US20230320535A1

US20230320535A1 - Modular Panel Assembly

Info

Publication number: US20230320535A1
Application number: US18/023,020
Authority: US
Inventors: Douglas F. Leavitt; Christophe Bucher; Ronald D. Barndt; Matthew Kuhns
Original assignee: AS America Inc
Current assignee: AS America Inc
Priority date: 2020-08-26
Filing date: 2021-08-25
Publication date: 2023-10-12
Also published as: WO2022046880A1; CA3187748A1

Abstract

A modular bath or shower panel assembly, comprising a left panel; a center panel; and a right panel, wherein the left panel comprises a side section and a center section having a functional end, the center panel comprises a left functional end and a right functional end, the right panel comprises a side section and a center section having a functional end, and wherein, upon installation of the assembly, the left panel functional end and the right panel functional end are configured to couple to the center panel left functional end and center panel right functional end, respectively.

Description

Described is a modular panel assembly, in particular, a modular assembly for a shower or bath.

BACKGROUND

Bathtub and shower enclosures to be installed over a tub or shower base generally require significant work and tools including clamps, bolts, screws, and the like. The enclosures are also large and are not easily displayed on store shelves or transported. This is not optimal, especially for increasingly important do-it-yourself installation.
Universal bathtub and shower enclosures that are easily stored, transported, and installed are highly desired.

SUMMARY

Accordingly, disclosed is a modular bath or shower panel assembly, comprising a left panel; a center panel; and a right panel, wherein the left panel comprises a side section and a center section having a functional end, the center panel comprises a left functional end and a right functional end, the right panel comprises a side section and a center section having a functional end, and wherein, upon installation of the assembly, the left panel functional end and the right panel functional end are configured to couple to the center panel left functional end and center panel right functional end, respectively.
Also disclosed is a modular bath or shower panel assembly, comprising a first panel having a functional end; and a second panel having a functional end, wherein the first panel functional end comprises a male connector and the second panel functional end comprises a female connector, or the first panel functional end comprises a female connector and the second panel functional end comprises a male connector, and wherein the male connector is configured to couple to the female connector.
Also disclosed is a panel for an assembly, the panel comprising an L-shape and having a functional end, or an I-shape and having a left functional end and/or a right functional end, wherein the functional ends comprise a male connector configured to couple to a female connector or, a female connector configured to couple to a male connector.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure described herein is illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, features illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some features may be exaggerated relative to other features for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.

FIG. 1A, FIG. 1B, and FIG. 1C show a shower panel assembly in various stages of assembly, according to an embodiment.

FIG. 2A shows a cross-section view of a shower panel, according to an embodiment.

FIG. 2B shows a shower panel assembly portion in cross-section, according to an embodiment.

FIG. 2C depicts an installed shower panel assembly in cross-section, according to an embodiment.

FIG. 3A, FIG. 3B, FIG. 3C, and FIG. 3D illustrate female connectors positioned on a flange, according to some embodiments.

FIG. 4 shows a top view of a tub panel assembly, according to an embodiment.

FIG. 5 shows a view of corner shower panel assembly, according to an embodiment.

