Bent Metal Panel Prefabricated Bathroom

Abstract

The disclosed technology relates to a modular structure having a floor, a ceiling and at least four walls. The walls being constructed from a plurality of bent metal panels. These bent metal panels create a rigid and continuous substrate. The walls are also pre-fabricated to incorporate embedded architectural and mechanical design elements. During the main assembly phase the floor is mounted to the walls, the sides of the walls are then mounted to each other and the ceiling is then mounted to the walls thereby forming a monolithic frame structure. This monolithic structure enables a more efficient fabrication and assembly process.

1 . A modular structure comprising:
 a floor;   a ceiling; and   at least four walls, the walls being constructed from a plurality of bent metal panels, the bent metal panels creating a rigid and continuous substrate, the walls being pre-fabricated to incorporate embedded architectural and mechanical design elements,   wherein the floor is mounted to the walls, the sides of the walls are mounted to each other and the ceiling is mounted to the walls thereby forming a monolithic frame structure, the monolithic structure enabling a more efficient fabrication and assembly process.   
     
     
         2 . The modular structure of  claim 1  wherein the floor is a honeycomb substrate. 
     
     
         3 . The modular structure of  claim 1  wherein the ceiling is constructed from bent metal panels. 
     
     
         4 . The modular structure of  claim 3  wherein the bent metal panels include tabs and flanges so that the panels may be connected to one another, as needed. 
     
     
         5 . The modular structure of  claim 1  wherein the architectural and mechanical design elements include at least one of notches, spacing, gypsum boards and tiles. 
     
     
         6 . The modular structure of  claim 1  wherein the mounting is performed by at least one of screws and adhesives. 
     
     
         7 . The modular structure of  claim 1  wherein the monolithic structure aids in the reduction of punch list items typically experienced during delivery and setting of the monolithic structures. 
     
     
         8 . The modular structure of  claim 1  wherein, once the monolithic structure is formed, bathroom fixtures, accessories, and finishes are installed. 
     
     
         9 . A prefabricated room module for use in the construction of a modular building comprising:
 a floor having at least four edges;   at least four walls being mounted atop the edges of the floor, the walls being constructed from a plurality of bent metal panels and are pre-assembled with embedded architectural and mechanical design elements, the walls having sides that are mounted to one another; and   a ceiling being mounted to a top section of the walls.   
     
     
         10 . The modular structure of  claim 1  wherein the floor is a honeycomb substrate. 
     
     
         11 . The modular structure of  claim 1  wherein the ceiling is constructed from bent metal panels. 
     
     
         12 . The modular structure of  claim 11  wherein the bent metal panels include tabs and flanges so that the panels may be connected to one another, as needed. 
     
     
         13 . The modular structure of  claim 1  wherein the architectural and mechanical design elements include at one of notches, spacings, gypsum boards, tiles. 
     
     
         14 . The modular structure of  claim 1  wherein the mounting is performed by screws and/or adhesives. 
     
     
         15 . The modular structure of  claim 1  wherein the prefabricated room module aids in the reduction of punch list items typically experienced during delivery and setting of prefabricated room module. 
     
     
         16 . The modular structure of  claim 1  wherein, once the prefabricated room module is formed, bathroom fixtures, accessories, and finishes are installed. 
     
     
         17 . A modular structure made by the following process:
 pre-assembling at least four walls and a ceiling structure, the walls and ceiling being constructed from a plurality of bent metal panels creating a rigid structure and continuous substrate and including embedded architectural and mechanical design elements;   mounting the at least four walls to a substrate;   attaching sides of the walls to one another; and   mounting the ceiling structure on top sections of the walls.   
     
     
         18 . The modular structure of  claim 17  wherein the bent metal panels include tabs and flanges so that the panels may be connected to one another, as needed. 
     
     
         19 . The modular structure of  claim 17  wherein the monolithic structure aids in the reduction of punch list items typically experienced during delivery and setting of modular structure. 
     
     
         20 . The modular structure of  claim 1  wherein, once the modular structure is formed, bathroom fixtures, accessories, and finishes are installed.