Prefabricated functional toilet module and connecting structure and construction method thereof

Abstract

The invention relates to a prefabricated functional toilet module which comprises a decoration structure, a sanitary appliance and a closed box body serving as a non-bearing structure, the closed box body comprises a top plate, a bottom plate and side walls, a caisson descending plate part is arranged in the bottom plate, and a sewer pipe of a toilet is arranged on the caisson descending plate part; the bottom plate and the caisson descending plate part are integrally prefabricated through high-strength concrete, and the top plate and the side walls are manufactured through formworks and then connected with the bottom plate to form a closed box body which is of a reinforced concrete structure. The construction of a decoration structure and the installation of sanitary appliances are carried out in the closed box body, so that the bathroom module is integrally prefabricated and delivered, and is directly arranged on a bearing beam of a building on a construction site. The invention further relates to a connecting structure of the prefabricated functional toilet module and a construction method of the connecting structure. The toilet module is only a functional module instead of a bearing module, so that the structure of the toilet module is greatly simplified, and the invention belongs to the technical field of prefabricated building structures.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated building structures, specifically to a prefabricated functional bathroom module, and also relates to a connection structure of the prefabricated functional bathroom module, and further relates to a construction method of the connection structure of the prefabricated functional bathroom module. Background Art

[0002] A prefabricated building refers to a structural form in which building components (such as wall panels, floor slabs, beam columns, etc.) are produced in a factory in a standardized manner and then transported to the site for assembly. Its main features include: (1) Industrial production: improving construction efficiency, reducing on-site wet operations, and shortening the construction period. (2) Quality control: The factory environment ensures the accuracy of components and reduces the quality fluctuations of traditional construction. (3) Environmental protection and energy conservation: reducing construction waste, reducing material waste, and conforming to the trend of green buildings.

[0003] The bathroom module is an important unit in prefabricated buildings. However, the existing bathroom modules have the following disadvantages:

[0004] (1) Existing bathroom modules are all combinations of structural modules (load-bearing) and functional modules. The module design includes load-bearing components (load-bearing beams), resulting in complex connections of the load-bearing components of the bathroom module and affecting the use and promotion of the bathroom module. Since the bathroom module includes load-bearing components, complex mechanical calculations are required.

[0005] (2) Most of the drain pipes in existing bathroom modules adopt the side drainage method, which seriously affects the layout of the drain pipes and causes complexity in maintenance and subsequent maintenance.

[0006] (3) Existing bathroom modules do not consider countermeasures in case of failures such as water seepage on the bottom plate, which has a greater adverse impact on the lower modules.

[0007] (4) Existing bathroom modules do not consider the connection design with the cast-in-place structure and do not consider the height difference problem between the bathroom and the rest of the rooms according to the residential design habits.

[0008] (5) Existing bathroom modules are mainly designed with steel structures and less with concrete as the design material.

[0009] The above disadvantages of existing bathroom modules all affect the popularization and use of bathroom modules. Therefore, it is necessary to improve the structure and connection method of bathroom modules. Summary of the Invention

[0010] Aiming at the technical problems existing in the prior art, the object of the present invention is to provide a prefabricated functional bathroom module, which prefabricates non-load-bearing structural components, decoration, and sanitary wares and delivers them out of the factory as a whole, and the overall structure is more streamlined.

[0011] Another object of the present invention is to provide a connection structure for a prefabricated functional bathroom module and a construction method thereof, which combines prefabricated structure and cast-in-place structure to not only ensure the bearing capacity but also ensure the integrity of the connection structure.

[0012] To achieve the above object, the present invention adopts the following technical solutions:

[0013] The prefabricated functional bathroom module includes a decoration structure, sanitary ware, and an enclosed box body as a non-load-bearing structure. The enclosed box body includes a top plate, a bottom plate, and side walls. A sunken floor part is provided in the bottom plate, and the sewer pipe of the toilet is arranged in the sunken floor part; the bottom plate together with the sunken floor part is integrally prefabricated with high-strength concrete, and the top plate and side walls are made of formwork and then connected to the bottom plate to form an enclosed box body, and the enclosed box body is a reinforced concrete structure; the construction of the decoration structure and the installation of the sanitary ware are carried out in the enclosed box body, so that the bathroom module is prefabricated and factory-produced and directly installed on the bearing beam of the building at the construction site.

