Patent Application
20060120799
1. Field of the Invention
The invention relates generally to decorative molding and trim used in building construction and remodeling, both residential and commercial. More particularly, the invention pertains to molding and trim featuring pre-finished molding pieces provided with a hidden fastener system, and pre-formed corner receptacles and couplers for use with molding and trim pieces.
2. Description of the Prior Art
The conventional and still most widely used method of installing decorative trim and molding pieces is to cut, install, and paint or stain finish the pieces in the field. The trim and molding pieces are typically made either from unfinished or primed paint grade material or from unfinished stain grade material. This unfinished material is sent to the building site uncut, for use as window or door trim, as baseboard, as crown molding, or as decorative trim on intermediate portions of walls.
When it comes time to install the trim or molding pieces, the installer measures and cuts the pieces, precisely to fit the dimensions of the particular job site application. Where the molding or trim must pass around a corner, accurate complementary miter cuts must be made, to avoid unsightly gaps in the molding. Similarly, where long, lineal runs of multiple pieces of baseboard or crown molding are made, right angle cuts must be accurate for the same reason. After the various pieces are properly cut to size, nails or screws are installed through the outer face of the pieces, to attach the trim to the door or window frame, or to the supporting wall.
After the installer completes the installation of the trim and molding pieces, a painter is called upon to caulk or fill the abutting joints, fill the nail or screw holes, and then sand the entire exposed surfaces of the pieces to present a smooth finish. Primer and finish coats of paint or stain are subsequently applied to complete the job.
Another less common method for nailing molding pieces into place is blind nailing. To blind nail, a small knife or gouging tool is used to raise a sliver of wood from the molding. The resultant cavity is large enough to hide the head of a finishing nail. The sliver is not entirely detached from the molding. By leaving a small portion of the sliver still attached to the molding, replacement into its natural position is possible. After pulling the sliver to the side, a finishing nail is driven into the cavity securing the molding to the backing board or frame. Then, the sliver is glued back into place, using a piece of masking tape to hold it fast until the glue is set. Finally, the spot is sanded to remove all trace of the sliver re-installation.
The above-described processes for installing and finishing trim and molding are both expensive and time consuming. In addition, these procedures are difficult for the average do-it-yourself home owner to accomplish successfully. The principal difficulties stem from the requirements for accurate field cutting and competent field finishing, of the trim and molding pieces.
The molding system of the present invention contemplates the use of completely or partially pre-finished molding pieces provided with hidden fasteners. The molding system may be used for any type of molding or trim application, for example, windows, doors, baseboards, ceiling crowns, wall decorations, chair rails, window stools, aprons, shelves, hook strips, or cleats. The pre-finished molding pieces may be milled, cut, formed or extruded from a variety of different materials, including wood, plastic, vinyl, and composites.
The fasteners for the molding are hidden by providing at least one elongated kerf or groove, in the outer face of each molding piece. The width of the groove is sufficient to accommodate the head of a nail or a screw fastener. The fasteners are installed in spaced relation within the groove, to extend through the molding and affix it securely to the wall or backing structure. The depth of the groove is such that the heads of the installed fasteners are recessed below the outer face of the molding. The groove is then filled with a strip of thin material or injected caulking, covering the heads of the fasteners therein.
Another feature of the molding system is the pre-formed corner receptacles and couplers for use with pieces of molding or trim. Pre-formed corner receptacles are employed where the molding encounters inside and outside corners. The couplers are used to join two lineal pieces of molding or as decorative accents along a length of the molding.
Receptacles and couplers include end receivers sized and configured to accommodate and cover the end or intermediate portions of a piece of molding. The receivers further include retaining means in the form of an upper lip and a lower trough, configured to surround the upper and lower portions of the molding. The upper lip and the lower trough, acting in concert with the back face of the receptacle or coupler, secure the receptacle or coupler to the molding. In this manner, the retaining means holds the receptacles and couplers in place without the use of fasteners or adhesives. The receptacles and couplers are therefore termed “fastener-less”. Optional lineal ribs may be provided within the recesses, to engage the kerf or groove within the molding and additionally secure the molding therein.
The hidden fastening system and the “fastener-less” pre-formed corner receptacles and couplers disclosed herein, eliminate the above-recited requirements of the prior art installation and finishing method. The hidden fastening system in combination with pre-finished trim and molding pieces, eliminates the additional time, skill, and expense of filling nail or screw holes, and sanding masking, and painting the molding pieces after installation. The “fastener-less” pre-formed corner receptacles and couplers eliminate the additional time, skill, and expense associated with making precise miter and other angle cuts, as well as eliminating filling, sanding, and finishing the joints which are created between exposed abutting pieces. In addition, the pre-formed corner receptacles and couplers may be used advantageously to create and enhance the decorative value of the trim and molding pieces in ways which are difficult and expensive to accomplish with the prior art installation and finishing methods.
These and other objects will be described below in the drawings and the detailed description of the preferred embodiment to follow.
Turning now to the drawings, and in particular to
An important aspect of the present invention is the partial or complete pre-finishing of all molding pieces prior to installation. By this it is meant that paint-grade molding has preferably been sanded, primed, and painted at the place of manufacture. Similarly, for stain-grade molding, pre-finishing means that it has been sanded, stained, and perhaps covered with a protective clear coat at the factory. It is also possible that the present invention could be practiced with something less than complete pre-finishing before installation, yet the major benefits of the invention could still be enjoyed. For example, paint-grade molding could be sanded and primed before installation, leaving final painting after all molding has been installed. Also, stained molding could also be coated with a varnish or other clear coat after installation. In either case, no sanding or other time-consuming preparatory work would be necessary.
While wood is the traditional molding material, other materials are becoming more popular and could be used to advantage in the present instance. Plastic, vinyl, or composite molding would be well adapted for use herein, as paint or stain coloring could be added to the material before it has been injected or cast into the shape of the molding. Thus, such injected or cast molding would have the advantage of being completely pre-finished at the factory, with a minimum of labor and finishing steps.
It is also preferable that the kerfs be strategically located within or adjacent a feature or detail in the molding, both to enhance and to merge the visual appearance of the two. Although molding 12 is a very plain example of decorative molding, it includes one such detail, a curved portion 21 extending along its upper edge. Upper kerf 18 is located adjacent curved portion 21, providing a lineal visual cue which draws further attention to portion 21. Other locations and arrangements for the kerfs and details will be discussed and shown herein.
A first type of fastener, namely, nails 22, are shown in
Yet another fastener, a screw 24, is shown in
The hidden fastener system of the present invention also includes a variety of means for filling the kerf or groove in the outer surface of the molding, and for covering the head of the fastener so it is completely hidden from sight. A first filling means is a resilient cord 27, made from vinyl, plastic, or rubber material. Cord 27 may be solid or hollow, and may also include a plurality of small ribs 28 or protuberances in its outer surface.
A second filling means is caulking 29, or another like material which can be injected in a fluid state, and then become hardened over time. As shown in
A third filling means, shown in
The baseboard molding system 11 disclosed herein may be installed using conventional methods, where separate pieces of molding 12 are joined in abutting relation. This occurs where the lineal pieces are joined in a corner, or where lineal pieces are joined in lineal relation to form a longer piece of molding. In other words, in attaching the molding 12 to the wall, the hidden fastener system 17 is employed. However, where discrete pieces of molding are joined, the prior art method of miter cutting for angled joints and butt cutting for straight line junctures may be used. As part of this process, a bead of caulking compound or a series of dabs of the caulking compound is applied onto one of the abutting surfaces, before assembly of the pieces. As the opposing pieces are pressed together tightly to form the joint, any excess caulking is forced outwardly and wiped off, filling any gaps or voids between the pieces which existed previously.
