Electrically heated facial sauna appliance

An electrically heated, hand-held portable facial sauna appliance has a top air inlet, side air inlet, an air flow adjustment arrangement and a fan to mix ambient air with steam generated from a quantity of water contained in an internal steam generating chamber having an associated electric heater and a bottom fill opening such that the appliance must be inverted to fill the chamber with water. A water trap and overflow arrangement in the container ensures that the chamber cannot be overfilled and enables the appliance to be overturned during use without leaking. The appliance is provided with attachments in the form of a facial mask, concentrator tube, brush and sponge, each designed to fit over a steam-air mixture outlet and control the quantity of air entering through the top air inlet.

BACKGROUND 
1. Field of the Invention 
This invention relates to hand-held electrically powered steam generating 
devices, such as a facial sauna, which cannot be overfilled, can be tilted 
in any direction when full without leaking and can mix air and steam in 
any desired proportions to control the concentration and temperature of 
the emitted steam. In addition, the facial sauna can be adapted to receive 
attachments such as a facial mask, concentrator, brush or sponge. 
2. Prior Art 
Prior steam generating devices and facial saunas have structures which 
permit them to be tilted in any direction without spilling. However, for 
the most part, these prior steam generating devices and facial saunas must 
be filled with a measured amount of liquid. In addition, they are not made 
to receive a self limiting amount through a fill means in the base. 
Thus, Hettinger, U.S. Pat. No. 2,343,458, issued Mar. 7, 1944 discloses a 
vaporizer constructed of two cylinders or cups of sheet metal which are 
telescoped so that they form, respectively, the bottom and inside of the 
container and outside and top of the container. The top is provided with 
an aperture at one side for reception of a long spout which extends within 
the container for a substantial distance and is inclined at a sufficient 
angle to the vertical to prevent the user from getting burned if the 
device is tipped forward. The long inclined extension prevents water from 
running out of the spout if the container is not filled above a line 
marked on it. 
Omohundro, U.S. Pat. No. 3,546,428, issued Dec. 8, 1970 discloses a steam 
generator which includes a water tank, electric heating unit and a spout 
that both expels steam from the water tank and receives water for 
introduction into the water tank. The spout has an inner portion extending 
into the water tank and spaced from the walls of the water tank a distance 
sufficient to permit retention of a predetermined amount of water, i.e., 
28-35 cubic centimeters, within the tank after filling while the steam 
generator is in an upright position and then inverting to pour out excess 
water. There is no structure which permits filling the water tank from the 
bottom. Also, Omohundro provides an extension having holes, which 
extension connects on the end of the spout to increase the velocity of the 
steam as it is being expelled and permits the expelled steam to mix with 
ambient air, lowering the temperature of the steam. No fans or adjustable 
air intakes are used. 
Doyel, U.S. Pat. No. 3,695,066, issued Oct. 3, 1972 discloses a portable 
hand-held steamer in which the housing is shaped so that when a certain 
quantity of water is contained therein, the housing has a capacity to 
contain the quantity of water in all directions taken about the geometric 
center thereof. A water fill hole is provided in the upper housing. A 
water measuring cup is provided which is designed to hold no more than the 
amount of water that is desirable to use in the vapor generator. 
Plasko, U.S. Pat. No. 3,742,629, issued July 3, 1973 discloses a portable 
hand-held electric clothes steamer with a one piece housing having an 
integral fill opening intermediate a water chamber and a combined steam 
chamber and water trap. The fill opening is positioned so that the water 
will overflow the opening when the proper amount is in the chamber. This 
enables the water trap to work effectively and prevents the water from 
leaking out when the device is overturned. 
Conlin, et al., U.S. Pat. No. 3,511,236, issued May 12, 1970 discloses a 
vaporizer in which air is drawn in by a fan through adjustable openings in 
the housing and is delivered to the vaporizing chamber. The steam 
generator of the present invention includes a fan which mixes air with the 
steam after the steam leaves the vaporizing chamber. 
Naritomi, U.S. Pat. No. 3,745,306, issued July 10, 1973 discloses a steam 
generating instrument for hair dressing having a blower and steam 
generating means wherein the blower delivers the steam from the steam 
generating means into a venting duct and then to the hair. 
There are no steam generating devices such as facial saunas which are 
filled from the bottom and cannot be overfilled, can be tilted in any 
direction without spilling or leaking and have the temperature of the 
steam controlled by mixing with air in the steam outlet pathway utilizing 
a fan and adjustable air inlet holes in the housing between the fan and 
steam generator. 
BRIEF SUMMARY OF THE INVENTION 
This invention provides a portable, hand-held, leakproof, electric steam 
generating apparatus which in its preferred embodiment is a facial sauna. 
