GB2592176A

GB2592176A - Prebuilt module for installing water-related fittings

Info

Publication number: GB2592176A
Application number: GB1910416.5A
Authority: GB
Inventors: Pattison Ian
Original assignee: Abacus Direct Ltd
Current assignee: Abacus Direct Ltd
Priority date: 2019-07-19
Filing date: 2019-07-19
Publication date: 2021-08-25
Anticipated expiration: 2039-07-19
Also published as: GB201910416D0; GB2592176B

Abstract

A prebuilt module 50 for use in the installation of sanitary ware, such as basins or showers. It has a frame 12, one or more mounting members 14 and 16, a cold water supply 24 which is pressure tested, and a waste pipe 36 with an inlet at one end and a connection point. It may also comprise two hot water pipes 20 and 28, the second of which branches form the first and which are pressure tested. The pipes and mounting members may align with fittings on additional modules. There may also be a second 30 and third 32 cold water pipe. The first hot and cold pipes may be fixed to the mount at multiple locations and they may be a flexible pipe. The module may have a frame for a WC and a mount for a basin. It may also have a mount for a showerhead or a bath tap. The module may be basin, WC and shower composite module.

Description

PREBUILT MODULE FOR INSTALLING WATER-

RELATED FITTINGS

The invention relates to a prebuilt module for use in the installation of water-related fittings such as washbasins, water closets (WCs), showerheads, bath spouts and shower controls.

It is common practice to install and secure such water-related fittings in a stud wall or other similar arrangement that is constructed in order that pipework to supply taps and to remove waste can be hidden to make the bathroom more attractive and easier to service.

Such installation of water-related fittings within a room involves multiple skilled tradesperson who are employed with differing responsibilities, such as wall construction, plumbing installation, testing and the like. More specifically, the stud wall on which the water-related fittings are mounted is built by joiners; mounting frames for toilet, washbasin and furniture, and valves and controls for hot and cold water are installed by plumbers or joiners; pressure tests on the water supply lines are conducted by plumbers; and waste pipes are connected and tested by plumbers. Such a conventional installation requires a lot of time and cost. In addition, it is not easy to assure the consistent build quality.

An object of the present invention is to provide a prebuilt module for use in the installation of a water-related fitting that overcomes or substantially mitigates the aforementioned problems.

According to the present invention, there is provided a prebuilt module for use in the installation of one or more water-related fittings in a room, comprising: a framing member to be secured on the floor and/or wall of the room; one or more mounting members for the one or more water-related fittings to be secured thereon; a first cold water supply pipe which has a connector to be connected to a supply source at one end, which is connected to a supply destination at the other end in a liquid-tight manner, and which is pressure tested; and a waste pipe which locates beneath the one or more mounting members, which has one or more inlet connection points for the one or more water-related fittings, and which has a drainage connection point at one end.

One of the remarkable advantages of the invented prebuilt module is that consistent build quality can be assured regardless of who installs the water-related fitting as the supply pipe is pre plumbed in a liquid-tight manner and tested as well as the waste pipe is pre plumbed. Therefore, not only a joiner or plumber, but also somebody who is simply trained to fit or anybody who is good at DIY (do-it-yourself) can install the water-related fitting with consistent build quality. The present invention also allows for a time-saving and cost-saving over the conventional plumbing installation as the supply pipe or pipes is or are pre plumbed and tested as well as the waste pipe is plumbed. Also, one of the main features of the prebuilt module is that the position of the connectors for the supply sources and drain are always consistent as rather than connect to a neighbouring module. That is, the prebuilt module may be connected to pipes in predetermined locations within a building shell. Therefore, if a plurality of prebuilt modules are formed with the same specifications and dimensions, they may be particularly advantageous for incorporation into an apartment or hotel having the same layout or floor plan.

Preferably, the prebuilt module further comprises a first hot water supply pipe which has a connector to be connected to a supply source at one end, which is connected to a supply destination at the other end in a liquid-tight manner, and which is pressure tested. The prebuilt module having the first hot water pipe is advantageous for constructing a shower system and/or a washbasin system in the wall.

Preferably, the prebuilt module further comprises a second hot water supply pipe, which branches from the first hot water supply pipe, which has a connecter to be connected to other module, and which is pressure tested. This arrangement is advantageous in that this module can be a hot water supplier and supply the hot water to another neighbouring module via the second hot water supply pipe.

Preferably, the framing member is constructed so that the first hot water supply pipe, the first cold water supply pipe, the second hot water supply pipe, and the one or more mounting members are to align with pipes and/or water-related fittings on the another neighbouring module. This arrangement allow a builder or installer not only to install a plurality of neighbouring modules easily, but also to set up the plurality of neighbouring modules in any order as a result of the alignments of each component on the framing member.

Preferably, the prebuilt module further comprises a second cold water supply pipe, which branches from the first cold water supply pipe, which has a connecter to be connected to other module, and which is pressure tested. This arrangement is advantageous in that this module can be a cold water supplier and supply the cold water to other module via the second cold water supply pipe.

Preferably, the framing member is constructed so that the first hot water supply pipe, the first cold water supply pipe, the second cold water supply pipe, and the one or more mounting members are to align with pipes and/or water-related fittings on the another neighbouring module. This arrangement allow a builder or installer not only to install a plurality of neighbouring modules easily, but also to set up the plurality of neighbouring modules in any order as a result of the alignments of each component on the framing member.

Preferably, the prebuilt module further comprises a third cold water supply pipe, which branches from the first cold water supply pipe, which is connected to other supply destination in a liquid-tight manner. This arrangement is advantageous in that more than one water-related fittings that need cold water can be provided within one prebuilt module.

Preferably, the first cold water supply pipe and/or the first hot water supply pipe is secured to the framing member and/or the mounting member at multiple locations. This arrangement is advantageous in that the installation work can be smoothly performed without interference by the pipes. Also, damage of the pipes which might occur during the shipment can be prevented.

Preferably, the first cold water supply pipe and/or the first hot water supply pipe is a flexible pipe. This arrangement allows for easier connection of the first cold water supply pipe and/or the first hot water supply pipe to the water supply source.

In a preferred example, the prebuilt module may be a prebuilt washbasin and water closet composite module, and may include a washbasin mounting plate and a water closet supporting frame as the mounting members.

In a preferred example, the prebuilt module may be a prebuilt shower module, and may include a showerhead mounting plate and/or bath spout fitting plate as the mounting member.

In a preferred example, the prebuilt module may be a prebuilt washbasin, water closet and shower composite module, and may include a washbasin mounting plate, a water closet support frame, a showerhead mounting plate, and/or bath spout fitting plate.

The present invention will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a front view of two exemplary prebuilt modules, each of them being in accordance with the present invention; Fig. 2 is a top view of one of the prebuilt modules shown in Fig. 1; Fig. 3 is a perspective view of a room in which hot and cold water supplies are projecting from the floor along the back wall as well as a soil stack extends through the room along a vertical corner; Fig. 4 is a perspective view of the room shown in Fig. 3 illustrating a first step of the installation of the prebuilt modules shown in Fig. 1; Fig. 5 illustrates a second step of the installation of the prebuilt modules shown in Fig. 1; and Fig. 6 illustrates a third step of the installation of the prebuilt modules shown in Fig. 1.

In Fig. 1, exemplary prebuilt modules 10, 50 are illustrated. Both modules 10, 50 are for use the installation of one or more water-related fittings (not shown) in a room. The water-related fitting is a concept that includes a washbasin, a water closet (WC), a showerhead, a bath spout, a sink, or the like. The room may be a bathroom, or any room with sanitary fittings where the one or more water-related fittings are fitted in. In the illustrated example, the prebuilt modules 10, 50 used for constructing a bathroom are shown. The prebuilt modules 10, 50 may be designed in conjunction with architectural drawings or measurements on site so that the prebuilt modules 10, 50 perfectly fit to the room size, resulting in less work on the building site.

