METHODS AND SYSTEMS FOR FLOORING AND SUBSTRATE STRUCTURES

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/684,057, filed Aug. 16, 2024, which is incorporated by reference in its entirety for all purposes.

FIELD

Embodiments of the present disclosure relate to flooring and substrate structures and methods of forming the same. In certain embodiments, cast or precast flooring members are provided that are contemplated for use with and are well suited for provision within a prefabricated building unit.

BACKGROUND

Various systems and devices exist for flooring and substrate structures. Such systems include, for example, poured flooring slabs, liners and basins for bathrooms and showers (for example).

Existing systems related to forming building structures include, for example, U.S. Pat. No. 8,365,496 to Saebi, which is hereby incorporated by reference in its entirety. Saebi discloses a method for forming a building structure including, for example, the provision of Glass Fiber Reinforced Concrete (“GFRC”) and bonding agents. Certain features, materials, methods and systems of Saebi are contemplated for use with embodiments of the present disclosure. Saebi and other references, however, fail to disclose various features, methods and aspects of the embodiments of the present disclosure including, but not limited to, floor and substrate systems and methods and molds of providing the same. Known systems, methods and devices, fail to disclose various aspects and benefits of the present disclosure as shown and described herein.

SUMMARY

There has been a long-felt and unmet need to provide systems, devices and methods for providing a flooring or substrate member for use in, for example, prefabricated building structures. There has further been a long-felt and unmet need to provide such a member that comprises special high-performance material (e.g., GFRC), drainage features, and/or enhanced sealing or waterproofing features as shown and described herein.

In some embodiments, flooring members are provided that comprise GFRC. It will be recognized, however, that inventive aspects and features of the present disclosure are not limited to the particular material(s) provided within the disclosed structures. It is contemplated, for example, that inventive and patentable features are provided herein that are related to a method of forming a flooring member, incorporating a drain or drainage system into a floor member, and waterproofing a flooring member. It is also contemplated that flooring members of the present disclosure may comprise structurally or functionally similar materials to GFRC in addition to or in lieu of GFRC. Such materials are contemplated as comprising various materials as will be recognized by one of ordinary skill in the art (e.g. fiber reinforced concrete, natural fiber composites, ultra-high-performance concrete, cast stone, and other materials).

In some embodiments, floor members comprise molded structures formed from a mold and wherein at least one member, component, or element is tailored to a specific project requirement including, for example, application in prefabricated modular building units (hereafter “pods”) such as bathroom pods. In various embodiments, floor members of the present disclosure comprise incorporated drains and/or drainage features, wherein the drains and/or drainage features are formed in the molding or casting process such that the features are integral with the finished product and do not need to be formed or retrofitted (e.g., drilled or machined out) in the finished product. While the drainage feature, containing the drain hole, may be referred to as a trench or a trough in the present disclosure, it is contemplated and understood that alternative (or additional) types or styles of drains and/or drainage features may be incorporated or combined in various embodiments discussed herein, which may include for example point (or center), linear, shower, trip lever, pop-up, flip, push-and-pull, lift-and-turn, toe touch, chain, plug, or grid drains as well as combinations thereof. In addition, the shape and slope(s) of the floor members of the present disclosure may vary based on the drainage feature provided. For example, the floor member may be sloped in one, two, or more directions to accommodate an elongate trench drain, or may comprise a generally concave shape to drain fluid(s) to a point or center drain feature. Furthermore, in various embodiments, floor members of the present disclosure are contemplated as comprising apertures, recesses, blockouts, and similar structural elements (or absences) into which additional components, parts, or articles may be situated before, during, and/or after installation, such as piping or tubing. Inclusion of at least one of these features, elements, or components allows for increased output and quality of floor members having fewer defects or issues relating to installation, seals, waterproofing, and gaps such as those within which moisture may gather and/or remain after use or cleaning. Additionally, incorporated members, components, or elements typically result in a faster, easier, and/or simpler installation process due to the singular nature of the product while incorporated recesses or apertures typically result in similarly quicker, easier, and/or simpler connectivity of fixtures during installation. Further, depending on the space and parameters involved, the formation of a singular floor member having at least one of the presently disclosed incorporated members, components, features, and/or elements allows for at least partial customization of design, dimensionality, and location of the floor member and components, elements thereof.

