SEAMLESS FLOOR-TO-WALL TRANSITION ASSEMBLY, KIT, AND METHOD OF INSTALLATION THEREOF

Abstract

A seamless floor-to-wall transition assembly, kit, and method of installation having a plurality of cove panels which overlie the joint between a floor and a base of a wall, each having a curved outer surface which collectively form a seamless exterior surface, and a floor covering material sufficient to form a coating to cover the floor and abutting an outer free end of the cove panels, to provide a substantially smooth transition from floor covering material to cove panels. In clinical applications, the assembly also including at least one topcoat material which is sufficient to form a continuous coating to overlie the floor covering material and at least a portion of the cove panels, to provide a seamless transition between the floor covering material and the cove panels, which is easier to clean and minimizes crevices which can harbor dirt or germs leading to a more sanitary environment.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit from U.S. Provisional Patent Application Ser. No. 61/475,026, filed Apr. 13, 2011, the contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is generally in the field of building materials, particularly, floor and wall coverings. More particularly, the present invention is directed to an assembly designed to provide a seamless transition from a flooring material to a wall material and accompanying manufacturing and installation method therefor.

The assembly according to the present invention can be used in any space requiring an easy to clean environment, but is particularly suitable for locations desiring sanitary conditions and infection control, such as operating rooms, emergency rooms, patient care rooms, intensive care rooms and/or bathrooms, etc. However, the invention is not limited to such applications and can be utilized for any desired space, such as, for example, in order to provide an easier to clean surface or for its aesthetic appearance.

2. Brief Description of the Prior Art

Often times dirt and germs can become trapped in seams or joints between floors and walls or around the corners thereof making it difficult to keep clean and/or maintain the sanitary condition of the same. Therefore, it is known in the prior art to provide various material assemblies to provide a transition from a floor to a wall and manufacturing and installation methods therefor, such as flash coving, vertical cove bases, and applied base trims, as discussed more fully below. However, each of these assemblies has certain deficiencies.

More particularly, it is known in the prior art to provide assemblies and methods of flash coving. Flash coving provides for an extension of the sheet flooring up the wall to form a wall base. Typically, the flooring material extends 4-6″ up the wall and can be accomplished by either a one-piece flash coving, a border flash coving, or a two-piece flash coving.

Typically, the first step in installing the flash coving is to nail or cement a cap or binder strip to the wall at the desired height. Next, a cove stick is installed at the juncture of the wall and the floor, to support the material where it coves up the wall. Disadvantageously, if there is no support behind the material, the material can be punctured. Usually cove sticks will have approximately a ⅞″ radius, although other sizes are available. Next, sheet flooring is installed and cut and mitered at the inside and outside corners, as required. All of the seams in the flash cove area are treated the same as seams throughout the rest of the installation. Flash coving is popular with end users because it eliminates the need for a floor/wall juncture and it is also easy to maintain.

However, there are certain drawbacks and disadvantages to flash coving assemblies and methods, namely, the radius is soft and can be punctured; the cap or binder strip creates additional areas of seams where bacteria can harbor through additional crevasses, creating an infection control issue; and the installation and/or final assembly is difficult at the inside and outside corners of the room, which can drive up the cost of installation.

Secondly, it is known in the prior art to utilize a vertical cove base. Generally, the vertical cove base assemblies utilize a trowelable flooring material, for example, terrazzo, a branded epoxy or other polymer, which is poured and hand worked to extend up the wall, to a typical height of 6″. This forms a curb or a vertical cove base and can be applied before or after the walls are installed. In most applications, a trim strip is used to terminate the top edge of the curb where the wall finish starts. The face of the curb can be co-planar with the wall finish, but most often it is not.

Similarly, there are several drawbacks and disadvantages to the vertical cove assemblies and methods, namely: if the curb is installed on site, as is the case for most polymer epoxy materials, the problem centers around having the polymer continuously drip down the wall while it is curing, requiring temporary form-work or continuous reworking as it cures. It is also very difficult to align the face of the wall with the curves, creating a cleaning and potentially an infection issue. Moreover, the curb is the most difficult part of the installation process, and has to be done in the field, driving up costs and time for installation. In addition, if the curb is pre-cast off site in a manufacturing facility, the precast parts are difficult to cut to size and install on site and the joint between the precast curb and the poured flooring are not seamless.

Thirdly, it is known in the prior art to utilize an applied base trim. Particularly, there are many trim products available on the market, often made of rubber, plastic, vinyl, metal, wood or similar materials, which are installed after the wall and floor materials are installed. These trim products can increase the ability to clean the corner between the wall and floor, but are also used as only an aesthetic treatment.

Since these trims are placed on top of the floor and in front of the wall, they create two gaps and/or changes in plane, which can be difficult to clean. Moreover, these applied trims are generally not allowed in many clinical and healthcare environments, including for example, operating rooms, emergency rooms, patient care rooms, and/or intensive care rooms and, instead, are more appropriate and best suited for public spaces where cleanablilty and infection control are not primary concerns.

Therefore, it is advantageous to provide a seamless floor-to-wall transition for a space requiring an easy to clean environment and with an emphasis on sanitary conditions and infection control, including, but not limited to operating rooms, emergency rooms, patient care rooms, intensive car rooms and/or bathrooms. It is also desirable to provide a seamless floor-to-wall transition which is less expensive, easier and more efficient to install, has a faster installation time, is more forgiving in situations where the walls and floor are not perfectly flat, level, plumb and/or square, and which provides better infection control and sanitary conditions.

Moreover, it is also advantageous to provide an assembly where all of the more difficult elements of the cove and the compound coves at the inside and outside corners can be manufactured offsite instead of the job site, which increases the quality and precision of the finished installation.

While the prior art discloses many types of floor-to-wall transition assemblies, so far as is known, none of these assemblies or installation methods therefor, resolve these problems in a simple, effective and highly advantageous manner, as in the present invention.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a novel seamless floor-to-wall transition assembly and method of installation thereof.

It is also an object of the present invention to provide a seamless floor-to-wall transition assembly which provides more sanitary conditions for a space requiring an easy to clean environment with a focus on infection control, such as, for example, operating rooms, emergency rooms, patient care rooms, intensive car rooms and/or bathrooms.

It is a further object of the present invention to provide a seamless floor-to-wall transition assembly which is less expensive than the prior art assemblies.

It is a yet another object of the present invention to provide a seamless floor-to-wall transition assembly which is easier and more efficient to install and has a faster installation time.

It is another object of the present invention to provide a seamless floor-to-wall transition assembly which is more forgiving in situations where the walls and floor are not perfectly flat, level, plumb and/or square.

It is also another object of the present invention to provide a seamless floor-to-wall transition assembly where the more difficult elements of the cove at the floor and the compound coves at the inside and outside corners can be manufactured offsite at the factory instead of the job site to increase the quality and precision of the finished installation.

Certain of the foregoing and related objects are readily attained according to the present invention by the provision of a seamless floor-to-wall transition assembly, comprising at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.

Preferably, the assembly further comprises at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel, to provide a seamless transition between said at least one floor covering material and said at least one cove panel. Advantageously, said at least one topcoat material, when in its cured state, defines an outer peripheral edge which is disposed along the center of curvature of said curved outer surface portion of said exterior surface of said at least one cove panel.

In a preferred embodiment, said curved outer surface portion of said at least one cove panel is concaved. Preferably, said concaved curved outer surface portion of said at least one cove panel has a radius of about ½″. It is also desirable that said lower leg of said at least one cove panel is elongate and generally planar defining an extended lip portion, wherein said at least one topcoat material overlies at least a portion of said extended lip portion. It is advantageous that said upper leg of said at least one cove panel is disposed substantially 90 degrees from said lower leg of said at least one cove panel.

In the preferred embodiment, the assembly further comprises a plurality of cove panels which are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface. Preferably, said plurality of cove panels are joined together by fusing. It is also preferable that said at least one of said cove panels is an inside corner cove panel. In addition, it is preferred that said at least one of said cove panels is an outside corner cove panel.

In the preferred embodiment, said at least one cove panel is made of an acrylic solid surface material. It is also desirable that said at least one floor covering material is trowelable. Advantageously, said at least one floor covering material is a resilient, urethane mortar comprising a urethane resin, a curing agent and a coarse rubber aggregate. Most desirably, said at least one topcoat material is an aliphatic, polyaspartic urethane, and a non-reflective, waterborne, aliphatic polyurethane.

It is also desirable that said outer free end of said lower leg is planar. Preferably, said outer free end of said lower leg has an irregular surface. It is also preferred that said outer free end of said lower leg has a mechanical interlock formed therein which engages with said at least one floor covering material and said mechanical interlock is a member selected from the group consisting of a back cut, a bevel, a dado, a V-shaped groove, and a lap joint. In addition, it is preferred that said at least one cove panel includes an angled chamfer section joining said lower end of said upper leg to said inner end of said lower leg. Desirably, said upper leg has a thickness of about ½″ and said extended lip portion has a length of about ⅜″ and a thickness of about ¼″.

Certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a method of providing a seamless floor-to-wall transition, comprising the steps of providing at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel; and arranging said at least one of cove panel to overlie the joint between the floor and the base of the wall, such that said inner surface of said upper leg abuts at least a portion of the wall and said inner surface of said lower leg abuts a portion of the floor generally adjacent to the base of the wall; affixing said at least one cove panel to at least one of the wall and the floor; applying said at least one floor covering material in its initial flowable state, sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel; and allowing said at least one floor covering material to cure, such that its cured state, said floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.

In the preferred embodiment, the method further comprises the steps of providing at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said floor covering material and at least a portion of said exterior surface of said at least one cove panel; and applying said at least one topcoat material in its initial flowable state, sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel; and allowing said at least one topcoat material to cure such that in its cured state, it provides a seamless transition between said at least one floor covering material and said at least one cove panel.

It is also desirable that the method further comprises providing a plurality of said cove panels which are adapted to be joined together and after said step of providing a plurality of said cove panels, joining said plurality of cove panels together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface. Advantageously, said cove panels are joined in situ. Desirably, at least one of said cove panels is an inside corner cove panel and least one of said cove panels is an outside corner cove panel. Preferably, said plurality of cove panels are joined via an adhesive.

In addition, certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a seamless floor-to-wall transition assembly kit, comprising a plurality of cove panels which are configured and dimensioned to overlie a joint between a floor and a base of a wall, each comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg, wherein said cove panels are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface; at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said cove panels such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower legs and a top surface portion having a height which is generally equal to the height of said outer free ends of said lower legs, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free ends of said lower legs of said cove panels; and at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surfaces of said cove panels, to provide a seamless transition between said at least one floor covering material and said cove panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and features of the present invention will become apparent from the detailed description considered in connection with the accompanying drawings, which disclose several embodiments of the invention. It is to be understood that the drawings are to be used for the purpose of illustration only and not as a definition of the limits of the invention.

FIG. 1 is a perspective view of a seamless floor-to-wall transition assembly, according to the present invention, installed in a room;

FIG. 2 is a fragmentarily-illustrated sectional view, in part elevation, of the seamless floor-to-wall transition assembly taken along line 2-2 of FIG. 1;

FIG. 2a is an enlarged sectional view of portion 2a in FIG. 2;

FIG. 3 is a perspective view of a straight cove panel;

FIG. 3a is an enlarged, elevational view of the configuration of the outer end of the cove panel in portion 3a in FIG. 3, having a V-shaped groove formed therein;

FIG. 3b is an elevational view of a dado formed in the outer end of the cove panel;

FIG. 3c is an elevational view of a planar outer end of the cove panel;

FIG. 3d is an elevational view of alternate shape of a dado formed in the outer end of the cove panel;

FIG. 3e is an elevational view of a lap joint formed in the outer end of the cove panel;

FIG. 3f is an elevational view of an irregular surface of the outer end of the cove panel;

FIG. 3g is an elevational view of a back cut formed in the outer end of the cove panel;

FIG. 4a is a fragmentarily-illustrated perspective view of a cove panel having a chamfer formed therein, an extend lip portion and an angled upper end;

FIG. 4b is a view similar to FIG. 4a, but with a rounded upper end;

FIG. 5 is a fragmentarily-illustrated perspective view of an alternate configuration for a cove panel, without the extended lip portion and having a planar upper end;

FIG. 6 is a perspective view of an inside corner cove panel installed in a room, between two straight cove panels; and

FIG. 7 is a perspective view of an outside corner cove panel installed in a room, between two straight cove panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now in detail to the drawings, and in particular FIG. 1, which illustrates the novel floor-to-wall transition assembly, generally designated by reference numeral 10, according to the present invention installed in a room. As seen best in FIG. 2, the assembly 10 of the present invention includes one or more cove panels generally designated by reference numeral 20, floor covering material generally designated by reference numeral 30, and in certain applications, topcoat material generally designated by reference numeral 40. Once installed, assembly 10 provides for a seamless transition between wall 200 and floor 100 which is easier to clean and provides enhanced sanitary conditions by minimizing any seams or crevices which may harbor dirt or infectious materials.

As seen in FIGS. 6 and 7, cove panels 20 can assume the shape of straight cove panels 20a, inside corner cove panel 20b (FIG. 6), and outside corner cove panel 20c (FIG. 7), (individually or collectively, referred to as cove panels 20) all of which are seamlessly joined together to form a seamless configuration, such as that shown in FIG. 1. Particularly, as seen best in FIG. 1, cove panels 20a, 20b, and/or 20c are configured and dimensioned to overlie a joint or seam 206 between floor 100 and a base of a wall 200. As seen in FIGS. 1 and 6-7, straight cove panels 20a can be used to cover the straight-edge joint sections between floor 100 and wall 200. As seen in FIG. 6, inside corner cove panels 20b can be used to cover the 90 degree corner 202 joints formed between floor 100 and wall 200 and, as seen in FIG. 7, outside corner cove panels 20c can be used to cover the 270 degree corner 204 joints formed between floor 100 and wall 200. However, other angled configurations of cove panels 20b and 20c are possible if the corners of the room are not 90 or 270 degrees, respectively.

Cove panels 20a, 20b, and 20c can be formed from a single unitary member or comprise multiple pieces joined together into a seamless member. Where cove panels 20 comprise multiple pieces, they can be manufactured and joined together off-site at the factory, instead of the job site, to increase the quality and precision of the finished installation. Particularly, cove panels 20 can be manufactured in a number of ways, such as joining multiple laminate strips together to create a suitable block of material and by using techniques and involving machines and tools commonly used by those having ordinary skill in the art within the solid surface industry.

As seen best in FIG. 2, cove panels 20 each have a generally L-shaped cross-section having a generally upright, upper leg 21 and a generally horizontal, lower leg 24. It is preferred that upper leg 21 is disposed about 90 degrees from said lower leg 24, however, other suitable angles can be utilized depending on the angle between floor 100 and wall 200. Preferably, upper leg 21 has a thickness of about ½″, however, other thicknesses can be utilized.

As also seen in FIGS. 4a, 4b and 5, upper leg 21 has an upper free end 22 and a lower end 23. Lower leg 24 has an inner end 25 and an outer free end 26. Inner end 25 of lower leg 24 is joined to lower end 23 of upper leg 21. As seen in FIGS. 4a and 4b, optionally, an angled chamfer 27 joins upper leg 21 to lower leg 24 in order to reduce the chance of interference from debris that can accumulate in the corner where the base of wall 200 and floor 100 meet. As seen in FIG. 2, upper leg 21 has a generally planar inner surface 28 which is adapted to abut wall 200 and lower leg 24 has a generally planar lower surface 29 which is adapted to abut floor 100 generally adjacent to the base of the wall 200.

