This invention relates to trim, especially wood trim, of the kind as used in houses for finishing the edges and frames of doors and windows, chair rails, baseboards or skirting-boards, framing around panelling, and the like.
Examples will now be described with reference to the accompanying drawings, in which:
a is a partly-exploded view of the components of the trim attachment system of
a is a side elevation of part of another cover.
a is a close-up of an area of
a is the same view as
b is the same view as
The apparatuses and procedures shown in the accompanying drawings and described below are examples. The scope of the patent protection sought is defined by the accompanying claims, and not necessarily by specific features of the examples.
In this description, some of the components in the drawings have been given numerals with letter suffixes. The same numeral without the suffix is used to indicate the component generically.
A door opening in a wall 21 includes a conventional upright two-by-four doorframe stud 23, to which sections of conventional drywall or plasterboard 25 are attached. A door jamb 27 fits across the width of the wall. Apart from its function as a component of the doorway, the jamb 27 serves to hide the unsightly stud 23, and to hide the cut ends of the plasterboards 25.
The jamb 27 has a surface 29 which, being visible, should be finished in a suitable manner, using e.g stain, varnish, paint, etc. The jamb 27 may be of a solid decorative wood, such as oak, or may be e.g fibre board, or solid particle board, to which a decorative veneer might be applied at least to the visible surface 29. The system as described herein applies when the jamb is made from other wood-based materials, or even from (e.g recycled) plastic materials. It is also known to make door jambs from bent/folded sheet metal, and the system is applicable in that case too, provided provision can be made for attaching the clip to the jamb.
The jamb 27 is supported and secured with respect to the wall 21 by means of spline-clips 30i,30o (collectively 30). The spline-clips 30 are formed as plastic extrusions, having an extruded profile as shown in
To install the assembly as shown in
When all the outside spline-clips 30o are properly stapled to the jamb 27, now the installer makes a final check as to the positions of the door jambs and lintel. When they are square and true, within the door opening, now the wall staples 40 can be applied. Now, the doorframe stands secured, square and true, at least as to its outside, to the wall 21. It is usually possible for a reasonably skilled installer to perform the task, without assistance, of securing a door and doorframe into the wall opening, with a perfectly acceptable degree of accuracy, in just a minute or two.
It cannot be ruled out that an installer might leave the jambs not quite vertical, or otherwise not perform the door installation properly—but, so long as the installer is not over-casual, and has the right tools to do the job, the installer can leave every door they install square and true, repeatably, in very short order, by the use of the spline-clips in the manner as described.
The same steps can now be performed with respect to the other side (the inside) of the door. That is to say, the inside spline-clips 30i are now stapled to the inside edge 34i of the jamb 27. Again, the lug 36 is used to position the clip correctly with respect to the jamb. With all the spline-clips 30i attached to the jamb 27, and with the installer checking once again, now from the inside, that everything is square and true, the spline-clips 30i can be stapled to the wall.
Now, as shown in
The task of squaring up the door and doorframe within the door opening in the wall is thus accomplished very quickly and easily. And the installer, with a minimum of skill and attention, has been able to ensure that the installation is square and true. The installer preferably should pre-attach the outside spline-clips 30o to the jamb 27, but should not pre-attach the inside spline-clips 30i (or vice versa, if the door is to be installed from the inside). It would be impossible (or at least very awkward) to assemble the door and frame into the opening in the wall if both the inside and the outside spline-clips were pre-attached.
Now, with the installation of the spline-clips 30 finished, the installer can turn to assembling the wood trim. The trim 43 is formed with a profile as shown in
At the other end of the wood trim 43, the wall-spline 49 of the spline-clip 30 is snagged on the entry to the wall-spline slot 50 of the wood trim 43. Now, if the installer pushes the wood trim 43 towards the wall 21, the entry-chamfer 52 on the end of the wall-spline 49 directs the wall-spline 49 to bend (leftwards, in
It will be understood that the two jamb pieces and the lintel that make up the doorframe are manufactured in-factory, and are accurately cut and finished. (The bottom ends of the left and right jambs might have to be trimmed by the installer in some cases, but that is a task that requires very little skill and attention from the installer.) Equally, the wood trim pieces 43 are factory-cut and finished, including the mitres thereof, whereby again no craft-type skill is required on the part of the installer.
It will be understood also that no nails or other fasteners are required in respect of the wood trim pieces themselves. The wood trim can be quickly and accurately installed by a non-skilled person. There is no need for patching or other remediation, such as filling, sanding, painting, etc, of any kind, to be done after installation. All required finishing of the trim can be done in-factory—although it is not ruled out, of course, that painting etc might be done after installation. It will also be noted that the trim can be removed, in the future, if desired, and then re-fitted, all by hand, in order to facilitate the task of painting, for example, or applying wallpaper to, the walls.
