Modular retro-fit pod

Abstract

A modular bathroom pod is described which is assembled on site. It has an enclosure with a floor, ceiling and walls. At least two of the walls have a stainless-steel frame with a flush outer cladding

Description

Field of the invention The present invention relates to a modular retro-fit pod for use in prisons and other custodial or similar establishments. Background of the invention The concept of a modular retro-fit pod is known and is used mainly within hotels and the like. The majority of UK prison cells do not have showers and there is a drive in the UK by the Ministry7 of Justice (MOJ) to increase decency in prisons and avoid communal showers. Furthermore, in 2018 the total UK prison population was 83,618 (0.088% of the population), 79,749 men and 3,869 women. In 2019 England and Wales have the largest prison population in Western Europe. However, furniture and fittings for use in prison cells needs to be extremely robust and safe, especially where there is a risk of "‘smash ups”. Custodial furniture, such as beds, desks, lockers, screens and the like, may compromise medium density fibreboard (MDF), solid grade high pressure laminate or a plywood substrate covered with a resin material. It is also essential that any ingress of water should be avoided which can cause, inter alia, fracturing of tire medium density fibreboard (MDF) or pressure bonded resin materials. Therefore, the present invention provides a modular pod comprising a showcr / WC / wash hand basin that can be suitably retro-fitted into a prison cell and which overcomes or mitigates the aforementioned problems and disadvantages. Summary of the Invention The present invention provides a new and improved modular bathroom pod for use in a prison or other custodial environment. According to one aspect of the present invention there is provided a modular bathroom pod comprising an enclosure defining a floor and walls, the walls comprising a metal frame with cladding, wherein the frame compromise a flush outer face; and the inner face compromising a laminate substrate bonded with a solid surface resin and secured to the metal frame with recessed mechanical fixings. According to a further aspect of the invention the modular pod comprises at least a shower, WC and wash hand basin. The entrance to the modular pod may be fitted with saloon style doors or a curtain secured in a way that the rail and fixings are ligature resilient. The metal frame will generally comprise a stainless steel fame or mild steel frame with stainless steel or mild steel outer face flush in appearance. The metal frame will be provided with a metal outer skin, e.g. a sheet stainless (or mild) steel plain outer skin where visible; a compact grade laminate substrate bonded with solid surface resin internal face fixed to the frame or a thicker solid surface resin internal face without a substrate bonded to the frame (this may depend on the pod size and the nature of the prison (Cat D to Cat A). Thus, the external appearance of the frame and cladding is that of a conventional wall found in most buildings, i.e. ready for decoration. There will generally be a cavity between inner and external surfaces, this cavity may desirably be substantially filled with non-combustible insulation material. The solid surface resin will generally be secured to the stainless steel frame with mechanical fixings (bolts and screws) which are recessed below the resin face, or proprietary- commercial adhesive, or a combination of both; and then concealed with resin pellets, thus making them invisible and inaccessible to the layperson under normal conditions. The mild or stainless steel frame may be manufactured in such a way that they bolt together and thus smaller sections can be combined to make a larger wall. Hie combination of smaller sections is advantageous because, inter alia, it makes manual handling and logistics easier. Similarly, the inner face comprising a laminate substrate bonded with a solid surface resin will generally comprise a compact grade laminate (sometimes also called solid grade laminate) substrate bonded with a solid surface resin. The inner face will generally comprise internal panels that may also be manufactured as smaller panels which are capable of being interlinked. The interlinking of the smaller panels may compromise a three stepped tongue and groove, with the addition of a solvent weld adhesive in order to make the joint watertight and invisible to the layperson under normal conditions. In the modular pod, one wall will define an entrance. The floor may be constructed of a cast of solid surface resin type with a prepositioned fall to a drain. The dimensions of the frame will vary depending upon, inter alia, the nature of the modular pod. However, such dimensions will be well understood by the person skilled in the art. The frame will be provided with means for securing it to a building which houses the modular pod. Thus, in use, the modular pod may be secured to the building at one or more fixing points. By way of example only, the modular pod may be adapted to be screwed or bolted to the floor or wall(s) of the prison building. It will be understood that any combination of the aforementioned fixing means and / or fixing points. Indeed it is preferable that more than one fixing point is used. The thickness of the panels may vary, depending upon, inter alia, the nature of the pod being provided. For example, it may be from about 10 to 50mm thick; or from about 15 to 50 mm thick; or from about 15 to 45mm thick; or from about 20 to about 45mm thick; or from about 20 to 40mm thick; or from about 20 to 35mm thick; or from about 20 to about 30mm thick; e.g., about 25mm thick. A variety of surface coating resins may be used. Such resins include, for example, acrylic polymers. A preferred material may compromise an acrylic polymer / alumina trihydrate composite, such as it available as Krion® from Porcelanosa or Corian™ from Du Pont. Another example of a substrate is a high pressure laminate plate material. A particular high pressure laminate plate material may compromise a phenolic resin. A preferred material may comprise Trespa™ which is commercially available from Trespa International BV. A variety of waterproof resins may be utilised for the waterproof base according to this aspect of the invention. In one embodiment, the waterproof base resin will compromise the same resin as that used in the substrate. Thus, for example, furniture comprising a Krion® or Corian™ coating may comprise an acrylic polymer base; or furniture comprising Trespa™ may comprise a phenolic resin base. However, it is within the scope of the present invention for a different resin to be used for the waterproof base. However, it will be understood by the person skilled in the art that any suitable thermoplastic or thermoset resin or cellulosic material may be used. The resin or polymer material should be water resistant and non-absorbent towards water and non-degradable. Thus, the resin or polymer may comprise a natural or synthetic material or a mixture of natural or synthetic material. Examples of natural materials include, but shall not be limited to, rubber based material. Examples of synthetic materials 5 include, but shall not be limited to, silica polymers, and the like. The modular pod will generally include appropriately positioned plumbing, ventilation and wiring. 10 Key features of the modular bathroom pod of the invention include: • Bespoke space savings design, built to suit existing waste outlets and water services • Incorporates ligature-resistant MOJ approved fixtures, fittings and sanitary 15 ware. • Tried and tested water resilient and fire retardant materials used throughout. • 304 or 316 grade stainless steel framework. • Water resilient triple lock panel joints minimalised as far as possible. • Panels incorporate self-cleaning and purification properties when subject to 20 natural or artificial light. • Modular construction for easy transportation and assembly on-site. • 10 year limited warranty on all resin materials. • Ligature resistant design throughout (excluding saloon doors if fitted). The modular pod is advantageous in that, inter alia, it can be suitably retro-fitted into a prison cell or other custodial establishment The term “custodial establishment” shall include for example, prisons, police cells, (high security) mental institutions, and the like. The watertight interlinking of smaller panels with a three stepped tongue combined with a solvent weld adhesive is novel per se. Therefore, according to a further aspect of the invention there is provided a panel comprising a plurality of smaller interlinked panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld. In particular, the watertight interlinked panels comprise a laminate substrate bonded with a solid surface resin, e.g. a compact grade laminate substrate bonded with a solid surface resin. Advantageously the joints between the smaller panels are watertight. Solvent welding refers to a process in which a solvent or solvent blend with no dissolved polymer is used to create a joint between two usually thermoplastic parts. Solvent welding and solvent cementing are simple and inexpensive processes that produce durable, hermetic joints. Compared with mechanical fastening, the joint may be lighter in weight, does not need additional components, and can be quicker to assemble. Hie solvent cementing process also avoids the stress concentrations usually found at mechanical fixings. The process gives a joint with low or zero visibility and, unlike adhesive bonding, there is no additional phrase at the joint. Compared with most thermoplastic welding techniques, solvent cementing can be used to assemble components containing irregular joints. Solvent welding and solvent cementing can produce welds with very little or no weld flashes, giving a better appearance than the welding techniques that use heat or friction. Furthermore, compared with frictional techniques, there is no risk of producing particulate debris. According to a further aspect of the invention there is provided a panel as herein described for use in the manufacture of a modular bathroom pod as herein described. According to a further aspect of the invention there is provided a method of manufacturing a modular bathroom pod as herein described which comprises interlinking a plurality of smaller metal frames and smaller panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive. The invention will now be illustrated by way of example only and with reference to the accompanying drawings in which: figures 1 and 2 illustrate typical illustration of left handed shower pod stainless steel metal framework; figures 3 and 4 illustrate typical illustration of right handed shower pod stainless steel metal framework figure 5 illustrates typical left-handed shower pod ceiling, base panels and shower tray; figure 6 illustrates typical left-handed shower pod frame; figure 7 illustrates typical left-handed shower pod plan; figures 8 and 9 illustrate typical left-handed shower pod sections; figures 10 and 11 illustrate typical left-handed shower pod wall panel; figure 12 illustrates typical right handed shower pod ceiling, base panels and shower tray; figure 13 illustrates typical right-handed shower pod frame; figure 14 illustrate typical right-handed shower pod plan; figures 15 and 16 illustrate typical right-handed shower pod sections; figures 17 and 18 illustrate typical right-handed shower pod wall panel; figure 19 illustrates typical version 1 left-handed shower pod base and ceiling panels and shower tray; figure 20 illustrates typical version 1 left-handed shower pod frame; figure 21 illustrates typical version 1 left-handed shower pod plan; figures 22 and 23 illustrate typical version 1 left-handed shower pod sections; figures 24 and 25 illustrate typical version 1 left-handed shower pod wall panel; figure 26 illustrates ty pical version 1 right-handed shower pod base, ceiling panels and shower tray; figure 27 illustrates typical version 1 right-handed shower pod frame; figure 28 illustrates typical version 1 right-handed shower pod plan; figures 29 and 30 illustrate typical version 1 right-handed shower pod sections; and figures 31 and 32 illustrate typical version 1 right handed shower pod wall panel. Optional embodiments of the invention are described in the clauses below: Clause 1. A modular bathroom pod comprising an enclosure defining a floor and walls, the walls comprising a metal frame with cladding, wherein the frame comprise a flush outer face; and the inner face comprising a laminate substrate bonded with a solid surface resin and secured to the metal frame with recessed mechanical fixings. Clause 2. A modular bathroom pod according to clause 1 wherein the modular pod comprises at least a shower, WC and wash hand basin. Clause 3. A modular bathroom pod according to any one of clauses 1 or 2 wherein the metal frame is a stainless steel frame. Clause 4. A modular bathroom pod according to any one of the preceding clauses wherein the stainless steel frame comprises a stainless steel outer face flush in appearance. Clause 5. A modular bathroom pod according to any one of the preceding clauses wherein the solid surface resin is generally secured to the stainless steel frame with mechanical fixings (bolts and screws) which are recessed below' the resin face, or proprietary commercial adhesive, or combination of both. Clause 6. A modular bathroom pod according to clause 5 wherein the mechanical fixings are concealed in resin pellets. Clause 7. A modular bathroom pod according to any one of the preceding clauses wherein the mild or stainless steel frame is manufactured in such a way that they bolt together and thus smaller sections can be combined to make a larger wall. Clause 8. A modular bathroom pod according to any one of the preceding clauses wherein the inner face comprising a laminate substrate bonded with a solid surface resin generally comprises a compact grade laminate substrate bonded with a solid surface resin. Clause 9. A modular bathroom pod according to any of the preceding clauses wherein the inner face generally comprises internal panels that may also be manufactured as smaller panels which are capable of being interlinked. Clause 10. A modular bathroom pod according to clause 9 wherein the interlinking of the smaller panels comprises three stepped tongue and groove, with the addition of a solvent weld adhesive. Clause 11. A modular bathroom pod according to clause 10 wherein the j oint between the interlinked smaller panels is watertight. Clause 12. A modular bathroom pod according to any one of the preceding clauses wherein one wall of the modular defines an entrance. Clause 13. A modular bathroom pod according to any one of the preceding clauses wherein the frame is provided with means for securing it to a building which houses the modular pod. Clause 14. A modular bathroom pod according to clause 13 wherein the modular pod is adapted to be screwed or bolted to the floor or wall(s) of the prison building. Clause 15. A modular bathroom pod according to any one of the preceding clauses wherein the resm includes acrylic polymers. Clause 16. A modular bathroom pod according to any one of the preceding clauses wherein the resin is an acrylic polymer / alumina trihydrate composite, such as is available as Corian™ from Du Pont. Clause 17. A modular bathroom pod according to any of the preceding clauses wherein the resin is a high pressure laminate plate material. Clause 18. A modular bathroom pod according to clause 17 wherein the high pressure laminate plate material comprises a phenolic resin, such as Trespa™ which is commercially available from Trespa International BV. Clause 19. A modular bathroom pod according to any one of the preceding clauses wherein the resm is a waterproof resm. Clause 20. A modular bathroom pod according to any one of the preceding clauses wherein the modular pod includes appropriately positioned plumbing and wiring. Clause 21. A panel comprising a plurality of smaller interlinked panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive. Clause 22. A panel according to clause 21 wherein the interlinked panels comprises a laminate bonded with a solid surface resin, e.g. a compact granted laminate substrate bonded with a solid surface resin. Clause 23. A panel according to clause 21 or 22 where the joints between the smaller panels are watertight. Clause 24. A panel according to any one of clauses 21 to 23 for use in tire manufacture of a modular bathroom pod according to clause 1. Clause 25. A method of manufacturing a modular bathroom pod according to clause 1 which comprises interlinking a plurality of smaller metal frames and smaller panels, wherein the smaller panels are interlinked in combination of a three stepped tongue and groove and application of a solvent weld adhesive. Clause 26. A modular bathroom pod, panel or method as herein described with reference to the accompanying description and figures.

