Integral toilet module

Abstract

The embodiment of the invention provides an integral toilet module which is mainly composed of a concrete chassis, a structural framework, a built-in system and an electromechanical system which are integrally formed in a pouring mode and can be matched with a steel structure fabricated building. The chassis is prefabricated by concrete and is integrally sealed and waterproof. And the structural framework is fixed on the chassis and is provided with the light enclosure wallboards, so that the overall weight of the module is effectively reduced, the transportation and construction cost is reduced, and the assembly efficiency is improved. The enclosure wallboards can be made of light materials such as foaming ceramics and have the properties of heat preservation, heat insulation, fire prevention, water prevention and the like. According to the module, pre-integration of all structures, built-in systems and electromechanical systems is completed in a factory, the module can be used only by being hoisted in place and connected with a main body structure on site, and rapid, efficient and reliable assembly type construction is achieved.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, and in particular to a modular bathroom. Background Technology

[0002] Prefabricated modular bathrooms, due to their significant advantages in construction speed, energy conservation and environmental protection, cost-effectiveness, functional integration, space utilization, and health and safety, have become one of the components that best exemplify the advantages of prefabricated construction. A prefabricated modular bathroom consists of a waterproof tray, wall panels, ceiling panels, and supporting joists as the main frame, combined with various sanitary ware and functional accessories, and is assembled as a whole on-site through hoisting.

[0003] The patent, with publication number CN 119571929 A and application date of December 17, 2024, is entitled "A Prefabricated Concrete Integrated Toilet and Its Production and Construction Method." This patent discloses an integrated toilet, mainly constructed by concrete pouring. Due to its overall prefabrication, it can improve construction efficiency to a certain extent. However, because it is made of concrete, the self-weight of each unit is relatively large, which not only increases transportation costs but also places higher demands on the selection of hoisting machinery at the construction site. Furthermore, the inherent weight characteristics of concrete material are fundamentally in conflict with the lightweight goal pursued by prefabricated buildings. Summary of the Invention

[0004] This invention provides an integrated bathroom module, which aims to solve the problem that existing integrated bathrooms are made of concrete, resulting in excessive weight of each unit, increasing transportation and construction costs, and failing to meet the lightweight goal pursued by prefabricated buildings.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This invention provides an integrated bathroom module, comprising: an integrally cast chassis, a structural frame, an interior system, and an electromechanical system, wherein the bottom of the structural frame is fixed to the chassis; and an enclosure wall panel is provided on the structural frame.

[0007] In one embodiment, the enclosure wall panel is made of foamed material.

[0008] In one embodiment, the foaming material is a foamed ceramic board.

[0009] In one embodiment, a support portion is provided on the outer side of the chassis; the support portion is used to support the crossbeam.

[0010] In one embodiment, the support portion includes a support sidewall formed by the inward contraction of the outer sidewall of the chassis and a support top wall connected to the top of the support sidewall, wherein the support top wall is horizontally arranged.

[0011] In one embodiment, the edge of the chassis is provided with an upwardly protruding water-retaining sidewall, and a number of lifting lugs are pre-embedded around the periphery of the water-retaining sidewall.

[0012] In one embodiment, the outer wall of the chassis is provided with a plurality of outwardly protruding reserved steel bars, which are used to connect and pour with the main concrete floor slab.

[0013] In one embodiment, the bottom of the structural frame is fixedly connected to the chassis via a pre-embedded connector.

[0014] In one embodiment, the pre-embedded connector includes a connecting plate and a plurality of connecting posts fixedly disposed on one end face of the connecting plate, wherein the end of the connecting post away from the connecting plate is provided with a connecting hook; the connecting post and the connecting hook are pre-embedded in the chassis; the side of the connecting plate away from the connecting post is fixedly connected to the structural frame.

[0015] In one embodiment, the interior system includes a decoration system, and the electromechanical system includes a water system, an electrical system, and a heating, ventilation, and air conditioning (HVAC) system.

[0016] The beneficial effects of this invention compared to existing technologies are as follows: The integrated bathroom module provided in this application has a precast concrete chassis, integrally cast to form a sealed and waterproof overall structure with excellent waterproofing performance. The structural frame combined with the wall panels avoids the need for the entire bathroom module to be cast in concrete. Compared to bathroom modules entirely made of concrete, this reduces the weight of the overall bathroom module, thereby reducing transportation and construction costs and improving assembly efficiency. Furthermore, the wall panels can be made of lightweight materials, further reducing the overall weight of individual units and facilitating subsequent assembly.

