Tile wall assembly system and method

Abstract

A system for assembling a tiled wall includes a base, a top, and a support. The top is rotatably coupled to the base. The top includes an upper member and a lower member translatably coupled to the upper member. The support is configured to support the base and defines a recess configured to receive the upper member.

Description

TILE WALL ASSEMBLY SYSTEM AND METHODCROSS- REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 622,306 filed January 18, 2024, the entire disclosure of which is incorporated by reference.FIELD

[0002] The present disclosure relates to a system and method for assembling a wall, and more particularly to a system and method for assembling a tiled wall.BACKGROUND

[0003] Tiled walls (e.g., for showers) are an important installation for a tile setter. Known wall-tiling systems and methods involve preparing and installing tiles and related materials at the site of the tiled wall installation. For example, tiled shower walls are assembled on-site by fastening a backer board and / or a waterproof membrane to the wall studs and adhering the tiles to the backer board. The tile is then grouted using ANSI standards. These systems and methods can lead to inefficiencies as materials and equipment often need to be moved from one location (e.g., a master bathroom) at the site to another location (e.g., a guest bathroom) at the site in order to complete different portions of a project. In some cases, these systems and method can also lead to flaws or errors due to variability in the process. To help avoid potential pitfalls during installation, trade books and / or trade manuals, such as The Tile Council of North America (TCNA) handbook, describe tiled shower wall constructions along with common shower configurations and shower receptor renovations. However, even with these guides, tile installations still continue to pose issues for tile setters or other tradesmen at jobs both large and small.

[0004] Manufacturers have developed many tile installation products over the past decade or so that seek to provide cost savings or reduced skill solutions for site-built construction of tile showers. While known systems and methods for constructing tiled walls may be acceptable for their intended purposes, there exists a continuous need in the pertinent art for an improved system and method for constructing a tiled wall that is cost-effective and scalable.

[0005] The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described inthis background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.SUMMARY

[0006] One aspect of the disclosure provides a system for assembling a tiled wall. The system includes a base, a top, and a support. The top is rotatably coupled to the base. The top includes an upper member and a lower member translatably coupled to the upper member. The support is configured to support the base and defines a recess configured to receive the upper member.

[0007] Another aspect of the disclosure provides a method of operating a system for assembling a tiled wall. The system includes a base, a top, and a support. The top is rotatably coupled to the base. The top includes an upper member and a lower member translatably coupled to the upper member. The support is configured to support the base and defines a recess configured to receive the upper member. The method includes rotating the top relative to the base. The method also includes translating the upper member relative to the lower member in a first direction. The method further includes receiving the upper member within the recess.

[0008] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will become more fully understood from the detailed description and the accompanying drawings.

[0010] FIG. 1 is a schematic front view of an example tile wall assembly system according to the principles of the present disclosure.

[0011] FIG. 2 is a schematic top view of the example tile wall assembly system of FIG. 1.

[0012] FIG. 3 is a schematic side view of the example tile wall assembly system of FIG. 1 in a first orientation.

[0013] FIG. 4 is a schematic side view of the example tile wall assembly system of FIG. 1 in a second orientation.

[0014] FIG. 5 is a perspective view of the example tile wall assembly system of FIG. 1.

[0015] FIG. 6 is a perspective view of a hydraulic strut of an example tile wall assembly system according to the principles of the present disclosure.

[0016] FIG. 7 is a perspective view of a controller of an example tile wall assembly system according to the principles of the present disclosure.

[0017] FIG. 8 is a perspective view of a recessed niche area of an example tile wall assembly system according to the principles of the present disclosure.

[0018] FIG. 9 is a perspective view of a motor of an example tile wall assembly system according to the principles of the present disclosure.

[0019] FIG. 10 is a cross-section view of an upper member of a top of an example tile wall assembly system according to the principles of the present disclosure.

[0020] In the drawings, reference numbers may be reused to identify similar and / or identical elements.DETAILED DESCRIPTION

[0021] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

[0022] Referring to FIGS. 1-4, a system 10 for constructing a tile wall (not shown) is illustrated. The system 10 may include a base 12, a top 14, a support 16, a first actuation system 18a (FIGS. 5-6), and a second actuation system 18b. As will be described in more detail below, during use in an environment 20, the system 10 may move between a first (e.g., stored) position (FIG. 3) and a second (e.g., operating) position (FIG. 4). In the stored position, the top 14 may rest on top of the base 12 and be in a substantially (e.g., + / - 10 degrees) horizontal orientation. In the operating position, the top 14 may rotate relative to the base 12 such that the top 14 and the base 12 and / or an upper surface 22 of the support 16 define an angle a therebetween. In the operating position, a user (not shown) may assemble at least a portion of the tile wall. The top14 may also move (e.g., translate) relative to the base 12 to allow the user to be in an ergonomic (e.g., upright) position when assembling the tile wall.

[0023] The base 12 may include one or more legs 26, one or more upper side rails 28, and one or more lower side rails 30. In some implementations, the base 12 includes four legs 26, with each leg 26 disposed at a comer of the base 12. Each leg 26 may be connected to adjacent legs 26 by one or more of the upper side rails 28 and lower side rails 30. In some implementations, the legs 26, upper side rails 28, and lower side rails 30 form a rectangular prism.

[0024] The top 14 may include a lower member 32 and an upper member 34. The upper member 34 may be located above, or on top of, the lower member 32 and may be translatably coupled to the lower member 32. For example, the upper member 34 may be translatably coupled to the lower member 32 by the second actuation system 18b. The support 16 may be coupled to the base 12 and support the base 12 during operation of the system 10. In some implementations, the support 16 is formed by a floor or ground surface of the environment 20. The support 16 (e.g., the upper surface 22) may define a recess 24. As will be explained in more detail below, during operation of the system 10, the recess 24 may receive at least a portion (e.g., upper member 34) of the top 14.

[0025] Referring now to FIGS. 5-6, the lower member 32 may include two side supports 36a, 36b and one or more cross-braces 38. The side supports 36a, 36b may be disposed across from, and parallel to, each other. The side supports 36a, 36b may be coupled to the cross-braces 38. The cross-braces 38 may be disposed perpendicular to the side supports 36a, 36b. In some configurations, three cross-braces 38 are coupled to the side supports 36a, 36b.

[0026] In some configurations, a first actuation system 18a and a second actuation system 18b rotatably couple the lower member 32 of the top 14 to the base 12. The first actuation system 18a may include a rod 40, gear 42, and a gear rack 44. The rod 40 may define an axis of rotation Al. In some implementations, the rod 40 (e.g., a metal rod) is coupled to the lower member 32 and the base 12. As will be described in more detail below, during operation of the system 10, the top 14 may rotate relative to the base 12 about the axis of rotation Al.

[0027] Each side support 36a, 36b may include a hole 46. The rod 40 may be disposed within the hole 46. A clamp 48 may be mounted on top of each of two adjacent legs 26 of the base 12. The ends of the rod 40 may be coupled to the clamps 48. The clamps 48 may hold the rod 40 securely in place, while still allowing the rod 40 to rotate freely.

[0028] The gear rack 44 may be coupled to the lower member 32 and mate with the gear 42. As will be explained in more detail below, during operation of the system 10, the gear 42 and the gear rack 44 may aid in the rotation of the top 14.

[0029] The second actuation system 18b (e.g., a hydraulic system) may include one or more sets of struts 50 and one or more hydraulic lines 52. The second actuation system 18b may control the movement of the struts 50 by controlling the amount of hydraulic fluid within the struts 50. A first set of struts 50a may connect the lower member 32 to the base 12. In some configurations, one end of the struts 50a is mounted on the lower side rail 28 that connects the two adjacent legs 26 upon which the clamps 48 are mounted. The other end of the struts 50a may be connected to one of the cross-braces 38 of the lower member 32. To rotate the top 14 relative to the base 12, the first set of struts 50a may be extended (e.g., by forcing more hydraulic fluid into the struts 50) applying a force on the top 14 and causing the top 14 to rotate about the axis of rotation Al.

[0030] The upper member 34 may include a frame 54 and an interior grid 56 connected to the interior of the frame 54. Both the frame 54 and the interior grid 56 may be made of beams (e.g., steel tubing). One or more layers of surface material 58 (e.g., tiles) may cover one side of the frame 54 and the interior grid 56. The surface material 58 may be substantially flat to aid in assembly of the tile wall.