DETAILED DESCRIPTION

FIG. 1A, FIG. 1B, and FIG. 1C show shower panel assembly 100 in various stages of assembly, according to an embodiment. As shown in FIG. 1A, reinforcement panels 101 are fastened directly to studs. Opening 102 is cut for a shower valve. Shower base 103 is installed. As shown in FIG. 1B, left panel 104 and right panel 105 are installed over shower base 103. In some embodiments, left panel 104, right panel 105, and center panel 106 are “dry fitted” to determine a proper fit and alignment and to determine where to cut opening 107 for a shower valve. Left panel 104 and right panel 105 are L-shaped panels. Visible are right panel 105 side section 105 s and right panel center section 105 c. Left panel 104 and right panel 105 have substantially perpendicular planar outward-facing surfaces. Visible also is functional end 108 of right panel 105. Functional end 108 contains female connector 109 positioned on flange 115 extending substantially parallel planar from end 108. Left panel 104 likewise contains a female connector. Female connector 109 essentially runs an entire length of end 108.
After dry-fitting, left panel 104 and right panel 105 are removed, and adhesive is applied to side reinforcement panels 101. Left panel 104 and right panel 105 are then fixed to reinforcement panels 101 and may be further fixed via one or more screws through upper flange 110 and side flange 111. Adhesive then may be applied to center reinforcement wall 101, and center panel 106 is coupled to left panel 104 and right panel 105. Center panel 106 is an I-shaped panel having a left functional end and a right functional end comprising male connectors (not visible) to couple to female connectors 109 on both left panel 104 and right panel 105. Joints 112 are formed at the connection point of left panel 104, right panel 105, and center panel 106. Joints 112 may be water-tight and may further be filled with a caulking adhesive to ensure they are water-tight. Screws may be driven into studs through flanges 110, 111, 113, 114, and a side flange on left panel 104 (not visible) corresponding to flange 111. Left panel 104 and right panel 105 are essentially mirror images of each other.
FIG. 2A shows a cross-section view of right panel 205 positioned on a shower base and reinforcement panel 201. Side section 205 s and center section 205 c have substantially planar outward-facing surfaces which are substantially perpendicular. Female connector 209 is coupled to flange 215 which is coupled to functional end 208. Functional end 208 is itself essentially a flange like 110 and 111, extending from panel 205, and substantially parallel planar with center section 205 c. Panel 205 comprises an L-shape.
FIG. 2B and FIG. 2C depict a portion of shower panel assembly 200 in cross-section, according to an embodiment. Male connector 216 of center panel 206 is coupled to female connector 209, thereby coupling center panel 206 to right panel 205, and forming joint 212. Center panel 206 is an I-shaped panel having left and right functional ends; right functional end 218 is visible. Male connector 216 extends substantially perpendicularly from center panel functional end 218. Male connector 216 and female connector 209 run essentially an entire vertical length of functional ends 218 and 208, respectively. Female connector 209 is positioned on flange 215 and comprises barbed gripping feature 217. Flange 215 and female connector 209 may comprise a coextruded thermoplastic. In some embodiments, female connector 209 may comprise a more flexible thermoplastic and flange 215 may comprise a more rigid thermoplastic. In some embodiments, barbed gripping feature 217 may comprise a flexible polymer while flange 215 and remainder of female connector 209 comprise a more rigid thermoplastic. Void 219 formed at the end of male connector 216 may be filled with for example silicone or other caulking substance or sealant to ensure a water-tight connection. Likewise joint 212 may be filled with a caulking substance or sealant.
FIG. 3A depicts flange 325 comprising barbed female connector 326, according to an embodiment. An assembly containing flange 325 and barbed female connector 326 may comprise an extruded thermoplastic.
FIG. 3B shows female connector 309 coupled to flange 315, according to an embodiment. Barbed gripping feature 317 is coupled to female connector 309. The flange/female connector assembly comprises a coextruded thermoplastic, wherein flange 315 comprises a rigid thermoplastic, such as a polystyrene (PS), a polyamide (PA), or a polyvinylchloride (PVC), and gripping feature 317 comprises a flexible thermoplastic, such as an elastomer like EPDM (ethylene propylene diene monomer) rubber.
FIG. 3C shows barbed female connector 329 extending from flange 327, according to an embodiment. Female connector 329 contains sets of opposing barbs. The assembly may comprise an extruded thermoplastic.
FIG. 3D depicts flange 328 comprising female connector 330. Female connector 330 is coupled to barbed gripping feature 331. The assembly may comprise a coextruded thermoplastic like the assembly of FIG. 3B.
FIG. 4 provides a top view of bathtub panel assembly 400, according to an embodiment. Right L-shaped panel 405, having side section 405 s and substantially perpendicular center section 405 c, is coupled to center I-shaped panel 406, which is coupled to left L-shaped panel 404, having center section 404 c and substantially perpendicular side section 404 s. Panels 404, 405 and 406 are coupled at joints 412, and are supported by reinforcement panels 401 which are positioned on studs. Left panel 404 and right panel 405 have a side width Ws of about 30 inches and a center width Wc of about 8 inches. Center panel 406 has a width Wcp of about 44 inches.
