Prefabricated Wall Base Assembly Leveling and Pivot Mechanism
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Solution Overview
Problem
Conventional prefabricated wall systems face challenges with leveling apparatuses that are unsightly and unsuitable for single-substrate panels, such as glass, and pivot door assemblies that can crack brittle materials during use.
Innovation Solution
The development of compact leveling assemblies that reside within base extrusions and tracks, allowing for adjustable leveling without disrupting the aesthetic, and pivot door assemblies that affix to single-substrate panels without creating holes, using half channels and a pivot door rail that receives the panel edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional leveling apparatuses are used in prefabricated wall systems, then the wall system can accommodate uneven floors, but the leveling apparatuses become large and unsightly
Solution Approach 1:
The leveling apparatus is nested within the base extrusion structure. The base extrusion contains internal cavities and channels that house the leveling mechanism, allowing the leveling function to be integrated within the aesthetic profile of the base assembly rather than protruding outward.
Solution Approach 2:
The base extrusion serves multiple functions: it provides structural support for the wall panel, conceals the leveling apparatus, and interfaces with both the floor and the wall panel. This multi-functionality eliminates the need for separate aesthetic covers or housing for the leveling mechanism.
2Shape
If thin wall modules are used to provide a sleek aesthetic, then the aesthetic appearance is improved, but the modules cannot accommodate conventional leveling apparatuses
Solution Approach 1:
The leveling apparatus is nested within the base extrusion structure. The base extrusion contains internal cavities and channels that house the leveling mechanism, allowing the leveling function to be integrated within the aesthetic profile of the base assembly rather than protruding outward.
3Ease of operation
If pivot door assemblies with holes in door panels are used, then the pivot door can be installed, but brittle materials like glass may crack during use
Solution Approach 1:
A pivot receiver assembly acts as an intermediary between the pivot door rail and the door panel. This receiver assembly distributes the mechanical loads and stresses across a larger area of the glass panel, preventing stress concentration at single holes and reducing the risk of cracking during door operation.
4Ease of operation
If conventional pivot door assemblies are used, then pivot doors can be installed in prefabricated wall systems, but the assemblies are unsuitable for single-substrate door panels composed of hard and brittle materials
Solution Approach 1:
A pivot receiver assembly acts as an intermediary between the pivot door rail and the door panel. This receiver assembly distributes the mechanical loads and stresses across a larger area of the glass panel, preventing stress concentration at single holes and reducing the risk of cracking during door operation.
Data Source
AI summary
A base assembly of a prefabricated wall system includes a base extrusion, a base track, and a leveling assembly. The base extrusion includes an upper channel that is at least partially defined by first and second vertical members, and the upper channel is configured to receive an edge of a prefabricated wall panel. The base extrusion includes a lower channel opposite to the upper channel. An opening of the upper channel and an opening of the lower channel are oriented in opposite directions. The base track comprises a base track channel configured to affix to a floor of a building. The leveling assembly is configured to reside within both the lower channel of the base extrusion and the base track channel of the base track. The leveling assembly is adjustable to adjust a vertical position of the base extrusion with respect to the base track.