Abstract:
Structure of bathroom for installation in a room intended for use as a bathroom including a multiplicity of covering panels ( 1, 2, 3 ) produced to measure for the continuous lining of at least a part of the walls and the floor of the room to be installed and a multiplicity of sanitary components or modules ( 4, 5, 6, 7 ) each predisposed with its own support structure and with its own tubes ( 41, 51, 61, 71 ) ready to be interconnected reciprocally and to be connected to hydraulic conducts of the room to be installed ( 100, 101 ) in such a way as to complete the hydraulic circuit of the bathroom; floor, ceiling and wall structures for a pre-assembled bathroom; method for installing a floor structure for pre-assembled bathroom and a method for the production and installation in a room of a complete pre-assembled bathroom including the phases of: produce panels of covering, factory produced to measure for the walls of the room; produce the self-bearing sanitary components provided with tubes and joints predisposed to be reciprocally connected and then connected up to the tubes of the room; installation of said panels and of said components without mural intervention or traditional constructions.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention regards the sector of construction and installation of bathrooms for hotel structures, for domestic use or offices.  
           [0002]    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.  
           [0003]    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 . . . .  
           [0004]    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.  
           [0005]    Further, the need to co-ordinate different staff and timing, results not always in a satisfactory quality of finish, considering the cost sustained.  
         AIM OF THE INVENTION  
         [0006]    The 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.  
           [0007]    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.  
           [0008]    In particular bathroom structures made of high value materials like marble and natural stones are considered.  
           [0009]    A third aim is to permit a savings in the cost of installation because of a better management of the costs.  
         SUMMARY OF THE INVENTION  
         [0010]    These 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.  
           [0011]    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.  
           [0012]    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.  
           [0013]    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.  
           [0014]    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.  
           [0015]    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  
           [0016]    In more detail:  
           [0017]    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.  
           [0018]    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.  
           [0019]    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.  
           [0020]    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.  
           [0021]    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.  
           [0022]    A third advantage consists in the elevated finish achieved of the coverings.  
           [0023]    A fourth advantage consists in the substantial lack of visible joints.  
           [0024]    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.  
           [0025]    A sixth advantage consists in the possibility to assemble very regular and continues flat surfaces, with minimum maintenance and cleaning problems.  
           [0026]    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.  
           [0027]    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.  
           [0028]    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.  
           [0029]    Mainly the external corners in the present invention are pre-built in the factory, allowing perfect matching.  
           [0030]    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. 
       
    
    
     LIST OF THE DRAWINGS  
       [0031]    These and further advantages will be comprehended by the following drawings, given as an non limiting example, in which:  
         [0032]    [0032]FIG. 1 shows a top exploded view of a bathroom according to the invention;  
         [0033]    [0033]FIG. 2 shows a top view of the bathroom of FIG. 1 with installation completed;  
         [0034]    [0034]FIG. 3 shows the standard components of a bathroom according to the invention with the relative predisposed tubes for the installation;  
         [0035]    FIGS.  4  to  7  show a top view of the single components of FIG. 3;  
         [0036]    [0036]FIG. 8, shows schematically a top view of a bathroom structure according to the invention;  
         [0037]    [0037]FIGS. 8 a - 8   m  show the installation sequence from step  1  to  22  of the wall panels and of the other components of the bathroom structure of FIG. 8;  
         [0038]    [0038]FIG. 9 shows the detail of a first embodiment according to the invention of adjustable means of fixture of the wall panels;  
         [0039]    [0039]FIGS. 9 a - 9   b  respectively show a section and a front view of a second embodiment according to the invention of adjustable means of fixture of the wall panels;  
         [0040]    [0040]FIGS. 10, 10 a  and  10   b  respectively show a section view, a detail of the same section view and a top view of a floor structure according to the invention;  
         [0041]    [0041]FIG. 10 c  shows a further embodiment of a floor structure according to the invention;  
         [0042]    [0042]FIGS. 10 d  and  10   e  shows a still further embodiment of a floor structure according to the invention;  
         [0043]    [0043]FIG. 11 schematically show the reciprocal position of wall panels installed according to the method of the invention;  
         [0044]    [0044]FIG. 12 shows a prefabricated wall structure provided with telescopic bars “T” according to the invention;  
         [0045]    [0045]FIG. 13 shows a ceiling structure according to the invention;  
         [0046]    [0046]FIGS. 14 a  and  14   b  show pre-assembled walls of FIG. 12, respectively before and after installation.  
