Multi-Piece Bath Wall Assembly with Flange-Channel Sealing
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Solution Overview
Problem
Bath and shower inserts with integrally formed walls are difficult to handle due to their large size, and traditional sealant materials used to create a water-tight seal are messy and do not completely hide seams, affecting the aesthetic of the enclosure.
Innovation Solution
A multi-piece bath wall assembly comprising a two-piece back wall section and two end wall panels, where the upper and lower back wall panels engage with a flange and channel system to form a water-tight seal without the need for sealant materials, reducing the overall footprint and improving aesthetics by concealing seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If integrally formed walls are used in bath and shower inserts, then water-tight seal is achieved, but handling becomes difficult due to large size
Solution Approach 1:
The back wall is divided into multiple separate panels (first back wall panel, second back wall panel, third back wall panel) that can be individually handled and installed. These panels are then joined together using flange and channel connections to form the complete back wall structure, maintaining water-tight sealing while improving ease of handling during installation
2Reliability
If traditional sealant materials are used to create water-tight seal, then sealing is achieved, but aesthetics are compromised due to visible seams and messiness
Solution Approach 1:
The flange and channel structures are merged to form an integrated connection system that simultaneously provides mechanical attachment and water-tight sealing. The flange extends from one panel and fits into a corresponding channel on the adjacent panel, creating a seamless joint that eliminates the need for external sealant materials and hides seams for improved aesthetics
Data Source
AI summary
Disclosed is a bath wall assembly. The bath wall assembly includes a first back wall panel and a second back wall panel. Each of the back wall panels are configured to be mounted to a structural wall of a bathroom. The first back wall panel includes a flange that extends at least partially along an edge of the first back wall panel. The second back wall panel includes a channel configured to receive a portion of the flange therein. The channel is configured to prevent relative movement between the first back wall panel and the second back wall panel in a vertical direction. Together, the flange and the channel form a substantially water-tight seam between the first back wall panel and the second back wall panel.