Cove elements and floor coatings and methods for installing

Abstract

Described herein is a monolithic flooring system that includes cove elements that are shaped to provide a transition between floor and wall such that a floor coating may be installed over the cove elements and sub-flooring to create a unitary floor-cove covering making for a surface that is more sanitary and easier to clean. Also described are various shaped cove elements that enable creation of a good transition between wall and floor. The cove elements are preferably made of material similar to the sub-floor, for instance a cementitious material. The floor coating is preferably a resinous material.

1 . A flooring system comprising: 
 at least one cove element having a predetermined contoured shape, said cove element for attachment to at least one of the following: a floor adjacent to a wall, and a wall adjacent to the floor;    said contoured shape of said cove element providing a non-perpendicular transition between the floor and the wall;    a floor coating extending along the surface of the floor and further extending over an exposed surface of said cove element thereby forming a monolithic floor surface.    
   
   
       2 . A flooring system as set forth in  claim 1 , wherein with the cove element installed, said contoured surface defines an angled surface that is approximately 35 degrees inclined from the wall and floor surfaces.  
   
   
       3 . A flooring system as set forth in  claim 1 , wherein with the cove element installed, a portion of said contoured surface defines a curved transition between the wall and floor surfaces.  
   
   
       4 . A flooring system as set forth in  claim 3  wherein said portion of said contoured surface has a radius of between ¼ inch and 24 inches.  
   
   
       5 . A flooring system as set forth in  claim 4  wherein said portion of said contoured surface has a radius of between ⅜ inches and 12 inches.  
   
   
       6 . A flooring system as set forth in  claim 1  wherein said cove element is formed from a cementitious material.  
   
   
       7 . A flooring system as set forth in  claim 1  wherein said cove element is formed from any one of the following: gypsum, cement, concrete, ceramic, plaster based compounds, urethane, polymer, latex, vinyl, epoxy and quartz sand mixtures with fiberglass reinforcement, epoxy and quartz sand mixtures without fiberglass reinforcement, high-density epoxy, high-density foam, polyurethane, cellular PVC, polyurea and resins.  
   
   
       8 . A flooring system as set forth in  claim 1  further comprising a plurality of differing cove elements.  
   
   
       9 . A flooring system as set forth in  claim 8  wherein each of said cove elements is formed with means for alignment during installation.  
   
   
       10 . A flooring system as set forth in  claim 9  wherein said means for alignment includes one of the following: a tongue and groove, at least one pin, and, peel and stick, and adhered alignment.  
   
   
       11 . A flooring system as set forth in  claim 1 , wherein said floor coating is comprised of one of the following: epoxy, resinous material, a polyurethane based composition, a methyl methacrylate based composition, apolycyclic polyamine based composition, a polysiloxane composition, a hydroxyl functional non-vinyl group composition and an acrylic urethane composition.  
   
   
       12 . A method of forming a monolithic flooring system comprising the steps of: 
 installing cove elements at the transition between a floor and walls abutting the floor;    coating the cove elements and the floor uniformly to form a seamless surface.    
   
   
       13 . A method as set forth in  claim 12  further comprising: 
 forming the cove elements of a cementitious material before said installing step.    
   
   
       14 . A method as set forth in  claim 12  further comprising: 
 forming the cove elements before said installing step using any one of the following: gypsum, cement, concrete, ceramic, plaster based compounds, urethane, polymer, latex, vinyl, epoxy and quartz sand mixtures with fiberglass reinforcement, epoxy and quartz sand mixtures without fiberglass reinforcement, high-density epoxy, high-density foam, polyurethane, cellular PVC, polyurea and resins.    
   
   
       15 . A method as set forth in  claim 12  wherein said installing step includes installing a plurality of interlocking cove elements.  
   
   
       16 . A method as set forth in  claim 12  wherein said installing step includes installing a plurality of interlocking cove elements formed of a cementitious material  
   
   
       17 . A method as set forth in  claim 12  wherein said installing step includes installing a plurality of interlocking cove elements formed of a polyurea material  
   
   
       18 . A method as set forth in  claim 12  wherein said coating step includes coating with a floor coating comprising one of the following: epoxy, resinous material, a polyurethane based composition, a methyl methacrylate based composition, apolycyclic polyamine based composition, a polysiloxane composition, a hydroxyl functional non-vinyl group composition and an acrylic urethane composition.  
   
   
       19 . A method for forming cove elements comprising the steps of: 
 providing an endless belt supported by a plurality of rollers thereby forming an endless belt mold having a flat portion, a concave portion and a convex portion;    pouring a mixture onto the endless belt; and    curing the mixture to form the cementitious cove element.