The apparatus comprises a generally circular housing with a lower portion 
having a larger circumference than the upper portion which generally acts 
as a steam outlet nozzle. The lower housing has in its base a water fill 
tube leading to a water tank inside the base. The base of the water tank 
seals the lower portion of the lower housing from the water or other 
aqueous fluid in the water tank. There are interior baffle portions in the 
lower housing which define the lower portion of the water tank. A heater 
having a heating element is in the sealed off portion of the lower housing 
and has a heat transfer surface in the water tank to generate steam. 
The upper housing which is sealed to the lower housing by a lap seam has 
air inlet means with means to control the volume of air, e.g. a 
circumferential row of air inlets between the top of the upper housing and 
the lap seam with a rotatable ring having holes around the upper outer 
housing over the circumferential row of air inlets. The ring is rotated to 
control the air flow volume. The housing contains walls defining an upper 
portion of the water tank connected to the lower portion of the water tank 
by passageways in a common baffle. The upper water tank inner baffle 
defines a steam exit pathway from the portion of the water tank where the 
steam is generated. The upper water tank also acts as a water trap when 
the apparatus is overturned. The steam exit pathway connects said steam 
generating area to a steam-air mixing chamber in a portion of the upper 
housing where the air enters from, e.g. the circumferential row of air 
inlets and preferably a second annular air inlet. A fan and a motor are 
attached to a motor housing defined by walls in the center top portion of 
the upper housing, with the fan in the steam-air mixing chamber. The steam 
mixed with air by the fan exits through an annular steam outlet around the 
motor housing. The second air inlet system which is a preferred 
construction is an annular air inlet between the annular steam outlet and 
the outer wall of the upper housing and is separated from the annular 
steam outlet by an inner wall in the upper housing. The inner wall has 
openings so the air can reach the air-steam mixing chamber. Another means 
to regulate the temperature is by use of specially structured attachments, 
i.e., brush, sponge, concentrator and facial mask.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT 
The preferred embodiment of this invention is an electric, hand-held, 
portable facial sauna having an outer housing that is shaped generally 
like a round flask with a slanted elongated neck. Inside the housing are a 
base defining an electrical enclosure, a lower housing enclosing a water 
tank-steam generating chamber, the upper part of the water tank functions 
as a water trap and has a steam exit passageway. The upper housing 
contains air inlets, a motor and fan in an air-steam mixing chamber and 
steam outlets. The water tank can never be overfilled; it is filled with 
the required amount of liquid e.g., water or aqueous solutions or 
emulsions containing medicaments, colognes or perfumes, moisturizers and 
the like, without the need to measure or utilize markings on the housing. 
The tank is filled from the bottom through a fill tube which conducts the 
liquid into the lower part of the water tank and thence into the upper 
part of the water tank. When the tank is full, the excess water will begin 
to run out the top of the sauna through the steam outlet. When this 
occurs, the sauna is placed upright. Subsequent tilting or overturning 
will not cause liquid to run out since it is trapped by baffles in the 
tank around the steam generating area and steam exit pathway. The water 
tank is constructed so that no matter which way the sauna is tilted, there 
is sufficient volume in the water tank around the point at which the steam 
exit passageway begins, to hold all the water. In the most preferred 
embodiment this point occurs at the intersection of the axial center lines 
of the upper and lower parts of the water tank. 
The upper housing contains air inlets through which air is drawn in by the 
fan and mixed with the steam from the steam generating area to cool the 
steam to a desired temperature. The amount of air drawn in by the fan is 
controlled by a rotating ring as described hereinafter. In addition, 
attachments such as a facial mask, concentrator tube, brush attachment and 
sponge attachment are structured so that when they are attached to the 
steam outlet they restrict air inflow from an air inlet in the top of the 
upper housing to the minimum amount of air required for safe use. 
With reference to FIGS. 1-4, the outer housing of the facial sauna provided 
by this invention is comprised of a lower housing 1, and an upper housing 
2 made of molded heat and impact resistant plastic such as ABS, an 
acrylonitrile butadiene styrene plastic. The upper housing 2 and the lower 
housing 1 are attached by, e.g., a lap seam 8. The seam 8 is sealed by 
conventional means, e.g., ultrasonic means, and is covered by a decorative 
ring 10. The base 11 of the lower housing 1 is detachable and is held in 
place by screws 38 which also hold feet 37 to the base 11. The feet 37 
provide a cushion for the sauna to rest on. There are usually three feet 
37. The base 11 is made of an impact and heat resistant moldable plastic 
such as phenolic resin and the feet are made of a resilient plastic. 
