The present invention relates to a prefabricated shell for forming a room in a building.

BACKGROUND TO THE INVENTION

In residential construction projects, it is necessary to install utilities such as heating, ventilation and electrical power. This requires installation of a number of utility units such as a water heating unit, a distribution board for the electricity supply, a mechanical ventilation unit, and sometimes appliances such as washing machines or tumble driers. The units and appliances must be connected to utility conduits such as electrical power cables, ventilation ducts, gas supply and water flow and return pipes.

In larger projects such as apartment buildings, it may be necessary to repeat a number of identical installations. It has been found that significant cost and time savings can be obtained by providing prefabricated utilities panels, incorporating some or all of the above units, appliances and connections fixed to a frame or board. This allows a significant amount of standardised work to be performed off-site, simplifying the overall construction process.

Such panels are typically installed in a dedicated utilities cupboard or room, separated from living spaces by a door. This is because the necessary connectors and conduits are generally considered unsightly and undesirable in a domestic environment.

A problem with this approach is that the dedicated cupboard or room cannot generally be used for any other purpose.

Prefabricated room structures are generally installed using cranes as the building is constructed. However, the lifting points are designed to be used by cranes and are unusable once the building has been constructed. Furthermore, there is little to no headroom to pick up and manoeuvre the prefabricated room into position.

To address the problems above, a prefabricated utility station, known in the construction field under the brand PUR (packaged utility room) were designed to be inserted into an appropriately sized void to provide a finished utility area that is suitable for a domestic environment. The inner wall of the PUR provides a visible face to face the interior of a room. The outer casing abuts the walls of the void and provides structural integrity. The inner wall and outer wall would be placed on the floor of the room. The room floors, created by screeding or similar methods, may not be level or have a particular surface texture which can cause issues with the PUR being installed. A floorpan has been added as a requirement for some PUR designs to allow its installation prior to a floor being screeded.

PURs were designed to be used with a complementary trolley designed to lift the PUR structure and allow its fitment within a building. However, these complementary trolleys are unsuitable for PURs with an integrated floorpan, because the integrated floorpan would abut portions of the trolley and prevent the lifting table of the trolley from reaching the lifting points of the PUR.

Furthermore, the room floor within a utility cupboard may support appliances, such as a washing machine and/or a dryer, which create vibration. During testing of PURs with a floorpan, the whole PUR structure would vibrate. As such, floorpans are unsuitable in positions where certain appliances are to be used, and this is in the majority of installations.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems.

STATEMENT OF INVENTION

According to the first aspect of the present invention, there is provided a prefabricated shell for forming a utility room in a building, the shell comprises a base unit and a substantially U-shaped wall extending upwardly from the base unit, the substantially U-shaped wall being connected to the base unit, the base unit having a substantially planar upper member for forming a floor within the utility room, and feet being provided underneath the substantially planar upper member, which support the substantially planar upper member in a raised position above the surface on which the feet are placed, a space being formed underneath the substantially planar upper member and substantially unimpeded access for forks of a forklift or pallet truck to slide underneath the substantially planar upper member from at least a front of the prefabricated shell, for lifting the prefabricated shell into position.

The prefabricated utility shell provides a unit that can be inserted into a void or alcove to provide a finished utility area that is suitable for a domestic environment. Advantageously, the shell can be lifted by a forklift or pallet truck from its base, facilitating movement within a partially constructed building, such as a block of flats or apartments.

The prefabricated utility shell may also be one of the first items to be installed on a floor in an apartment complex. All the required utilities conduits, such as the piping for underfloor heating, can be aligned and fitted before screeding or finishing of the apartment or room, allowing for less wastage of the utility conduits.

The U-shaped wall provides a visible face to face the interior of a room. The added base unit provides structural rigidity and strength to a single skinned U-shaped wall.

Although the base unit prevents access for a trolley, the ability to lift the shell with conventional lifting apparatus on site, is a significant advantage. The base also provides structural rigidity for lifting.

The prefabricated shell allows easy access to the necessary utility conduits, such as connectors, pipes and cables. The utility conduits are hidden from view by the U- shaped wall so that the prefabricated shell presents an acceptable aspect for a domestic space. The concavity of the U-shaped wall provides additional working or living space.

According to a second aspect of the present invention there is provided a prefabricated utility shell for forming a utility room in a building comprising a base unit and at least one wall, the base unit including: a substantially planar upper member for forming a floor, the planar upper member being provided with a resilient area for isolating the at least one wall from a vibration source disposed on the resilient area of the base unit.

Advantageously, an appliance, for example a washing machine, can be placed on the resilient area and vibration from the washing machine (for example due to spinning) is isolated by the resilient area and not transmitted to the wall. The resilient area isolates the larger structure from vibration which may cause damage or distortion.

Furthermore, the base unit provides a means to add strength and rigidity to a prefabricated utility shell. The base can be installed prior to screeding or finishing of the apartment or flat allowing utilities conduits, such as pipes for underfloor heating or conductive wires for an electricity distribution board, to be routed with minimum wastage.

The base unit may comprise at least two fork receiving means for receiving and guiding the forks of the forklift or pallet truck. The fork receiving means may be disposed on the underside of the planar upper member and to either side of the transverse centre line of the base unit. The fork receiving means may disposed in the space formed underneath the substantially planar upper member. The fork reiving means may also be consider fork lifting points.

The fork receiving means improves safety while lifting and moving prefabricated utility shells. The position of the fork receiving means allows them to be hidden from view in the finished utility cupboard.

The base unit may comprise at least two pairs of lifting points for lifting the shell from above. Each pair of the lifting points may be disposed on either side of the longitudinal centre line of the base unit. Each pair of lifting points may extend upwardly from the planar upper member. Each lifting point may be detachable from the base unit.

The additional lifting points allows for other lifting means to be used. For example, a crane, or forklift, may use straps or other means to lift from above. This can be useful for removing the item from a vehicle.

The base unit may comprise a plurality of reinforcing members extending transversely (front to back) across the underside of the planar upper member. The transverse reinforcing members may depend from the underside of the planar upper member.

The feet of the first aspect of the present invention can be considered to be any part of the base which is located underneath the substantially planar upper member and support the substantially planar upper member in a raised position above the surface on which the feet are placed. For example, the transverse reinforcing members may be considered the feet of the first aspect of the present invention. Additionally, height adjustable feet may be considered the feet of the first aspect of the present invention.

The base unit may comprise two reinforcing members extending longitudinally across the underside of the planar upper member. The reinforcing members may depend from the underside of the planar upper member. The prefabricated shell in the first aspect of the invention may comprise a vibration isolation means for substantially dampening vibration. The vibration isolation means may be a resilient portion of the base unit.

The resilient portion may be resiliently mounted in a cut-out provided in the planar upper member. The resilient portion may be provided by a floating plate disposed in the cut-out for supporting the appliance.

A support means may extend across the cut-out and at least one resilient member may be disposed between the floating plate and the support means. The resilient member may be made from rubber. It may be a plurality of rubber bushes.

The base unit may have an aperture provided in the planar upper member. The aperture may provide access to the space formed underneath the substantially planar upper member. The aperture may include a cover. The cover may be biased to a position in which it closes the aperture. The cover may be a rigid material. The cover may be a flexible material.

The cover allows for underfloor heating pipes, or other utilities conduits routed to run below the base unit.

The planar upper member, the longitudinal reinforcing members, and/or transverse reinforcing members may be steel.

The floating plate and support means may be steel. The support means may be coupled to the longitudinal reinforcing members or the transverse reinforcing members.

The U-shaped wall may have a first side, a second side substantially parallel to the first side and a rear side substantially orthogonal to both the first and second sides. The rear side may be joined to the first side and/or the second side. The substantially U-shaped wall may be provided by a plurality of sheets or a continuous sheet.

The first side of the substantially U-shaped wall and/or the second side of the substantially U-shaped wall may be offset from a periphery of the base unit. The offset may be provided by the walls being inwardly spaced from the periphery of the base unit. The offset may provide a receiving space for receiving utilities conduits. A prefabricated shell for forming a utility room may comprise at least one utility unit disposed on or in the U-shaped wall.

The prefabricated shell may include a cupboard for housing a utility unit.

The substantially U-shaped wall may have at least one aperture for providing a route for utilities conduits from the receiving space to the space which will form the utility room.

