A prefabricated bathroom and a method of forming the same

Abstract

The application relates to a prefabricated bathroom and a forming method thereof, and belongs to the technical field of building engineering, which solves the problem that the connecting mode of the bathroom bottom plate and the surrounding main body in the prior art is not conducive to transportation and on-site construction. The prefabricated bathroom comprises a main body and a bottom plate, the main body and the bottom plate are connected through a connecting piece, the bottom of the bottom plate comprises a plurality of grooves, the connecting piece comprises a transverse part and a vertical part which are connected with each other, the transverse part is arranged in the groove, and the vertical part is connected with the main body. The bathroom bottom plate is convenient for transportation and on-site construction, and storage space is saved.

Description

Technical Field

[0001] This invention relates to the field of building engineering technology, and in particular to a prefabricated toilet and its formation method. Background Technology

[0002] Existing bathrooms are typically cast-in-place structures, meaning they are usually formed using on-site wet construction methods. However, on-site construction can lead to leakage problems due to factors such as the environment and the operator's techniques. The main causes of leakage are: firstly, micro-cracks in the concrete slab; secondly, poor quality of the retaining wall; and thirdly, insufficient compaction of the concrete around pipe openings.

[0003] With the continuous development of prefabricated buildings, most existing construction structures are prefabricated in production workshops with corresponding dimensions, and then installed on the construction site by transportation equipment. This construction method greatly improves construction efficiency.

[0004] In recent years, improving waterproofing quality and stability through factory prefabrication of bathroom structures and bases has become a new research direction. The connection between the bathroom structure and base typically involves pre-installing reinforcing bars on the base to connect with the surrounding structure. However, these pre-installed reinforcing bars are quite long, which is inconvenient for transportation and on-site construction. Summary of the Invention

[0005] Based on the above analysis, the present invention aims to provide a prefabricated toilet and its formation method to solve the problem that the existing connection method between the toilet chassis and the surrounding main body is not conducive to transportation and on-site construction.

[0006] The objective of this invention is mainly achieved through the following technical solutions:

[0007] On one hand, the present invention provides a prefabricated toilet, including a main body and a chassis, the main body and the chassis being connected by a connector; the bottom of the chassis includes a plurality of grooves, the connector includes a horizontal portion and a vertical portion that are connected to each other, the horizontal portion being placed in the grooves, and the vertical portion being connected to the main body.

[0008] Optionally, the groove is located at the edge of the chassis and extends to the side of the chassis.

[0009] Optionally, it also includes an embedded part, which is disposed within the main body, and the vertical portion is connected to the main body through the embedded part.

[0010] Optionally, the length of the horizontal portion is 30-40cm and the width is 20cm; the length and width of the vertical portion are 15-20cm.

[0011] Optionally, the horizontal portion and the vertical portion are an integral structure.

[0012] Optionally, a gusset is provided at the junction of the vertical portion and the horizontal portion.

[0013] Optionally, the embedded part is in the shape of a cuboid and has intersecting reinforcing ribs inside. The reinforcing ribs extend from one surface of the cuboid and out from the opposite surface.

[0014] Optionally, the connector is made of fiber cement-based composite material.

[0015] Optionally, one end of the horizontal portion is connected to one end of the vertical portion, and the horizontal portion is inclined at 2°-5° away from the vertical portion.

[0016] On the other hand, the present invention also provides a method for forming a toilet, comprising the following steps:

[0017] Embedded parts are embedded into the main structure of the bathroom;

[0018] Connect the connector to the embedded part;

[0019] Install chassis;

[0020] The gaps around the base are poured.

[0021] Optionally, a prefabricated bathroom chassis may be included before embedding the embedded parts into the main body of the bathroom.

[0022] Optionally, the transverse portion is provided with a protrusion, the protrusion is arranged in the direction of the groove, and a limiting groove adapted to the protrusion is provided at a corresponding position of the groove. The groove and the limiting groove form a two-level groove, and the depth of the limiting groove is greater than the depth of the groove.

[0023] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0024] (1) The present invention connects the main body and the base of the toilet by means of connectors, instead of connecting the main body by reserving steel bars on the base of the toilet as in the prior art. By setting a structure on the base that matches the connectors, the toilet base of the present invention is easy to transport and construct on site, and saves storage space.

[0025] (2) By setting a groove on the bathroom base that matches the horizontal part of the connector, it is easy to connect the connector to the base and make construction easier.

[0026] (3) Through the cooperation of the positioning pin and the positioning hole, the lateral part of the connector can be placed in the groove at the bottom of the chassis accurately and quickly, so as to realize the quick connection between the connector and the chassis.

[0027] (4) By tilting the horizontal part of the connector at a certain angle away from the vertical part, the side wall of the chassis fits into the main body after the chassis is placed on the connector, preventing gaps between the side wall of the chassis and the main body, so that the precast concrete bathroom in this embodiment has a good anti-seepage effect.

[0028] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages will become apparent from the description or may be learned by practicing the invention. Attached Figure Description

[0029] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0030] Figure 1 This is a schematic diagram of the overall chassis structure;

[0031] Figure 2 This is a schematic diagram of the connector structure;

[0032] Figure 3 This is a schematic diagram of the overall structure of the embedded parts;

[0033] Figure 4 This is a schematic diagram of a connector with a haunch structure.

[0034] Figure label:

[0035] 1-Chassis; 2-Connector; 3-Groove; 4-Vertical part; 5-Horizontal part; 6-Through hole; 7-Embedded part; 8-Reinforcing rib; 9-Hammack. Detailed Implementation

[0036] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0037] Example 1

[0038] One specific embodiment of the present invention discloses a precast concrete bathroom. The precast concrete bathroom includes a main body and a base 1, which are connected by connectors 2. The main body forms the side walls of the bathroom, and the base 1 forms the floor slab of the bathroom.

[0039] See Figure 1The bottom of the chassis includes several grooves 3. In a preferred embodiment, to achieve a tight fit between the chassis and the main body, multiple grooves are provided at the edge of the chassis, and the depth of the grooves extends to the side of the chassis. The number of grooves 3 is the same as the number of connectors 2.

[0040] Generally, to improve the stability of the connection between the chassis 1 and the main body, at least two opposite edges of the bottom of the chassis 1 need to be provided with grooves 3, or grooves 3 can be provided on all four edges of the bottom of the chassis 1. Preferably, in a more specific embodiment, grooves 3 are provided on two edges along the length direction of the bottom of the chassis 1, that is, two rows of grooves are provided. Depending on the size of the chassis 1, the number of grooves in each row is 2, 3, or more.

[0041] like Figure 2 As shown, the connector 2 includes a horizontal portion 5 and a vertical portion 4 that are interconnected, and its shape is similar to an L-shape. Specifically, one end of the horizontal portion is connected to one end of the vertical portion. The vertical portion 4 is connected to the main body through a pre-embedded part 7. The shape and size of the horizontal portion 5 are adapted to the groove 3 provided at the bottom of the chassis 1 to realize the connection between the pre-embedded part 7 and the chassis 1.

[0042] In addition, in order to allow the lateral portion 5 of the connector 2 to be smoothly placed in the groove 3 on the chassis, the size of the groove in this embodiment is slightly larger than the size of the lateral portion of the connector, for example, the groove is 3-5 mm larger than the lateral portion.

[0043] In a preferred embodiment, the transverse portion 5 of the connector 2 is provided with a protrusion (not shown in the figure), which is oriented towards the groove 3, i.e., extends away from the vertical portion. A corresponding limiting groove adapted to the protrusion is provided at the corresponding position of the groove 3 at the bottom of the chassis. The groove and the limiting groove constitute a two-stage groove, with the depth of the limiting groove greater than the depth of the groove. This embodiment, through the mutual cooperation of the protrusion and the limiting groove, facilitates accurate and rapid placement of the transverse portion of the connector into the groove at the bottom of the chassis, achieving rapid connection between the connector and the chassis. Furthermore, it effectively prevents relative movement between the groove 3 and the transverse portion 5 after they are engaged, ensuring the stability of the connection between the connector and the chassis. Considering the weight of the chassis, when the chassis 1 is placed on the connector 2, the transverse portion 5 will tilt downwards, causing a gap between the sidewall of the chassis and the main body, leading to leakage. Preferably, the transverse portion of the connector is tilted at a certain angle away from the vertical portion. For example, the angle is 2°-5°. By setting the aforementioned angle, this embodiment ensures that after the chassis is placed on the connector, the side wall of the chassis fits snugly against the main body, preventing gaps between the side wall of the chassis and the main body. This results in the precast concrete bathroom of this embodiment having excellent anti-seepage effect.

[0044] In one possible implementation, in order to enhance the structural stability and strength of the connector itself, the horizontal and vertical portions of the connector are integral structures, that is, the horizontal and vertical portions are integrally formed.

[0045] Preferably, a shank 9 is provided in the horizontal and vertical stress areas of the connector 2 (i.e., the connection between the vertical and horizontal parts) to enhance the strength of the horizontal and vertical stress areas and prevent deformation of the connector 2 from causing changes in the relative position of the main body and the chassis, resulting in micro-cracks and thus causing leakage in the bathroom.

[0046] See Figure 4 In this embodiment, the armhole is not provided at the entire connection between the vertical and horizontal portions, but rather at partial connections, such as at both ends. The specific structure of the armhole 9 only needs to enhance the strength of the horizontal and vertical stress zones and prevent deformation of the connector from causing changes in the relative position of the main body and the chassis. For example, the armhole includes a first armhole plate, a second armhole plate, and a third armhole plate connected end-to-end. The first armhole plate contacts the horizontal portion with a contact length of one-third of the horizontal portion's length; the second armhole plate contacts the vertical portion with a contact length of one-third of the vertical portion's length.

[0047] In addition, the vertical portion of the connector has multiple through holes 6, which are arranged perpendicular to the main body. The fastener passes through these through holes to connect the connector 2 and the embedded part 7. For example, the fastener is a bolt.

[0048] Specifically, both the horizontal and vertical sections are flat rectangular prisms. For example, the horizontal section is 30-40cm long, 20cm wide, and 5-10cm thick. The vertical section is 15-20cm long and wide, and 5-10cm thick.

[0049] In order to increase the contact area between the horizontal portion and the groove, and the contact area between the vertical portion and the main body, and to enhance the firmness of the precast concrete bathroom, in another possible embodiment, the surface with a larger area in the horizontal portion contacts the groove, and the surface with a larger area in the vertical portion contacts the main body.

[0050] The number of through holes 6 varies depending on the size of the connector. For the arrangement of multiple through holes, as long as a secure connection between the connector and the embedded part is achieved, it is acceptable. For example, two rows of through holes can be provided on the vertical section, one row near the connection end between the vertical and horizontal sections, and the other row near the other end of the vertical section. Specifically, one row of through holes corresponds to one embedded part, meaning the number of rows of through holes is the same as the number of embedded parts. For example, when the vertical section has the above dimensions, four through holes can be provided on the vertical section. The four through holes are respectively located at the four corners of the vertical section, and the through holes penetrate the larger surface area of ​​the vertical section.

[0051] The following describes the embedded part 7. Embedded part 7 is cast into the main body and is rectangular in shape. It has mounting holes, which are oriented along two opposite surfaces of the rectangular prism. Specifically, they are oriented along the larger set of surfaces.

[0052] See Figure 3 The embedded part 7 has intersecting reinforcing ribs 8, such as steel bars, which protrude from two opposite surfaces of the embedded part 7 that do not have mounting holes. That is, the reinforcing ribs 8 enter from one surface of the cuboid, extend from the opposite surface, and extend out of the surface of the cuboid. The number of embedded parts 7 is the same as the number of rows of through holes 6 on the vertical part of the connector 2, that is, one row of through holes shares one embedded part.

[0053] To enhance the connection strength and durability of the chassis and main body, the embedded parts and connectors are all made of fiber cement-based composite material. This fiber cement-based composite material is another innovation of this invention. It has the advantages of being dense, lightweight, high-strength, high-toughness, good impact resistance, and strong corrosion resistance. It is a material with excellent comprehensive performance, especially suitable for use in cold outdoor environments, and is easy to disassemble and transport.

[0054] The raw materials for preparing this fiber cement-based composite material include ordinary silicate cement, fly ash, silica fume, natural river sand, polypropylene fiber, tap water, and additives such as polycarboxylate superplasticizer.

[0055] Fly ash and silica fume can improve the workability and density of cement-based composite materials, while polypropylene fibers are selected, as they can effectively improve the strength and toughness of the material. Compared with other fibers, polypropylene fibers are more economical, pollution-free, and chemically stable, while possessing good elastic modulus and tensile strength.

[0056] In one specific embodiment, the water-cement ratio (the water-cement ratio refers to the ratio of the mass of water to the mass of cementitious material) of the above-mentioned fiber cementitious composite material is 0.24. Under the low water-cement ratio, the strength and durability of the material can be greatly improved.

[0057] The proportions of ordinary Portland cement, fly ash, and silica fume in the cementitious material (a mixture of ordinary Portland cement, fly ash, and silica fume) are 82%, 10%, and 8%, respectively. The sand ratio (the proportion of natural river sand to the sum of the masses of natural river sand and cementitious material) is 45%, and the water-reducing agent dosage is 0.5% of the cement mass. The appropriate dosing amount of polypropylene fiber is controlled between 0.2% and 0.5% (this means the polypropylene fiber dosing amount is 0.2%-0.5% of the total volume of the mixture of water, cementitious material, water-reducing agent, and natural river sand). Excessive or insufficient dosing will negatively impact the material's performance.

[0058] The compressive strength and flexural strength tests showed that the fiber cementitious composite material with the above mix proportions could achieve a compressive strength of 90 MPa and a flexural strength of 14 MPa at 28 days of age, and there would be an additional strength increase of about 10% at 56 days of age.

[0059] Water absorption and electrical flux tests revealed that the fiber-cement composite material with the above mix proportion had a water absorption rate of only 0.15% after 28 days, while the water absorption rate of ordinary concrete is generally around 3%. This indicates that the internal density of the fiber-cement composite material of this invention is far superior to that of ordinary concrete. The electrical flux was 240C (coulombs), while the electrical flux of ordinary concrete is often between 1000 and 1500C. This demonstrates that the impermeability of the fiber-cement composite material is already far superior to that of ordinary concrete, indicating that the material possesses high density and high durability. At 56 days of age, the hydration reaction within the material continues, further enhancing its density and durability.

[0060] Based on the above performance test results of the fiber cementitious material, it can be seen that the characteristics of the fiber cementitious material with the above-mentioned proportions are mainly reflected in the following aspects:

[0061] (1) The material has high strength, which can effectively reduce the structural size and increase the usable space.

[0062] (2) The material exhibits high toughness and good impact resistance, making it suitable for protection and reinforcement projects. Specifically, the ultimate strain of the fiber-reinforced cementitious material of this invention can reach 1.5%, significantly higher than the 0.003–0.007 of existing materials, indicating its high toughness. Furthermore, the minimum elastic modulus of the fiber-reinforced cementitious composite material of this invention is 1.36 × 10⁻⁶. 4 MPa, while the elastic modulus of ordinary cement-based materials is generally (2.0~3.0)×10 4 The MPa value indicates that the fiber-reinforced cementitious composite material has low stiffness, high deformation capacity, and better toughness. Furthermore, the Poisson's ratio of the fiber-reinforced cementitious composite material of this invention reaches above 0.45, while the Poisson's ratio of ordinary cementitious materials is around 0.2, which also demonstrates that the fiber-reinforced cementitious composite material has excellent deformation capacity and toughness.

[0063] (3) The material has good density and impermeability, strong corrosion resistance, and can be used in harsh environments.

[0064] Example 2

[0065] Another specific embodiment of the present invention discloses a method for forming a precast concrete toilet, comprising the following steps:

[0066] Step 1: Prefabricate the bathroom chassis, connectors, and embedded parts.

[0067] The prefabricated bathroom chassis is installed in a reverse sequence, that is, the ground part is constructed first, followed by the pre-embedded pipes, and then the floor slab part, including the following steps:

[0068] Step 11: Arrange the floor tiles, which will serve as the ground surface, neatly and orderly in the bottom layer of the mold (first layer mold);

[0069] Step 12: Assemble the pre-buried pipelines, accurately position and fix them using a template (second layer mold), and place them above the ground section;

[0070] Step 13: Pour lightweight cement mortar into the first and second mold layers;

[0071] Step 14: After the cement mortar has solidified, install the third layer of mold and pour concrete to form the precast floor slab. After the precast floor slab has solidified, demold the entire structure and cure it to obtain the bathroom chassis.

[0072] Step 2: Conduct a waterproof test on the bathroom base.

[0073] Step 3: Transport the bathroom chassis, embedded parts, and connectors to the site.

[0074] Step 4: Locate the pre-embedded parts in the main structure by measuring the dimensions, and then embed them in the corresponding positions in the main structure around the bathroom. Finally, fix them with the help of steel bar binding and molds.

[0075] Step 5: After the embedded parts are securely installed, connect the connectors to the embedded parts using bolts.

[0076] Step 6: Install the bathroom base, including the following steps:

[0077] Step 61: Provide support at the bottom of the pre-installed bathroom chassis, locate the bathroom chassis using the positioning posts on the horizontal part of the connector, and connect the groove at the bottom of the chassis to the horizontal part of the connector by hoisting.

[0078] Step 62: Erect formwork around the gaps of the bathroom base to prepare for subsequent pouring.

[0079] Step 7: Cast the main structure around the bathroom as a whole, so that the embedded parts are completely integrated with the main structure. The gaps between the bathroom base and the main structure around it are also filled and sealed with cement mortar.

[0080] Step 8: After the concrete has solidified and reached the required strength, remove the mold and the support at the bottom of the chassis.

[0081] The reverse order used in this embodiment has the following advantages:

[0082] First, it ensures the smoothness and flatness of the bathroom floor, because unevenness and roughness are often caused by manual troweling on the upper surface of the mold during pouring, while the other three sides can achieve a smooth and flat effect.

[0083] Secondly, the floor slab is poured last. The lower surface of the slab will also be rough and uneven, but because the floor below has a suspended ceiling and other features, the rough surface will not be exposed. This ensures the highest possible quality and aesthetics for the entire bathroom floor.

[0084] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A prefabricated toilet, characterized in that, The device includes a main body, a chassis, and embedded parts. The main body and the chassis are connected by a connector. The bottom of the chassis includes several grooves. The connector includes interconnected horizontal and vertical portions. The vertical portion is located at the lower end of the horizontal portion. One end of the horizontal portion is connected to one end of the vertical portion, and its shape is similar to an L-shape. The horizontal portion is placed in the grooves. The shape and size of the horizontal portion are adapted to the grooves provided on the bottom of the chassis to realize the connection between the embedded parts and the chassis. The vertical portion is connected to the main body. The horizontal portion of the connector is inclined at 2°-5° away from the vertical portion. The groove is located at the edge of the chassis and extends to the side of the chassis; The embedded part is disposed within the main body, and the vertical portion is connected to the main body through the embedded part; The vertical portion of the connector has multiple through holes, which are arranged in a direction perpendicular to the main body. The fastener passes through the through holes to connect the connector and the embedded part. The embedded part is in the shape of a cuboid, and the embedded part is provided with mounting holes. The mounting holes are arranged to extend along two opposite surfaces of the cuboid. The embedded part has intersecting reinforcing ribs distributed inside, which protrude from the other two sets of opposite surfaces of the embedded part that do not have mounting holes; The prefabricated toilet is formed by the following methods: Embedded parts are embedded in the main body of the prefabricated bathroom; Connect the connector to the embedded part; Install prefabricated bathroom chassis; Formwork is erected around the gaps of the precast bathroom chassis to prepare for subsequent pouring; The main structure around the prefabricated bathroom is cast as a whole, so that the embedded parts are completely integrated with the main structure. The gaps between the prefabricated bathroom chassis and the main structure around it are also filled and sealed with cement mortar.

2. The prefabricated toilet according to claim 1, characterized in that, The horizontal portion is 30-40cm long and 20cm wide; the vertical portion is 15-20cm long and wide.

3. The prefabricated toilet according to claim 2, characterized in that, The horizontal portion and the vertical portion are an integral structure.

4. The prefabricated toilet according to claim 1, characterized in that, A gusset is provided at the connection between the vertical portion and the horizontal portion.

5. The prefabricated toilet according to claim 3 or 4, characterized in that, The connector is made of fiber cement-based composite material.

6. A method for forming a prefabricated toilet, characterized in that, The method for forming a prefabricated toilet according to any one of claims 1-5 includes the following steps: Embedded parts are embedded in the main body of the prefabricated bathroom; Connect the connector to the embedded part; Install prefabricated bathroom chassis; Formwork is erected around the gaps of the precast bathroom chassis to prepare for subsequent pouring; The main structure around the prefabricated bathroom is cast as a whole, so that the embedded parts are completely integrated with the main structure. The gaps between the prefabricated bathroom chassis and the main structure around it are also filled and sealed with cement mortar.

7. The forming method according to claim 6, characterized in that, The process also includes the prefabricated bathroom chassis before embedding the prefabricated parts into the main body of the prefabricated bathroom.

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