US2712863A - Prefabricated bathroom unit - Google Patents

Description

July 12, 1955 F. w. BUSCH PREFABRICATED BATHROOM UNIT 5 Sheets-Sheet 1 Filed April 16. 1949 INVENTOR. FRANK w.BuscH ATTOR EY 5 Sheets-Sheet 2 F. w. BuscH PREFABliICATED BATHROOM UNIT July 12, 1955 Filed April 16. 1949 ax: \\\x' li a\\ I'I1.:'..J"

INVENTOR.

FRANK w. BUSCH BY W ATTORNEY July 12, 1955 F. w. BUSCH PREFABRICATED BATHROOM UNIT 5 Sheets-Sheet 5 Filed April 16. 1949 F IG.

2 INVENTOR. FRANKAV. Busc H ATTORNEY July 12, 1955 F. w. BUSCH PREFABRICATED BATHROOM UNIT 5 Sheets-Sheet 4 Filed April 16. 1949 INVENTOR.

FRANK w. BUSCH BY W ATTORNEY July 12, 1955 F. w. BUSCH PREFABRICATED BATHROOM UNIT.

5 Sheets-Sheet 5 Filed April .16. 1949 LUZ INVENTOR.

FRANK w, BUSCH BY j ATTORNEY United States atent @fice Patented July E2, 1955 This invention relates to a prefabricated building unit and more particularly to a prefabricated bathroom complete with plumbing fixtures.

An object of the present invention is to provide a prefabricated bathroom unit which is constructed in such a manner as to facilitate its transportation as a cubical unit from the factory to construction site; and from the construction site into the building in which it is to be located, without requiring the necessity or use of cranes, heavy rigging, pipe rollers, or the like.

Another object of the invention is to provide a unitary bathroom structure which includes, as an integral and basic part thereof, a base element including peripheral members which are constructed and arranged to overlappingly engage and span structural support members provided in the building which define an opening or well into or over which the unit is to be received or located.

A further object of the invention is to provide a unitary bathroom structure including a base element which is reenforced in such a manner as to support the floor, wall and ceiling portions of the room, wherein the floor is constructed in such a manner as to positively preclude the passage of water therethru.

A further object of the invention is to provide a unitary bathroom structure the walls and ceiling of which are fabricated from standard panels, and where in cerrain of the wall panels are fabricated whereby to define window and linen-storage offsets.

Still a further object of the invention is to provide a unitary bathroom structure wherein all service connections are available along one side wall, and wherein the structural relationship of said side wall with reference to the base element of the unit is such as to provide a utility shaft non obstructed throughout its length and breadth thereby providing passageway for accommodating heating, power, water, sewage, electric and other services.

Another object of the invention is to provide a unitary bathroom structure having the hereinabove described characteristics wherein the walls are constructed in such a manner as to facilitate the erection of other permanent building walls in spaced relationship therewith, and wherein the space between such walls may be expeditiously insulated.

Still another object of the invention is to provide a unitary bathroom structure complete with plumbing fixtures and all piping connections, including water and waste lines, the ends of which are located exteriorly of the structure for ease of access for being permanently connected to the conventional Water and waste service lines of the building in which the bathroom is located without requiring the presence of workmen in the bathroom until after the fixtures thereof have been connected to their various service lines after which it may be desired or necessary to pressure-test the waste line as required by the sanitary code of certain localities.

Still a further object of the invention is to provide a prefabricated unitary bathroom structure having the hereinabove described characteristics wherein the toilet waste connection terminates in a standard T, crow foot or similar fitting including a vertical leg securely anchored relative to the base element for determining the location of the stack or riser pipes to be connected to the vertical leg thereof.

A further object of the invention is to provide a unitary bathroom structure which is inexpensive to fabricate, and adapted to be manufactured using modern mass production techniques.

These and other objects are attained by the means described herein and as disclosed in the accompanying drawings, in which:

Fig. l is a perspective view of a bathroom unit embodying the teachings of the present invention, shown in an elevated or raised position with reference to the well provided in a building in which it is to be received;

vertical section thru the left side of the illustrating certain details of construction. horizontal sectional view of the unit of installed in the well of a building.

4 is an enlarged view illustrating the structural det s of the window-sill and window construction comprising a detail of the invention.

Fig. 5 is a vertical section taken on line 5-5 of Fig. 3.

ig. 6 is a side view of the outer face of the right wall of the unit of Fig. 5 illustrating certain details of construction.

Fig. 7 is an enlarged sectional view of a portion of the left wall of Fig. 3, illustrating certain details of construction.

With reference now to Fig. l, the numeral 8 indicates generally a prefabricated cubical bathroom unit dimensioned to be received within well ill provided in a building structure. Well 10 may be defined by a plurality of header members denoted generally by the numerals 12, 14, 16 and i3 constructed in any suitable manner.

in the illustration headers 18 are disposed adjacent and parallel with an outer wall, denoted generally by the numeral 19, in which a window is provided. it should be understood that wall 19 may be fabricated from any suitable building material, and that, if desired, a suitable ledge may be provided on the top of a foundation, or made integral with the wall in lieu of headers 18.

The bathroom unit comprises, generally Speaking, at base member or frame work 29, a floor 22, side walls 24, and a ceiling 26. With particular reference now to Figs. 1, 3 and 5, it will be observed that base member 20 is a substantially U-shaped load bearing frame Work comprising side angles or members 3%} and an end member 32. A load bearing element 34 is provided in spanning relationship between side members 30 and spaced inwardly from those ends of members 30 remote from end member 32. In those instances in which members 36, 32, and 3 which collectively comprise the load bearing frame work 28 are of L-shaped angle construction, a portion of the vertical leg or web may be removed adjacent the free ends of side legs 39 for providing flat bearing members 36 which are adapted to overlappingly engage headers 16, see Fig. 5.

Members 36 and 32 are dimensioned whereby their respective horizontal legs 61 will overlappingly engage the upper surface of headers 12, id and 18, and load bearing element 34 will be disposed in spaced parallelism with header 16 thereby defining a utility shaft area denoted generally by the numeral 4-0, Figs. 3 and 5. A plurality of load bearing elements, such as angles denoted generally by the numerals 4-2 are secured as by welding to and disposed in spanning relationship between members 32 and 34, thereby defining a rigid load bearing framework constructed and arranged to be received within and spanningly engage the upper peripheral supporting edges of well ill.

With reference to Figs. 1, 5 and 6, it will be noted .bolts may be used in lieu of screws 63.

. supported thereon to be transported from place to place,

such as, from the factory onto a truck or other means of conveyance; from the conveyance to the building site and thence from the building site into the building of which the unit is to become an integral part. After the unit structure has been delivered to the building site, it may be rolled over the sub flooring, or over boards temporarily laid over the joists and across the well defined by headers 12, 14, 16 and 18. When the members 30, 32 and 34 which define base member 29 of the unit engage these headers the unit will be rigidly and permanently secured in place without the necessity of further anchorage.

Since each unit is entirely self-contained it may be installed as soon as well has been defined, after which the building may be erected around the unit.

With reference now to Fig. 2, floor 22 may comprise a sheet or layer 59 of sound deadening material such as, by way of example, commercial insulation board be- 7 neath a sheet of plywood 52. A sheet 54 of waterproof material, such as aluminum, may be disposed on the upper surface of plywood 52, and a sheet of linoleum 56 may be secured, as by an adhesive, to the upper face of sheet 54. The resultant composite floor structure thus formed will be characterized by its inherent strength and sound deadening characteristics, its water proofness and durability.

In the preferred embodiment of the invention, the peripheral edges of the floor overlappingly engage portionsof members 31 32 and 34 of base member 26 and rest upon the horizontal legs of angles 42.

In the preferred embodiment of the invention, I secure a U-shaped channel, defined by laterally spaced sidewalls 60 and a bottom Wall 62, to the upper face of horizontal leg 61 of the base member defined by angles 30, 32 and 34. As illustrated in Fig. 2, bottom channel wall 62 may be permanently secured to the base member by means of a suitable fastening element 63, the shank 65 of which may be imbedded in header 14. If desired, In this manner I provide a double walled peripheral member with which the lower ends of a plurality of stud channels are associated.

Preferably, channels 70 are substantially C-shaped in cross section, see Figs. 3, 4, and 7, and comprise side and end walls 72 and 74 respectively, wherein the free ends of side walls 72 are turned inwardly as at 76. These channels may be secured to base panel 60 by means of rivets, screws 78, or other suitable fastening means An L-shaped channel including a horizontal leg and a vertical leg 82 may be secured to the upper end of vertical channels 70 by suitable fastening means, such as, by way of example, self-tapping screws 84 or the like, leg 80 being disposed in spaced parallelism with bottom wall 62 for providing a horizontal shelf or ledge engageable by outturned flange 88 of the side wall panels 86.

The side walls 24 of the structure may be fabricated from lengths of sheet material formed whereby to provide an elongated panel portion 86, the upper end of which is turned outwardly or rearwardly to provide a flange 88 constructed and arranged to overlappingly engage the upper surface of leg 80 of the panel which circumscribes the upper ends of vertical panels 70.

