MODULAR WET AREA CONSTRUCTION

Field of the Invention

[0001 ] The present invention relates to a panel or panel module, and panel assembly, for modular wet area or wet room construction. The present invention also relates to a method of constructing a wet area or wet room and a corresponding modular wet area or wet room construction. A method of producing such panels is also disclosed.

[0002] In the context of the present invention, wet areas may be understood as areas in buildings, such as rooms or sections of rooms, like bathrooms, washrooms, powder rooms, laundries and/or kitchens, in which walls, floors, and/or ceilings may be regularly exposed to wetting and dampness and thus typically require waterproofing. The same may apply to areas in buildings that are at least partially exposed to the weather, such as balconies or terraces. It will be convenient to describe the present invention herein in this exemplary context of a bathroom or laundry. It will be appreciated, however, that the panel member, panel assembly and method for modular wet area construction is not limited to bathrooms or laundries but may find use in any number of applications that are subject to wetting and dampness.

Background of the Invention

[0003] The following discussion of background is intended to enable an understanding of the present invention only. This discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the date of this patent application.

[0004] The modular construction of a building or room typically involves prefabrication of parts or components of the building or room off-site that are subsequently connected together to reduce the complexity and labour requirements of constructing that building or room entirely on-site. In modular construction, at least some of the construction tasks are moved to off-site locations, e.g. to factories or controlled manufacturing sites. The components and objects manufactured off-site are then transferred on-site for assembly with other parts of the structure. Coupled with good design and planning, the change from on-site construction to off-site production that come with modular construction can significantly reduce waste, increase efficiency, and improve quality control, all of which can result in time and cost savings and greater product consistency, especially if the individual components can be made in a single factory.

[0005] Where waterproofing of buildings or rooms is required, the conventional tasks and labour required to achieve effective waterproofing account for significant workload and time in building construction. Water leakage and water damage claims also account for a large proportion of construction quality claims, and defects in bathrooms, laundries and balconies result in many of these claims. Although building design and construction materials and methods, as well as qualifications of trades people, are heavily regulated, on-site consistency remains difficult to achieve because of variations in the construction conditions, trade persons’ skills, and complications in project management.

[0006] Wet areas are usually understood as waterproofed areas where the floor and/or walls, for example, of a bathroom or laundry, form the boundaries of the wet area itself. In most countries a bathroom or washroom is a room for personal hygiene and typically contains a basin, a bathtub and/or a shower, and often also a toilet. The design of a bathroom or a laundry must account for the use of hot and cold water in significant quantities for cleaning the human body or for washing clothing and linens. Water may be splashed on the floor and walls, and warm, humid air may cause condensation on cold surfaces. Ceiling, wall, and floor materials and coverings should be impervious to, or at least resistant to, water while also being resistant to or tolerant of strong cleaning agents, such as bleach. Ceramics and glass, as well as plastic materials, are therefore common in bathrooms and laundries for their water resistance and ease of cleaning.

[0007] Conventionally, the walls of bathrooms and laundries, whether of post and lintel construction or cement block, are built with free space therein to accommodate conduits for water, heat, ventilation and cooling systems, electrical power, sewage, and air vents within the free space in the wall. The conduits are connected with a source or supply of the respective utilities and corresponding fixtures in the bathroom or laundry. For this reason, wet areas, such as bathrooms and laundries, typically require a variety of skilled trade persons, making these labour-intensive and expensive areas per square metre of a building. With the costs of labour and materials on an upward trend, conventional home construction has become more expensive and time consuming. Likewise, the waiting period for completion of new home construction is often drawn out due to the need for, and shortage of, specialised skilled trade persons. [0008] Modular construction techniques have been used for bathrooms at least since the 1960s. There are two main types of modular bathrooms available in the market, and these may be broadly classified as: (i) an assembled modular bathroom, and (ii) a fully constructed bathroom pod. An assembled modular bathroom typically consists of a one- piece waterproof floor base, light-weight wall and roof panels, and other accessories. It can either be pre-assembled offsite or assembled onsite. A fully constructed bathroom pod, on the other hand, is constructed on steel truss and frame using similar or same materials and processes as for constructing conventional bathrooms. Once completed, the fully constructed pod with truss and frame is transported and lifted into place for installation. The fully constructed bathroom pods are typically heavy and require special arrangements for transportation, lifting and installation. They are generally only suitable for certain building types and construction methods. An assembled modular bathroom is more versatile but is still limited by the single piece waterproof floor base. The base can be made from lightweight but less durable and less desirable plastic materials, such as sheet moulding compound (SMC), or from sturdier and heavier materials, such as steel framed fibreglass or glass-reinforced cement (GRC). However, the limitations presented by the floor base still restrict the applications and design flexibility.

[0009] In view of the above issues, it would be desirable to provide new techniques for the construction of wet areas in buildings. In this context, it would be useful to provide a modular panel and a panel assembly for wet area construction, especially for modular wet area construction.