Many home-owners want to make use of a decorative hardwood, not only for the trim 43, but also for the jambs 27 and lintel. To cater for such customers, the jamb and lintels, together with the required six pieces of wood trim 43 (two upright-pieces and one cross-piece, both inside and outside the door) and the associated spline-clips 30, may be done up for sale as a kit. It is also helpful for customers to be able to purchase a set of the three pieces of wood trim, and an appropriate set of spline-clips, as required to trim one side of a door. The pieces again are factory-made and finished (including mitred corners).
The door itself might or might not be included in a kit. It is customary for doors to be manufactured to very tight tolerances as to dimensions, squareness, and so on. This fact means that it is possible to sell the kits containing the jambs, trim, etc, separately from the doors, knowing that the kit will be bound to accurately fit any door of the nominal size for which it has been prepared. Thus, the designer really can arrange for the wood trim pieces, in the kit, to be mitred in-factory, whereby the mitres can be done perfectly accurately, and completely finished, before being added to the kit. This leaves the installer with the task of simply pressing the wood trim pieces into place, and the job is finished.
In the above-described cases, the system of spline-clips and trim can in fact be used with already existing doors and jambs. Thus, a kit comprising just the (pre-mitred and pre-finished) wood trim, without the jambs and lintel, may be offered for sale.
The following variant requires that the spline-clips be secured to the edges of the jamb using a groove in the jamb. As such, the following variant system cannot be used with jambs that have not been suitably grooved.
Now, the installer lines up the door and doorframe with the opening in the wall, and, when all is square and true, staples the spline-clips 60 to the wall in the manner as previously described with reference to
FIGS. 3,4,5 show the preliminary stages of the assembly. In
Whether the installer chooses to go with (preferred)
It is traditional for installers to insert tapered shims between the door jamb and the wall stud, whereby the jamb can be held solidly and securely with respect to the wall. An aspect of the installers traditional skill has been the art of selecting and placing suitable shims, within the very short time which is all that can be economically allocated for the task. If the installers have not got the shims quite right, in that allocated time, they tend to move on anyway to the next door installation, and poor door jamb shimming is all too common a fault in the building trade.
It will be understood that the system of spline-clips, as described herein, can do away with the need for shims and shimming, in many cases, and still the door jamb is secured to the wall just as, if not more, securely and rigidly than when shims were used. There is a shorter time per installation, and the installations are more nearly perfect, more often. In some jurisdictions, the provision of shims in door jambs is a code requirement, and in that case, the installer should of course provide them.
The spline-clips system, as described, does not preclude the use of shims. In fact, the use of the spline-clips system makes the task of shimming easier, in that the shims can be inserted after the door jambs have been secured to the wall. When using the spline-clips system, as described, some installers prefer to add shims at critical points, e.g around the door hinges and at the latch and at or near the mitred joints. Thus, the installer might shim above and below the hinge area.
Indeed, door installers often prefer to provide a shim actually behind the hinge, and then run a long screw through one of the hinge screw-holes, right through the jamb, the shim, and into the door stud 23. This measure couples the strength and rigidity of the stud to that of the jamb, at the critical points. If the installer were to insert such a long screw without shimming, that might cause the jamb to distort, and shimming is therefore recommended for the through-screw case. Again, the fact that the jambs (and the whole doorframe) are already fixed in place, as a result of using the spline-clips system, means that the shimming task is not even slightly onerous or skill-demanding. Of course, if shims are to be inserted, that must be done when the trim is not present.
In the further variant as shown in FIGS. 6,7,7a the jambs are each in two pieces. The completed split-jamb arrangement is shown in
The outside and inside jamb pieces 70,72 are held together with a key 74, and the grooves 76 that receive the key correspond to the grooves 63 in the edges of the jambs that receive the barbed lugs 61 of the spline-clips 60. That is to say, the outside jamb pieces can be reversed, in that both edges of the outside jamb pieces are equally grooved. Likewise, the inside jamb pieces. This can be advantageous when it comes to a choice of fitting the door with the hinge end either to the left or to the right. The hinges, and the latch socket, can be built one into the left, and the other into the right, outside pieces of the jamb, which can easily be switched around if need be.
One of the benefits of the split-jamb arrangement is that it permits the spline-clips to be pre-assembled, in the factory, to all the jamb pieces. Indeed, the clips can be permanently secured into the grooves in the jamb pieces, in-factory, e.g with adhesive. (Of course, the wood trim 78 is kept separate (i.e is not pre-assembled), and is only assembled and tapped onto the spline-clips 60 once the clips have been stapled to the wall.)
There is an argument against pre-attaching the spline-clips to the jambs, which is that the resulting sub-assembly is of a form that might make it vulnerable to being damaged during shipping. For those who wish to avoid this danger, and ship the jambs and spline-clips separately, it is an advantageous aspect of the spline-clip system that the spline-clips are so easily assembled to the jambs by the installer, on the job—and not only easily, but in a manner whereby even an inept installer can hardly misplace or misalign the spline-clips on the jambs. Also for those who fear damage to the jambs during transit, the presence of the slots in the edges of the jambs means that suitable protectors can be easily fixed over the edges of the jambs.
a shows a close-up of some of the components, and illustrates the assembly stages.
