Patent Application
20070068098
This invention relates to decorative molding and more particularly to systems and methodologies of manufacture and application of millwork assemblies for use in finish carpentry applications.
A carpenter is a skilled craftsman who performs a wide range of woodworking tasks. For example, a carpenter can perform projects that range from making furniture to constructing complete buildings of wood. As such, carpentry work generally involves significant precision, skill and manual labor.
Much of carpentry's knowledge is gained through on-the-job experience. A rough carpenter is one who does rough carpentry; that is, framing, roofing, and other structural or other large-scale work that need not be finely joined or polished in appearance. On the other hand, a finish carpenter is one who performs finish carpentry; that is, cabinetry, furniture making, fine woodworking, instrument making or other carpentry where exact joints and minimal margins of error are important.
Today, homeowners have exhibited an increased emphasis on “do-it-yourself” (DIY) skills. For example, DIY-based big-box stores and supply houses have emerged to accommodate this growing trend of performing many traditionally skilled tasks without the support of the skilled journeyman. Some areas of carpentry is included in these tasks.
Conventionally, a homeowner would contact a skilled craftsman (e.g., carpenter) to perform home improvements and projects that require specialized knowledge and skill. The ever-increasing emergence of the DIY stores has led to many homeowners and “do-it-yourselfers” to tackle projects traditionally left to the skilled craftsman. However, there exist skills and projects that continue to be left to the craftsman; finish carpentry is one of these skills.
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The invention disclosed and claimed herein, in one aspect thereof, comprises a modular millwork assembly that can be removably applied to a window opening. The modular millwork assembly can enable a “do-it-yourselfer” to achieve professional results without the possessing the skills and/or tools of a trained craftsman. Additionally, the modular millwork assembly described herein can reduce costs and time involved with traditional millwork installations.
The modular finishing kit can include a trim unit and a set of connectors or retaining means. The trim unit can be shaped to outline an opening, for example, a window opening. The set of connectors can include one retaining means mounted to the window frame and/or rough opening. Another compatible retaining means can be mounted to the millwork trim kit. In operation, the retaining means attached to the millwork trim kit can facilitate removable, or permanent, engagement to the compatible retaining means positioned on the window frame and/or rough opening.
In still another aspect, a modular millwork assembly can be applied to a door opening. For example, the modular millwork assembly can quickly and easily enable a layman to apply a professional finished look to an installed door. Yet another aspect is directed to a fireplace or hearth application. Again, a professional result can be achieved without finish carpentry skills and availability to specialized tools.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the invention are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention can be employed and the subject invention is intended to include all such aspects and their equivalents. Other advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
The invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject invention. It may be evident, however, that the invention can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the invention.
Referring initially to the drawings,
More particularly, window assembly 102 can include 1 to M, male pins or connectors, where M is an integer. It is to be understood that 1 to M connectors can be referred to individually or collectively as connectors 106. In one aspect, four connectors are positioned on opposite edges of the window frame 102 as illustrated. Additionally, the connectors 106 (e.g., pins) can be placed equidistantly from the centerline of each vertical side of the frame 102. However, it is to be understood that, depending on the particular application, the connectors 106 can be placed in any position on the frame 102 even if such positioning is not equidistant from the centerline. Alternatively or in addition, connectors 106 can be placed on the top and or bottom of the frame 102 in a similar manner as that shown and described herein. For example, for an opening that has a wider width than height it might be more practical to place the connectors 106 on the top and bottom rather than, or in addition to, the sides of the opening. By way of illustration and not limitation, a window may be 2 feet high and 6 feet wide. In this example, having connectors 106 along the width of the window allows for placement of more connectors than if the connectors 106 were placed on the sides of the window.
Although the aspect illustrated in
Referring now to the trim kit 104, 1 to M connectors can be positioned on the inner flange portion of the assembly. Continuing with the example above, four female connectors can be positioned on the outer frame of the trim kit 104. As described with respect to the window frame 102, the connectors 108 can be positioned, according to one embodiment, equidistant from the centerline of the vertical sides of the trim kit 104 as illustrated. It is to be understood that the placement of the female connectors 108 is substantially similar to the placement of the male connectors 106. While male connectors 106 are shown on the window frame 102 and female connectors 108 are illustrated on the trim kit 104, it is to be understood that the female connectors 108 can be on the window assembly 102 and the male connectors on the trim kit 104. Additionally, while specific connectors 106 and 108 are illustrated, the disclosed embodiments work equally well with any of a plurality of suitable connecting means, provided there is an easy way to assemble and/or disassembly the unit while securely engaging the unit to the opening.
The connectors 106, 108 are situated on each assembly 102, 104 such that the assemblies 102, 104 can easily connect to form a single finished unit 100, allowing anyone to install regardless of skill and/or knowledge. As described above, conventionally, finishing millwork requires the skill and craftsmanship of a trained professional. Additionally, specialized tools are oftentimes required in order to achieve a tight and precise frame. For example, a miter saw, jointer and planer are often needed to achieve a professional product. Unfortunately, the layman does not often have access to these tools and/or possess these skills, thus, the embodiments disclosed herein allow usage by anyone, even without access to such tools and/or skills.