Summary of the Invention

[0010] According to one aspect, therefore, the present invention provides a panel, or a panel module, for modular construction of a wet area. The panel or panel module has or comprises: a base for supporting the panel on or against a generally flat and/or planar expanse of a structural frame, e.g. a floor or wall frame; a barrier layer that substantially entirely covers the base and provides a barrier to moisture; and an outer layer that substantially entirely covers the barrier layer and presents or has a functional, utilitarian, and/or decorative outer surface for a wet area. An edge region of the outer layer and the barrier layer projects beyond a peripheral edge of the base along at least one side of the panel to form a recess below the projecting edge region, the recess extending along the side of the panel. In this way, the panel is configured to be joined or connected side- by-side with an adjacent panel along the edge region and at the recess to provide for a continuous moisture barrier or waterproofing across the joined panels.

[001 1 ] In a preferred embodiment, the base comprises a polymer material, preferably a polymer composite material, having a thickness in the range of about 10 mm to about 100 mm, and preferably in the range of about 10 mm to 60 mm. The base may, for example, be comprised of a reactive or thermosetting polymer, e.g. a polymer resin or polymer composite, such as a polyurethane or polyurethane composite. The base is preferably formed by moulding as a base layer, especially as a substantially monolithic base layer. By forming the base from a polymer composite, e.g. a glass-fibre reinforced polymer, the mass of the base can be kept relatively low, while retaining relatively high strength, stability and durability.

[0012] In a preferred embodiment, the barrier layer comprises a polymer membrane or a polymer film. The barrier layer is therefore typically thin and flexible and preferably in the form of a waterproofing membrane. In this regard, the membrane of the barrier layer may preferably be applied in liquid form, e.g. by spraying, and then cured.

[0013] In a preferred embodiment, the outer layer comprises one or more of a ceramic, stone, or glass material, which are preferably provided in the form of tiles, to present a functional, utilitarian, and/or decorative outer surface.

[0014] In this way, wet area construction with panels according to the present invention can be simplified to modular assembly of the panels, thus eliminating several of the on site steps used in conventional construction, such as panelling (for walls), screeding (for floors), waterproofing and tiling.

[0015] In the modular wet area construction concept described herein, the projecting edge region of the panel of the invention is configured to abut or adjoin with an edge region of an adjacent panel for connection of the adjacent panels along those edge regions. In doing so, the adjacent panels are configured or designed to provide an outer surface that is substantially uninterrupted or continuous across the panels as well as a continuous or uninterrupted barrier to moisture penetration between the panels. The wet area modular construction and panel assembly of the present invention contemplates different ways of achieving this interconnection of adjacent panels. The panel modules are thus designed to be interconnectable with a waterproofing joint design. In this way, the assembly of the panels can meet the requirement for continuous waterproofing for the wet area construction.

[0016] In a preferred embodiment, the projecting edge region is configured to abut or adjoin with a corresponding projecting edge region of an adjacent panel for connection therewith along respective sides of the panels to provide a substantially uninterrupted or continuous outer surface across the panels. To this end, the recess may be configured to receive a connecting member for sealing against barrier layers of adjacent panels in abutting or adjoining projecting edge regions of adjacent panels to provide a continuous or uninterrupted barrier to moisture penetration between the panels.

[0017] In such a preferred embodiment, the recess is configured to receive an elongate connecting member extending below the abutting or adjoining projecting edge regions of adjacent panels for interconnecting the panels, such that the elongate connecting member extends within, and preferably fills or fully occupies, the recess along a full length of the side of the panel. The recess may therefore be configured to receive and accommodate an elongate connecting member in the form of a strip or elongate block to support abutting or adjoining projecting edge regions of adjacent panels along a full length of the sides of the panels.

[0018] In a preferred embodiment, an edge region of the outer layer and the barrier layer may project beyond a peripheral edge of the base along two opposite sides of the panel to form a recess extending along each of the opposite sides of the panel below each projecting edge region. In this way, the panel may be configured for connection with an adjacent panel at each of the two opposite sides.

[0019] In an alternative preferred embodiment, the projecting edge region of the panel is configured to overlap and/or adjoin with a complementary recessed edge region of an adjacent panel. In this context, the complementary recessed edge region comprises a region that extends along a side of the panel in which the outer layer is recessed or set back from a peripheral edge of the base and the barrier layer by an amount or extent that complements or essentially corresponds to an extent of the projecting edge region for snugly accommodating same in a lapped relationship. In this embodiment, therefore, the recess below the projecting edge region of the one panel is configured to receive or accommodate the base of the adjacent panel in a complementary recessed edge region along the respective panel side. [0020] In this alternative preferred embodiment, therefore, a panel may be configured such that, along one side of the panel, an edge region of the outer layer and the barrier layer projects beyond a peripheral edge of the base, and, along an opposite side of the panel, the outer layer is recessed or set back from a peripheral edge of the base and a peripheral edge of the barrier layer to form a complementary recessed edge region. In this way, the panel may be configured for connection with an adjacent panel at each of the two opposite sides in a lapped relationship.

[0021 ] In a preferred embodiment, the base has a largely flat underside for supporting the panel on a generally flat or planar expanse of floor. In this case, therefore, the panel is conceived as a floor panel. The base preferably has one or more recesses, fittings and/or markings at the underside to assist placement, location, alignment and/or fixture of the panel in use.

[0022] In another preferred embodiment, an underside of the base is configured for supporting the panel on a generally vertical flat or planar expanse of a wall frame. In this case, therefore, the panel is conceived as a wall panel. The base may again optionally have one or more fittings and/or markings at the underside to assist in the placement, location, alignment and/or fixture of the panel in use.

[0023] In a preferred embodiment, the base includes one or more accessory, such as a conduit or drain outlet, which is mounted in, and preferably extends through the base.

[0024] In a preferred embodiment, the panel further comprises a flashing section that extends upwards above the outer layer at an edge of the panel for providing a moisture barrier at an interface with an adjacent, perpendicularly oriented panel. Thus, a flashing section will typically be provided at the sides of floor panels that will adjoin wall panels; i.e. will border a periphery of a wet area floor. The flashing section therefore preferably extends along a full length of the side of the panel. The flashing section may be set or fixed along the side of the panel between the outer layer and the barrier layer of the panel. To this end, the flashing section is desirably provided having an L-shaped profile, with the horizontal part of the L-profile set or fixed between the outer layer and barrier layer and the vertical part of the L-profile extending upwards above the outer layer at the edge of the panel.

[0025] In a preferred embodiment, the sides of the panel have dimensions in the range of about 1 metre to about 3 metres. The panel sides may preferably have dimensions to provide panels of sizes of about 1 metre x about 2 metres. For example, a floor panel will preferably have a size of about is 1 .5 metres x 2 metres, whereas a wall panel will preferably have a size of about 1 .2 metres x 2.4 metres. The panel modules are made strong and lightweight by optimising the formulation of the composite materials. Each panel module desirably has a mass of less than or equal to about 50 kg in order to be lifted and manoeuvred by two workers manually or with the assistance of simple tools. No heavy lifting equipment may thus be required to assemble or construct the wet area.

[0026] In this way, the invention provides for the design, manufacture and assembly of waterproofed panel modules that can be joined or interconnected with one another and expanded as required to construct large wet areas with continuous waterproofing. The waterproofed panel modules are lightweight and include a sturdy load-bearing base, waterproof barrier layer, and decorative outer layer or facing, optionally with one or more embedded accessories for watertight penetration of services. The modular or expandable feature enables the application of these panels in many types of wet area construction, including, for example, bathroom, kitchen, laundry, balcony, terraces and roof gardens.

[0027] According to another aspect, the present invention provides a panel assembly for modular wet area construction, comprising a plurality of panels according to any one of the embodiments of the invention described above, wherein each panel is connected with an adjacent one of the plurality of panels at respective adjoining edge regions such that the panels provide a substantially uninterrupted and/or continuous outer surface across the panels, and wherein the barrier layers in the adjoining edge regions along the respective sides of the panels are sealed together to provide an uninterrupted or continuous barrier to moisture penetration between the panels.

[0028] In a preferred embodiment, the projecting edge regions of adjacent panels abut or adjoin one another along the respective sides of the panels to provide a substantially uninterrupted and/or continuous outer surface across the panels; and

an elongate connecting member is received in and extends within the recesses below the abutting or adjoining projecting edge regions of the adjacent panels for inter connecting the panels, wherein the elongate connecting member is sealed against the respective barrier layers in those projecting edge regions along the sides of the panels to provide an uninterrupted or continuous barrier to moisture penetration between the panels. [0029] In a preferred embodiment, the elongate connecting member extends within, and preferably substantially fills or fully occupies, the recesses of the abutting and/or adjoining projecting edge regions of adjacent panels along a full length of the sides of the panels. The elongate connecting member is typically sealed against the barrier layers of abutting or adjoining projecting edge regions along a full length of the sides of the panels by a sealant or an adhesive applied to a surface of the elongate connecting member facing the barrier layers in those projecting edge regions.

[0030] In a preferred embodiment, the elongate connecting member is provided in the form of strip or elongate block to support the abutting or adjoining projecting edge regions of adjacent panels along a full length of the sides of the panels. As noted above, the elongate connecting strip or block may comprise a moisture barrier layer that faces and is sealed against the barrier layers in the abutting and/or adjoining projecting edge regions. To this end, the moisture barrier layer of the elongate connecting member preferably comprises a polymer membrane or polymer film, which is bonded to an elongate filler block or strip, e.g. via an adhesive.

[0031 ] In an alternative preferred embodiment, the projecting edge region of one panel overlaps and/or adjoins a complementary recessed edge region of an adjacent panel. In this context, the projecting edge region of the one panel is fittingly or snugly received or accommodated in the complementary recessed edge region of the adjacent panel in a lapped relationship and an adhesive or sealant applied between the overlapping barrier layers provides an uninterrupted or continuous barrier to moisture penetration between the panels.

[0032] According to a further aspect, the invention provides a panel assembly kit for constructing a modular wet area, the kit comprising: a plurality of panels according to any one of the embodiments of the invention described above. Each of the panels is configured for connection with an adjacent panel, wherein edge regions of the adjacent panels are configured to abut or adjoin one another along respective sides of the panels to provide a substantially uninterrupted and/or continuous outer surface across the panels, and wherein barrier layers in the abutting or adjoining edge regions of adjacent panels are to be sealed, e.g. to each other, along the sides of the panels to provide an uninterrupted or continuous barrier to moisture penetration between the panels. [0033] In a preferred embodiment, the kit comprises a sealant or adhesive for sealing the barrier layers in the abutting or adjoining edge regions of adjacent panels, preferably to each other, along the sides of the panels to provide an uninterrupted or continuous barrier to moisture penetration between the panels.

[0034] In a preferred embodiment, the kit comprises a plurality of panels in which the projecting edge regions of adjacent panels are configured to abut or adjoin one another along the respective sides of the panels to provide a substantially uninterrupted and/or continuous outer surface across the panels; and

an elongate connecting member configured to be received in and extend within the recesses below abutting or adjoining projecting edge regions of adjacent panels to be sealed against barrier layers in the abutting and/or adjoining projecting edge regions along the sides of the panels to provide an uninterrupted or continuous barrier to moisture penetration between the panels, thereby also to interconnect the panels.

[0035] In a preferred embodiment, the elongate connecting member is configured to extend within, and preferably substantially fill or fully occupy, the recesses of abutting and/or adjoining projecting edge regions of adjacent panels along a full length of the sides of the panels.

[0036] In a preferred embodiment, the sealant or adhesive is a liquid and configured to be applied to a surface of the elongate connecting member facing the barrier layers in abutting and/or adjoining projecting edge regions of adjacent panels.

[0037] In an alternative preferred embodiment, the kit comprises a plurality of panels in which the projecting edge region of one panel is configured to overlap and/or adjoin with a complementary recessed edge region of an adjacent panel. In this way, the projecting edge region of the one panel is configured to be fittingly received or accommodated in the complementary recessed edge region of the adjacent panel in a lapped relationship and the sealant or adhesive is applied between the overlapping barrier layers to provide the uninterrupted or continuous barrier to moisture penetration between the panels.

[0038] In accordance with still yet another aspect, the invention provides a modular wet area construction including: a plurality of wall panels and/or a plurality of floor panels; wherein each of the wall panels and/or floor panels includes: a composite base, a waterproofing membrane, and an outer decorative layer, wherein an edge region of the outer decorative layer and the waterproofing membrane extends or projects beyond an edge of the composite base in each panel; and wherein a waterproofing strip is provided or arranged to engage and interconnect adjacent panels and provide a waterproof seal.

[0039] Preferably, a filler element is arranged or placed underneath the waterproofing membrane in the projecting edge region to support the waterproofing membrane. In this regard, the filler element is preferably arranged to be received or accommodated in a recess formed below the projecting edge region between the bases of adjacent panels.

[0040] Preferably, one or more wall fasteners or brackets is arranged in the composite base for fixing each wall panel to a substantially vertical building frame. In a similar way, one or more fastening means may preferably be arranged in the composite base for fixing each floor panel to the floor of a building. Each of the wall and floor panels may include conduits or passageways arranged to receive wiring and piping. Preferably, the floor and wall panels are placed against an existing frame and joined together from an internal side of the frame. The floor and wall panels may optionally be retrofitted into an existing structure.

[0041 ] According to a further aspect, the invention provides a method of producing or fabricating a panel for modular wet area construction, the method comprising steps of: lining an upwardly facing surface of a lower mould part with material to form an outer layer of the panel, whereby an outer surface of the material of the outer layer faces the surface of the lower mould part;

applying a barrier layer that substantially entirely covers the upwardly facing rear side of the outer layer material;

setting a spacer member upon and extending along an edge region of the outer layer material and the applied barrier layer, so that the spacer member defines or occupies a space corresponding to a recess below the edge region of the outer layer and barrier layer along a side of the panel;

filling the lower mould part with liquid polymer material that substantially covers the material of the outer layer and the barrier layer, except for the space occupied by the spacer member; and

curing the liquid polymer material to form a panel base that is integrated and/or consolidated with the barrier layer and outer layer material.

[0042] In a preferred embodiment, the step of lining the upwardly facing surface of the lower mould part comprises placing or laying an array of tiles over that mould part surface to form the outer layer of the panel. The tiles have a functional, utilitarian, and/or decorative outer surface for the wet area.

