Prefabricated bathroom assembly and methods of its manufacture and installation
A prefabricated bathroom assembly and methods for its manufacture and installation are disclosed. For example, a prefabricated tub and/or shower assembly may be provided. In some embodiments, the prefabricated assembly may include at least a bathtub or a shower pan, tile surround(s), and a ceiling. The prefabricated assembly may be constructed substantially entirely off-site relative to a construction site and shipped to the construction site, for example, in substantially a single piece. Finishing face trim for making a seamless transition from the prefabricated assembly to the adjoining walls and ceiling may also be provided. In other embodiments, at least partially prefabricated panels (e.g., 3 wall panels and 1 ceiling panel), a tub or shower pan, the face trim, and/or other components may be shipped separately to the construction site for on-site assembly.
This is a continuation-in-part of U.S. patent application Ser. No. 11/473,651, filed Jun. 22, 2006, and claims priority to U.S. Provisional Patent Application No. 60/993,385, filed Sep. 11, 2007, the entire disclosures of which are hereby incorporated by reference herein in their entireties.
FIELD OF THE INVENTIONEmbodiments of the present invention relate to a prefabricated bathroom assembly and methods of its manufacture and installation. For example, some embodiments of the present invention provide a tub and/or shower assembly at least partially prefabricated off site relative to and methods of its manufacture and installation.
BACKGROUND OF THE INVENTIONPresently, the on-site construction of bathrooms requires various craftsmen such as general contractors, framers, carpenters, electricians, plumbers, plasterers, tilers, and painters to take turns performing their respective tasks. This inevitably results in excessive delay and slow turnaround times for the construction of such bathrooms. This also typically results in high labor costs for bathroom construction due to the large number of parties involved in the construction process.
For example, the on-site construction of a bathroom in a new residential building typically begins once the underlying structure of the building has been completed. The underlying structure is typically formed of wood/metal and masonry or from concrete. First, the carpenters may move on-site to construct a frame for the bathroom, which may involve the erection of stud walls. Then, the plumbers and electricians may move on-site, one after the other, to run the water and drain pipes and to install the requisite wiring, electrical connections, and junction boxes. After the external walls have been erected, the plasterers/drywallers and tilers may move on-site to construct the internal walls and flooring. Subsequently, the carpenters may return to install doors, windows, cabinets, and other fixtures. The plumbers and electricians may then return to install utility and light fixtures. Lastly, the painters may arrive on-site. Of course, all of these operations must be coordinated and spaced in time to avoid interference on site. Because bathrooms require many trades to work in a confined space, it is common for delays of one trade to impact all the others thereby lengthening construction time.
Attempts have been made in the prior art to modularize bathroom structures in order to allow for the construction of bathrooms off site. For example, U.S. Pat. No. 5,438,713 relates to a “SEAMLESS BATHROOM MODULE FOR A MARINE VESSEL”, in which the floors and walls are formed from a seamless, molded fiberglass structure that can be installed onto the deck of a marine vessel. The floor of this modular bathroom is approximately six inches above the deck, due to a drain assembly that protrudes from the bottom of the module. Another molded fiberglass bathroom is described in U.S. Pat. No. 5,903,937 for a “BATHROOM MODULE ACCESSIBLE TO WHEELED ASSEMBLIES”. This bathroom must be installed in a recessed well within the floor to prevent an entrant to the bathroom from encountering a significant step of about 3.5 to 4.5 inches or more, due to the floor support members and drainage trough included in the design.
Practically, these prior modular bathrooms are not suitable for use in structures, such as residential buildings, that are required to comply with the Americans with Disabilities Act (“ADA”). Particularly, the ADA requires the bathroom floor to be no more than ½ inch higher than the floor in the adjacent room so that the bathroom is accessible to, for example, wheelchairs. Any greater of a transition in floor height from room to room requires the installation of a ramp. It is also unfeasible from a construction perspective to use a modular bathroom that must be placed within a pre-formed recess in the building floor. Such a requirement complicates the construction of the building floor and is not cost effective. For example, for a poured concrete building floor, about 4 inches or more of poured concrete must be added to a concrete slab so to allow the slab to accommodate the recess. Thus, any savings realized from the use of a such a modular bathroom is offset, at least in part, by the increase in material and labor costs involved in forming the required recess. The modular bathrooms noted above also are not readily customizable in terms of size and/or according to aesthetic taste due to their molded fiberglass design.
In view of the foregoing, it would be desirable to provide an improved prefabricated bathroom assembly and methods of its manufacture and installation, for example, for use in reducing the time required to install bathrooms in comparison to traditional on-site construction.
SUMMARY OF THE INVENTIONThe above and other objects and advantages of the present invention are provided in accordance with the principles of the present invention described herein. Embodiments of the present invention relate to a prefabricated bathroom assembly and methods of its manufacture and installation. In a preferred embodiment, the bathroom assembly includes at least some of the same or similar building materials (e.g., stud construction, tile finishing, wallpaper, floor-mounted toilets, bathtubs, etc.) traditionally used for on-site construction, in order to provide maximal aesthetic quality and comfort as well as the ability for a purchaser to customize the design. The bathroom assembly is preferably pre-fabricated substantially in its entirety off-site for delivery to the site in a single piece, and needing only fastening into place and connection to utilities at the site in order to complete the installation. The prefabricated bathroom assemblies described herein may be particularly suited for installation in residences, commercial buildings, industrial buildings, or any other structures built on land. Nevertheless, it will be understood that embodiments disclosed herein may also be used in marine applications (e.g., state rooms in cruise ships). In an embodiment, the prefabricated bathroom assembly may include a low-profile floor that complies with applicable provisions of the Americans with Disabilities Act (“ADA”).
In an embodiment, a prefabricated bathroom assembly is provided that is preferably substantially entirely prefabricated off site for delivery to a construction site. The prefabricated bathroom includes a frame formed from a plurality of studs. The frame may house at least one (e.g., all) of a toilet, shower, bathtub, and vanity. The prefabricated bathroom assembly also includes a floor fixed to the frame, where the floor includes a floor finishing material that is fixed to a top of a honeycomb composite. For example, the floor may include ceramic tile fixed to polypropylene or aluminum honeycomb with an adhesive such as Bonstone T-2000 tile setting epoxy.
In another embodiment, a method for manufacturing a floor of a prefabricated bathroom assembly is provided. Generally, tile or other floor finishing material is fixed to a honeycomb composite with an adhesive. Then, the combined structure of tile, adhesive, and honeycomb composite is exposed to ultraviolet light which may, for example, reduce cure time.
In yet another embodiment, a pre-engineered wall assembly is provided for use in the manufacture of a prefabricated bathroom assembly. A wall assembly is said to be “pre-engineered” when the studs (and optionally at least a portion of the wallboard) thereof are assembled together prior to the being fixed to the floor. The pre-engineered wall assembly may be fixed to the floor material with, for example, an adhesive such as an acrylic adhesive manufactured by LORD, epoxy, construction adhesive or fasteners. The pre-engineered wall-assembly may be manufactured through the use of a computer numerically controlled (“CNC”) cutter (e.g., to ensure that the wall panels are cut to the correct size and shape).
In another embodiment, studs that are pre-formed (e.g., drilled) with holes are provided for use in manufacturing a prefabricated bathroom assembly. The studs may be preformed with (i) fastener holes for making connections with other studs and/or fixtures, and/or (ii) pathways for plumbing and/or electrical connections. The locations of the holes may be determined during the design of the bathroom assembly. In an embodiment, load strength characteristics of the studs are maximized by pre-forming in the studs only the holes that are needed for a particular design of a prefabricated bathroom assembly.
In still another embodiment, a prefabricated bathroom assembly is provided in which plumbing connections extend through the top and/or bottom of the assembly. For example, a prefabricated bathroom assembly having a floor-mounted toilet (in contrast to a wall mounted toilet) may be provided. Once the prefabricated bathroom assembly arrives at a construction site, the prefabricated bathroom assembly may be connected to site-installed drain and vent stacks, a tub drain, a p-trap, a toilet flange, and/or a soil stack.
In another embodiment, a “top-down” method is provided for installing in a multi-storied building a plurality of prefabricated bathroom assemblies that have plumbing connections extending through the top and/or bottom thereof. The prefabricated bathroom assembl(ies) at the top of the building are tied in to the building's plumbing utilities first, followed by the assembl(ies) in the floor immediately below, and so on until the last of the prefabricated bathroom assemblies (e.g., on the first floor) have been installed. After installation, the prefabricated bathroom assemblies are substantially vertically aligned.
In yet another embodiment, a template is provided that models to scale the floor plan (or a portion thereof) of a prefabricated bathroom assembly. The template may be a substantially planar material (e.g., paper, plastic, metal, or other suitable material). The template may include various cutouts (e.g., holes) or other markings that show the location(s) where the hole(s) in the building floor should be formed (e.g., drilled) in order to accommodate the prefabricated bathroom assembly. The template may be delivered to the construction site well in advance of the arrival of the prefabricated bathroom assembly, such as shortly after the design of the prefabricated bathroom assembly is finalized but before the completion of the assembly.
In another embodiment, a prefabricated bathroom assembly is fitted with a caster system that facilitates transportation of the bathroom assembly and final placement of the bathroom assembly at the construction site.
In another embodiment, a prefabricated bathroom assembly is designed, at least in part, with Computer Aided Design (“CAD”) technology. CAD can be used to design a prefabricated bathroom assembly down to even the smallest details, and may be useful for customizing the design for, for example, a particular living space and/or size tile(s) selected by a customer. In one embodiment, CAD design is used to map the placement of plumbing, electrical components (e.g., wires or conduits), stud dimensions and connections, and/or other fixtures and connections. Such a mapping may be used to determine the exact cutting of wall panel materials such as gypsum board. In another embodiment, CAD design is used to map the layout of tiles on the floor and/or wall(s) of the prefabricated bathroom assembly. At least a portion of the CAD design may be automated. For example, one or more customized scripts may be created for automatically designing the framing layout for wall panels based on input(s) representing the dimensions of the finished wall and/or for automatically mapping placement of the floor tiles based on inputs indicative of the floor dimensions, tile size, toilet placement, and/or tub placement. A library of plumbing and electrical fixtures may be provided that can be inserted into any design, thereby reducing design time.
In an embodiment, a prefabricated tub and/or shower assembly is provided that includes a rear wall panel, a first side wall panel, a second side wall panel, a ceiling panel, and a tub or a shower pan, where at least one of the first side wall panel and the second side wall panel includes at least one of a shower head and a tub spout. For example, the assembly may be substantially entirely fabricated off site for delivery to the construction site. Alternatively, each of the rear wall panel, the first side wall panel, the second side wall panel, and the ceiling panel may be substantially entirely fabricated off site but delivered to the construction site separately for assembly at the construction site. The ceiling panel may be removable (e.g., via slidable engagement with the first and second side wall panels) from the assembly subsequent to installation of the assembly at a construction site.
In some embodiments, a prefabricated tub and/or shower assembly is provided that includes face trim (e.g., formed from cultured marbled) for the first side wall panel, the second side wall panel, and the ceiling panel. The face trim may make a seamless transition from the assembly to the adjoining walls and ceiling at the construction site.
In some embodiments, one or more (e.g., all) of the rear wall panel, the first side wall panel, and the second side wall panel includes a frame, backer board affixed to the frame, and a molded material (e.g., cultured marble) affixed to the backer board with, for example, an adhesive. For example, in some embodiments, the backer board of one of the panels may include a male or female connector for mating with a corresponding female or male connector formed in another one of the panels.
In some embodiments, each of the first side wall panel and the second side wall panel is configured for mechanical interlocking with the rear wall panel. For example, each mechanical interlock may be substantially water-tight such that no caulking is necessary at the juncture between the panels.
In another embodiment, a prefabricated tub and/or shower assembly is provided that includes a rear wall panel, a first side wall panel, a second side wall panel, a ceiling panel, and a tub or a shower pan, where the tub or the shower pan is removable from the apparatus subsequent to installation of the apparatus at a construction site.
Other features and advantages of embodiments of the present invention will be apparent from the detailed description, drawings, and claims.
For a better understanding of the present invention, reference is made to the following description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
In the example shown in
The example shown in
Additional features of various embodiments of the present invention will now be described. The following features may be used alone or in combination with the features described above regarding a prefabricated bathroom assembly with a low-profile floor. For example, in one embodiment, all (or any subset) of the features described in this application may be used in the construction and/or installation of a prefabricated bathroom assembly. In another embodiment, a no-floor prefabricated bathroom assembly may be provided that includes any or all of the features described below and that, in addition to requiring connection to utilities at a construction site, requires the on-site installation of a floor (e.g., tile).
In an embodiment, the prefabricated bathroom assembly is manufactured with studs (e.g., steel studs) that are pre-formed (e.g., pre-drilled) with (i) fastener holes for making connections with other studs and/or fixtures, and/or (ii) pathways for plumbing and/or electrical connections. The locations of the holes may be determined by a computer during a design process that involves, for example, CAD. In an embodiment, load strength characteristics of the studs are maximized by pre-punching in the studs only the holes that are needed for a particular design of a prefabricated bathroom assembly. For example,
In some embodiments, the tub and/or shower assembly including some or all of components 1502-1518 and/or other components may be pre-fabricated substantially entirely off-site for delivery to a construction site in substantially a single piece, and needing only fastening into place and connection to utilities at the site in order to complete the installation. The assembly may be shipped to the construction site in a protective material including, for example, a plastic wrapping or coating. In some embodiments, finishing face trim 1520 (e.g., including separate top, left, and right pieces) may be provided (e.g., shipped detached from the prefabricated assembly). Upon installation, face trim 1520 may make a seamless transition from the prefabricated assembly to the adjoining walls and ceiling. Face trim 1520 may be formed from, for example, cultured marble or other molded product and may be fixed in place with, for example, a suitable adhesive. Each piece of face trim 1520 may be about ¾×2 inches in thickness and width, respectively, although other thicknesses and widths may be provided.
In other embodiments, at least partially prefabricated panels (e.g., 3 wall panels and 1 ceiling panel), the tub or shower pan, the finishing face trim, the steel frame (in one or more pieces), and/or other components may be shipped separately to the construction site for on-site assembly.
In some embodiments, due to the precision cutting (e.g., less than ⅛ inch tolerance) and tight fit of backer board 1518 and tile surrounds 1506 of the wall panels, a water-tight connection may be provided at the juncture of the wall panels with little or no caulking (e.g., less caulking than is used at the juncture between tiles in traditional on-site construction). In some embodiments, caulking (if any) may be provided only at the juncture of the wall panels with the tub. In some embodiments, adhesive may be provided on the backside of tile surrounds 1506 that further ensures a water-tight connection between the wall panels and/or the tub.
Thus it is seen that a prefabricated bathroom assembly (e.g., tub and/or shower assembly) and methods for its manufacture and installation are provided. Although particular embodiments have been disclosed herein in detail, this has been done by way of example for purposes of illustration only, and is not intended to be limiting with respect to the scope of the appended claims, which follow. In particular, it is contemplated by the inventors that various substitutions, alterations, and modifications may be made without departing from the spirit and scope of the invention as defined by the claims. Other aspects, advantages, and modifications are considered to be within the scope of the following claims. The claims presented are representative of the inventions disclosed herein. Other, unclaimed inventions are also contemplated. The applicant reserves the right to pursue such inventions in later claims.
Claims
1. An apparatus comprising:
- a rear wall panel;
- a first side wall panel;
- a second side wall panel;
- a ceiling panel; and
- a tub or a shower pan,
- wherein at least one of the first side wall panel and the second side wall panel comprises at least one of a shower head and a tub spout, and wherein the ceiling panel is removable from the apparatus subsequent to installation of the apparatus at a construction site.
2. The apparatus of claim 1, wherein the apparatus is substantially entirely fabricated off site for delivery to the construction site.
3. The apparatus of claim 1, wherein each of the rear wall panel, the first side wall panel, the second side wall panel, and the ceiling panel is substantially entirely fabricated off site but delivered to the construction site separately for assembly at the construction site.
4. The apparatus of claim 1, wherein the ceiling panel is slidably engageable with the first side wall panel and the second side wall panel.