[0031] A second set of struts 50b may connect the upper member 34 and the lower member 32. In some configurations, one end of the struts 50b is connected to one of the cross-braces 38 of the lower member 32. The other end of the struts 50b may be connected to the frame 54 of the upper member 34. The struts 50b may allow the upper member 34 to move (e.g., translate) relative to the lower member 32 by applying a force on the upper member 34. Specifically, the upper member 34 may translate downwards into the recess 24 (FIG. 4). By translating the upper member 34 into the recess 24, the user may maintain an ergonomic position (e.g., upright) throughout the assembly of the tile wall. In an ergonomic position, the user may assemble the tile wall more quickly and / or with a reduced risk of injury (e.g., repetitive use injury).

[0032] Referring now to FIG. 10, the interior grid 56 may include one or more beams 57 defining one or more chambers 60. The beams 57 may include an inlet 64 and an outlet 66. As will be explained in more detail below, during operation of the system 10, the chambers 60 may be filled with a pressurized gas (e.g., air). For example, a series of conduits 62 (FIG. 5) may supply pressurized gas from a source (e.g., an air compressor; not shown) to the chambers 60 via the one or more inlets 64.

[0033] The layers of surface materials 58 may form one or more chambers 68a, 68b therebetween. In some implementations, the chambers 68a, 68b are formed by fastening one of the layers of surface material 58 to another of the layers of surface material 58. The one or more chambers 68a, 68b may be separated from one another by a layer of adhesive material 69 (e.g., caulk, silicone, construction adhesive, glue, etc.). Each chamber 68a, 68b may include at least one inlet 70 and at least one outlet 72 in fluid communication with a respective chamber 66a, 66b and chamber 60. During operation of the system 10, the pressurized gas may flow (e.g., by pumping) from the chambers 60 and into the chambers 68a, 68b through the outlets 66 (e.g., apertures) and inlets 70 (e.g., apertures) formed in one or more of the layers of surface material 58. The pressurized gas may then be transmitted through the outlets 72 to help lift the tile wall off of the surface material 58 to aid the user in removing the tile wall. In some implementations, the user controls which of the one or more chambers 68a, 68b is pressurized with gas in order to aid the user in removing certain portions of the tile wall.

[0034] Referring to FIGS. 8 and 9, in some configurations, the upper member 34 includes a recessed niche area 74. During assembly of a tile wall, the recessed niche area 74 may receive a niche (e.g., an area built into the tile wall to hold soap, shampoo bottles, etc.; not shown) of a tile wall to be built using the system 10. In configurations where the upper member 34 includes a recessed niche area 74, one or more beams of the interior grid 56 may be recessed relative to one or more other beams of the interior grid 56. In some configurations, the niche area 74 is movable (e.g., by one or more motors 76). When building tile walls without a niche, the niche area 74 may be flush with the rest of the surface material 58. When building tile walls with a niche, the niche area 74 may be recessed relative to the surface material 58.

[0035] In some configurations, the upper member includes a guide 78 (FIG. 3) located at a bottom of and substantially perpendicular to the upper member 34 and designed to hold the tile wall when the upper member 34 is in the second (e.g., operating) position (FIG. 4).

[0036] Referring now to FIG. 7, the system 10 may include a control panel 80 (e.g., a pendant) that controls the operation of the system. The control panel 80 may be mounted on a post 82 located near the base 12. The control panel 80 may include one or more buttons 84. Each button 84 may control a different function of the system 10. For example, a first button may rotate the top 14 relative to the base 12 by controlling the second actuation system 18b. A second button may translate the upper member 34 relative to the lower member 32 by controlling the second actuation system 18b. A third button may raise or lower the niche area 74 by controlling the oneor more motors 76. The control panel 80 may also include an emergency stop button that cuts all power to the system 10.

[0037] Operation of the system 10 will now be described with reference to FIGS. 3-6. The system 10 may be used in an environment 20. The system 10 may start in a first (e.g., stored) position (FIG. 3). When the user is ready to build the tiled wall, the user may move the system (e.g., by the control panel 80) into a second (e.g., operating) position (FIG. 4).