[0014] As a preference, the side wall includes an outer partition wall and an inner partition wall, or the side wall includes an inner partition wall; the outer partition wall faces the outside of the building, and the outer partition wall is provided with a window; a door is provided on one of the inner partition walls.

[0015] As a preference, the decoration structure includes a bathroom ceiling, and the bathroom ceiling is arranged below the top plate.

[0016] The connection structure of the prefabricated functional bathroom module is used to install the prefabricated functional bathroom module. The bearing frame of the building includes a bearing beam, and the bearing beam connected to the bathroom module is a composite beam; between the upper and lower adjacent bathroom modules, the composite beam encloses an annular composite beam module, and the outer shape of the composite beam module corresponds to the outer shape of the side walls enclosing the ring. The composite beam module is located on the lower bathroom module, and the upper bathroom module is placed on the composite beam module. The sunken floor part of the upper bathroom module is located within the composite beam module, and concrete is filled between the upper bathroom module, the lower bathroom module, and the composite beam module.

[0017] As a preference, the composite beam includes a lower precast part and an upper cast-in-place part. The steel bars of the composite beam are embedded in the precast part, and the upper part of the steel bars extends out of the precast part and is covered by the cast-in-place part; a mortar layer is provided between the lower end surface of the precast part and the lower bathroom module, and a mortar layer is provided between the upper end surface of the cast-in-place part and the upper bathroom module.

[0018] As a preference, a corbel protruding outward is provided on the outer side of the precast part of the composite beam; the floor slab includes a precast composite slab and a cast-in-place floor slab. The precast composite slab is placed on the corbel, and the steel bars of the precast composite slab extend out laterally. The steel bars of the precast composite slab are connected to the steel bars extending upward from the precast part of the composite beam and are covered by the cast-in-place part of the composite beam; the cast-in-place floor slab is cast on the precast composite slab, and the end of the cast-in-place floor slab is connected to the cast-in-place part of the composite beam and integrally cast.

[0019] As a preference, on the same floor, the upper end surfaces of the cast-in-place floor slab and the bottom plate of the enclosed box are flush; the distance between the sunken slab part of the upper toilet module and the top plate of the lower toilet module is 100 - 150 mm.

[0020] As a preference, an upper installation space is left in the sunken slab part of the upper toilet module, and the sewer pipe of the upper toilet module is arranged in the upper installation space; a lower installation space is left between the upper toilet module, the lower toilet module and the composite beam module, and a bath heater is installed on the top plate of the lower toilet module, and the upper part of the bath heater is located in the lower installation space.

[0021] The construction method of the connection structure of the prefabricated functional toilet module includes the following steps:

[0022] (1) After the installation of the lower toilet module is completed, construct the bearing beam of the current floor. Among them, the bearing beam connected to the toilet module adopts a composite beam structure. First, construct the precast part of the composite beam. Before the construction of the precast part, lay a mortar layer on the upper end surface of the lower toilet module;

[0023] (2) Place the precast composite slab of the floor slab on the corbel, and cast the cast-in-place part of the composite beam and the cast-in-place floor slab on site;

[0024] (3) Lay a mortar layer on the cast-in-place part of the composite beam, and place the upper toilet module on this mortar layer;

[0025] (4) Fill the space between the upper toilet module, the lower toilet module and the composite beam module with concrete.

[0026] As a preference, in step (2), control the thickness of the cast-in-place floor slab to ensure that the upper end surface of the cast-in-place floor slab is flush with the upper end surface of the bottom plate.

[0027] The principle of the present invention is:

[0028] Design a functional toilet module with an enclosed box, which integrates a non-load-bearing box structure, a decoration structure and sanitary wares. Since the enclosed box is a non-load-bearing structure, the overall structure is concise, easy to design, manufacture and install, avoiding the influence of the toilet module on the calculation of structural forces and the complexity of the structure.