Claims

24Claims1. A modular bathroom pod having a modular construction assembled on-site in a custodial establishment, the modular bathroom pod comprising:5 an enclosure defining a floor, a ceiling and walls,wherein at least two of the walls comprises:a wall stainless steel frame with an outer cladding, wherein the outer cladding comprises stainless steel sheet and wherein the outer cladding forms a flush outer wall face; and10 a wall inner panel, wherein the wall inner panel comprises a solid surface resin, wherein the inner wall panel forms an inner wall face, and wherein the wall inner panel is secured to the wall frame with mechanical fixings recessed below the resin face;wherein the ceiling comprises:a ceiling stainless steel frame; and15 a ceiling inner panel, wherein the ceiling inner panel comprises a solid surface resin,wherein the ceiling inner panel forms an inner ceiling face, and wherein the ceiling inner panel is secured to the ceiling frame with mechanical fixings recessed below the resin face.20 2. A modular bathroom pod according to claim 1 wherein the modular podcomprises at least a shower, WC and wash hand basin.

3. A modular bathroom pod according to any one of the preceding claims wherein the sold surface resin is substantially secured to the stainless steel frame witha combination of mechanical fixings which are recessed below the resin face and a proprietary commercial adhesive.12 09 244. A modular bathroom pod according to claim 1 or 3 wherein the mechanical 5 fixings are concealed with resin pellets.

5. A modular bathroom pod according to any one of the preceding claims wherein the wall inner panel comprises a plurality of inner panel sections interlinked on-site to form the wall inner panel.

106. A modular bathroom pod according to claim 5 wherein each joint between the interlinked inner panel sections comprises a three stepped tongue and groove with the addition of a solvent weld adhesive.15 7. A modular bathroom pod according to claim 6 wherein the j oint between theinterlinked inner panel sections is watertight.

8. A modular bathroom pod according to any one of the preceding claims wherein one wall of the modular bathroom pod defines an entrance.

