US2655745A - Electric steam iron - Google Patents

Description

J. O. THIBAULT ELECTRIC STEAM IRON Oct. 20, 1953 3 Sheets-Sheet.

Filed May 16, 1950 \5, Ii 1 A R 3nventor Oct. 20, 1953 Filed May 16, 1950 J. 0. TH IBAU LT ELECTRIC STEAM IRON 3 Sheets-Sheet 2 (Jase 07? 0. Th (64a! (Ittomcgs Oct. 20, 1953 J. o. THIB'AULT 2,655,745

ELECTRIC STEAM IRON Filed May 16, 1950 5 Sheets-Sheet 3 Jase 7: 0 Thiau Zz Gttornegs Patented Oct. 20, 1953 UNITED STATES ATENT OFFICE ELECTRIC STEAM IRON Application May 16, 1950, Serial No. 162,177

This invention relates to steam irons, particularly electric steam irons of the type manufactured for domestic use, in the home.

Heretofore electric steam irons of the above type have generally adhered to a structural design characterized by the boiler, which was mounted above the sole plate, also constituting the casing of the iron. These boiler-casings were either made as castings of aluminum or the like, or as composite sheet-metal structures employing welding, soldering or similar fastening means in their fabrication.

Presumably the purpose behind such prior designs was to obtain a large water capacity, together with simplicity of construction and economy of manufacture.

One prior type of composite sheet-metal boiler construction consisted of an upper section in the form of a dished drawn sheet-metal shell having the usual dome-like casing shape with a depending skirt engaging the sole plate, and a cooperable lower section comprising a bottom plate provided along its edge portions with downturned or outturned flanges engaging the inner upright Walls of the skirt of the upper or casing section. The engaging portions of the two sections, which were in overlapping relation, were then seam-welded together. This procedure marred the outside surfaces of the skirt of the casing section, and produced a difiicult problem in the matter of finishing the casing. This problem was aggravated by the fact that the casing sections were made of stainless steel, which is particularly resistant to polishing and finishing operations where pockets are formed and appreciable material has to be removed to provide smooth surfaces.

As a consequence, the matter of finishing the boiler-casing assembly was time-consuming and expensive, and not conducive to quality finishing. Moreover, with this prior type of construction there was another significant disadvantage in that the portions to be seam-welded did not lie in a single, flat plane, but instead followed a curved, devious path necessitating turning and twisting of the assembly during the welding. This was not only difiicult, time-consuming and costly, but often resulted in imperfect welds, causing leaky boilers in which the defects had to be first located and then corrected. A further difliculty arose if the boiler-casing developed defects after being put into service. Where such defects involved leakage, which was often the case, the boiler-casing assemblage would have to be removed and replaced by a complete new 5 Claims. (01. 38-47) assemblage, which was usually done at a service or field station. This caused quite appreciable expense to the customer, since the replacement did not involve simply a boiler but instead also involved a highly finished casing part, produced at relatively great cost due not only to its being made of stainless steel but also because the welding formed pockets in the outer surface, which had to be removed by the finishing process.

In another prior type of iron a composite stainless steel combined casing and boiler was formed of an upper section comprising a dome-shaped shell constituting the casing and a cooperable lower section comprising a bottom and back plate, which had upturned and inturned flanges around its edge portions, engaging the innerand undersurfaces of the top section. In this particular prior art construction silver solder was used to join together the two sections. While this eliminated the pitting of the outer surfaces of the upper or casing section, it was not particularly well adapted to simple and rapid, economical production and did not completely remedy the leakage problem (requiring subsequent correcting operations), nor the high cost of finishing a stainless steel casing part, nor the high cost of replacement if the casing-boiler assembly developed defects after being put into use.

The present invention overcomes the difliculties and disadvantages of these prior constructions mentioned above, it being an object of the invention to provide an improved electric steam iron of exceptional quality and sturdy and rugged construction, characterized by reliable performance and large water capacity while at the same time being simple to construct and manufacture, and easy and economical to service.

