PANEL MOUNTING SYSTEM AND METHOD USING AN ADHESIVE MOUNTING CONFIGURATION

BACKGROUND
1. Field of Disclosure

The present invention is directed to panel mounting systems and methods. More particularly, systems and methods are directed to porcelain panel mounting systems using an adhesive dot mounting method.

2. Description of Related Art

Porcelain shower surrounds are becoming more commonly used in residential and commercial bathrooms due to their durability, water resistance, and ease of maintenance. However, the TCNA (Tile Council of North America) defined method/industry standard of installing porcelain shower surrounds involves using full spread, thin-set mortar over a waterproofed substrate, which can be time-consuming and labor intensive. Additionally, the mortar can crack or break over time, which can lead to water infiltration and damage as these cracks will transfer through the product.

SUMMARY

Applicants recognized the problems noted above herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for mounting panels using an adhesive mounting method.

In an embodiment, a method for installing a set of panels includes preparing a substrate at an installation location, the substrate extending to a first location, a second location, and a third location. The method also includes dry-fitting one or more panels at the installation location. The method further includes applying, to a first portion of the substrate at the first location, an adhesive according to a pattern. The method includes installing a first panel to the first location. The method further includes applying, to a second portion of the substrate at the second location, the adhesive according to the pattern. The method also includes installing a second panel to the second location. The method includes applying, to a third portion of the substrate at the third location, the adhesive according to the pattern. The method further includes installing a third panel to the third location. The method includes applying one or more barriers along seams associated with the first panel, the second panel, and the third panel.

In another embodiment, a kit for installing a set of panels at an installation location includes a plurality of panels for installation at the installation location, wherein each panel of the plurality of panels is pre-cut to a respective dimension associated with a designated position at the installation location. The kit also includes an adhesive particularly selected for a material associated with the panels and the installation location. The kit further includes sealant (e.g., silicone sealant) particularly selected for the material associated with the panels and the installation location. The kit also includes one or more trim pieces.

BRIEF DESCRIPTION OF DRAWINGS

The present technology will be better understood on reading the following detailed description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which:

FIG. 1A illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure;

FIG. 1B illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure;

FIG. 1C illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure;

FIG. 1D illustrates an example of an adhesive dot mounting pattern, in accordance with embodiments of the present disclosure;

FIG. 1E illustrates an example of an adhesive dot mounting pattern, in accordance with embodiments of the present disclosure;

FIG. 1F illustrates an environment for installation of a door including a panel, in accordance with embodiments of the present disclosure;

FIG. 1G illustrates an environment for installation of trim pieces, in accordance with embodiments of the present disclosure;

FIG. 1H illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure;

FIG. 1I illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure;

FIG. 1J illustrates an environment for installation of panels, in accordance with embodiments of the present disclosure; illustrates an environment for installation of a door including a panel, in accordance with embodiments of the present disclosure;

FIG. 2 illustrates an example panel installation kit, in accordance with embodiments of the present disclosure;

FIG. 3 is a flow chart of a method for installing a panel using an adhesive pattern, in accordance with embodiments of the present disclosure; and

FIG. 4 is a flow chart of a method for installing a panel using an adhesive pattern, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose. Additionally, like reference numerals may be used for like components, but such use should not be interpreted as limiting the disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. Like numbers may be used to refer to like elements throughout, but it should be appreciated that using like numbers is for convenience and clarity and not intended to limit embodiments of the present disclosure. Moreover, references to “substantially” or “approximately” or “about” may refer to differences within ranges of +/−10 percent.

Embodiments of the present disclosure are directed toward systems and methods for installing panels, including by way of example porcelain shower and tub surrounds, directly to a substrate using an adhesive mounting method, which in various embodiments may be a dot mounting method. Various embodiments overcome deficiencies of current systems and methods where panel installation is accompanied by full spread thin-set mortar over a waterproofed substrate. Specifically, systems and methods of the present disclosure enable faster installation, simplified installation, and greater efficiency in installation with less waste and material use, thereby providing an attractive option for installers servicing the largest commercial and residential production builders, as well as individual installers for smaller scale installation.