In various embodiments, floor members of the present disclosure comprise at least one of a perimeter, a flange, a lip, and a curb (typically sized, thinned, or thickened) extending around at least a portion of the outer perimeter of the member(s). The perimeter feature (e.g., flange, curb, or lip) is contemplated as providing water containment benefits as well as providing for the application of an resinous flooring layer to the final cast floor prior to pod construction. The perimeter is also contemplated as providing a frame within which at least one floor panel may be situated. Accordingly, the resinous layer can be applied outside of (e.g., prior to) a production/construction process of the pod thereby reducing time required for pod construction on a pod production line and increasing manufacturing efficiencies. The features and methods presently disclosed herein further increase quality by contemplating and providing for full access to a finished area of a floor space (e.g., top, sides, bottom) prior to the provision of the flooring member into a larger unit (e.g., pod) into which the flooring member is to be incorporated. For example, quality in the form of enhanced water proofing is thus provided from at least one of the resinous layer(s), the absence of extraneous seams or gaps, and/or additional features disclosed herein.

Embodiments of the present disclosure are well suited for and are adapted for use with flooring members for prefabricated units, such as bathroom pods. It will be recognized, however, that no limitation is provided with respect to a specific intended use or final positioning of the flooring members and features of the present disclosure. For example, flooring members of the present disclosure (or portions/features thereof) may be provided as stand-alone members to be delivered as finished (or nearly finished) to an installation site, as a stand-alone feature of a larger member or unit, and/or in a setting that does not employ pods and/or pre-fabrication as part of the construction. Additionally, flooring members (provided in connection with pods or not) are contemplated for use with various applications and are not limited to use with bathrooms unless specifically indicated. For example, flooring members of the present disclosure are contemplated for use in pools, hot tubs, saunas, water parks and individual water park features, entryways, garages, mud rooms, car wash facilities, laundry rooms, etc. It should also be recognized that methods, systems, and/or members of the present disclosure are not limited to rooms or environments that are expected to comprise water or moisture. Pre-formed flooring members of the present disclosure are contemplated as being provided in various settings, only some of which being mentioned herein.

In one embodiment, a substrate member is provided that comprises at least one of a perimeter (or at least one perimeter feature) having a predetermined shape, a first side and an opposing second side, an upstanding lip portion extending vertically above the first side and extending at least partially along the perimeter, and a drain extending through at least one of the first side and the second side. At least a portion of at least one of the first side and second side is sloped such that liquid is operable to flow under gravity away from the perimeter (or perimeter feature) toward the drain, and the substrate member comprises at least one of a poured and a cast member such that the member is substantially devoid of connected components. Alternatively, or additionally, the at least one perimeter (or at least one perimeter feature) has a predetermined shape and a recessed portion configured to receive and retain a flooring member, or a panel thereof, wherein the perimeter is level while the flooring member/panel is sloped.

In certain embodiments, a substrate member is provided that is unlevel, tapered, or sloped, such that liquid is directed towards at least one component, feature, or element incorporated (or generally present) therein (e.g., a drain). It is contemplated that a substrate or flooring member is provided having at least partially sloped floors wherein liquid advantageously flows towards a surface drain, or other drainage feature/element (e.g., trough or trench, alternate drain or combination of drain types). It is further contemplated that the complementary sloping, tapering, or non-level aspect of the present disclosure is incorporated in the mold thereby forming the advantageous flow feature in the substrate member during the casting. It is also contemplated that any such sloping, tapering, or non-level aspects of the present disclosure can be added to a non-sloped or flat flooring member after molding, or that additional sloping or tapering may be added to the flooring member after molding.