Although the aspect illustrated in
The modular millwork assembly 100 can be particularly useful to easily alter the aesthetic appearance of a window opening. For example, the modular millwork assembly 100 can be useful to change a particular style of millwork (e.g., colonial, ranch) to coincide with a user preference. Traditionally, because millwork was attached with nails and the like, replacing existing millwork would result in damage to the surrounding plaster and opening. The subject millwork assembly 100 enables quick and easy installation and/or replacement of decorative trim. Moreover, the modular millwork assembly can be useful in new construction and remodeling projects to greatly enhance productivity, lower cost and enable a “do-it-yourselfer” to achieve professional millwork results without possessing the skills or having the tools otherwise necessary.
By way of illustration and not limitation, the millwork assembly 100 can be also applied to windows along the exterior of a house, building, or other structure. This would be particularly useful for holiday decorations, such as for Halloween. A user can apply millwork assembly 104 to all or some windows that have a Halloween theme to alter the appearance of the structure, such as to make it appear “haunted.” After the holiday, the user may not desire the structure to have the themed appearance and may easily remove the millwork assembly 104 and replace it, altering the appearance of the structure without having to make drastic (and expensive) changes.
Turning now to
The operation of the connecting means 106 and 108 will now be discussed in order to fully appreciate the invention. While a window opening is described, the disclosed features work equally well with any type of opening. In a window application, the window frame 102 can be installed in the opening. The window frame 102 can be separate from the actual window itself or it may be an integral portion of the window. The trim kit 104 is placed in removable engagement with the frame 102 such that the catch 210 of the female connector 102 engages the male connector 106. The head 220 is inserted into and substantially within the catch 210. The trim kit 104 is then slid forward (or another appropriate direction) to move the male connector 106 from the first end 202 to a second end 204, engaging the male connector in the receiver 212. Thus, with the trim kit 104 in position, the male connector 106 is operatively engaged, providing a secure fit. It is to be appreciated that the other connectors of the window frame 102 and trim kit 104 operate in a substantially similar fashion and are operatively engaged at a substantially similar time. That is to say, the placement of the female connector 108 in relationship to the trim kit 102 is such that when the trim kit 108 is placed and then moved in a direction to engage the male connector 106, all connectors are operatively engaged.
Referring to
In an alternative aspect of the application of connectors 108, a user can employ a routing means to countersink connectors 108 beneath the surface of millwork assembly 302. As such, this countersunk application can provide for a guide when attaching the millwork assembly 302 to a frame thereby enhancing alignment and/or ease of application.
In operation,
As described above, finished carpentry requires precise talent and skill not often possessed by laymen. For this reason, the subject millwork assembly 104 can be pre-manufactured and equipped with connectors 108 capable of interfacing and/or engaging with compatible connectors (e.g., 106) mounted on the inner portion of a rough opening 402.
In one aspect, the finished millwork assembly 104 can be assembled by connecting individual lengths of wood trim (e.g., mitered and unmitered). In one aspect, the individual lengths can be joined together forming a corner; usually both sides are bevelled at a 45-degree angle to form a 90-degree corner, although other angles are contemplated.
In another aspect, the finished millwork assembly 104 can be constructed of a composite material. In this example, individual lengths of composite material can be employed to construct the finished millwork assembly frame 104. As well, a single composite assembly can be manufactured (e.g., plastic injection molding) to effect the modular millwork frame 104.
Turning now to
Referring first to the door assembly 602, as described with reference to the window millwork aspect above, connectors 606 can be positioned onto the perimeter of the door assembly 602 as shown. In one example, these connectors 606 can be male pin-type connectors positioned equidistant along the vertical lengths of the frame 608. Although
Turning now to the millwork assembly 604 of the example, this assembly is a finish frame that can be constructed of three individual lengths of millwork; one horizontal (e.g., top) length and two vertical (e.g., side) lengths. The lengths can be connected employing any means known in the art including, but not limited to, nails, glue, brackets or the like. As well, the joints can be formed by flat cutting or miter cutting (e.g., 45 degree) the ends of the lengths.
Connectors 610 can be included and mounted on the inner portion of the millwork assembly 604. In other words, connectors 610 can be connected on the inner portion of the assembly 604 such the connectors 610 align with the connectors (e.g., pins 606) mounted on the inward portion of the frame 608. In one example, the connectors 608, 610 are male and female connectors respectively. As described with reference to
Yet another aspect of the invention is illustrated in
Referring now to
As can be seen in
In either case, the decorative trim kit 804 can be equipped with compatibly mounted and arranged connectors 810. Thus, the decorative trim kit 804 can be interconnected to window frame 808 (or, rough opening (not shown)) thereby creating an autonomous unit, window millwork assembly 800.
The window millwork assembly 800 particularly illustrates a decorative manner in which window trim kit 804 can be employed. For example, theme-based assemblies can be manufactured and applied as desired (e.g., interiorly or exteriorly). By way of example, holiday themes such as the Thanksgiving, Christmas, Hanukkah, or the like can be applied to (e.g., printed upon) the window trim kit 804. As such, the ease of installing and uninstalling the window trim kit 804 can be used to change an appearance in view of a holiday.
Illustrated in
With continued reference to
In order to comply with different manufacturers, alignment pin guides 1006 are supplied. These alignment pin guides 1006 can accept an alignment pin (not shown) thus positioning the jig 1000 for proper retaining means placement. In operation, once aligned, a user can drill a guide hole through the drill guide 1004 into a window frame or rough opening. Accordingly, this hole can be used to position the retaining means (e.g., pins).
What has been described above includes examples of the invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject invention, but one of ordinary skill in the art may recognize that many further combinations and permutations of the invention are possible. Accordingly, the invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