As mentioned, the split-jambs variant is advantageous because it enables all the spline-clips to be glued into, or to be otherwise pre-assembled to, their respective jamb-pieces, while enabling the two pieces of the jamb to be assembled into the opening in the wall from opposite sides of the wall.
The split-jamb variant is advantageous also because it accommodates walls of different thickness. Generally, in the case of a wall made from plasterboard panels secured over studs, the two opposite surfaces of wall are, for practical purposes, perfectly parallel. Thus, the thickness of the finished wall, around the door opening, is the same over the whole area of the wall surrounding the opening.
However, even though a given wall is (usually) consistent as to thickness, it does not follow that all walls, though made to the same nominal dimensions, have exactly the same thickness. Thus, jambs (and lintels) made in-factory to the nominal thickness, do not always exactly fit the actual wall. The split-jamb variant readily accommodates itself to walls that differ slightly in thickness.
The split-jamb variant, however, does not so easily accommodate variations of thickness within one particular wall. Plasterboard walls are commonly finished by taping over the joints and corners and nail/screw heads, and then applying filler compound to conceal the tape and heads. When the walls have been finished in this way, it is not uncommon for there to be slight thickness variations, i.e variations in the thickness of the grout. Usually, if a wall does vary in thickness, it does not do so in a regular manner, but rather the variations take the form of ripples.
In one common form of thickness-variation, the wall is of uniform thickness from top to bottom, except that at the very bottom of the wall, the filler compound is slightly thicker. The split-jamb variant of the spline-clip system, as described herein, cannot accommodate thickness bumps and ripples, as such; but it has been found that it can, in typical cases, substantially reduce the effects of those bumps and ripples, by halving, for example, the amplitude thereof.
The use of a location-and-securement lug and groove, as in
The door jamb piece 83 of
Another variant on the split-jamb theme is shown in
Also shown in
There is no access to the region from which the staple 98 is inserted, once the jamb has been assembled and applied to the wall, so a design in which a fastener passes through the lug 81 can only be used with split-jambs. If the jamb is in one unitary piece, at least the set of either the inside clips or the outside clips must be left to the installer to attach to the jamb, after the jamb has been positioned in the opening—and of course the staple 98 cannot be inserted at that stage.
The designer might wish to arrange the spline-clip to extend the full height of the door jamb, and the full width of the door lintel, as respective long lengths of the spline-clip extrusion. However, it is preferred that the spline-clips be in separate pieces, spaced some forty or fifty cm apart, as illustrated in
Each individual spline-clip should be long enough to allow ample room for the staples or other fasteners that will secure them to the wall. Each piece of the spline-clip preferably should be about three cm long or more (“long” being in the direction of the extrusion), and about five cm long is preferred. Preferably, the spline-clip should be sized and dimensioned to encourage the installer to put the staples where they will enter the studs.
As to width, door trim mouldings vary as to their width, typically between about five and ten cm. The width of the spline-clip has to be less than the width of the trim, so as to leave respective engagement lands 101,103 (
The designer need not seek every scrap of width available, however, and a manufacturer of trim might prefer the emphasis that several different trim profiles all use a single spline-strip extrusion.
The designer should also see to it that the spline-clip profile is so dimensioned that the staples or other fasteners that are used to secure the trim to the wall are assured of passing into the door frame stud 23, and not into the space beyond. Securing the spline-clip to the plasterboard, rather than to the stud, is inadvisable.
The profile of the trim has to be matched to the profile of the spline strip (or vice versa). In fact, the profile of the spline strip imposes some limitations to the flexibility of design of the profile of the trim. Again referring to
Preferably, the two splines (i.e the jamb-spline and the wall-spline) are positioned right at the very ends of the spline-clip. The splines on the spline-clip define a dovetail shape. It should be regarded that a male dovetail structure exists between the two spline slots in the wood trim, while the two splines on the spline-clip define a female dovetail structure.
It might be thought that it would be equivalent if the male and female roles were reversed; however, reversal of these roles is not preferred. If the wood trim were to form the female dovetail structure, the wood material between the slots would then be subjected to tensile stresses, rather than to the preferred compressive stress, which could lead to premature failure.
There is another reason also why it is advantageous for the splines on the spline-clip to be arranged as the female dovetail, which is that the female-dovetail splines, upon being urged apart by the presence of the male dovetail of the wood trim, insofar as the plastic spline-clip is flexible and capable of deflecting, tend to curl or rotate (slightly) into closer contact with the wall and with the jamb. This rotation of the ends of the spline-clip is desirable, because it urges a tighter degree of contact between the engagement lands 101,103 of the wood trim to the wall and to the jamb.
The profile of the plastic spline-clip is formed by extrusion, and therefore the designer is at liberty to call for re-entrant features, if desired. On the other hand, the wood trim profile is formed by cutting, using rotating saws, which practically forbids the formation of re-entrant shapes in the profile. The dovetail format, using flat-sided slots, is preferred because that shape enables forces to be exerted onto the wood trim, without having to resort to re-entrant features in the profile of the wood trim.
The flat-sided dovetail form is preferred also in that components can vary slightly dimensionally, due to tolerances, and the flat-sided dovetail form allows the springiness of the splines (or at least of the wall-spline) to maintain the force urging the wood trim against the wall and jamb, even though the dimensions of the components might vary slightly.
Even so, the requirement for accurate cutting of the wood trim is rather high, with the system as described herein, and the system should not be considered unless high tolerance standards can be assured and maintained during manufacture of the wood trim. However, using modern profile cutting machines, and with reasonably careful tool-setting, the required accuracy can be attained with reasonable ease. The flat-sided male-dovetail form contributes to this ease.
For economical cutting of the wood trim profile, preferably the axes of the rotating saws should be all vertical. That is to say, defining the direction of movement of the wood trim through the cutters as horizontal and north-south, the axes of all the cutters should appear to be vertical when viewed from east or west, and should all appear to be east-west when viewed from above the table. Preferably, the axes should be kept stationary, while the wood is being fed through the saws. The slots as required in the trim, in order to make use of the spline-clips system, are perfectly in keeping with this preference for economical cutting.
It is not required that the axes of the saws be all parallel when viewed from the north or south. Preferably, the two slots in the wood trim, as illustrated, are cut by saws the axes of which are angled mutually at the required mutual angle of the slots.
It is not necessary, in the spline-clip system, for the slots in the wood trim to be parallel-sided, i.e for the slots to be of constant width along their depth. However, making the slots parallel-sided does make for slightly simpler tooling and preparation of the cutting saws. Also, the bottoms of the slots need not be square with sharp corners, as illustrated; the sharper the bottom corners of the slots, the more there might be a problem of a premature crack starting at the (most stressed) corner.
The steeper the slope of the splines, the more they tend to urge their respective ends of the wood trim into contact with the wall and jamb. In fact, it is the slope of the wall of the slot in the wood trim, at the contact point, that determines the force with which the trim is held against the wall or jamb. The wall of the slot in the wood trim, at the point where contact is made between the wall and the engaging spline, lies at an angle with respect to a perpendicular to the plane of the wall. Preferably, the angle should be about ten degrees or more.
The angle AJ in respect of the jamb-spline-slot may be steeper than the angle AW in respect of the wall-spline-slot, since the jamb-spline does not have to deflect, or does not have to deflect as much as the wall-spline. More particularly, preferably the angle AJ should be about thirty degrees or more, while the angle AW preferably should be about twenty degrees or more.
As mentioned, the jamb-spline 49 is provided with a lead-in chamfer 52. As shown in
There is no need for the jamb-spline, at the other end, to be formed with a corresponding lead-in chamfer. The jamb-spline 47 on the spline-clip 30 can be entered into the jamb-spline-slot 45 in the wood trim 43, by simple positioning of the wood trim 30i, as shown in
Thus, the two splines perform different functions, and can be shaped differently to reflect this. Since the jamb-spline is not required to bend (although it is not detrimental if the jamb-spline can bend somewhat), the jamb-spline can be short and stumpy, while the wall-spline must be flexible enough (which means long and thin enough) to deflect far enough to permit installation without damage to the wall-spline.
The different roles as described for the deflection of the jamb-spline, and the non-deflection of the wall-spline, could be reversed. That is to say, the designer might arrange for the wood trim to be assembled wall-spline first, and then be tapped down onto the jamb-spline, rather than jamb-spine first, as shown.
As to both the jamb slot and the wall slot, in the wood trim, only one side of each slot is functionally effective, being the side of the slot that is closer to the other slot. The respective splines press against these functional sides of the slots, and the pressure urges the wall end of the wood trim firmly against the wall 21, and urges the jamb end of the wood trim firmly against the jamb 27.
The other sides of the slots in the wood trim are not contacted by their respective splines. In fact, the slots should be wide enough to ensure that such contact does not happen, since contact of the spline with both sides of the slot would probably make it impossible to assemble the wood trim to the spline-clip. Similarly, the designer should see to it that the tips of the splines cannot make contact with the bottoms of the slots. Apart from that, the slots should be as narrow and as shallow as possible, since the slots can only weaken the mechanical integrity of the wood trim profile.
Regarding the groove 76 (see
The groove in the edge of the jamb should preferably be parallel to the overall width of the jamb, i.e at right angles to the edge of the jamb; if the groove were to lie at an angle, forces acting on the jamb, e.g due to normal (and abnormal) operation of the door, might cause the barbed lug 61 to tend to ride out of the groove 76.
The material of the wood trim may be solid wood, having an attractive decorative grain, such as oak. Such woods tend to be strong, and resistive to cracks. However, cutting slots into what is inevitably a rather thin profile is bound to lead to an increased risk of cracking, especially during assembly (and dis-assembly, since it is a feature of the described trim-attachment system that the trim can be removed, e.g for the purposes of decorating the wall).
As mentioned, placing the female dovetail form in the (plastic) spline-clip, rather than the wood trim, minimises this increased risk. Still, the designer of the wood trim profile should see to it that an ample thickness of the wood material lies over and around the cut slots. Also, the type of wood should be selected in deference to the form or profile of the particular wood trim, and if a particularly-favoured profile should require the wood to be rather thin, over and around the slots, a wood that is especially resistant to cracking should be selected for that profile.