209. A modular bathroom pod according to any one of the preceding claims wherein the wall frame comprises fixing means for securing it to the custodial establishment which houses the modular bathroom pod.12 09 2410. A modular bathroom pod according to claim 9 wherein the modular bathroom pod comprises fixing means and fixing points to screw or bolt the modular bathroom pod to the floor or wall(s) of the custodial establishment.5 11. A modular bathroom pod according to any one of the preceding claimswherein the resin of the wall inner panel and the resin of the ceiling inner panel comprises acrylic polymers.

12. A modular bathroom pod according to any one of the preceding claims 10 wherein the resin of the wall inner panel and the resin of the ceiling inner panel is anacrylic polymer / alumina trihydrate composite.

13. A modular bathroom pod according to any one of the preceding claims wherein the resin of the wall inner panel and the resin of ceiling inner panel is a 15 waterproof resin.

14. A modular bathroom pod according to any one of the preceding claims wherein the modular bathroom pod comprises ventilation, plumbing and wiring.20 15. A modular bathroom pod according to any one of the preceding claims,wherein the wall frame comprises a plurality of wall frame sections connected together to form the wall frame.

16. A modular bathroom pod according to claim 1 or 3 wherein the mechanical 25 fixings comprises bolts and screws.12 09 2417. A modular bathroom pod kit to assemble on-site at a custodial establishment, the kit comprising:a first wall stainless steel frame with a first wall outer cladding, wherein the first wall5 outer cladding comprises stainless steel plate forming a first flush outer wall face ofthe modular bathroom pod;a first wall inner panel, wherein the first wall inner panel comprises a solid surface resin, wherein the first wall inner panel is securable to the first wall stainless steel frame on-site forming a first inner wall face of the modular bathroom pod and wherein10 the first wall inner panel is securable to the first wall stainless steel frame with mechanical fixings recessed below the solid surface resin face;a second wall stainless steel frame with a second wall outer cladding, wherein the second wall outer cladding comprises stainless steel plate forming a second flush outer wall face of the modular bathroom pod;15 a second wall inner panel, wherein the second wall inner panel comprises a solidsurface resin, wherein the second wall inner panel is securable to the second wall stainless steel frame on-site forming a second inner wall face of the modular bathroom pod and wherein the second wall inner panel is securable to the first wall stainless steel frame with mechanical fixings recessed below the solid surface resin face;20 a ceiling stainless steel frame; anda ceiling inner panel, wherein the ceiling inner panel comprises a solid surface resin, wherein the ceiling inner panel is securable to the ceiling frame on-site forming an inner ceiling face of the modular bathroom pod, and wherein the ceiling inner panel is securable to the ceiling frame on-site with mechanical fixings recessed below the resin25 face.Application No: GB2400066.3Examiner: Claire TreaseClaims searched: 1-17Date of search: 11 March 2024Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance A - ES 1027515U (ALONSO DOMINGUEZ JOSE RAMON) Figures and description [0009] show a modular bathroom pod installed whole, with a flush metal exterior and metal frame 4. A - GB 2519280 A (HELMORE IAN STEWART) figures and description show a panel system for a bathroom with a metal frame 2 and a solid surface resin cladding 1. A - WO 2016 / 115534 Al (SMITH ALBERT BARRY) figures and description disclose a shower cubicle with metal rails 139 and solid surface sheets 136. A - GB 2552206 A (MEIBAN INT PTE LTD) figures and description show a prefabricated modular bathroom with a metal frame 5 and plastic wall panels 12. A - WO 2017 / 173491 Al (AUSCO MODULAR PTY LTD) figures and description show a modular panelised bathroom with a flush exterior and frame 1.Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of same category. before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority' date earlier than, the filing date of this application.Field of Search:www.gov.uk / ipoInternational Classification:Subclass Subgroup Valid From A47K 0004 / 00 01 / 01 / 2006 E04B 0001 / 348 01 / 01 / 2006www.gov.uk / ipo

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