In the illustrated example, one prebuilt module 10 is a washbasin WC composite module and the other prebuilt module 50 is a shower module. Both of the prebuilt modules 10, 50 have already been plumbed up and pressure tested in a factory as described below in detail. The great advantage is that not only can consistent build quality be assured, but also these modules 10, 50 can be fitted in by a joiner or a plumber or somebody who is simply trained to fit these modules in or anybody who is good at DIY (do-it-yourself). Furthermore, this removes a lot of the time-consuming work from the work-site to specialist facilities, thereby allowing the parallel production of the building itself and the fitments. The time-saving and the cost-saving over the conventional plumbing is self-evident.

Now, referring to Figs. 1 and 2, framing members 12, 52 are provided in the prebuilt modules 10, 50. These framing members 12, 52 may be separate from one another when shipped from the factory, but may be coupled to one another upon installation. The framing members 12, 52 are to be secured on the floor and/or wall of the bathroom with fasteners such as screws, bolts and nails. The framing members 12, 52 may include upper plates 12a, 52a, lower plates 12b, 52b, and studs or vertical supports 12c, 52c extending between the upper plates 12a, 52a and the lower plates 12b, 52b. The framing members 12, 52 may further include blockings or horizontal supports 12d, 52d. The structure of the framing members 12, 52 are not limited to the illustrated example. The framing members 12, 52 can be made of any material such as wood, steel and aluminium as long as the desired strength is assured.

As shown in Fig. 1, the framing member 12 and/or 52 may include at least one recessed storage installation frame 13 to accommodate a recessed storage (not shown) such as a cupboard or shelves. The recessed storage may be fitted in the recessed storage installation frame 13. The position, size, and number of recessed storage installation frames 13 are not limited to the illustrated example. The framing member 12 and/or 52 may include two or more recessed storage installation frames 13.Each prebuilt module 10, 50 further comprises one or more mounting members for the one or more water-related fittings to be secured thereon. The water-related fittings may be secured on the mounting members with fasteners such as screws, bolts and hooks. Additionally or alternatively, the water-related fittings may engage with the mounting members. In the illustrated example, the prebuilt module 10 has a WC supporting frame 14 and a washbasin mounting plate 16 as the mounting members. Likewise, the prebuilt module 50 has a showerhead mounting plate 54 and a bath spout fitting plate 56 as the mounting members. These mounting members are secured on the framing member 12, 52 with fasteners such as screws, bolts and nails, or via one or more brackets 18 which may be secured on the framing member 12, 52 with fasteners such as screws, bolts and nails. In the illustrated example, each prebuilt module 10, 50 has two mounting members, but the number of mounting members is not limited to two, and may be one, or three or more.

The prebuilt module 10 further may comprise a first hot water supply pipe 20. As described later, for example, in the case of a prebuilt module only for the WC system, the first hot water supply pipe 20 may be not provided. The first hot water supply pipe 20 has a connector 20a to be connected to a hot water supply (supply source) HS at one end, and is connected to an outlet or isolation valve 22 of the washbasin system (supply destination) in a liquid-tight manner. The first hot water supply pipe 20 is pressure tested in a factory at a predetermined pressure such as 10 bar.

The prebuilt module 10 further comprises a first cold water supply pipe 24. The first cold water supply pipe 24 has a connector 24a to be connected to a cold water supply (supply source) CS at one end, and is connected to an isolation valve 26 of the washbasin system (supply destination) in a liquid-tight manner. The first cold water supply pipe 24 is pressure tested in a factory at a predetermined pressure such as 10 bar.

The prebuilt module 10 may further comprise a second hot water supply pipe 28. The second hot water supply pipe 28 branches from the first hot water supply pipe 20. The second hot water supply pipe 28 has a connecter 28a to be connected to another neighbouring module (the prebuilt module 50 in this example). The second hot water supply pipe 28 is also pressure tested in a factory at a predetermined pressure such as 10 bar.

The prebuilt module 10 may further comprise a second cold water supply pipe 30. The second cold water supply pipe 30 branches from the first cold water supply pipe 24. The second cold water supply pipe 30 has a connecter 30a to be connected to another neighbouring module (the prebuilt module 50 in this example). The second cold water supply pipe is also pressure tested in a factory at a predetermined pressure such as 10 bar.