Even so, wood and wood products do have a tendency to split and crack, and it is an advantage of the system as described that the wood, though slotted, is substantially not subjected to forces which might tend to apply tensile stress to the corners of those slots.
On the other hand, if the material of the trim were, for example, plastic, there would be little point in employing the attachment system as described herein. Where trim is formed as a plastic extrusion, the extruded profile can readily be formed with intricate re-entrant features of shape, as can the spline-clips, such that really almost any shape would do to secure the profile. It is mainly because wood is so liable to split and to crack, when subjected to tensile stresses, that the system as described, with its avoidance of tensile stresses in the profile of the trim, is advantageous.
The same shortcoming that wood has, i.e its tendency to split and crack, is present also in many manufactured wood-based materials. Thus, manufactured materials such as particle board, and especially the fibre boards, are, like wood itself, also liable to split and crack if overstressed in tension. (Such materials are sometimes used as a base for trim profiles, often being wrapped with a veneer of a decorative wood). The layered-paper type of wood-like products are, if anything, even more likely to split and crack.
The system as described is most advantageous when used with materials that do indeed tend to split and crack if and when subjected to tensile stresses. Materials like (most) plastics and metals, by contrast, tend to stretch and yield when subjected to excessive tensile stress. The prior art is replete with attachment systems suitable for use with those non-crackable materials, which are highly unsuitable for use with wood and wood-based liable-to-split materials.
The system has been described herein as it applies to doors requiring wood trim on both sides, i.e both in the room inside the door, and in the room outside the door. In some cases, wood trim might only be required on one side of the door, e.g because the other side of the door faces an unfinished room. In that case, the installer should not seek to secure the jamb to the wall by placing the spline-clips just on the one side of the door.
One function of the spine clips, as described, is to support the jamb relative to the wall, and if spline-clips were provided just one side of the door, the door jamb would not have proper support. So, where it is desired to apply trim just to one side of the door, still the spline-clips should be provided on both sides of the door; either that, or the jambs (and lintel) could be shimmed in the conventional manner.
Although described for doors, the system can also be used for windows—especially in cases, again, where wood trim is required both inside and outside the window. This is not a common situation, however, in that usually the outside of a window is exposed to the elements.
The system can however be used advantageously with outside windows, in some cases. For new installations, the as-manufactured jamb of the windowframe can be provided with a groove, for receiving a key, e.g the kind of groove as shown in FIGS. 6,7a,8.
It should be understood that the windowframe 110 is already secured into the opening in the wall, being shimmed and (rigidly) attached to the stud 23, in the conventional manner.
The spline-clip 60 is already secured into its groove in the split-jamb-piece 114. When the spline-clip 60 makes contact with the wall surface 116, the installer can then staple the spline-clip 60 to the wall. After that, it only remains for the installer to assemble and tap home the (already pre-mitred) wood trim onto the spline-clips, and the installation is finished.
This may be contrasted with what has to be done when wood trim is installed around a window in the conventional manner. Windowframes, though square and accurate as to their in-factory manufacture, after installation very rarely reside accurately straight and upright in the opening in the wall. In particular, the distance from the (grooved) inside edge 111 of the windowframe 110 to the inside surface 116 of the wall is not constant around the whole perimeter of the window.
Typically, when conventionally finishing a window, the installer first attaches jamb-pieces (similar to 114 in
By the use of the system as described, the front edges 115 of the split-jamb-pieces automatically align themselves flush and straight with the wall surface 116, simply as a consequence of the spline-clip 60 making contact with the wall-surface.
After installation, there will probably be a non-constant gap between the jamb-piece 114 and the windowframe 110. A piece of corner trim 117 readily conceals this gap.
The system can also be used with existing windowframes (which do not have grooves 112), as shown in
It should be understood that this variant of the system, as described in relation to outside windows, can also be used for outside doors.
A craftsman carrying out the task of applying lengths of baseboard moulding at the foot of the walls of a room generally finds it a simple matter to apply long straight lengths of baseboard moulding to a long wall. The difficult part of the craftsman's task arises at the corners. Indeed, if it were not for the difficulties posed by the corners, the job would hardly require the skill and experience that merits the term “craftsman”.
Generally, at the corners of the room, the lengths of baseboard moulding have to be mitred together. Alternatively, one of the baseboards can be coped at its end to the profile of the other, but that too is a skill- and time-consuming task. The task of forming perfect mitres and copings is rendered the more difficult in that corners of rooms in houses are very rarely perfectly square. The craftsman knows, however, that the householder will not accept that badly-mitred baseboards can be excused because of the difficulties caused by the out-of-squareness of the walls. The craftsman is expected to produce perfect-looking mitres, in the baseboard mouldings, whatever the squareness condition of the corners of the walls of the room.