[0043] In a preferred embodiment, the step of applying the barrier layer comprises applying a polymer material in liquid form, preferably by spraying, to cover the rear side of the outer layer material essentially entirely. The barrier layer is preferably applied in a number of passes, and optionally in a number of coats, whereby each coat may at least partially dry or cure before a next coat is applied.

[0044] In a preferred embodiment, the spacer member comprises an elongate block, especially an elongate rectangular block. Thus, the step of setting the spacer member includes arranging and/or fixing the elongate block upon and extending along the edge region of the outer layer material and the applied barrier layer.

[0045] In a preferred embodiment, the liquid polymer material for filling the lower mould part comprises a reactive polymer or thermosetting resin, such as polyurethane. In a preferred embodiment, the method includes a step of adding reinforcing material, such fibres (e.g. glass fibres), to the liquid polymer material that fills the lower mould part.

[0046] In a preferred embodiment, the step of curing the liquid polymer material includes closing an upper mould part over the lower mould part, and optionally applying pressure to the mould parts during curing.

[0047] In a preferred embodiment, the method further comprises a step of setting a flashing section upon the outer layer material extending along a side thereof such that the flashing section extends into the lower mould part beyond the outer layer material before the step of applying a barrier layer. The setting of the flashing section preferably involves adhering the flashing section to the rear side of the outer layer material.

[0048] In a preferred embodiment, the method further comprises a step of setting a conduit or drain inlet in the lower mould part for extending through the panel before the step of filling the lower mould part with liquid polymer material.

Brief Description of the Drawings

[0049] For a more complete understanding of the invention and advantages thereof, exemplary embodiments of the invention are explained in more detail in the following description with reference to the accompanying drawing figures, in which like reference signs designate like parts and in which:

Fig. 1 is a schematic side view of a floor panel for modular construction of a wet area according to a preferred embodiment;

Fig. 2 is a schematic side view of two floor panels in a floor panel assembly of a modular wet area constructed according to a preferred embodiment;

Fig. 3 is a schematic cross-sectional side view of the floor panel assembly seen in Fig. 2 taken in the direction of arrows Ill-Ill in Fig. 2;

Fig. 4 is a schematic side view of two floor panels in a floor panel assembly of a modular wet area constructed according to an alternative preferred embodiment;

Fig. 5 is a schematic cross-sectional side view of a wall panel for modular wet area construction according to a preferred embodiment;

Fig. 6 is a schematic cross-sectional side view of a floor panel having a drain accessory for modular construction of a wet area according to a preferred embodiment;

Fig. 7 is a schematic side view of a floor panel and a wall panel in a panel assembly of a modular wet area constructed according to a preferred embodiment;

Fig. 8 is a schematic side view of a mould assembly for a method of producing a panel according to a preferred embodiment of the invention;

Fig. 9 is a flow diagram representing a method of modular construction of a wet area according to a preferred embodiment.

[0050] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate particular embodiments of the invention and together with the description serve to explain the principles of the invention. Other embodiments of the invention and many of the attendant advantages will be readily appreciated as they become better understood with reference to the following detailed description.

[0051 ] It will be appreciated that common and/or well understood elements that may be useful or necessary in a commercially feasible embodiment are not necessarily depicted in order to facilitate a more abstracted view of the embodiments. The elements of the drawings are not necessarily illustrated to scale relative to each other. It will also be understood that certain actions and/or steps in an embodiment of a method may be described or depicted in a particular order of occurrences while those skilled in the art will understand that such specificity with respect to sequence is not actually required.

Description of the Preferred Embodiments

[0052] With reference firstly to Fig. 1 of the drawings, a panel 10, and particularly a floor panel 10, is shown for modular construction of a wet area according to a preferred embodiment. The panel 10 includes a base 18 for supporting the panel 10 on or against a generally flat or planar expanse of a structural frame (not shown), such as a floor or a wall frame. In this example, the base 18 is moulded as a substantially solid layer of a polymer composite, e.g. a glass-fibre reinforced polymer (GFRP), such as polyurethane composite. In this way, the mass of the base 18 is kept relatively low, while retaining high strength, stability and durability. The base 18 typically has a thickness in the range of about 10 mm to 60 mm, and preferably in the range of about 20 mm to 50 mm. A barrier layer 16 in the form of a flexible polymer film or membrane substantially entirely covers the base 18 to provide a water-impervious barrier to moisture. In this way, the barrier layer 16 forms a waterproofing membrane and is thin compared to the base 18, with a thickness in the range of about 0.1 mm to 5 mm, preferably in the range of about 0.5 mm to about 2 mm depending on requirements of the application. An outer layer 14 of the panel 10 then substantially entirely covers the barrier layer 16 and has a functional and decorative outer surface for the wet area. In this regard, the outer layer may be comprised of a plurality of tiles 12, especially ceramic or stone tiles. The panel 10 may optionally be formed with the outer layer 14 having a“fall” or slope such that water will run off the panel 10 in a predetermined direction. As seen in Fig. 1 , an edge region 20 of the outer layer 14 and the barrier layer 16 projects beyond a peripheral edge of the base 18 along a side of the panel 10 to form a recess 22 below the projecting edge region 20. As such, the recess 22 also extends along the side of the panel 10.

