EP4467739A1

EP4467739A1 - Bathroom floor module and method for providing such a bathroom floor module

Info

Publication number: EP4467739A1
Application number: EP24176528.8A
Authority: EP
Inventors: Christer Carlsson
Original assignee: Concept Holding I Sverige AB
Current assignee: Concept Holding I Sverige AB
Priority date: 2023-05-23
Filing date: 2024-05-17
Publication date: 2024-11-27
Also published as: SE2350622A1; SE546777C2

Abstract

Disclosed herein is a bathroom floor module (200) and a method (100) for providing such a bathroom floor module (200). The method (100) comprises receiving (10) a plurality of beams (220) arrangeable as a floor panel frame (201), assembling (20) a composite lavatory pan beam (222) by a first lavatory pan beam (222-1), a second lavatory pan beam (222-2), and an intermediate lavatory pan beam (222-3) connecting to the first (222-1) and the second (222-2) lavatory pan beams by a set of lavatory pan beam mounting members (230), assembling (30) a composite door step beam (224) by a first door step beam (224-1), a second door step beam (224-2), and an intermediate door step beam (224-3) connecting to the first (224-1) and the second (224-2) door step beams by a set of door step beam mounting members (240), assembling (40) the composite lavatory pan beam (222), the composite door step beam (224), and remaining beams (226, 228) of the plurality of beams (220) by a plurality of corner connection devices (250), and mounting (50) a set of laterally extending support beams (210) at the floor panel frame (201) for supporting a floor panel to be arranged thereon.

Description

TECHNICAL FIELD

The present disclosure belongs to bathroom floor modules and methods for providing such bathroom floor modules.

BACKGROUND

Manufacturing of bathroom modules for installation in real estate buildings is a complicated and precise task. For instance, installation of a prefabricated bathroom module, or a room module in general, in an apartment or hotel building is equipped with several challenges compared to a site-built bathroom. One such challenge is the mutual slight irregularity of the dimensions of spaces/rooms oftentimes present between different apartments of the apartment or hotel building. Even if such mutual dimensional irregularities are of the order of centimeters, this may severely complicate installation of a prefabricated bathroom module.
With the above in mind, there is a need for an a more flexible approach to prefabricate a bathroom module to be installed in a building.