A prefabricated shell for forming a utility room may comprise a worktop. The worktop may be attached to the substantially U-shaped wall by brackets.

Utility units, such as a water heater, may be mounted to the substantially U-shaped wall. The utility units are mounted to the internal side of the U-shaped wall (the space which forms the utility room) so that they are accessible, while the required conduits are hidden from view behind the substantially U-shaped wall.

The base unit may include adjustable feet for levelling the base during and/or after fitment. At least some of the adjustable feet may be disposed underneath the planar upper member. The means to adjust the adjustable feet may be disposed on the upper side of the planar upper member.

The base unit may comprise a plurality of attachment points for securing a prefabricated wall to the substantially planar upper member. The attachment points may be disposed in the upper surface of the planar upper member. The prefabricated wall may be substantially U-shaped. The prefabricated wall may be that discussed above.

In another aspect of the invention the base unit may include a rigid base layer connected to the at least one wall, a resilient layer disposed on the base layer and the substantially planar upper member being provided by a rigid layer disposed on the resilient layer.

The resilient layer may be made from rubber. The layers may be bonded together. An upper vinyl layer may be provided. Alternatively, a wooden flooring, or wood effect flooring may be provided.

A gap may be provided around the periphery of the substantially planar upper member, for preventing transfer of vibration of the substantially planar upper member to the rest of the base unit and utility shell.

Advantageously, the resilient area may extend across substantially the whole floor area of the base unit, with a small space of 2-5mm around the outside.

According to a further aspect of the present invention, there is provided a base unit for a prefabricated utility shell, the base comprising a substantially planar upper member for forming a floor within the utility room, the planar upper member being provided with a cut-out, and a vibration isolation means for isolating vibration caused by an appliance, the vibration isolation means comprising a floating plate disposed in the cut out for supporting the appliance, a support means extending across the cut-out and a resilient member disposed between the floating plate and the support means.

A prefabricated shell according to the first aspect of the present invention may be provided with the base unit according to the second aspect of the present invention. The prefabricated shell according to the first aspect of the present invention may be provided with the base unit according to any other aspect of the present invention. Furthermore, the base unit in the first aspect may be used separately from the substantially U-shaped wall.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which:

Figure 1 shows a perspective of a prefabricated shell according to an embodiment of the invention;

Figure 2 shows a front view of the prefabricated shell shown in Figure 1 ;

Figure 3 shows a top view of the prefabricated shell shown in Figures 1 and 2; Figure 4 shows a perspective view of the base unit according to an embodiment of the invention;

Figure 5 shows a view of the underneath of the base unit shown in Figure 4;

Figure 6 shows a perspective view of the base unit according to an embodiment of the invention;

Figure 7 shows a perspective view of the base unit shown in Figure 6 without the floating base plate;

Figure 8 shows a perspective view of the base unit according to an embodiment of the invention;

Figure 9 shows a schematic perspective view of an alternative embodiment of base unit; and

Figure 9A shows a cross section through part of the flooring structure of the base unit of Figure 9.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring firstly to Figures 1, 2 and 3, a prefabricated shell is generally indicated at 10.

The prefabricated shell 10 includes a base unit 12 and a wall 14 extending upwardly from the base unit 12. In the embodiment shown in Figures 1 to 3, the base unit 12 is that shown in Figure 4 and 5. Further embodiments of the base unit are shown in Figures 6 to 9.

The wall 14 extends upwardly from the base unit 12. The wall 14 is rigidly fixed to the base unit 12.

The wall 14 is substantially U-shaped when viewed from above. The wall 14 includes a first side 16, a second side 18 and a rear side 20, joined together to form the U- shape. The first side 16, second side 18 and rear side 20 of the substantially U-shaped wall 14 may be provided as separate panels or may be provided as a single continuous sheet of material, such as steel.

The first side 16, second side 18 and rear side 20 are each substantially planar, substantially rectangular and substantially the same height.

The first side 16 is inwardly spaced from the periphery of the base unit 12, this offset provides a space for receiving utilities conduits, such as pipes and or electrical wire trunking. The second side 18 and/or the rear side 18 may be inwardly spaced from the periphery of the base unit 12, the offsets may provide a space for receiving utility conduits.

A first frontal section 22 may extend from the first side 16 of wall 14 to obscure the space for receiving the utility conduits when viewed from the front. A second frontal section 24 may extend from the second side 18 of wall 14 to obscure the space for receiving the utility conduits created by the offset. Both the frontal sections 22, 24 may be separate panels or they may be integral with the panel(s) forming the substantially U-shaped wall 14.

When the frontal sections are made integral, they are formed by folding a portion of the U-shaped wall. When separate panels, the front sections may be attached to the U-shaped wall around an overlap between the panels forming the frontal section and the side of the u-shaped wall, the overlap may be formed by a fold.

The first side 16, second side 18 and the rear side 20 may have apertures providing access from one side of the substantially U-shaped wall to the other. For example, the apertures may provide a path for a utility conduit from the utility conduit receiving space to the internal space. The “internal space” should be understood to mean the inside of the U-shaped profile which forms the domestic space or the space forming the utility room once the prefabricated shell has been fitted.

A cover for each aperture may be provided, for example cover 25 which closes an aperture in the second side 18.

A cupboard 26, or a plurality of cupboards, may be provided on the substantially U- shaped wall. Cupboards may be provided on the first side 16, second side 18 and/or rear side 20 of the U-shaped wall. In some embodiments, the cupboards may cover an aperture in the U-shaped wall.

In the embodiments shown in Figures 1 to 3, the prefabricated shell 10 also includes a first upper section 28. The first upper section extends from the rear side 20 along the top of the prefabricated shell 10 until it reaches a second upper section 30. The second upper section 30 extends from the first upper section 28 along the top side of the prefabricated shell 10 until it reaches the front side of the prefabricated shell 10. Once the second upper section 30 reaches the front side of the prefabricated shell 10 it extends at least partially down forming an L-shape. In other embodiments, the second upper section 30 may instead extend angularly down to the front side of the prefabricated shell 10.

A plurality of brackets (not shown) can be disposed on the U-shaped wall 14. The brackets each sit within a plane, the plane being perpendicular to the wall 14.

A worktop 32 is provided. The worktop 32 is a planar member having an outline shaped to conform to the profile of the wall 14. The worktop 32 is supported on the brackets.

Figure 4 to 8 generally indicate a base unit 12 suitable for forming a floor of a utility cupboard. Figures 4 and 5 show a first embodiment of the base unit 12, Figures 6 and 7 show a second embodiment of the base unit 12, and Figure 8 shows a third embodiment of the base unit 12.

In the embodiments shown in the Figures, the base unit 12 includes a planar upper member 36 which forms the floor of the utility room when fitted in a building and a wall has been attached, two longitudinal reinforcing members 38 and six transverse reinforcing members 40. In other embodiments, the number of longitudinal and transverse reinforcing members may vary.

The planar upper member 36 has an upper side which forms the surface of the floor of the utility room when fitted.

The two longitudinal reinforcing members 38 run substantially parallel to each other. Both the first and second longitudinal reinforcing members 38 depend from the underside of the planar upper member 36 and are disposed on either longitudinal edge of the planar upper member 36. In the embodiments shown in the Figures, one of the reinforcing members is considered to be a rear reinforcing member as it is proximate the rear side of the U- shaped wall when the wall is fitted. The other longitudinal reinforcing member is considered the front reinforcing member as it is opposite the rear member.

The six transverse reinforcing members 40 run substantially parallel to each other. Each transverse reinforcing members 40 depend from the underside of the planar upper member 36. The transverse reinforcing members 40 create a space underneath the substantially planar upper member 36 which provides substantially unimpeded access for forks of a forklift or pallet truck to slide underneath the substantially planar upper member 36 from at least the front.

Prior to lifting, the forks of the forklift or pallet truck are moved underneath the underside of the planar upper member 36, through the space provided by the transverse reinforcing members 40, until the forks extend across the transverse extent of the base unit 12. The forks are slowly raised until they are in contact with the longitudinal reinforcing members 38.

In the embodiment shown in Figures 6 and 7, the base unit 12 includes two fork receiving means 42. Each fork receiving means 42 comprises a pair of elements sized and shaped to receive a fork of a forklift or pallet truck. A first element of the pair of elements is located towards the front of the base unit 12 and a second element of the pair of elements is located towards the rear of the base unit 12. The fork receiving points are formed from a substantially U-shaped steel element 42 depending downward. The U-shaped steel element extends down at least the same distance as the transverse reinforcing members 40.

The base unit 12 may include removable lifting points 44 which allow a lifting means, such as a crane or other device which lifts from above, to be used. Figures 4, 5 and 8 all show four removable lifting points 44 fitted to the base unit 12, while Figures 6 and 7 show apertures used for attaching the removable lifting points. The lifting points 44 are attached by attachment means, such as bolts and nuts, to the transverse reinforcing means 40 disposed on either end of the base unit 12. The bolts and nuts allow the additional lifting points to be attached and removed as needed. The removable lifting points 44 have a body with a receiving aperture. The receiving aperture is sized and shaped to receive a strap or other common means used to lift items on a construction site.

The base unit 12 may include a means to isolate vibration caused by an appliance. In the embodiments shown in Figures 4 to 7, the planar upper member 36 includes a cut out in the surface for receiving a part of a vibration isolation means and an aperture providing access to a space formed underneath the planar upper member 36. The embodiment shown, in Figure 8 only includes an aperture for providing access to the space formed underneath the planar upper member 36.

The cut-out is a square aperture cut in the planar upper member 36.

The vibration isolation means includes a support means 46, a floating plate 48 and a resilient means 50 disposed between the floating plate 48 and the support means 46.

The floating plate 48 provides a surface for receiving an appliance which may vibrate, for example, a washing machine 52 (as shown in Figure 6). The floating plate 48 and cut-out are sized and shaped to accept various sized appliances, such as domestic washing machines 52.

In the embodiments shown in Figure 4 to 7, particularly Figure 7 which shows the floating plate removed, four rubber bushings provide the resilient means 50. In other embodiments, the number, location, material or structure of the resilient means may vary.

Each bushing is attached to the floating plate 48 by means of a screw or a similar fixing device. Each bushing is also attached to the support means by means of a further screw or a similar fixing device. In other embodiments, there may be at least two bushings, or other suitable resilient means, per support member.

The support means 46 is provided by three support beams which extend across the cut-out from the rear reinforcing member to the front reinforcing member. The support means may be provided at a height which allows the surface of the floating plate to be approximately level with that of the planar upper member. The aperture for providing access to the space formed underneath the planar upper member may be provided with a cover 54.

The base unit 12 includes a plurality of adjustable feet 56 spaced around the footprint of the base unit 12 formed by the planar upper member 36. The adjustable feet allow the base unit to be levelled during fitment within the building. In the embodiments shown in the Figures, five adjustable feet are provided. Four feet are disposed proximate each corner of the base unit and the fifth foot disposed along the front longitudinal edge of the base unit. The four adjustable feet disposed in each corner have an adjustment means which extends through the planar upper member.

A plurality of apertures 58 to allow a fixing means, such as a rivet, to rigidly fix a wall to the planar upper member. When the base unit 12 is used in the embodiment described above, the plurality of apertures generally follow the periphery of the planar upper member with some being inwardly spaced.

Referring now to Figures 9 and 9A, an alternative embodiment of the base unit is shown at 60. The base unit 60 incorporates a tray having a rigid base layer 62. A peripheral flange 64 extends around the rigid base layer 62 and forms part of the rigid structure of the shell. A resilient mat 66, which can be of rubber, is bonded to the rigid base layer. A substantially planar upper member 68, for example, a steel sheet, is bonded on top of the resilient mat 66. To finish the floor, a floor covering 70, such as vinyl, wood or other product is bonded to the upper member 68.

Importantly, a gap 72 is provided around the periphery of the substantially planar upper member 68. The gap may be around 2mm, or 3mm, or 4mm, or 5mm. This gap prevents any vibration generated on top of the substantially planar upper member 68, which is damped by the resilient mat 66, from passing to the base unit through the sides of the substantially planar upper member 68.

The floor arrangement in Figure 9 and 9A has an underside structure, similar to that described with reference to Figure 8, for example. However, the floor arrangement can be utilised with any arrangement of prefabricated utility shell.

The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.