[0053] With further reference to Fig. 1 , the panel 10 is also seen to include a flashing section 15 that extends upwards above the outer layer 14 at an edge of the panel 10 for providing a moisture barrier at an interface with an adjacent, perpendicularly oriented wall panel (not shown). Thus, the flashing section 15 is provided at the side of the floor panel 10 that will adjoin a wall panel; i.e. at a periphery of the wet area flooring. The flashing section 15 extends along a full length of the side of the panel and has an L- shaped profile, with the horizontal part of the L-shaped profile set or fixed via a layer of adhesive sealant 13 between the outer layer 14 and the barrier layer 16 and with the vertical part of the L-shaped profile extending upwards above the tiles 12 of the outer layer 14 along an edge of the panel. The adhesive sealant 13 may be a polyurethane, but a skilled person will recognise that other adhesive sealants can also be used. The L-shaped flashing section 15 in this example is formed of a thermoplastic polymer, such as PVC, which permits it to be welded or fused with a flashing section 15 of an adjacent panel (not shown). It will be noted that the base 18 of the floor panel 10 has a largely flat underside for supporting the panel on a generally flat expanse of a floor frame. To this end, the base 18 may optionally have one or more fittings and/or markings 21 at the underside to assist placement, location and/or alignment of the panel in use.

[0054] With reference now to Figs. 2 and 3 of the drawings, one way in which the floor panel 10 of this embodiment is configured to be interconnected with an adjacent floor panel 10 to provide a modular panel assembly and wet area construction is illustrated. In this embodiment, the projecting edge region 20 of one panel 10 is arranged to abut or adjoin a corresponding projecting edge region 20 of an adjacent panel 10 for connection of the adjacent panels 10, 10 along those projecting edge regions 20, 20 such that they provide a substantially uninterrupted or continuous outer layers 14, 14 and outer surface across the panels. Prior to arranging the panels 10 in this way, however, an elongate rectangular connecting member or strip 17, that is sized to match and substantially fill or occupy a combined space of rectangular recesses 22, 22 formed below the adjoining or abutting projecting edge regions 20, 20 of the adjacent panels 10, 10, is first inserted or set into the recess 22 along the side of one of the two panels 10. The other panel 10 is then positioned with its projecting edge region 20 abut that of the first panel, as shown in Fig. 2, such that the connecting member or strip 17 is received within and essentially fills the combined space of the two recesses 22, 22. It will be noted that some fastening means (e.g. complementary mating elements) could be provided for securely setting the connecting strip 17 in each recess 22, and/or an adhesive could be used. It will be seen that the connecting strip 17 extends along a full length of the sides of the panels 10, 10 and has an uppermost moisture barrier layer or film 25 (e.g. a PVC film) bonded via an adhesive layer 19 at an upper side of the filler strip 17, which may be like a long block of solid plastic of timber. As shown schematically in Fig. 2, the connecting strip 17 is sized such that a small gap or space, e.g. of about 1 mm to 3 mm, is provided between the barrier layer or film 25 of the strip 17 and the barrier layer 16 on an under-side of the adjoining or abutting projecting edge regions 20, 20 of adjacent panels 10, 10. that faces and is sealed against the barrier layers in the abutting and/or adjoining projecting edge regions.

[0055] Referring further to the drawing Figs. 2 and 3, the elongate connecting strip 17 is sealed against the respective barrier layers 16 in the abutting or adjoining projecting edge regions 20, 20 along the sides of the panels 10, 10 by applying - in this case, by injecting - a liquid sealant 23 into the space or gap between the barrier film 25 and the barrier layers 16. This injection of the sealant 23 may be performed via a suitable thin nozzle inserted between the abutting or adjoining projecting edge regions 20, 20 of the panels 10, 10 and is performed along the entire length of the panel sides. The injected sealant 23 fills the space or gap and cures to seal against the barrier layers 16 and thereby provides a seam or join establishing an uninterrupted or continuous barrier to moisture penetration between the two panels 10, 10. As can be seen in Fig. 3, the cross-sectional view taken in the direction of the arrows Ill-Ill in Fig. 2 shows that the connecting member or strip 17 extends beyond the sides of panels 10, 10 and vertically upwards behind flashing section 15 for guiding the flow of the sealant 23 upwards behind the flashing section 15. In particular, the barrier layer 25 on top of connecting strip 17 extends up behind the flashing section 15 to extend a sealed seam between the panels 10, 10 and to promote closure and sealing of a join between the flashing sections 15, 15 of the adjacent panels.

[0056] With reference now to Fig. 4 of the drawings, an alternative example of a way in which the projecting edge region 20 of a floor panel 10 according to the invention may be configured to be interconnected with an adjacent floor panel 10 to provide a modular panel assembly. In this embodiment, the projecting edge region 20 of one floor panel 10 is configured to overlap and/or adjoin a complementary recessed edge region 24 of an adjacent floor panel 10. In this recessed region 24, the outer layer 14 is recessed or set back from a peripheral edge of the base 18 and from a peripheral edge of the barrier layer 16 to an extent sized to complement the projecting edge region 20 of the first panel. In this way, the projecting edge region 20 of the one panel 10 is fittingly received or accommodated in the complementary recessed edge region 24 of the adjacent panel 10 in a lapped relationship to provide outer layers 14 that are substantially uninterrupted or continuous across the panels. As before, an adhesive sealant 23 is applied between the overlapping barrier layers 16 to establish a sealed seam or join between the barrier layers 16 that provides an uninterrupted or continuous barrier to moisture penetration between the panels 10, 10.

[0057] Referring now briefly to Fig. 5 of the drawings, a wall panel 10’ according to a preferred embodiment is shown, the panel 10’ again comprising a composite base 18, a waterproofing membrane 16, and an outer layer 14 of decorative and functional surface tiles 12. In this embodiment, the wall panel 10' has conduits or passageways 27 with access flanges 28 embedded or incorporated through a thickness of the wall panel 10’. The conduits or passageways 27 are selectively located and arranged to receive wiring or water pipes, as needed, in the wet area to be constructed with the panel 10’.

[0058] Referring also briefly to drawing Fig. 6, a floor panel 10 according to a preferred embodiment is shown, that floor panel 10 including an embedded drain 30. A widened drain inlet 32 is set into a hole formed in the base 18 extending up from below the floor panel 10. The waterproofing membrane 16 extends into that drain hole and overlaps an inner surface of the drain inlet 32 to ensure the integrity of the moisture barrier and the waterproofing seal. A drain cover 31 having an upper grate 33 and a depending skirt 34 that complements inner dimensions of the drain inlet 32 is inserted into the drain inlet 32 to capture, fix and seal the waterproofing membrane 16 there-between.

[0059] Fig. 7 of the drawings shows another example of a panel assembly for modular construction of a wet area according to a preferred embodiment, this time illustrating the connection of a floor panel 10 and a wall panel 10’ against a vertical building frame 50. The composite base 18 of the wall panel 10’ includes one or more fittings, such as brackets 52, at the underside to assist the positioning, alignment, and/or fixture of wall panel 10’ to the building vertical frame 50 via wall fasteners 54. The wall fasteners 54 may, for example, include screws, wall anchors, or otherwise, and may include one or more bracket 54 extending from the vertical frame 50 that is adapted to cooperate with a bracket 52 in the base 18 of the panel 10’; e.g. for mounting or hanging the wall panel 10’. That is, the panel bracket 52 may engage with the wall bracket 54 to secure or fix the wall panel 10’ in place. It will also be seen in Fig. 7 that the vertical wall panel 10’ overlaps with the vertical part of the L-shaped flashing section 15 extending up from the floor panel 10. Further, the side edge of the wall panel 10' is seated upon and is sealed against (again via a sealant 23, such as a silicone sealant) the tiles 12 at the outer layer 14 along an edge of the floor panel 10. During installation, the mounting of the floor panels 10 and/or wall panels 10’ is performed in a vertical direction. As a result, the assembly of the floor panels 10 and wall panels 10’ can be undertaken from the internal side of an existing frame or wall of the respective rooms. This allows the entire installation work to be carried out inside the perimeter of the building unit, thus enabling the assembly of the panel modules 10, 10’ at any stage of building construction including the renovation and retrofitting of existing buildings.

[0060] With reference to Fig. 8 of the drawings, a method of producing or fabricating a panel or panel module 10, 10’ according to a preferred embodiment is illustrated. It will be noted that the method involves a moulding process, so the apparatus shown in Fig. 8 includes a mould assembly 60 comprising an upper mould part 62 and a lower mould part 64 for forming a modular panel 10, 10’. The mould assembly 60 is typically made of a steel or steel alloy, such as stainless steel, and reinforced to withstand the pressures of the moulding process. The upper and lower mould parts 62, 64 are movable relative to one another to be pressed together to form the panel 10. The mould assembly 60 of Fig. 8 is for a floor panel 10 having a drain 30. A channel or slot 66 is formed at a lateral edge of the lower mould part 64 to fit or accommodate a waterproof flashing section 15. A spacing block 67 is used for producing a recess 22 as needed based on the design of the modular panels 10 being formed.