SUMMARY

An object of the present inventive concept is provision of a flexible approach to prefabricate a bathroom module, or more specifically, a bathroom floor module, to be installed in a space in a building.
Another object is to provide a simpler approach for manufacturing and/or assembling a bathroom floor module.
Another object is to provide a faster approach for manufacturing and/or assembling a bathroom floor module.
Another object is to provide a less heavy bathroom floor module.
Another object is to provide a less costly bathroom floor module.
Another object is to provide a bathroom floor module having a reduced construction height.
According to a first aspect of the inventive concept, there is provided a method for providing a bathroom floor module, the method comprising receiving a plurality of beams arrangeable as a floor panel frame, assembling a composite lavatory pan beam by a first lavatory pan beam, a second lavatory pan beam, and an intermediate lavatory pan beam connecting to the first and the second lavatory pan beams by a set of lavatory pan beam mounting members, assembling a composite door step beam by a first door step beam, a second door step beam, and an intermediate door step beam connecting to the first and the second door step beams by a set of door step beam mounting members, assembling the composite lavatory pan beam, the composite door step beam, and remaining beams of the plurality of beams by a plurality of corner connection devices, and mounting a set of laterally extending support beams at the floor panel frame for supporting a floor panel to be arranged thereon.
An advantage of the inventive concept is customizability of the geometrical dimensions of the floor panel frame. That is, at little or substantially no extra manufacturing time or cost, a bathroom floor module having specific geometrical dimensions may be manufactured. For instance, the present inventive concept facilitates accounting for geometrical irregularities in a space in which the bathroom floor module is to be installed. An example in connection hereto is an obstructed floor space being a rectangular shaft (e.g., a chimney or the like) protruding laterally into the space in which the bathroom floor module is to be installed. This thus provides a faster, cheaper, more flexible, and more customizable manufacturing of the bathroom floor module. Other, more frequently occurring dimensionality concerns, may involve customizing a substantially rectangular bathroom floor module to have specific (side) dimensions. As appreciated, also parallel epipedic or any quadrangular geometries may in principle be feasible within the scope of the claims.
A typical footprint of the bathroom floor module is approximately 2x3 m. Larger or smaller dimensions are manifestly also possible.
The support beams are arranged in a plane of a final flooring of the floor panel frame. The support beams are of adequate dimensions and number for supporting the final flooring, persons, furniture to be installed in the final bathroom module, etc. Preferably, the support beams are manufactured by a durable material, such as a metal or metal alloy, e.g., steel, aluminum, or the like. Other alternatives may be reinforced plastic, wood, or the like. Further, a subset of the support beams may be manufactured by a specific material or compound, whereas another subset of the support beams may be manufactured by another specific material or compound. As appreciated by the skilled person, the manufacture material of the support beams generally apply to other members of the bathroom module, such as the beams and the mounting members of the bathroom floor module. The support beams may facilitate a reduced vertical height of the bathroom floor module and may thus facilitate installation while maintaining an adequate ceiling height of the prefabricated bathroom module. The support beams are preferably mounted between two of the plurality of beams.
The mounting members may be viewed as mounting plates, i.e., having dimensions such that a thickness of the mounting members is substantially smaller than any one of their other extensions.
Spatial terms such as "lateral" and "vertical", as used herein, are to be understood in relation to a final flooring of the bathroom module, or, equivalently, to a floor in a space in which the bathroom module is to be installed. Hence, during manufacturing/assembling of the bathroom floor module, regardless of a temporary orientation of, e.g., the floor panel frame, a vertical direction/extension refers to a direction/extension along a surface normal of a geometrical plane of the floor panel frame. The lateral extension in relation hereto, thus refers to an extension/direction substantially parallel (within 0-10 degrees) to the geometrical plane of the floor panel frame. The terms "upper", "lower", "top", "bottom", "above", "under", "underneath", and "below" thereby refers to a relative vertical position along the vertical extension.
Each beam of the plurality of beams may have an extruded profile.
Hence, cutting of a beam provide a similar cross-sectional profile regardless of where cutting is done, rendering, e.g., mounting of the mounting members easier. Hence, this facilitates assembling of the floor panel frame, reduces mounting time, etc.
The set of lavatory pan beam mounting members and the set of door step beam mounting members may be of a same type.
This facilitates assembly of the floor panel frame since no distinction between the involved mounting members is necessary.
Provided a length of a beam of the plurality of beams is to be modified, the method may further comprise modifying the length of the beam by means of CNC cutting.
CNC cutting is a particularly advantageous approach for cutting beams and may further provide a clean cut of the beam.
The method may further comprise mounting a lavatory pan suspension member on the lavatory pan beam for suspending a wall mounted lavatory pan.
This provides a robust and sturdy suspension of a lavatory pan and facilitates suspension of the relatively large loads/torques associated with wall mounted lavatory pans. For instance, this facilitates meeting present industry requirements stating withstanding a weight corresponding to 450 kg loading an utmost portion (relative to a wall at which the lavatory pan is to be mounted on) of the lavatory pan. Further, this feature facilitates a reduced construction height with respect to the wall at which the lavatory pan is to be mounted on, i.e., the mounted lavatory pan extends relatively little from the wall.
Each corner connection device of the plurality of corner connection devices may comprise a lifting arrangement for lifting the bathroom floor module.
This facilitates transporting/movement of the bathroom floor panel while assembled, and further facilitates installation of the bathroom floor panel in a building. Further, lifting the bathroom floor module by gripping on vertically low grip points may prevent unnecessary forces/torques/shears on the bathroom module.
Each corner connection device of the plurality of corner connection devices may comprise an adjustment rod for adjusting a geometry of the floor panel frame.
This facilitates adjusting the geometry of the floor panel frame while the floor panel frame is partly or completely assembled and/or installed on its final location. The adjustment rod from respective corner connection device extends, when adequately installed, in an extension substantially perpendicular to a geometrical surface of the floor panel frame. A vertical height of one or more corners of the floor panel frame may thus be adjusted by the adjustment rod. The adjustment rod may extend to a corresponding horizontally aligned ceiling corner of the bathroom module. Hence, the vertical adjustment of the corner may be done from an elevated level, being particularly advantageous should the corner to be vertically aligned facing a corner in a building. It is appreciated that one or more corner connection devices comprising an adjustment rod may be enough for vertical adjustment of the bathroom floor module.
The method may further comprise arranging a first floor panel layer, forming part of the floor panel, on the laterally extending supporting beams, wherein the first floor panel layer is a pre-varnished chipboard.
This type of floor panel reduces the weight of the bathroom module. Further, this type of floor panel may have vibration damping properties and may thus act as a sound-absorbing component in the bathroom module. Varnishing of the first floor panel may prevent moisture damage in events of the corresponding untreated chipboard be sensitive to moisture, which is generally the case for chipboards. Further, the first floor panel may facilitate laterally stabilizing the floor panel frame. The first floor panel layer may be viewed as a support floor panel layer.
The method may further comprise arranging a second floor panel layer, forming part of the floor panel, above the first floor panel layer, wherein the second floor panel layer is a fiber plaster panel.
Fiber plaster material for use as a floor panel facilitates reducing the weight of the bathroom module. By way of example, compared to a corresponding concrete flooring, the fiber plaster material may reduce the weight by 100-200 kg/m². Hence, installation of the bathroom module may be facilitated due to the reduced weight. Further, the fiber plaster material may provide adequate fire protection/prevention, as well as being resistant to dampness/moisture/liquid in wet room environments due to its water-resistant properties. The second floor panel layer may thus be viewed as a top floor panel layer.
According to a second aspect of the inventive concept, there is provided a bathroom floor module comprising a floor panel frame comprising a plurality of beams comprising a composite lavatory pan beam having a first lavatory pan beam, a second lavatory pan beam and an intermediate lavatory pan beam connected to the first and the second lavatory pan beams by a set of lavatory pan beam mounting members, and a composite door step beam having a first door step beam, a second door step beam and an intermediate door step beam connected to the first and the second door step beams by a set of door step beam mounting members, wherein the composite lavatory pan beam, the composite door step beam, and remaining beams of the plurality of beams are connected by a plurality of corner connection devices to form the floor panel frame. The bathroom floor module further comprises a set of laterally extending support beams arranged at the floor panel frame for supporting a floor panel to be arranged thereon.
The above-mentioned features, advantages, and definitions in connection with the first aspect apply, when applicable, to this second aspect as well. In order to avoid undue repetition, reference is thus made to the above.
Each beam of the plurality of beams may have an extruded profile.
Each corner connection device of the plurality of corner connection devices may comprise an adjustment rod for adjusting a geometry of the floor panel frame.
Each corner connection device of the plurality of corner connection devices may comprise a lifting arrangement for lifting the bathroom floor module.
The floor panel may comprise a first floor panel layer on the laterally extending supporting beams, wherein the first floor panel layer is a pre-varnished chipboard.
The floor panel may comprise a second floor panel layer above the first floor panel layer, wherein the second floor panel layer is a fiber plaster panel.
A further scope of applicability of the present invention will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the inventive concept will become apparent to those skilled in the art from this detailed description.
Hence, it is to be understood that the present inventive concept is not limited to the particular component parts of the device described or acts of the methods described as such device and method may vary. It is also to be understood that the terminology used herein is for purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in the specification and the appended claim, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements unless the context clearly dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, and the like. Furthermore, the words "comprising", "including", "containing" and similar wordings does not exclude other elements or steps.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as additional objects, features, and advantages of the present inventive concept, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments, with reference to the appended drawings, where the same reference numerals will be used for similar elements.

Fig. 1 shows a flowchart of a method for providing a bathroom floor module.
Fig. 2 shows a bathroom floor module.
Fig. 3 shows a cross-sectional view of a beam forming part of a floor panel frame of a bathroom floor module.
Fig. 4 shows a corner connection device arranged to connect beams of a floor panel frame of a floor panel frame.
Fig. 5A shows a bathroom floor module.
Fig. 5B shows a drain pipe opening of a floor panel frame.
Fig. 5C shows a mounting member used in composite beams of a floor panel frame.
Fig. 5D shows a corner connection device while assembled with beams of a floor panel frame.
Fig. 6 shows a lavatory pan suspension plate attachable to a lavatory pan beam of a floor panel frame.
Fig. 7A shows a top view of a bathroom floor module.
Fig. 7B shows a floor drain of a bathroom floor module.
Fig. 8A shows a side view of a bathroom floor module.
Fig. 8B shows a side view of a support beam of a bathroom floor module.

DETAILED DESCRIPTION

The present inventive concept will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the inventive concept are shown. This inventive concept may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and to fully convey the scope of the inventive concept to the skilled person.
An initial remark regarding the forthcoming description is that there, by way of example, will be discussed "a plurality of beams 220", "a plurality of corner connection devices 250", and other pluralities of a specific part, wherein respective "plurality of X's" may comprise possibly mutually structurally differing X's. Whenever the description refers to features of "a/the beam 220", this beam may refer to any specific beam 222, 224, 226, 228 of the plurality of beams 220; this to simplify reading and understanding the inventive concept. However, the skilled person appreciates that the plurality of beams 220 may be mutually different along the lines of the description. For instance, the below described lavatory pan beam 222 is generally different to the specific beam 226, etc. This applies, mutatis mutandis, to, e.g., the plurality of corner connection devices 250.
Further, it is to be noted that the terms "bathroom floor module", "floor panel frame", "bathroom module" may occasionally be used interchangeably, which should not confuse the skilled person. However, in general the bathroom floor module 200 refers to a floor panel frame 201 having a flooring 214, 216 and possibly other parts attached thereto, whereas the bathroom module (not shown in its entirety) generally refers to the bathroom floor module 200 including walls and ceiling, etc.
The bathroom module may be installed in any adequate space. Examples of such spaces are spaces in apartment buildings, hotels, trailers, boats, houses, cottages/cabins, etc.
In connection with Fig. 1 there is shown a flowchart of a method 100 for providing a bathroom floor module 200. A substantial portion of the bathroom floor module 200 is shown in Fig. 2. Hence, Figs 1 and 2 may preferably be viewed in parallel while reading the description of the method 100 below. Optional method steps 60-90 are illustrated by dashed boxes.
The method 100 comprises receiving 10 a plurality of beams 220. The plurality of beams 220 are arrangeable as a floor panel frame 201; see Fig. 2. The floor panel frame 201 may have, in an assembled state, a quadrangular geometry in a form of a rectangle having substantially right angles between adjacent beams. However, should, e.g., a shaft being present in a space in which the bathroom module is to be installed, the floor panel frame 201 may have a geometry different from a quadrangular/rectangular geometry. That is, if such a shaft by way of example itself has a (relatively small) rectangular geometry, the floor panel frame may be arranged to extend along the rectangular geometry of the shaft by adequately cutting and arranging one or more beams accordingly. On such occasions, more than four beams may constitute the floor panel frame 201 of the bathroom floor module 200. Other geometries of an obstacle similar to the above shaft may be possible and accounted for upon manufacturing/mounting of the bathroom floor module, as appreciated by the skilled person.
The method 100 further comprises assembling 20 a composite lavatory pan beam 222 by a first lavatory pan beam 222-1, a second lavatory pan beam 222-2, and an intermediate lavatory pan beam 222-3 connecting to the first 222-1 and the second 222-2 lavatory pan beams by a set of lavatory pan beam mounting members 230. The lavatory pan beam mounting members 230 may be welded on the ends of the intermediate lavatory pan beam 222-3. Alternatively, the lavatory pan beam mounting members 230 may be fastened to the ends of the intermediate lavatory pan beam 222-3 by other fastening means such as screws or bolts. The lavatory pan beam mounting members 230 may have the form of plates 230, i.e., having a thickness being relatively small compared to the remaining extensions. The first lavatory pan beam 222-1 may comprise a through-going opening 280, best viewed in Fig. 5B. The through-going opening 280 may function as a drain pipe opening 280 of the floor panel frame 201, in which drain pipe opening 280 a drain pipe may be passed through. This may facilitate saving vertical space of the bathroom floor module. The through-going opening may be present on any one of the beams 220 with remained function. If needed, a plurality of such through-going openings 280 may be present on one or more of the beams 220.
Related to the drain pipe opening 280, Fig. 7A depicts a top view of the bathroom floor module 200, emphasizing a floor drain (Fig. 7B) 282. Although not shown in Fig. 7A, the schematic tile flooring 216 (second floor panel layer 216) depicted in Fig. 2 is manifestly possible also here. The floor drain 282 is preferably located in a corner of the bathroom floor module 200. This facilitates a substantially horizontal drain of water out from the bathroom floor module through the drain pipe opening 280, thus saving vertical construction height of the bathroom floor module 200. Drain water from the lavatory pan is directed similarly for a similar reason.
The method 100 further comprises assembling 30 a composite door step beam 224 by a first door step beam 224-1, a second door step beam 224-2, and an intermediate door step beam 224-3 connecting to the first 224-1 and the second 224-2 door step beams by a set of door step beam mounting members 240. The door step beam mounting members 240 may be welded on the ends of the intermediate door step beam 222-3. Alternatively, the door step beam mounting members 230 may be fastened to the ends of the intermediate door step beam 222-3 by other fastening means such as screws or bolts. The door step beam mounting members 240 may have the form of plates 240, i.e., having a thickness being relatively small compared to the remaining extensions. The intermediate lavatory pan beam 222-3 is preferably shorter than the intermediate door step beam 224-3.
The method 100 further comprises assembling 40 the composite lavatory pan beam 222, the composite door step beam 224, and remaining beams 226, 228 of the plurality of beams 220 by a plurality of corner connection devices 250.
Each beam 222, 224, 226, 228 of the plurality of beams 220 may have an extruded profile. Hence, regardless of where a beam is cut, the cross-sectional profile is substantially the same. A cross section of one of the beams 226 is shown in Fig. 3. The beam 226 shown therein may apply to the remaining beams as well, apart, possibly, from the lavatory pan beam 222-3 and the door step beam 224-3. Hence, when discussing features of a beam, e.g., beam 226 of Fig. 3, it should be understood that these features may apply to the remaining beams 222, 224, 228 accordingly, unless not explicitly stated otherwise. The beam 226 has a cross-sectional profile being U-shaped. Other cross-sectional profiles may be possible within the scope of the claims. The beam 226 may comprise a plurality of screw pockets 260. The screw pockets 260 may be viewed as elongated channels extending along a main extension of the beam 226. At least some of the screw pockets 260 may be threaded. However, preferably, every one of the screw pockets 260 is unthreaded. Hence, upon screwing a screw in a screw pocket 260, the screw may create sufficient threads in the screw pocket 260 such that, e.g., a mounting member 230, 240 may be securely fastened to the beam 226. Further, each screw pocket 260 may have an open portion between two prongs 262, 264. This may facilitate a structural flexibility between the prongs 262, 264. The opening is preferably between 40 and 80 degrees (referring to a circle sector), and a diameter of the screw pocket is preferably in the range 6-9 mm. More preferably, the opening is approximately 60 degrees, and the diameter approximately 7.5 mm.
A bottom surface 270 of the beam 226 is preferably facing a flooring of the bathroom floor module. The bottom surface 270 thus has a surface normal pointing in the lateral extension when the floor panel frame 201 is in an assembled state. A left portion 272 and a right portion 274 of the beam 226, i.e., the two prongs 272, 274 of the U-shaped beam 226, are preferably mirror symmetric, which facilitates flexibility upon assembling the floor panel frame 201.
In connection with Fig. 4, the corner connection device(s) are described in further detail. The corner connection devices 250 are, as understood, used to assemble the beams 220, and to facilitate forming a relatively rigid floor panel frame 201. Hence, four corner connection devices 250 are used to assemble the floor panel frame 201, provided no shaft, chimney or other geometrical irregularities of the installation space is/are to be accounted for. The corner connection devices 250 are preferably mutually similar. The corner connection device 250 may comprise a corner portion 252 to be present at a corner of the floor panel frame 201. A first 254 and a second 256 side portion of the corner portion 252 may thus correspond to a width W1 of the U-shaped beam 226 (when arranged as depicted in Fig. 3). The corner connection device 250 may further comprise a plurality of through-going openings 258. The corner connection device 250 may thus be screwed/bolted to respective beam 220 by screws or bolts through the through-going openings 258 into the previously described screw pockets 260. Preferably, the corner connection device 250 may be fastened by six screws/bolts to each of the (two) beams 220 connecting to the corner connecting device 250, that is, the same number of screws/bolts as the number of screw pockets 260 present on the beam 226. Another number of screws/bolts is of course possible within the scope of the claims.
The corner connection device 250 may further comprise a first 251 and a second 253 prong being mutually substantially perpendicular. The prongs 251, 253 thus substantially extend in the extension of the beams attached to the corner connection device 250, and may thus be fastened, by any adequate fastening means, to the beams 220.
Each corner connection device 250 of the plurality of corner connection devices 250 may comprise a lifting arrangement 2510, 2530 for lifting the bathroom floor module 200. The lifting arrangement 2510, 2530 may be a through-going opening 2510, 2530 present on respective prong 251, 253 of the first 251 and the second 253 prong of the corner connection device 250. Herein, a lifting device (not shown) such as a hook, a grapple, or the like, connected to a flexible lifting element (e.g., rope, chain, etc.) may be inserted into at least a subset of the through-going openings 2510, 2530 of the corner connection devices 250 to lift and transport the bathroom floor module 200. Preferably the lifting device may have a widened portion, e.g., a ball-like portion, insertable in an insertion portion of the through-going opening. Upon inserted, a narrowed portion (i.e., a "neck"), in connection with the widened portion, may be guided along the through-going opening towards a vertically extending elongated lifting portion of the through-going opening, the width of the lifting portion being similar to the narrowed portion of the lifting device. Repeating this for at least some of the remaining corner connection devices 250 may facilitate a secure lifting of the bathroom module 200. Hence, as appreciated, the final bathroom module 200 may be lifted and transported by means of the lifting arrangement.
Each corner connection device 250 of the plurality of corner connection devices 250 may comprise an adjustment rod (not shown) for adjusting a geometry of the floor panel frame 201. The adjustment rod may be selectively removable/adaptable from/to the corner connection device 250. The adjustment rod may be at least partially threaded and configured to be received, by screwing, in a threaded portion 255 of the corner connection device 250. An example of such a threaded portion 255 is shown in Fig. 4 being an adjustment rod nut 255. The adjustment rod nut 255 may be fastened on a laterally extending bottom corner connection device member 257 by, e.g., welding or the like. Alternatively, the bottom corner connection device member 257 may comprise a threaded through-going opening. The adjustment rod may extend through a through-going opening 2550 in a top corner connection device member 2570. This through-going opening 2550 may be unthreaded, and thus primarily aimed for stabilizing/guiding the adjustment rod in along a substantially vertical direction. Alternatively, the through-going opening 2550 may be threaded. A bottom end portion of the adjustment rod may comprise a suspension support (not shown). The suspension support may have a bottom surface area substantially larger than a cross section area of the adjustment rod for suspending a specific corner of the floor panel frame to an elevated level in relation to a floor on which the bathroom floor module 200 is to be placed on. The suspension support may at least partially be made of rubber, plastic, or a compound thereof. Hence, provided the above-described adjustment rod is present on one or more corners of the floor panel frame 201, a vertical alignment may be achieved by adjusting or tuning one or more of the adjustment rods. The adjustment rod may extend to a corresponding horizontally aligned ceiling corner of the bathroom module. Hence, the vertical alignment may be facilitated even if the corner to be vertically aligned faces a corner in a space in which the bathroom floor module 200 is to be installed.
Figs 5A-D show an overall perspective view of the floor panel frame 201 (Fig. 5A), which is similar to Fig. 1, and highlights of specific parts thereof upon the floor panel frame 201 being assembled, i.e., the drain pipe opening 280 (Fig. 5B), one of the lavatory pan mounting members 230 (Fig. 5C), and the corner connection device (Fig. 5D).
The set of lavatory pan beam mounting members 240 (see Fig. 5C) and the set of door step beam mounting members 240 may be of a same type. A specific mounting member 240 of the set of mounting members 240 may be a rectangular plate having an area being substantially similar to an area spanned by the cross-sectional area of the beam 220. The mounting members 240 may comprise through-going openings matching the screw pockets 260 of the beams 220. Hence, the mounting members 240 may be fastened by screws to the beams 220 similarly to the fastening of the corner connection devices 250 to the beams 220.
The method 100 may further comprise, provided a length of a beam 222, 224, 226, 228 of the plurality of beams 220 is to be modified, modifying 60 the length of the beam 222, 224, 226, 228 by means of CNC cutting. Alternatively, a beam 222, 224, 226, 228 may be cut by a conventional metal cutter or metal saw.
The method 100 may further comprise mounting 70 a lavatory pan suspension plate 290 on the lavatory pan beam 222-3 for suspending a wall mounted lavatory pan. The lavatory pan suspension plate 290 is shown in Fig. 6.
The method 100 further comprises mounting 50 a set of laterally extending support beams 210 at the floor panel frame 201 for supporting a floor panel 214, 216 to be arranged thereon. A second floor panel layer 216 (further discussed below) is, in Fig. 2, schematically depicted being a tile flooring, but any adequate type of second (top) floor panel layer 216 is possible. The laterally extending support beams 210 are shown in Figs 8A and 8B being a side view of the floor panel frame 201. This approach for supporting a floor panel 214, 216 to be arranged on the floor panel frame 201 may facilitate a reduced construction height.
Preferably, the laterally extending support beams 210 are aligned substantially along (e.g., parallel to) a shorter side of the floor panel frame 201. This may prevent unnecessary bending of the flooring upon carrying a load such as a person, furniture, a bathtub etc. The support beams 210 may be secured to the beams 220 by screws or bolts via a set of screw pockets present 211 on each end of respective support beam 210. The screw pockets 211 may extend along the support beam 210 and may have a similar structure and function as the screw pockets 260 of the beams 220 discussed above. The support beams 210 may further be arranged on flanges (not shown) present on the bottom surface 270 on respective beam 222, 224, 226, 228, i.e., inwardly (towards the floor panel 214, 216) protruding flanges, prior to being further secured by bolting/screwing the support beam to the floor panel frame 201.
The method 100 may further comprise arranging 80 a first floor panel layer 214 on the laterally extending supporting beams 210, wherein the first floor panel layer 214 is a pre-varnished chipboard 214. The first floor panel layer 214 may comprise board-like portions 214 arranged to rest on recessed protruding flanges 212 between adjacent support beams 210. A vertical height of the first floor panel layer may correspond to a vertical height of the recessed protruding flanges 212 in relation to a top surface 218 of the support beams 210. Hence, the top surfaces 218 of the support beams 210 and the first floor panel layer 214 may, together, form a substantially flat top surface.
The method 100 may further comprise arranging 90 a second floor panel layer 216 above the first floor panel layer 214, wherein the second floor panel layer 216 is a fiber plaster panel 216. The second floor panel layer 216 may thus be arranged on the substantially flat top surface formed by the support beams 210 and the first floor panel layer 214. The fiber plaster panel 216 may be understood as a fiberglass reinforced gypsum, FRG, board, a fiberglass gypsum board, a glass fiber reinforced gypsum board, or a reinforced gypsum panel, each describing a gypsum-based construction material being fiber reinforced by, e.g., glass fiber.
Below follows a description of the bathroom (floor) module 200 per se considered in the present disclosure, thus occasionally repeating portions of the above-mentioned text in connection with the method 100. Hence, for the sake of sufficiency, and in line with the appended claims, the corresponding bathroom (floor) module 200 is described below. Reference is thus made to the already above-mentioned drawings.
The bathroom floor module 200 comprises a floor panel frame 201.
The floor panel frame 201 comprises a plurality of beams 220.
The plurality of beams 220 comprises a composite lavatory pan beam 222 having a first lavatory pan beam 222-1, a second lavatory pan beam 222-2 and an intermediate lavatory pan beam 222-3 connected to the first 222-1 and the second 222-2 lavatory pan beams by a set of lavatory pan beam mounting members 230.
The plurality of beams 220 further comprises a composite door step beam 224 having a first door step beam 224-1, a second door step beam 224-2 and an intermediate door step beam 222-3 connected to the first 224-1 and the second 224-2 door step beams by a set of door step beam mounting members 240.
The composite lavatory pan beam 222, the composite door step beam 224, and remaining beams 226, 228 of the plurality of beams 220 are connected by a plurality of corner connection devices 250 to form the floor panel frame 201.
The bathroom floor module 200 further comprises a set of laterally extending support beams 210 arranged at the floor panel frame 201 for supporting a floor panel to be arranged thereon.
The support beams 210 are advantageously manufactured by a durable material such as steel, reinforced plastic, wood, or the like. Further, a subset of the support beams 210 may be manufactured by a specific material or compound, whereas another subset of the support beams may be manufactured by another specific material or compound. As appreciated by the skilled person, the manufacture material of the support beams preferably apply to other members of the bathroom module, such as the beams, the mounting members, the corner connection devices, screws/bolts/nuts, etc. of the bathroom floor module. Further, respective component/part of the bathroom floor module may have rounded corners/edges obtainable by, e.g., chamfering or grinding. This to avoid having sharp edges/corners on the components/parts, which thus may prevent undesirable harmful cutting during manufacturing and/or end use.
Each beam 222, 224, 226, 228 of the plurality of beams 220 may have an extruded profile; see, e.g., Fig. 3.
Each corner connection device 250 of the plurality of corner connection devices 250 may comprise an adjustment rod (not shown) for adjusting a geometry of the floor panel frame 201.
Each corner connection device 250 of the plurality of corner connection devices 250 may comprise a lifting arrangement for lifting the bathroom floor module 200.
The floor panel may comprise a first floor panel layer 214 on the laterally extending supporting beams 210. The first floor panel layer 214 may be a pre-varnished chipboard 214.
The floor panel may comprise a second floor panel layer 216 above the first floor panel layer 214. The second floor panel layer (216) may be a fiber plaster panel 216.
Accordingly, and in summary, in some embodiments discussed above, there has been described an approach to provide a bathroom floor module 200. The bathroom floor module 200 is associated with customizable sizing, relatively easy to assemble, and relatively lightweight.
The person skilled in the art realizes that the present inventive concept by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. Variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

Claims

A method (100) for providing a bathroom floor module (200), the method (100) comprising:
receiving (10) a plurality of beams (220) arrangeable as a floor panel frame (201);

assembling (20) a composite lavatory pan beam (222) by a first lavatory pan beam (222-1), a second lavatory pan beam (222-2), and an intermediate lavatory pan beam (222-3) connecting to the first (222-1) and the second (222-2) lavatory pan beams by a set of lavatory pan beam mounting members (230);

assembling (30) a composite door step beam (224) by a first door step beam (224-1), a second door step beam (224-2), and an intermediate door step beam (224-3) connecting to the first (224-1) and the second (224-2) door step beams by a set of door step beam mounting members (240);

assembling (40) the composite lavatory pan beam (222), the composite door step beam (224), and remaining beams (226, 228) of the plurality of beams (220) by a plurality of corner connection devices (250); and

mounting (50) a set of laterally extending support beams (210) at the floor panel frame (201) for supporting a floor panel (214, 216) to be arranged thereon.
The method (100) according to claim 1, wherein, provided a length of a beam (222, 224, 226, 228) of the plurality of beams (220) is to be modified, modifying (60) the length of the beam (222, 224, 226, 228) by means of CNC cutting.
The method (100) according to any one of claims 1-2, further comprising mounting (70) a lavatory pan suspension plate (290) on the lavatory pan beam (222) for suspending a wall mounted lavatory pan.
The method (100) according to any one of claims 1-3, further comprising arranging (80) a first floor panel layer (214), forming part of the floor panel, on the laterally extending supporting beams (210), wherein the first floor panel layer (214) is a pre-varnished chipboard.
The method (100) according to any one of claims 1-4, further comprising arranging (90) a second floor panel layer (216), forming part of the floor panel (214, 216), above the first floor panel layer (214), wherein the second floor panel (216) layer is a fiber plaster panel.
A bathroom floor module (200) comprising:
a floor panel frame (201) comprising a plurality of beams (220) comprising
a composite lavatory pan beam (222) having a first lavatory pan beam (222-1), a second lavatory pan beam (222-2) and an intermediate lavatory pan beam (222-3) connected to the first (222-1) and the second (222-2) lavatory pan beams by a set of lavatory pan beam mounting members (230); and

a composite door step beam (224) having a first door step beam (224-1), a second door step beam (224-2) and an intermediate door step beam (224-3) connected to the first (224-1) and the second (224-2) door step beams by a set of door step beam mounting members (230),

wherein the composite lavatory pan beam (222), the composite door step beam (224), and remaining beams (226, 228) of the plurality of beams (220) are connected by a plurality

of corner connection devices (250) to form the floor panel frame (201); and

a set of laterally extending support beams (210) arranged at the floor panel frame (201) for supporting a floor panel (214, 216) to be arranged thereon.
The bathroom floor module (200) according to claim 6, wherein each beam (222, 224, 226, 228) of the plurality of beams (220) has an extruded profile.
The bathroom floor module (200) according to any one of claims 6-7, wherein each corner connection device (250) of the plurality of corner connection devices (250) comprises a lifting arrangement (2510, 2530) for lifting the bathroom floor module (200).
The bathroom floor module (200) according to any one of claims 6-8, wherein the floor panel (214, 216) comprises a first floor panel layer (214) on the laterally extending supporting beams (210), wherein the first floor panel layer (214) is a pre-varnished chipboard.
The bathroom floor module (200) according to any one of claims 6-9, wherein the floor panel (214, 216) comprises a second floor panel layer (216) above the first floor panel layer (214), wherein the second floor panel layer (216) is a fiber plaster panel.