Various embodiments of the present disclosure may be directed to panels that are adhered to a surface, which may also be referred to as “surrounds” or with particularity “shower and tub surrounds” in embodiments where the panels are used with showers and tubs. It should be appreciated that the recitation of shows and tubs is not intended to be limited, but is provided as one non-limiting example. Systems and methods of the present disclosure may be used in a wide variety of applications in which surrounds or non-porous surfaces may be desirable, including but not limited to spas, pools, outdoor showers, pet washing stations, vehicle washing stations (e.g., bicycles, scooters, etc.), kitchens and food preparation areas (e.g., indoor and outdoor), and/or the like. Embodiments may be suited in different areas in which water-resistance and/or easy clean up may be desired. In at least one embodiment, the surrounds are formed from a porcelain material, but it should be appreciated that systems and methods may further extend to other material types, and porcelain is provided by way of non-limiting example. Porcelain shower and tub surrounds are becoming more commonly used in residential and commercial bathrooms due to their durability, water resistance, and ease of maintenance. However, the TCNA (Tile Council of North America) defined method/industry standard of installing porcelain shower surrounds involves using full spread thin-set mortar over a waterproofed substrate, which can be time-consuming and labor intensive. Additionally, the mortar can crack or break over time, which can lead to water infiltration and damage as these cracks will transfer through the product. Embodiments of the present disclosure address and overcome these problems, among others, by providing improved systems and methods for installation.

In at least one embodiment, the method includes installing panels (e.g., porcelain shower and tub surrounds) directly to a substrate (e.g., greenboard, backerboards, etc.) using an adhesive dot mount method. The adhesive dots may be made of a strong, flexible material that adheres to both the panels and the various substrates. The adhesive may also be waterproof or substantially water proof (e.g., water resistant). This method eliminates and/or reduces the need for fully spread thin-set mortar and manual waterproofing prior to installation that is now used with existing methods.

The adhesive dot mount method of the present embodiments offers several advantages over the industry standard method of installing surrounds/panels (e.g., porcelain shower and tub surrounds/porcelain panels), including but not limited to faster installation times, easier installation, strong adhesion, and a reduced risk of cracking or breaking. For example, the adhesive dot mount method reduces and/or eliminates the need for a fully spread thin-set mortar, which saves time, allowing installers to on average complete upwards of 300% more installations within the same period. Furthermore, the adhesive dots are easy to apply and require limited special tools and skills. Additionally, the adhesive dots provide a strong, flexible bond between the porcelain and substrate. In at least one embodiment, the adhesive dots may facilitate a waterproof and/or water resistant bond between the porcelain and the substrate, thereby decreasing a likelihood of water infiltration and damage. It should be appreciated that references to “waterproof” and/or “water resistant” may refer to a threshold level and is not intended to imply only situations in which all water infiltration is blocked or prevented by use of the surrounds and/or the adhesive dots. Moreover, unlike full spread thin-set mortar, the adhesive dots are flexible and can absorb the stress and movement that occurs over time, which reduces the risk of cracking or breaking. Accordingly, various embodiments of the present disclosure improve a frequent problem directed toward panel installation, such as porcelain shower surrounds that are mounted directly to a substrate. Embodiments provide systems and methods that are faster, easier, and more efficient installation than existing solutions, while still providing for strong adhesion and reduced damage risks.

Various embodiments may further be directed toward a kit for installing panels using an adhesive mounting method. In at least one embodiment, the kit includes installation of porcelain shower and tub surrounds using pre-cut panels that are particularly selected (e.g., cut according to intended specifications) to fit one or more standard or pre-determined shower sizes. The kit may include all or substantially all materials to install the panels within a designed area. Systems and methods may be directed toward panel installation, and in at least one embodiment, particularly to porcelain panels.

