ARCHITECTUARL MOLDING SYSTEM AND METHOD

Abstract

A fully integrated system of accessible architectural molding which eliminates the need to tape and finish drywall. The system of components relies on a mechanical friction fit assembly that allow for easy installation and removal for future renovations or access to the chase areas of a wall.

Description

BACKGROUND OF THE INVENTION

The present invention relates to architectural molding, and more particularly, to architectural moldings placed between adjoining sections of drywall.

Typical drywall installations generate significant amounts of dust and debris when sealing the joints between adjoining sections of drywall. A gypsum joint compound, or “mud”, is typically applied to the gaps between adjoining drywall sections. Many times, a tape is applied to help span the gap and provide a surface for the mud compound.

Once the joint compound has dried, is then sanded to provide a seamless wall surface. However, the process of finishing drywall seams represents a substantial portion of the labor and materials associated with typical drywall installation and repairs. Moreover, the released gypsum particulates from the sanding present a health hazard to the workers.

Some architectural molding systems are available in the art, however, they still contemplate the use of joint compound or sealers. Once installed, none provide accessibility to the area beneath the molding without the subsequent removal of the joint compounds and sealers. Moreover, the limited systems available do not eliminate the need to tape and finish at least a portion of the drywall.

As can be seen, there is a need for a system of components that relies on a mechanical friction fit assembly for easy installation and removal of architectural moldings in the event of future renovation projects or to provide access to the cased areas for other repairs.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an architectural molding assembly is provided for application to a wall surface of a room. The architectural molding assembly includes: an elongate bracket having a plurality of channels formed in a wall facing surface of the elongate bracket, an upper edge surface spaced apart from the wall facing surface, a lower edge surface extending from a room facing surface of the elongate bracket having an upturned portion and an inwardly turned lip extending from an end of the upturned portion, the inwardly turned lip oriented to face the room facing surface, the lower edge surface and upturned portion defining a lower channel along a lower portion of the elongate bracket; and a molding adapted to substantially enclose the bracket member, the molding having an arm extending downwardly from a top portion of the molding, the arm and a wall facing surface of the molding defining a top channel, a latch extending downwardly from a bottom edge surface of the molding, wherein the upper edge surface is adapted to be received in the top channel and the latch is adapted to be received in the lower channel. In a preferred embodiment, the latch is adapted to engage with the inwardly turned lip in a snap fit attachment. The plurality of channels, the upper edge surface and the lower channel may be formed along the longitudinal length of the molding. Similarly, the top channel and the latch may be formed along the longitudinal length of the molding.

In other embodiments, a toe molding arm extends from a room facing surface of the molding and descends downwardly to define a toe molding channel between the toe molding arm and the latch. The assembly may also include a spacer adapted to be received between the room facing surface of the bracket and the wall facing surface of the molding. A ledge may be formed to extend from a top portion of the wall facing surface of the molding, and the ledge adapted to receive a top edge surface of the spacer. The elongate bracket and the molding are preferably formed from an extruded material.

Other aspects of the invention include a method of removably applying an architectural molding to a wall surface of a room. The method includes: 1) providing an elongate bracket having a plurality of channels formed in a wall facing surface of the elongate bracket, an upper edge surface spaced apart from the wall facing surface, a lower edge surface extending from a room facing surface of the elongate bracket having an upturned portion and an inwardly turned lip extending from an end of the upturned portion, the inwardly turned lip oriented to face the room facing surface, the lower edge surface and upturned portion defining a lower channel along a lower portion of the elongate bracket; 2) attaching the elongate bracket to a wall surface with a fastener; 3) providing a molding adapted to substantially enclose the bracket member, the molding having an arm extending downwardly from a top portion of the molding, the arm and a wall facing surface of the molding defining a top channel, a latch extending downwardly from a bottom edge surface of the molding, and 4) attaching the molding to the bracket, wherein the upper edge surface is received in the top channel and the latch is received in the lower channel. The method may also include the steps of releasing the latch from the lower channel; and removing the upper edge surface from the top channel.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. A illustrates architectural moldings of the present invention applied to finish a room.

FIG. B is an enlarged detail of an inside corner capital and crown molding.

FIG. C is an enlarged detail of an inside corner floor base pedestal and corner.

FIG. D is an enlarged detail of a floor base and wall molding.

FIG. 1A is cross sectional view of a floor base and bracket.

FIG. 1B is a view of a floor base and bracket.

FIG. 2A is a cross sectional view of a wall molding and bracket

FIG. 2B is a perspective view of a wall molding and bracket

FIG. 3A is a view of an inside corner floor base pedestal.