The other end of panels 36 are adapted to be received between the adjacent faces of base channel 60 and sidewalls 72 of channels 76, see Fig. 2. If desired, a trim or finish strip comprising legs 81 and 83 may be secured in place around the outer edge of the composite floor 22 by means of fastening elements 85.

With reference now to Fig. 7 it will be noted that one of the side edges of elongated panels 86 are provided with an outturned flange 2 whereas the other edge is turned outwardly as at 94, thence over as at 96 and thence inwardly as at 93 for providing an elongated U-shaped groove into'which flange 92 of a similar adjacent panel is receivable. The outer face of leg 98 abuts end wall 74 of channel 70, being secured thereto by suitable fastening means, such as a metal screw 100, Fig. 2, which passes through flange 92, and legs 94 and 98 of the U-shaped groove of an adjacent panel for providing an interlocked rigid connection.

The ceiling and side wall constructions are similar. In the ceiling, a plurality of channels 70 are provided lengthwise of the unit, see Figs. 1 and 2, the ends of said channels engaging ledge-forming horizontal channel leg 89. The elongated panels denoted by the numeral 98 in Pig. 2 are similar in all respects to panels 86 of the side walls. The sides and ends of panels are provided with flanges and U-grooves, the same as panels 86, as evidenced by use of similar numerals. It will be noted that the ceiling panels may be secured in place by means of fastening members 97.

In the preferred embodiment of the invention, I provide a window opening 99 and a storage-space opening through certain of the side walls. Such openings, the storage-space being denoted generally by the numeral 110, Figs. 3 and 5, are fabricated by providing an outturned lip 112 in a side wall panel 86, wherein the end of lip 112 is turned outwardly as at 114 for providing a flange. -t should be understood that the side walls 113 of the storage space 10 are likewise formed by being folded outwardly in a plane at substantial right angles with the main plane of panel 86 in a manner similar to lip 112. The ends of walls 118 are turned outwardly to provide a flange 115, Fig. 3. A backing member 116 fabricated from a piece of suitable sheet material may be securely attached to flanges 114 and 115.

Substantially the same construction may be followed in forming a Window-receptive opening, it being noted that similar portions of the window opening and linen storage compartment have been given the same identifying numbers in Figs. 3 and 4, wherein Fig. 4 relates soley to a window construction.

As disclosed in Fig. 4, the outer peripheral mounting flange 120 of a casement window of any standardized construction may be secured to outturned flanges 114 and by suitable fastening means indicated generally by the numeral 122. The window construction will have a sill member defined by lip 112 free of joints or other crevices into which water, vapor or other penetrable substance may enter.

From the foregoing, it will be noted that the resultant cubical structure comprises a reenforced base elemerit, a floor, side walls and ceiling. Suitable plumbing fixtures, such as, a bathtub 192, toilet 104, washstand 14 soap dishes 142, towel bars 144, tissue holder 146, medicine cabinet 148, may be placed within the room.

lreferably all of the plumbing connections are made through a common side wall, the one adjacent utility shaft 48.

As best disclosed in Fig. 6, hot and cold water pipes 154) and 152, respectively, may be installedfor servicing the bathtub 102, shower head 103, toilet 104 and washstand 145. Each of these pipes may terminate in lengths of downwardly projecting portions, the lower ends of which preferably extend below elementS-i of the base member 26 thereby facilitating ease of access thereto by the plumber, after the unit room has been integrated into the building structure.

With reference now to Figs. 5 and 6, it will be noted that a fitting 179, such as, by way of example, a T

connection, crow foot, double outlet T, or triple outlet T, may be operatively connected to a conventional closet ring 172 by means of a bend 174. Fitting 170 is preferably secured to and carried by the base member by suitable clamps suc as are denoted by the numerals 175 and 177. By thus providing outlet 17% in fixed relationship with reference to the unit the vertical leg of the outlet may be used as a template for accurately locating the position of stack, vent or drain pipes to be connected thereto.

After the hot and cold water pipes 15% and 152 have been connected to supply pipes and proper connections made with fitting 170, the room may be entered for the first time when it becomes necessary or desirable to pressure-test the drain line. This may be done by removing the toilet fixture for exposing closet ring 172. A suitable plug is introduced into the exposed end of bend 174 for enabling the drain connection to be tested for leaks. After the test has been completed the plug is removed and the toilet replaced whereupon the bathroom is eady for use.

In those instances where the wall and ceiling panels are of sheet metal regular automobile paint may be spray applied for providing an attractive, durable finish.