The base 11 has two openings, one for a water fill tube 15 and one for a 
power cord 16. The water fill tube 15 is sealed, after the sauna is 
filled, by a screw plug 17. The tube 15 and plug 17 are made of moldable 
heat resistant plastic with a coefficient of expansion such that the plug 
will not loosen when cold and not bind when hot. The fill tube 15 passes 
through a hole in the base plate 39 of the lower water tank 9 and is 
sealed against water leakage through the tank base plate 39 by a plastic 
grommet 14 such as one made from, for example, ethylene-propylene. 
The base 11 which is sealed against water by a base inner wall 12 at the 
sides and a metal bottom plate 39 on the lower tank 9 has a resistance 
heater 43 therein in which the heating element is enclosed. The heater 43 
has a heat transfer dome 40 on the top thereof. The dome 40 projects 
through a hole in the metal bottom plate 39 into the steam generating 
chamber 45 which is enclosed by the interior baffles 18 of the lower water 
tank 9. The heat transfer dome 40 is sealed against leakage through the 
hole in the tank bottom plate 39 by a gasket 48. The heater 43 is fastened 
to the plate 39 by a nut 42. The heater housing 43 shown in FIG. 2 is made 
of diecast aluminum. Other suitable heaters such as a ceramic resistance 
or positive temperature coefficient (PTC) heater enclosed in an aluminum 
case can also be used. 
A thermostat 44 calibrated to about 100.degree.-110.degree. C. is attached 
to the heater 43 and the underside of the tank base plate 39. 
The base 11 also has a hole 16 for a power cord 46 which powers the heater 
43 and the fan motor 31 in the upper housing 2. The wiring for the fan 
motor 31 is in a wiring tube 35 which extends from inside the base 11 
along the inside of the walls of the lower outer housing 1 and upper outer 
housing 2 through the motor housing 33 to the motor 31. The wiring tube 35 
is supported on the inside by the lower inner housing (water tank housing) 
5 and upper inner housing 3. 
The lower tank 9 and the upper tank 7 are defined by the tank housing 5; 
the upper tank 17 being separated from the lower housing 1 by a partially 
angulated annular casing 5A. The lower tank is annular shaped and is 
defined by the tank housing 5 as the outer wall, inner baffle 18 which 
surrounds the inner chamber 45, and bottom plate 39 which is water-tightly 
sealed to the outer wall of the tank housing 5 by conventional sealing 
means, for example, a crimp 41 as illustrated in FIG. 2. The top baffle 6 
of the lower tank 9 separates the lower tank 9 from the upper tank 7. 
However, in order for water to pass between the upper tank 7 and the lower 
tank 9, there are holes 19 in the top baffle 6 of the lower tank 9 which 
is also the floor of the upper tank 7. 
The upper tank 7 is annular and its outside wall is the tank housing 5, its 
inside baffle 20 forms a steam exit passageway 13 for the steam generated 
from the inner chamber 45 to travel to the air-steam mixing chamber 22, as 
shown by the wavy arrows. The top 24 of the upper tank 7 seals it from the 
air-steam mixing chamber 22. When the water tanks 7 and 9 are in the 
process of being filled through the fill tube 15, they reach a point at 
which they are full. When more water is added through the fill tube 15, it 
overflows into the steam exit pathway 13 and thence out the steam outlet 
25. This prevents excess water from entering into and staying in the 
system. When the sauna is turned upright then overturned, the water in the 
tanks 7 and 9 is trapped by the baffles 18, 19, 20 and 24 and the wall 5. 
Other water traps such as valves can be used but are not preferred. 
The water tanks 7 and 9 hold a sufficient volume of water to enable the 
sauna to operate for about 10 to 12 minutes before refilling is necessary. 
The tank capacity is about 65 to 75 cubic centimeters. Of course, these 
dimensions can be changed to suit any particular design or use of a steam 
generating device which may not necessarily be a facial sauna. 