In one embodiment, a substrate or flooring member is provided having a perimeter feature, such as a lip, within a range of approximately 2 inches to approximately 10 inches in height, as measured from the underside of the substrate or flooring member but is further understood to be customizable to specific dimensions and parameters of a given space. It is also contemplated, in at least one embodiment, that the perimeter feature has a width within a range of approximately 2 inches to approximately 4.5 inches, depending at least upon the dimensionality of the space available and the inclusion of any apertures, recesses, and/or blockouts necessary for further installation. At least a portion of the lip is contemplated as incorporating a cove radius within a range of approximately 0.5 inches to approximately 1.25 inches but is further understood to be customizable to specific dimensions and parameters of a given space. It is contemplated that the cove radius is included within the mold or cast and is therefore integral to at least one embodiment of the present disclosure. The cove radius, or radius of curvature spanning the intersection of the lip with the substrate, flooring member, or a floor panel thereof improves the capability of the present disclosure to retain and direct fluid flow as well as minimize the accumulation of dust, dirt, and debris which tends to gather in corners. In at least one embodiment, a lip having a right angle at the intersection with the flooring member, or a panel thereof, is avoided due to the higher likelihood of defects, cracks, occlusions, or the like forming and/or propagating.

In one embodiment, it is further contemplated that the perimeter feature, such as a lip, may incorporate a recess, step, or ledge portion (or structural equivalent thereto) whereupon another component, feature, part, or element of the present disclosure may rest, attach, or affix. For example, a step, ledge, or recess of a lip, such as along its top face, may allow for the incorporation or installation of a wall or panel element wherein the bottom of said wall or panel element rests or is affixed thereupon. At least a portion of the presently disclosed step, ledge, or recess of the lip is contemplated as being within a range of approximately 0.25 inches to approximately 1.25 inches but is further understood to be customizable to specific dimensions and parameters of a given space. Additionally, it is contemplated that a width of the step (dependent upon any walls, panels, finishes, or layers added to the present disclosure) is within a range of approximately 0.5 inches to approximately 1.0 inch.

In one embodiment, it is contemplated that the present disclosure incorporates an elongated drainage feature, such as a trench or trough, into the cast or mold process, such that the aforementioned slope will direct liquid toward and into said feature. It is understood that dimensions of this feature may vary depending on, at least, the available space and dimensionality substrate/flooring member. However, it is contemplated that in one embodiment the width of the drainage feature is within a range of approximately 2.5 inches to approximately 4.5 inches, while the length of the drainage feature is between approximately 36 inches and approximately 84 inches. It is further understood that a drainage cover or protective element, such as a grate, is installable overtop and/or affixable to the drainage feature to prevent non-liquid from entering the drainage system and causing damage, blockage, or disruption thereto.

It is contemplated that in an embodiment of the present disclosure the height of a cove, as measured from the substrate or flooring member base to the bottom of the step or ledge portion is within the range of approximately 3.5 inches to approximately 6.5 inches. It is understood that this range is based on typical casting, molding, and substrate/flooring contemplated herein, but could vary based on customization of a presently disclosed member to a specific set of dimensions and parameters of a given space. It is further understood that this cove, or rounded base of the perimeter (or of a perimeter feature) where it meets the floor panel, has a radius of curvature that improves the efficiency and effectiveness of the flooring member to direct fluid flow and to prevent dirt/debris from accumulating, while also lessening the capability for defects (i.e., cracks) to form and/or propagate. It is further contemplated that the cove can have a radius between approximately 0.5 inches and approximately 1.25 inches. It is understood that, depending upon the requirements of the substrate member and the space available, the cove can embody at least one cant cover, adhesive cove, painted-on resinous cove, or other types of coves known in the art, as well as combinations thereof and/or augmented versions thereof, such as a cant cove having rounded ends that smoothly transition into a wall, perimeter, lip, or floor portion.

It is further contemplated that the substrate or flooring member includes gaps in perimeter features discussed herein. In one embodiment, it is contemplated that at least one portion of a wall, perimeter, or perimeter feature includes a gap, aperture, recess, or blockout to accommodate any tubing, piping, or general elements/parts required for a fixture or appliance to be installed, attached, or affixed within the space. For example, a toilet requires piping, tubing, and/or plumbing as well as at least some empty space around the installation area within which a professional may operate, therefore it is understood that an element may stop before and restart after this gap, aperture, recess, or blockout area to account for this requisite space. It is understood that additional components, parts, or articles may need to be situated before, during, and/or after installation of the substrate or flooring member to accommodate any number of fixtures/appliances. In one embodiment, it is contemplated that at least one portion of a wall, perimeter, or perimeter feature includes a gap to accommodate the entry and exit of a user.

In one embodiment of the present disclosure, it is contemplated that additional features not discussed herein, but commonplace in rooms or environments contemplated herein, are capable of inclusion in the casting and/or molding process, or are capable of installation within apertures, recesses, blockouts, and/or similar structural elements (or absences) of the present disclosure. Examples of an additional feature include, but are not limited to, seats, steps, and receptacles for appliances, fixtures, and/or personal effects. In one embodiment of the present disclosure, at least one protective element may be disposed in, through, or around any apertures, recesses, blockouts, and/or similar structural elements (or absences) present within the fabricated unit or elements thereof.

It is understood that the figures discussed herein are not limited to all embodiments of the present disclosure but merely indicate the possible structural nature and orientations available to the substrate or flooring member, wherein alternatively sized, shaped, oriented, or dimensioned members (and components/elements thereof) are contemplated by the present disclosure.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. However, it is understood that methods and materials either similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In addition, the materials, methods, and examples presently disclosed herein are illustrative only and are not intended to be necessarily limiting unless otherwise indicated or claimed.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

The use of “substantially” in the present disclosure, when referring to a measurable quantity (e.g., a width or other distance) and used for purposes of comparison, is intended to mean within 5% of the comparative quantity. The terms “substantially similar to,” “substantially the same as,” and “substantially equal to,” as used herein, should be interpreted as if explicitly reciting and encompassing the special case in which the items of comparison are “similar to,” “the same as” and “equal to,” respectively. The term “parallel” means two objects are oriented at an angle within plus or minus 0° to 5° unless otherwise indicated. Similarly, the term “perpendicular” means two objects are oriented at angle of from 85° to 95° unless otherwise indicated.

As used herein, unless otherwise specified, the terms “about,” “approximately,” etc., when used in relation to numerical limitations or ranges, mean that the recited limitation or range may vary by up to 10%. By way of non-limiting example, “about 750” can mean as little as 675 or as much as 825, or any value therebetween. When used in relation to ratios or relationships between two or more numerical limitations or ranges, the terms “about,” “approximately,” etc. mean that each of the limitations or ranges may vary by up to 10%; by way of non-limiting example, a statement that two quantities are “approximately equal” can mean that a ratio between the two quantities is as little as 0.9:1.1 or as much as 1.1:0.9 (or any value therebetween), and a statement that a four-way ratio is “about 5:3:1:1” can mean that the first number in the ratio can be any value of at least 4.5 and no more than 5.5, the second number in the ratio can be any value of at least 2.7 and no more than 3.3, and so on.

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein. The use of “engaged with” and variations thereof herein is meant to encompass any direct or indirect connections between components.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. § 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary, brief description of the drawings, detailed description, abstract, and claims themselves.

All external references are hereby incorporated by reference in their entirety whether explicitly stated or not.

These and other advantages will be apparent from the disclosure contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. Moreover, references made herein to “the present disclosure,” or aspects thereof should be understood to mean certain embodiments of the present disclosure and should not necessarily be construed as limiting all embodiments to a particular description. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

It is to be appreciated that any embodiment, feature, or aspect described herein can be claimed in combination with any other embodiment(s), feature(s), or aspect(s) as described herein, regardless of whether the features or aspects come from the same described embodiment. For example, any one or more aspects described herein can be combined with any other one or more aspects described herein. In addition, any one or more features described herein can be combined with any other one or more features described herein. Further, any one or more embodiments described herein can be combined with any other one or more embodiments described herein.

DESCRIPTION OF THE DRAWINGS

Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made to illustrate the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.

FIG. 1 is a perspective view of a flooring member according to one embodiment of the present disclosure.