However, this prior art method of conjoining molding pieces takes a substantial amount of time and skill, as it requires accurate measurements, accurate cutting, and skillful assembly. Another aspect of the present invention simplifies and quickens the assembly of multiple pieces of molding through the use of pre-formed corner receptacles and pre-formed couplers. These receptacles and couplers may be used advantageously with the pre-finished molding and hidden fastener system described above, or the receptacles and couplers may be used with conventionally attached molding, as well.
Corner receptacles are employed where the molding encounters and must pass smoothly around, the inside and outside corners in a building's walls or around the corners of a door or window frame. The corner receptacles may be formed to join molding piece at various angles, ranging from acute angles to obtuse angles. The corner receptacles are designed to be used on both inside and outside corners, to install baseboard, crown molding, chair rails, picture molds, or wainscot. In addition, corner receptacles can be made specifically for either a square corner or a radius corner application.
The couplers, on the other hand, are primarily used to join two lineal pieces of molding and maintain them in lineal relation. However, the couplers may also be slid over and arranged in spaced relation along a piece of molding, to provide decorative accents. Both the corner receptacles and the couplers may be manufactured from wood, plastic, vinyl, or composite materials.
A 90°, outer corner, baseboard receptacle 32 is shown in
An upper rib 41 and a lower rib 42 are provided on the inner walls 43 and 44 of receptacle 32. Ribs 41 and 42 extend or protrude inwardly into recesses 33 and 34. Ribs 41 and 42 are sized and configured to conform to the size and configuration of upper kerf 18 and lower kerf 19, in the outer surface of molding 12. In addition, the axes of ribs 41 and 42 are at vertical heights which respectively align with upper kerf 18 and lower kerf 19, when a piece of molding 12 is inserted into either end of receptacle 32.
Also shown in
The piece of molding 12 which extends between receptacle 32 and receptacle 46 is cut to a length which corresponds to the distance between the outer and inner corners, less ½ of the total horizontal extent of the receivers 34 and 47. This will result in a piece of molding which is inserted into the receivers of the two receptacles, approximately ½ of their horizontal depth or extent. A typical length for the receivers 33, 34, 47, and 48 would be 2″, although these components may be extended up to 12″, or more, as desired, depending upon the application. In
It is apparent that through the use of such receptacles, the installer need not precisely cut the molding pieces to be joined together to pass around corners. Nor do the cuts themselves have to be perfectly executed, since the ends of the pieces of molding are completely covered by the receptacles. Installation of the molding is easier, faster, and produces visual results which are aesthetically pleasing. Use of caulking to fill miter corners is entirely eliminated, and instead, a solid, perfectly formed corner is presented by every receptacle.
Another variant of the receptacle construction is a 90° inner corner radius receptacle 52, shown in
Examples of receptacles designed to accommodate different angular orientations for abutting walls are shown in
These 135° and 120° inner corner receptacles also maybe constructed as outer corner receptacles, for the same angular orientations. These constructions of receptacles assembled in combination are shown in
For the purpose of joining lineal runs of molding, preformed couplers are provided. In
The length of coupler 71 may vary with the application, but typical lengths would be in the 2″ to 12″ range. There is sufficient room in the combined lengths of first receiver 72 and second receiver 73 to accommodate the end portions of the two pieces of molding 12 yet maintain some adjustment flexibility. In other words, if the coupler were 6″, the end portions of the molding may extend 2″ or so into respective receivers, leaving 2″ between the molding ends for adjustment and ease of installation.
Another use of coupler 71 is for decorative purposes, mounted along the length of a piece of molding rather than joining two separate pieces of molding. In this application, the coupler 71 may also include additional details or features on its outer surface, to draw more attention to the coupler as an aesthetic feature along the molding. No change in the internal structural aspects of the coupler 71 would be required for this different application. The coupler 71 would simply be slid over a single piece of molding until the desired location is reached. Then, the piece of molding would be installed as previously described, preferably but not necessarily, using the hidden fastener system.