         [0047]    [0047]FIG. 15 shows a W.C cistern unit according to the invention, with covering panels removable for inspection;  
         [0048]    [0048]FIG. 16 schematically shows wall panels of the invention with having connection means. 
     
    
     DETAILED DESCRIPTION  
       [0049]    With reference to the attached drawings of FIGS.  1  to  7 , a pre-assembled bathroom according to the invention includes: a multiplicity of panels of covering to measure, among which wall panels  1 , floor panels  2  and, in the event that a ceiling be required (for example, in the bathrooms of a hotel structure) ceiling panels  3 ; and a multiplicity of accessories among which a vanity unit  4 , a bath tub  5  with a complex of water taps  6 , a cistern for WC  7 .  
         [0050]    With reference in particular to FIG. 2 the covering wall panels may be reciprocally connected in a traditional way or using connection plates  9  in such a way that the plates enter and are hidden behind the adjacent panel. (FIG. 16) Advantageously the plates  9  of adjacent panels are in alternate position so as not to interfere with each other.  
         [0051]    During the assembly, the plates integral with a panel are fixed to the wall with normal screws, while the plates  9  of the adjacent panel may be inserted between the panel and wall and so remain blocked.  
         [0052]    In the case of corner panels  1 , the plates of one of two adjacent panels can be “L” shaped in such a way that the plates  9  of the second panel are inserted and are hidden between the side surfaces of the first and the wall.  
         [0053]    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.  
         [0054]    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 vanity unit  4 ′ in FIGS. 8 and 8 a - 8   m  can be considered.  
         [0055]    In that case the width of  4 ′ is bigger then the space available between the lateral panels marked R 10  and R 11 —FIG. 8I, sequence step  20 .  
         [0056]    It is possible, thanks to the invention, to displace panel R 11  so that the latter is translated of the needed distance along the wall panel R 12  in the direction of the arrows. As an alternative, the complex made of panels R 11  and R 12  could also be rigidly displaced so that R 12  slides behind R 13 .  
         [0057]    Then (FIG. 8 m —sequence  21 ) unit  4 ′ can be inserted after that R 11  and R 12  can be translated to contact with the unit (sequence  22 ).  
         [0058]    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.  
         [0059]    According to a further aspect of the invention a floor structure is described.  
         [0060]    In a first preferred technical solution and with particular reference to the FIG. 10 c , the panels  2  may be provided with self-bearing adjustable supports. The supports are formed by plates  28  supplied with screws for regulation  29  agents on the floor  50  pre-existent, to be adjusted according to the required level of the support of the panels  2 .  
         [0061]    During installation, a side of the first panel  2  is placed on a fixed match R and supplied along the other side with two or more plates  28  fixed with normal screws  27 . Through the plate  28  a pressure screw  29  is screwed down which may be adjusted according to the level required. The second panel  2  is then placed with a side on the plate  28  (if necessary cavities  200  may be foreseen to house the screw head  29 ) and placed with the other on a following plate  28 , until the covering is completed.  
         [0062]    According to a second preferred technical solution of the invention, and with particular reference to the FIGS. 10, 10 a ,  10   b , the floor panels  2  of the invention may be provided with self-bearing adjustable supports. The supports are formed by plates  280  which can rotate on the horizontal plane being pivotally fixed to the floor  50  by a vertical pin  200 . Plates  280  are supplied with supporting disks  201  integral with screws for regulation  290  and acting between the floor panels  2  and the pre-existent floor  50 , to be adjusted according to the required level of the support of the panels  2 .  
         [0063]    During installation, panels  2  are placed on a number of disks  201  preferably aligned in correspondence of the sides of adjacent panels so that each disk supports both the adjacent panels  2  in order to guarantee an uniform height of the panels above floor  50 .  
         [0064]    Possible positioning errors of disks  201  can be corrected by a rotation of plates  280  around the pin  200 .  
         [0065]    Alternatively, according to a third embodiment illustrated in FIGS. 10 d  and  10   e , the adjustable support for the panels  2  can consist of simple bolt  110  and nuts  111  that are positioned at the extreme of the marble—granite floor slab  2  and allow adjustment when a second slab should be installed.  