FIG. 5 provides a view of panel assembly 500 for a corner shower. Assembly 400 comprises L-shaped panel 505 having side section 505 s and center section 505 c. Center section 505 c comprises a male or female functional end. Panel 506 has a male or female right functional end to couple to the female or male functional end of panel 505. Panel 505 is joined with I-shaped panel 506 at joint 512. Joint 512 is formed with male/female connecters as described herein. A functional end on panel 506 and panel 505 may have a complimentary male or female connector. In another embodiment, a left side wall may have an L-shape and a right side wall may have an I-shape.
In general, assemblies for installation for a corner shower over a shower base may comprise 2 panels. In general, assemblies for installation over a bathtub may comprise 3 panels, left, right, and center.
In some embodiments, a panel of a modular panel assembly may be an L-shaped side panel or an I-shaped center panel. Such an arrangement provides for an assembly wherein a center panel is not so large that it is difficult to store and transport. In general, an L-shaped panel will comprise one functional end and an I-shaped panel will comprise two functional ends. A functional end may mean an end containing one or more connectors configured to couple to one or more connectors of another panel.
In some embodiments, L-shaped and I-shaped panels may have a height (length) of from any of about 65 inches, about 66 inches, about 67 inches, or about 68 inches, to any of about 69 inches, about 70 inches, about 71 inches, about 72 inches, about 73 inches, about 74 inches, about 75 inches, or more.
In some embodiments panels may comprise a thickness of from any of about 1.7 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.3 mm, about 2.4 mm, or about 2.5 mm, to any of about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, or more.
Panels may comprise a single layer or, alternatively, may comprise multiple layers, for instance 2 or more thermoplastic layers. Multiple layers may be employed for instance to apply a layer having a certain texture, design, or pattern. In some embodiments, multiple layers may be employed to add functional features, for example shelves and the like. In some embodiments, functional features may be obtained in a single sheet layer.
In some embodiments, panels may comprise a thermoset material, for instance one or more of sheet molding compound (SMC), fiberglass laminates (gelcoat fiberglass), epoxy, vinyl esters, unsaturated polyesters, etc.
In some embodiments, thermoplastics or thermosets may comprise a filler, for example glass fibers, clays, silicates, calcium carbonate, talc, kaolin, mica, metal oxides and/or hydroxides, carbon black, graphite, wood flour or fibers, synthetic fibers, and the like.
In some embodiments, panels may comprise a composite comprising a thermoplastic and a thermoset. For instance, panels may comprise an outer acrylic layer and glass filled unsaturated polyester/vinyl ester inner layer.
In some embodiments, an L-shaped side panel may have a side (long) width of from any of about 25 inches, about 27 inches, about 29 inches, about 31 inches, or about 33 inches, to any of about 35 inches, about 37 inches, about 39 inches, or more.
In some embodiments, an L-shaped side panel may have a center (short) width of from any of about 5.5 inches, about 5.8 inches, about 6.1 inches, about 6.4 inches, or about 6.7 inches, to any of about 7.0 inches, about 7.3 inches, about 7.7 inches, about 8.0 inches, about 8.3 inches, or more.
In some embodiments, an I-shaped center panel may have a width of from any of about 38 inches, about 39 inches, about 40 inches, or about 41 inches, to any of about 42 inches, about 43 inches, about 44 inches, about 45 inches, about 46 inches, or more.
In some embodiments, connectors include “male” and “female” connectors configured to couple with each other. In some embodiments, a male connector may simply extend from a functional end of a panel (an extension of a panel). In some embodiments, a female connector may be positioned on a flange (flange/female connector assembly). A female connector may extend from a flange and provide for and define an opening to receive a male connector.
In some embodiments, a panel may comprise a flange at a left side and/or right side and/or top and/or bottom thereof. In some embodiments, a flange may surround and entire panel. Thus, a flange/female connector assembly may itself be positioned on a panel flange. A flange/female connector assembly may be positioned at or on a panel functional end.
In some embodiments, a female connector may comprise a feature configured to aid in coupling it to a male connector (a gripping feature). In some embodiments, a gripping feature may be or comprise a set of barbs, in some embodiments, sets of opposing barbs. In other embodiments, a gripping feature may simply comprise a flexible polymer, for example an elastomer.
In some embodiments, a panel may comprise a thermoplastic, for example a vacuum formed (thermo-formed) thermoplastic. Suitable thermoplastics may include polyvinylchloride (PVC), acrylonitrile-butadiene-styrene copolymer (ABS), a poly(meth)acrylate, a polystyrene (PS), a polyolefin, a polyamide, or a polyester. Polyolefins include polypropylene (PP), polyethylene (PE), blends thereof and copolymers thereof. In some embodiments, a flange/female connector assembly may also comprise such a thermoplastic or extruded thermoplastic. In some embodiments, a flange/female connector assembly may comprise coextruded thermoplastics, in some cases wherein a flange comprises a rigid thermoplastic such as PVC, a polystyrene such as high impact polystyrene (HIPS), or a polyamide; and wherein a gripping portion comprises a flexible elastomer. Having a rigid flange and a flexible portion may allow for necessary strength while allowing for sufficient coupling of connectors.
Flexible elastomers include EPDM, silicones, polybutadiene, chloroprene, isoprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, ethylene propylene rubber, polyacrylic rubber, silicone rubber, ethylene-vinyl acetate, and the like.
In some embodiments, a flange/female connector assembly may comprise an injection molded thermoplastic. In some embodiments, a flange/female connector assembly may comprise a thermoplastic and a thermoset. In some embodiments, a flange may comprise a thermoset and a female connector may comprise a thermoplastic. In some embodiments, a flange may comprise a metal, for instance aluminum. Thermoplastics and/or thermosets may comprise fillers as discussed above.
In some embodiments, a flange and female connector may be prepared in an extrusion or coextrusion method. In other embodiments, a flange and female connector may be prepared as separate parts, and coupled via mechanical fastening and/or adhesive bonding.
In some embodiments, a flange of a flange/female connector assembly may have a greater thickness than the female connector, allowing for a rigid flange and a flexible or partly flexible female connector.
In some embodiments, a panel functional end may comprise a single male or a single female connector. In some embodiments, a male or a female connector may have a length of greater than about 50% of the length of the functional end, for example greater than about 60%, greater than about 70%, greater than about 80%, greater than about 90%, or greater than about 95% of the length of the functional end. In some embodiments, a male or a female connector may essentially run an entire length of the functional end.
In other embodiments, a panel functional end may comprise a plurality of connectors, for instance a plurality of male and/or female connectors.
In general, an L-shaped side panel comprises a side section and a center section, which may be substantially perpendicular to each other. A side section and center section may each have substantially planar outward-facing surfaces, that is, facing a shower or bath.
In some embodiments, a panel assembly may comprise one or more water-tight joints formed at connection points, which may be visible in an outward-facing panel assembly surface. A formed joint may be filled with a caulking substance, such as silicone to ensure the joint is water-tight. In some embodiments, a void may be formed within a connection point, not visible in an outward-facing surface. Such void may be filled with a caulking substance/sealant to ensure a water-tight connection.
In some embodiments, a left panel and a right panel may be substantially mirror images of each other.
In some embodiments, a left panel and right panel may each comprise a functional end having a male connector, and a center panel may comprise left and right functional ends having female connectors. In other embodiments, a left panel and right panel may each comprise a functional end having a female connector, and a center panel may comprise left and right functional ends having male connectors. In still other embodiments, a center panel may comprise a functional end having a male connector and a functional end having a female connector; and a left panel and a right panel would comprise a corresponding female or male connector.
In some embodiments, a method of assembly may comprise installing left and right side panels first, followed by a center panel. In other embodiments, a method of assembly may comprise installing a center panel first followed by left and right side panels.
In some embodiments, connectors are configured such that strong connection points are formed upon panel coupling, and also such that panels may be de-coupled for adjustment and re-connected prior to final installation.
In some embodiments, a flange/female connector assembly may be coupled to a panel at a production site or at an installation side. Coupling may be via one or more of adhesive bonding, screws, staples, and the like.
A panel assembly as described herein comprises a minimum number of joints and potential leak paths upon installation. In some embodiments, coextruded parts forms a water-tight bond of rigid and flexible materials.
In some embodiments, textures, designs, and/or patterns may be formed in a panel, for example over an entire panel or over a specific portion of a panel. In some embodiments, thermoplastic panels are UV stable. Accordingly, a thermoplastic may have incorporated therein an ultraviolet light (UV) stabilizer, for example one or more of a hindered amine light stabilizer (HALS) and/or one or more of a hydroxyphenyltriazine-based (HPT) or hydroxyphenylbenzotriazole-based (BZT) UV absorber.
Following are a non-limiting set of certain embodiments of the disclosure.
In a first embodiment, disclosed is a modular bath or shower panel assembly, comprising a left panel; a center panel; and a right panel, wherein the left panel comprises a side section and a center section having a functional end, the center panel comprises a left functional end and a right functional end, the right panel comprises a side section and a center section having a functional end, and wherein, upon installation of the assembly, the left panel functional end and the right panel functional end are configured to couple to the center panel left functional end and center panel right functional end, respectively.
