Prefabricated bathroom assembly and methods of its manufacture and installation

Abstract

A prefabricated bathroom assembly and methods for its manufacture and installation are disclosed. For example, a prefabricated tub and/or shower assembly may be provided. In some embodiments, the prefabricated assembly may include at least a bathtub or a shower pan, tile surround(s), and a ceiling. The prefabricated assembly may be constructed substantially entirely off-site relative to a construction site and shipped to the construction site, for example, in substantially a single piece. Finishing face trim for making a seamless transition from the prefabricated assembly to the adjoining walls and ceiling may also be provided. In other embodiments, at least partially prefabricated panels (e.g., 3 wall panels and 1 ceiling panel), a tub or shower pan, the face trim, and/or other components may be shipped separately to the construction site for on-site assembly.

1 . An apparatus comprising:
 a rear wall panel;   a first side wall panel;   a second side wall panel;   a ceiling panel; and   a tub or a shower pan,   wherein at least one of the first side wall panel and the second side wall panel comprises at least one of a shower head and a tub spout, and wherein the ceiling panel is removable from the apparatus subsequent to installation of the apparatus at a construction site.   
     
     
         2 . The apparatus of  claim 1 , wherein the apparatus is substantially entirely fabricated off site for delivery to the construction site. 
     
     
         3 . The apparatus of  claim 1 , wherein each of the rear wall panel, the first side wall panel, the second side wall panel, and the ceiling panel is substantially entirely fabricated off site but delivered to the construction site separately for assembly at the construction site. 
     
     
         4 . The apparatus of  claim 1 , wherein the ceiling panel is slidably engageable with the first side wall panel and the second side wall panel. 
     
     
         5 . The apparatus of  claim 1 , further comprising face trim for the first side wall panel, the second side wall panel, and the ceiling panel. 
     
     
         6 . The apparatus of  claim 5 , wherein the face trim is formed from cultured marble. 
     
     
         7 . The apparatus of  claim 1 , wherein one or more of the rear wall panel, the first side wall panel, and the second side wall panel comprises:
 a frame;   backer board affixed to the frame; and   a molded material affixed to the backer board.   
     
     
         8 . The apparatus of  claim 7 , wherein the molded material comprises cultured marble affixed to the backer board with an adhesive. 
     
     
         9 . The apparatus of  claim 7 , wherein the backer board of one of the rear wall panel, the first side wall panel, and the second side wall panel comprises a male or female connector for mating with a corresponding female or male connector formed in another one of the rear wall panel, the first side wall panel, and the second side wall panel. 
     
     
         10 . The apparatus of  claim 1 , wherein each of the first side wall panel and the second side wall panel is configured for mechanical interlocking with the rear wall panel. 
     
     
         11 . The apparatus of  claim 10 , wherein each mechanical interlock between the first side wall panel and the rear wall panel, and between the second side wall panel and the rear wall panel, is substantially water-tight such that no caulking is necessary at the juncture between the panels. 
     
     
         12 . An apparatus comprising:
 a rear wall panel;   a first side wall panel;   a second side wall panel;   a ceiling panel; and   a tub or shower pan,   wherein at least one of the first side wall panel and the second side wall panel comprises at least one of a shower head and a tub spout, and wherein the tub or the shower pan is removable from the apparatus subsequent to installation of the apparatus at a construction site.   
     
     
         13 . A method of manufacturing a tub and/or shower assembly, the method comprising:
 at least partially fabricating the tub and/or shower assembly off site relative to a construction site for delivery to the construction site, said at least partially fabricating said assembly comprising:
 assembling a rear wall panel; 
 assembling a first side wall panel; 
 assembling a second side wall panel; and 
 assembling a ceiling panel that is insertable to and removable from the assembly via slidable engagement with the first side wall panel and the second side wall panel. 
   
     
     
         14 . The method of  claim 13 , further comprising attaching the rear wall panel, the first side wall panel, the second side wall panel, and the ceiling panel to one another off-site relative to the construction site. 
     
     
         15 . The method of  claim 14 , further comprising removing the ceiling panel from the assembly subsequent to installation at the construction site. 
     
     
         16 . The method of  claim 13 , further comprising affixing face trim to edges of the first side wall panel, the second side wall panel, and the ceiling panel. 
     
     
         17 . The method of  claim 13 , wherein one or more of assembling the rear wall panel, assembling the first side wall panel, and assembling the second side wall panel comprises:
 forming a frame;   affixing backer board to the frame; and   affixing a molded material to the backer board.   
     
     
         18 . The method of  claim 17 , wherein affixing the molded material to the backer board comprises affixing cultured marble to the backer board with an adhesive. 
     
     
         19 . The method of  claim 17 , further comprising:
 forming a male or female connector in the backer board of one of the rear wall panel, the first side wall panel, and the second side wall panel, the male or female connector configured for mating with a corresponding female or male connector formed in another one of the rear wall panel, the first side wall panel, and the second side wall panel; and   forming the corresponding female or male connector in the another one of the rear wall panel, the first side wall panel, and the second side wall panel.   
     
     
         20 . The method of  claim 13 , further comprising mechanically interlocking each of the first side wall panel and the second side wall panel with the rear wall panel. 
     
     
         21 . The method of  claim 13 , wherein said mechanically interlocking comprises mechanically interlocking each of the first side wall panel and the second side wall panel with the rear wall panel to form a water-tight connection such that no caulking is necessary at the juncture between the panels. 
     
     
         22 . A method of manufacturing an assembly comprising a tub or a shower pan, the method comprising:
 at least partially fabricating the assembly off site relative to a construction site for delivery to the construction site, said at least partially fabricating said assembly comprising:
 assembling a rear wall panel; 
 assembling a first side wall panel; 
 assembling a second side wall panel; and 
 assembling a ceiling panel, 
 wherein the tub or the shower pan is engageable with and removable from the assembly subsequent to installation of the assembly at a construction site.