Other typical uses for the molding, receptacle, and coupler constructions of the present invention include the door 74 and the window 76 trim applications, as shown in
Molding 80 is different from the previously described molding 12, only in that more detail and relief are used on its outer surface 16. Such detail and relief are typical with picture-frame molding or trim. It should be noted, though, that molding 80 includes an upper kerf 18 and a lower kerf 19 in its outer surface, identical to those kerfs used in molding 12. It should also be noted that nails 22 and resilient cord 27 are used in this application as part of the hidden fastening system to affix the molding 80. All of the variations on the fastening system previously described may be used, or alternatively, the molding may be affixed conventionally, and only the receptacles 77 used.
A first receiver 78 and a second receiver 79 are provided to receive respective ends of a piece of molding 80. The receivers 78 and 79 may also include an upper rib 41 and a lower rib 41, to mate with upper kerf 18 and lower kerf 19 in the outer surface 16 of each piece of molding 80. However, the above-described retaining means, provided by the upper lip and the lower trough, are entirely adequate to secure the molding ends within the “fastener-less” picture-frame corner receptacle 77, without the use of the upper and lower ribs. In all other respects, as well, receivers 78 and 79 are constructed identically to the receivers of the receptacles described above, so in the interest of brevity, no further explanation regarding their structure will be provided.
Receivers 78 and 79 meet at picture-frame juncture 81, to form a 90° corner transition between the molding pieces. This allows the picture-frame corner receptacle 77 to be used to apply the inverted U-shaped trim around doors, or to form a complete picture frame trim arrangement around windows. For a typical assembly of molding 80 around a door 74, the left hand piece may initially be fitted with additional molding couplers 71 along its length, merely included in this application for decorative purposes. The second receiver 79 of a receptacle 77 is installed over the upper end of the left-hand piece of molding, before the molding is attached to the door frame. Then, an upper piece of molding 80 is installed in the first receiver of the receptacle 77 and in the first receiver of a second receptacle 77, at the upper right hand corner. The right hand piece of molding may be fitted with molding couplers 71 to match those on the left hand piece. Then the right hand piece of molding is installed in the second receiver of the second receptacle 77. Then, all of the remaining molding is attached to the door frame, and the installation is complete. If the hidden fastening system is used, the two kerfs will be filled. If conventional fastening is used, the holes must be filled and sanded before the final finish can be applied.
A final application for the molding, receptacle, and coupler constructions of the present invention is for crown molding. This application is shown in detail in
“Fastener-less” crown molding corner receptacles are provided to transition lineal runs of crown molding 83 around corners, in a manner identical to the receptacles used in the previously described baseboard molding application. For example, a 90° outer corner crown molding receptacle 84, having a first receiver 86 and a second receiver 87 are shown in
The corner receptacles also include internal ribs 41 and 42, to engage respective kerfs in the outer surfaces of the molding 83. Once the ends of the molding 83 are inserted into the receivers of the receptacle 84, the molding pieces are permanently affixed to the wall and to the ceiling. No nails, screws, or adhesives are necessary to hold the receptacle 84 in place.
A 90° inner corner crown molding receptacle 89 is also provided, to handle 90° transitions of the crown molding 83 through an inner corner. Crown molding receptacle 89 includes a first receiver 91 and a second receiver 92, identically configured as receivers 86 and 87 of the crown molding receptacle 84. An inner corner juncture 93 is also provided to join the two receivers together and maintain them in proper alignment within a 90° inner corner. In all other respects, receptacle 89 functions identically as receptacle 84 does, to form an integral component of the trim and molding installation without the use of fasteners or adhesives, to cover the ends of the crown molding pieces, and to present a smooth transition of the molding through a corner without the additional time and skill required for a miter cut.
Pursuant to the provisions of 35 U.S.C. Section 119(e), Applicants claim the priority benefits of their Provisional Patent Application Ser. No. 60/439,583, filed Jan. 10, 2003, entitled Pre-Finished Fastenerless And Concealed Fastener Door Frame And Molding System.
| Number | Date | Country | |
|---|---|---|---|
| 60439583 | Jan 2003 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10738355 | Dec 2003 | US |
| Child | 11336235 | Jan 2006 | US |