5. The apparatus of claim 1, further comprising face trim for the first side wall panel, the second side wall panel, and the ceiling panel.
6. The apparatus of claim 5, wherein the face trim is formed from cultured marble.
7. The apparatus of claim 1, wherein one or more of the rear wall panel, the first side wall panel, and the second side wall panel comprises:
- a frame;
- backer board affixed to the frame; and
- a molded material affixed to the backer board.
8. The apparatus of claim 7, wherein the molded material comprises cultured marble affixed to the backer board with an adhesive.
9. The apparatus of claim 7, wherein the backer board of one of the rear wall panel, the first side wall panel, and the second side wall panel comprises a male or female connector for mating with a corresponding female or male connector formed in another one of the rear wall panel, the first side wall panel, and the second side wall panel.
10. The apparatus of claim 1, wherein each of the first side wall panel and the second side wall panel is configured for mechanical interlocking with the rear wall panel.
11. The apparatus of claim 10, wherein each mechanical interlock between the first side wall panel and the rear wall panel, and between the second side wall panel and the rear wall panel, is substantially water-tight such that no caulking is necessary at the juncture between the panels.
12. An apparatus comprising:
- a rear wall panel;
- a first side wall panel;
- a second side wall panel;
- a ceiling panel; and
- a tub or shower pan,
- wherein at least one of the first side wall panel and the second side wall panel comprises at least one of a shower head and a tub spout, and wherein the tub or the shower pan is removable from the apparatus subsequent to installation of the apparatus at a construction site.
13. A method of manufacturing a tub and/or shower assembly, the method comprising:
- at least partially fabricating the tub and/or shower assembly off site relative to a construction site for delivery to the construction site, said at least partially fabricating said assembly comprising: assembling a rear wall panel; assembling a first side wall panel; assembling a second side wall panel; and assembling a ceiling panel that is insertable to and removable from the assembly via slidable engagement with the first side wall panel and the second side wall panel.
14. The method of claim 13, further comprising attaching the rear wall panel, the first side wall panel, the second side wall panel, and the ceiling panel to one another off-site relative to the construction site.
15. The method of claim 14, further comprising removing the ceiling panel from the assembly subsequent to installation at the construction site.
16. The method of claim 13, further comprising affixing face trim to edges of the first side wall panel, the second side wall panel, and the ceiling panel.
17. The method of claim 13, wherein one or more of assembling the rear wall panel, assembling the first side wall panel, and assembling the second side wall panel comprises:
- forming a frame;
- affixing backer board to the frame; and
- affixing a molded material to the backer board.
18. The method of claim 17, wherein affixing the molded material to the backer board comprises affixing cultured marble to the backer board with an adhesive.
19. The method of claim 17, further comprising:
- forming a male or female connector in the backer board of one of the rear wall panel, the first side wall panel, and the second side wall panel, the male or female connector configured for mating with a corresponding female or male connector formed in another one of the rear wall panel, the first side wall panel, and the second side wall panel; and
- forming the corresponding female or male connector in the another one of the rear wall panel, the first side wall panel, and the second side wall panel.
20. The method of claim 13, further comprising mechanically interlocking each of the first side wall panel and the second side wall panel with the rear wall panel.
21. The method of claim 13, wherein said mechanically interlocking comprises mechanically interlocking each of the first side wall panel and the second side wall panel with the rear wall panel to form a water-tight connection such that no caulking is necessary at the juncture between the panels.
22. A method of manufacturing an assembly comprising a tub or a shower pan, the method comprising:
- at least partially fabricating the assembly off site relative to a construction site for delivery to the construction site, said at least partially fabricating said assembly comprising: assembling a rear wall panel; assembling a first side wall panel; assembling a second side wall panel; and assembling a ceiling panel, wherein the tub or the shower pan is engageable with and removable from the assembly subsequent to installation of the assembly at a construction site.
Type: Application
Filed: Sep 11, 2008
Publication Date: Apr 23, 2009
Applicant: Eggrock, LLC (Concord, MA)
Inventors: Jeffrey L. Barrett (Concord, MA), Adam Hedgcock (Alston, MA)
Application Number: 12/283,315
International Classification: A47K 4/00 (20060101);