In addition, as seen in FIGS. 2-3, 4a-4b and 5-7, upper leg 21 has an outer surface 51 and lower leg 24 has an outer surface 52 which merge together along a curved outer surface portion 53 to collectively form a seamless exterior surface, generally designated by reference numeral 50. Exterior surface 50 extends from upper free end 22 of upper leg 21 to outer free end 26 of lower leg 24. Outer surfaces 51 and 52 merge along a curved surface in order to avoid any seams, crevices, or joints in exterior surface 50 to prevent dirt and debris from being trapped therein and making exterior surface 50 easier to clean. However, other configurations of exterior surface 50 are possible as long as they do not form seams, joints or crevices. Upper free end 22 of upper leg 21 can have a planar configuration, as seen in FIG. 2, and angled configuration as seen in FIG. 4a, or a rounded configuration as seen in FIG. 4b. However, other suitable shapes are possible.

Curved outer surface portion 53 is preferably concaved and having generally semi-circular curvature having a radius of ½″. However, the radius can be modified to be in the range of 1/16″ to 6″ or even larger radii are possible. In addition, curved outer surface portion 53 can assume other curvatures such as that of an ellipse or other non-circular spline, as long as it has a continuous curved and/or linear surface to prevent dirt, germs or other debris from being trapped therein.

The height of cove panels 20 relative to the wall 200 or their width relative to the floor 100 can be altered according to the desired dimensions. Particularly, cove panels 20 can be used as a base trim, in which case it would most commonly have a height of 6″, as seen in FIG. 1. Alternatively, cove panels 20 can be half-height wall panels, such as, having a height of 48″ (not shown) or full height wall panels which extend to the ceiling (not shown).

Cove panels 20 are preferably made of acrylic-based thermoplastics commonly referred to as acrylic solid surfaces, which can be chemically joined together to form a larger seamless cove panel, such as, for example and preferably, CORIAN material made by E. I. du Pont de Nemours and Company of Wilmington, Del. However, cove panels 20 can be made from any material, which can be machined, thermoformed or otherwise manufactured to assume the preferred geometry and joined together in a seamless fashion.

During installation, as seen in FIG. 1, a plurality of cove panels 20 are arranged along the perimeter of a room to overlie the joint between floor 100 and the base of the wall 200, preferably along the entire perimeter of a room. Particularly, as seen best in FIGS. 6-7 straight cove panels 20a are arranged along all of the straight-edge joints of a room, inside corner cove panels 20b are arranged at all of the 90 degree corner 202 joints, and outside corner cove panels 20c are arranged at all of the 270 degree corner 204 joints. The exact configuration and number of cove panels 20a, 20b, and 20c will depend on the shape and configuration of the room in which it is installed and their placement can be modified as desired to suit the particular installation. As seen best in FIG. 2, one or more cove panels 20 are placed such that inner surface 28 of upper leg 21 abuts wall 200 and inner surface 29 of lower leg abuts floor 100. Preferably, as seen in FIG. 2, cove panels 20 are affixed via an adhesive 60 to wall 200, and optionally to floor 100 (not shown). Suitable adhesives would be well known to those having ordinary skill in the art.

Cove panels 20 are adapted to be joined together by methods well known to those having skill in the art, so that exterior surface 50 of each of cove panels 20a, 20b, and/or 20c once joined together, collectively form a single substantially seamless exterior surface, as seen in FIGS. 1, 6 and 7. In particular, once installed, it is desirable that all of the cove panels 20 are joined together so that all exterior surfaces 50 form a single seamless exterior surface about the entire perimeter of a room. Preferably, cove panels 20 are joined together through the use of an adhesive, such as, Joint Adhesive for DUPONT CORIAN Solid Surfaces manufactured by E. I. du Pont de Nemours and Company of Wilmington, Del. However, other suitable adhesives would be well known to one having ordinary skill in the art. Cove panels 20 can be joined together off-site prior to installation, on-site during installation, or in situ during the installation process, or a combination thereof, so long as all of cove panels 20 form a single seamless exterior surface.

In addition, as seen in FIG. 2, assembly 10 also includes at least one floor covering material, generally designated by reference numeral 30. Preferably, floor covering material 30 is trowelable, and curable from an initially flowable state to a cured state, such as, for example, terrazzo. The floor covering material 30 according to the preferred embodiment is a three-component, ultraviolet (UV) resistant, resilient, urethane mortar comprising a urethane resin, a curing agent and a coarse rubber aggregate, such as the STONRED RTZ base made by STONHARD of Maple Shade, N.J. However, other materials suitable for floors can be utilized.

A sufficient amount of floor covering material 30, when in its initially flowable state, is applied over floor 100 to form a coating to cover floor 100 and, particularly, floor 100 adjacent to cove panels 20, as seen in FIGS. 1 and 2. Preferably, cove panels 20 are disposed around the entire perimeter of a room and floor covering material 30 covers all of the floor disposed between the plurality of cove panels 20 so that it abuts all of cove panels 20. The application of floor covering material would be well known to those having ordinary skill in the art.

Floor covering material 30 is allowed to cure sufficiently to its cured state. Once cured, as seen in FIG. 2a, floor covering material 30 defines a lateral edge portion 31 which abuts outer free ends 26 of lower legs 24 of all the installed cove panels 20. As also shown in FIG. 2a, floor covering material 30 also has a top surface portion 32 having a height which is generally equal to the height of outer free end 26 of said lower leg 24. Once cured, as seen best in FIGS. 2 and 2a, floor covering material 30 provides a substantially smooth and flush transition from top surface portion 32 of floor covering material 30 and free ends 26 of said lower legs 24 of all of cove panels 20. Particularly, exterior surfaces 50 of cove panels 20 and top surface portion 32 of floor covering material form a substantially smooth surface therebetween, as seen in FIG. 2.

It is preferable that outer free end 26 of lower leg 24 of cove panel 20 each has a mechanical interlock formed therein, as seen in FIGS. 3a-3g, which engages with floor covering material 30, to provide for a more secure bond therebetween. Various mechanical interlock end configurations and shapes are possible, such as back cuts or bevels as seen in FIG. 3g, dados or trenches, as seen in FIGS. 3b and 3d, or lap joints, as seen in FIG. 3e. However, it is preferred that outer free end 26 include a V-shaped groove, formed centrally on outer free end 26, as seen in FIG. 3a. Alternatively, outer free end 26 of lower leg 24 of cove panels 20 may be planar, as seen in FIG. 3c or have an irregular or wavy surface as seen in FIG. 3f, to better bond with floor covering material 30.

Additionally, as seen in FIG. 2, for clinical applications, such as, for example, operating rooms, emergency rooms, patient care rooms, intensive care rooms, assembly 10 further comprises at least one topcoat material 40. A single layer of topcoat 40 may be utilized or, as seen best in FIG. 2a, multiple layers of the same of different topcoats can be used. As illustrated in FIG. 2a, topcoat 40 seals a seam or joint 34 between cove panels 20 and flooring material 30, to prevent for example, dirt, germs, or infectious materials from being trapped therein, in order to provide for an easier to clean and, thus, a more sanitary installation. Topcoat 40 is preferably a material that is curable from an initially flowable state to a cured state such as, for example, a urethane or polyurethane material.

In the preferred embodiment, topcoat 40 comprises a bottom layer 41 of a two-component clear, UV resistant, aliphatic, polyaspartic urethane, such as STONRED RTZ Grout Coat manufactured by STONHARD of Maple Shade, N.J. and at least one top layer 42 of a two-component, non-reflective, waterborne, aliphatic polyurethane, such as STONSEAL GS7 CLEAT FLAT manufacture by STONHARD of Maple Shade, N.J. Preferably, two layers of topcoat layer 42 are applied. However, other suitable topcoats or number of layers can be utilized.