The degree of out-of-squareness of any one particular room corner is not predictable. Therefore, it is practically not possible for the mitred joints to be prepared ahead of time, e.g in a factory. Therefore, it falls to the craftsman himself, on the job, to assess the degree of out-of-squareness, and to assess the compensatory compound-angle cuts that will be required, and generally to determine just how best to match the ends of the baseboard mouldings so as to achieve the appearance of perfectly-mitred joints. And this task falls to the craftsman on the basis of starting afresh in every single corner of every single room.
In the present case, it will be understood that, as far as the baseboards themselves are concerned, leaving the baseboards 120,121 short, as in
Of course, merely to leave the ends of the baseboards open, and uncovered, as in
The cover 123 is shown in detail in
Another baseboard moulding profile would require a different profile of trim. However, this is not particularly onerous in terms of marketing and stock-keeping. A baseboard moulding stockist can only stock so many baseboard profiles, and it is a simple matter to locate respective boxes of corresponding covers alongside the stocks of the baseboards.
The cover 123 should be quite thin, as to its material thickness. However, it is recognised that, with a cover of the form as illustrated, it is not necessary to make the cover 123 so thin that the cover practically disappears when placed over the baseboard mouldings 120,121. It is recognised that, so long as the cover is roughly (or exactly) of the same appearance and finish as the baseboards themselves, the cover makes a decorative (though not obtrusive) feature of the corner. It is recognised that, without having to make the cover so thick and chunky as to be obtrusive, the designer has ample scope to specify an adequate thickness for the material of the cover, from the standpoint of strength and rigidity, without compromising appearance.
It is preferred that the cover be made out of wood, or wood products. Thus, the cover may be formed as a compression moulding, comprising wood chips in an adhesive matrix. Manufactured thus, a thickness of about one-and-a-half or two millimetres would give rise to a product having sufficient strength and resilience as to survive reasonably careful installation. The prudent installer would make sure to provide a number of spare covers, in case of accidental breakages. (Baseboard mouldings themselves are not completely free of the danger of breakage and spoilage, and the installer would provide some spare lengths of that, also.)
As may be seen in
The visible outer surface of the cover (seen in
The cover 123 can alternatively be manufactured as a plastic injection-moulding. Now, the thickness can be reduced, e.g down to a minimum of about one-half millimetre, although one millimetre would be preferred.
A variant manner of manufacture of the cover, when it is done in plastic, would be as an extrusion. Now, the cover described herein would be formed as a mitred corner comprising two pieces of the extruded profile, glued together at a mitred joint. The mitred joint would be manufactured in-factory, whereby the joint could be perfectly aligned, and could be assured of being stronger than the extruded form itself.
Alternatively again, the cover could be manufactured as a pressing in sheet metal, and be thinner still. However, metal is less preferred, in that it can be difficult to procure a finish, in metal, that has the appearance of wood. That difficulty would not arise if the baseboards were to be painted, of course. On the other hand, metal ages and settles differently from wood, and a metal cover might be more likely to become obtrusive after a time.
As illustrated, the cover 123 is formed with an upper platform 125. The platform 125 is provided in order to serve the following function. It is all too common, especially in rooms in which the walls are plastered, for the profile of the intersection of two walls 129,130 to have the form as shown in
The cover 123, with its platform 125, can ease this difficulty. First, the baseboard mouldings 120,121 are installed into the corner (that is to say, just short of the actual corner, as in
It is a simple matter for the installer to remove those places on the thin material of the platform 125 of the cover 123 with a trimming knife, file, etc. In fact, the installer can very quickly learn how to trim the platforms 125 in this manner, and thereby can enable the cover 123 to fit reasonably perfectly into the corner, in just a few moments with a trimming knife or file.
It is also not unheard of for one of the walls at a corner to be indented at the corner, rather than to protrude. To cater for that case, the designer should provide for the platform 125 to overhang the profile of the baseboards, by a couple of millimetres.
As illustrated in
Provision for enabling the cover 123 to be adhered to the already-in-place baseboard mouldings 120,121 takes the form of the adhesive patches 136, as shown. The cover 123 is attached to the baseboards after the baseboards have been installed on the wall, and therefore the task of applying (or activating) the adhesive, falls to the installer. The adhesive patch preferably uses the type of glue that sticks on contact. Prior to application, the patch 136 is protected by a covering strip, which is removed just before (final) assembly of the cover into the corner, over the baseboards. The designer might specify the kind of glue that holds the corner-cover firmly to the baseboards, but yet allows the user to remove the corner-cover (by carefully pulling it off) from the baseboards. Some glues also are, upon the corner-cover being replaced, capable of re-sticking the corner-cover to the baseboards.
The designer might also wish to secure the corner-cover to the baseboards by driving a nail through the corner-cover, and into the studs of the wall, in the corner. However, this is not preferred, for a couple of reasons:—the nail holes would then have to be filled and finished; and the driving of the nail might cause distortion of the corner-cover, or might cause the material of the corner-cover (or of the baseboard) to split.