[0017] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention, it can be implemented according to the contents of the specification. In order to make the above and other objects, features and advantages of the present invention more obvious and understandable, preferred embodiments are described in detail below. Attached Figure Description

[0018] Figure 1 A three-dimensional structural diagram of an integrated bathroom module provided in an embodiment of the present invention;

[0019] Figure 2 A cross-sectional view along the horizontal direction of the chassis of an integrated bathroom module provided in an embodiment of the present invention;

[0020] Figure 3 for Figure 2 A cross-sectional view along the AA direction;

[0021] Figure 4 for Figure 2 Cross-sectional view along the BB direction;

[0022] Figure 5 for Figure 4 A magnified view of a portion of region I;

[0023] Figure 6 for Figure 2 A cross-sectional view along the CC direction.

[0024] Figure label:

[0025] 1. Chassis; 11. Water-retaining sidewall; 12. Supporting part; 121. Supporting sidewall; 122. Supporting top wall;

[0026] 2. Structural framework; 21. Frame vertical members; 22. Frame horizontal beams;

[0027] 3. Lifting lugs;

[0028] 4. Reserve steel reinforcement;

[0029] 5. Embedded connectors; 51. Connecting plate; 52. Connecting column; 53. Connecting hook;

[0030] 6. Crossbeam, 61. Steel structure crossbeam. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0033] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0034] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0035] Please see Figure 1-6 This invention provides an integrated bathroom module, comprising: an integrally cast chassis 1, a structural frame 2, an interior system, and an electromechanical system. The bottom of the structural frame 2 is fixed to the chassis 1. Enclosure wall panels are provided on the structural frame 2.

[0036] This application provides a modular bathroom unit, with a precast concrete chassis 1 formed by integral casting to create a single, integrated structure. Because the concrete is vibrated sufficiently during precasting, reducing air pockets within the concrete, the chassis 1 forms a sealed, waterproof structure with excellent waterproofing properties. In this embodiment, the chassis 1 is cast in one piece using C30 concrete, which is characterized by high compressive strength, durability, and stability.

[0037] The structural frame 2, combined with the enclosing wall panels, avoids the entire bathroom module being constructed from cast concrete. Compared to a fully concrete-cast bathroom module, this reduces the overall weight of the bathroom module, thereby reducing transportation and construction costs and improving assembly efficiency. Furthermore, the enclosing wall panels can be made of lightweight materials, further reducing the overall weight of the bathroom module and facilitating subsequent assembly.

[0038] It is important to note that the chassis 1 in this application serves as both the sunken area of ​​the bathroom and a conventional floor slab. In other words, this application differs from existing integrated bathroom technologies, which require placement on a floor slab, resulting in a two-layer structure consisting of the bathroom floor and the floor slab. In this integrated bathroom module, the chassis 1 simultaneously functions as both the bathroom sunken area and the floor slab; essentially, the chassis 1 is both the floor slab and the bathroom sunken area. Therefore, the integrated bathroom module in this application is more suitable for steel-structure prefabricated buildings, as it can be directly hoisted onto the steel structural beams of the main structure.

[0039] It should also be noted that the enclosure wall panels in this application are wall panels of the main building structure. During installation, there is no need to add additional main walls, thus saving the later manufacturing of main walls and not taking up extra space.

[0040] In a further embodiment, the enclosure wall panel is made of foamed material.

[0041] Foamed materials are lightweight, reducing the overall structural weight. They also possess excellent thermal insulation properties, blocking external heat in summer and maintaining indoor temperature in winter, significantly reducing energy consumption for air conditioning and heating, resulting in outstanding energy savings and meeting green building standards. Furthermore, this embodiment uses flame-retardant foamed materials, characterized by high fire resistance, non-combustibility upon contact with fire, and no release of toxic fumes, ensuring extremely high fire safety. They are also waterproof and moisture-proof, preventing deformation or strength reduction due to moisture absorption.

[0042] In a further embodiment, the lightweight foamed material is a foamed ceramic board.

[0043] Foamed ceramic panels, used as bathroom wall panels, offer unparalleled advantages in sound insulation, waterproofing, tile adhesion, and fire resistance. They effectively address two major pain points in bathroom renovation: waterproofing and tile detachment. The resulting savings in structural, labor, and time costs, along with long-term reliability and maintenance-free operation, make them a highly cost-effective solution.

[0044] In one embodiment, such as Figure 1 As shown, the structural frame 2 includes several vertically arranged frame rods 21 and frame beams 22 fixedly connected to the tops of the frame rods 21. In this application, both the frame rods 21 and the frame beams 22 are hollow, which further reduces the weight of the overall bathroom module without affecting the overall strength.

[0045] In one embodiment, such as Figure 1 As shown, the edge of the chassis 1 is provided with an upwardly protruding water-retaining sidewall 11, and several lifting lugs 3 are pre-embedded around the periphery of the water-retaining sidewall 11.

[0046] The upward-protruding water-retaining sidewall 11 can erect a waterproof barrier at the edge of the chassis 1, thereby effectively preventing water leakage when using the bathroom. In conjunction with the waterproof coating and waterproof layer on the inner surface of the chassis 1, a better waterproof effect can be achieved.

[0047] In addition, this application provides lifting lugs 3 on the outer perimeter of the water-retaining sidewall 11. During the hoisting process, the chassis 1 serves as the load-bearing part, thereby ensuring the stability of the hoisting and the convenience of installation.

[0048] In one embodiment, such as Figure 2 As shown, the outer wall of the chassis 1 is provided with several outwardly protruding reserved steel bars 4, which are used to connect and pour with the main concrete floor slab.

[0049] To improve the stability of the connection between the prefabricated bathroom module and the main concrete floor slab during casting, several pre-reserved reinforcing bars 4 are installed on the outer wall of the base 1. Some of these reinforcing bars 4 are pre-embedded in the base 1 during the one-time casting process, and are firmly fixed to it. Additionally, during the connection casting of the prefabricated bathroom module and the main concrete floor slab, the lifting lugs 3 can also be connected to the main concrete floor slab, further enhancing the connection strength between the prefabricated bathroom module and the main concrete floor slab.

[0050] In one embodiment, such as Figure 2 and Figure 6 As shown, the bottom of the structural frame 2 is fixedly connected to the chassis 1 through a pre-embedded connector 5.

[0051] In this application, the structural frame 2 is fixedly connected to the chassis 1 through the pre-embedded connector 5. Thus, the pre-embedded connector 5 can be pre-embedded in the chassis 1 when the chassis 1 is cast in one go. Then, the structural frame 2 and the pre-embedded connector 5 are connected together to realize the assembly line production of the whole bathroom module and improve production efficiency.

[0052] In a further embodiment, such as Figure 6 As shown, the pre-embedded connector 5 includes a connecting plate 51 and a plurality of connecting posts 52 fixedly disposed on one side end face of the connecting plate 51. The end of the connecting post 52 away from the connecting plate 51 is provided with a connecting hook 53. The connecting post 52 and the connecting hook 53 are pre-embedded in the chassis 1. The side of the connecting plate 51 away from the connecting post 52 is fixedly connected to the structural frame 2.

[0053] During the one-time casting of the base plate 1, the connecting column 52 and connecting hook 53 are pre-embedded in the concrete, while the connecting plate 51 floats on the surface of the concrete. During concrete vibration, the connecting column 52 and connecting hook 53 can fully contact the concrete. The pre-embedded connecting column 52 and connecting hook 53 ensure a firm connection between the connecting column 52 and the base plate 1, and the addition of the connecting hook 53 increases the connection strength between the connecting column 52 and the base plate 1. The connecting plate 51 prevents the connecting column 52 and connecting hook 53 from sinking into the concrete during vibration. Simultaneously, the connecting plate 51 acts as a load-bearing component, transmitting the force exerted on the base plate by the structural frame 2. The area of ​​the connecting plate 51 is larger than the cross-sectional area of ​​the frame beam 22, thus increasing the load-bearing area and making the force exerted on the base plate 1 by the structural frame 2 more uniform.

[0054] The side of the connecting plate 51 away from the connecting column 52 can be fixedly connected to the structural frame 2. In this embodiment, the connecting plate 51 is fixed to the bottom of the structural frame 2 by welding.

[0055] In one embodiment, a support portion 12 is provided on the outer side of the chassis 1; the support portion 12 is used to support the crossbeam 6.

[0056] To facilitate the installation of the modular bathroom unit of this application, a support portion 12 is provided on the outer wall of the chassis 1. The support portion 12 can be mounted on the crossbeam 6, and the modular bathroom unit is mounted on the crossbeam 6, which facilitates the installation of the overall structure.

[0057] In a further embodiment, such as Figures 3 to 5 As shown, the support portion 12 includes a support side wall 121 formed by the inward contraction of the outer side wall of the chassis 1 and a support top wall 122 connected to the top of the support side wall 121, wherein the support top wall 122 is horizontally arranged.

[0058] like Figure 3 As shown, taking a modular steel structure prefabricated building for a complete bathroom as an example, the base 1 is supported on two steel structural beams 61 on both sides, with a distance L between the two beams and a spacing S between the side walls 121 on both sides of the base 1, where S < L. This allows the side walls 121 to be smoothly placed between the two beams 61. The side walls 121 serve a positioning function, ensuring the base 1 can be smoothly placed on the beams 61 and reducing positional deviations during installation. The top wall 122, as a load-bearing component, contacts the beams 61, and its width on the beams 61 should be greater than 80mm. Reinforcing bars 4 are placed above the support 122, allowing them to connect with the concrete formwork for pouring after the top wall 122 is placed on the beams 61. Similarly, when installing on a concrete building, simply follow the steps above and place the chassis 1 directly on the concrete beam.

[0059] In one embodiment, the interior system includes a decoration system; the electromechanical system includes a water system, an electrical system, and a heating, ventilation, and air conditioning system.

[0060] The interior decoration system includes structural elements such as the ceiling, while the water system comprises drainage and water supply systems. Both systems utilize integrated piping, with pre-installed pipe channels within the chassis 1, structural frame 2, and enclosing wall panels, as well as on the top of the overall bathroom module. The electrical system wiring is also pre-laid within the chassis 1, structural frame 2, and enclosing walls, with secure junction boxes installed. The HVAC system piping is also pre-laid. All related interior system piping is pre-installed at the factory. On-site installation and use require only connection.

[0061] The following is a specific implementation process for a modular bathroom unit in this embodiment, which can be used for reference:

[0062] The first step is to determine the parameters of each part of the overall bathroom module and the hoisting plan. Then, according to the overall bathroom module, make a chassis mold of the corresponding size. Then, cast the chassis 1 in the mold. During the casting, the reserved steel bars 4, lifting lugs 3, and pre-embedded connectors 5 are pre-embedded in the concrete in the chassis mold. After the concrete solidifies, remove the chassis mold to obtain chassis 1.

[0063] The second step is to reassemble the structural frame 2, the enclosure wall panels, the interior system, and other structures, and to test their construction feasibility and accuracy, and to evaluate their performance in all directions to guide whether adjustments and improvements are needed.

[0064] The third step involves hoisting a modular bathroom unit using mechanical equipment, placing the base 1 on the crossbeam 6, and then placing the top wall 122 in contact with the crossbeam 6. After that, the reserved steel bars 4 are connected to the concrete floor slab and then poured. After that, it can be used after being connected to the relevant equipment on site.

[0065] Therefore, the integrated bathroom module provided in this embodiment is assembled and produced in the factory and can be directly transported to the construction site for installation. After installation, it can be used after being connected to relevant equipment. It has the characteristics of light weight, reduced transportation costs and convenient assembly.

[0066] This embodiment provides a modular bathroom unit. The base 1 is a precast concrete structure, integrally cast, forming a sealed and waterproof structure with excellent waterproofing. The structural frame 2, combined with the enclosing wall panels, avoids the entire bathroom module being cast in concrete. Compared to a fully concrete-cast bathroom module, this reduces the overall weight, thereby reducing transportation and construction costs and improving assembly efficiency. Furthermore, the enclosing wall panels can be made of lightweight materials, further reducing the overall weight of each unit and facilitating subsequent assembly.

[0067] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A modular bathroom unit, characterized in that, include: The chassis, structural frame, interior system and electromechanical system are integrally cast, with the bottom of the structural frame fixed to the chassis; The structural frame is equipped with enclosure wall panels.

2. The integrated bathroom module according to claim 1, characterized in that, The enclosure wall panels are made of foamed material.

3. The integrated bathroom module according to claim 2, characterized in that, The foaming material is a foamed ceramic board.

4. The integrated bathroom module according to claim 1, characterized in that, The chassis has a support portion on its outer side; the support portion is used to support the crossbeam.

5. The integrated bathroom module according to claim 4, characterized in that, The support portion includes a support sidewall formed by the inward contraction of the outer sidewall of the chassis and a support top wall connected to the top of the support sidewall, wherein the support top wall is horizontally arranged.

6. The integrated bathroom module according to any one of claims 1 to 5, characterized in that, The chassis has an upward-protruding water-retaining sidewall at its edge, and several lifting lugs are pre-embedded around the periphery of the water-retaining sidewall.

7. The integrated bathroom module according to any one of claims 1 to 5, characterized in that, The outer wall of the chassis is provided with several outwardly protruding reserved steel bars, which are used to connect and pour the main concrete floor slab.

8. The integrated bathroom module according to any one of claims 1 to 5, characterized in that, The bottom of the structural frame is fixedly connected to the chassis via pre-embedded connectors.

9. The integrated bathroom module according to claim 8, characterized in that, The pre-embedded connector includes a connecting plate and a plurality of connecting posts fixedly disposed on one end face of the connecting plate. The ends of the connecting posts away from the connecting plate are provided with connecting hooks. The connecting posts and the connecting hooks are pre-embedded in the chassis. The side of the connecting plate away from the connecting posts is fixedly connected to the structural frame.

10. The integrated bathroom module according to any one of claims 1 to 5, characterized in that, The interior system includes a decoration system; the electromechanical system includes a water system, an electrical system, and a heating, ventilation, and air conditioning system.

Images