The prebuilt module 10 may further comprise a third cold water supply pipe 32 which branches from the first cold water supply pipe 24. The third cold water supply pipe 32 is connected to other supply destination (a WC cistern 34 in this example) in a liquid-tight manner. The third cold water supply pipe 32 is also pressure tested in a factory at a predetermined pressure such as 10 bar. For this purpose, the end of the third cold water supply pipe 32, at which the WC cistern 34 is connected, may be plugged with a discardable plug (not shown).

The prebuilt module 10 may further comprise a waste pipe 36 which locates beneath the WC cistern 34 and the washbasin mounting plate 16. The waste pipe 36 may have one or more inlet connection points 36a, 36b for the one or more water-related fittings. The waste pipe 36 has a drainage connection point 36c at one end. The connection point 36a locates at the other end and is to be connected to the drainage side of a WC pan (not shown). The connection point 36b has already been connected in a factory to the outlet of a wall trap 38 of the washbasin system. In a preferable arrangement, the waste pipe 36 is secured to the WC support frame 14 and/or the framing member 12. Preferably, the waste pipe 36 is leakage tested in a factory.

The prebuilt module 10 may further comprise a WC flushing connection 40 which is to be connected to the flushing side of the WC pan. The WC flushing connection 40 and the WC cistern 34 may be leakage tested in a factory.

In the illustrated example, the framing member 12 is constructed so that the first hot water supply pipe 20, the first cold water supply pipe 24, the second hot water supply pipe 28, the second cold water supply pipe 30, and the one or more mounting members are to align with pipes 58, 60 on the another neighbouring module 50. This arrangement allow a builder or installer not only to install a plurality of neighbouring modules 10, 50 easily, but also to set up the plurality of neighbouring modules 10, 50 in any order as a result of the alignments of each component on the framing member 12.

Referencing back to the prebuilt module 50, a first hot water supply pipe 58 and a first cold water supply pipe 60 are provided.

The first hot water supply pipe 58 has a connector 58a to be connected to the second hot water supply pipe 28 of the prebuilt module 10 (supply source) at one end, and is connected to a mixture valve (supply destination) 62 in a liquid-tight manner. The first hot water supply pipe 58 is pressure tested in a factory at a predetermined pressure such as 10 bar.

The first cold water supply pipe 60 has a connector 60a to be connected to the second cold water supply pipe 30 of the prebuilt module 10 (supply source) at one end, and is connected to the mixture valve (supply destination) 62 in a liquid-tight manner. The first cold water supply pipe 60 is pressure tested in a factory at a predetermined pressure such as 10 bar.

The prebuilt module 50 may further comprise one or more fourth supply pipes 64, 66 for mixed water, which extend from the mixture valve 62 to the showerhead mounting plate 54 or to the bath spout fitting plate 56 and have connectors 64a, 66a at the distal ends. The fourth supply pipes 64, 66 are pressure tested in a factory at a predetermined pressure such as 10 bar. For this purpose, the ends of the fourth supply pipes 64, 66, at which the showerhead or bath spout is connected, may be plugged with discardable plugs.

In the illustrated example, the framing member 52 is constructed so that the first hot water supply pipe 58, the first cold water supply pipe 60 and the one or more mounting members are to align with pipes 28, 30 on the another neighbouring module 10. This arrangement allow a builder or installer not only to install a plurality of neighbouring modules 10, 50 easily, but also to set up the plurality of neighbouring modules 10, 50 in any order as a result of the alignments of each component on the framing member 52.

In a preferable arrangement, at least first cold water supply pipe 24, 60 and/or the first hot water supply pipe 20, 58 is a flexible pipe.

In a preferable arrangement, the connectors 20a, 24a, 28a, 30a, 58a, 60a are demountable hose couplings, such as screw coupling, quick coupling and snap coupling.

The following discussion, with reference to Figs. 3 to 6, provides an exemplary installation operation of these modules 10, 50 to construct a bathroom working wall. Duplicate descriptions are omitted with referring to the same reference numerals indicated in Figs 1 and 2.