In a second embodiment, disclosed is a modular panel assembly according to the first embodiment, wherein the left panel, the right panel, and the center panel comprise substantially planar outward-facing surfaces. In a third embodiment, disclosed is a modular panel assembly according to the first or second embodiments, wherein the left panel and the right panel each comprise substantially perpendicular planar outward-facing surfaces.
In a fourth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the left panel functional end and/or the right panel functional end and/or the center panel left functional end and/or the center panel right functional end comprise a male connector configured to couple to a female connector.
In a fifth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the left panel functional end and/or the right panel functional end and/or the center panel left functional end and/or the center panel right functional end comprise a female connector configured to couple to a male connector.
In a sixth embodiment, disclosed is a modular panel assembly according to embodiment 5, wherein the female connector is positioned on a flange (flange/female connector assembly), and the flange is positioned on the left panel functional end and/or on the right panel functional end and/or on the center panel left functional end and/or on the center panel right functional end. In a seventh embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 6, wherein the male connector extends substantially perpendicularly from the functional end.
In an eighth embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 7, wherein the center panel left and right ends each comprise a flange comprising a female connector, and the left panel functional end and the right panel functional end each comprise a male connector, wherein the male connectors are configured to couple to the female connectors. In a ninth embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 7, wherein the center panel left and right ends each comprise a male connector, and the left panel functional end and the right panel functional end each comprise a flange comprising a female connector, wherein the male connectors are configured to couple to the female connectors.
In a tenth embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 9, wherein the female connector comprises one or more gripping features. In an eleventh embodiment, disclosed is a modular panel assembly according to embodiment 10, wherein the gripping features comprise barbs. In a twelfth embodiment, disclosed is a modular panel assembly according to embodiments 10 or 11, wherein the gripping features comprise opposing barbs.
In a thirteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the panels comprise a vacuum formed thermoplastic. In a fourteenth embodiment, disclosed is a modular panel assembly according to embodiment 13, wherein the thermoplastic is one or more of polyvinylchloride, acrylonitrile-butadiene-styrene copolymer, a poly(meth)acrylate, a polystyrene, a polyolefin, a polyamide, or a polyester.
In a fifteenth embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 14, wherein the female connector comprises an elastomer. In a sixteenth embodiment, disclosed is a modular panel assembly according to embodiment 15, wherein the female connector is positioned on a flange, and wherein the female connector is more flexible than the flange. In a seventeenth embodiment, disclosed is a modular panel assembly according to any of embodiments 6 to 16, wherein the flange/female connector assembly comprises an extruded or coextruded thermoplastic.
In an eighteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein upon coupling the left panel functional end and the right panel functional end to the center panel left end and right end, respectively, one or more voids are formed, the one or more voids configured to receive a sealant.
In a nineteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein upon coupling the left panel functional end and the right panel functional end to the center panel left end and right end, respectively, water-tight joints are formed.
In a twentieth embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 19, wherein coupling of the male connector to the female connector provides a substantially flush outward-facing surface.
In a twenty-first embodiment, disclosed is a modular panel assembly according to any of embodiments 4 to 20, wherein the functional ends comprise a length, and wherein the male connector and the female connector have a length of greater than about 50% of the functional end length.
In a twenty-second embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the left panel and the right panel comprise an L-shape and the center panel comprises an I-shape.
In a twenty-third embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the assembly is configured to be installed on a shower base or on a bathtub.
In a twenty-fourth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the left panel and the right panel are substantially mirror images of each other.
Following is another set of non-limiting embodiments of the disclosure.
In a first embodiment, disclosed is a modular bath or shower panel assembly, comprising a first panel having a functional end; and a second panel having a functional end, wherein the first panel functional end comprises a male connector and the second panel functional end comprises a female connector, or the first panel functional end comprises a female connector and the second panel functional end comprises a male connector, and wherein the male connector is configured to couple to the female connector.
