The present embodiments relate generally to a moulding assembly, such as a crown moulding assembly or chair rail moulding assembly, that provides decorative enhancement to a wall or ceiling surface.
Interior decorative mouldings, such as crown mouldings, door and window casings, chair rails, baseboards, etc., are commonly used in the construction industry. Typically these mouldings have a flat surface on one side to mount flush against an interior wall surface, and a decorative surface on the opposite, exposed side. The visually appealing decorative surface is usually formed in three dimensions.
One conventional type of moulding is an elongated structure, such as one made of wood or extruded material. This moulding typically has a uniform cross-sectional profile created by milling the decorative design into one surface of the material, or in the case of extruded plastic moulding, by extruding through a uniform profile die.
Crown moulding typically is manufactured in long sections for installation by a carpenter who miter cuts the moulding into sections, and fastens the moulding directly to the wall or ceiling surface. Installation of the crown moulding in this way, however, can create undesirable visible defects. For example, improper fastening of the moulding trim portion can damage the trim surface. In addition, in applications where the wall and ceiling surfaces are not flat or square, it may be difficult to install the crown moulding so that it appears level and flush with the wall and ceiling surfaces—the installed crown moulding may appear uneven, undesirably accentuating the imperfections in the underlying structures.
The description herein of certain advantages and disadvantages of known methods and devices is not intended to limit the scope of the present invention. Indeed, the present embodiments may include some or all of the features described above without suffering from the same disadvantages.
In view of the foregoing, one or more embodiments described herein provide a moulding or trim assembly that has a retainer coupled with a removable trim member. The moulding or trim assembly can improve the ease of installation of the moulding assembly, when compared to traditional moulding assemblies. In addition, the trim member can be removable and replaceable, enabling design flexibility.
In one embodiment, a moulding assembly has a retainer and a trim member. The retainer has a central section, a first mounting leg extending from a first end of the central section, and a second mounting leg extending from a second end of the central section. A first fastening component is disposed at least partially on the central section of the retainer. The trim member includes a second fastening component that couples with the first fastening component.
In another embodiment, a moulding assembly has an elongated retainer, an elongated trim member, and an elongated fastener assembly that couples the trim member with the retainer. The elongated retainer has a central section, a first mounting leg extending from said central section in a first plane, and a second mounting leg extending from the central section in a second plane that is substantially orthogonal to the first plane.
Purposes and advantages of the exemplary embodiments will be apparent to those of ordinary skill in the art from the following detailed description in conjunction with the drawing figures in which like reference characters are used to indicate like elements, in which:
The following description is intended to convey a thorough understanding of the embodiments by providing a number of specific embodiments and details involving a moulding assembly. It is understood, however, that the invention is not limited to these specific embodiments and details, which are exemplary only. One possessing ordinary skill in the art, in light of known devices, systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments.
Generally speaking, the moulding assemblies of the various exemplary embodiments described herein have an elongated retainer and an elongated trim member. The retainer may be fastened to one or more mounting surfaces, such as, for example, a wall or a ceiling surface. The retainer and trim member have mating mounting components by which the trim member may be removably coupled with the retainer. The two-piece moulding assembly may be easier to install than traditional moulding because it is more forgiving of imperfections of the underlying mounting surfaces, and it may provide an improved fit against the mounting surfaces with reduced or no gapping around the edges. The removable trim member may be interchangeable with other trim members, providing flexibility in design options. In addition, the trim member may be removed for ease of painting an underlying wall or ceiling surface without the need to tape off the trim member.
The various exemplary embodiment generally describe devices suitable for crown moulding trim applications, i.e., those hung in the upper corner of a room. However, the embodiments are not so limited. In various embodiments, the moulding assembly may be adapted for other trim applications, such as, for example, chair rail trim, baseboard trim, door or window trim applications, or other moulding or trim applications. In other exemplary embodiments, the moulding assembly may be suitable for use in exterior applications, such as siding applications. Upon review of the description provided herein, it will be apparent how to adapt the embodiments to other applications.
Referring now to
In exemplary embodiments retainer 200 and trim member 300 may be made of wood, metal, molded or extruded plastic, composite material, or other suitable material. In exemplary embodiments, the retainer 200 and trim member 300 may have a uniform cross section along their respective lengths. The outer surface 304 of trim member 300 may be configured to have a decorative shape, so as to present an ornamental appearance. For example, the outer surface 304 of member 300 may be rounded to present a bead, may be patterned in an egg and dart design or may be square or angular in shape. In exemplary embodiments, the decorative surface may be molded or extruded into the outer surface 304, or it may be machined (in whole or in part) into the outer surface 304 of trim member 300.