In the upper part of the upper outer housing 2 is contained a motor housing 
33 having therein a DC fan motor 31 connected to the writing leading to 
the power cord 46 and having diodes 32 as a bridge rectifier. In addition, 
the motor 31 rests on a foam gasket 34 which is on the bottom of the motor 
housing 33. The foam gasket 34 helps reduce vibration. On a shaft 30 
extending through the bottom of the motor housing 33 from the motor 31 is 
an axial fan 29. Although an axial fan is illustrated, other fans such as 
centrifugal or transverse types can be used. The fan 29 draws air from air 
inlet holes 21 in the upper housing 2 placed circumferentially near the 
bottom of air-steam mixing chamber 22 and an annular air inlet 27 as 
hereinafter discussed. The air inlet holes 21 are aligned with similar 
sized holes 21A in wall 3. The air inlet holes 21 are covered by a 
rotating sliding ring 23 which has holes 23A in it about the same size and 
number as the air inlet holes 21. The ring 23 is slidably supported on the 
upper outer housing 2. When the ring 23 is rotated the inlet holes 21 are 
either covered, partially covered or uncovered, thus controlling the 
amount of air flow. Generally, the amount of air led in should be 
sufficient to cool the steam enough so it will not scald the operator. The 
wall of the motor housing 33 forms an inside wall of an annular steam 
outlet 25. The steam-air mixture from the mixing chamber 22 is blown 
through the steam outlet 25 by the fan 29. The bottom of the outlet 25 
passes the base of the motor housing 33 through large apertures between 
radial bars 50 which fix the housing 33 to the outer wall 3 of the steam 
outlet 25. The outer wall 3 of the steam outlet 25 is attached by radial 
bars 26 at the top to the upper outer housing 2 and at the bottom to the 
top of the upper tank 7. There are holes 21A in the inner wall 3 which 
match the air inlet holes 21 in the upper housing 2, enabling air to enter 
the mixing chamber 22. An annular air inlet 27 is defined by the upper 
outer housing 2 and an upper inner wall 3. The air enters, as shown by the 
straight arrows, through the spaces 27A between the bars 26, flows down 
the air inlet passage 27 and enters the mixing chamber 22 through the 
circumferential row of holes 21A in the inner wall 3 where it mixes with 
the steam generated in the inner chamber 45, as shown by the presence of 
straight and wavy arrows. 
The amount of air entering the air inlet 27 is controlled by the 
attachments shown in FIGS. 5-8 which attach to the outlet end of the 
facial sauna by e.g., a bayonet attachment. The attachments, i.e., facial 
mask 47, concentrator tube 49, brush attachment 51 and sponge attachment 
53 are hollow to allow the steam-air mixture to escape. Except for the 
facial mask, they have segmented lower flanges 54 on their attaching ends 
52. The attaching end 52 is inserted into the annular steam outlet 25 so 
as to occupy its outer circumference while permitting the steam-air 
mixture to escape through the inner circumference of the steam outlet 25 
and subsequently through the attachment. The segmented flanges 54 rest on 
top of the facial sauna while allowing air flow to pass first through the 
segmented portion and then through air inlet 27 to the extent needed to 
ensure a safe steam-air mixture temperature at a predetermined level. The 
size of the segments varies depending on the particular predetermined 
temperature level desired. These attachments allow the user different 
proximity to the air-steam mixture because of their different uses and 
shapes. Thus, the sponge attachment 53 and brush attachment 51 allow the 
user to place bristles 51A and sponges 53A, respectively, directly on the 
skin. In order to prevent the user from being scalded, the amount of air 
entering the mixing chamber has to be controlled. This is done by making 
the openings in the segmented flanges 54 of a size which will permit 
sufficient air to enter the top air inlet 27 and by controlling the side 
air inlets 21 with the rotating ring 23. 
In order to prevent the air-stream mixture from becoming too hot if the 
user blocks the top of the attachment, slots 50 are provided in the walls 
thereof which permit the air-steam mixture to escape. The facial mask 47 
need not have slots because it cannot readily be blocked, however, if 
desired slots can be provided. 
The attaching flanges 52 of the facial mask 47 preferably have no segments 
and the openings between the segments 54 of the concentrator 49 need not 
be as wide as those for the brush 51 and sponge 53 because the temperature 
need not be as cool since the user can move the face away from the 
steam-air outlet into a cooler region and still obtain the desired effect. 
However, since it is still possible to block the concentrator 49, slots 50 
are provided in the walls thereof. 
An alternative construction could eliminate the top air inlets 27, however, 
in this case, stops on the rotatable ring 23 would be needed to insure 
that at all times air is being brought in to mix with the steam. Another 
alternative construction could provide detachable heads on the attaching 
ends 52. 
The upper outer housing 2 is angled from the vertical for ease of use and 
manufacture. The upper housing 2 need not be angled, however, the sauna 
operates satisfactorily when the upper housing 2 is angled from about 
0.degree. to 90.degree. from the vertical. The preferred angle is 
generally about 23.degree.. 
In use the sauna operates as follows, the operator takes the empty, cold 
sauna and turns it upside down, then removes the plug 17 from the water 
fill tube 15 and pours water or other aqueous fluid into the fill tube 15 
until water drips out the steam outlet 25. This indicates the appliance is 
full. The plug 17 is reinserted, the sauna is turned upright, the desired 
attachment is attached to the outlet end, the sliding ring 23 is adjusted 
and the power cord 46 is plugged in. After a wait of about three minutes 
for heat up of the water, steam emerges from the steam outlet 25 and the 
appliance is ready to use.