Fig. 3 illustrates a room R in which hot and cold water supplies HS, CS are projecting from the floor rl along the back wall r2. Also, a soil stack SS extends through the room R along a vertical corner.

In the first step shown in Fig. 4, one of the prebuilt modules 10 is placed at a predetermined distance from the back wall r2. Then, the prebuilt module 10 is secured to the floor r1 and/or side wall r3 with the fasteners (not shown). The first hot water supply pipe 20 is connected to the hot water supply HS. Also, the first cold water supply pipe 24 is connected to the cold water supply CS.

In this drawing, two connectors 28a, 30a can be seen, which are provided at the ends of the second hot and cold supply pipes 28, 30. These connectors 28a, 30a project from the right side of the framing member 12.

In the next step shown in Fig. 5, an extending waste pipe EP is connected between the connection point 36c of the waste pipe 36 and the soil stack SS.

In the next step shown in Fig. 6, the other prebuilt module 50 is placed next to the prebuilt module 10. The prebuilt module 50 is secured to the floor rl, the opposite side wall (not shown) and/or the ceiling (not shown) with the fasteners (not shown). The two prebuilt modules 10, 50 may be secured to one another with fasteners (not shown). The extending waste pipe EP sits behind the prebuilt module and can be completely hidden. The first hot water supply pipe 58 is connected to the second hot water supply pipe 28. Also the first cold water supply pipe 60 is connected to the second cold water supply pipe 30.

The above installation is an example, and the present invention is not limited thereto. The installation of the modules 10, 50 and the connection of the pipes may be performed in any order as a result of the alignments of each component of the modules 10, 50.

The above installation is an example, and the present invention is not limited thereto. Either one of the modules 10, 50 may not be used. For example, if a toilet and washbasin are planned but a shower is not, the module 50 is not used, and vice versa. Also, if only the washbasin system is needed, the WC system is omitted in the module 10. Alternatively, if only the WC system and the shower system are needed, the washroom system is omitted. In this case, the WC system and the shower system may be provided in the same prebuilt module. Alternatively, if only the WC system is needed, the first hot water supply pipe 20 may not be provided in the prebuilt module 10.

After these prebuilt modules 10, 50 are fitted in, covering boards and/or tiles (not shown) are provided on the front side of the framing members 12, 52.

As evident also from these fewer steps, as the plumbing installation and testing have already been done in a factory, only minimal connecting operations are made on site, resulting in the time-saving and cost-saving over conventional plumbing installation. Also, it should be highlighted that not only consistent build quality is assured but also these modules 10, 50 can be fitted in by a joiner or a plumber or somebody who is simply trained to fit these modules 10, 50 in or anybody who is good at DIY (do-it-yourself).

Further, the exemplary prebuilt module 10 is advantageous in that this module 10 can be a hot water supplier and supply the hot water to another neighbouring module 50 via the second hot water supply pipe 28. This allows for easy installation of additional modules 50. In another arrangement, two or more second hot water supply pipes 28 may be provided.

Furthermore, the exemplary prebuilt module 10 is advantageous in that this module 10 can be a cold water supplier and supply the cold water to the neighbouring module 50 via the second cold water supply pipe 30. This allows for easy installation of additional modules 50. In another arrangement, two or more second cold water supply pipes 30 may be provided.

Furthermore, the exemplary prebuilt module 10 is advantageous in that cold water can be supplied to the additional water-related fitting (WC system) within the same module 10 via the third cold water pipe 32. Additionally or alternatively, a third hot water pipe which branches from the first hot water supply pipe 20 and which is connected to other supply destination within the same module 10 may be provided.

Furthermore, the exemplary prebuilt module 10 allows for more time-saving and cost-saving over conventional plumbing installation as the waste pipe 36 is pre plumbed.