         [0066]    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.  
         [0067]    In all the above floor structures, is preferable that liquid grout is poured later on from below through a pouring channel  121 , till the gap  120  between panels  2  and floor  50  is completely filled.  
         [0068]    According to a still further aspect of the invention a method to install a floor structure, preferably by using panels  2 , comprises the following steps:  
         [0069]    a) fixing to floor  50  a plurality of adjustable supports preferably aligned along lines corresponding to the side of floor panels  2  to be posed;  
         [0070]    b) installation of a first panel  2 ;  
         [0071]    c) adjusting the level of the first panel acting on the regulating means of the supports of the panels;  
         [0072]    d) adjusting if needed the position of one or more supports;  
         [0073]    e) placing, possibly on the side aligned supports, floor panels adjacent to the already installed panel;  
         [0074]    f) pouring anti-retractable liquid cement into the gap between panels  2  and surfaces  50  underneath, in such as way as to prefect the regularity of the support.  
         [0075]    The mortar/cement may, for example, be poured from the side of the last panel posed  2  near to the room wall, or in large areas, be pumped.  
         [0076]    Alternatively, using the same system, grids (metallic or plastic) suitable as support for ceramic tiles may be applied instead of the panels  2 .  
         [0077]    Advantageously, and aside from the regularity of the surface  50 , 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.  
         [0078]    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.  
         [0079]    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.  
         [0080]    A still further advantage is that marble panels of any size can be installed by unskilled labour.  
         [0081]    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.  
         [0082]    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.  
         [0083]    In the case of the ceiling panels  3 , if ceiling be required, the installation can be carried out by installing the panels  3 , complete with eventual electrical works, on the side panels  1 .  
         [0084]    Advantageously, the dimensions of the panels  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.  
         [0085]    According to a further aspect of the invention, illustrated in the example of FIG. 13, a ceiling structure is described in the following.  
         [0086]    Ceiling panels  3  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.  
         [0087]    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  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 of studs  33  can then be placed on the wall panels  1  so that the panels  3  are self supporting instead of being hanged from the ceiling, as in the traditional decorative—low ceiling also called “hanged ceiling”.  
         [0088]    The above ceiling structure has the following advantages:  
         [0089]    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;  
         [0090]    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.  
         [0091]    According to a still further aspect of the invention, the installation of the panels  1  to the wall  40  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.  
         [0092]    In a first preferred example of realisation described in FIG. 9, these means consist in a first drilled plate  20  which may be fixed on the back of a panel  1  using common screw means  23 . At the centre of the plate  20  a drilled round  21  is foreseen, partially superimposed to the plate  20  in such a way as to leave between the panel I and round  21  a gap  22  in which a washer  26  internally threaded may be placed and may turn freely.  
         [0093]    A screw  24  may engage itself in the washer  26  and be activated by a screwdriver  25  passing through the corresponding hole  11  made in the panel  1 .  
         [0094]    Advantageously, the diameter of the hole  11  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 the panel  1  that can be fixed later on.  
         [0095]    The means of fixture include also a second plate  30  which may be fixed to the wall  40  using common screws  32  in correspondence to the plate  20 .  
         [0096]    The plate  30  consists in the centre of a threaded bolt  31  suitable to receive the screw  24 .  
         [0097]    During installation, the screw  11  is inserted for pre-determined length through the washer  26  and then inserted into the bolt  31 .  
         [0098]    Screwing down the screw  24  in the bolt  31 , the washer  26  turns in the gap  22  and is drawn to the wall  40  dragging the panel  1  the position of which in this way may be easily regulated.  
         [0099]    Advantageously, in correspondence to the bolt  31  a hole  41  may be made in the wall  40  in such a way as to leave room for the progress of the screw  24 . In FIGS. 9 a ,  9   b  a second preferred solution of adjustable fixture means of the lateral panels  1  is illustrated.  
         [0100]    In this case a first plate  20 ′ can be fixed (for example by glue or screw means) to the back face of a wall panel  1  sticking out the lateral side of the panel.  
         [0101]    A second plate  30 ′ is also provided which can be fixed to a room wall  40  by common screws  32 ′. The central portion of plate  30 ′ has a concave shape emerging from the wall  40  and which presents a transversal slot  24 ′.  
         [0102]    Plate  20 ′ presents passing holes  11 ′ and a transversal slot  56  having a countersunk hole.  
         [0103]    Holes  11 ′ respectively face in the use the screws  32 ′ of the second plate.  
         [0104]    A regulating screw  31 ′ can be inserted through the slot  56  of the plate  20 ′ and through the slot  24 ′ of the second plate  30 ′ to engage a regulating bolt  31 ′ made integral to plate  30 ′ by locking nut  54 . By rotating bolt  31 ′ it is thus possible to adjust the distance between the first and second plates  20 ′,  30 ′.  
         [0105]    Further locking nut  57  and  58  can also be provided in order to keep the desired distance between the plates.  
         [0106]    In the installation, a wall panel  1  is provided with one or more plate  20 ′.  
         [0107]    Through the holes  11 ′ can be operated screws  24 ′ to fix the second plate  30 ′ to the wall  40  in the correct position.  
         [0108]    After that the regulating bolt  31 ′ is placed and the distance between plates  20 ′ and  30 ′ is adjusted as well as the lateral position can be adjusted thanks to the elongated shape of slot  24 ′.  
         [0109]    With reference now to FIGS. 8, 8 a - 8   m , and FIG. 16, once a first panel  1  is fixed to the wall  40 , a second adjacent panel can be applied over the plate  20 ′ so that the latter is hidden from sight.  
         [0110]    Preferably, that second panel is provided with one or more lateral plates  9  capable of being inserted between the hidden face of the first panel and the wall  40 .  
         [0111]    Usually, three plates will be prefixed to the panel on one side, while the other side will have two flat plates  9  to be inserted between the three plates of the previous panel. The first panel will have of course fixing adjustable plates on both sides.  
         [0112]    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.  
         [0113]    [0113]FIGS. 8 a - 8   d  show the installation of lateral panels  1  identified with progressive reference number R 01 -R 16 .  
         [0114]    [0114]FIG. 8 shows a bathroom completely covered by lateral panels  1  marked with correspondent progressive reference numbers R 01 -R 16 .  
         [0115]    Advantageously, with this solution the fixtures means are completely hidden from sight and at the same time panels  1  are easy to be remove for inspection or to be substituted.  
         [0116]    With reference to the FIGS.  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.  
         [0117]    In the example described, the wash basin  4  is provided with tubes  41  with terminal joints  42  corresponding to the hot and cold water circuit and to the waste conduct.  
         [0118]    In the same way, the bath tub  5  with the water tap complex for shower  6  and the cistern  7  of the WC are provided with corresponding tubes  51 ,  61 , and  71  and terminal joints  52 ,  62  and  72 .  
         [0119]    During installation, the tubes  61  of the complex  6  are connected to the hot and cold water columns  100  existent in the room and, by the joints  62 , to the corresponding joints  72  and  52  of the cistern  7  and the bath tub  5 .  
         [0120]    In turn, the tubes  51  of the bath tub  5  are connected to the corresponding tubes  41  of the wash basin  4  and to the waste conduct  101  and the tubes  71  of the cistern  7  are connected to a WC (not shown in the Figure) of the known type.  
         [0121]    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.  
         [0122]    According to a further characteristic of the invention, the tubes of all of the components  4 - 7  are easily inspected. For example, in the case of the bath tub  5 , the W.C unit  7  and of the water tap complex  6  this is possible by simply removing one or more cover panels  53 ,  63  suitably predisposed.  
         [0123]    During the installation, the operator proceeds as described assembling the panels  1 - 3  already made to measure.  
         [0124]    The assembly may be carried out on a previous covering as well as directly to the wall, after which the components  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.  
         [0125]    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 holes  11 . 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.  
         [0126]    According to a further aspect of the invention, illustrated in FIG. 12 pre-assembled bathroom walls  300  can be provided when the distance from an existing wall has to be created.  
         [0127]    In that case a metal structure  301  is prepared behind panels  1 , possibly provided with telescopic bars “T” to adjust the distance.  
         [0128]    When there is no wall (FIGS. 14 a ,  14   b ) 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.  
         [0129]    This wall or section of walls can be adjusted in position and then mechanically connected between themselves, creating a complete bathroom.  
         [0130]    One or more of the walls will possibly include a prefixed door and door frame.  
         [0131]    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.  
         [0132]    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.