In exemplary embodiments, the retainer 200 and each of its components may be unitary, i.e., forming a single workpiece. For example, the retainer 200 may be extruded, molded, or machined out of a single material. However, in some exemplary embodiments the retainer 200 may include more than one material. For example, the retainer 200 may include two materials that are co-extruded or molded to form a single workpiece, or may include separately formed parts that are fastened or joined together to form the retainer 200. Likewise, in exemplary embodiments, the trim member 300 and each of its components may be unitary, i.e., forming a single workpiece. For example, the trim member 300 may be extruded, molded, or machined out of a single material. However, in some exemplary embodiments the trim member 300 may include more than one material. For example, the trim member 300 may include two materials that are co-extruded or molded to form a single piece, or may include separately formed parts that are fastened or joined together to form the trim member 300.
Referring to
In an exemplary embodiment, the retainer 200 may have two legs 202, 204. Legs 202, 204 may be parallel to each other, or may be configured at an angle, such as orthogonal. For example, referring to
In some embodiments, retainer 200 may be configured so that the angle between legs 202, 204 may change. For example, legs 202, 204 may be configured to flex (e.g., up to about 15 degrees), so that when fastened to an irregular mounting surface, it may lay flush with the surface. In some embodiments, retainer 200 may be configured to maintain a 90 degree angle between legs 202, 204, regardless of the actual angle between wall 10 and ceiling 20. For example, referring to
Referring to
In exemplary embodiments, elongated trim member 300 may be operably coupled with the retainer 200 so that at least a portion of the trim member 300 extends from the outer surface 208 of the retainer 200. For example, referring to
In exemplary embodiments, the trim member 300 and retainer 200 may be configured so that at least portions of the trim member 300, when coupled with the retainer 200, contact the mounting surface of the wall 10, the ceiling 20, or both. For example, referring to
In various exemplary embodiments, the trim member 300 may be removably coupled with the retainer 200. As such, trim member 300 may be removed and reattached, or removed and replaced with another trim member 300. In exemplary embodiments, multiple interchangeable trim members 300 may be provided with varied decorative surfaces so that the outer decorative appearance of the moulding assembly 100 may be changed without removing the retainer 200.
In exemplary embodiments, retainer 200 and the trim member 300 may have one or more mating mounting components that enable the two parts to be coupled. In various exemplary embodiments, the retainer 200 and trim member 300 may each have a corresponding component of a male/female connector or fastener. For example, referring to
In exemplary embodiments, mating mounting components may provide a mechanical connector such as a snap interference fit. In other words, the mating components snap together in a way that creates a mechanical interference between the mating parts. This mechanical interference provides a stable connection between the retainer 200 and the trim member 300. In exemplary embodiments, a snap interference fit may be provided by any suitable mechanism as necessary and/or desired. For example, referring to
Referring to the figures, in exemplary embodiments, the mating mounting components may include one or more receptacles 214 on the retainer 200, and one or more flanges 306 on the trim member 300. Referring to
In exemplary embodiments, elongated trim member 300 may include one or more mounting flanges 306 that mate with the one or more mounting receptacles 214 of the retainer. For example, referring to
In exemplary embodiments, the mounting flange 306 or the mounting receptacle 214 may have one or more features configured to improve the engagement properties of the mating mounting components. For example, as discussed above, the mounting flange 306 of the trim member 300 may have one or more projections 316, or ridges or corrugations 308 that provide mechanical interference with corresponding projections 218 or ridges or corrugations 216 disposed on the mounting receptacle 214. It will be appreciated that other features may be used in combination with or instead of this feature, to improve the engagement or interference between the mating mounting components. For example, referring to
In exemplary embodiments, the mating mounting components may be elongated and substantially continuous along the longitudinal direction of the retainer 200 and trim member 300, respectively. Elongated and substantially continuous mating mounting components provides a more continuous engagement along the mounting surfaces, and may reduce potential gapping between the trim member 300 and the wall 10 or ceiling 20 surface. For example, where individual fastener clips may be used to fasten trim member 300 to a mounting surface, the trim member 300 may sag between clips, creating a gap between the trim member 300 and a wall 10 or ceiling 20 surface. A more continuous engagement along the length of retainer 200 and trim member 300 may significantly reduce this sagging and gapping effect. This may enable the use of a more flexible (less rigid) trim member 300, without increased sagging. In addition, an elongated and substantially continuous engagement between the retainer 200 and trim member 300 may provide a more secure engagement between the retainer 200 and trim member 300. However, one or more of the mating mounting components may be discontinuous along the length of the respective parts. For example, mounting flanges 306 may be replaced with one or more posts that are disposed intermittently along the inner surface 302 of the trim member 300. In various exemplary embodiments, the trim member 300 and the retainer 200 may substantially co-extensive. Where the trim member 300 and retainer 200 are co-extensive, the engagement between the retainer 200 and trim member 300 may be more secure. In various exemplary embodiments, the retainer 200 may be shorter in length than the trim member 300. For example, gaps may be provided between adjacent strips of retainer 200.
