Wall-Mounted Toilet Carrier Frame Assembly for Lightweight Installation
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Solution Overview
Problem
Existing closet carriers for wall-mounted toilets are heavy, making transport and installation difficult, often requiring multiple people and inefficient in material usage.
Innovation Solution
A lightweight closet carrier assembly with plastic frames, adjustable components, and structural reinforcements, allowing for easy assembly and single-person installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid metal components are used to ensure robust load support, then structural strength is improved, but weight increases making transport and installation difficult
Solution Approach 1:
The closet carrier assembly is divided into multiple separate components including front legs, rear legs, crossbars, face plates, and waste pipe chases. These modular segments can be transported separately and assembled on-site, reducing the weight handling burden while maintaining overall structural strength through proper connection design.
Solution Approach 2:
The patent employs composite construction by combining different materials for different functional requirements. Metal components provide structural strength and load-bearing capacity, while plastic or lighter materials may be used for non-structural elements like face plates or insulation components, optimizing the strength-to-weight ratio of the overall assembly.
2Strength
If heavy solid metal components are used, then load-bearing capacity is improved, but installation complexity increases requiring multiple people
Solution Approach 1:
By segmenting the closet carrier into manageable components (front legs, rear legs, crossbars, face plates), each piece becomes light enough for single-person handling. The modular design allows these segments to be assembled step-by-step on-site, transforming a heavy single-piece installation into a series of lighter, more manageable assembly steps.
Solution Approach 2:
The design incorporates adjustable elements such as adjustable face plates and positioning mechanisms that allow installers to adapt the assembly during installation. This dynamic adjustability simplifies the installation process by allowing real-time adjustments without requiring precise pre-positioning, reducing the need for multiple people to hold and position heavy components.
3Strength
If solid metal components are used, then structural integrity is improved, but material usage efficiency decreases
Solution Approach 1:
Segmenting the structure allows for optimized material distribution where metal is used only where structurally necessary (legs, crossbars for load-bearing) while non-structural components can use lighter materials. This reduces overall material consumption while maintaining structural integrity in critical areas.
Solution Approach 2:
Different materials and thicknesses are applied locally based on functional requirements. High-strength metal is concentrated in load-bearing elements, while lighter materials are used for face plates, covers, and non-structural components. This localized material optimization maintains structural integrity where needed while reducing overall material usage.
4Ease of operation
If adjustable components are added to facilitate installation, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The adjustable components are designed as separate, modular segments that can be independently adjusted and positioned. This segmentation of adjustment functions into discrete, manageable components reduces the overall complexity compared to a monolithic adjustable system, allowing each adjustment mechanism to be simple and straightforward.
Data Source
AI summary
A closet carrier assembly for a wall-mounted toilet includes two spaced apart frames that are typically identical. Each frame includes a front leg and a rear leg with an arm connecting the front and rear legs to form an opening. At least one face plate has a passageway with an inlet for coupling to a wall mounted toilet. The face plate is preferably adjustably secured to the front legs of the frames. A waste pipe chase couples to an outlet of the passageway of the face plate. The waste pipe chase has at least one conduit extending through the opening between the legs of one of the frames.