[0061 ] The lower mould 62 and upper mould 64 are brought together using hydraulic, pneumatic, electric or mechanical actuators. When producing a floor panel 10 having an embedded drain 30, the surface 65 of the lower mould part 64 may be angled to form the required slope or‘fall’ towards the drain 30 for desired water drainage. This allows slope and drainage angles to be customised for a floor during the moulding process. In one embodiment the fall has a gradient of at least 1 :60. To this end, the upper mould part 62 may include one or more recess 63 to allow placement of a drain inlet 32. The mould assembly 60 typically also includes framework to allow placement of embedded conduits, connectors, passageways or fittings (not shown). To fabricate modular panels using the mould assembly 60, materials and elements are introduced into the mould assembly 60 layer by layer. These include decorative surface material 12, waterproofing membrane 16, and optionally flashing section 15 and embedded elements, like drain 30, and then filling with polymer composite material for the base 18. [0062] The polymer composite used for moulding the base 18 in the production method is polyurethane based and is preferably formulated comprising: 40% to 60% (by weight) isocyanate, 40% to 60% (by weight) blend of polyols and additives; and 5% to 20% (by weight) fibreglass and additives. The polyurethane composite in the mould assembly 60 has a thickness in the range of 10 mm to 60 mm, a density of in the range of 100 kg/m ³ to 400 kg/m ³ , a pot life in the range of about 3 minutes to 10 minutes, and a demoulding time in the range of about 15 minutes to 45 minutes. Thus, the polymer composite for the base 18 presents the physical properties and characteristics in Table 1 :

Table 1

Properties and Characteristics of Polyurethane Composite

[0063] The composite material is put in liquid form where it has good flowability to fill the mould 60 of various sizes and thickness within its designed pot life. This ensures the complete filling of the mould and the manufacturing of the panels with the desired gradient for water drainage. The reactive polyurethane composite is designed to have high reactivity enabling fast demould and high productivity.

[0064] Finally, referring to Fig. 9 of the drawings, a flow diagram is shown to illustrate schematically the steps in a method of producing a panel 10 according to any one of the embodiments described above with respect to Figs. 1 to 7 using a moulding assembly 60 shown in Fig. 8. In this regard, the first box i of Fig. 9 represents the step of lining an upwardly facing surface 65 of a lower mould part 64 with material 12 to form an outer layer 14 of the panel 10, whereby an outer surface of the outer layer material 12 faces the surface 65 of the lower mould part 64. As noted above, this may involve laying an array of tiles 12 having a functional, utilitarian, and/or decorative outer surface for the wet area over that mould part surface 65 to form the outer layer 14 of the panel 10. The second box ii then represents the step of applying a barrier layer 16 that substantially entirely covers the upwardly facing rear side of the tiles 12 of the outer layer 14. This may involve spraying a liquid polymer material, such as polyurethane, to entirely cover the rear side of the tiles 12. The barrier layer 16 may be applied in a number of passes, optionally in a number of coats, with the liquid polymer. In this way, the waterproofing membrane 16 is created. The third box iii represents the step of setting a spacer member 67 upon and extending along an edge region 20 of the outer layer material 12 and the applied barrier layer 16, so that the spacer member 67 defines or occupies a space corresponding to a recess 22 below the edge region 20 of the outer layer 14 and barrier layer 16 along a side of the panel 10. In this regard, the spacer member 67 comprises an elongate rectangular block and setting the spacer member 67 typically includes arranging and fixing the elongate block extending along the edge region 20 of the outer layer material 12 and the applied barrier layer 16. The final box iv in Fig. 9 of the drawings represents the steps of filling the lower mould part 64 with a liquid polyurethane resin that substantially covers the tiles 12 of the outer layer 14 and the barrier layer 16, except for the space occupied by the spacer block 67, and curing the polyurethane resin to form a panel base 18 that is integrated and/or consolidated with the barrier layer 16 and outer layer material 12 in a panel 10. As described with reference to Fig. 8, this method may include the step of setting and adhering or boning a flashing section 15 upon the outer layer material 12 along a side thereof, such that the flashing section 15 extends into a channel or slot 66 in the lower mould part 64 beyond the outer layer material 12, before the step of applying the barrier layer 16. The method may also include the step of setting a fitting or fixture, such as a drain 30, in the lower mould part for extending through the panel before the step of filling the lower mould part with liquid polymer material.

Variations and Modifications

[0065] Although specific embodiments of the invention are illustrated and described herein, it will be appreciated by persons of ordinary skill in the art that a variety of alternative and/or equivalent implementations exist. It should be appreciated that each exemplary embodiment is an example only and is not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

[0066] It will also be appreciated that the terms "comprise", "comprising", "include", "including", "contain", "containing", "have", "having", and any variations thereof, used in this document are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus, assembly or system described herein is not limited to the features, integers, parts, elements, or steps recited but may include other features, integers, parts, elements, or steps not expressly listed and/or inherent to such process, method, process, method, device, apparatus, assembly or system. Also, the terms "a" and "an" used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms "first", "second", "third", etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects. In addition, reference to positional terms, such as“lower" and“upper”, used in the above description are to be taken in context of the embodiments depicted in the figures, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee in the appropriate context.