Abstract:
A bathing enclosure wall panel and framing therefor are disclosed. In one embodiment there is a frosted, translucent, colored acrylic that is backed by a mirroring metal such as aluminum. There can also be a waterproofing paint layer behind the reflective material, as well as a cellulosic backing layer to reduce flexing. The material reflects light but does not present a risque appearance.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     Not applicable. 
     STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     The present invention relates to wall paneling for use in bathing enclosures such as showers and shower baths, and more particularly to such paneling that presents interesting and unique aesthetic effects. 
     Contemporary showers commonly have wall panels that are made from plastic materials. Such materials are lightweight, easy to install, and to some extent heat insulating. However, when they are transparent or translucent they can present privacy problems. When they are opaque they reduce the privacy concern but may create a bland and dark appearance unless strong lighting is provided (because they block light and do not reflect it very well). 
     Some double-layer laminates have been developed for various construction applications. Some of these provide frosting in clear acrylic. This gives the acrylic material a frosted appearance (e.g., semi-translucent and cloudy with or without identifiable speckled particles), which makes the surface of the acrylic appear more interesting. However, it does not address the lighting issue. 
     Other double-layer laminates have been designed to have a clear, colored acrylic layer coated with a rear mirroring material (such as a reflective metal). However, if this laminate were to be used as a bathing enclosure wall, it would present an appearance considered overly flashy or risque by many consumers. Exemplary dual-layer laminates that employ colored acrylic material backed by reflective material include the “Acrylic Mirror” products manufactured by Plaskolite, Inc. of Columbus, Ohio. 
     Another problem with adapting such laminates for application in a showering environment is that acrylic materials (while somewhat resistant to disfigurements) could be exposed to a variety of abrasive and scratching forces and harsh chemicals in a shower environment. Over time, this could harm the overall appearance of exposed acrylics. 
     Further, standard acrylics, even if backed by a reflective metal, are flexible. ANSI building codes require that the flexibility of shower units be restricted (e.g., to less than a ¼″ deformation of a panel upon application of a 25 lb force to that panel). Application of conventional backing materials, such as a fiberglass resin, to the back of the double-layer laminate (along the reflective material layer), has a tendency to damage thin reflective metal layers. 
     Further, there are problems involved in how to hold the various wall panels together, without leaving unsightly connectors or leakage pathways. 
     Thus, it can be seen that a need exists for an improved type of bathing enclosure wall panel. 
     SUMMARY OF THE INVENTION 
     In one aspect the present invention provides a bathing enclosure wall panel. It has a first layer of acrylic material with a translucent and frosted appearance, a second layer of reflective material that is coupled to the first layer, and at least a third layer of an additional material that is coupled to one of the first layer and the second layer. 
     In preferred forms the first layer is extruded acrylic material and includes a frosting additive and colorant. The second layer can be a suitable mirroring metal such as aluminum. The third layer can be a backing layer connected to the second layer and be made of a spacer material. The spacer material can be a cellulosic material such as a double-faced hexacomb cardboard material, or any of a variety of other materials, particularly non-absorbent materials such as polymeric foam materials. 
     In other forms there can be a protective paint coating sandwiched between the third layer and the second layer, wherein the protective paint coating is urethane paint. 
     In especially preferred forms, two or three of the panels can be mounted in frame supports that surround the four edges of each panel. The frame supports include internal, inwardly facing grooves for receiving the edges of the panels. The legs of the frame support can be screwed to each other. 
     The paneling has a bright, visually stimulating and aesthetically pleasing, unique appearance that provides enhanced lighting within a shower without having to increase electrical usage or bulb wattage, and without resorting to designs that are overly flamboyant. 
     An anti-scratch coating is preferably applied to the front surface of the panel on top of the frosted acrylic material. This provides a longer useful life. 
     The legs of the frame support are preferably seven or ten (depending upon whether two or three panels are being supported) extruded bars with receiving grooves to receive the panels. The legs can be screwed together, or potentially several (e.g., three) of them can be formed together. For example, in a two-panel assembly, potentially three of the legs surrounding each of the panels can be formed together, positioned onto their respective panels, and then an intermediate leg can be positioned between the two panels to complete the assembly. 