In various embodiments, a moulding assembly 100 may include multiple lengths of retainers 200, and trim members 300. In various embodiments, adjacent portions of the retainers 200 or trim members 300 may abut, so as to provide the appearance of a continuous workpiece. The retainers 200 or trim members 300 may be made or modified so as to provide the appearance of a continuous workpiece, such as by providing precision cut edges, or mitering the edges of adjacent trim members 300. In various exemplary embodiments, an additional trim piece, such as, for example, a decorative cornice, may be provided to cover the butt seam of two adjacent trim members 300. In such embodiments, the edges of adjacent trim members may be rough cut, and need not provide the appearance of a continuous workpiece, because the additional trim piece will cover over the edges to provide a finished appearance.
In various exemplary embodiments, a method for installing the moulding assembly 100 is provided. According to the method, an installer may select suitable moulding assembly components, including at least one elongated retainer 200, and an elongated trim member 300. The components may be selected according to their intended application, such as crown moulding application, or chair rail application. In exemplary embodiments, the trim member 300 has a decorative outer surface 304. The decorative outer surface may be provided with the trim member 300, or it may be later machined into the surface of the trim member 300. According to exemplary methods, the retainer 200 and/or trim member 300 may be provided in predetermined lengths and may be continuous or discontinuous. According to the exemplary methods, the retainer 200 and/or trim member 300 may be modified so that when adjacent lengths of the part abut, the abutting portion is smooth. For example, the retainer 200 and/or trim member 300 may be pre-mitered to provide a smooth butt joint, or an installer may miter the edges of adjacent lengths of the retainer 200 and/or trim member 300 so that the mitered edges of the respective parts meet at a butt joint.
According to various exemplary embodiments the method for installing the moulding assembly 100 may further include the step of fastening one or more retainers 200 to a mounting surface, such as a wall or ceiling surface. According to the method, an installer may fasten the retainer 200 to a mounting surface by inserting a fastener or plurality of fasteners, such as a screw or nail or like fastener, through a leg of the retainer 200 and through to the mounting surface. In some embodiments, the retainer 200 may be adhered to one or more surfaces, such as with the application of a glue bead between the retainer 200 and the mounting surface instead of or in addition to the other fastening means. In some embodiments, the fastener(s) may be inserted through a fastener guide groove 210, which may be provided to assist in properly locating the fastener on the retainer 200. According to the exemplary embodiments, the retainer 200 may be continuous or discontinuous along the mounting surface. For example, the installer may provide gaps between adjacent lengths of the retainer 200, such as along a single mounting surface, or across a corner, between two adjacent mounting surfaces.
According to various exemplary embodiments the method for installing the moulding assembly 100 may further include the step of coupling one or more elongated trim members 300 with the one or more retainers 200 that have been secured to the mounting surface. According to the method, retainer 200 and trim member 300 have mating fastening members, such as mounting receptacle 214 and mounting flange 306, described above. An installer may join the mating fastening members, so that the retainer 200 and trim member 300 are at least temporarily fastened. For example, the installer may insert mounting flange 306 into mounting receptacle 214, engaging the projections 316 or ridges or corrugations 308 of the mounting flange 306 with the corresponding projections 220, or ridges or corrugations 216 of the mounting receptacle 214.
According to various exemplary embodiments, the installer may adjust the position of the trim member 300 to achieve a predetermined visual effect. According to the various exemplary embodiments, the trim member 300 may move longitudinally relative to the retainer 200, such as by sliding the trim member 300. In various exemplary embodiments, the trim member 300 may move proximally and distally relative to the retainer 200, such as by adjusting the degree of insertion of the mounting flange 306 within the mounting receptacle 214. According to various exemplary embodiments, when the trim member 300 is coupled with the retainer 200, the retainer 200 is hidden from plain view. In exemplary embodiments, when the trim member 300 is coupled with the retainer 200, at least a portion of the trim member 300 contacts a portion of the mounting surface(s), so that there appears to be little to no gap between the edge of trim member 300 and the respective mounting surface.
Although various preferred exemplary embodiments have been described with reference to the accompanying drawings, it will be evident that various modifications and changes may be made thereto, and additional exemplary embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.
The present invention claims priority to U.S. Provisional Application No. 61/055,324, filed May 22, 2008, the contents of which are incorporated herein by reference in their entirety.
Number | Date | Country | |
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61055324 | May 2008 | US |