FIG. 2 is a top plan view of the flooring member of the embodiment of FIG. 1.

FIG. 3A is a top plan view of a flooring member according to one embodiment of the present disclosure.

FIG. 3B is a cross-sectional elevation view taken at line 3B-3B of FIG. 3A.

FIG. 3C is a cross-sectional elevation view taken at line 3C-3C of FIG. 3A.

FIG. 3D is an alternative cross-sectional elevation view taken at line 3C-3C of FIG. 3A according to one embodiment of the present disclosure.

FIG. 4 is a perspective view of a flooring member according to one embodiment of the present disclosure.

FIG. 5 is a perspective view of a flooring member according to one embodiment of the present disclosure.

FIG. 6A is a perspective view of a flooring member according to one embodiment of the present disclosure.

FIG. 6B is an isometric view of the flooring member of FIG. 6A.

FIG. 7 a cross-sectional elevation view of a flooring member according to one embodiment of the present disclosure.

FIG. 8 is a cross-sectional elevation view of a flooring member according to one embodiment of the present disclosure.

FIG. 9A is a front elevation view of a flooring member lip according to one embodiment of the present disclosure.

FIG. 9B is a front elevation view of a flooring member lip according to one embodiment of the present disclosure.

The drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

Reference to an element by the indefinite article “a” or “an” does not exclude the possibility that more than one element is present, unless the context clearly requires that there be one and only one element. The indefinite article “a” or “an” thus usually means “at least one.”

As used herein, “about”, “approximately”, and/or “substantially” means within a statistically meaningful range of a value or values such as a stated concentration, length, molecular weight, pH, sequence identity, time frame, temperature or volume. Such a value or range can be within an order of magnitude, typically within 20%, more typically within 10%, and even more typically within 5% of a given value or range. The allowable variation encompassed by “about”, “approximately”, and/or “substantially” will depend upon the particular system under study, and can be readily appreciated by one of skill in the art.

FIG. 1 is a perspective view of a flooring member 2 according to one embodiment of the present disclosure. As shown, the flooring member 2 comprises a perimeter 4 of a desired shape and size. The perimeter 4 of FIG. 1 is shown as comprising a polygonal shape. Various polygonal shapes are contemplated and no limitation with respect thereto is provided. The member 2 further comprises a lip 6 that extends at least partially around the perimeter 4 of the member 2. The lip 6 comprises an upstanding feature that is operable to contain fluid(s) and/or provide connection point(s) to additional elements (not shown in FIG. 1). A floor panel 8 comprising a surface area is provided generally within the lip 6 that corresponds to a usable or living space and upon which additional features may be provided. At least one floor panel 8 is also contemplated as being provided within a cavity of the member 2. For example, additional flooring materials such as laminates, tiling, etc. and/or fixtures (e.g. sinks, toilets, etc.) including any necessary components there (e.g., conduits, piping, etc.) are contemplated as being provided on, in, or through the surface area. The member 2 further comprises a sump, trough, trench, or general drainage feature 10 to collect liquid(s). A drain hole 12 is provided in the drainage feature 10 that is operable to convey liquids away from the member 2. At least one of the drain hole 12 and drainage feature 10 is contemplated and understood as incorporating at least one drain type or style, as generally known in the art and included herein, or combination(s) thereof. In preferred embodiments, portions of the member 2 are provided with a slope such that fluids drain to the drainage feature 10 and the drain hole 12 under the force of gravity. As further shown in FIG. 1, a gap 14 is provided in the lip 6 to accommodate a door, entryway, or similar feature.

In various embodiments, including that shown in FIG. 1, the flooring members 2 are formed or molded using concrete. In certain embodiments, at least portions of the members 2 comprise GFRC and the member(s) 2 are formed or poured using a mold. It will be recognized, however, that various materials and methods suitable for the structural requirements of a floor member 2 (e.g. a bathroom floor) are contemplated for use with embodiments of the present disclosure.