With reference to Fig. 3, it will be noted that an adjoining wall 117 may be erected along that side of utility shaft 40 remote from the adjacent wall of the unit. Wall 117 completes the utility shaft which may be utilized to accommodate other service lines, such as heat, power, telephone, water, drainage and the like.

In Fig. 7, I have illustrated the ease with which the walls of my unit may be insulated. The numeral 156 denotes generally a barrier element fabricated, if desired, from an open mesh wire suitably fastened to channels 70. Insulating material 152 may be placed between the outer face of side panels 86 and barrier element 150, as illustrated. Such insulation is beneficial from a heating insulating as well as soundproofing standpoint, although highly satisfactory results may be obtained when the insulation is omitted.

What is claimed is:

1. A prefabricated bathroom unit associated with and spanningly engaging at least three sides of a room-supporting, well-defining structure, said unit comprising a load-bearing, support-spanning, substantially continuous base member including horizontal legs which overlappingly engage the upper portions of the sides of said structure, and vertical legs depending therefrom adapted to be received within said structure in close proximity with said sides of said structure, vertical channels the lower ends of which are secured to and carried by those portions of said horizontal legs remote from said vertical legs, a floor spanning said base member and overlappingly engaging those portions of said horizontal legs substantially over said vertical legs, side walls suspended from the tops of said vertical channels, the bottom edges of said side walls terminating adjacent said horizontal legs between said vertical channels and the edges of said floor.

2. A prefabricated bathroom unit associated with and spanningly engaging at least three sides of a room-supporting, well-defining structure, said unit comprising a load-bearing, substantially continuous base member including horizontal legs the outer portions of which engage the upper portions of sides of said structure and vertical legs depending from the inner portions of said horizontal legs adapted to be received within said structure in close proximity with said sides of said structure, a base channel secured to and carried by the outer portions of said horizontal legs, said base channel including upwardly projecting inner and outer flanges, vertical channels received between said upwardly projecting flanges and secured to and carried by said base channel, side walls the upper ends of which are suspended from said vertical channels and the lower ends of which are received between the adjacent faces of said vertical channels and said inner upwhich engage the upper portions of the sides of said structure and vertical legs depending from the inner portions of said horizontal legs adapted to be received within said structure in close proximity with said sides of said structure, a substantially U-shaped base channel, including laterally spaced, upwardly projecting inner and outer legs, secured to and carried by the outer portions of said horizontal legs, vertical channels, each including an end wall and laterally spaced inner and outer legs projecting therefrom, said vertical channels being carried by, and received between the inner and outer legs of said base channel, the outer legs of said vertical channels being secured in face-to-face engagement with the outer leg of said base channel providing elongated slots between adjacent faces of the inner legs of said vertical channels and the inner leg of said base channel, a substantially continuous angle member extending around the upper ends of said vertical channels, said angle member including a horizontal leg overlappingly engaging said ends of the vertical channels and a vertical leg depending therefrom secured adjacent to the outer surfaces of the outer legs of said vertical channels, side walls comprising elongated panels the upper ends of which terminate in outwardly projecting flanges adapted to overlappingly engage the horizontal leg of said angle member for suspending said panels from said angle member, means securing said flanges to said horizontal leg of the angle member, adjacent vertical edges of said panels being provided one with an outturned flange and the other with a U-shaped groove dimensioned to receive said outturned flange for providing a complementary interlocking means for said panels, said interlocking means being secured to the end walls of the vertical channels for holding the panels adjacent to and in substantial parallelism with the inner legs of said vertical channels for providing a rigid, reinforced, continuous wall, the lower ends of said panels being complementarily received in the slots between adjacent faces of the inner legs of the vertical channels and the inner leg of the base channel, rigid cross members secured to and spanning opposite top portions of the vertical legs of said base member, the top surfaces of said cross members being in substantially horizontal alignment with the top surface of the horizontal leg of said base member, a floor spanning said base member over and in engagement with said cross members and overlappingly engaging the inner portions of the horizontal legs of said base member, said floor terminating adjacent that surface of the inner leg of the base channel remote from said panels.

References Cited in the file of this patent UNITED STATES PATENTS 28,295 OBrien May 15, 1860 628,579 Ennis July 11, 1899 1,556,565 Walsh Oct. 6, 1925 1,730,547 Wallace Oct. 8, 1929 1,978,842 Hooton Oct. 30, 1934 2,087,121 Samelow July 13, 1937 2,131,124 Smith Sept. 27, 1938 2,272,910 Gobberdiel Feb. 10, 1942 2,343,896 Fishko Mar. 14, 1944 2,562,050 Lankton July 24, 1951 OTHER REFERENCES Architectural Forum, September 1947pages 119 and 120.

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