Porcelain panels are durable, scratch-resistant, and easy to clean, making them a growing, yet minority choice for kitchen and bathroom countertops. As a result, most porcelain panels on the market are marketed for use on countertops and are available in sizes that are suitable for this purpose. However, these panels are also well-suited for use in shower and tub surrounds, among other areas, due to their water resistance and minimal maintenance requirements. Such panels may now be cut to size for use for particular applications, including but not limited to shower and tub surrounds. However, one of the main challenges with using porcelain panels in shower and tub surrounds is ensuring that the panels are the correct size to fit seamlessly together (e.g., without significant gaps between panels, without gaps large enough to permit fluid ingress, without gaps large enough to be visually unappealing due to a quantity of material used to connect the panels, etc.). When installing a shower and/or tub surround, it is important to have as few seams as possible to minimize the risk of water infiltration and to create a clean, streamlined appearance. To address this issue, systems and methods may incorporate porcelain panels that are specifically designed for use in shower surrounds. These panels are pre-cut to fit standard shower and tub sizes, which eliminates the need for cutting and measuring on-site. By providing pre-cut panels, end users can ensure that the panels fit together seamlessly and create a waterproof barrier that is both functional and aesthetically pleasing. In addition to pre-cut panels, various embodiments further provide a range of trim pieces that are designed to cover the edges of the panels and create a finished look. These trim pieces may be available in an assortment of colors and finishes to match the porcelain panels, allowing for a customized appearance that complements the bathroom's overall design.

Embodiments of the present disclosure may include one or more components provided as a kit for installing panels, such as porcelain shower and tub surrounds, including pre-cut panels tailored to fit a particular shower size. The kit may provide all or substantially all necessary materials for installing the surround, such as pre-cut porcelain panels, adhesive, sealant (e.g., silicone sealant), and trim pieces. This kit and associated method of installation eliminates the need for on-site measuring and cutting of the porcelain panels, resulting in a more efficient installation process that saves time and reduces the possibility of errors. By eliminating the requirement for expensive cutting equipment, material waste, and a higher risk of breakage, the kit provides a cost-effective and practical solution for installing porcelain shower and tub surrounds.

In at least one embodiment, a kit (e.g., a porcelain shower and tub surround kit) includes one or more of pre-cut porcelain panels, adhesive, sealant (e.g., silicone sealant), and trim pieces and may be installed using the installation method noted herein. The pre-cut porcelain panels may be specifically designed to fit standard shower or tub sizes and come in a variety of colors and patterns. The adhesive may be a high-quality adhesive that is specially formulated for porcelain and provides a strong, durable bond. The sealant may be a pre-mixed silicone that is specifically designed for use with porcelain panels and provides a waterproof (e.g., substantially waterproof) seal. As noted herein, waterproof may refer to a threshold level of water resistance such that there is a decreased likelihood of water infiltration when compared with non-waterproof materials. The trim pieces may be designed to cover the edges of the porcelain panels and provide a finished look.

Systems and methods associated with the kit provide advantages over the problems found with existing systems, including but not limited to faster installation time, easy installation, using high-quality materials, providing a consistent appearance, and also using materials for water-resistance suitable for various wet applications, such as showers and tubs. For example, the pre-cut porcelain panels reduce and/or eliminate the need for measuring and cutting, which saves time and reduces the risk of errors. Additionally, the kit contains all or substantially all materials required to install the surround, making it easy for both professional and DIY installers. Furthermore, the kit includes high-quality porcelain panels, adhesive, sealant (e.g., silicone sealant), and trim pieces that are specifically designed for use with porcelain in one or more specific installations (e.g., tub and shower surrounds, among others). Moreover, the pre-cut porcelain panels ensure a consistent appearance and fit, which provides a professional look. Also, the full-sized panels and approved caulking (e.g., silicone) provide a waterproof seal (e.g., a substantially waterproof seal with a reduced risk of water infiltration compared to a non-waterproof seal), which helps prevent and/or reduce a likelihood of water infiltration and damage.

Various embodiments provide a solution to existing panel installation problems. Specifically, the kit and/or the associated installation method provide a faster, easier, more eco-friendly, and more efficient installation system than traditional installation methods or traditional materials. The pre-cut porcelain panels ensure a consistent appearance and fit, and the high-quality materials provide a durable, water-resistant solution. The porcelain shower or tub surround kit with pre-cut panels is an attractive option for both national production single and multifamily builders, as well as the single-family home remodel market.

