Shower enclosure system for aligning lower and upper enclosure members
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Solution Overview
Problem
Existing enclosure formation methods face challenges such as heavy and flexible substrate boards, which complicate installation, and ornamental features that may shift due to gravity, leading to a sloppy finish. Additionally, imperfections in wall studs can affect the quality and appearance of the installed materials.
Innovation Solution
The enclosure design features substrates that are selectively movable between disassembled and assembled configurations, allowing ornamental features to be affixed while the substrate is in the disassembled state, with a weight ratio of at least 3:1, and using attachment sleeves to secure the substrates to a stable base, compensating for wall stud imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If substrate boards are installed in an upright position before affixing ornamental features, then the substrate boards provide structural support, but the ornamental features may shift due to gravity resulting in a sloppy finish
Solution Approach 1:
The patent applies preliminary action by affixing ornamental features to substrate boards while the boards are still in a horizontal, disassembled configuration on the base. This allows precise alignment and attachment of ornamental features before the substrate boards are raised to their final upright position, preventing gravity-induced shifting and ensuring a precise finished appearance.
2Strength
If substrate boards are made heavy for structural stability, then the enclosure gains strength, but the installation process becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the enclosure into modular substrate boards that can be independently assembled and installed. Each substrate board can be handled separately in a horizontal position during the affixing process, making installation easier, while the complete assembly provides the necessary structural stability when raised to the upright position.
3Ease of manufacture
If materials are attached directly to wall studs, then the installation is straightforward, but imperfections in wall studs are transferred to the installed materials affecting quality
Solution Approach 1:
The patent applies the intermediary principle by introducing a base and disassembled substrate board configuration as an intermediate stage between the wall studs and the final upright installation. This intermediate horizontal configuration allows for precise alignment and attachment of materials, isolating them from wall stud imperfections, while still maintaining a straightforward installation process through modular assembly.
Data Source
AI summary
A shower wall system is mounted to a wall frame having a plurality of vertical studs. The system comprises a plurality of attachment pieces, a lower piece, and an upper piece. Each attachment piece is attached to a stud, and either the lower or upper piece is attached to attachment pieces. The lower piece is aligned to the upper piece by a wall alignment assembly. The wall alignment assembly comprises a first alignment member proximate the top portion of the lower piece that mates with a second alignment member near the bottom portion of the one upper piece. The alignment members are configured to mate together in at least a partially interlocking manner, and the plurality of attachment pieces are positioned relative to the wall frame so that the upper piece is aligned with the lower piece regardless of whether the wall frame studs are co-planar and plumb.