FIG. 2 is a top plan view of the flooring member 2 according to the embodiment of FIG. 1. As noted, the particular size, shape, and orientation of the member 2 (and its components) of FIGS. 1-2 are provided for illustrated purposes. No limitation is provided with respect to the size, shape, or intended use or placement of the flooring member 2 (or its components) of the present disclosure. In various embodiments, it is contemplated that the member 2, and components thereof, of the present disclosure are provided and sized such that they can be transported and/or shipped with relative ease (e.g. on a flatbed truck or as an installed component of a prefabricated bathroom module or pod). In at least one embodiment, the flooring member 2 is molded to have a cavity present within which flooring panel 8 is operable to be situated.

FIG. 3A is a top plan view of a flooring member 2 according to an embodiment of the present disclosure. FIG. 3B is a cross-sectional elevation view of the member 2 and the lip 6 taken at line 3B-3B of FIG. 3A. As shown, the lip 6 extends upwardly and substantially perpendicularly to the floor panel 8 while a curved radius 26 (or a cove) is disposed about where the lip 6 and floor panel 8 meet and is curved to direct fluid flow toward drain hole 12 situated in the drainage feature 10 and/or minimize the likelihood of dirt, debris, or moisture entering the joint between the lip 6 and the floor panel 8. As shown, the floor panel 8 comprises a thickness of approximately 1.5 inches at its thickest point and may slope to at least one thinner portion thereby supporting liquid flow/drainage and/or liquid containment. In some embodiments, the thickness of the floor panel 8 may remain generally constant, while the floor panel 8 still possesses at least a partial slope to support flow/drainage and/or liquid containment. The lip 6 comprises a height of between approximately 3 inches and 9 inches and preferably of about 6 inches, however, the height, shape, and form of the lip 6 is variable and will depend upon, at least, the available space within a pod or module and/or specific user-desired shape, size, and form of the flooring member 2 and components thereof. In some embodiments, an inner corner 16 disposed between the floor panel 8 and the lip 6 comprises a curved radius (or cove) 26. In some embodiments, the radius 26 comprises a radius of approximately 1.0 inches. The radius is preferably formed in the molding process. Alternatively, however, it is contemplated that the radius is formed later.

FIGS. 3C and 3D are a cross-sectional elevation views of the flooring member of FIG. 3A and taken at line 3C-3C of FIG. 3A according to various embodiments of the present disclosure. Opposing portions of the floor panel 8 on either side of the drainage feature 10 are contemplated as comprising a slope to allow fluid to drain to the drainage feature 10. In some embodiments, the slope comprises a slope of approximately 0.25 inches of vertical drop per horizontal foot. It will be recognized, however, that no limitation with respect to this slope is provided. It is further contemplated that the floor slope need not be constant along a length or width of the floor panel 8, but rather may vary depending upon the overall design, layout, and orientation of the flooring member 2 (and its components) relative to the available space and job-specific preferences.

FIGS. 4-6A are additional perspective views of a flooring member 2 according to an embodiment of the present disclosure. FIG. 6B is an isometric view of the perspective view shown in FIG. 6A. Various features shown and described with respect to FIGS. 1-3 are similarly provided in FIGS. 4-6B. As shown in FIGS. 4-5, but as equally applicable to FIGS. 6A and 6B, the drainage feature 10 is contemplated as being provided with a grate or drain cover 18. The flooring member 2 as shown comprises a monolithic flooring member that is operable to be installed as a flooring member 2 in a pod and/or shipped to a site for installation. The fully formed flooring member 2 of FIGS. 4-5 comprises a unitary construction that is contemplated as being treated (e.g., coated) and wherein access is provided to all sides of the flooring and in contrast with known systems and methods. Additionally, the embodiment shown in FIGS. 6A and 6B comprises an aperture through the lip 6 wherein a fixture or appliance, or a conduit therefor, may be installed. As shown in FIGS. 9A-9B, such an aperture may be partially contained within the lip 6 (as in FIG. 9A) or wholly contained within the lip 6 (as in FIG. 9B).