     It will be appreciated that the panel is relatively lightweight, can be preassembled/constructed in an automated factory, and is particularly well designed for use in a showering environment. These and other advantages of the invention will be apparent from the detailed description and drawings which follow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross-sectional view of a preferred bathing enclosure wall panel of the present invention; 
     FIG. 2 is a perspective view of a two-paneled bathing enclosure incorporating two of the wall panels of FIG. 1, in which the panels are shown to be supported in a frame including end legs, top legs, bottom legs, and a corner leg; and 
     FIG. 3 is a perspective view of a three-paneled bathing enclosure incorporating three of the wall panels of FIG. 1, in which the panels are shown to be supported in a frame including end legs, top legs, bottom legs, and corner legs; 
     FIG. 4 is a perspective view of one of the end/top legs employed in the frames of FIGS. 2 and 3; 
     FIG. 5 is a perspective view of one of the corner legs employed in the frames of FIGS. 2 and 3; and 
     FIG. 6 is a perspective view of one of the bottom legs employed in the frames of FIGS.  2  and  3 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring first to FIG. 1, a panel  10  includes eight different layers. The first layer of the laminate is a frosted acrylic material layer- 20  made from any of a variety of different types of acrylic materials such as, for example, the PL 25  extruded acrylic available from Plaskolite, Inc. of Columbus, Ohio. Although somewhat translucent, the layer  20  includes an organic or inorganic frost additive that causes the frosted acrylic material layer to have a frosted appearance (e.g., somewhat cloudy with or without identifiable speckled particles), such that only a portion of the light incident on the layer is transmitted through the layer. One example of a frosted acrylic material layer including such a frost additive and having such a translucent, frosted appearance is the Optix Frost acrylic sheet available from Plaskolite, Inc. 
     Other sources of frosted acrylic material layer are Plexiglas® frosted acrylic available from Elf Atochem North America Inc. of Philadelphia, PA, and Acriglas® custom acrylic material available from Acrilex Inc. of Jersey City, NJ. The layer  20  can also include a color additive to tint the layer a particular color. For example, in one embodiment, the frosted acrylic material layer  20  includes a 3030 green color concentrate additive (available from a variety of acrylic manufacturers), such that the layer has a light green appearance. 
     Behind the frosted acrylic material layer  20  is a reflective layer  30 , which has a shiny, metallic, reflective appearance (and acts as a mirror). The layer  30  is very thin, and can be applied in vaporous form (e.g., vacuum-deposited) onto the frosted acrylic material layer  20 . In one embodiment, the reflective material layer  30  is a layer of aluminum that is 900-1100 angstroms thick, although in alternate embodiments the layer can be formed from other materials (e.g., silver) and can have any of a variety of different thicknesses based upon the type and amount of reflective material that is employed. 
     The combination of the frosted acrylic material layer  20  and the reflective material layer  30  primarily provides the panel  10  with its distinctive appearance. Some of the light that is incident upon a front surface  5  of the frosted acrylic material layer  20  (e.g., the surface of that layer that is not in contact with the reflective material layer  30 ) is transmitted through that layer to the reflective material layer, reflected by the reflective material layer, and transmitted back through and out of the frosted acrylic material layer. However, other of the incident light instead is reflected by the frosted acrylic material layer. 
     The combination of the frosted acrylic material layer  20  (whether colored or not) and the reflective material layer  30  provides the shower wall panel  10  a bright, visually stimulating appearance that, at the same time, is not as flashy or flamboyant as in the case of a conventional double-layer laminate having a clear acrylic material layer backed by a reflective material layer. Due to the combination of the frosted acrylic material layer  20  and the reflective material layer  30 , the lighting conditions in a shower in which the shower wall panel  10  is installed are relatively consistent and not overly bright or dark. 
     A preferred additional layer is a protective coating layer  40  affixed to the front surface  5  of the frosted acrylic material layer  20 . This protective coating layer  40 , which is preferably completely transparent and can be colored or colorless, provides the shower wall panel  10  with abrasion and stain resistance as well as resistance to exposure to chemicals such as soaps, shampoos, and cleansers. Although a variety of different materials could be used, in one embodiment the layer is ARmadillo scratch-resistant coating available from Plaskolite, Inc. 
     There may also be a protective paint layer  50 , which is painted directly upon the surface  15  of the layer  30 . In one embodiment, the protective paint layer can be a urethane-based paint. The paint layer is added to prevent scratching or other damage to the reflective material layer  30 , as well as to waterproof the panel  10 . 
     Affixed successively behind the protective paint layer  50  are a first adhesive layer  60 , a spacing layer  70 , a second adhesive layer  80 , and a support layer  90 . In the embodiment shown, the first and second adhesive layers  60  and  80  are employed to attach the spacing layer  70  to the protective paint layer  50  and the support layer  90 , respectively. However, in alternate embodiments some or all of these three layers  50 , 70  and  90  can be attached to one another without discrete layers of adhesives. The adhesive layers  60  and  80 , when employed, can be any of a variety of adhesives such as, for example, the NF-FB30 adhesive available from the  3 M Company of St. Paul, Minn. 
     The support layer  90  can be any stiff (e.g., relatively unbendable) material that is relatively lightweight such as, for example, the Formica® laminate manufactured by the Formica Corporation of Cincinnati, Ohio. The spacing layer  70  can be any of a variety of different types of spacing materials such as cellulosic spacing materials (e.g., cardboard or paper), plastics, polymeric foam (or other types of foam), or other materials, particularly non-absorbent materials. 
     In a preferred embodiment, the spacing layer  70  is a layer of double-faced hexacomb cardboard available from Pactiv Corp., of Lake Forest, Ill. Hexacomb cardboard is preferred because it allows the support layer  90  to provide desired support to the frosted acrylic material layer  20  and the reflective material layer  30  without directly contacting those materials (or contacting the protective paint layer  50 ), and at the same time is lightweight and resistant to compression and expansion. The support layer  90  in particular provides desired support against bending of the layers  20 , 30  (as well as layers  40 , 50 ) both because the support layer resists bending of itself and also because the support layer counteracts tensile forces that occur along the length of the support layer when the layers  20 , 30  are being bent. 
     Referring to FIGS. 2 and 3, two of the panels  10  (specifically, panels  10 A and  10 B) and three of the panels (specifically, panels  10 C, 10 D and  10 E) are shown to be supported, respectively, by a two-panel frame support  100  and a three-panel frame support  200 . Specifically with respect to FIG. 2, the two-panel frame support  100  includes two end legs  110  and  120 , two top legs  130  and  140 , and two bottom legs  150  and  160 , and a single corner leg  170  The end legs  110  and  120  are positioned respectively along end edges  115  and  125  of the panels  10 A and  10 B, respectively, the end top legs  130  and  140  are positioned respectively along top edges  135  and  145  of the panels  10 A and  10 B, respectively, the bottom legs  150  and  160  are positioned along bottom edges  155  and  165  of the panels  10 A and  10 B, respectively, and the corner leg  170  is positioned along each of inner edges  175  and  176  of the panels  10 A and  10 B, respectively. The edges of the panels  10 A and  10 B are shown in phantom. 
     As for the frame support  200 , that frame support includes two end legs  210  and  220 , three top legs  230 ,  240  and  250 , three bottom legs  260 ,  270  and  280 , and two corner legs  290  and  295 . The end legs  210  and  220  are positioned respectively along end edges  215  and  225  of the outer panels  10 C and  10 E, respectively, the top legs  230 , 240  and  250  are positioned respectively along top edges  235 , 245  and  255  of the panels  10 C, 10 D and  10 E, respectively, the bottom legs  260 , 270  and  280  are positioned along bottom edges  265 ,  275  and  285  of the panels  10 C, 10 D and  10 E, respectively, the first corner leg  290  is positioned along inner edges  291  and  292  of the panels  10 C and  10 D, respectively, and the second corner leg  295  is positioned along inner edges  296  and  297  of the panels  10 D AND  10 E, respectively. The edges of the panels  10 C, 10 D and  10 E are shown in phantom. 
     The frame supports  100  and  200  provide both additional support to prevent bending of the shower wall panels  10 A- 10 E, and also support to hold the panels in position with respect to other structures. The legs  110 - 170 ,  210 - 290  and  295  preferably are made from lightweight, inexpensive and water resistant materials such as extruded aluminum or fiberglass. In alternate embodiments, different configurations of legs forming different frame supports are possible, including frame supports holding different numbers of panels  10 . For example, it would be possible to form a frame support for a single wall panel  10  using the bottom leg  150 , the top leg  130 , and the end legs  110  and  120 . Also, it would be possible to mount two panels back-to-back to provide a double-sided panel assembly. Such a back-to-back panel assembly could employ the various legs discussed above in a frame support, or employ a frame support of a different design. 
     Turning to FIG. 4, a perspective view is provided of one of the end or top legs  110 , 120 , 130 , 140 ,  210 , 220 , 230 , 240  and  250  (e.g., the end leg  110 ), each of which has an identical cross section (and, in some embodiments, an identical length). As shown, the end leg  110  (and each of the other end or top legs) has a base portion  300  and a flange portion  310 . The base portion  300  has a generally rectangular cross-section with first and second openings  320 , 325 . The first opening  320  is along an interior side  330  of the base portion  300  and forms a C-bracket (or C-clamp)  335 , which extends the entire length of the leg  110 . The second opening  325  opens up to the remainder of the base portion exclusive of the C-bracket  335 . When the end leg  110  is assembled onto its corresponding edge  115  of the shower wall panel  10 A, the edge of the panel extends into the C-bracket  335 , abuts the C-bracket, and is supported therein. 
     Referring further to FIG. 5, a perspective view is provided of one of the corner legs  170 ,  290  and  295  (e.g., the corner leg  170 ), each of which has an identical cross section (and, in some embodiments, an identical length). As shown, the corner leg  170  (and each of the other corner legs) has first and second main components  360 , 370  and additionally a diagonal interface component  380  (for clarity, the respective ends of the first and second main components are shown to be differently cross-hatched, and the end of the diagonal interface component  380  is not cross-hatched). Further as shown, the first main component  360  is secured with respect to the second main component by way of a first end  365 , which fits within a channel  375  and is fastened therein (by way of screws, bolts, snap fittings, or any of a variety of other fastening techniques). Each of the first and second main components  360 , 370  also has a respective C-bracket  367 , 377  that are oriented perpendicularly to one another when the first and second main components are coupled together. When installed as part of the frame support  100 , the corner leg  170  receives and supports the edges  175  and  176  within the C-brackets  367 , 377 , respectively. 
     The diagonal interface component  380  covers over the junction between the first and second main components  360 , 370  and provides a relatively smooth transitioning between respective interior surfaces  368 , 378  of those components. In the embodiment shown, the first and second main components  360 , 370 , their interior surfaces  368 , 378  and their C-brackets  367 , 377  are respectively perpendicular such that the panels  10 A and  10 B supported by the corner leg  170  are respectively perpendicular. However, in alternate embodiments, different orientations of these components is possible (e.g., such that the panels  10 A and  10 B would be  120  degrees apart). In the embodiment shown, in which the interior surfaces  368 , 378  are respectively perpendicular, an outer face  382  of the diagonal interface component  380  forms an approximately 135 degree angle with each of the interior surfaces  368 , 378 . 
     The diagonal interface component  380  can be fastened to the first and/or second main components  360 , 370  by way of a number of fastening devices. As shown, in this embodiment, the second main component  370  includes a second channel  379 , which is capable of receiving a screw, bolt, clip, magnet, or other fastening component. In one embodiment, screws, magnets or bolts are used to fasten the diagonal interface component  380  (or an extension thereof extending toward the second channel  379 , which is not shown) to the second main component  370  or another component that itself is fastened to the second channel  379  of the second main component (not shown). 
     Referring to FIG. 6, a perspective view is provided of one of the bottom legs  150 , 160 , 260 , 270  and  280  (e.g., the bottom leg  150 ), each of which has an identical cross section (and, in some embodiments, an identical length). As shown, the bottom leg  150  (and each of the other bottom legs) has a base portion  390  and a flange portion  395 . The base portion  390  has a generally rectangular cross-section with a C-bracket  392 , which extends the entire length of the leg  150 . When the bottom leg  150  is assembled onto its corresponding edge  155  of the shower panel  10 A, the edge is received by the C-bracket  392  and supported therein. An additional notch  398  is provided along the bottom of the bottom leg  150 , which is designed to receive sealing tape to provide for waterproofing along the bottom of the frame support  100 . 
     In certain embodiments, a further layer of silicone foam tape (not shown) is adhered along the edges of the shower wall panels  10 A- 10 E which extend into the C-brackets  195 , 367 , 377  and  392 , such that the tape is positioned in between the C-brackets and the edges of the shower wall panels. The tape seals the interface between the shower wall panels  10  and the C-brackets  195 , 367 , 377  and  392 , and also provides waterproofing. Specifically, the tape covers all portions of the shower wall panels  10  that are in contact with (or potentially in contact with) the C-brackets  195 , 367 , 377  and  392 , e.g., the tape is positioned both along the outer edges of the shower wall panels (perpendicular to the layers  20 - 50 ) as well as on the portions of the outer surfaces of the outermost layers that extend into the C-brackets  195  (e.g., the perimeters of the outer surfaces of the layers  40  and  50 ). Such foam tape can be adhered to the shower wall panel  10  by any of a number of acrylic adhesives. In alternate embodiments, different types of tape or other materials can be employed. 
     In alternate embodiments, the C-brackets  195 , 367 , 377  and  392  can include rounded or other protrusions that protrude farther into the interior of the C-bracket by the rounded protrusions  200 . Although not shown with respect to the end/top leg  110  or corner leg  170  of FIGS. 4 and 5, exemplary rounded protrusions  397  are shown in the C-bracket  392  of FIG. 6 (although in such protrusions in the preferred embodiment are not present). When employed, the rounded protrusions extend far enough into the C-brackets so as to effectively grip the shower wall panel(s)  10  into place, but not so far as to scrape or otherwise damage the edges the shower wall panels. 
     While all of the layers of the shower wall panel  10  could conceivably extend into the C-brackets  195 , 367 , 377 , 392 , in the preferred embodiment only the protective coating layer  40 , the frosted acrylic material layer  20 , the reflective material layer  30  and the protective paint layer  50  extend into the C-brackets  195  while the remaining layers  60 - 90  extend up to (or nearly up to) the respective interior sides  190  of the frame members  110 , 120 , 130  and  140 . In an alternate embodiment, the first adhesive layer  60  also extends into the C-brackets. In another alternate embodiment, only the frosted acrylic material layer  20 , which provides the bulk of the material of the layers, would extend into and be supported by the frame support  100 . It should be noted that the thicknesses of the layers shown in FIG. 1 are not drawn to exact scale, although FIG. 1 does show figuratively some of the relative thicknesses. 
     As shown in FIG. 2, the respective legs  110 , 120 , 130 , 140 , 150 , 160  and  170  of the frame support  100  can be held together by way of a four screws or bolts  199  (shown in phantom). Although not shown in FIG. 3, the legs of the frame support  200  can also be held together in this manner. The screws/bolts  199  extend from the end and corner legs  110 , 120 , 210 , 220 , 170 , 290 , 295 , through holes (not shown) in those legs, into grooves  400  that exist within each of the neighboring top legs  130 , 140 , 230 , 240 , 250  and bottom legs  150 , 160 , 260 , 270 , 280  (see FIGS.  4  and  6 ). 
     Because in the present embodiment each of the top legs shares the same cross-section with each of the end legs, each of the end legs likewise have a respective groove  400 . Also, the corner legs  170 , 290  and  295  each have grooves  401 . However, rather than being used to receive screws/bolts  199  for coupling together the various legs of the frame supports  100 , 200 , the grooves  400 , 401  of the end and corner legs instead are configured to receive fasteners (e.g., clips) from face pieces  405 , 410  (see FIGS. 2 and 3) that are used to close off the ends of the end and corner legs, respectively. The face pieces  405 , 410  close off the ends of the hollow end and corner legs, respectively, which otherwise would be exposed. Although the face pieces  405 , 410  are only shown in FIGS. 2 and 3 along the top of the frame supports  100 , 200 , similar face pieces also exist along the bottom of those supports. 
     The frame support  100  holding the shower wall panel  10  can be affixed to other frame supports for other shower wall panels, as well as to the walls or other structures within the room in which the shower is to be located, by way of a variety of techniques. In one embodiment, the legs are mounted to stud walls and/or are interlocked with one another. In another embodiment, holes (not shown) are formed within the flange portions  310  of the end and top legs  110 , 120 , 130 , 140 , 210 , 220 , 230 ,  240 , 250 , such that screws or bolts can be employed to affix the frame supports  100 , 200  to other structures. As shown in FIGS. 2 and 3, the legs of the frame supports  100 , 200  are assembled to one another so that the edges of the panels  10 A- 10 E are entirely surrounded by the frame supports  100 , 200 , as shown in phantom in FIG.  2 . 
     While the foregoing illustrates and describes the preferred embodiments of this invention, it is to be understood that the invention is not limited to the precise construction herein disclosed. The invention can be embodied in other forms without departing from the spirit or essential attributes of the invention. For example, in certain alternate embodiments, only a few of the layers, e.g., the layers  20 , 30 , 40  or the layers  20 , 30 , 50 , are included within the panel  10 . In other embodiments, the invention can relate only to the particular configuration or design of the frame supports (or the legs or other frame support members), rather than to (and independent of) the design, type or number of panels that are supported by the frame supports. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention. 
     Therefore, the invention should not be limited to just the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced. 
     INDUSTRIAL APPLICABILITY 
     The invention provides improved panels useful in constructing bathing enclosures.