[0029] Adopt the method of high-strength integrated bottom plate, fully considering the layout of the sewer pipe and the waterproof effect; at the same time, fill the space between the modules with concrete to prevent the upper module from seeping water and affecting the lower module, and ensure the connection between modules, between modules and composite beams, and between the toilet module and the floor slab.

[0030] Both the composite beam and the floor slab adopt the combination of precast structure and cast-in-situ structure, which not only ensures the bearing capacity but also the tightness of the connection between structures.

[0031] The floor slab adopts the combination of precast structure and cast-in-situ construction, which is easy to control the flatness between the floor slab and the bottom plate of the toilet module.

[0032] The present invention has the following advantages:

[0033] 1. The toilet module is only a functional module, not a load-bearing module, which greatly simplifies the structure of the toilet module. At the same time, it can achieve the effect of full prefabrication of non-load-bearing structural components, interior decoration and sanitary ware, etc., greatly reducing the workload at the construction site and improving the construction efficiency.

[0034] 2. The bottom plate of the toilet module adopts a high-strength integrated bottom plate design, using high-strength concrete (such as UHPC, etc.), significantly reducing the thickness of the bottom plate; the integrated design and production ensure the waterproof effect, and at the same time integrate the sunken box lowering plate, which can more conveniently place the sewer pipe, avoiding the complexity of inspection and maintenance caused by the side discharge of the sewer pipe in the previous design.

[0035] 3. The toilet module is made of reinforced concrete, which has lower cost and better fire resistance.

[0036] 4. When making the load-bearing frame of the building, reserve some load-bearing beams as the installation positions of the toilet modules. These composite beam structures combined with prefabricated and cast-in-situ materials of the load-bearing beams not only ensure the load-bearing requirements but also the tightness of the structural connection, significantly simplifying the construction and decoration time of the most complex and highly integrated toilet part in the building design, shortening the construction period and reducing the construction difficulty.

[0037] 5. The composite beam adopts the method of additional corbels, which can ensure the reliable connection with the floor slab in the horizontal direction and at the same time solve the height difference problem between the traditional toilet module and the living room.

[0038] 6. There is a certain gap between the bottom plate of the upper toilet module and the sunken box lowering plate part and the top plate of the lower toilet module, which not only prevents the upper toilet module from seeping water and affecting the lower toilet module, but also ensures the connection between modules and between modules and composite beams, and at the same time leaves space for equipment positions such as bathroom ceiling fans, etc., so that the ceiling and the top plate can be integrated and produced, ensuring the net space of the bathroom and improving the use comfort. Description of the Drawings

[0039] Figure 1 It is a three-dimensional view of a single bathroom module.

[0040] Figure 2 It is the front view of a single bathroom module.

[0041] Figure 3 It is the rear view of a single bathroom module.

[0042] Figure 4 It is the right view of a single bathroom module.

[0043] Figure 5 It is the left view of a single bathroom module.

[0044] Figure 6 It is the exploded view of the connection between upper and lower layer bathroom modules.

[0045] Figure 7 It is the three-dimensional view of the connection between upper and lower layer bathroom modules.

[0046] Figure 8 It is the three-dimensional view of the bottom plate.

[0047] Figure 9 It is the schematic diagram of the connection between the bathroom module and the surrounding structure.

[0048] Figure 10 It is the schematic diagram of the connection method among the bathroom module, the composite beam and the floor slab.

[0049] Figure 11 It is the floor plan of the layout of the bathroom module in the building.

[0050] Figure 12 It is the exploded view of the connection between the decorated bathroom module and the composite beam.

[0051] Figure 13 It is the structural schematic diagram of the bathroom module.

[0052] In the figure, 1 - top plate, 2 - bottom plate, 3 - outer partition wall, 4 - inner partition wall, 5 - sunken slab part of the caisson, 6 - door, 7 - window, 8 - bathroom ceiling, 9 - composite beam, 10 - precast part of the composite beam, 11 - cast-in-place part of the composite beam, 12 - steel bars of the composite beam, 13 - mortar layer, 14 - corbel, 15 - floor slab, 16 - precast composite slab, 17 - cast-in-place floor slab, 18 - steel bars of the precast composite slab, 19 - steel bars of the cast-in-place floor slab, 20 - upper installation space, 21 - lower installation space, 22 - bathroom module. Specific embodiments

[0053] The present invention will be further described in detail below in conjunction with specific embodiments.

[0054] Embodiment 1

[0055] Figures 1-5 As shown, the prefabricated functional toilet module includes a decoration structure, sanitary wares, and an enclosed box as a non-load-bearing structure. The enclosed box includes a top plate, a bottom plate, and side walls. A sunken floor part is provided in the bottom plate, and the sewer pipe of the toilet is arranged in the sunken floor part; the bottom plate together with the sunken floor part is integrally prefabricated with high-strength concrete, and the top plate and side walls are made by formwork and then connected to the bottom plate to form an enclosed box, and the enclosed box is a reinforced concrete structure; the construction of the decoration structure and the installation of sanitary wares are carried out in the enclosed box, so that the toilet module is prefabricated and factory-produced and directly installed on the load-bearing beam of the building at the construction site. Preferably, the top plate and side walls can be integrally formed or assembled after forming. In this embodiment, the top plate and side walls are integrally formed. Compared with the ordinary concrete bottom plate, the thickness of the high-strength concrete bottom plate can be further reduced, and it is integrally made with the sunken floor part in the factory, and the waterproof effect is better.

[0056] The side walls include an outer partition wall and an inner partition wall; the outer partition wall faces the outside of the building, and a window is provided on the outer partition wall; a door is provided on one of the inner partition walls. The outer partition wall is thicker and the inner partition wall is thinner.

[0057] The decoration structure includes a toilet ceiling, and the toilet ceiling is arranged below the top plate. The top plate and the toilet ceiling are integrally made, which can ensure the clear height of the toilet, avoid the depression caused by the lower clear height of the traditional toilet, and give users a more comfortable toilet use experience.

[0058] The decoration structure includes a ceiling, a floor, wall tiles, a mirror cabinet, a floor cabinet, a dry-wet partition door, a shower head, a faucet, etc. The sanitary wares include a toilet, a washbasin, a bathtub, etc. The equipment includes a bathroom heater, a towel dryer, a mini washing machine, a mini dryer, etc. The toilet module can include all the functions required for the toilet, and all can be prefabricated without on-site installation, reducing the on-site workload and improving the on-site construction efficiency.

[0059] The sewer pipe of the toilet is arranged in the sunken floor part; the sunken floor part is cubic in shape. Arranging the sewer pipe in the sunken floor part takes into account the layout of the sewer pipe of the toilet and can avoid the difficulty of maintenance caused by the side discharge of the sewer pipe.

[0060] The toilet module is integrally prefabricated in the factory, and the manufacturing method is as follows: Use high-strength concrete to make an integrated bottom plate, and half of the area of the bottom plate forms a sunken floor part in the form of a sunken floor. Then, formwork is supported in the factory to make the upper components of the toilet module, including one outer partition wall and three inner partition walls, and a top plate, and connect them to the bottom plate. Then, decoration is carried out, pipelines are laid and wires are laid, doors and windows are installed, and sanitary wares and equipment are installed. After prefabrication is completed, the module is transported to the construction site.

[0061] Embodiment Two

[0062] In this embodiment, the side wall includes an inner partition wall; a door is provided on one of the inner partition walls. The toilet module of this embodiment is used in the middle of the house.

[0063] The parts not mentioned in this embodiment are the same as those in Embodiment 1.

[0064] Embodiment 3

[0065] The connection structure of the prefabricated functional toilet module is used to install the prefabricated functional toilet module of Embodiment 1. The load-bearing frame of the building includes load-bearing beams, and the load-bearing beam connected to the toilet module is a composite beam; between the upper and lower adjacent toilet modules, the composite beams enclose an annular composite beam module. The outer shape of the composite beam module corresponds to the outer shape of the side wall enclosing the ring. The composite beam module is located on the lower toilet module, and the upper toilet module is placed on the composite beam module. The sunken slab part of the upper toilet module is located within the composite beam module, and concrete is filled between the upper toilet module, the lower toilet module, and the composite beam module.

[0066] The composite beam includes a precast part at the lower layer and a cast-in-place part at the upper layer. The steel bars of the composite beam are embedded in the precast part, and the upper part of the steel bars extends out of the precast part and is covered by the cast-in-place part; there is a mortar layer between the lower end face of the precast part and the lower toilet module, and there is a mortar layer between the upper end face of the cast-in-place part and the upper toilet module.

[0067] The outer side of the precast part of the composite beam is provided with outwardly protruding corbels; the floor slab includes a precast composite slab and a cast-in-place floor slab. The precast composite slab is placed on the corbels. The steel bars of the precast composite slab extend out laterally. The steel bars of the precast composite slab are connected to the steel bars extending upward from the precast part of the composite beam and are covered by the cast-in-place part of the composite beam; the cast-in-place floor slab is poured on the precast composite slab, and the end of the cast-in-place floor slab is connected to the cast-in-place part of the composite beam and integrally cast. Only the composite beam that needs to connect the floor slab needs to be provided with corbels.

[0068] On the same floor, the upper end face of the cast-in-place floor slab is flush with the upper end face of the bottom plate of the closed box; the distance between the sunken slab part of the upper toilet module and the top plate of the lower toilet module is 100 - 150 mm. Since there is a certain space between the upper and lower toilet modules, an installation space can be reserved in this space for installing a ceiling heater, while ensuring that the lower toilet module is not affected by water seepage from the upper toilet module.

[0069] An upper installation space is left inside the sunken slab part of the upper toilet module, and the drain pipe of the upper toilet module is arranged in the upper installation space; a lower installation space is left between the upper toilet module, the lower toilet module, and the composite beam module. The top plate of the lower toilet module is equipped with a ceiling heater, and the upper part of the ceiling heater is located within the lower installation space.

[0070] When designing the building, a composite beam module structure reserved as a load-bearing beam is used to place the toilet module. The toilet modules of the whole building are arranged and constructed successively from bottom to top. The toilet module on the first floor is directly set on the foundation. The load-bearing frame includes load-bearing columns, load-bearing beams and shear walls, and its construction method is the prior art.

[0071] The construction method of the connection structure of the prefabricated functional toilet module includes the following steps:

[0072] (1) After the installation of the lower toilet module is completed, construct the load-bearing beam of the current floor. Among them, the load-bearing beam connected to the toilet module adopts a composite beam structure. First, construct the precast part of the composite beam. Before the construction of the precast part, lay a mortar layer on the upper end face of the lower toilet module;

[0073] (2) Place the precast composite slab of the floor on the corbel, and cast the cast-in-place part of the composite beam and the cast-in-place floor on site. Control the thickness of the cast-in-place floor to ensure that the upper end face of the cast-in-place floor is flush with the upper end face of the bottom plate.

[0074] (3) Lay a mortar layer on the cast-in-place part of the composite beam, and place the upper toilet module on this mortar layer;

[0075] (4) Fill the concrete between the upper toilet module, the lower toilet module and the composite beam module. The grouting hole is grouted after the composite beam module is drilled. If a bath heater is to be installed, use a template to reserve the installation space for the lower layer.

[0076] The above embodiments are the preferred embodiments of the present invention, but the embodiments of the present invention are not limited by the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principle of the present invention shall be equivalent replacement methods and are all included in the protection scope of the present invention.

Claims

1. Prefabricated functional toilet module, characterized in that: It includes a decoration structure, sanitary ware, and an enclosed box as a non-load-bearing structure. The enclosed box includes a top plate, a bottom plate, and side walls. A sunken floor part is provided in the bottom plate, and the drain pipe of the toilet is arranged in the sunken floor part. The bottom plate together with the sunken floor part is integrally precast with high-strength concrete. The top plate and side walls are made with formwork and then connected to the bottom plate to form the enclosed box, and the enclosed box is a reinforced concrete structure. The construction of the decoration structure and the installation of the sanitary ware are carried out inside the enclosed box, so that the toilet module is prefabricated and factory-produced as a whole, and is directly installed on the load-bearing beams of the building at the construction site.

2. The prefabricated functional toilet module according to claim 1, wherein: The side walls include an outer partition wall and an inner partition wall, or the side walls include only an inner partition wall. The outer partition wall faces the outside of the building, and a window is provided on the outer partition wall. A door is provided on one of the inner partition walls.

3. The prefabricated functional toilet module according to claim 1, characterized in that: The decoration structure includes a toilet ceiling, which is arranged below the top plate.

4. Connecting structure of prefabricated functional toilet module, used for installing the prefabricated functional toilet module according to any one of claims 1 to 3, characterized in that: The load-bearing frame of the building includes load-bearing beams, and the load-bearing beams connected to the toilet module are composite beams. Between the upper and lower adjacent toilet modules, the composite beams enclose an annular composite beam module. The outer shape of the composite beam module corresponds to the outer shape of the side walls enclosing the ring. The composite beam module is located on the lower toilet module, and the upper toilet module is placed on the composite beam module. The sunken floor part of the upper toilet module is located inside the composite beam module, and concrete is filled between the upper toilet module, the lower toilet module, and the composite beam module.

5. The connecting structure of the prefabricated functional toilet module according to claim 4, characterized in that: The composite beam includes a lower precast part and an upper cast-in-place part. The steel bars of the composite beam are embedded in the precast part, and the upper parts of the steel bars extend out of the precast part and are covered by the cast-in-place part. There is a mortar layer between the lower end face of the precast part and the lower toilet module, and there is a mortar layer between the upper end face of the cast-in-place part and the upper toilet module.

6. The connection structure of the prefabricated functional toilet module according to claim 5, characterized in that: There are outward-protruding corbels on the outside of the precast part of the composite beam. The floor slab includes a precast composite slab and a cast-in-place floor slab. The precast composite slab is placed on the corbels. The steel bars of the precast composite slab extend out laterally. The steel bars of the precast composite slab are connected to the steel bars extending upward from the precast part of the composite beam and are covered by the cast-in-place part of the composite beam. The cast-in-place floor slab is poured on the precast composite slab, and the end of the cast-in-place floor slab is connected to the cast-in-place part of the composite beam and integrally cast.

7. The connecting structure of the prefabricated functional toilet module according to claim 6, characterized in that: On the same floor, the upper end face of the cast-in-place floor slab is flush with the upper end face of the bottom plate of the enclosed box. The distance between the sunken floor part of the upper toilet module and the top plate of the lower toilet module is 100 - 150 mm.

8. The connection structure of the prefabricated functional toilet module according to claim 4, characterized in that: There is an upper installation space left inside the sunken floor part of the upper toilet module, and the drain pipe of the upper toilet module is arranged in the upper installation space. There is a lower installation space left between the upper toilet module, the lower toilet module, and the composite beam module. The ceiling heater is installed on the top plate of the lower toilet module, and the upper part of the ceiling heater is located inside the lower installation space.

9. The construction method of the connection structure of the prefabricated functional bathroom module according to any one of claims 4-8, characterized in that, It includes the following steps: (1) After the installation of the lower toilet module is completed, construct the load-bearing beams of the current floor. Among them, the load-bearing beams connected to the toilet module adopt a composite beam structure. First, construct the precast part of the composite beam. Before the construction of the precast part, lay a mortar layer on the upper end face of the lower toilet module. (2) Place the precast composite slab of the floor slab on the corbels, and cast the cast-in-place part of the composite beam and the cast-in-place floor slab on-site. (3) Lay a mortar layer on the cast-in-place part of the composite beam, and place the upper toilet module on this mortar layer; (4) Fill the concrete between the upper toilet module, the lower toilet module and the composite beam module.

10. The construction method of the connection structure of the prefabricated functional toilet module according to claim 9, characterized in that: In step (2), control the thickness of the cast-in-place floor slab to ensure that the upper end surface of the cast-in-place floor slab is flush with the upper end surface of the bottom plate.

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