FIGS. 7-8 are cross-sectional elevation views of a flooring member 2 according to an embodiment of the present disclosure. Both FIGS. 7 and 8 depict the flooring member 2 having a floor panel 8 and a lip 6 connected via a cove 26, wherein the radius of curvature is approximately 1 inch. As discussed herein, cracks and defects tend to propagate from corners of fabricated structures (i.e., right angles) such that employing an intersection between the lip 6 and the floor panel 8 having a radius of curvature 26 will improve the longevity and integrity of the flooring member 2. The inclusion of a radius of curvature 26 will also improve the efficacy of the flooring member's 2 capability to retain fluid and direct flow toward the drainage feature 10 for drainage via the drain hole 12. Additionally depicted in FIGS. 7-8 is the lip 6 having a recessed notch region 18 along an uppermost area of its inward facing portion wherein a wall, tile, panel member, or structural equivalent thereto is capable of being installed. Further depicted in FIG. 7 are two coatings 20 affixed overtop the components of flooring member 2 to assist with and/or improve upon the capability of elements of the flooring member 2 to retain fluid and direct flow to the drainage system including the drainage feature 10 and the drain hole 12. The coatings 20 include waterproof and protective layers of materials, contemplated herein as being an resinous waterproof membrane and an resinous flooring, but understood as being alternatively composed of any material capable of accomplishing the same or substantially similar objective. Also present in FIG. 7, though not claimed herein, are components of the building unrelated to the flooring member 2 or its components. For example, wall materials (i.e., gypsum, drywall, metal studs) illustrate how the member 2 is incorporated into a building where a stud is fastened to the top face 24 of the lip 6 using at least one screw and bracket while layers of gypsum and/or drywall are positioned between the stud and the tile/wall installed atop the notch region 18. Additionally, layers of material which may include waterproof materials, adhesives, sealants, or fabrics are disposed between flooring member 2 and the tile, wall, gypsum, and/or drywall. This should not be understood as limiting the installation of the flooring member 2 within a pod, building, or structure to this design, but merely reflects a single illustrative example of how member 2 can be installed therein.

FIGS. 9A and 9B are front elevation views of a lip 6 of a flooring member 2 according to at least one embodiment of the present disclosure wherein the lip 6 has an aperture 22 therethrough for the running of conduits, pipes, tubes, or the like necessary for the installation and operation of fixtures, appliances, and/or features within the fabricated unit. As depicted in FIG. 9A, it is possible that this aperture 22 extends through the lip 6 including a top face 24 thereof such that it is no longer contiguous, or as depicted in FIG. 9B, it is possible that this aperture 22 extends through the lip 6 in such a way that the top face 24 runs along the lip 6 uninterrupted. Furthermore, as depicted in FIG. 9A, it is possible that the aperture 22 through the lip 6 does not extend through the curved portion 26 extending from the lip 6 to the floor panel 8, while, as depicted in FIG. 9B, it is also possible that the aperture 22 through the lip 6 also causes a disruption in the curved portion 26. As shown in FIG. 9B, a segment of the curved portion 26 is absent, as between the lip 6 and the floor panel 8, within which the aperture 22 having a protective element 28 thereabout is disposed. However, while a segment of the curved portion 26 is absent, the recessed notch 18 discussed above in relation to the lip 6 is still present up until the outer edges 30 of the protective element 28 of the aperture 22.

Flooring members 2 of various embodiments of the present disclosure, including those shown in FIGS. 1-9B comprise one piece or monolithic flooring members that are preferably cast or poured as a single member, thereby eliminating or reducing unions and connections that could present gaps, seams, or other opportunities for leakage and/or moisture retention.

The examples set forth above are provided to give those of ordinary skill in the art a complete disclosure and description of how to make and use the embodiments of the methods for providing and erecting structures and are not intended to limit the scope of what the inventors regard as the scope of the disclosure. Modifications of the above-described modes for carrying out the disclosure can be used by persons of skill in the art and are intended to be within the scope of the following claims.

It is to be understood that the disclosure is not limited to particular methods or systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The use of “including,” “comprising,” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items. Further, it is to be understood that the claims is not necessarily limited to the specific features, components, elements, or steps described herein.

A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims.