FIELD OF THE INVENTIONThe invention regards the sector of construction and installation of bathrooms for hotel structures, for domestic use or offices.[0001]
In particular the invention regards complete pre-assembled structures for bathrooms, capable of being installed rapidly and economically for a first time installation as well as a re-modernising of rooms used for bathrooms in hotels or other buildings.[0002]
At present, in order to realise a complete bathroom, many hours of work are required and the collaboration of skilled labour from various sectors, plumbing, constructional, electrical etc . . . .[0003]
This requirement involves periods of time, and therefore costs, quite high, taking into consideration in particular the fact that for a hotel the days lost for re-modernisation imply also lost revenue from the occupation of the room.[0004]
Further, the need to co-ordinate different staff and timing, results not always in a satisfactory quality of finish, considering the cost sustained.[0005]
AIM OF THE INVENTIONThe aim of the present invention is to eliminate the drawbacks of the known type of pre-fabricated structures for bathroom and to propose a bathroom with an easy and rapid installation, carried out also by unskilled labour.[0006]
A second aim is to propose a bathroom with a high quality finish that does not have delimitation of a prefabricated product by measures or quality and which can be installed in site without the necessity of the intervention of skilled labour.[0007]
In particular bathroom structures made of high value materials like marble and natural stones are considered.[0008]
A third aim is to permit a savings in the cost of installation because of a better management of the costs.[0009]
SUMMARY OF THE INVENTIONThese aims have been reached according to the invention realising structures for a pre-assembled bathroom complete in all its necessary components, the hydraulic parts and electric as well as the coverings.[0010]
The coverings (walls, floor and, if required, the ceiling) are preferably in the form of continues panels, factory produced to measure, in marble or other suitable material.[0011]
According to the invention, the prefabricated wall panels which have to be placed at the corners are preferably able to reciprocally slide in order to correct possible error of their dimensions in respect to the real dimensions of the room or of the bathroom components to be installed.[0012]
Once the desired finish of the covering is obtained the panels can be connected reciprocally and fixed to the wall by means of distance adjustable fixtures, which in this case may permit the easy removal of one or more panels to consent the inspection of the hydraulic or electric system of the bathroom.[0013]
The sanitary components (for example the vanity unit, bath tub, WC cistern, hydro-massage) are predisposed with their support structure and with the tubes ready to be reciprocally connected to complete the hydraulic circuit of the bathroom to be connected then to the already existent water adduction column/waste pipes of the room and without the need of further intervention, as in the electrical system. Floors and ceiling can be prepared in the factory to be installed on site, but again the measures are quite flexible in order to match final requirements on site.[0014]
In fact different than other prefabricated systems, according to a further aspect of the invention, the floor and ceiling structures are done “cut to size” but all parts can slide one on top of the other for final measurement requirements, vertical and horizontal walls and floors or ceilings and can be used separately one from the others as in the traditional works[0015]
In more detail:[0016]
floors are installed at first traditionally or with the “up side down” method as defined later on, and walls are installed on the finished floor, so they can slide on top when required.[0017]
The invention refers also to a method for the fabrication, the pre-assembly and the installation of the complete bathroom as well as of the floor structure and of the ceiling structure.[0018]
The advantages achieved essentially consist in the fact that it is possible to install completely a “turn-key” bathroom without skilled labour for the structural of mural work or, for the marble work, without the intervention of the marble-cutter or installer, and with a minimal need of labour for the hydraulic parts, while the planning of the bathroom may be carried out in the factory, manually or assisted by computerised instruments.[0019]
A second advantage consists in the possibility to define in the factory with accuracy the dimensions, specifications and materials of the bathroom to be assembled and then to correct in site possible errors without the intervention of skilled labour.[0020]
The panels walls, when they are made of marble/granite or other natural stone, are slabs of large solid stone that are both structural and finishing.[0021]
A third advantage consists in the elevated finish achieved of the coverings.[0022]
A fourth advantage consists in the substantial lack of visible joints.[0023]
A fifth advantage consists in the fact that no preparative mural work is needed, but only the assembly, in the room to be installed there is no work-site, which permits to have a reduced time of installation on sight and minimum disruption (of noise, dust or other), damaging to the concerned hotel structure or habitation.[0024]
A sixth advantage consists in the possibility to assemble very regular and continues flat surfaces, with minimum maintenance and cleaning problems.[0025]
A seventh advantage consists in the possibility to easily and rapidly inspect the hydraulic parts of the components, which remain accessible by removing one or more of the cover panels.[0026]
A further advantage is the “perfect” quality of all the parts which are factory made and therefore can achieve an high level of accuracy, whilst maintaining high quality of finishing. In fact no cutting/polishing(gluing or fixing of components are necessary on site.[0027]
In case of ceramic tiles, tiles are applied on a support panel (such as aluminium honey-comb or gypsum board) in the factory that allows to carry out all the cutting of parts of tiles with a factory machine, and to have perfect joints which is usually very difficult to achieve on site.[0028]
Mainly the external corners in the present invention are pre-built in the factory, allowing perfect matching.[0029]
In the case that the panels are made of marble (or other natural stone) a thickness of 2 cm or less of the floor and of the side panels it is sufficient to have both structural and finishing function. In fact the bathroom components can be fixed using the same material (marble) and loading all weight to the floor, avoiding any structural back-falls in the future. For example a vanity top of the bathroom can positioned on two or three vertical marble side panels. That allow fast fixing, laterally just positioning and require no fixing on site, no building material on site and no work on site, and therefore just any simple workers.[0030]
LIST OF THE DRAWINGSThese and further advantages will be comprehended by the following drawings, given as an non limiting example, in which:[0031]
FIG. 1 shows a top exploded view of a bathroom according to the invention;[0032]
FIG. 2 shows a top view of the bathroom of FIG. 1 with installation completed;[0033]
FIG. 3 shows the standard components of a bathroom according to the invention with the relative predisposed tubes for the installation;[0034]
FIGS.[0035]4 to7 show a top view of the single components of FIG. 3;
FIG. 8, shows schematically a top view of a bathroom structure according to the invention;[0036]
FIGS. 8[0037]a-8mshow the installation sequence fromstep1 to22 of the wall panels and of the other components of the bathroom structure of FIG. 8;
FIG. 9 shows the detail of a first embodiment according to the invention of adjustable means of fixture of the wall panels;[0038]
FIGS. 9[0039]a-9brespectively show a section and a front view of a second embodiment according to the invention of adjustable means of fixture of the wall panels;
FIGS. 10, 10[0040]aand10brespectively show a section view, a detail of the same section view and a top view of a floor structure according to the invention;
FIG. 10[0041]cshows a further embodiment of a floor structure according to the invention;
FIGS. 10[0042]dand10eshows a still further embodiment of a floor structure according to the invention;
FIG. 11 schematically show the reciprocal position of wall panels installed according to the method of the invention;[0043]
FIG. 12 shows a prefabricated wall structure provided with telescopic bars “T” according to the invention;[0044]
FIG. 13 shows a ceiling structure according to the invention;[0045]
FIGS. 14[0046]aand14bshow pre-assembled walls of FIG. 12, respectively before and after installation.
FIG. 15 shows a W.C cistern unit according to the invention, with covering panels removable for inspection;[0047]
FIG. 16 schematically shows wall panels of the invention with having connection means.[0048]
DETAILED DESCRIPTIONWith reference to the attached drawings of FIGS.[0049]1 to7, a pre-assembled bathroom according to the invention includes: a multiplicity of panels of covering to measure, among whichwall panels1,floor panels2 and, in the event that a ceiling be required (for example, in the bathrooms of a hotel structure)ceiling panels3; and a multiplicity of accessories among which avanity unit4, abath tub5 with a complex of water taps6, a cistern forWC7.
With reference in particular to FIG. 2 the covering wall panels may be reciprocally connected in a traditional way or using[0050]connection plates9 in such a way that the plates enter and are hidden behind the adjacent panel. (FIG. 16) Advantageously theplates9 of adjacent panels are in alternate position so as not to interfere with each other.
During the assembly, the plates integral with a panel are fixed to the wall with normal screws, while the[0051]plates9 of the adjacent panel may be inserted between the panel and wall and so remain blocked.
In the case of[0052]corner panels1, the plates of one of two adjacent panels can be “L” shaped in such a way that theplates9 of the second panel are inserted and are hidden between the side surfaces of the first and the wall.
According to a further aspect of the invention, in FIG. 11 it is schematically shown the reciprocal position of corner panels and their position after adjustment (illustrated in dotted lines) which can be needed due to a possible difference from the measured dimensions and the true dimensions of the room to be installed or of a component to be inserted.[0053]
The panels o FIG. 11 are adjustable as they can slide one in to the other. In other words, the panels, though produced in measures as in drawings, can slide one next to the other creating in such a way smaller and smaller room. For example, the installation of the[0054]vanity unit4′ in FIGS. 8 and 8a-8mcan be considered.
In that case the width of[0055]4′ is bigger then the space available between the lateral panels marked R10 and R11—FIG. 8I,sequence step20.
It is possible, thanks to the invention, to displace panel R[0056]11 so that the latter is translated of the needed distance along the wall panel R12 in the direction of the arrows. As an alternative, the complex made of panels R11 and R12 could also be rigidly displaced so that R12 slides behind R13.
Then (FIG. 8[0057]m—sequence21)unit4′ can be inserted after that R11 and R12 can be translated to contact with the unit (sequence22).
Therefore, it is evident that the invention permits an unskilled user to completely install with high accuracy the bathroom components and panels without the need of cutting or other difficult operations.[0058]
According to a further aspect of the invention a floor structure is described.[0059]
In a first preferred technical solution and with particular reference to the FIG. 10[0060]c, thepanels2 may be provided with self-bearing adjustable supports. The supports are formed byplates28 supplied with screws forregulation29 agents on thefloor50 pre-existent, to be adjusted according to the required level of the support of thepanels2.
During installation, a side of the[0061]first panel2 is placed on a fixed match R and supplied along the other side with two ormore plates28 fixed with normal screws27. Through the plate28 apressure screw29 is screwed down which may be adjusted according to the level required. Thesecond panel2 is then placed with a side on the plate28 (ifnecessary cavities200 may be foreseen to house the screw head29) and placed with the other on a followingplate28, until the covering is completed.
According to a second preferred technical solution of the invention, and with particular reference to the FIGS. 10, 10[0062]a,10b, thefloor panels2 of the invention may be provided with self-bearing adjustable supports. The supports are formed byplates280 which can rotate on the horizontal plane being pivotally fixed to thefloor50 by avertical pin200.Plates280 are supplied with supportingdisks201 integral with screws forregulation290 and acting between thefloor panels2 and thepre-existent floor50, to be adjusted according to the required level of the support of thepanels2.
During installation,[0063]panels2 are placed on a number ofdisks201 preferably aligned in correspondence of the sides of adjacent panels so that each disk supports both theadjacent panels2 in order to guarantee an uniform height of the panels abovefloor50.
Possible positioning errors of[0064]disks201 can be corrected by a rotation ofplates280 around thepin200.
Alternatively, according to a third embodiment illustrated in FIGS. 10[0065]dand10e, the adjustable support for thepanels2 can consist ofsimple bolt110 andnuts111 that are positioned at the extreme of the marble—granite floor slab2 and allow adjustment when a second slab should be installed.
As in the above cases, it is advisable that the bolts and nuts will be shared for the second slabs, to guarantee that floor surface is perfectly continuous.[0066]
In all the above floor structures, is preferable that liquid grout is poured later on from below through a pouring[0067]channel121, till thegap120 betweenpanels2 andfloor50 is completely filled.
According to a still further aspect of the invention a method to install a floor structure, preferably by using[0068]panels2, comprises the following steps:
a) fixing to floor[0069]50 a plurality of adjustable supports preferably aligned along lines corresponding to the side offloor panels2 to be posed;
b) installation of a[0070]first panel2;
c) adjusting the level of the first panel acting on the regulating means of the supports of the panels;[0071]
d) adjusting if needed the position of one or more supports;[0072]
e) placing, possibly on the side aligned supports, floor panels adjacent to the already installed panel;[0073]
f) pouring anti-retractable liquid cement into the gap between[0074]panels2 and surfaces50 underneath, in such as way as to prefect the regularity of the support.
The mortar/cement may, for example, be poured from the side of the last panel posed[0075]2 near to the room wall, or in large areas, be pumped.
Alternatively, using the same system, grids (metallic or plastic) suitable as support for ceramic tiles may be applied instead of the[0076]panels2.
Advantageously, and aside from the regularity of the[0077]surface50, this solution allows an accurate realisation of the floors without skilled intervention for the traditional realisation of the pier and the subsequent pose of the covering.
Advantageously, in case of marble floor panels for areas relatively large (2 m×2 m and more), the present structure and method allow to reach high quality avoiding breakage risks of the panels thanks to the substantially complete support guaranteed by the cement poured under the marble panels.[0078]
A further advantage is that large marble panels can be installed obtaining even surfaces and avoiding the need of final polishing on site as in the traditional method.[0079]
A still further advantage is that marble panels of any size can be installed by unskilled labour.[0080]
A still further advantage is that the structure floor is structurally sound so that one can walk on the panels immediately after the installation also before being cemented from below.[0081]
It is evident that the described floor structure and installation method have been described with reference to a bathroom, but the same solution can be applied to any floor structure, for example of floor structure of airports, hotel halls and the like.[0082]
In the case of the[0083]ceiling panels3, if ceiling be required, the installation can be carried out by installing thepanels3, complete with eventual electrical works, on theside panels1.
Advantageously, the dimensions of the panels[0084]1-3, are already predisposed according to the measurements of the room and to the configuration of installation and therefore consent to complete the covering in a short time and with an elevated level of finish.
According to a further aspect of the invention, illustrated in the example of FIG. 13, a ceiling structure is described in the following.[0085]
[0086]Ceiling panels3 are pre-assembled with large sheets of traditional gypsum board or aluminium honey-comb both already structurally self supporting and include any lighting system and paint.
In case of gypsum board, the number of sheets which are needed to cover the ceiling will be prepared in the factory, with steel studs[0087]33 (that are used for partition gypsum walls inside supporting structures) or aluminium profiles, glued and mechanically fixed along the ceiling panels to keep them flat. The ends ofstuds33 can then be placed on thewall panels1 so that thepanels3 are self supporting instead of being hanged from the ceiling, as in the traditional decorative—low ceiling also called “hanged ceiling”.
The above ceiling structure has the following advantages:[0088]
very easy and just installation, as the slabs are simply positioned on the edge of the vertical wall already equipped with lighting system and finishing coating;[0089]
it is always easy to remove them for any maintenance or inspection of pipes (that are in many cases below the above concrete floor), the electric system or air extract system just by lifting them as they are not fixed anywhere.[0090]
According to a still further aspect of the invention, the installation of the[0091]panels1 to thewall40 is completed by means of adjustable fixtures which permit the rapid installation and the removal of the panels to allow possible inspection after the assembly of the bathroom.
In a first preferred example of realisation described in FIG. 9, these means consist in a first drilled[0092]plate20 which may be fixed on the back of apanel1 using common screw means23. At the centre of the plate20 a drilledround21 is foreseen, partially superimposed to theplate20 in such a way as to leave between the panel I and round21 agap22 in which awasher26 internally threaded may be placed and may turn freely.
A[0093]screw24 may engage itself in thewasher26 and be activated by ascrewdriver25 passing through the correspondinghole11 made in thepanel1.
Advantageously, the diameter of the[0094]hole11 may be extremely limited (even 5-6 mm or less) in such a way as not to have a relevant aesthetic impact on the external side of thepanel1 that can be fixed later on.
The means of fixture include also a[0095]second plate30 which may be fixed to thewall40 usingcommon screws32 in correspondence to theplate20.
The[0096]plate30 consists in the centre of a threadedbolt31 suitable to receive thescrew24.
During installation, the[0097]screw11 is inserted for pre-determined length through thewasher26 and then inserted into thebolt31.
Screwing down the[0098]screw24 in thebolt31, thewasher26 turns in thegap22 and is drawn to thewall40 dragging thepanel1 the position of which in this way may be easily regulated.
Advantageously, in correspondence to the bolt[0099]31 ahole41 may be made in thewall40 in such a way as to leave room for the progress of thescrew24. In FIGS. 9a,9ba second preferred solution of adjustable fixture means of thelateral panels1 is illustrated.
In this case a[0100]first plate20′ can be fixed (for example by glue or screw means) to the back face of awall panel1 sticking out the lateral side of the panel.
A[0101]second plate30′ is also provided which can be fixed to aroom wall40 bycommon screws32′. The central portion ofplate30′ has a concave shape emerging from thewall40 and which presents atransversal slot24′.
[0102]Plate20′presents passing holes11′ and atransversal slot56 having a countersunk hole.
Holes[0103]11′ respectively face in the use thescrews32′ of the second plate.
A regulating[0104]screw31′ can be inserted through theslot56 of theplate20′ and through theslot24′ of thesecond plate30′ to engage a regulatingbolt31′ made integral to plate30′ by lockingnut54. By rotatingbolt31′ it is thus possible to adjust the distance between the first andsecond plates20′,30′.
Further locking[0105]nut57 and58 can also be provided in order to keep the desired distance between the plates.
In the installation, a[0106]wall panel1 is provided with one ormore plate20′.
Through the[0107]holes11′ can be operatedscrews24′ to fix thesecond plate30′ to thewall40 in the correct position.
After that the regulating[0108]bolt31′ is placed and the distance betweenplates20′ and30′ is adjusted as well as the lateral position can be adjusted thanks to the elongated shape ofslot24′.
With reference now to FIGS. 8, 8[0109]a-8m, and FIG. 16, once afirst panel1 is fixed to thewall40, a second adjacent panel can be applied over theplate20′ so that the latter is hidden from sight.
Preferably, that second panel is provided with one or more[0110]lateral plates9 capable of being inserted between the hidden face of the first panel and thewall40.
Usually, three plates will be prefixed to the panel on one side, while the other side will have two[0111]flat plates9 to be inserted between the three plates of the previous panel. The first panel will have of course fixing adjustable plates on both sides.
Panels can therefore be adjustable in positioning between themselves giving to the bathroom different dimensions, and can be all removed mechanically for modifications, substitution, or rebuilding in another site.[0112]
FIGS. 8[0113]a-8dshow the installation oflateral panels1 identified with progressive reference number R01-R16.
FIG. 8 shows a bathroom completely covered by[0114]lateral panels1 marked with correspondent progressive reference numbers R01-R16.
Advantageously, with this solution the fixtures means are completely hidden from sight and at the[0115]same time panels1 are easy to be remove for inspection or to be substituted.
With reference to the FIGS.[0116]1-7, the accessories of a bathroom according to the invention are made up of traditional components, pre-assembled with the tubes and the hydraulic parts to be connected reciprocally.
In the example described, the[0117]wash basin4 is provided withtubes41 withterminal joints42 corresponding to the hot and cold water circuit and to the waste conduct.
In the same way, the[0118]bath tub5 with the water tap complex forshower6 and thecistern7 of the WC are provided withcorresponding tubes51,61, and71 andterminal joints52,62 and72.
During installation, the[0119]tubes61 of the complex6 are connected to the hot andcold water columns100 existent in the room and, by thejoints62, to the correspondingjoints72 and52 of thecistern7 and thebath tub5.
In turn, the[0120]tubes51 of thebath tub5 are connected to the correspondingtubes41 of thewash basin4 and to thewaste conduct101 and thetubes71 of thecistern7 are connected to a WC (not shown in the Figure) of the known type.
Advantageously, all the terminal joints of the various accessories are predisposed in such a way as to correspond exactly at the moment of installation of the bathroom and to be easily connected remaining however completely hidden from sight.[0121]
According to a further characteristic of the invention, the tubes of all of the components[0122]4-7 are easily inspected. For example, in the case of thebath tub5, theW.C unit7 and of thewater tap complex6 this is possible by simply removing one ormore cover panels53,63 suitably predisposed.
During the installation, the operator proceeds as described assembling the panels[0123]1-3 already made to measure.
The assembly may be carried out on a previous covering as well as directly to the wall, after which the components[0124]4-7 are connected to the hydraulic circuit already existent in the room and connected reciprocally without the need of any structural intervention or particular competence.
At the end of the installation all the tubes are hidden from sight, as well as all the means of fixture of the panels of covering apart from the[0125]holes11. The bathroom, so completed presents therefore an elevated level of finish and at the same time a remarkable simple installation and finally is easily accessible for eventual inspections of the tubes.
According to a further aspect of the invention, illustrated in FIG. 12[0126]pre-assembled bathroom walls300 can be provided when the distance from an existing wall has to be created.
In that case a[0127]metal structure301 is prepared behindpanels1, possibly provided with telescopic bars “T” to adjust the distance.
When there is no wall (FIGS. 14[0128]a,14b) complete position of wall can be prepared in the factory including a structural self supporting metal frame, gypsum board (generally two layers) already pre-painted, to the room side, insulation (such as rock wool, or glass wool) the finishing cover such as marble slabs or any kind of tiles (to the bathroom side) and all plumbing/electrical piping, all completely installed.
This wall or section of walls can be adjusted in position and then mechanically connected between themselves, creating a complete bathroom.[0129]
One or more of the walls will possibly include a prefixed door and door frame.[0130]
In a preferred form of the realisation the covering panels are made up slabs of marble, but it is understood that the material used may be of various suitable types including panels of ceramic tiles, wood, synthetic material, glass and other, pre-assembled and then installed on site.[0131]
It also understood that there is no limitation of design, materials, sizes, details, fixing visible elements or anything that could be linked to the pre-assembled process. On the contrary, works can be done with “infinitive” details or design solutions, that traditional works on site would not allow.[0132]