In the exemplary prebuilt module 10, 50, the first cold water supply pipe 24, 60 and/or the first hot water supply pipe 20, 58 and/or the second hot water supply pipe 28 and/or the second cold water supply pipe 30 and/or the third cold water supply pipe 32 is secured to the framing member 12, 52 and/or the mounting member 14, 16, 54, 56 at multiple locations. This arrangement is advantageous in that the installation work can be smoothly performed without interference by the pipes 20, 24, 28, 30, 58, 60. Also, damage of the pipes 20, 24, 28, 30, 58, 60 which might occur during the shipment can be prevented.

In the exemplary prebuilt module 10, 50, the first cold water supply pipe 24, 60 and/or the first hot water supply pipe 20, 58 is a flexible pipe. This arrangement allows for easier connecting operation of the first cold water supply pipe 24, 60 and/or the first hot water supply pipe 20, 58 to the water supply source. Additionally, the second hot water supply pipe 28 and/or the second cold water supply pipe 30 and/or the third cold water supply pipe 32 is a flexible pipe.

Although not shown, a prebuilt washbasin, water closet and shower composite module may be provided. That is, the illustrated prebuilt modules 101 50 may be manufactured as a single prebuilt module. In this arrangement, one or more mounting members may include the washbasin mounting plate 16, the water closet support frame 14, the showerhead mounting plate 54, and/or the bath spout fitting plate 56.

Claims

Claims 1. A prebuilt module for use in the installation of one or more water-related fittings in a room, comprising: a framing member to be secured on the floor and/or wall of the room; one or more mounting members for the one or more water-related fittings to be secured thereon; a first cold water supply pipe which has a connector to be connected to a supply source at one end, which is connected to a supply destination at the other end in a liquid-tight manner, and which is pressure tested, and a waste pipe which locates beneath the one or more mounting members, which has one or more inlet connection points for the one or more water-related fittings, and which has a drainage connection point at one end.
2. The prebuilt module according to claim 1, further comprising a first hot water supply pipe which has a connector to be connected to a supply source at one end, which is connected to a supply destination at the other end in a liquid-tight manner, and which is pressure tested.
3. The prebuilt module according to claim 2, further comprising a second hot water supply pipe, which branches from the first hot water supply pipe, which has a connecter to be connected to another neighbouring module, and which is pressure tested.
4. The prebuilt module according to claim 3, wherein the framing member is constructed so that the first hot water supply pipe, the first cold water supply pipe, the second hot water supply pipe, and the one or more mounting members are to align with pipes and/or water-related fittings on another neighbouring module.
5. The prebuilt module according to any one of claims 1 to 4, further comprising a second cold water supply pipe, which branches from the first cold water supply pipe, which has a connecter to be connected to other module, and which is pressure tested.
6. The prebuilt module according to claim 5, wherein the framing member is constructed so that the first hot water supply pipe, the first cold water supply pipe, the second cold water supply pipe, and the one or more mounting members are to align with pipes and/or water-related fittings on another neighbouring module.
7. The prebuilt module according to any one of claims 1 to 6, further comprising a third cold water supply pipe, which branches from the first cold water supply pipe and which is connected to other supply destination within the same prebuilt module in a liquid-tight manner.
8. The prebuilt module according to any one of claims 1 to 7, wherein the first cold water supply pipe and/or the first hot water supply pipe is secured to the flaming member and/or the mounting member at multiple locations.
9. The prebuilt module according to any one of claims 1 to 8, the first cold water supply pipe and/or the first hot water supply pipe is a flexible pipe.
10. The prebuilt module according to any one of claims 1 to 9, wherein the prebuilt module is a prebuilt washbasin and water closet composite module, and wherein one or more mounting members include a washbasin mounting plate, and a water closet supporting frame.
11. The prebuilt module according to any one of claims 1 to 9, wherein the prebuilt module is a prebuilt shower module, and wherein one or more mounting members include a showerhead mounting plate and/or bath spout fitting plate.
12. The prebuilt module according to any one of claims 1 to 9, wherein the prebuilt module is a prebuilt washbasin, water closet and shower composite module, and wherein one or more mounting members include washbasin mounting plate, a water closet support frame, a shower head mounting plate, and/or bath spout fitting plate.