US3148380A - Service station restrooms - Google Patents

Service station restrooms Download PDF

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US3148380A
US3148380A US263994A US26399463A US3148380A US 3148380 A US3148380 A US 3148380A US 263994 A US263994 A US 263994A US 26399463 A US26399463 A US 26399463A US 3148380 A US3148380 A US 3148380A
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shells
shell
units
mold
wall
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Paul C Hanson
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Rohr Inc
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Rohr Inc
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/12Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles
    • E04H1/1205Small buildings erected in the open air
    • E04H1/1216Public W.C.s
    • EFIXED CONSTRUCTIONS
    • E03WATER SUPPLY; SEWERAGE
    • E03CDOMESTIC PLUMBING INSTALLATIONS FOR FRESH WATER OR WASTE WATER; SINKS
    • E03C1/00Domestic plumbing installations for fresh water or waste water; Sinks
    • E03C1/01Domestic plumbing installations for fresh water or waste water; Sinks for combinations of baths, showers, sinks, wash-basins, closets, urinals, or the like

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  • An object of the present invention is to make provision for the factory fabrication of such restroom constructions in order to secure the recognized advantages and to eifect the economies and efiiciencies which naturally flow from the utilization of factory methods, procedures and techniques in the manufacture of items which lend themselves to mass production.
  • Another object is to provide service station restroom structures which may largely be unitized and/or constructed as major components at the factory thereby greatly to minimize the time and skill required in the onsite construction of such structures.
  • Still another object resides in the provision of service station restroom structures of largely unitized and continuous wall and floor surface areas in order greatly to minimize the amount of work required to maintain a high standard of cleanliness of such structures notwithstanding the generally great and continuous demand for and frequency of use of the services afforded by such structures.
  • Yet another object is to provide service station restrooms of this character having provision for access to the utility connections to the units and having provision for the ready draining of copious quantities of water such as may be applied with a water hose to wash down the walls and the floor of the units.
  • Still another object is to provide bathroom structures having smooth and contoured wall and floor surfaws which inherently are well suited to avoid the collection of dust, dirt, and grime while at the same time providing a pleasing appearance, with possibili'des also of presenting a wide variety of color and design effects while avoiding the need for recurrent redecoration and/ or maintenance.
  • Still another object is to provide interior bathroom structures and effects as aforedescribed, which will also lend themselves to the adaptation and application of desired secondary bathroom fixtures such, for example, as wall hung stools, mirrors, vanities, towel waste baskets, and the like.
  • Yet another object is to provide service station bathroom structures, as aforedescribed, which contemplates an overall and structurally integrated rest room facility consisting of separately but similarly formed mens and womens units providing an accessible utility wall area and passage therebetween.
  • Still another object in service station bathroom structures, as :aforecontemplated, is to render such structures adaptable to the use of prefabricated plumbing trees and waste lines.
  • An additional object resides in the provision of factory fabricated service station bathroom structures providing the aforedescribed interior features and constructions which may readily be integrated with the exterior wall construction and plan of the service station of which it is to form a pant and a facility.
  • FIG. 1 is a view in perspective of the mold used to form the molded shells employed in the construction of the service station restrooms of the present invention
  • FIG. 2 is a plan view of the restrooms as viewed substantially along the line 22 of FIG. 3, certain parts being shown in section;
  • FIG. 3 is a partial elevational view in section of the restrooms as viewed along the line 33 of FIG. 2;
  • FIG. 4 is a view in elevation of an interior wall as seen along the line 44 of FIG. 2;
  • FIG. 5 is a sectional view, somewhat enlarged, of a door and its mounting frame, and the manner of mounting the frame to the interior plastic shell and the exterior metal framework of the restrooms, the section being viewed at the level of one of the hinge supports for the door;
  • FIG. 6 is a somewhat enlarged sectional view of the floor drain construction as it appears in FIG. 3;
  • FIG. 7 is a somewhat enlarged sectional view illustrating the beam construction of a shell unit as viewed along the line '7-7 of FIG. 3.
  • a service station restrooms structure comprising an exterior sheet metal wall and framework it) which generally extends around and encloses a generally plastic interior wall construction which forms the subject matter of the present invention.
  • the exterior framework it will suffice herein to point out that it comprises the usual J-stud construction 11 which is duplicated, that is, two such studs are used, as required, in the corners of the exterior framework as at 12.
  • the exterior construction and framework will generally follow the overall design of the service station and forms no part of the present invention except that access openings as at 13 must be provided, the internal construction of the present invention otherwise being fully designed and adapted to the exterior construction, as will hereinafter more fully appear.
  • the service station restrooms 10 comprise a mens room generally designated 14 and a womens room generally designated 16. These rooms are identical and identically formed except that the access door 15 for the mens room is located on the left of the unit and the access door 17 for the womens room is located on the right of the unit, as viewed in FIG. 2.
  • Each of rooms 14 and 16 is formed of two molded glass fiber reinforced polyester shells generally designated 18 and 19, which shells together provide the floor, walls, and ceiling of their respective rooms. Shells 18 and 19 have vertically extending wall portions 20 which project inwardly into the room of which they form a part and serve as beams to provide the requisite strength for the plastic walls.
  • each of rooms 14 and 16 tends to be divided, as indicated by the dashed lines 21, 22, and 23 into three compartments in each room, for example, the compartment bounded by the dashed line 21 provides a toilet area or stall in which is located a wall hung stool 24.
  • the compartments bounded by the dashed lines 22 tend to define a lavatory area, or compartment, in which is located the lavatory 25, mirror 26, and a towel waste basket 27.
  • the dashed lines 23 suggest a third compartment in which a wall hung urinal 28 is located, and in the womens room, the dashed lines 23 tend to define a vanity compartment in which is located a vanity shelf 29 which may be formed of any material suitable for the purpose such, for exa ample, as manufactured marble.
  • An appropriate stool or chair 30 and a mirror 31 for the vanity shelf 29 completes the vanity compartment.
  • FIG. 1 discloses the mold per so, this being generally designated 32.
  • the mold is a unitary structure except for the removable door plug 33 which is secured thereto by suitable means (not shown).