FIGS. 1A-1G illustrate a sequence of operations to install one or more panels within a designated area, such as an area associated with a shower. In at least one embodiment, the panels may further be referred to as “surrounds” and installation of such surrounds for a shower may also be referred to as “shower and tub surrounds.” It should be appreciated that example embodiments directed to installations associated with showers and tubs are provided by non-limiting example and that various systems and methods may be applicable to various other locations, including but not limited to, backsplashes, spas, pools, water features, cleaning areas for pets/bikes/the like, and various other applications in which a resilient surface is desired in a location where moisture may be present.

In this example, FIG. 1A illustrates an environment 100 in which one or more surrounds may be installed. The surrounds may be made of porcelain, and in at least one embodiment, may come from a kit in which dimensions of the surrounds are pre-cut based on an intended installation location. A substrate 102 may be positioned about an installation location 104, which may be associated with a shower and bathtub 106 (e.g., shower/tub, shower and tub, etc.) in this non-limiting example. As noted herein, various embodiments may be implemented with a shower and bathtub combination, as shown, or with only a shower, only a bathtub, or a variety of other applications. The substrate 102 may be substrate particularly selected for the installation location to resist water and/or mold and mildew. Non-limiting examples include one or more of Greenboard, Denshield, Hardibacker, Kerdi board, and/or cement backers, but different substrates may also be used within the scope of the present disclosure. A thickness of the substrate may be particularly selected to prevent interference with an intended depth of one or more side panels.

The existing walls of the substrate 102 may be prepared prior to installation, such as by ensuring the wall surface is dry, smooth, and free of elevated nails, screws, drywall mud, residue, and/or the like. Furthermore, an alcove 108 may be checked for dimensionality (e.g., plumb and square) and, moreover, the shower/tub 106 may be checked for installation and anchoring to a floor location. Various other pre-operational checks may be performed to ensure a suitable installation location for the panels.

One or more embodiments may further include a dry-fitting process, as shown in FIG. 1B, which may occur in the same environment 100 after one or more pre-installation preparation operations are completed. In at least one embodiment, dry-fitting may include steps such as hanging and installing one or more panels prior to the use of adhesive to measure and position various components. For example, suction cups may be used for handling and installation of wall panels and also for drawing seams together during installation. Furthermore, braces may be included for the dry-fitting process. Dry-fitting may begin at a rear wall 102A and may maintain a gap (not pictured) above a tub deck 110 or shower pan for all panels. Panels may be leveled, such as by using shims, to achieve such a gap. In at least one embodiment, the gap is approximately ⅛ inch (3 mm). It should be appreciated that the gap may be larger or smaller. In certain embodiments, a minimum value for the gap is ⅛ inch. In certain embodiments, a maximum value for the gap is ¼ inch. These dimensions may permit expansion and contraction while also maintaining a desirable appearance. After dry-fitting the rear wall 102A, the side walls 102B, 102C (FIG. 1C) may be dry fit. In at least one embodiment, the panels used for the side walls 102B, 102C are not book matched and there are no finished edges, and as a result, the panels are non-directional. This may simplify installation because either panel can be positioned at either location, thereby reducing a likelihood of errors.

Various embodiments may use one or more components, such as shims, to align different panels into position such that the panels are plumb with one another and also so that the gaps do not exceed one or more thresholds. In at least one embodiment, the side panels may be positioned to overlap the rear panel at one or more seams. Furthermore, in embodiments, there may not be an overlap but there may be a second gap, which may be less than approximately ¼ inch. However, it should be appreciated that larger second gaps may be used and that other supporting components, such as side strips, may be used to accommodate embodiments where second gaps exceed ¼ inch. Upon completion of dry-fitting, one or more areas may be marked on the side panels to permit installation of various components, such as plumbing locations (e.g., shower heads, water supply features, etc.). The panel may be drilled, such as by using a diamond bit, and then the holes may be formed for installation.

FIG. 1C illustrates the environment 100 in which panels 112 are positioned over the substrates 102. For example, a rear panel 112A is over the rear wall 102A, a side panel 112B is over a side wall 102B, and a side panel 112C is over a side wall 102C. As noted, in at least one embodiment, portions of the side panels 112B, 112C overlap a portion of the rear panel 112A. Furthermore, in this example, openings 114 have been formed in the side panel 112B to accommodate fittings, such as shower heads, valves, and the like. As noted herein, the one or more openings 114 may be variable based on an installation location/use of the panels 112. For example, in an embodiment with only a bathtub, there may be no opening for a shower head. Similarly, in an embodiment for a wash station, there may additional openings for expandable wands and/or the like. Accordingly, a number of openings 114 may be based, at least in part, on an given application. In at least one embodiment, such a configuration as that shown in FIG. 1C may be part of the dry-fitting process to verify positions after forming the openings 114.

FIG. 1D illustrates an adhesive application pattern 120, which may be used with embodiments of the present disclosure. For example, such patterns 120 may be applied to the substrates 102 to secure the panels 112 to the respective substrates 102. However, one or more embodiments may also include application of the pattern 120 or portions thereof to the panels 112. In this example, adhesive dots 122 may be applied after the substrates and/or panels have been wiped to remove dust and debris and after verification the substrates and/or panels are dry. The rear panel 112A may be installed first, as shown in FIG. 1C, using the pattern 120, which as noted herein, may be applied to the substrate 102. While embodiments may describe installing the pattern 120 on the substrates 102, it should be appreciated that adhesive, in the pattern or not, may also and/or alternatively be applied to the panels 112. The pattern 120 may include the plurality of dots 122 positioned in a spaced-apart configuration. The dots 122 may have a diameter of approximately 1 inch. The number of dots 122 that are approximately one inch by one inch may further be determined by the following equation:

$# of 1^{″} Dimples = \frac{Panel Weight}{10 lb f drywall paper strength} * Safety Factor$

The dots 122 may be applied in a configuration such that there is one dot 122 per square foot of panel. Accordingly, a panel that is four square feet will use four dots. In this example, the panel 112 may have dimensions of 58.5 inches by 60 inches, which provides a surface area of 3,510 square inches or approximately 24.375 square feet, and as a result, there are 25 dots 122 on the substrate 102.

In at least one embodiment, the dots 122 are positioned a horizontal distance 124 from adjacent dots 122, a vertical distance 126 from adjacent dots 122, and a diagonal distance 128 from adjacent dots. These dimensions may not be the same or some may be substantially equal with another is different. For example, the horizontal and vertical distances 124, 126 may be equal but the diagonal distance 128 may be less than the horizontal and vertical distances 124, 126. In at least one embodiment, the dots 122 may be substantially evenly spaced along the substrate 102.

FIG. 1E illustrates another example of the pattern 120 in applications in which the panels are installed with or without the openings 114 for different plumbing fixtures. As noted, the pattern 120 includes the dots 122. In at least one embodiment, with the aid of suction cups, the back panel 112A is installed and pressed to secure the back panel 112A in place, for example to ensure firm contact to enable the adhesive to hold the back panel 112A on the substrate. In at least on embodiment, one or more mallets or tools may be used to aid in applying the back panel 112A, but it should be appreciated that excessive force may cause damage. In at least one embodiment, braces may be used to permit time for the adhesive to form a bond, as will be discussed herein.

In at least one embodiment, when applying the dot adhesive for the side panels 112B, 112C, it may also be necessary to run a vertical bead 130 of adhesive on the substrate 102, the entire height of both panels 112B, 112C. In one or more embodiments, these beads 130 may be approximately 1 inch thick/wide and spaced approximately 1 inch from each outside wall. The inclusion of the vertical beads 130 may permit installation of various fittings or finishing components, such as Schluter strips, as one example, and may also provide further support for inclusion of features such as doors. Furthermore, in certain embodiments, such as those that include the openings 114, a bead 132 may also be applied around valves, spickets, and other components associated with the openings. The beads 130, 132 may be continuous beads.

In certain embodiments, the side panels 112B, 112C may be similarly installed as the back panel 112A using one or more suction cups and/or using various components, such as shims (e.g., ⅛ inch to ¼ inch) under the side panels 112B, 112C. Furthermore, various installation techniques may also include maintaining or providing gaps and the like between components, such as gaps at the corners between side panels and the real panels, which may accommodate adhesion and expansion. In at least one embodiment, the gaps are approximately ⅛ inch. The gap may be larger or smaller in various embodiments, as noted herein with respective to various other gaps between the panels and other components.

The side panels 112B, 112C may be secured in place and their thickness may be checked with respect to the substrate. For example, an installed thickness of approximately ⅜ inch from the substrate to a face of the panels 112B, 112C may be desirable. It should be appreciated additional build out may be required, for example due to particular considerations such as an out-of-plumb rear wall, and in various embodiments the adhesive may be configured to supported approximately ¾ inch of build-out. Final adjustments may be made to ensure the tops of each of the panels 112A, 112B, 112C are plumb and aligned, for example by shimming different panels.

FIG. 1F illustrates an embodiment in which a door is installed. As noted above, the pattern 120 is used with the dots 122 for door installation. As noted above, the pattern 120 provides for approximately one dot 122 per square foot. This example door illustrates dimensions of 31.5 inches by 60 inches, or approximately 1,890 square inches (approximately 13.125 square feet). As a result, the figure illustrates more than 13 dots 122. A mount 134 is provided for a door panel 136, which as noted herein, may be a porcelain panel. The mount 134 may be secured to a stud behind the panels and the adhesive may be spread for “full coverage” on both six by six inch upper corners of the panels. One or more holes may also be pre-drilled in the panel for appropriate hardware. Moreover, after installation, sealants, such as silicone sealants, may be installed around the perimeter of the door. Systems and methods of the present disclosure may include various types of sealants, adhesives, and the like.

FIG. 1G illustrates an example configuration in which trim pieces 138 are installed. In this example, the trim pieces of Schuler strips, but it should be appreciated that various other trim pieces may be used with embodiments of the present disclosure. In at least one embodiment, the trim pieces 138 are installed after confirming the installed thickness of the side panels 112B, 112C. Thereafter, the trim pieces 138, illustrated as Schluter strips, are installed along each vertical wall of the side panels 112B, 112C. In at least one embodiment, a standard thickness is approximately ¼ inch, but modifications may change the thickness based, at least in part, on side panel installation characteristics. As shown, the trim pieces 138 are trimmed to length and then slid under the panel edges. The spacing of the vertical bead (described above) may permit installation of the trim pieces 138. Upon installation, the trim pieces 138 may appear flat with the edge and touching the adhesive bead installed earlier. Embodiments may also include steps to clean any adhesive that presses out because of the installation.

FIGS. 1H and 1I illustrate installation locations for silicone and exterior caulking. As shown in FIG. 1H, once all panels 112A, 112B, 112C are installed, interior silicone sealant may 140 may be applied to all wet seams. Wet seams, as illustrated, are all joints inside the shower/tub. Excess may then be cleaned off. Continuing with FIG. 1I, an adhesive sealant 142 (e.g., caulking) may be applied to any exterior dry edges and against the trim pieces 138. Similarly, excess adhesive may be cleaned during and after installation. In at least one embodiment, the panels may be permitted to cure for up to 7 days. Furthermore, in at least one embodiment, an adhesive and/or paintable caulk may be applied along the tops of the panels and/or the trim pieces. For example, an adhesive and/or paintable caulk 144 may be applied to exterior dry edges of the panels and/or the trim pieces. Thereafter, accessories may be installed, such as shower heads, handles, bath spouts, and the like. In at least one embodiment, these accessories may be installed according to manufacturer instructions and after a period of time for silicone sealants to dry, such as approximately 24 hours.

FIG. 1J illustrates an example embodiment in which braces 146 are used to supported the panels 112 after installation. For example, the braces 146 may be positioned to provide further support to enable the adhesive to set and secure each of the panels.

FIG. 2 is an example kit configuration 200 that may be included with embodiments of the present disclosure. In this example, the kit 200 may include components necessary for installation of a variety of panels in a predetermined location, such as a shower. This example includes pre-cut panels 112A, 112B, 112C. The panels may be cut with dimensions 202, 204 that are particularly selected for a given installation location, which may be standardized by one or more industry groups or by manufacturers for other components, such as bathtubs and shows. In this example, the rear panel 112A includes a height of 202A and a width of 204A. Similarly, the side panels 112B, 112C may include heights of 202B and widths of 204B. It should be appreciated that various patterns may also be applied to the panels 112A, 112B, 112C to apply an aesthetically pleasing appearance.