[0038] In a first step, the user may rotate the top 14 relative to the base 12. In some configurations, rotating the top 14 relative to the base 12 includes rotating the top 14 around the axis of rotation Al . In some configurations, the gear 42 meshes with the gear rack 44 as the top 14 rotates. In some configurations, rotating the top 14 relative to the base 12 includes applying a first force on the top 14 by the second actuation system 18b.

[0039] In a second step, the user translates the upper member 34 relative to the lower member 32 in a first direction. In some configurations, translating the upper member 34 includes applying a second force on the upper member 34 by the second actuation system 18b. In some configurations, translating the upper member 34 places the user in an ergonomic position to assemble the tile wall. After translating the upper member 34, the user may assemble a first portion of the tile wall. The user may further translate the upper member 34 in the first direction and then assemble a second portion of the tile wall. This process may be repeated until the tile wall is fully assembled. As the upper member 34 translates relative to the lower member 32, the support 16 may receive the upper member 34 within the recess 24.

[0040] In some configurations, after the tile wall is fully assembled, the user may translate the upper member 34 relative to the lower member 32 in a second direction. The second direction may be opposite the first direction.

[0041] In some configurations, pressurized gas is expelled out of one more pathways (e.g., defined by the outlets 72 in the surface material 58) of the upper member 34. The pressurized gas may help to lift the tile wall off of the upper member 34 making it easier for the user to remove the tile wall from the upper member 34.

[0042] Finally, in some configurations, the system 10 is returned to the first (e.g., stored) position (FIG. 3) by rotating the top 14 relative to the base 12.

[0043] The following Clauses provide an exemplary configuration for a system for constructing a tiled wall, as described above.

[0044] Clause 1 : A system for assembling a tiled wall, the system comprising: a base; a top rotatably coupled to the base and including an upper member and a lower member translatably coupled to the upper member; and a support configured to support the base and defining a recess configured to receive the upper member.

[0045] Clause 2: The system of clause 1 wherein: the top is rotatably coupled to the base by a rod, the rod defines an axis of rotation, and the top rotates around the axis of rotation.

[0046] Clause 3: The system of clause 2 wherein: the rod includes a gear; and the lower member includes a gear rack configured to mate with the gear.

[0047] Clause 4: The system of any of clauses 1 through 3 further comprising a strut coupled to the base and the top and configured to: apply a force on the top, and rotate the top in a first direction.

[0048] Clause 5 : The system of any of clauses 1 through 4 further comprising a strut coupled to the upper member and the lower member and configured to: apply a force on the upper member, and translate the upper member in a second direction.

[0049] Clause 6: The system of any of clauses 1 through 5 wherein the upper member includes at least one recessed area configured to receive a niche of the tiled wall.

[0050] Clause 7 : The system of any of clauses 1 through 6 wherein the upper member includes at least one layer of a surface material.

[0051] Clause 8: The system of clause 7 further comprising a pressurized gas source configured to pressurize gas, wherein the upper member includes at least one gas chamber configured to receive the pressurized gas.

[0052] Clause 9: The system of clause 8 wherein the surface material includes at least one aperture in fluid communication with the at least one gas chamber and the environment.

[0053] Clause 10: The system of any of clauses 1 through 9 further comprising a control panel configured to control at least one of: rotation of the top, or translation of the upper member.

[0054] Clause 11: A method of operating a system for assembling a tiled wall, wherein the system comprises, a base, a top rotatably coupled to the base and including an upper member and a lower member translatably coupled to the upper member, and a support configured to support the base and defining a recess configured to receive the upper member, the method comprising: rotating the top relative to the base; translating the upper member relative to the lower member in a first direction; and receiving the upper member within the recess.

[0055] Clause 12: The method of clause 11 wherein the top is rotatably coupled to the base by a rod, and the rod defines an axis of rotation, the method further comprising rotating the top around the axis of rotation.

[0056] Clause 13: The method of clause 12 wherein the rod includes a gear, and the lower member includes a gear rack, the method further comprising mating the gear rack with the gear.

[0057] Clause 14: The method of any of clauses 11 through 13 wherein the system further includes a first set of struts coupling the base to the top, the method further comprising: applying a first force on the top to rotate the top relative to the base.

