U.S. patent application number 13/473519 was filed with the patent office on 2013-04-11 for bent metal panel prefabricated bathroom.
This patent application is currently assigned to XSite Modular. The applicant listed for this patent is Jonathan Clouser, Michael Hathaway. Invention is credited to Jonathan Clouser, Michael Hathaway.
Application Number | 20130086849 13/473519 |
Document ID | / |
Family ID | 48041154 |
Filed Date | 2013-04-11 |
United States Patent
Application |
20130086849 |
Kind Code |
A1 |
Clouser; Jonathan ; et
al. |
April 11, 2013 |
Bent Metal Panel Prefabricated Bathroom
Abstract
The disclosed technology relates to a modular structure having a
floor, a ceiling and at least four walls. The walls being
constructed from a plurality of bent metal panels. These bent metal
panels create a rigid and continuous substrate. The walls are also
pre-fabricated to incorporate embedded architectural and mechanical
design elements. During the main assembly phase the floor is
mounted to the walls, the sides of the walls are then mounted to
each other and the ceiling is then mounted to the walls thereby
forming a monolithic frame structure. This monolithic structure
enables a more efficient fabrication and assembly process.
Inventors: |
Clouser; Jonathan;
(Brooklyn, NY) ; Hathaway; Michael; (Eatontown,
NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Clouser; Jonathan
Hathaway; Michael |
Brooklyn
Eatontown |
NY
NJ |
US
US |
|
|
Assignee: |
XSite Modular
Clinton
NJ
|
Family ID: |
48041154 |
Appl. No.: |
13/473519 |
Filed: |
May 16, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61518993 |
May 16, 2011 |
|
|
|
Current U.S.
Class: |
52/79.9 ;
52/745.02; 52/79.1 |
Current CPC
Class: |
E04B 1/34869 20130101;
E04H 1/00 20130101 |
Class at
Publication: |
52/79.9 ;
52/79.1; 52/745.02 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A modular structure comprising: a floor; a ceiling; and at least
four walls, the walls being constructed from a plurality of bent
metal panels, the bent metal panels creating a rigid and continuous
substrate, the walls being pre-fabricated to incorporate embedded
architectural and mechanical design elements, wherein the floor is
mounted to the walls, the sides of the walls are mounted to each
other and the ceiling is mounted to the walls thereby forming a
monolithic frame structure, the monolithic structure enabling a
more efficient fabrication and assembly process.
2. The modular structure of claim 1 wherein the floor is a
honeycomb substrate.
3. The modular structure of claim 1 wherein the ceiling is
constructed from bent metal panels.
4. The modular structure of claim 3 wherein the bent metal panels
include tabs and flanges so that the panels may be connected to one
another, as needed.
5. The modular structure of claim 1 wherein the architectural and
mechanical design elements include at least one of notches,
spacing, gypsum boards and tiles.
6. The modular structure of claim 1 wherein the mounting is
performed by at least one of screws and adhesives.
7. The modular structure of claim 1 wherein the monolithic
structure aids in the reduction of punch list items typically
experienced during delivery and setting of the monolithic
structures.
8. The modular structure of claim 1 wherein, once the monolithic
structure is formed, bathroom fixtures, accessories, and finishes
are installed.
9. A prefabricated room module for use in the construction of a
modular building comprising: a floor having at least four edges; at
least four walls being mounted atop the edges of the floor, the
walls being constructed from a plurality of bent metal panels and
are pre-assembled with embedded architectural and mechanical design
elements, the walls having sides that are mounted to one another;
and a ceiling being mounted to a top section of the walls.
10. The modular structure of claim 1 wherein the floor is a
honeycomb substrate.
11. The modular structure of claim 1 wherein the ceiling is
constructed from bent metal panels.
12. The modular structure of claim 11 wherein the bent metal panels
include tabs and flanges so that the panels may be connected to one
another, as needed.
13. The modular structure of claim 1 wherein the architectural and
mechanical design elements include at one of notches, spacings,
gypsum boards, tiles.
14. The modular structure of claim 1 wherein the mounting is
performed by screws and/or adhesives.
15. The modular structure of claim 1 wherein the prefabricated room
module aids in the reduction of punch list items typically
experienced during delivery and setting of prefabricated room
module.
16. The modular structure of claim 1 wherein, once the
prefabricated room module is formed, bathroom fixtures,
accessories, and finishes are installed.
17. A modular structure made by the following process:
pre-assembling at least four walls and a ceiling structure, the
walls and ceiling being constructed from a plurality of bent metal
panels creating a rigid structure and continuous substrate and
including embedded architectural and mechanical design elements;
mounting the at least four walls to a substrate; attaching sides of
the walls to one another; and mounting the ceiling structure on top
sections of the walls.
18. The modular structure of claim 17 wherein the bent metal panels
include tabs and flanges so that the panels may be connected to one
another, as needed.
19. The modular structure of claim 17 wherein the monolithic
structure aids in the reduction of punch list items typically
experienced during delivery and setting of modular structure.
20. The modular structure of claim 1 wherein, once the modular
structure is formed, bathroom fixtures, accessories, and finishes
are installed.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/518,993 filed May 16, 2011, hereby incorporated
by reference.
BACKGROUND
[0002] Prefabricated modular bathrooms are structures that are
completely built in factory conditions. One common type of modular
bathroom comprises a wood frame mounted on a structural floor of
plywood. This structural arrangement provides high strength and
rigidity for the transport and final placement but the structure is
very heavy and prone to damage during shipping and placement.
[0003] Another type of prefabricated bathroom is manufactured for
the noncombustible market. Typically, these structures are
constructed using conventional metal stud framing, metal blocking
for the support of fixtures and accessories, and metal bridging,
cross bracing and/or shear sheathing. These components are required
to keep the prefabricated unit rigid and counteract the stresses
experienced by bathroom during the delivery and setting
process.
[0004] The typical manufacture process of these prefabricated
bathrooms comprises a main production assembly line where the
bathrooms are assembled from smaller subassemblies such as floors,
walls, and ceiling panels. Individual floor, wall, and ceiling
panels are fabricated elsewhere in the production facility offline
of the main assembly line and delivered and to the main assembly
line for incorporation into the manufactured bathroom unit. The
wall and ceiling panels comprise conventional metal studs that
typically include multiple pieces of stud and track and require
precise assembly jigs.
[0005] The typical small footprints of these bathrooms typically
have framed corners that are in close proximity to each other and
require additional stud placement for corner reinforcing. Nailers
are also typically used and add to the complexity of the
coordination of mechanical infrastructure occupying and passing
through this same geometry. Also, additional cross bracing and/or
corner bracing typically is required for door openings. Arrangement
of this cross bracing is often limited based on the arrangement of
fixtures.
[0006] These modular bathrooms are more lightweight and less prone
to damage during shipment then the wood frame design but the
offsite manufacturing process is long. Mostly due to the frame
design but also because manufacturers want to completely furnish
the pod with all contents such as fixtures and finishes at the
off-site manufacturing plant so that a builder may simply insert
the pod into position and connect to building services. That is,
once the prefabricated shell is completed, the bathroom is
outfitted with plumbing and electrical systems, tiled, bathroom
accessories are installed and then the final testing, cleaning and
quality control is performed. The process as a whole is time
consuming.
SUMMARY OF THE DISCLOSED TECHNOLOGY
[0007] The disclosed technology relates to a method of assembling a
modular bathroom in less time.
[0008] A prefabricated bathroom of the disclosed technology
comprises a bent metal panel framing wall and ceiling system that
solves many problems associated with the design, fabrication,
delivery, setting, field completion, and finishes punch list of a
prefabricated bathroom. The disclosed prefabricated bathroom is a
monolithic structural frame system that includes individually
designed and fabricated bent metal panels incorporating all
embedded architectural and mechanical design elements. The frame
system enables a more efficient fabrication and assembly process of
a prefabricated bathroom by using a bent metal panel system that
creates a rigid structure and continuous substrate for the
installation of bathroom fixtures, accessories, and finishes. The
bent metal panel assemblies by their nature also aid in the
reduction of finish punch list items typically experienced during
delivery and setting of prefabricated bathrooms comprised of
conventional metal stud framing.
[0009] In one embodiment, a modular structure comprises a floor, a
ceiling and at least four walls. The floor may be a honeycomb
substrate and the walls and ceiling may be constructed from a
plurality of bent metal panels. These bent metal panels may include
tabs and flanges so that the panels may be connected to one
another, as needed thereby creating a rigid and continuous
substrate. The walls may also be prefabricated to incorporate
embedded architectural and mechanical design elements, e.g,
punch-outs, notches, spacing, gypsum boards and tiles.
[0010] During the main assembly phase, the floor is mounted to the
walls with screws and/or adhesives, the sides of the walls are
mounted to each other with screws and/or adhesives and the ceiling
is mounted to the walls with screws and/or adhesives thereby
forming a monolithic frame structure. Once the monolithic structure
is formed, bathroom fixtures, accessories, and finishes are
installed. This monolithic structure enables a more efficient
fabrication and main assembly process. The monolithic structure
also aids in the reduction of punch list items typically
experienced during delivery and setting of the monolithic
structures.
[0011] In another embodiment, a prefabricated room module for use
in the construction of a modular building comprises a floor having
at least four edges, at least four walls being mounted atop the
edges of the floor, and a ceiling being mounted to a top section of
the walls. The floor may be a honeycomb substrate and the walls and
ceiling may be constructed from a plurality of bent metal panels.
These bent metal panels may include tabs and flanges so that the
panels may be connected to one another, as needed thereby creating
a rigid and continuous substrate. The walls may also be
pre-fabricated to incorporate embedded architectural and mechanical
design elements, e.g, punch-outs, notches, spacing, gypsum boards
and tiles.
[0012] During the main assembly phase, the floor is mounted to the
walls with screws and/or adhesives, the sides of the walls are
mounted to each other with screws and/or adhesives and the ceiling
is mounted to the walls with screws and/or adhesives thereby
forming a monolithic frame structure. Once the prefabricated room
module is formed, bathroom fixtures, accessories, and finishes are
installed. This prefabricated room module enables a more efficient
fabrication and main assembly process. The prefabricated room
module aids in the reduction of punch list items typically
experienced during delivery and setting of the modules.
[0013] In another embodiment, a modular structure may be made by
the following process. At least four walls and a ceiling structure
are pre-assembled. The walls and ceiling may be constructed from a
plurality of bent metal panels that include tabs and flanges so
that the panels may be connected to one another, as needed. This
creates a rigid structure and continuous substrate and may include
embedded architectural and mechanical design elements. The walls
are then mounted to a substrate and the sides of the walls are
adhered to one another. A ceiling structure is then mounted on top
sections of the walls. Once the modular structure is formed,
bathroom fixtures, accessories, and finishes may be installed. This
modular structure aids in the reduction of punch list items
typically experienced during delivery and setting of modular
structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a prospective view of a modular bathroom in
accordance with the disclosed technology;
[0015] FIG. 2 is a top view of a floor of a modular bathroom used
in accordance with the disclosed technology;
[0016] FIG. 3 is a top view of a panel framing plan in accordance
with the disclosed technology;
[0017] FIGS. 4a-f are side views of a wall panels of a modular
bathroom used in accordance with the disclosed technology;
[0018] FIG. 5 is a top view of a ceiling of a modular bathroom used
in accordance with the disclosed technology;
[0019] FIGS. 6a-d are fire rating detail used in accordance with
the disclosed technology;
[0020] FIGS. 7a-c are plumbing details of a modular bathroom used
in accordance with the disclosed technology;
[0021] FIG. 8 are electrical details of a modular bathroom used in
accordance with the disclosed technology;
[0022] FIG. 9 is a top view of a floor plan for a modular bathroom
used in accordance with the disclosed technology;
[0023] FIGS. 10a-d are side views of elevation heights for modular
bathroom used in accordance with the disclosed technology; and
[0024] FIG. 11 shows a side view of an entry threshold used in
accordance with the disclosed technology.
DETAILED DESCRIPTION
[0025] FIG. 1 shows a modular bathroom structure 1. The disclosed
embodiment consists of six panel walls 3-8, a ceiling 9 and a floor
2. Please note that the modular structure may come in many
different shapes, sizes and uses, e.g., kitchens, garages, etc.
[0026] The bathroom structure 1 is prefabricated in a factory and
then installed on site. These structures 1 may be used in
conjunction with any modular or pre-existing structures, e.g.,
houses, high-rise buildings, hospital, dorms, etc. In this
embodiment, manufacturers may completely furnish the structure 1
with all contents, such as, fixtures and finishes at the off-site
manufacturing plant as shown in FIGS. 8, 9 and 10a-d. A builder
then simply inserts the structure 1 in position at site and
connects to the building services.
[0027] FIG. 2 shows a floor 2 of the bathroom pod. The floor 2 may
be a honeycomb floor substrate of 1/4''-3'' preferably 3/4''.
Honeycomb floor substrates are lightweight and have a high
strength. The substrate 2 has excellent stiffness and deflection
properties. These substrates can withstand extreme moisture and
humidity. When used as a bathroom floor, they are durable and will
not rot due to wetness. These floors also make the pods lightweight
so they are easier to transport and install. The floors are strong
enough to support the weight of the bathroom components during
shipping and installation while also having a thickness that is
approximately the same height as an adjacent floor, e.g., a wood
floor. A saddle 12 may be used for the transition as shown in FIG.
1.
[0028] As shown in FIG. 3, the floor 2 may be marked with a panel
wall framing plan. In the disclosed embodiment, six panel walls 3-8
are used to construct the structure 1 but the invention is not
limited to this layout. The panel walls 3-8 are constructed during
a pre-assembly process as will be discussed more fully below. These
panel walls 3-8 solve many problems associated with the design,
fabrication, delivery, setting, field completion, and finishes
punch list of a existing prefabricated bathrooms because the panel
walls 3-8 comprise individually designed and fabricated bent metal
panels incorporating all embedded architectural and mechanical
design elements which enables a more efficient fabrication and
assembly process of a prefabricated bathrooms.
[0029] The bent metal panel system creates a rigid structure and
continuous substrate for the installation of bathroom fixtures,
accessories, and finishes. The bent metal panel assemblies also by
their nature also aid in the reduction of finish punch list items
typically experienced during delivery and setting of prefabricated
bathrooms comprised of conventional metal stud framing. (In the
U.S. construction industry, a punch list is the name of a contract
document used in the architecture and building trades to organize
the completion of a construction project. Examples of punch list
items include damaged building components (e.g. repair broken
window or appliances, replace stained wallboard, repair cracked
paving, etc.), or problems with the final installation of building
materials or equipment (e.g., reinstall broken tiles, reinstall
peeling carpet, replace missing roof shingles, fire and pressure
test boiler, obtain elevator use permit, activate security system,
etc.).)
[0030] The panel walls 3-8 may be constructed using any number of
metal panels. The metal panels may be eighteen-gauge, galvanized
metal panels but other types of material and gauges of metal may be
used. The individual panels vary in width but typically are 16''.
The panel walls 3-8 are made in a pre-manufacturing process where
multiple individual panels are pieced together using a bent metal
panel design 13a-d and 14a-c shown in FIG. 1. That is, in a bent
metal panel design, each panel includes a bent tab and a bent tab
with flange. In use, panels are connected to one another by
marrying the bent tab to the bent tab with flange from an adjacent
panel. Other attachment methods are contemplated.
[0031] Incorporation of a bent metal panel system over conventional
metal stud framing has the following benefits:
[0032] 1. Integration of imbedded architectural and mechanical
infrastructure in the individual panel walls 3-8 and ceiling 9
provides a more consistent and quality product.
[0033] 2. Elimination of multiple studs, track, blocking, and cross
bracing and corner bracing simplifies production and increases
output of sub-assembled panel wall 3-8 and ceiling 9.
[0034] 3. Elimination of additional reinforcing and corner bracing
on the assembly line increases output of the assembled bathrooms
1.
[0035] 4. Bent panel technology creates a rigid and continuous
substrate for the installation of bathroom fixtures, accessories,
and finishes thus eliminating the need for additional metal
blocking, cross bracing and corner bracing.
[0036] 5. Reduce delivery related punch list issues by creating a
more rigid structure to counteract the stresses experienced by
bathroom 1 during the delivery and setting process.
[0037] Each wall panel 3-8 is constructed as needed as shown in
FIGS. 4a-f. For example, in the disclosed embodiment, (1) panel
wall 2 includes bent panels 41a-d, a door frame section 42 and a
punched-out electric outlet and switch section 43. (2) panel wall 4
includes five bent panels 44a-f, (3) panel wall 5 includes bent
panels 45a-e, punch-outs for the sink, toilet and electrical
components 46, 47, 49 and 50 and a framing member for a medicine
cabinet 48, (4) panel wall 6 is a single bent panel 51 that
includes a wall notch for an adjacent panel wall 5 and punch-outs
for plumbing and electrical components 53-56, (5) panel wall 7
includes bent panels 57a-b and punch-outs for bathtub and shower
components 58-62, and (6) panel wall 8 has bent panels 65a-d.
[0038] Once the panel walls 3-8 are constructed, the panel walls
3-8 may be finished as much as possible during the pre-assembly
phase. For example, the panel walls 3-8 may be embedded with
architectural and mechanical design elements, e.g., gypsum boards
to cover the skin of the wall panel 3-8 and tiles may be attached
to the gypsum board as needed. It is important to note that each
step performed in the pre-assembly phase streamlines the assembly
process by allowing each 3-D structure to be built within a minimal
time requirement.
[0039] FIG. 5 shows a ceiling 9 for the bathroom pod 1. The ceiling
9 is also made with a galvanized bent panels 70a-e and outer frame
channels 73. The outer frame channels 73 are used for attaching the
ceiling 9 to the top portions of the wall panels 308. The ceiling 9
may also include a ceiling fan 72.
[0040] During a main assembly process, the wall panels 3-8 may be
attached atop the floor 2 using any adherence methods, e.g.,
adhesive glue or screws. The panel walls 3-8 are then adhered to
each other at the ends and the ceiling 9 is set on top of the panel
walls and secured into place. Each of the components are adhered to
each other by screws or adhesives or both. This design does not
need any traditional framing such as stud or bracing which allows
the 3-D structure to be built quickly and efficiently. The metal
panels also allow the exterior of the pod to withstand more impact
with considerable less damage potential.
[0041] FIGS. 6a-d show the fire rating plan for the bathroom pod.
The perimeter of the ceiling may have a fire stop of gypsum board,
steel studs, and fire caulking 80-91.
[0042] FIGS. 7a-c show the plumbing design for the bathroom pod.
The plumbing may also be assembled during a pre-assembly phase.
That is, vents, vent outlets, water supplies, waste pipes, water
spouts and shower heads 90-106 may be partially or fully assembled
according to the design and installed as a single unitary piece
during the main assembly phase.
[0043] FIG. 8 shows a wiring diagram for the electric of the
bathroom pod. The bathroom 1, during the main assembly phase, may
be equipped with lighting components, GFCI circuits and electrical
plugs 110,113.
[0044] FIGS. 9 and 10a-d shows floor plan and elevation heights for
the final assembly phase. In a final assembly phase, the bathroom
may be equipped with the toilet, sink, tub, doors, towel racks,
toilet paper holders, soap dishes, hooks, vanities 200-213 and any
other functional or aesthetic piece needed. In this phase, all
edges are caulked and sanded. This phase begins after the pod in
assembled into a 3-D box.
[0045] FIG. 11 shows the entry threshold of the bathroom door using
gypsum leveling compound 90, 92, floor 2, crack suppressant and
grout layer 88, hardwood flooring 91 and saddle 12.
[0046] The foregoing Detailed Description is to be understood as
being in every respect illustrative and exemplary, but not
restrictive, and the scope of the invention disclosed herein is not
to be determined from the Detailed Description, but rather from the
claims as interpreted according to the full breadth permitted by
the patent laws. It is to be understood that the embodiments shown
and described herein are only illustrative of the principles of the
present invention and that various modifications may be implemented
by those skilled in the art without departing from the scope and
spirit of the invention. Those skilled in the art could implement
various other feature combinations without departing from the scope
and spirit of the invention.
* * * * *