Other kinds of adhesive might be preferred. Instead of providing localised patches, the designer may prefer to provide adhesive over the whole area of the back (i.e the area visible in
In the alternative of
Upon assembly of the cover, the thickness of the layer 140 would be visible between the material of the outer cover 141 and the baseboard 142. However, the foam may be suitably coloured, so the layer 140 is practically invisible—or rather camouflaged—when the cover 138 is in place. The presence of the layer 140 thus enables the cover to appear to fit perfectly to the baseboards 142,143 even in cases where there might be some slight mis-alignment.
The layer 140 is pre-glued inside the wood material of the outer cover 141, in-factory. The adhesive by which the layer 140, in turn, is adhered to the baseboards 142,143 is applied to the surface of the material of the layer, and again this adhesive is activated by the installer.
The covers as previously described were for internal corners. The described style of structure can also be used for external corners, as illustrated at 149 in
The two arms or limbs of the corner piece are set at right angles. The limbs should be equal in length. (There might be cases where the designer might wish to make the two limbs unequal in length, or to set the limbs at some angle other than a right angle. For example, a stockist might wish to make covers with the limbs set at 135° available as a stock item.
The lengths of the limbs would typically be three cm. Preferably, the limbs should not be less than about fifteen mm in length, or the cover could hardly be expected to fulfil its function of covering the ends of the baseboards; or, even if it did at least cover the ends of the baseboards, such short limbs might make installation requirous of almost as much craftsmanship as mitring the joints.
The limbs should preferably not be more than about six cm long, because covers longer than that would probably be regarded as too obtrusive. That is just an aesthetic aspect, however, since there is no technical reason why the limbs cannot be longer. The longer the limbs, also, the greater the possibility that covers in closely adjacent corners might interfere with each other.
As noted, one of the aspects of wall construction, in houses, is that the very bottoms of the walls tend to be provided with an abundance of filling compound, and to stand slightly proud of the surface of the rest of the wall. This is disadvantageous from the standpoint of conventional baseboards. If a baseboard were to stand even slightly away from the surface of the wall, the resulting gap is very noticeable and obtrusive; and a bulge at the foot of the wall has the effect of exacerbating such a gap between the wall and the top of the baseboard. Conventional installers therefore tend to cut the mitres between baseboards at a slight compound angle, so that the baseboards, at least at the corners, where the problem is likely to be worst, lie with the bottoms of the baseboards slightly further out from the wall than the tops of the baseboards. The use of the covers, as described, eliminates this aspect, as a practical problem.
In the baseboard attachment system shown in
The system included a hook-clip 176. The hook-clip is formed as an extrusion in plastic, and its extruded profile is shown in
Above the attachment-element 178, the profile of the hook-clip 176 includes a hook-element, comprising a hook 181 and a hook-extender 183. Below the attachment-element 178, the profile of the hook-clip 176 includes a buffer-element, comprising a buffer 185 and a buffer-extender 187.
The hook-element is springy. The nominal (i.e unstressed) profile of the hook-clip 176, is shown in
The surface of the hook 181 is indented, as shown, so that the hook can engage both sides of the groove 167, and not become jammed therebetween. The indentations or ripples mean that the baseboard is retained quite firmly on the hooks of the hook-clips, against accidental dislodgement, but the baseboard can be lifted off the clips without undue effort.
The buffer-element also is springy. Again, in
The forces generated by bending the hook-element and the buffer-element are reacted against the baseboard 165. Together, the hook-force and the buffer-force produce a turning moment or couple or torque on the baseboard, urging the baseboard to rotate in a counter-clockwise direction. The baseboard 165 is, however, prevented from so rotating by the engagement of a land 189 against the surface of the plasterboard 160.
Thus, the resilience of the hook, and the resilience of the buffer, combine together to urge the baseboard into what can be regarded as a very tight contact between the top edge of the baseboard and the wall. It is recognised that this tight contact is very effective in creating a very good appearance of the baseboard relative to the wall.
With conventional baseboard attachment systems, it is all too common for gaps to appear between the baseboard and the wall. Even though very small, these gaps can be unsightly.
Because the force or pressure of the baseboard against the wall is the result of resilience, the system as described provides some margin whereby, even if the baseboard should change its position, or its size, slightly, still the top edge of the baseboard is pressed tightly against the wall surface.
And, of course, changes can take place in the dimensions of the components. Components of houses settle, dry out, shrink, warp, and undergo many other changes. Most of these are very small, but they can be enough to make the trim in a room, which appeared perfect when it was first installed, look rather shabby after a few years.
With the attachment system as described, however, such changes can be accommodated. The system makes it possible for the changes to take place, but not to lead to any tiny, but unsightly, gaps. What happens is that the baseboard rotates slightly (counter-clockwise in
On the other hand, if the baseboards are indeed allowed to rotate, the tendency is for any mitred joints between adjacent baseboards now to start to open up, at the bottom. However, combining the hook-clip system with the joint covers 123,149, as described, can mask such opening-up of the mitres that might result from a slight rotation of the baseboards.