FIG. 3B is a perspective view of an inside corner floor base pedestal.

FIG. 4A is a cross sectional view of an inside corner capital.

FIG. 4B is a perspective view of an inside corner capital.

FIG. 5A is a cross sectional view of a ceiling beam and bracket.

FIG. 5B is a perspective view of a ceiling beam and bracket

FIG. 6A is a cross sectional view of an inside vertical corner molding.

FIG. 6B is a perspective view of an inside vertical corner molding.

FIG. 7A is a cross sectional view of a crown molding and bracket.

FIG. 7B is a perspective view of a crown molding and bracket.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a system for finishing the walls of a room without the need for drywall joint compound. The components of the system generally include a bracket and a molding cover. The bracket is applied along a seam between one or more adjacent wall, ceiling, and floor members. The molding cover is configured for a snap fit connection to the bracket member to provide a desired architectural finish to the seams within the room. The moldings and brackets are preferably formed by an extrusion of any suitable material. The moldings may prefer

As best seen in reference to FIG. 1, a system and method finishing a room with an architectural molding is illustrated. The system of architectural moldings of the present invention permit the finishing of drywall panels without the need for applying or sanding a joint compound. The architectural moldings may include a floor base molding assembly 30 that is applied along a seam between a wall and a floor of a room or structure, as seen in the detail view of FIG. D. A wall molding assembly 40 that may be applied along a seam between adjacent wall panels, such as drywall panels is also shown in reference to FIG. D. As seen in reference to FIG. C, an inside corner flor base pedestal 50 is intended to be applied to an inside corner in a space between the ends of adjacent floor base moldings 30. As seen in reference to FIG. B, an inside corner capital 60 is intended to be applied to an inside corner between the ends of adjacent crown molding assemblies 90 applied along the seam between the wall panel and a ceiling panel of the room. When needed, a ceiling beam assembly 70 is provided for covering the seams between adjoining ceiling panel members. An inside vertical corner molding assembly 80 may be applied to an inside corner seam between adjoining walls.

In reference to FIGS. 1A and 1B, the floor base assembly includes an interlocking pair of elongate members including a floor base bracket member 31 and a floor base molding 30. The floor base bracket member 31 is defined with a plurality of channels to provide added strength along the length of the bracket member 31, and provide for mounting the components of the floor base assembly 30 to the bracket 31. An upper edge surface of the floor base bracket 31 is spaced away from a wall mounting surface of the bracket. A lower edge surface of the bracket 31 is formed with and upturned wall facing lip 36 extending along the longitudinal length of the bracket 31.

The floor base bracket member 31 has a plurality of holes 37 disposed in a spaced apart relation in a wall facing channel face formed along a longitudinal length of the floor bracket member 31. The holes 37 receive a fastener, such as a screw, nail, or the like, to secure the bracket assembly to the structural members along the base of the wall.

A floor base spacer 32 may be secured to the floor base bracket member 31 by a plurality of tabs, or pins 34 extending from a wall facing surface of the spacer 32. The tabs 34 are received through a plurality of holes (not shown) that are defined in a spaced apart relation along a room facing channel face of the bracket 31. The tabs 34 secure the floor base spacer 32 to the floor base bracket member 31. The floor base spacer 32 may include a plurality of grooves defined in a room facing surface of the spacer. The grooves form a plurality of extensions that are adapted for shock absorption for items that may strike the base molding assembly 30.

The floor base molding 30 may be formed so as to cover and substantially enclose the bracket 31. The top edge of the floor base molding 30 is provided with a finger 38 extending from a wall facing surface of the molding 30. The finger 38 extends so as to be positioned adjacent or in abutment with the wall surface. An arm 33 runs along the longitudinal of the base molding 30 subjacent to the finger 38. The arm 33 defines a channel along an interior surface of the base molding 30 and is adapted to receive the upper edge surface of the floor base bracket 31 so as to retain the upper portion of the base molding with the bracket 31.

A lower edge surface of the base molding 30 is defined with a latch 35 with a room facing protrusion extending from the latch 35. The protrusion is adapted to engage with the wall facing lip 36 of the bracket 31 to engage the base molding 30 in a snap-fit manner. A toe molding arm extends from a room facing surface of the molding 30 to define a toe molding along the longitudinal length of the base molding 30. The toe molding arm is shaped to conceal the wall facing lip 36 with and end thereof positioned adjacent to the floor.

The base molding 30 may also have a ledge formed at an upper portion of thereof that extends from the wall facing surface of the molding 30. The ledge is adapted to rest upon a top room facing edge of the spacer 32 and the face of the spacer may be positioned against the wall facing surface on the interior of the molding 30.

As seen in reference to FIGS. 2A and 2B, a wall molding 40 and bracket 43 are provided for covering the gaps between adjacent wall boards mounted in parallel, such as along the span of a wall. The wall molding bracket 43 has a slightly tapered wall facing surface that is designed to conform to the tapered edge portions extending along the longitudinal length of a conventional gypsum wall board. The wall molding bracket 43 has upturned ends 46 formed along the lateral sides thereof. The molding 40 has a substantially flat room facing surface with and a substantially flat side surfaces 41 and a channel defined in an interior surface of the side surfaces 41 to provide structural strength. A ridge 42 is formed and extends along a midline of the wall facing surface of the molding 40. A pair of opposed inwardly facing latch fingers 44 are formed along an intermediate line of the wall facing surface of the wall molding 40. The latch fingers 44 define a pair of channels oriented towards the centerline of the molding 40. The upturned ends 46 of the bracket are adapted to be received by the latch fingers 44 to secure the wall molding 40 to the bracket 41. The ridge 42 is oriented to impart a flexing moment to the molding 40 so that the latch fingers 44 maintain the molding 40 in a snug fitting arrangement with the bracket 41. A plurality of holes (not shown) are disposed in a spaced apart relation along the length of the wall bracket 41 to receive a fastener, such as a screw or nail there through to secure the bracket to a structural member in the wall.

As seen in reference to FIGS. 3A and 3B, the inside corner base pedestal molding 50 is depicted with an inside corner base support 55. The inside corner base pedestal 50 is formed to provide continuity of the floor base moldings 30. The corner base support 55 is installed in a corner of wall structure adjacent to the floor. The corner base support has a plurality of ribs 54 to provide structural support. A plurality of apertures 53 may be defined along a face of the support 55 for engagement with cooperating fingers defined on an interior, wall facing surface of the molding 51.

As seen in reference to FIGS. 4A and 4B, an inside corner capital molding 60 is provided for a corner of a room between adjoining, perpendicular wall surfaces. The inside corner capital molding is adapted for snap fitting with an inside corner bracket 83 that is also utilized with an inside vertical corner molding. An interior wall facing surface of the corner capital molding 60 has a pair of attachment fingers 67 adapted for snap fitting engagement with a pair of inwardly facing hoked ends 65 of the bracket 83.

As seen in reference to FIGS. 5A and 5B, a ceiling beam molding 70 and ceiling beam bracket 73 is provided as an option to utilizing the wall molding 40 of FIGS. 2A and 2B. The beam molding 70 has a greater depth than the wall molding 40. The beam molding 70 may have a channel 71 defined in a room facing surface of the molding 70. On an interior surface of the molding a pair of latch fingers 74 are formed along the longitudinal length of the molding 70. Like the wall molding bracket 43, the ceiling beam bracket 73 has a pair of upturned arms 77 with a slightly hooked portion 75 defined along the longitudinal length of the bracket 73. The latch fingers 74 have protrusions adapted to engage with the hooked portion 75 of the upturned arms 77 to secure the beam molding to the bracket 73. The bracket 73 is provided with a plurality of spaced apart holes 76 to receive a fastener, such as a screw or a nail to secure the bracket 73 to a ceiling structural member. The beam molding 70 may define a cavity 72.

As seen in reference to FIGS. 6A and 6B an inside corner vertical molding assembly includes an inside corner molding 80 and an inside corner molding bracket 83. The molding 80 has lateral side flanges 81 and 82 defined at the ends of an arcuate mid portion to give the appearance of a conventional corner molding. The arcuate mid portion may be either concave or convex. A pair of latching fingers 85 having protrusions on an outer lateral surface of the latching fingers 85 are defined along a longitudinal length of the molding 80. The bracket 83 is formed with substantially perpendicular sidewalls 83 extending from a corner engaging midsection. The corner bracket 83 has bent arm portions 84 and opposed hook portions 86 defined along the longitudinal length of the bracket. The opposed hook portions 86 are adapted to engage with the protrusions of the latching fingers 85 so that the molding may be snap fit to the bracket 83. When attached to the bracket 83 the molding 80 and bracket define an interior cavity 87.

As seen in reference to FIGS. 7A and 7B a crown molding assembly is provided having a crown molding 90 and a crown molding bracket 93. The crown molding 90 has lateral side flanges 91 and 92 defined at the ends of an arcuate mid portion to give the appearance of a conventional crown molding. The arcuate mid portion may be either concave or convex. A pair of latching fingers 96 having protrusions on an outer lateral surface of the latching fingers 96 are defined along a longitudinal length of the crown molding 90. The bracket 93 is formed with substantially perpendicular sidewalls extending from a corner engaging midsection. The crown molding bracket 93 has bent arm portions 95 and opposed hook portions 94 defined along the longitudinal length of the bracket 93. The opposed hook portions 94 are adapted to engage with the protrusions of the latching fingers 96 so that the crown molding may be snap fit to the crown molding bracket 93. When attached to the bracket 93 the crown molding 90 and bracket define an interior cavity 97 within the assembly.

As indicated, the architectural molding system of the present invention provides for a complete fitting to a room that may be applied to finish the seams between adjoining drywall panels without the use of a joint compound and the associated particulate hazards. According to the system of the present invention, the wall surfaces may also be treated, such as with paint, wall paper, or other treatments before architectural members of the present invention are installed. This will protect the moldings from being marred with paint or paste drippings.

To install the system, the room may first be fitted with the attachment brackets designed to the particular part of the room. The length of the brackets are cut to accommodate the respective corner components, whether a floor base pedestal or a corner capital and their associated supports. The brackets are secured to the structural members of the room with a fastener, such as a screw or a nail. Once the respective brackets have been installed, the associated moldings may be cut to length and snap fit to their corresponding brackets.

In the event that the room needs to be redecorated, the moldings may be removed from the brackets. The walls may then be retreated while again protecting the moldings from being damaged or marred by spillage or drippings. Once the wall treatment has been applied the moldings may be returned to the brackets. Similarly, if the interior of the walls need to be accessed for plumbing, ventilation, or wiring, the moldings and brackets may be removed and reutilized. The wall panels may be removed without significant destruction or demolition. In like manner, should a molding become damaged, particularly for the floor base moldings, it may be readily replaced without the need for carpentry and painting.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. An architectural molding assembly for application to a wall surface of a room comprising: an elongate bracket having a plurality of channels formed in a wall facing surface of the elongate bracket, an upper edge surface spaced apart from the wall facing surface, a lower edge surface extending from a room facing surface of the elongate bracket having an upturned portion and an inwardly turned lip extending from an end of the upturned portion, the inwardly turned lip oriented to face the room facing surface, the lower edge surface and upturned portion defining a lower channel along a lower portion of the elongate bracket;a molding adapted to substantially enclose the bracket member, the molding having an arm extending downwardly from a top portion of the molding, the arm and a wall facing surface of the molding defining a top channel, a latch extending downwardly from a bottom edge surface of the molding, wherein the upper edge surface is adapted to be received in the top channel and the latch is adapted to be received in the lower channel.

2. The assembly of claim 1, wherein the latch is adapted to engage with the inwardly turned lip in a snap fit attachment.

3. The assembly of claim 2, wherein the plurality of channels, the upper edge surface and the lower channel are formed along the longitudinal length of the molding.

4. The assembly of claim 2, the top channel and the latch are formed along the longitudinal length of the molding.

5. The assembly of claim 2, further comprising: a toe molding arm extending from a room facing surface of the molding and descending downwardly to define a toe molding channel between the toe molding arm and the latch.

6. The assembly of claim 2, further comprising: a spacer adapted to be received between the room facing surface of the bracket and the wall facing surface of the molding.

7. The assembly of claim 6, wherein the molding further comprises: a ledge extending from a top portion of the wall facing surface of the molding, the ledge adapted to receive a top edge surface of the spacer.

8. The assembly of claim 2, wherein the elongate bracket and the molding are formed from an extruded material.

9. A method of removably applying an architectural molding to a wall surface of a room comprising: providing an elongate bracket having a plurality of channels formed in a wall facing surface of the elongate bracket, an upper edge surface spaced apart from the wall facing surface, a lower edge surface extending from a room facing surface of the elongate bracket having an upturned portion and an inwardly turned lip extending from an end of the upturned portion, the inwardly turned lip oriented to face the room facing surface, the lower edge surface and upturned portion defining a lower channel along a lower portion of the elongate bracket;attaching the elongate bracket to a wall surface with a fastener;providing a molding adapted to substantially enclose the bracket member, the molding having an arm extending downwardly from a top portion of the molding, the arm and a wall facing surface of the molding defining a top channel, a latch extending downwardly from a bottom edge surface of the molding, attaching the molding to the bracket, wherein the upper edge surface is received in the top channel and the latch is received in the lower channel.

10. The method of claim 9, further comprising: releasing the latch from the lower channel; andremoving the upper edge surface from the top channel.