  • the door plug 33 In the position shown in FIG. 1, the door plug 33 is located on the mold 32 so as to provide the door opening for shell 18 of womens room 16, this opening being for door 17 of this room.
  • plug 33 would be removed from mold section A, as seen in FIG. 1, and similarly secured to the corresponding side of mold section C.
  • Sections A, B, and C each comprises a surface 34 which extends upwardly from a peripheral flange 35 which extends all around the mold.
  • the mold as disclosed in FIG. 1, is in the position in which the shell 18 is molded thereon, the face of the mold including the flange 35 thus constituitng the bottom of the mold.
  • the shell portions which are molded on the mold faces 34 form top surfaces of the shells and therefore form ceiling portions 36 of the rooms, as viewed in FIG. 3. That portion of the shell which is molded against the peripheral flange 35 provides a flange 37 as viewed in FIG. 3.
  • the back faces of the mold i.e., those faces disposed opposite the front faces 34 are similarly formed, and the shell portions molded thereagainst form the bottom surfaces for shell portions 38 which form the floor surfaces of the room.
  • the shell portion formed against the peripheral flange 35 results in a flange 39, these flanges merging with the shell floor portions 38.
  • the drain 40 is a trough or channel formed in the concrete slab 41, the channel being enlarged at the surface to provide a seat, as at 42, for the turned down edges of an elongated drain cover 43 which, like the shells 18 and 19, is formed of molded glass reinforced polyester. Cover 43 is suitably perforated, the small openings not being shown.
  • the usual trap 44 is employed at the base of gutter 4t and a waste line 45 extends from the trap to the main drain line 46, FIG. 3.
  • the front and back faces of mold 32 merge into surfaces 47 which parallel the base or flange 35 of the mold.
  • the shell wall portions 48, FIG. 3 extend vertically from the floor level.
  • beams 20, which result from intermediate mold surfaces 49, FIG. 1 also rise vertically from the floor level, but like the wall surfaces 48, FIG. 3, merge with the floor shell surface 38 in rounded inside corners 50.
  • These inside corners 50 are similarly formed where ceiling surfaces 36 meet the wall surfaces 48.
  • Portions of the surfaces 47 of the mold may be waxed, or otherwise treated, or blocked, so that a resultant opening 51, FIG. 3, is formed behind the mirrors 26 for access when this is required, to the utility lines between the units 18 and 19.
  • the mold surfaces 49, FIG. 1 rise considerably short of the faces 34 and merge with surfaces 52 which slope considerably more than the faces 34 toward flange 35, and at the flange, are set back somewhat therefrom, as at 53.
  • the vertical surface of beam 20, FIG. 3 merges by way of an inside corner 54 with a steeply rising ceiling beam portion 55 which, in turn, terminates in an outside corner 56 which merges with the flange 37.
  • Mold sections A, B, and C are formed symmetrically, the arcuate surfaces 57, FIG. 1, on opposite sides of each section, being identical.
  • the side walls 58, FIG. 2, of each of shells 18 and 19 are arcuately formed and merge by way of outside and inside corners 59 and 60, respectively, with the vertical walls 20 and 48, respectively, and also by way of outside corners 61 with the flange 37.
  • These outside corners 61 also appear at the floor flanges 39 and cover plate 43, FIG. 6.
  • the manner in which the rounded beam 28 thus merges into the ceiling beam 55 is best seen in FIG. 7.
  • Wall surfaces 58 in the ceiling beam region 55 form outside corners 62 therewith and form inside corners 63 with the ceiling surfaces 36.
  • Shell 19 is formed on mold 32 without the door plug 33 thereon and, hence, flange 37 is fully formed on the three lips of each shell 19, flange 39 being formed on the fourth lip of the shell.
  • surfaces 64 and 65 on plug 33 produce side and top flanges in the door opening in the shell.
  • a resulting side flange 66 forms the side of the door opening opposite flange 37 in shell 19, as best seen in FIGS. 2 and 5, and this merges by way of an outside corner 67 with arcuate wall 58, FIG. 2.
  • Plug surface 65 forms a flange (not shown) on each shell 18 which lies at the top of the door opening and extends from flange 66 to flange 37 in the companion shell 19.
  • An inside corner joins this flange, and arcuate wall surface 58.
  • exterior frame 10 is flanged as at 68, and a conventional door frame 69 is secured to this flange as by metal screws 70.
  • Frame 69 is also secured, as by screws 71, to flange 37 of shell 19 and to flange 66 of shell 18, thereby securing the same together in the door region of the composite shell.
  • the door 17 is mounted, as by the usual hinges 72, to the frame 69, and includes the additional hardware, such as locks, latches, and the like (not shown).
  • Door 15, of course, is similarly mounted and furnished.
  • the shells 18 and 19 for each of units 14 and 16, as aforedescribed, are spaced from each other by the width of drain channel 40 or, as best appears in FIG. 2, by the width of a drain cover 43.
  • the openings between flanges 37 for both units 14 and 16 are closed, as by metal louvers 73, and the openings above doors 15 and 17, FIG. 4, are similarly closed by a short section of louvers 73.
  • the opening between flanges 37 in the ceiling in each unit is left open, except where the flanges are joined by fasteners 74, FIGS. 3 and 4.
  • the rooms are thus vented to a plenum chamber provided by the exterior framework 10, and this plenum may contain an exhaust fan, as desired or required.
  • Each of rooms 14 and 16 is furnished with a molded glass fiber reinforced reflector sofit 75 for a fluorescent light fixture 76 and its ballast 77.
  • Light switches and convenience outlets (not shown) understandably are provided.
  • Units 14 and 16 are spaced from each other by 1 /2 to 2 feet, or more, to provide a space for the utility lines and to admit a maintenance or repair man by way of the access openings 13.
  • This spacing of the units is fixed by three metal frameworks, each of which comprises a pair of back-to-back upright plates 78 to which are secured, at each side, a pair of spacer bars 79, FIGS. 2 and 3.
  • the plates 78 are curved to interfit with the shells 19 and thus provide support therefor as well as to serve as carriers for the lavatories 25, Wall hung stools 24 and urinal 28, and also to support,
  • Hot and cold water lines (not shown), preferably in the form of a plumbing tree, are also provided in the utility space.
  • the stool compartments preferably are partitioned by a partial Wall $6 and coacting door 87 which is suitably hinged by means (not shown) to a strip 88, in turn, secured by any suitable means (not shown) to beam 20.
  • Wall panels 86 for both units are supported in cantilevered channel members 89 which extend through the utility space and into both rooms.
  • the units preferably are lashed or strapped together at the top as by molded glass reinforced polyester tie members 99 which are U-shaped n1 cross section to interfit within the ceiling beams, as may best be visualized from the corresponding U-shaped configuration of the ceiling beam as it appears in cross section in FIG. 7.
  • shells 18 and 19 may be formed of any material suitable for the purpose such as the aforementioned glass fiber reinforced polyester resin to provide thin wall, light weight construction of great strength.
  • the shells are formed of a glass impregnated, promoted and pigmented polyester resin adapted for application and layup with a gun in a known manner upon a male mold such as mold 32 hereinbefore disclosed. Mold 32 with its almost severe draft lines and contours is ideal for the purpose, since the shell once formed thereon may readily be stripped from the mold.
  • a suitable parting agent is first applied to the surfaces of the mold.
  • a gel coat of a suitably pigmented polyester resin is next applied to the mold, and the interface of this coat with the smooth surface of the mold assures a smooth interior Wall surface in the restroom of which it is to form a major component and part.
  • the gel coat moreover, being pigmented, may have desired color and design effects, and will be long lasting to thus obviate the need for redecoration and/or repairs.
  • the shell is then completed on the mold by application of the glass impregnated polyester resin to the gel coat.
  • the resulting shell with its inherent beam construction and thin, but tough and strong walls, will have great structural integrity while also presenting a contoured and smooth wall, floor, and ceiling interior surface which will resist the accumulation of dust, dirt and grime, and such soil materials as do collect, may readily be removed as by washing the same down under pressure of water from a hose.
  • the floor surfaces it may be desirable to use a very thin gel coat so that the glass fibers lie just below the surface to provide some traction to avoid the adverse consequences of a too slippery floor surface.
  • The. surface in such case, will nevertheless be sufiiciently smooth for free flow of water to the drain 40.
  • the thin, strong shells have an additional advantage in that the same may readily be shipped in sets, as required; in some cases, for example, the shells being telescoped, one shell within the other.
  • the spacer metal frameworks 78, 79 and their supported plumbing trees, waste and supply lines may first be installed on the concrete slab, which is prepared with the gutters 4i), traps 44, lines 45, and main drain 46 in position as shown.
  • an asphalt compound, or like undercoating be applied to the concrete slab to retain the shells more or less in position thereon.
  • the shells 19 are positioned on the slab first, being set back-to-back in interfitting relation with the plates 78.
  • the Wall hung fixtures 24 to 26, 28, 29 and 31 together with the lighting system 75 to 77 may now be installed, or alternatively, this may be accomplished when the rooms have been completed structurally, or during preferred stages of the assembly.
  • the channel supports 39 and the partial walls 86 will probably best be installed before the shells 18 are positioned on the slab.
  • the positioning and location of the shells 18, as hereinbefore alluded to, is determined by the gutters 40, and this assures that the shells 18 and 19 will be properly spaced to receive and accommodate the door frames 69 more or less interfittingly therewith, such that the frames may readily be mounted in position on the shells, and the doors l5, 17 may thereafter be mounted in the frames.
  • the louvers 73 likewise, will readily mount in the spaces provided therefor between the shells when the same are properly spaced to receive the drain covers 43.
  • the shells thus positioned may simply be secured together at their flanges 37 as by the fasteners 74 and additionally lashed together as in the region of the ceiling beams 55 by the straps 90, or the like.
  • shells 19 are bonded to the carrier plates 78 in back-to-back relation and to the straps 90 with all fixtures md appurtenances installed on the shells, and with the plumbing trees connected thereto at the factory.
  • the toilet stall partitions to 89 may also be installed to their respective shells 18 and 19 at the factory to facilitate and expedite the on-site assembly.
  • this assembly is installed on the slab in relation to the main drain line 46 and the gutters 40.
  • Shells 18 are next set'on the slab in relation to the gutters and secured to the shells 19 at the top by the fasteners 74, the louvers 73 and door frames 39 being installed any time after the shells are set on the slab.
  • Service station restrooms of the character disclosed comprising, in combination, identical and separate mens and womens plastic shell units spaced from each other on a concerte slab support therefor, said slab support having for each of said units an elongated drainage trough which extends centrally of the unit from the front to the back thereof, each of said units comprising a pair of dish-shaped flanged molded plastic shells positioned on said slab support with their flanged portions vertically disposed in confronting and spaced relation to each other on opposite sides of said trough, said confronting flanged portions disposed adjacent said trough being depended therewithin, said shells on the interior surfaces thereof providing the wall, ceiling and floor surfaces of said units, louvre means interposed between certain confronting flange portions of the shells of each said pair of shells, and fastener means for securing certain other flange portions of the shells of each said pair of shells together in said mutually spaced relation and with respect to their common trough.
  • each shell of each said pair of shells having a peripheral flange, the portion of each said flange adjacent to the floor surface of its shell being disposed in depending relation into its associated trough, said trough comprising a shouldered A surface opening in said slab support, and an elongated perforated cover plate for said trough adapted to interfit with the shell flange portions within said shouldered opening, said cover plate having depending flange portions disposed in seated relation on the shouldered surfaces of said shouldered opening.
  • Service station restrooms of the character disclosed comprising identical and separate mens and womens" plastic shell room units spaced from each other on a common concrete slab support therefor, at least one metal framework disposed between said units and comprising a pair of spaced plates which respectively interfit with the adjacent exterior plastic surfaces of the units, each of the units having at least one Wall hung fixture supported on said adjacent plate, each of said units comprising a molded plastic shell structure having inwardly offset wall and ceiling surface portions defining externally disposed channels and internally disposed beams, said channels of one unit being aligned respectively with the channels of the other unit, means for lashing said spaced units together, said lashing means comprising plastic strips each of which extends across the space between said units and is secured at the ends thereof to the confronting shell structures of the units, said secured ends being disposed respectively within a pair of said aligned channels of the spaced units, said beams defining room compartments therebetween in each said unit, there being one said wall hung fixture in each of said compartments, and there being one said fixture supporting framework for each
  • Service station restrooms of the character disclosed for integration within an exterior framework structure comprising a pair of plastic shell room units disposed within said exterior structure and in spaced relation backto-back to form a utility space therebetween, said units comprising a plurality of wall hung fixtures mounted on the confronting Walls of the units, plumbing lines and connections disposed in said space and connected to said fixtures, said lines including a main vent extended through the roof of said exterior structure, each of said units having an access door, and said exterior framework structure comprising access panels to said utility space and doorway openings for the access doors of the units, each of said plastic shell units comprising a pair of dishshaped and flanged shells, the flanged portions of said shells being disposed vertically and in mutually spaced and confronting relation, one of said shells being recessed in its flanged region to form with the adjacent flanged portion of the other shell an opening for the access door of the units, louvre means for closing the space disposed between said flanged portions and above said door opening, and similar louvre
  • a pair of dish-shaped flanged plastic shells positioned with their flanged portions vertically disposed and in confronting spaced relation on a common support having an elongated drain channel, said shells being disposed on opposite sides of said channel and spaced thereby and having the adjacent flanged portions thereof depended within the channel, a cover plate for said channel, a door opening defined by said confronting flanged portions of the shells in one wall of the restroom structure, and louvre means closing the remaining openings between the flanged portions of the shells in said one wall and the wall opposite thereto in said structure.
  • each of said shells having flat surfaces parallel to the flanged surface of the shell, certain of said flat surfaces being offset inwardly from other of the flat surfaces to constitute beam construction for said shells and tosimulate a plurality of compartments in said restroom structure.
  • a dish-shaped glass reinforced plastic shell having a peripheral flange, flat bottom surfaces, flat end surfaces which converge from the flange toward said bottom surfaces, and arcuate side surfaces which converge from said flange toward said bottom surfaces, certain of said bottom surfaces being offset inwardly from other of the bottom surfaces and interconnected by arcuate partial side surfaces to form a bottom beam construction, said certain bottom surfaces extending short of the opposite ends of said other bottom surfaces, one of said end surfaces comprising steeply sloping portions which merge with said certain bottom surfaces and said arcuate partial side surfaces thereby to form a beam construction in said one of the end surfaces, said beamed end of the shell forming beamed ceiling surfaces of said structure, the other end surface of the shell forming a bottom surface of the structure said beamed bottom of the shell forming beamed side wall surfaces of the structure, and said arcuate side surfaces of the shell forming front and back wall surfaces of the structure.
  • Service station restrooms of the character disclosed comprising identical and separate mens and womens plastic shell room units spaced from each other on a common concrete slab support therefor, at least one metal framework disposed between said units andcomprising a pair of spaced plates which respectively interfit with the adjacent exterior plastic surfaces of the units, each of the units having at least one wall hung fixture supported on said adjacent plate, each of said units comprising a molded plastic shell structure having inwardly offset wall and ceiling beam forming portions defining room compartments therebetween, there being one said wall hung fixture in each of said compartments, there being one said fixture supporting framework for each said fixture, a pair of cantilevered horizontally disposed channels extended from within one of said units into the other through adjacent wall beam forming portions of said structures, one of said channels being spaced above the floor of said units and the other spaced below the ceilings thereof, each of said units having a partial wall seated within said channel members, and each of said units having a partial door for coaction with its partial Wall.

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Description

Se t. 15, 1964 P. c. HANSON 3,148,380
SERVICE STATION RESTROGMS Filed March 8, 1965 4 Sheets-Sheet 1 INVENTOR. PAUL c. HANSON ATTORNEY Se t, 15, 1964 P. c. HANSON 3,148,380
7 SERVICE STATION RESTROOMS Filed March 8, 1963 4 Sheets-Sheet 3 FIG. 3 INVENTOR.
PAUL C. HANSON ATTORNEY Sept. 15, 1964 P. c. HANSON 3,148,380
SERVICE STATION RESTROOMS Filed March 8, 1963 4 Sheets-Sheet 4 INVENTOR. PAUL C. HANSON Mi. (1.4m.
ATTORNEY United States Patent 3,148,389 SERVICE STATEGN RESTRGOMS Paul C. Hanson, San Diego, Caiif, assignor to Rob: Corporation, Chuia Vista, Caiii, a corporation of Caiitornia Filed Mar. 8, 1963, Ser. No. 263,994 19 Claims. (Ci. 4-2) This invention relates generally to bathroom structures and more particularly to new and improved constructions for the so-called service station restrooms.
An object of the present invention is to make provision for the factory fabrication of such restroom constructions in order to secure the recognized advantages and to eifect the economies and efiiciencies which naturally flow from the utilization of factory methods, procedures and techniques in the manufacture of items which lend themselves to mass production.
Another object is to provide service station restroom structures which may largely be unitized and/or constructed as major components at the factory thereby greatly to minimize the time and skill required in the onsite construction of such structures.
Still another object resides in the provision of service station restroom structures of largely unitized and continuous wall and floor surface areas in order greatly to minimize the amount of work required to maintain a high standard of cleanliness of such structures notwithstanding the generally great and continuous demand for and frequency of use of the services afforded by such structures.
Yet another object is to provide service station restrooms of this character having provision for access to the utility connections to the units and having provision for the ready draining of copious quantities of water such as may be applied with a water hose to wash down the walls and the floor of the units.
Still another object is to provide bathroom structures having smooth and contoured wall and floor surfaws which inherently are well suited to avoid the collection of dust, dirt, and grime while at the same time providing a pleasing appearance, with possibili'des also of presenting a wide variety of color and design effects while avoiding the need for recurrent redecoration and/ or maintenance.
Still another object is to provide interior bathroom structures and effects as aforedescribed, which will also lend themselves to the adaptation and application of desired secondary bathroom fixtures such, for example, as wall hung stools, mirrors, vanities, towel waste baskets, and the like.
Yet another object is to provide service station bathroom structures, as aforedescribed, which contemplates an overall and structurally integrated rest room facility consisting of separately but similarly formed mens and womens units providing an accessible utility wall area and passage therebetween.
It is also an object in the fabrication of such unitized and structurally integrated mens and womens units to further etfect the sectionalizing of each such unit into toilet, lavatory, and vanity stalls, or compartments.
Still another object in service station bathroom structures, as :aforecontemplated, is to render such structures adaptable to the use of prefabricated plumbing trees and waste lines.
An additional object resides in the provision of factory fabricated service station bathroom structures providing the aforedescribed interior features and constructions which may readily be integrated with the exterior wall construction and plan of the service station of which it is to form a pant and a facility.
Still other features, advantages and objects of the present invention will best be understood from the following 3,1485% Patented Sept. 15, 1964 detailed description of a preferred embodiment of a service station restrooms construction and design, reference being had to the accompanying drawings wherein;
FIG. 1 is a view in perspective of the mold used to form the molded shells employed in the construction of the service station restrooms of the present invention;
FIG. 2 is a plan view of the restrooms as viewed substantially along the line 22 of FIG. 3, certain parts being shown in section;
FIG. 3 is a partial elevational view in section of the restrooms as viewed along the line 33 of FIG. 2;
FIG. 4 is a view in elevation of an interior wall as seen along the line 44 of FIG. 2;
FIG. 5 is a sectional view, somewhat enlarged, of a door and its mounting frame, and the manner of mounting the frame to the interior plastic shell and the exterior metal framework of the restrooms, the section being viewed at the level of one of the hinge supports for the door;
FIG. 6 is a somewhat enlarged sectional view of the floor drain construction as it appears in FIG. 3; and
FIG. 7 is a somewhat enlarged sectional view illustrating the beam construction of a shell unit as viewed along the line '7-7 of FIG. 3.
Referring now to the drawings for a more complete understanding of the invention, and first more particularly to FIG. 2 thereof, there is shown thereon, a service station restrooms structure comprising an exterior sheet metal wall and framework it) which generally extends around and encloses a generally plastic interior wall construction which forms the subject matter of the present invention. With respect to the exterior framework, it will suffice herein to point out that it comprises the usual J-stud construction 11 which is duplicated, that is, two such studs are used, as required, in the corners of the exterior framework as at 12. The exterior construction and framework will generally follow the overall design of the service station and forms no part of the present invention except that access openings as at 13 must be provided, the internal construction of the present invention otherwise being fully designed and adapted to the exterior construction, as will hereinafter more fully appear.
With continued reference to FIG. 2, it will be seen that the service station restrooms 10 comprise a mens room generally designated 14 and a womens room generally designated 16. These rooms are identical and identically formed except that the access door 15 for the mens room is located on the left of the unit and the access door 17 for the womens room is located on the right of the unit, as viewed in FIG. 2. Each of rooms 14 and 16 is formed of two molded glass fiber reinforced polyester shells generally designated 18 and 19, which shells together provide the floor, walls, and ceiling of their respective rooms. Shells 18 and 19 have vertically extending wall portions 20 which project inwardly into the room of which they form a part and serve as beams to provide the requisite strength for the plastic walls. By reason of these projections 26, each of rooms 14 and 16 tends to be divided, as indicated by the dashed lines 21, 22, and 23 into three compartments in each room, for example, the compartment bounded by the dashed line 21 provides a toilet area or stall in which is located a wall hung stool 24. Similarly, in each room, the compartments bounded by the dashed lines 22 tend to define a lavatory area, or compartment, in which is located the lavatory 25, mirror 26, and a towel waste basket 27. In the mens room, the dashed lines 23 suggest a third compartment in which a wall hung urinal 28 is located, and in the womens room, the dashed lines 23 tend to define a vanity compartment in which is located a vanity shelf 29 which may be formed of any material suitable for the purpose such, for exa ample, as manufactured marble. An appropriate stool or chair 30 and a mirror 31 for the vanity shelf 29 completes the vanity compartment.
The shape of the shells 18 and 19 and the specific crosssectional configuration imparted thereto by the mold is best seen comparatively with FIG. 1 which discloses the mold per so, this being generally designated 32. The mold is a unitary structure except for the removable door plug 33 which is secured thereto by suitable means (not shown). In the position shown in FIG. 1, the door plug 33 is located on the mold 32 so as to provide the door opening for shell 18 of womens room 16, this opening being for door 17 of this room. To ready the mold for forming the shell 18 to accommodate door 15 of the mens room, plug 33 would be removed from mold section A, as seen in FIG. 1, and similarly secured to the corresponding side of mold section C.
Sections A, B, and C each comprises a surface 34 which extends upwardly from a peripheral flange 35 which extends all around the mold. The mold, as disclosed in FIG. 1, is in the position in which the shell 18 is molded thereon, the face of the mold including the flange 35 thus constituitng the bottom of the mold. The shell portions which are molded on the mold faces 34, however, form top surfaces of the shells and therefore form ceiling portions 36 of the rooms, as viewed in FIG. 3. That portion of the shell which is molded against the peripheral flange 35 provides a flange 37 as viewed in FIG. 3. The back faces of the mold, i.e., those faces disposed opposite the front faces 34 are similarly formed, and the shell portions molded thereagainst form the bottom surfaces for shell portions 38 which form the floor surfaces of the room. In this back region of the mold, the shell portion formed against the peripheral flange 35 results in a flange 39, these flanges merging with the shell floor portions 38.
Faces 34 of mold 32 and the corresponding faces on the back side of the mold converge upwardly slightly from the peripheral flange 35 to provide adequate draft for molding purposes. Thus, the molded shell is readily stripped from the mold after the shell has been formed thereon. The resulting slope in the ceiling 36 has no significance, but the same slope in the floor surface 38 assures that water will flow freely to the central drain or gutter 40 which extends fully from the front to the back of each of units rooms 14 and 16.
As may best be seen in FIGS. 3 and 6, the drain 40 is a trough or channel formed in the concrete slab 41, the channel being enlarged at the surface to provide a seat, as at 42, for the turned down edges of an elongated drain cover 43 which, like the shells 18 and 19, is formed of molded glass reinforced polyester. Cover 43 is suitably perforated, the small openings not being shown. The usual trap 44 is employed at the base of gutter 4t and a waste line 45 extends from the trap to the main drain line 46, FIG. 3.
Returning again to FIGS. 1 and 3, the front and back faces of mold 32 merge into surfaces 47 which parallel the base or flange 35 of the mold. Hence, the shell wall portions 48, FIG. 3, extend vertically from the floor level. Similarly, beams 20, which result from intermediate mold surfaces 49, FIG. 1, also rise vertically from the floor level, but like the wall surfaces 48, FIG. 3, merge with the floor shell surface 38 in rounded inside corners 50. These inside corners 50 are similarly formed where ceiling surfaces 36 meet the wall surfaces 48. Portions of the surfaces 47 of the mold may be waxed, or otherwise treated, or blocked, so that a resultant opening 51, FIG. 3, is formed behind the mirrors 26 for access when this is required, to the utility lines between the units 18 and 19.
The mold surfaces 49, FIG. 1 rise considerably short of the faces 34 and merge with surfaces 52 which slope considerably more than the faces 34 toward flange 35, and at the flange, are set back somewhat therefrom, as at 53. As a result of this mold configuration, the vertical surface of beam 20, FIG. 3, merges by way of an inside corner 54 with a steeply rising ceiling beam portion 55 which, in turn, terminates in an outside corner 56 which merges with the flange 37.
Mold sections A, B, and C are formed symmetrically, the arcuate surfaces 57, FIG. 1, on opposite sides of each section, being identical. As a result of this mold configuration, the side walls 58, FIG. 2, of each of shells 18 and 19 are arcuately formed and merge by way of outside and inside corners 59 and 60, respectively, with the vertical walls 20 and 48, respectively, and also by way of outside corners 61 with the flange 37. These outside corners 61 also appear at the floor flanges 39 and cover plate 43, FIG. 6. The manner in which the rounded beam 28 thus merges into the ceiling beam 55 is best seen in FIG. 7. Wall surfaces 58 in the ceiling beam region 55 form outside corners 62 therewith and form inside corners 63 with the ceiling surfaces 36.
Shell 19 is formed on mold 32 without the door plug 33 thereon and, hence, flange 37 is fully formed on the three lips of each shell 19, flange 39 being formed on the fourth lip of the shell. The portion of flange 37 which is formed on each shell 19, in the space otherwise occupied by door plug 33, forms part of the opening for door 15, or 17, as the case may be. In the forming of shell 18 on mold 32, however, with the door plug 33 thereon, surfaces 64 and 65 on plug 33 produce side and top flanges in the door opening in the shell. A resulting side flange 66 forms the side of the door opening opposite flange 37 in shell 19, as best seen in FIGS. 2 and 5, and this merges by way of an outside corner 67 with arcuate wall 58, FIG. 2. Plug surface 65 forms a flange (not shown) on each shell 18 which lies at the top of the door opening and extends from flange 66 to flange 37 in the companion shell 19. An inside corner (not shown) joins this flange, and arcuate wall surface 58.
Referring now particularly to FIG. 5, exterior frame 10 is flanged as at 68, and a conventional door frame 69 is secured to this flange as by metal screws 70. Frame 69 is also secured, as by screws 71, to flange 37 of shell 19 and to flange 66 of shell 18, thereby securing the same together in the door region of the composite shell. The door 17 is mounted, as by the usual hinges 72, to the frame 69, and includes the additional hardware, such as locks, latches, and the like (not shown). Door 15, of course, is similarly mounted and furnished.
The shells 18 and 19 for each of units 14 and 16, as aforedescribed, are spaced from each other by the width of drain channel 40 or, as best appears in FIG. 2, by the width of a drain cover 43. On the back side, the openings between flanges 37 for both units 14 and 16 are closed, as by metal louvers 73, and the openings above doors 15 and 17, FIG. 4, are similarly closed by a short section of louvers 73. The opening between flanges 37 in the ceiling in each unit is left open, except where the flanges are joined by fasteners 74, FIGS. 3 and 4. The rooms are thus vented to a plenum chamber provided by the exterior framework 10, and this plenum may contain an exhaust fan, as desired or required.
Each of rooms 14 and 16 is furnished with a molded glass fiber reinforced reflector sofit 75 for a fluorescent light fixture 76 and its ballast 77. Light switches and convenience outlets (not shown) understandably are provided.
Units 14 and 16 are spaced from each other by 1 /2 to 2 feet, or more, to provide a space for the utility lines and to admit a maintenance or repair man by way of the access openings 13. This spacing of the units is fixed by three metal frameworks, each of which comprises a pair of back-to-back upright plates 78 to which are secured, at each side, a pair of spacer bars 79, FIGS. 2 and 3. As best seen in FIG. 2, the plates 78 are curved to interfit with the shells 19 and thus provide support therefor as well as to serve as carriers for the lavatories 25, Wall hung stools 24 and urinal 28, and also to support,
as required, the waste lines 8%, 81, 82 therefrom, respectively. Secondary vent lines 83 and 84 from the urinal 28 and lavatory lines 89, respectively rise to the main vent 85 which rises from stool waste lines 81 connected to main drain 46 through the plenum and thence through the roof of the exterior framework It Hot and cold water lines (not shown), preferably in the form of a plumbing tree, are also provided in the utility space.
' The stool compartments preferably are partitioned by a partial Wall $6 and coacting door 87 which is suitably hinged by means (not shown) to a strip 88, in turn, secured by any suitable means (not shown) to beam 20. Wall panels 86 for both units are supported in cantilevered channel members 89 which extend through the utility space and into both rooms.
The units preferably are lashed or strapped together at the top as by molded glass reinforced polyester tie members 99 which are U-shaped n1 cross section to interfit within the ceiling beams, as may best be visualized from the corresponding U-shaped configuration of the ceiling beam as it appears in cross section in FIG. 7.
It will be understood that shells 18 and 19 may be formed of any material suitable for the purpose such as the aforementioned glass fiber reinforced polyester resin to provide thin wall, light weight construction of great strength. Preferably, the shells are formed of a glass impregnated, promoted and pigmented polyester resin adapted for application and layup with a gun in a known manner upon a male mold such as mold 32 hereinbefore disclosed. Mold 32 with its almost severe draft lines and contours is ideal for the purpose, since the shell once formed thereon may readily be stripped from the mold.
In operation, in forming the shells on mold 32, a suitable parting agent is first applied to the surfaces of the mold. A gel coat of a suitably pigmented polyester resin is next applied to the mold, and the interface of this coat with the smooth surface of the mold assures a smooth interior Wall surface in the restroom of which it is to form a major component and part. The gel coat, moreover, being pigmented, may have desired color and design effects, and will be long lasting to thus obviate the need for redecoration and/or repairs.
The shell is then completed on the mold by application of the glass impregnated polyester resin to the gel coat. The resulting shell with its inherent beam construction and thin, but tough and strong walls, will have great structural integrity while also presenting a contoured and smooth wall, floor, and ceiling interior surface which will resist the accumulation of dust, dirt and grime, and such soil materials as do collect, may readily be removed as by washing the same down under pressure of water from a hose. In the case of the floor surfaces, it may be desirable to use a very thin gel coat so that the glass fibers lie just below the surface to provide some traction to avoid the adverse consequences of a too slippery floor surface. The. surface, in such case, will nevertheless be sufiiciently smooth for free flow of water to the drain 40.
The thin, strong shells have an additional advantage in that the same may readily be shipped in sets, as required; in some cases, for example, the shells being telescoped, one shell within the other. The symmetry of the shells, moreover, as where identical shells 19 are employed back-to-back, and where shells 18 differ only from shells 19 by the provision of the door opening, necessitates the fabrication and use at the factory of one mold only, and thus greatly simplifies and reduces the cost of the manufacturing process.
On-site, the spacer metal frameworks 78, 79 and their supported plumbing trees, waste and supply lines, may first be installed on the concrete slab, which is prepared with the gutters 4i), traps 44, lines 45, and main drain 46 in position as shown. In the on-site installation of shells 18 and 19, it is preferred that an asphalt compound, or like undercoating, be applied to the concrete slab to retain the shells more or less in position thereon. The shells 19 are positioned on the slab first, being set back-to-back in interfitting relation with the plates 78. The Wall hung fixtures 24 to 26, 28, 29 and 31 together with the lighting system 75 to 77 may now be installed, or alternatively, this may be accomplished when the rooms have been completed structurally, or during preferred stages of the assembly. The channel supports 39 and the partial walls 86 will probably best be installed before the shells 18 are positioned on the slab.
The positioning and location of the shells 18, as hereinbefore alluded to, is determined by the gutters 40, and this assures that the shells 18 and 19 will be properly spaced to receive and accommodate the door frames 69 more or less interfittingly therewith, such that the frames may readily be mounted in position on the shells, and the doors l5, 17 may thereafter be mounted in the frames. The louvers 73, likewise, will readily mount in the spaces provided therefor between the shells when the same are properly spaced to receive the drain covers 43.
\Vith the shells thus positioned, the same may simply be secured together at their flanges 37 as by the fasteners 74 and additionally lashed together as in the region of the ceiling beams 55 by the straps 90, or the like.
The simplified interior construction, as exemplified by the wall hung fixtures, and the simple manipulators there for, as exemplified by the actuator 91 for the wall hung, no-closet stools, will greatly simplify the maintenance of the restrooms as hereinbefore disclosed, and it will be appreciated, that these and other features of the hereinbefore disclosed structures and constructions are well adapted to fulfill the aforestated objects of the invention.
In accordance with an alternative installation procedure, shells 19 are bonded to the carrier plates 78 in back-to-back relation and to the straps 90 with all fixtures md appurtenances installed on the shells, and with the plumbing trees connected thereto at the factory. The toilet stall partitions to 89 may also be installed to their respective shells 18 and 19 at the factory to facilitate and expedite the on-site assembly. On site, this assembly is installed on the slab in relation to the main drain line 46 and the gutters 40. Shells 18 are next set'on the slab in relation to the gutters and secured to the shells 19 at the top by the fasteners 74, the louvers 73 and door frames 39 being installed any time after the shells are set on the slab.
It will be understood, moreover, that this invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present embodiment of the invention is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Having thus described my invention what I claim as new and useful and desire to secure by Letters Patent is:
1. Service station restrooms of the character disclosed comprising, in combination, identical and separate mens and womens plastic shell units spaced from each other on a concerte slab support therefor, said slab support having for each of said units an elongated drainage trough which extends centrally of the unit from the front to the back thereof, each of said units comprising a pair of dish-shaped flanged molded plastic shells positioned on said slab support with their flanged portions vertically disposed in confronting and spaced relation to each other on opposite sides of said trough, said confronting flanged portions disposed adjacent said trough being depended therewithin, said shells on the interior surfaces thereof providing the wall, ceiling and floor surfaces of said units, louvre means interposed between certain confronting flange portions of the shells of each said pair of shells, and fastener means for securing certain other flange portions of the shells of each said pair of shells together in said mutually spaced relation and with respect to their common trough.
2. Service station restrooms as in claim 1, said slab support having surfaces which slope toward said drainage troughs and said shells having mold draft lines such that said floor surfaces of the shells conform to said slope in the slab support surfaces.
3. Service station restrooms as in claim 1, each shell of each said pair of shells having a peripheral flange, the portion of each said flange adjacent to the floor surface of its shell being disposed in depending relation into its associated trough, said trough comprising a shouldered A surface opening in said slab support, and an elongated perforated cover plate for said trough adapted to interfit with the shell flange portions within said shouldered opening, said cover plate having depending flange portions disposed in seated relation on the shouldered surfaces of said shouldered opening.
4. Service station restrooms of the character disclosed comprising identical and separate mens and womens" plastic shell room units spaced from each other on a common concrete slab support therefor, at least one metal framework disposed between said units and comprising a pair of spaced plates which respectively interfit with the adjacent exterior plastic surfaces of the units, each of the units having at least one Wall hung fixture supported on said adjacent plate, each of said units comprising a molded plastic shell structure having inwardly offset wall and ceiling surface portions defining externally disposed channels and internally disposed beams, said channels of one unit being aligned respectively with the channels of the other unit, means for lashing said spaced units together, said lashing means comprising plastic strips each of which extends across the space between said units and is secured at the ends thereof to the confronting shell structures of the units, said secured ends being disposed respectively within a pair of said aligned channels of the spaced units, said beams defining room compartments therebetween in each said unit, there being one said wall hung fixture in each of said compartments, and there being one said fixture supporting framework for each said fixture.
5. Service station restrooms of the character disclosed for integration within an exterior framework structure comprising a pair of plastic shell room units disposed within said exterior structure and in spaced relation backto-back to form a utility space therebetween, said units comprising a plurality of wall hung fixtures mounted on the confronting Walls of the units, plumbing lines and connections disposed in said space and connected to said fixtures, said lines including a main vent extended through the roof of said exterior structure, each of said units having an access door, and said exterior framework structure comprising access panels to said utility space and doorway openings for the access doors of the units, each of said plastic shell units comprising a pair of dishshaped and flanged shells, the flanged portions of said shells being disposed vertically and in mutually spaced and confronting relation, one of said shells being recessed in its flanged region to form with the adjacent flanged portion of the other shell an opening for the access door of the units, louvre means for closing the space disposed between said flanged portions and above said door opening, and similar louvre means for closing the space disposed between said flanged portions and in the unit wall opposite the door opening.
6. In a restroom structure of the character disclosed, a pair of dish-shaped flanged plastic shells positioned with their flanged portions vertically disposed and in confronting spaced relation on a common support having an elongated drain channel, said shells being disposed on opposite sides of said channel and spaced thereby and having the adjacent flanged portions thereof depended within the channel, a cover plate for said channel, a door opening defined by said confronting flanged portions of the shells in one wall of the restroom structure, and louvre means closing the remaining openings between the flanged portions of the shells in said one wall and the wall opposite thereto in said structure.
7'. In a restroom structure as in claim 6, each of said shells having flat surfaces parallel to the flanged surface of the shell, certain of said flat surfaces being offset inwardly from other of the flat surfaces to constitute beam construction for said shells and tosimulate a plurality of compartments in said restroom structure.
8. In a restroom structure, a dish-shaped glass reinforced plastic shell having a peripheral flange, flat bottom surfaces, flat end surfaces which converge from the flange toward said bottom surfaces, and arcuate side surfaces which converge from said flange toward said bottom surfaces, certain of said bottom surfaces being offset inwardly from other of the bottom surfaces and interconnected by arcuate partial side surfaces to form a bottom beam construction, said certain bottom surfaces extending short of the opposite ends of said other bottom surfaces, one of said end surfaces comprising steeply sloping portions which merge with said certain bottom surfaces and said arcuate partial side surfaces thereby to form a beam construction in said one of the end surfaces, said beamed end of the shell forming beamed ceiling surfaces of said structure, the other end surface of the shell forming a bottom surface of the structure said beamed bottom of the shell forming beamed side wall surfaces of the structure, and said arcuate side surfaces of the shell forming front and back wall surfaces of the structure.
9. In a restroom structure as in claim 8, said flange being offset in one of said arcuate side surfaces to provide a door opening for said structure.
10. Service station restrooms of the character disclosed comprising identical and separate mens and womens plastic shell room units spaced from each other on a common concrete slab support therefor, at least one metal framework disposed between said units andcomprising a pair of spaced plates which respectively interfit with the adjacent exterior plastic surfaces of the units, each of the units having at least one wall hung fixture supported on said adjacent plate, each of said units comprising a molded plastic shell structure having inwardly offset wall and ceiling beam forming portions defining room compartments therebetween, there being one said wall hung fixture in each of said compartments, there being one said fixture supporting framework for each said fixture, a pair of cantilevered horizontally disposed channels extended from within one of said units into the other through adjacent wall beam forming portions of said structures, one of said channels being spaced above the floor of said units and the other spaced below the ceilings thereof, each of said units having a partial wall seated within said channel members, and each of said units having a partial door for coaction with its partial Wall.
References Cited in the file of this patent UNITED STATES PATENTS 1,639,705 Schmiedknecht Aug. 23, 1927 2,220,482 Fuller Nov. 5, 1940 2,968,130 Bascom Jan. 17, 1961 3,110,907 King Nov. 19, 1963
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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3775919A (en) * 1972-04-13 1973-12-04 Fulton & Partners Inc Modular structures
US3905048A (en) * 1972-04-26 1975-09-16 Moeller Hans Guenter Room modules with sanitary devices
US4156998A (en) * 1976-12-13 1979-06-05 Mcclure James B Equipment shelter
US4655011A (en) * 1984-09-12 1987-04-07 Borges Anthony A Prefabricated building system
US5319904A (en) * 1991-07-30 1994-06-14 Pascoe Jack F Portable prefabricated modularized clusterable structures
US5903937A (en) * 1997-03-19 1999-05-18 Amtech Corporation Bathroom module accessible to wheeled assemblies

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1639705A (en) * 1926-12-02 1927-08-23 Victor E Schmiedeknecht Bath appliance
US2220482A (en) * 1938-05-12 1940-11-05 Phelps Dodge Corp Prefabricated bathroom
US2968130A (en) * 1957-11-29 1961-01-17 American Home Shelters Protective underground shelter
US3110907A (en) * 1961-12-11 1963-11-19 Rohr Corp Unitized bathroom structure

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1639705A (en) * 1926-12-02 1927-08-23 Victor E Schmiedeknecht Bath appliance
US2220482A (en) * 1938-05-12 1940-11-05 Phelps Dodge Corp Prefabricated bathroom
US2968130A (en) * 1957-11-29 1961-01-17 American Home Shelters Protective underground shelter
US3110907A (en) * 1961-12-11 1963-11-19 Rohr Corp Unitized bathroom structure

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3775919A (en) * 1972-04-13 1973-12-04 Fulton & Partners Inc Modular structures
US3905048A (en) * 1972-04-26 1975-09-16 Moeller Hans Guenter Room modules with sanitary devices
US4156998A (en) * 1976-12-13 1979-06-05 Mcclure James B Equipment shelter
US4655011A (en) * 1984-09-12 1987-04-07 Borges Anthony A Prefabricated building system
US5319904A (en) * 1991-07-30 1994-06-14 Pascoe Jack F Portable prefabricated modularized clusterable structures
US5903937A (en) * 1997-03-19 1999-05-18 Amtech Corporation Bathroom module accessible to wheeled assemblies

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