The baseboard 170 is supported as to its height on the wall by the contact of a nose 190 of the baseboard onto the ledge formed by the hook extender 183. Preferably, the thing that defines the rest position of the baseboard should not be the engagement of the top of the hook 181 with the end of the groove 167, as that might interfere with the force arising from the hook element urging the baseboard towards the wall.
The baseboard is assembled over the hook-clips 176 simply by placing the baseboard flat against the wall, slightly above the clips, and then lowering the baseboard down until the nose 190 abuts the ledge 183. That is the end of the installation process. The chamfer 184 at the entrance to the groove 167 ensures that the hook 181 easily enters the groove.
To remove the baseboards, all that is required is to lift them off. When they are replaced, they immediately adopt the position whereby the tops of the baseboards are pressed firmly against the surface of the wall. This aspect is very convenient when it is desired to re-decorate the wall, either with paint or with a covering such as wallpaper.
The dimensions of the profile of the hook-clip 176 are important. The clip should be of such dimensions and form as to hold the baseboard firmly against the wall, so that the baseboard is not dislodged by everyday impacts thereagainst. The clip should not be so tight that the installer might find it difficult to assemble the baseboard over the clip.
The profile of the plastic hook-clip preferably should be between ½ mm and 2 mm thick. The distance apart of the hook element and the buffer element (as measured between their respective points of contact with the baseboard) should be between 2 cm and 6 cm. The top of the hook 181 should be between 1 cm and 5 cm below the very top of the baseboard.
It will be observed that the foot 192 of the baseboard 160 is not touching anything. Thus, if a person were to press against the foot of the baseboard, the baseboard would rotate—clockwise, in
It will be understood that, if the bottom of the baseboard were to be secured to the wall, that would prevent or impede the very top of the baseboard from pressing tightly against the wall. Thus, the absence of restraint at the bottom of the baseboard is in fact a contributory factor regarding the capability of the baseboard to move to rotate and thus to maintain the pressure of the top of the baseboard against the wall.
It is not required that there be no restraint at all, at the bottom of the baseboard, but rather that any restraint experienced by the bottom of the baseboard should be small. In the case as shown in
The channel-strip 194 exerts only a very small force tending to press the bottom of the baseboard against the wall. The profile of the channel-strip includes a long arm 196 that fits behind the baseboard 165, and the channel-strip is secured to the wall by means of staples 197 that lie at or near the top of the long arm.
Dimensioned and secured in this manner, the channel-strip really does not restrain the bottom of the baseboard from adopting its own position relative to the wall. At the same time, the channel-strip effectively does mask any gaps there might be between the bottom of the baseboard and the floor. Of course, the channel-strip is installed on the wall prior to the baseboard being installed. (If the channel-strip 194 were omitted at the time the baseboard was installed, it could easily be put in later, simply upon lifting the baseboard off the clips 176.)
The installer might prefer to locate the clips 176 such that the staples go through into the stud 161 behind. Alternatively, the installer might prefer to locate the clips 176 between the studs such that the staples go through only the plasterboard 161.
This can be advantageous for the following reason. It often happens that plasterboard bends inwards slightly, between the studs. When the clips are placed between the studs, therefore, the clips can serve to draw the baseboard and the plasterboard together, in the areas between the studs, where the gaps would otherwise be largest.
The clips can be attached to the plasterboard by means of so-called expanding staples, which engage the remote or distal surface of the plasterboard, and thus draw the clip and plasterboard together very strongly. It may be noted that it is not practical to attach regular baseboard to plasterboard, between the studs, using expanding staples, because the heads of the staples are visibly highly obtrusive—but the heads are not visible when used on the clips.
Now, because there is no buffer, the lower part of the chair rail 207 has to touch against something (in this case, against wainscot panels 210 attached to the wall) in order to provide a reaction to enable the forces arising from the hook 209 to be exerted upon the chair-rail 207. Particularly in the case of a chair rail, which is generally shorter in height than a baseboard, there can be enough resilience just in the hook to hold the chair rail firmly against the wall.
Also, there is more reason for wanting the bottom of a chair rail to touch the surface of the wall than there is for wanting the bottom of a baseboard to touch the surface of the wall. And, it should not be ruled out that, in some cases, the designer might be able to omit the buffer in the case also of a baseboard.
The baseboard attachment system illustrated in
This rotation, if it occurs, could cause the mitres at the corners of converging pieces of the baseboard to open up, near the bottom of the baseboards. The designer might regard it as a pity if the excellent visual effect of the tight fit of the tops of the baseboards were to be marred by mitres that have cracked open; and fortunately this all-too-possible condition can be alleviated by using the corner-covers 123,149 at the corners, when the baseboards are attached by the
In this specification, reference is made to walls having outside and inside surfaces. This is for identification. In the terminology of split-frame window or doorframes, the outside frame is typically the half of the frame in which the door or window is actually mounted, which is usually regarded is being towards the outside of the room. Outside with respect to one room is inside with respect to the other room, and, although the terms should be applied consistently, the use of the terms should not be regarded as being limiting in scope.
Number | Date | Country | Kind |
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0616553.4 | Aug 2006 | GB | national |