In accomplishing this object I have departed from the usual and accepted procedure followed in the past, of making the boiler and easing as a single unit. Instead, I make the boiler and casing as separate units, the boiler being formed of sheet-metal sections secured together, and the casing of a separate dome-shaped sheet-metal shell adapted to overlie and surround the boiler. I have found that by so doing, contrary to expectations, desirable economies in the finishing operations of the casing and in the fabrication, particularly the welding, of the boiler may be effected. The welding, besides being quicker and less costly, is more effective, thereby eliminating leaks and reprocessing and providing greater reliability in boiler performance and life. In addition, servicing of the iron is made easier, and boiler replacement is less costly.

By the present invention, the construction and arrangement of the boiler may be worked out without regard to its finish and appearance, so that the factors of ease and reliability in the welding of the boiler sections may be given the fullest consideration. The casing according to the present invention may be separate from the boiler, and may, be. made ofa metal difierent from stainless--'steel or' other metals-which are diflicult to finish and are rust and corrosion reh The casing metal may be chosen for:

sistant. its ease and economy in forming and-finishing. I have found it advantageous to form the boiler of upper and lower, facing,zdishedssections,.each; section comprising a sheetemeta lgshell having ae rim including an outturned flange disposed" in a single, fiat plane. circumferential overlapping portions, and'are se cured together in water-tight relation-.toform;

Thus there may be employed a quick a vessel. and economical; continuousseam-welding procedure, whichxmay; be. doneon semiautomatic equipment, prod ueinga highly, efl'icient; seam. or. joint which. is completely water-tight and. also reliable-in use even. though subjected; to stresses imposed bythe manipulating. ofithe iron.-

I' have' found that. the welded joint formed by, the outturned. fiangestwhich: are. disposed in flat planes, overlapping each other, is so sturdy;

and rugged that,advantagemay.betakenof this manufacture. of. the. iron; but when. it. becomes.

necessary to dismantle itheirontdcarry, out servicingoperations.

By making the. casing and boiler, separate and. distinct-from each .other, notnnly can. the .casing; be economically finished because it.can be. made. of metal. difierentfrom. the rusteproofmetal. of

theboiler, .but .in-the..event..that.at. a .later. date the boiler shows somedefect and; requires re placement, the cost of such. replacementwillbe relatively low because. it. does not. involve the discarding. of. a. finishedv casing. as was. heretofore thev case.-.

Theinvention is embodiedin an. iron of the. type. having a. pivoted; handle, which can be swungback. from. operative. position to expose thefiller. openingfor. the. boiler, and in connec tion with this organization-L'dispose the fasteningmeans i'orthe..casing.so astobe normally concealed by thehandle, and to beexposed .when

the handle is swung. back to filling... position,.

thereby. simplifying. the dismantling of .theiron whenservicing is necessary.

In order to. obtain. relatively large water capacity Itrim'the welded outturned fiangesof theboiler after. the welding thereof, to reduce the. width of. the flanges to.a relatively small.

figure. Accordingly'the side walls of the boiler maybe brought into. close proximity to the side walls. of. the-casing, reducing. the unused. space between the boiler. and; casing, and. enabling a' relatively large boiler. capacity to. be obtained for a'given casing size: Moreover, .by. theprovision' of the aforesaidlspace between. the. boiler and"the;casing, that-latter functions:- as. an ef fective shield, being; maintained at a? relatively:

The flanges have continuous 4 cool temperature whereby it is not so hot to the touch and not so likely to cause burns or discomfort if a user should inadvertently come in contact with the casing.

I utilize the welded flanges of the boiler as part of the means for securing the boiler to the casing, thereby providing an extremely simple and. reliable mounting...

Other features-and advantages will hereinafter appear.

In the accompanying drawings:

EigureLis a vertical, longitudinal sectional view'ofan'electric steam iron embodying the invention:.

Fig'zzfis an enlarged fragmentary detail of the steamdome=and upper portions of the boiler and easing, illustrating. the means for fastening the casing to the boiler.

Fig.3 is an enlarged fragmentary detail of the filler opening of the boiler, showing the gasketetype-seali-ng. meansinterposed.betweenthe boiler, and thecasing;v

Fig. 4 is a rearr elevational View of the iron, with. portions broken. away and. shownin. section to illustrate. interiondetails...

Fig. 5 isa top. view ofthecasingofthe iron.

Rig. 6-- is a. top View. of; the.- complete. sheetmetal boiler.

Fig. 7 is a side elevationalview of the boiler.

Fig. 8 isa top viewoftheboiler.afterassembly and. weldingof the-parts, but. prior: to trimming, off excess material, and:

Fig. 9..is aplan view=ofaheahconducting. shim such as is interposed ..betWeen.the-.-sole. plate and.

. boiler, and between the sole plateandthermo:

stat.

The ironembodyingthe.invention as shown in Fig; 1, comprises -a. soleplate. lilhaving. anelectric heating element. .connectedwitli a thermostatv [2. which. is vmounted on. the. rear portion. of the. sole. plate- The.-thermostat-. l2iisof. the usual .type, having a frame. ljiiImounting ,contacts. i4 and [5-, the latter contact .being. actuated. .by. alever. it engagedby. allow expansion. strip. l'il" which. is. securedlto a high. expansion, strip -v 18.

attached. toathe .fiame. I 3? Adjustmentof the thermostat I2 is providedf fonby aknob .liiicarriedjona shaftitiwhich engages.the...contact ieandis threaded'into alsleeve 2] 'carriedby the frame 131 Atthefrontof the .soleplate lil a' steam chamb.er..'22v isprovidd, ,enclosediby a. cover plate 23 into, which there. is: threaded. an. upright steam tube. 25!. having .an.-extension 24a. of reduced diameter. The. steam tubeZAhas notches. 25b in" its end, to. accommodate v a wrench.

In accordance with the invention a novel assemblage of sheet-.metal boiler and separate sheet-metall casing is provided, in conjunction. with the sole plate liljto produce a superior quality steam iron characterized by low manufacturingcost, high performance and reliability, ease..of disassembly and servicing, and'low-cost' boiler replacement should thiseverbe necessary.

As shown in Figs. 1,. 6,,T'and 8, the boiler of this assemblage, indicated by the numeral 25, comprises a dished, upright, lower sheet-metal section 26' and a. dished; inverted, upp'er sheetmetal section 21'. The sections. 26 and 21 are shaped. and formed by the. usual. punches and. dies and after leaving thetoolshavethe.con= figurations shown in Fig. 8, with irregular shaped, outturned flanges 23. and 29. Inassernbly, the boiler sections. 26 and 27 are placed; together.

with. their flangesimengagement andisubjected;

to a seam-welding operation which joins the flanges together closely adjacent the walls of the sections. After this, the assembled sections are placed in a trimming tool, and the excess material removed from the flanges, leaving the configurations shown in Figs. 6 and 7, including apertured mounting ears or lugs 30.

Prior to the assembly of the boiler sections, the upper section 2'! is provided with a filler opening 3| having a valve seat 32 depending therefrom. The valve seat 3| may be advantageously made of a drawn sheet-metal cup, and may have a crimped flange 33 and a, second flange 34 between which the upper wall 35 of the boiler is securely gripped.

Also, prior to assembly of the boiler sections, the upper section 21 is provided with a second opening 36 in its front upper portion, around which a hollow threaded boss 31 is secured. As will be seen in Fig. 1, the extension 24a of the steam tube 24 passes upwardly through the boss 37 and projects above the top of the boiler 25. Between the openings 3! and 35 of the boiler a depressed portion 38 is provided, to provide clearance for a latching structure as shown in Fig. 1.

Enclosing the boiler 25 and secured to it is a dome-shaped casing 39 in the form of an elongate shell, which is also drawn of sheet-metal. The bottom edge or rim 40 of the shell engages the edge portions of the sole plate l0, being received in a peripheral recess 4| provided for this purpose. The front upper portion of the casing 39 is provided with an opening 52 through which the boss 3'! of the boiler extends, and a steam dome 43 in the form of a drawn sheet-metal thimble is threaded onto the boss 3'! so as to enclose the upper portion of the steam tube extension 24a and to securely fasten together the adjacent upper portions of the boiler 25 and casing 39. For this latter purpose, the steam dome it has an outturned flange 44 engaging a washer 45 which surrounds the boss 31 and rests on the casing 39.

Referring to Figs. 1, 4 and 6, the apertured lugs 36 of the boiler 25 receive screws 45, which are threaded into upstanding bosses 41 on the sole plate I0, thus fastening the rear portion of the boiler to the sole plate.

The rear central part d8 of the casing 39 is depressed. It has a downward and backward slope-cl fiat portion 45, merging with a horizontal edge portion 5|) which terminates in a transverse depending flange 5|. The horizontal edge portion 5|) at its center extends forwardly at 52 and is provided with a screw hole 53. A steep sloping wall 54 joins the portions 49 and 52 together. As seen in Fig. 1, a screw 55 passes through the hole 53 and is threaded into a boss 56 on the sole plate N for the purpose of securing the casing 39 to the sole plate. In order to steady the casing on the sole plate without employing additional fastenings, two upright bosses 55a are provided on opposite sides of the boss 56 and spaced therefrom a substantial distance, the bosses 56c engaging the underside of the horizontal edge portion 55 of the casing. To provide clearance for the thermostat shaft 20, the portion 49 of the casing is provided with an aperture 51 substantially larger than the shaft.

In order to obtain a steady, smooth-acting bearing for the shaft 20 a bearing bracket 58 is provided, in accordance with the invention, having an opening 59 through which the shaft passes and against the walls of which it bears. The bracket 58 has apertured ears 50 through'which 6. fastening screws 6| pass, said screws being threaded into the upper wall portion 48 of the casing.

The top of the casing 39 has a large central opening 62 which is aligned with the filler opening 3| of the boiler. Around the edge of the opening 62 a depending flange 63 is provided, and encircling the flange 53 is a washer or gasket 64, interposed between the top walls of the casing and boiler to provide a seal and prevent water from leaking between the casing and boiler when the latter is being filled.

The casing 39 has at its rear a pair of inwardly facing walls 55 which are apertured to receive spring loaded trunnion pins 65 carried in the rear portion 67 of a handle structure 58. The handle structure 58 is similar generally to that shown and described in my copending application Serial No. 103,437, filed July 7, 1949, entitled Steam Electric Iron. It consists of a broad flat base plate 59 having upstanding front and rear posts ill and H respectively which are connected together at their tops by a handle proper 52. The rear post 'H- has a recess 13 to accommodate the thermostat knob I9, and the front post H3 has a recess M to accommodate the steam dome i3.

As shown in Fig. 1, the handle structure 68 may be swung backward to a filling position indicated by the broken lines. When in this position it exposes the filler opening 3| of the boiler 25. On the underside of the base 69 of the handle a valve 75 is mounted, for cooperation with the valve seat 32 carried by the upper wall of the boiler 25.

To releasably lock the handle structure 68 in operative position a latch 16 is provided.

For the purpose of reinforcing the top wall of the boi er 25 around the filler opening 3| thereof, so as to minimize distortion of said wall by pressure imposed upon it by the closure 15, reinforcing ribs 11 are embossed in the boiler wall, Fig. 6. These ribs prevent the boiler wall and easing wall from separating at the gasket 64, and maintain the gasket in tight sealing relation with the said walls.

It will be seen that by the above construction the handle structure 68 is secured to the casing 39 at the rear by the trunnions 56, and to the forward portion of the casing by the releasable latch 15. The casing 39, in turn, is secured to the sole plate ID at the rear thereof by the single screw 55, and at the front is not fastened directly to the sole plate but instead to the top forward portion of the boiler 25 by means of the steam dome 43.

I have found that, by making a composite boiler of sections having outturned flanges lying in substantially flat planes, and seam-welding the flanges together, an extremely strong and sturdy unitary structure results which will not develop weakness or failure even with the handle transmitting force to the sole plate through the forward portion of the boiler. The casing 39 is nowhere at its forward portion secured directly tothe sole plate. Instead, it is secured to the upper portion of the boiler, and the lower forward portion of the boiler is secured to the sole plate by the steam pipe 24. Thus, as a consequence of effecting a strong weld between the boiler sections 25 and 21, I have obviated the necessity of securing the casing 39 directly to the sole plate at the front of the iron. Accordingly I have accomplished a simplification of the fastening means, resulting in a desirable economy in manufacture and assembly of the iron, and

simplifying-the dismantling ;of .theiron for service ing or replacementzof.the.;boiler:

Moreover, by making the boiler 25 separate from thecasing 39; replacement-pf the boilermay berefieetedwithout-.requiringr replacement of the highly finishedi casingpart.39.- Thusetheacuse tomen in 1 the eventeoffailure .of the :boiler. need not. payfor. aefinished. casing part, but 1 instead only-for. a boiler as such... Since-the boiler'does not have a highly finishedsu-rface which is ;ex-. pensive.- to: produce, its initial. cost is= relatively low and as a result replacement of -thezboiler'- does not involve an .appreciablyg high: expense-.

sinceethee boiler. 25;- and: the: casing, 3.91am

entirely separate.from. each: other, the.- material fonthe boiler rnay-;be.-chosen-from any of various rust? and corrosion-resistant metals-ewithontregard;.-to-.-the. problem t finishing. and the -mate-- rialsof the? casing -may bezchoserr primarily or largely. with regard ,tothe finishing. Irraddition, since there is. no. welding. involved: inothe cone struction-ot. the casing; 39,-'.to.'cause= pockets or markings on the exterior. surface. thefinishing of the casingmay be done quicklyand economically.

Considering the: boiler. itself, the provision of the flatfianges. 28-. and .29.'enab1e. the. boiler secs tions-to. beseamewelded-together: at the. flan e by semiautomaticeqnipment; anditis not reqniredrthatthe boilerbetwisted or maneuvered along-an. intricate curvedpath during the welding; operation. Accordingly the welding. maybe carried.- out quickly and economically, and may be made --very effective. to. provide completely watertight joints. at the. flanges.

By virtue oi. the flanges. 28.. and. 29-. being trimmedoff close to..the.,side. walls. of the boiler 25 latter the welding theboiler. walls. and casing walls maybe brought.int0..cl0se.proximity, minimizing, the amount. of spacenot utilized. for water, between the boiler. and. casing wallsand resulting in. a relatively. large. boiler. capacity. Therelatively smalliair space. whichdoes exist between the walls of the..boil'er.-v and. the: casing. however, provides an effective heat insulator. to prevent the. casing from .becomingashot as ,the walls of the boilen. Thusthelikelihood .of'aauser becoming burned 'ifJheinadVertentIy touchesthe casing is considerably. reduced...

Because of the simplified welding procedure .by which the boiler of this inventionmay be.fabri cated, together withthe. ease and rapidity of .fin.-. ishingthe casing surrounding the.boiler, I. have efiected a; desirable economy, in themanufacture of the iron. Contributing to this also. is the effectiveness of the weldin which. minimizes leakage defects andlsubsequent corrective processing operations, and the simplification of fastening means .by which the sole. plate, boiler and casing, are secureditogether;

In-order toiprovide a more efiicient. heat trans+ fer from the sole plate I0 to the boiler 25 I provide, in'accordance with this-invention, fluted or ribbedshims 18, Figs: 1 and 9, which are inter-'- posed between-the bottom wall of theboilerandthe top walliof the-sole plate along the area-dis posed directly overthe heating element ll.

Referring torFig 4; animproved cord anchor age-isprovided -to;securely fastenthe supply cord- 1 9: to .the-iron atthe point :where it passesithrough; the wall of;th,e .casing 3.9. This-:cordanchorage comprises. anexternally threaded hollow boss. or bushing Bil. whichis mounted onthe casing 39,. said bushinghavingataperedbore 81. The electrier cord 19tpasses throughthe. bushingjfl. and

is..engag ed .and..grip pedl.by spring. fingers BZ. ex.-.-

tendinggiromzaafiatlwashen-likeebody ,83subjected to forceseexer-tedlbyea cap-84 threaded omthe bushing 8.0L, The.fingers.821areeforcedlongitudh nallydnwardaga-inst thetapered bore. 8L of the bushing-whenthecap :.83.is tightened. thussforcs ingthe. fingers inward against. the. cord-19-to securely grimthelatter.

A ihelical ..wire,-cord- :protector. 85= is, .providedzon the. cord,- 1 9 one: 811G386 :of the: protector having anenlarged. diameter and-fitting within the cap 84.to beheld...theretdbyvaneinner. flange 81 on theccap.

Variations. and; modifications: may be; made within.the scope .ot. the: claims portions. or the improvements may be used without others...

Lclaimr.

L In .a ,steam .iron,..a sole:plate;..a boiler. dis.- ppsed. above. thev sole. plate}. a: shell-like. casing having a .top. and depending. sides, enclosing. the boiler; removable. means en aging the. forward interior. bottom; portion ,ot. the boiler, releasably securing the -,forw ard bottom ortion .to the. sole plate; meanssreleasablyr securing. the rear. of. the boiler to. .the. sole, plate; means, independent of both,-.-said,preceding, means,. releasably. securing the rearotthecasing to the .sole'plate; and means releasably securing the. forward upper. ortions of-the boiler andcasing together, said casing: and boiler being separablefromthe.sole. plate. and from each. other whereby, replacement of, the boiler. may be readily effected.

2; ma steam iron...a.sole,plate;-a boiler dis: posed above. the-sole.p late;.a shell-like. casing having .a .top anddepending sidesenclosing the boiler; removable means engaging the forward interior bottom .portion ..,of'.the. boiler, .releasably securing the.forwardlbiottomlportion to .the. sole plate; means .r'elea'sablir. securing.,the rear, of the boiler. to the sole plate; means. independent. of both saidflpreceding means, .releasably. securing the rear of. thecasing to. the sole p1ate;.and means releasably. securing. the. forward upper portions ofthe' boiler and casing together, said casing portion having an opening and said means including;aibushingpassing through said open: ing and 'a" steam dome removably attached .to the bushing and" projecting upwardly from the casing, said-casing and 'boiler'beingseparable from thesole plate and fromeachiother whereby replacement of'th'e boiler may be readily efiected.

3." The invention' as defined in claim 1, in which the means;for fastening; the rear of the casing tothesole plttteromprises solely a centrally; located screw passing through .a. top, wall ofthe casing" and threaded into;the .sole plate, andlin which the? sole platehas means .engaging theun'dersurfaceoffthecasing top wall on opposite sides'ofsaid screw, for steadyingthecasing,

4. In aisteam iron; asole plate; aboilermounted on the :soleplate; a casing enclosing the top and sides of the boiler; means releasably fasten-v ing together the front upper portions of the boiler and casing, 'means releasably fastening the: rear of the casingto thesole plate; a handle disposed above the... casing; having means. overl'yingand concealingjooth said fastening means; andmeans securingthe.handleinoperativeposittion. on the casing, said handlesecuring means being'manuall'y releasable to enablethe handle to beshifted out of operative position to expose both saidfastening means:

5; .In asteam iron, a soleplate; a sheet-metal boiler secured. to the sole. plate;.. a .casing .come prisinga sheet-metal shell...enclosing, theboiler,

said. casing and; boiler having alignedi openin s 9 in superposed upper portions to enable the boiler to be filled; gasket means disposed between and sealing the edge portions of both the openings of the boiler and casing to prevent leakage of fluid therebetween, said casing having a down-turned flange around the opening in its top portion, extending into said gasket means and positioning the same; and means remote from said gasket means, securing the casing to the sole plate and maintaining the gasket means under compression to preserve said seal.

JOSEPH O. THIBAULT'.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date Jones Nov. 26, 1940 Wiggins Feb. 20, 1940 Finlayson Sept. 8, 1942 Riddington et a1. July 22, 1943 Morton Mar. 28, 1944 Ellinwood et a1 Oct. 24, 1950 FOREIGN PATENTS Country Date France Aug. 18, 1930 France June 20, 1938

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