In a second embodiment, disclosed is a modular panel assembly according to the first embodiment, wherein the first panel comprises an L-shape having one functional end and the second panel comprises an I-shape having a left functional end and/or a right functional end. In some embodiments, the second panel may comprise an I-shape having one functional end; in this embodiment, a corner shower wall assembly may be prepared.
In a third embodiment, disclosed is a modular panel assembly according to embodiment 1, wherein the first and second panels comprise substantially planar outward-facing surfaces. In a fourth embodiment, disclosed is a modular panel assembly according to embodiments 2 or 3, wherein the first panel comprises substantially perpendicular planar outward-facing surfaces.
In a fifth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the female connector is positioned on a flange, and the flange is positioned on the first panel functional end or on the second panel functional end.
In a sixth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the male connector extends substantially perpendicularly from the functional end.
In a seventh embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the female connector comprises one or more gripping features. In an eighth embodiment, disclosed is a modular panel assembly according to embodiment 7, wherein the gripping features comprise barbs. In a ninth embodiment, disclosed is a modular panel assembly according to embodiments 7 or 8, wherein the gripping features comprise opposing barbs.
In a tenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the panels comprise a vacuum formed thermoplastic. In an eleventh embodiment, disclosed is a modular panel assembly according to embodiment 10, wherein the thermoplastic is one or more of polyvinylchloride, acrylonitrile-butadiene-styrene copolymer, a poly(meth)acrylate, a polystyrene, a polyolefin, a polyamide, or a polyester.
In a twelfth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the female connector comprises an elastomer. In a thirteenth embodiment, disclosed is a modular panel assembly according to embodiment 12, wherein the female connector is positioned on a flange, and wherein the female connector is more flexible than the flange. In a fourteenth embodiment, disclosed is a modular panel assembly according to any of embodiments 5 to 13, wherein the flange and the female connector comprise an extruded or a coextruded thermoplastic.
In a fifteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein upon coupling the first panel to the second panel, one or more voids are formed, the one or more voids configured to receive a sealant. In a sixteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein upon coupling the first panel to the second panel, a water-tight joint is formed.
In a seventeenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein coupling of the male connector to the female connector provides a substantially flush outward-facing surface.
In an eighteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the functional ends comprise a length, and wherein the male connector and the female connector have a length of greater than about 50% of the functional end length.
In a nineteenth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, wherein the assembly is configured to be installed on a shower base or on a bathtub.
In a twentieth embodiment, disclosed is a modular panel assembly according to any of the preceding embodiments, comprising a third panel, wherein the first panel is a left panel comprising a side section and a center section having a functional end, the second panel is a center panel comprising a left functional end and a right functional end, the third panel is a right panel comprising a side section and a center section having a functional end, and wherein, upon installation of the assembly, the left panel functional end and the right panel functional end are configured to couple to the center panel left functional end and center panel right functional end, respectively.
In a twenty-first embodiment, disclosed is a modular panel assembly according to embodiment 20, wherein the first panel and the third panel are substantially mirror images of each other.
Following is another set of non-limiting embodiments of the disclosure.
In a first embodiment, disclosed is a panel for an assembly, the panel comprising an L-shape and having a functional end, or an I-shape and having a left functional end and/or a right functional end, wherein the functional ends comprise a male connector configured to couple to a female connector or, a female connector configured to couple to a male connector. In another embodiment, disclosed is a panel having an I-shape having a left functional end or a right functional end, the panel configured to couple to a L-shaped panel having a functional end, wherein the functional ends comprise a male connector configured to couple to a female connector or, a female connector configured to couple to a male connector.
In a second embodiment, disclosed is a panel according to the first embodiment, wherein the L-shaped panel and the I-shaped panels comprise substantially planar outward-facing surfaces. In a third embodiment, disclosed is a panel according to embodiments 1 or 2, wherein the L-shaped panel comprises substantially perpendicular planar outward-facing surfaces.
In a fourth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the female connector is positioned on a flange, the flange is positioned on the functional end.
In a fifth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the male connector extends substantially perpendicularly from the functional end. In a sixth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the female connector comprises one or more gripping features. In a seventh embodiment, disclosed is a panel according to embodiment 6, wherein the gripping features comprise barbs. In an eighth embodiment, disclosed is a panel according to embodiments 6 or 7, wherein the gripping features comprise opposing barbs.
In a ninth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the panel comprises a vacuum formed thermoplastic. In a tenth embodiment, disclosed is a panel according to embodiment 9, wherein the thermoplastic is one or more of polyvinylchloride, acrylonitrile-butadiene-styrene copolymer, a poly(meth)acrylate, a polystyrene, a polyolefin, a polyamide, or a polyester.
In an eleventh embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the female connector comprises an elastomer. In a twelfth embodiment, disclosed is a panel according to embodiment 11, wherein the female connector is positioned on a flange, and wherein the female connector is more flexible than the flange. In a thirteenth embodiment, disclosed is a panel according to any of embodiments 4 to 12, wherein the flange and the female connector comprise an extruded or coextruded thermoplastic.
In a fourteenth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein upon coupling a male connector to a female connector, a panel assembly having one or more voids is formed, the one or more voids configured to receive a sealant. In a fifteenth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein upon coupling a male connector to a female connector, a panel assembly having a water-tight joint is formed.
In a sixteenth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein coupling of a male connector to a female connector provides a panel assembly having a substantially flush outward-facing surface.
In a seventeenth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the functional ends comprise a length, and wherein the male connector and the female connector have a length of greater than about 50% of the functional end length.
In an eighteenth embodiment, disclosed is a panel according to any of the preceding embodiments, configured to be installed on a shower base or on a bathtub.
In a nineteenth embodiment, disclosed is a panel according to any of the preceding embodiments, wherein the panel is an L-shaped left panel comprising a side section and a center section having a functional end, or the panel is an L-shaped right panel comprising a side section and a center section having a functional end, or the panel is an I-shaped center panel having a left functional end and/or a right functional end, and wherein, the panel is part of a modular panel assembly.
In a twentieth embodiment, disclosed is a panel according to any of embodiments 1 to 18, wherein the panel is an I-shaped side panel for a corner shower modular panel assembly, wherein the I-shaped panel comprises a left functional end or a right functional end.
The term “adjacent” may mean “near” or “close-by” or “next to”.
The term “coupled” means that an element is “attached to” or “associated with” another element. Coupled may mean directly coupled or coupled through one or more other elements. An element may be coupled to an element through two or more other elements in a sequential manner or a non-sequential manner. The term “via” in reference to “via an element” may mean “through” or “by” an element. Coupled or “associated with” may also mean elements not directly or indirectly attached, but that they “go together” in that one may function together with the other. The term “positioned on” may mean “coupled to”.
The term “towards” in reference to a of point of attachment, may mean at exactly that location or point or, alternatively, may mean closer to that point than to another distinct point, for example “towards a center” means closer to a center than to an edge.
The term “like” means similar and not necessarily exactly like. For instance “ring-like” means generally shaped like a ring, but not necessarily perfectly circular.
The articles “a” and “an” herein refer to one or to more than one (e.g. at least one) of the grammatical object. Any ranges cited herein are inclusive. The term “about” used throughout is used to describe and account for small fluctuations. For instance, “about” may mean the numeric value may be modified by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more. All numeric values are modified by the term “about” whether or not explicitly indicated. Numeric values modified by the term “about” include the specific identified value. For example “about 5.0” includes 5.0.
The term “substantially” is similar to “about” in that the defined term may vary from for example by ±0.05%, ±0.1%, ±0.2%, ±0.3%, ±0.4%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10% or more of the definition; for example the term “substantially perpendicular” may mean the 90° perpendicular angle may mean “about 90° ”. The term “generally” may be equivalent to “substantially”.
Features described in connection with one embodiment of the disclosure may be used in conjunction with other embodiments, even if not explicitly stated.
Embodiments of the disclosure include any and all parts and/or portions of the embodiments, claims, description and figures. Embodiments of the disclosure also include any and all combinations and/or sub-combinations of embodiments.

Claims

1. A modular bath or shower panel assembly, comprising

a left panel;

a center panel; and

a right panel,

wherein

the left panel comprises a side section and a center section having a functional end,

the center panel comprises a left functional end and a right functional end,

the right panel comprises a side section and a center section having a functional end, and

wherein,

upon installation of the assembly, the left panel functional end and the right panel functional end are configured to couple to the center panel left functional end and center panel right functional end, respectively, and

the left panel, the right panel, and the center panel comprise substantially planar outward-facing surfaces.

2. The modular panel assembly according to claim 1, wherein the left panel and the right panel each comprise substantially perpendicular planar outward-facing surfaces.

3. The modular panel assembly according to claim 1, wherein the left panel functional end and the right panel functional end each comprise a female connector configured to couple to a male connector.

4. The modular panel assembly according to claim 1, wherein the center panel functional ends each comprise a male connector configured to couple to a female connector.

5. The modular panel assembly according to claim 3, wherein the female connector is positioned on a flange.

6. The modular panel assembly according to claim 4, wherein the male connectors extend substantially perpendicularly from the center panel functional ends.

7. The modular panel assembly according to claim 3, wherein the female connector comprises one or more gripping features.

8. The modular panel assembly according to claim 7, wherein the gripping features comprise one or more barbs.

9. The modular panel assembly according to claim 8, wherein the gripping features comprise opposing barbs.

10. The modular panel assembly according to claim 1, wherein the panels comprise a vacuum formed thermoplastic.

11. The modular panel assembly according to claim 3, wherein the female connector comprises an elastomer.

12. The modular panel assembly according to claim 3, wherein the female connector is positioned on a flange, and wherein the female connector is more flexible than the flange.

13. The modular panel assembly according to claim 5, wherein the flange and female connector comprise an extruded or coextruded thermoplastic.

14. The modular panel assembly according to claim 1, wherein upon coupling the left panel functional end and the right panel functional end to the center panel left end and right functional end, respectively, one or more voids are formed, the one or more voids configured to receive a sealant.

15. The modular panel assembly according to claim 1, wherein the functional ends comprise a length, and wherein the male connector and the female connector have a length of greater than about 50% of the functional end length.

16. A modular bath or shower panel assembly, comprising

a first panel having a functional end; and

a second panel having a functional end,

wherein

the first panel functional end comprises a male connector and the second panel functional end comprises a female connector, or

the first panel functional end comprises a female connector and the second panel functional end comprises a male connector, and

wherein the male connector is configured to couple to the female connector.

17. The modular panel assembly according to claim 16, wherein the first panel comprises an L-shape having one functional end and the second panel comprises an I-shape having a left functional end and/or a right functional end.

18. A panel for a modular assembly, the panel comprising

an L-shape and having a functional end, or

an I-shape and having a left functional end and/or a right functional end,

wherein the functional ends comprise a male connector configured to couple to a female connector or, a female connector configured to couple to a male connector, and

wherein the L-shaped panel and the I-shaped panels comprise substantially planar outward-facing surfaces.

19. The panel according to claim 18, wherein

the panel is an L-shaped left panel comprising a side section and a center section having a functional end, or

the panel is an L-shaped right panel comprising a side section and a center section having a functional end, or

the panel is an I-shaped center panel having a left functional end and/or a right functional end, and

wherein, the panel is configured to be part of a modular panel assembly.

20. A modular panel assembly or panel according to claim 1, wherein the assembly or panel is configured to be installed on a shower base or on a bathtub.