[0058] Clause 15: The method of any of clauses 11 through 14 wherein the system further includes a second set of struts coupling the upper member to the lower member, the method further comprising: applying a second force on the upper member.

[0059] Clause 16: The method of any of clauses 1 1 through 15 further comprising translating the upper member relative to the lower member in a second direction opposite the first direction.

[0060] Clause 17: The method of any of clauses 11 through 16 further comprising: pressuring gas; and expelling the pressurized gas out of an aperture in the upper member.

[0061] Clause 18: The method of any of clauses 11 through 17 wherein the upper member includes a recessed area, the method further comprising receiving a niche of the tiled wall in the recessed area.

[0062] Clause 19: The method of any of clauses 11 through 18 wherein the upper member includes at least one layer of a surface material.

[0063] Clause 20: The method of any of clauses 1 1 through 19 wherein translating the upper member relative to the lower member in the first direction includes placing a user in an ergonomic position to assemble the tiled wall.

[0064] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0065] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0066] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections. These elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

[0067] The term “set” generally means a grouping of one or more elements. The elements of a set do not necessarily need to have any characteristics in common or otherwise belong together. The phrase “at least one of A, B, and C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The phrase “at least one of A, B, or C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR.

[0068] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure

Claims

CLAIMSWhat is claimed is:1 . A system for assembling a tiled wall, the system comprising: a base; a top rotatably coupled to the base and including an upper member and a lower member translatably coupled to the upper member; and a support configured to support the base and defining a recess configured to receive the upper member.

2. The system of claim 1 wherein: the top is rotatably coupled to the base by a rod, the rod defines an axis of rotation, and the top rotates around the axis of rotation.

3. The system of claim 2 wherein: the rod includes a gear; and the lower member includes a gear rack configured to mate with the gear.

4. The system of claim 1 further comprising a strut coupled to the base and the top and configured to: apply a force on the top, and rotate the top in a first direction.

5. The system of claim 1 further comprising a strut coupled to the upper member and the lower member and configured to: apply a force on the upper member, and translate the upper member in a second direction.

6. The system of claim 1 wherein the upper member includes at least one recessed area configured to receive a niche of the tiled wall.

7. The system of claim 1 wherein the upper member includes at least one layer of a surface material.

8. The system of claim 7 further comprising a pressurized gas source configured to pressurize gas, wherein the upper member includes at least one gas chamber configured to receive the pressurized gas.

9. The system of claim 8 wherein the surface material includes at least one aperture in fluid communication with the at least one gas chamber and an environment around the system.

10. The system of claim 1 further comprising a control panel configured to control at least one of: rotation of the top, or translation of the upper member.

11. A method of operating a system for assembling a tiled wall, wherein the system comprises, a base, a top rotatably coupled to the base and including an upper member and a lower member translatably coupled to the upper member, and a support configured to support the base and defining a recess configured to receive the upper member, the method comprising: rotating the top relative to the base; translating the upper member relative to the lower member in a first direction; and receiving the upper member within the recess.

12. The method of claim 11 wherein the top is rotatably coupled to the base by a rod, and the rod defines an axis of rotation, the method further comprising rotating the top around the axis of rotation.

13. The method of claim 12 wherein the rod includes a gear, and the lower member includes a gear rack, the method further comprising mating the gear rack with the gear.

14. The method of claim 11 wherein the system further includes a first set of struts coupling the base to the top, the method further comprising applying a first force on the top to rotate the top relative to the base.

15. The method of claim 11 wherein the system further includes a second set of struts coupling the upper member to the lower member, the method further comprising applying a second force on the upper member.

16. The method of claim 15 further comprising translating the upper member relative to the lower member in a second direction opposite the first direction.

17. The method of claim 16 further comprising: pressuring gas; and expelling the pressurized gas out of an aperture in the upper member.

18. The method of claim 11 wherein the upper member includes a recessed area, the method further comprising receiving a niche of the tiled wall in the recessed area.

19. The method of claim 11 wherein the upper member includes at least one layer of a surface material.

20. The method of claim 11 wherein translating the upper member relative to the lower member in the first direction includes placing a user in an ergonomic position to assemble the tiled wall.

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