The kit 200 also includes additional installation components, such as adhesives 206, silicone sealant 208, and trim pieces 132. Each of these pieces may be provided within a singular package or kit that a user may obtain and then use to install the component within an installation location. In embodiments, different configurations may be provided, such as different patterns or colors, but the base components may be standardized for installation within a given location area. By standardizing the components, the manufacturer may also be able to provide additional guidance, such as by determining a number of dots to use for each panel and providing that information as an instruction to the user, thereby reducing the risk of user error by not using enough dots. Furthermore, in at least one embodiment, the kit 200 may provide preferred brands and types of adhesives, grouts, etc. to provide an increased likelihood of satisfactory performance.

FIG. 3 is a flow chart of a method 300 for installing a panel to a substrate. It should be appreciated that steps for the method may be performed in any order, or in parallel, unless otherwise specifically stated. Moreover, the method may include more or fewer steps. In this example, a substrate is prepared at an installation location 302. For example, Greenboard may be prepared for installation at a shower or bathing area. One or more panels may be dry fit at the installation location 304. Dry-fitting may include positioning and shimming one or more panels into a position prior to installation of adhesive to secure the one or more panels in place. In at least one embodiment, an adhesive to applied to a selected substrate a prescribed pattern 306. The prescribed pattern may be a dot pattern in which dots or regions of adhesive are applied in a configuration that is less than covering all or substantially all of a surface of the selected substrate panel. The panel may then be installed against the selected substrate 308, such as by pressing the panel against the substrate. The panel may then be secured to the corresponding substrate 310. Thereafter, interior and exterior moisture barriers may be applied 312, 314, such as silicone and caulking. This may be repeated for a number of panels and may be done by using a kit including one or more components for performing the method. In various embodiments, bracing may also be included to further secure the panels.

FIG. 4 is a flow chart of an embodiment of a method 400 for installing a set of panels at an installation location. In this example, an existing substrate at an installation location is prepared 402. In at least one embodiment, first, second, and third panels are dry-fit at the installation locations to respective first, second, and third locations 404. An adhesive may be applied to a first substrate at the first location panel according to a pattern 406, and the first panel may be installed at the first location against the first substrate 408. In at least one embodiment, the first location 408 is a rear wall. The first panel may be secured to the first location 410, such as by the adhesive, which may include pressing the panel against the substrate, applying a force, and/or the like. The step of installing may also include and or encompass the securing step. In at least one embodiment, adhesive may be applied to a second substrate panel and a third substrate panel, according to the pattern 412, and the second and third panels may be installed at the respective second and third locations 414. In at least one embodiment, the second and third locations correspond to side walls that are arranged near the rear wall. Each of the second and third panels may then be secured to their respective installation locations 416, which as noted above may include applying a force to the panels and, in certain embodiments, may be at least partially accomplished via applying the panels to the substrates. In at least one embodiment, the panels may be left for a period of time, such as a duration to allow the adhesive to cure, among other options. Furthermore, in at least one embodiment, trim pieces may also be installed 418, for example along outer edges of the second and third panels. Thereafter, one or more barriers may be applied to interior and exterior seams 420. By way of non-limiting example, the barriers may include panel adhesive and/or paintable caulk along a top of the panels and/or trim pieces, for example along exterior dry edges. Furthermore, as noted herein, the barriers may also include application of panel adhesive along panel sides and/or to exterior dry edges. Furthermore, additional moisture barriers and/or adhesives may be applied at various seams and/or locations, as noted herein. In this manner, multiple panels may be installed at an installation location using an adhesive arranged in a pre-determined pattern to reduce a total amount of adhesive used while also improving installation simplicity.

Although the technology herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present technology. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present technology as defined by the appended claims.

PANEL MOUNTING SYSTEM AND METHOD USING AN ADHESIVE MOUNTING CONFIGURATION

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