, sheet-like FIR heating element  150 , as previously explained. It will also be seen that the endmost vertical members  146  have three vertically spaced apart magnetic coupler bodies  152 , 154 , 156 .  
         [0037]     All of the magnetic coupler bodies described above, namely bodies  70 , 72 , 92 - 100 , 108 , 110  and  152 - 156 , are preferably of the same physical construction, except for size difference.  FIG. 10  depicts an exemplary coupler body  70  in the form of an annular segment  158 , with a fastening screw  160  extending through the central opening thereof. It will be seen that the segment  158  presents a substantially planar outer surface  162 . The segments  158  may all be formed of magnetic material, with adjacent segments being of opposite polarity. Alternately, some of the segments may be formed of magnetic material, while mating segments may be fabricated from steel or other magnetically susceptible material. In any case, it is important that adjacent segments  158  used for connection purposes be magnetically complemental, i.e., so as to generate the requisite magnetic coupling attraction and force between the adjacent segments. One suitable magnetic material is available under the model designation NF38 from Wuxi Rare-Earth Permanent Magnet Plant of Dong Bei Tang Zhen, Wuxi, JiangSu, China. This company is accessible via Internet at the following two address www.magnet888.com or www.chinae-com.com/CompanySite/6006/eng/index.asp?SiteID=6006. More specifically, the preferred magnetic material has the following properties:  
                                                                                                         Br   HcB   Hcj   BH max   Max. temperature            Model   T   kgs   KA/m   koe   KA/m   Koe   KJ/M 3     MGOe   ° C.               N38   1.21-1.25   12.1-12.5   ≧899   ≧11.3   ≧955   ≧12   287-310   38-39   80                  
 
         [0038]     The construction of sauna  20  is a simple and straightforward proposition, which is greatly facilitated through use of the previously described magnetic coupler bodies. Moreover, use of this type of interconnection substantially eliminates unsightly fasteners, brackets and other connection hardware which can detract from the aesthetic appearance of the finished sauna.  
         [0039]     Specifically, in the first step, the base panel  22  is appropriately positioned, and the front panel  50  is inserted into the forward lateral run of groove  42 . While the front panel is held in place, the left hand panel  52  is positioned within the left hand run of groove  42  in such fashion that the forward trim piece  82  covers the joint between the front and left hand panels  50 , 52  (see  FIG. 13 ). In addition, by virtue of the magnetically complemental nature and mating location of the coupler bodies  70 , 72  and  92 , 94 , a strong magnetic connection is established between these panels. In order to achieve the most secure connection, the coupler bodies come into direct face-to-face contact with each other.  
         [0040]     The rear panel  54  is next inserted into the rear run of the groove  42 , again in a manner such that the rearmost trim piece  82  of panel  52  covers the joint. Furthermore, the magnetic coupler bodies  108 , 110  of rear panel  54  mate in direct face-to-face contact with the rear set of magnetic coupler bodies  92 , 94  carried by the panel  52 .  
         [0041]     The right hand panel  56  is then installed in the same fashion, so that the trim pieces  82  cover the joints between right hand panel and front and rear panels  50 , 54 . The fore-and-aft sets of magnetic coupler bodies  92 , 94  carried by the right hand panel  56  magnetically couple with the couplers  70 , 72  and  108 , 110  of the front and rear panels (see  FIG. 9 ).  
         [0042]     Appropriate electrical wiring is fed through base panel  22  and the panel cableways  101 , 120  for purposes of providing electrical power to the heaters  30  and  32 , as well as to the control panel  74  and accessories  128 - 134 . At this point, the individual FIR heaters  140  and  142  are installed. This involves making a suitable electrical connection with the heaters and pressing them into the corresponding recesses  84  and  112 . During this installation, the magnetic coupler bodies  96 - 100  of the panel risers come into direct face-to-face contact with the coupler bodies  152 - 156  carried by the panel frames  144 . As such, the heaters are magnetically coupled to the associated panels, again with the complete avoidance of threaded fasteners or other types of conventional connection hardware.  
         [0043]     The final installation step involves placement of top panel  26 . This is accomplished by simply pressing panel  26  downwardly over the upright panels  24 , i.e., with the upper ends of the panels  50 - 56  being inserted into groove  136 . No further connection of the panel  26  is required. Of course, the accessories  128 - 134  are connected to the sauna wiring.  
         [0044]     The saunas of the invention can be modified in a number of ways. For example, in some instances it is desirable to install mechanical connection structure between the upright panels  50 - 56 , but without creating undesirable visible evidence of such connection structure. As illustrated in  FIG. 13 , the connection ends of the panels can be provided with mating recesses  164 , 166  which cooperatively form a U-shaped slot  168  which bridges an internal wall of one of the panels. A complemental U-shaped connection clip  170  is inserted into the slot  168  to provide an additional connection. However, this clip  170  is entirely recessed and covered upon installation of top panel  26 .  
         [0045]     The saunas may also be provided with a conventional bench or other types of seating. To this end, the panels  52 , 56  may be equipped with vertical and horizontal wooden mounts  172 , 174 , allowing a vertical kickplate and horizontal bench (not shown) to be installed. Of course, other seating assemblies may be used.  
         [0046]     While the invention is particularly concerned with saunas, the principles thereof are not so limited. That is to say, use of magnetic connection hardware to effect coupling of the wall components can be adapted for other types of personal care enclosures, for example, wet saunas and dressing facilities such as cabanas.  
         [0047]     The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.  
         [0048]     The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.  
         [0049]     Having thus described the preferred embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: