Integrated plumbing system apparatus and method of manufacture thereof

Abstract

An apparatus 2 suitable for use as an integrated plumbing system (IPS) unit including a core member and an outer later attached to the core member, wherein the core member and outer layer are formed f

Description

The present invention relates to an integrated plumbing system (IPS) apparatus, or part thereof, and method for assembling said apparatus or part thereof. Although the following description refers exclusively to IPS systems in medical or hospital settings, the person skilled in the art will appreciate that the present invention can be used in a variety of locations and is not limited to hospitals or other medical buildings. IPS units are typically sanitary units whereby the plumbing and cisterns etc, for the sanitaryware (such as wash basins, sinks, toilets and / or the like) is concealed at the rear of the unit behind one or more panels. Conventional IPS panels are placed in a variety of commercial washroom or wash-station locations and helping prevent vandalism and ensure the washroom is easier to clean. It is the easy cleaning and unitary nature of the IPS that make them attractive to use in hospital wash stations and toilets where the number of exposed surfaces that must be cleaned can be minimised. A problem with conventional IPS units, particularly those around sinks, washstands and in wetrooms is that they are constructed from composite panels, including; melamine faced chipboard (MFC), high-pressure laminate (HPL), solid grade laminate (SGL), and real wood veneer where, save for SGL, water ingress into the panel is a serious structural problem as well as presenting a hygiene and cleaning issue. PG G I- Ug Even in the case of panels that are impervious to water themselves, such as SGL panels for example, water ingress at the joints between the panels remains a cleaning and hygiene issue. 5 It is therefore an aim of the present invention to provide an apparatus which addresses the abovementioned problems. It is a further aim of the invention to provide a method of manufacturing an apparatus that addresses the abovementioned 10 problems. It is a yet further aim of the invention to provide a method of installing an apparatus that addresses the abovementioned problems. 15 In a first aspect of the invention there is provided an apparatus according to claim 1. 20 Typically the antimicrobial agent is metal based. Further typically the antimicrobial agent includes silver ion, zinc or copper. Preferably the antimicrobial agent or additive includes silver. 25 In one embodiment the antimicrobial agent is a biocide. Typically the biocide is a phenolic biocide, quaternary ammonium compound trichlorohydroxydiphenylether, a methyl urea, or imidazolcarbamate. Further typically the biocide is any one or any combination of phenolic biocide, quaternary ammonium compound trichlorohydroxydiphenylether, a methyl urea, and / or imidazolcarbamate In a preferred embodiment the core member is constructed from polyvinyl chloride (PVC). Typically the core member is primarily constructed from PVC or a PVC derivative polymer. Preferably the core member is formed from a single or unitary sheet of polymer or polymeric material. Typically the single sheet is PVC polymer. In a preferred embodiment the outer layer or sheet is constructed from PVC. Typically both the core member and outer layer or sheet are formed from PVC or a PVC based polymer. In one embodiment the core member and outer layer or sheet are attached together using at least one adhesive or glue. In a preferred embodiment the adhesive is a vinyl adhesive. Typically the adhesive a spray adhesive, for example TensorGrip® L71 vinyl spray adhesive or the like. Typically the apparatus includes one or more bends or corners formed in the same. Further typically these bends or corners are seamless. Typically the apparatus is bent or folded into the desired shape without cutting the same. Further typically the apparatus is bent or folded to form a single unit with two or more surfaces formed at an angle to one another whereby the edge or bend where the two surfaces meet is a continuous surface with no cutting to at least the outer layer or sheet. In one embodiment the apparatus is substantially U-shaped. Typically the apparatus is U shaped when view along a longitudinal or vertical axis of the apparatus. Further typically the apparatus is substantially U-shaped when viewed in horizontal cross section. Typically the apparatus includes at least a front surface and two side surfaces. Typically the apparatus substantially surround pipework and / or cisterns etc. when attached to a wall. Typically the apparatus includes one or more apertures. Further typically the one or more apertures allow one or more doors, access hatches, pipes, sanitary fittings and / or the like to be attached or mounted on the apparatus. In one embodiment the apparatus is provided with sanitaryware attached to the same. In a second aspect of the invention there is provided a IPS unit including a solid or homogeneous polymer core and an outer polymeric layer wherein at least the outer layer includes an antimicrobial or biocidal compound. Preferably the core and outer layer comprise PVC. In a third aspect of the invention there is provided a method of manufacturing an apparatus for use in an IPS unit including a polymer core and an outer layer including a antimicrobial composition, said method including the step of adhering or gluing the core and outer layer together. Typically the apparatus includes two or more surfaces, said surfaces formed by folding said core and outer layer. Further typically said folding occurs after the core and outer layer are attached together. In one embodiment a groove or notch is cut into the rear surface of the core member thereby forming the fold line or corner when the core member and outer layer are bend or folded. Typically heat is applied to at least the core member and / or the outer layer to impart some flexibility and aid folding or shaping. In one embodiment the groove or notch is substantially V-shaped. Typically the groove or notch is cut using CNC machine. In one embodiment once the outer layer is bonded or attached to the core member heat is applied to bend or form the same into the required shape. Typically the core member is a flat sheet of PVC which is folded and / or formed after attachment of the outer layer. In one embodiment the apparatus includes a floor plinth member. The floor plinth can be constructed in the same manner as the core and outer layer as the unit. In one embodiment the plinth member is rebated so a flooring layer can be attached to the same. In a further aspect of the invention there is provided a method of installing an apparatus for use as an IPS unit including a polymer core and an outer layer including a antimicrobial composition, said method including the step of attaching or mounting at least part of said apparatus to a wall, floor and / or ceiling of a building structure. Specific embodiments of the invention are now described with reference to the following figures wherein: Figures 1 shows an image of an IPS unit in accordance with one embodiment of the invention; and Figure 2 shows an alternative view of the IPS unit in accordance with o an embodiment of the invention. The present invention concerns the world’s first antimicrobial modular IPS unit. Primarily designed to encapsulate the pipework, the unit is an aesthetically pleasing, hygienic finish to a common trade problem. The unit is pre-fabricated with no joints, and can include access panels, sanitaryware such as basins and taps, and is wrapped in an antimicrobial or biocide containing layer. The present invention provides a joint free, fully accessible, ultra-hygienic unit, that is easy to install, but even easier to clean and maintain. The unit can be delivered pre-plumbed, reducing the installation period. The simple install procedure allows you to reduce the amount of trades required, saving you time and money. Turning now to figure 1 wherein there is shown an IPS wash station unit 2 that includes a sink 4 and taps attached to a single jointless outer surface 6. The outer surface 6 is a layer of PVC that includes antimicrobial silver encapsulated in the polymer. The outer surface 6 is bonded to a PVC core (not shown) to form a unit that is impervious to water, and even in the event of water ingress, the unitary nature of the polymer core and surface ensures that no deleterious effects can occur. The unit 2 is particularly easy to clean as it is essentially one continuous surface with no joints in which dirt can accumulate. This example includes a rebated plinth section 8 to which a vinyl floor can be lapped to form an aligned surface with the unit 2. A number of access hatches 10 are also formed in this example so that the concealed pipework 12, shown in figure 2 can be accessed for installation and maintenance. Figure 2 shows the hatches 10 open showing the pipework 12 concealed behind. Although a wash station is shown in this example, the skilled person will appreciate that the invention is not limited to a wash station; showers, sluice units or WC basins can also be provided. The benefits of the present invention over the prior art is the joint free shell which is easy to clean with no additional areas for bacteria or germs to colonise. The single PVC core also eliminates any problems associated with water ingress. The antimicrobial properties of the silver ions included in the outer 5 layer also mean that the IPS unit has surfaces upon which microbes do not survive. Laboratory and real-life testing has proved this technology reduces microbes by 80% in just 15 minutes and 99.9% in just two hours. It 10 has been proven effective against MRSA, E.Coli and even at deactivating the Influenza (H1N1) virus. PG G I- Ug

Claims

1. An apparatus suitable for use as, or at least as part of, an IPS unit, said apparatus including a core member and an outer layer or sheet 5 attached to said core member, said core member and outer layer are formed from polymer material, at least the outer layer or sheet including at least one antimicrobial agent or additive wherein the apparatus is bent or folded to form a single unit with two or more surfaces formed at an angle to one another whereby the edge or bend where the two10 surfaces meet is a continuous surface with no cutting to at least the outer layer or sheet such that the bends or corners formed are seamless.

2. An apparatus according to claim 1 wherein the antimicrobial agent is metal based.

153. An apparatus according to claim 2 wherein the antimicrobial agent includes silver ion, zinc or copper.

4. An apparatus according to claim 1 wherein the antimicrobial agent 20 is a biocide.

5. An apparatus according to claim 4 wherein the biocide is a phenolic biocide, quaternary ammonium compoundtrichlorohydroxydiphenylether, a methyl urea, or imidazolcarbamate.

6. An apparatus according to any preceding claim wherein the core member is constructed from polyvinyl chloride (PVC).PG G I- Ug7. An apparatus according to any preceding claim wherein the core member is formed from a single or unitary sheet of polymer or polymeric material.5 8. An apparatus according to any preceding claim wherein the outerlayer or sheet is constructed from PVC.

9. An apparatus according to any preceding claim wherein the core member and outer layer or sheet are attached together using at least 10 one adhesive or glue.

10. An apparatus according to claim 9 wherein the adhesive is a vinyl adhesive.15 11. An apparatus according to claim 10 wherein the adhesive a sprayadhesive.

12. An apparatus according to claim 1 wherein the apparatus is substantially U-shaped.2013. An apparatus according to claim 12 wherein the apparatus includes at least a front surface and two side surfaces substantially surrounding pipework and / or cisterns when attached to a wall.25 14. An apparatus according to any preceding claim wherein theapparatus includes one or more apertures formed to allow one or more doors, access hatches, pipes, sanitary fittings and / or the like to be attached or mounted on the apparatus.PG G I- Ug15. An apparatus according to any preceding claim wherein the apparatus is provided with sanitaryware attached to the same.

16. An IPS unit according to claim 1 including a solid or homogeneous 5 polymer core.

17. A method of manufacturing an apparatus for use in an IPS unit including a polymer core and an outer layer including an antimicrobial composition according to claim 1, said method including the step of 10 adhering or gluing the core and outer layer together.

18. A method of installing an apparatus for use as an IPS unit including a polymer core and an outer layer including a antimicrobial composition according to claim 1, said method including the step of attaching or 15 mounting at least part of said apparatus to a wall, floor and / or ceilingof a building structure.

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