During installation, as seen in FIGS. 2 and 2a, a sufficient amount of topcoat 40 is applied, in its initial flowable state, to form a continuous coating which overlies all of floor covering material 30 and at least a portion of exterior surface 50 of cove panels 20, in order to seal joint 34 between floor covering material 30 and cove panels 20, and provide a seamless transition therebetween. Preferably topcoat 40 is applied over said exterior surface 50 of cove panels 20, including at least a portion of curved outer surface portion 53, as seen in FIG. 2. Topcoat 40 is allowed to cure to its curable state so that it provides a seamless transition between floor covering material 30 and all of cove panels 20. When in its curable state, topcoat material 40 defines an outer peripheral edge 43. As seen in FIG. 2, it is preferred that outer peripheral edge 43 is disposed along the center of curvature of curved outer surface portion 53 of exterior surface 50 of cove panels 20, in order to provide a more aesthetic appearance by masking the change in the reflection between the topcoat 40 and the exterior surface 50 without topcoat 40. It is desirable that topcoat 40 extends at least ⅜″ past outer free end 26 of lower leg 24 on exterior surface 50 of cove panels 20, however, the length of overlap on exterior surface 50 can be modified.

In an application where seamless performance is less important, such as a non-clinical applications, topcoat 40 is optional. Furthermore, where the floor covering material can chemically or otherwise bond to cove panels 20 in a seamless manner that eliminates the need for topcoat 40, topcoat 40 could become optional even in healthcare and/or clinical environments.

Additionally, as seen best in FIGS. 2a, 4a and 4b, it is preferred that lower legs 24 of cove panels 20 include an elongate and generally planar extended lip portion 54 which is coplanar with the top surface portion 32 of the floor covering material 30. Extended lip portion 54 provides the benefits of a level and true edge to use as a screed when applying the floor covering material 30, eliminating the need for additional trim pieces or temporary fixtures to assist in the leveling of the floor covering material 30. Topcoat 40 is applied over extended lip portion 54 and increases the distance between the edge of floor covering material 30 and wall 200, allowing for more room to clean and finish floor covering material 30. Extended lip portion 54 also allows for an increased overlap distance of topcoat 40 to extend from floor covering material 30 to cove panel 20. In the preferred embodiment, extended lip portion 54 has a length of about ⅜″ and a thickness of about ¼″. However, other suitable dimensions can be utilized. Alternatively, as seen in FIG. 5, cove panels 20 can be configured without the extended lip portion 54, so that curved outer surface portion 53 extends to outer free end 26.

While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the prior art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that other modifications could be made thereto without departing from the spirit and scope of the invention.

Claims

1. A seamless floor-to-wall transition assembly, comprising:

at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and

at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.

2. The assembly according to claim 1, further comprising:

at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel, to provide a seamless transition between said at least one floor covering material and said at least one cove panel.

3. The assembly according to claim 2, wherein:

said at least one topcoat material, when in its cured state, defines an outer peripheral edge which is disposed along the center of curvature of said curved outer surface portion of said exterior surface of said at least one cove panel.

4. The assembly according to claim 1, wherein:

said curved outer surface portion of said at least one cove panel is concaved.

5. The assembly according to claim 4, wherein:

said concaved curved outer surface portion of said at least one cove panel has a radius of about ½″.

6. The assembly according to claim 2, wherein:

said lower leg of said at least one cove panel is elongate and generally planar defining an extended lip portion, wherein said at least one topcoat material overlies at least a portion of said extended lip portion.

7. The assembly according to claim 1, wherein:

said upper leg of said at least one cove panel is disposed substantially 90 degrees from said lower leg of said at least one cove panel.

8. The assembly according to claim 1, further comprising:

a plurality of cove panels which are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface.

9. The assembly according to claim 8, wherein:

said plurality of cove panels are joined together by fusing.

10. The assembly according to claim 8, wherein:

said at least one of said cove panels is an inside corner cove panel.

11. The assembly according to claim 8, wherein:

said at least one of said cove panels is an outside corner cove panel.

12. The assembly according to claim 1, wherein:

said at least one cove panel is made of an acrylic solid surface material.

13. The assembly according to claim 1, wherein:

said at least one floor covering material is trowelable.

14. The assembly according to claim 1, wherein:

said at least one floor covering material is a resilient, urethane mortar comprising a urethane resin, a curing agent and a coarse rubber aggregate.

15. The assembly according to claim 2, wherein:

said at least one topcoat material is an aliphatic, polyaspartic urethane, and a non-reflective, waterborne, aliphatic polyurethane.

16. The assembly according to claim 1, wherein:

said outer free end of said lower leg is planar.

17. The assembly according to claim 1, wherein:

said outer free end of said lower leg has an irregular surface.

18. The assembly according to claim 1, wherein:

said outer free end of said lower leg has a mechanical interlock formed therein which engages with said at least one floor covering material.

19. The assembly according to claim 18, wherein:

said mechanical interlock is a member selected from the group consisting of a back cut, a bevel, a dado, a V-shaped groove, and a lap joint.

20. The assembly according to claim 1, wherein:

said at least one cove panel includes an angled chamfer section joining said lower end of said upper leg to said inner end of said lower leg.

21. The assembly according to claim 6, wherein:

said upper leg has a thickness of about ½″ and said extended lip portion has a length of about ⅜″ and a thickness of about ¼″.

22. A method of providing a seamless floor-to-wall transition, comprising the steps of:

providing at least one cove panel which is configured and dimensioned to overlie a joint between a floor and a base of a wall, comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg; and at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel;

arranging said at least one of cove panel to overlie the joint between the floor and the base of the wall, such that said inner surface of said upper leg abuts at least a portion of the wall and said inner surface of said lower leg abuts a portion of the floor generally adjacent to the base of the wall;

affixing said at least one cove panel to at least one of the wall and the floor;

applying said at least one floor covering material in its initial flowable state, sufficient to form a coating to cover at least a portion of the floor adjacent to said at least one cove panel; and

allowing said at least one floor covering material to cure, such that its cured state, said floor covering material defines a lateral edge portion which abuts said outer free end of said lower leg and a top surface portion having a height which is generally equal to the height of said outer free end of said lower leg, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free end of said lower leg of said at least one cove panel.

23. The method according to claim 22, further comprising the steps of:

providing at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said floor covering material and at least a portion of said exterior surface of said at least one cove panel; and

applying said at least one topcoat material in its initial flowable state, sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surface of said at least one cove panel; and

allowing said at least one topcoat material to cure such that in its cured state, it provides a seamless transition between said at least one floor covering material and said at least one cove panel.

24. The method according to claim 22, further comprises:

providing a plurality of said cove panels which are adapted to be joined together.

25. The method according to claim 24, further comprising:

after said step of providing a plurality of said cove panels, joining said plurality of cove panels together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface.

26. The method according to claim 25, wherein:

said cove panels are joined in situ.

27. The method according to claim 24, wherein:

at least one of said cove panels is an inside corner cove panel.

28. The method according to claim 24, wherein:

at least one of said cove panels is an outside corner cove panel.

29. The method according to claim 24, wherein:

said plurality of cove panels are joined via an adhesive.

30. A seamless floor-to-wall transition assembly kit, comprising:

a plurality of cove panels which are configured and dimensioned to overlie a joint between a floor and a base of a wall, each comprising a generally upright, upper leg having an upper free end and a lower end, and a generally horizontal, lower leg having an inner end joined to said lower end of said upper leg and an outer free end, said upper leg having an inner surface which is adapted to abut at least a portion of the wall, and said lower leg having a lower surface which is adapted to abut a portion of the floor generally adjacent to the base of the wall, said upper and lower legs each having an outer surface which merge together along a curved outer surface portion to collectively form a seamless exterior surface generally extending from said upper free end of said upper leg to said outer free end of said lower leg, wherein said cove panels are adapted to be joined together, such that said exterior surfaces of each of said cove panels collectively form a substantially seamless surface;

at least one floor covering material which is curable from an initially flowable state to a cured state and sufficient to form a coating to cover at least a portion of the floor adjacent to said cove panels such that, when in its cured state, said at least one floor covering material defines a lateral edge portion which abuts said outer free end of said lower legs and a top surface portion having a height which is generally equal to the height of said outer free ends of said lower legs, to provide a substantially smooth transition from said top surface portion of said at least one floor covering material to said free ends of said lower legs of said cove panels; and

at least one topcoat material which is curable from an initially flowable state to a cured state, and which is sufficient to form a continuous coating to overlie said at least one floor covering material and at least a portion of said exterior surfaces of said cove panels, to provide a seamless transition between said at least one floor covering material and said cove panels.