U.S. patent application number 12/471069 was filed with the patent office on 2009-12-03 for moulding assembly.
Invention is credited to Tim Dykstra, Steven Mitchell, Brian Stafford.
Application Number | 20090293392 12/471069 |
Document ID | / |
Family ID | 41360176 |
Filed Date | 2009-12-03 |
United States Patent
Application |
20090293392 |
Kind Code |
A1 |
Dykstra; Tim ; et
al. |
December 3, 2009 |
Moulding Assembly
Abstract
A moulding assembly comprising a retainer coupled with a trim
member. The retainer may be fastened to a mounting surface, such as
a wall or ceiling surface. The trim member may be removably coupled
with the retainer to hide the retainer, and provide a decorative
outer surface. The trim member need not be fastened directly to the
wall or ceiling surface.
Inventors: |
Dykstra; Tim; (Acworth,
GA) ; Mitchell; Steven; (Chilhowie, VA) ;
Stafford; Brian; (Bristol, VA) |
Correspondence
Address: |
HUNTON & WILLIAMS LLP;INTELLECTUAL PROPERTY DEPARTMENT
1900 K STREET, N.W., SUITE 1200
WASHINGTON
DC
20006-1109
US
|
Family ID: |
41360176 |
Appl. No.: |
12/471069 |
Filed: |
May 22, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61055324 |
May 22, 2008 |
|
|
|
Current U.S.
Class: |
52/288.1 |
Current CPC
Class: |
E04F 19/0436 20130101;
E04F 2019/0413 20130101; E04F 19/0468 20130101; E04F 2019/0454
20130101 |
Class at
Publication: |
52/288.1 |
International
Class: |
E04F 13/00 20060101
E04F013/00; E04F 19/02 20060101 E04F019/02 |
Claims
1. A moulding assembly comprising: a retainer comprising a central
section, a first mounting leg extending from a first end of the
central section, a second mounting leg extending from a second end
of the central section, and a first fastening component disposed at
least partially on said central section; and a trim member
comprising a second fastening component that couples with said
first fastening component.
2. The moulding assembly of claim 1, wherein said second fastening
component removably couples with said first fastening
component.
3. The moulding assembly of claim 1, wherein said first and second
fastening components comprise mating male and female
connectors.
4. The moulding assembly of claim 3, wherein said first fastener
component comprises a female connector, and said second fastener
component comprises a corresponding male connector.
5. The moulding assembly of claim 3, wherein said first fastener
component comprises a male connector, and said second fastener
component comprises a corresponding female connector.
6. The moulding assembly of claim 3, wherein said female connector
has a slot, and said male connector has a flange.
7. The moulding assembly of claim 3, wherein said first and second
fastening components provide a snap interference fit.
8. The moulding assembly of claim 7, wherein said female connector
comprises a surface having at least one projection or ridge or
corrugation that engages or mechanically interferes with at least
one corresponding projection or ridge or corrugation on a surface
of said corresponding male connector.
9. The moulding assembly of claim 1, wherein said first and second
mounting legs are substantially orthogonal.
10. The moulding assembly of claim 9, wherein the angle between
said first and second mounting legs can change.
11. The moulding assembly of claim 1, wherein said first and second
mounting legs are flexible.
12. The moulding assembly of claim 1, wherein said first fastening
component is recessed at least partially within said central
section.
13. The moulding assembly of claim 1, wherein said first fastening
component extends at least partially from a surface of said central
section.
14. The moulding assembly of claim 1, wherein said retainer is an
elongated member having a substantially uniform transverse
cross-section.
15. The moulding assembly of claim 14, wherein said transverse
cross-section defines, in part, said central section, said first
mounting leg, said second mounting leg, and said first fastening
component.
16. A moulding assembly comprising: an elongated retainer having a
central section, a first mounting leg extending from said central
section in a first plane, and a second mounting leg extending from
said central section in a second plane that is substantially
orthogonal to said first plane; an elongated trim member, an
elongated fastener assembly that couples said trim member and said
retainer.
17. The moulding assembly of claim 16, wherein said elongated
retainer has a substantially uniform cross-section.
18. The moulding assembly of claim 16, wherein said elongated trim
member has a substantially uniform cross-section.
19. The moulding assembly of claim 16, wherein said elongated
fastener assembly has a substantially uniform cross-section.
20. The moulding assembly of claim 16, wherein said fastener
assembly comprises a first fastening component disposed on said
retainer and a second fastening component disposed on said trim
member.
21. The moulding assembly of claim 20, wherein said second
fastening component removably couples with said first fastening
component.
22. The moulding assembly of claim 16, wherein said fastening
assembly comprises mating male and female connectors.
23. The moulding assembly of claim 22, wherein said female
connector has a slot, and said male connector has a flange.
24. The moulding assembly of claim 20, wherein said fastener
assembly provides a snap interference fit.
25. The moulding assembly of claim 20, wherein said female
connector comprises a surface having at least one projection or
ridge or corrugation that engages or mechanically interferes with
at least one corresponding projection or ridge or corrugation on a
surface of said corresponding male connector.
Description
[0001] 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.
FIELD OF THE INVENTION
[0002] 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.
BACKGROUND
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
SUMMARY
[0007] 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.
[0008] 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.
[0009] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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:
[0011] FIG. 1 is a cross-sectional view of a moulding assembly
according to an exemplary embodiment described herein;
[0012] FIG. 2 is a cross-sectional view of an elongated trim member
according to an exemplary embodiment;
[0013] FIG. 3 is a cross-sectional view of an elongated retainer
according to an exemplary embodiment;
[0014] FIG. 4 is a cross-sectional view of a moulding assembly
according to an exemplary embodiment described herein;
[0015] FIG. 5A is a cross-sectional view of a trim member and
retainer of a moulding assembly according to an exemplary
embodiment described herein;
[0016] FIG. 5B is a cross-sectional view of a trim member and
retainer of a moulding assembly according to an exemplary
embodiment described herein;
[0017] FIG. 5C is a cross-sectional view of a trim member and
retainer of a moulding assembly according to an exemplary
embodiment described herein; and
[0018] FIG. 5D is a cross-sectional view of a trim member and
retainer of a moulding assembly according to an exemplary
embodiment described herein.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] 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.
[0020] 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.
[0021] 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.
[0022] Referring now to FIGS. 1 and 4, in an exemplary embodiment,
the moulding assembly 100 may trim an upper corner 30 of a room at
the intersection of ceiling 20 and vertical wall 10. In exemplary
embodiments, moulding assembly 100 may include an elongated
retainer 200 and elongated trim member 300. Retainer 200 may be
attached to a mounting surface. For example, the elongated retainer
200 may extend across the corner 30, fastening to the interior
surfaces of wall 10 and ceiling 20. In exemplary embodiments, the
elongated trim member 300 may be operably coupled with the retainer
200, extending along the length of the retainer 200 and hiding the
retainer 200 from view. In exemplary embodiments, the elongated
trim member 300 is not fastened directly to the wall 10 or ceiling
20, and may be removable from the retainer 200. Various exemplary
features of the retainer 200 and trim member 300 are described
below.
[0023] 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.
[0024] 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.
[0025] Referring to FIGS. 1 and 4, retainer 200 may include outer
surface 208 facing away from corner 30 and an inner surface 206
facing toward the corner 30. Retainer 200 may include one or more
legs 202, 204. In one embodiments, legs 202, 204, may be configured
to be fastened to a mounting surface such as a wall 10 or a ceiling
20, or underlying structures, such as with a staple, nail, screw,
or other such fastener. To assist with the correct placement of a
fastener through the retainer 200, the outer surface 208 of the
legs 202, 204, may include one or more fastener grooves 210 located
along the length of one or both legs 202, 204. In exemplary
embodiments, retainer 200 may be adhered to the underlying mounting
surface, such as with the application of a glue bead between the
underlying surface and legs 202 and/or 204. One of ordinary skill
in the art will recognize how to properly fasten the retainer 200
to an underlying structure, so as to provide suitable support for
the moulding assembly 100.
[0026] 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 FIG. 5B, legs 202, 204 may be substantially co-planar,
such as for attachment to a single surface. Referring to FIGS. 1
and 4, in an exemplary embodiment in which the moulding assembly
100 is intended as a crown moulding, legs 202, 204 may be generally
orthogonal to each other, joining each other at a central section
or throat 212, so that leg 202 may be fastened to ceiling surface
20, and leg 204 may be mounted to wall surface 10. In a crown
moulding trim application, it may be advantageous to mount the
retainer 200 to both the wall 10 and the ceiling 20 surface to
distribute the weight between the two surfaces. Mounting the
retainer 200 to both the wall 10 and ceiling 20 may also enable a
better fit between the trim member 300 and the ceiling 20.
[0027] 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 FIGS. 1 and 4, when legs 202, 204 of retainer
200 are attached to adjacent wall 10 or ceiling 20 surfaces, at
least a portion of throat 212 may be spaced from the corner 30 of
the room. In this configuration, the retainer 200 provides a
consistent mounting structure shape, regardless of irregularities
in the surface of the wall 10 and ceiling 20.
[0028] Referring to FIGS. 1 and 4, in exemplary embodiments, the
retainer 200 may be symmetrical about a centerline, so that legs
202 and 204 have a similar size and shape. A symmetrical shape may
enable the retainer 200 to be reversible, so that leg 202 and leg
204 may be reversed without diminishing the functionality of the
retainer 200. Referring to FIGS. 5A and 5B, in other exemplary
embodiments, the retainer 200 may be asymmetrical about a
centerline, such as by providing only a single leg 202, or by
distributing the retainer 200 off-center to the legs 202, 204, or
by providing a leg 202 that is longer or shorter or having a
different shape than leg 204. In certain embodiments, an
asymmetrical profile may be configured to enable distribution the
load of the mounting assembly 100 more toward one leg or the other.
An appropriate length, size and shape may be selected as necessary
and/or desired.
[0029] 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 FIGS. 1 and 4, the trim
member 300 may be configured so that, when it is attached to the
retainer 200 that is attached to the upper corner 30 of a room, the
trim member 300 generally covers the outer surface 208 of the
retainer 200, hiding it from plain view. When coupled with the
retainer 200, the outer surface 304 of trim member 300 faces the
room. In exemplary embodiments, the outer surface 304 may have a
decorative surface to provide an ornamental appearance when viewed
from the room. In exemplary embodiments in which the moulding
assembly is a crown moulding assembly, trim member 300 generally
may be disposed at a predetermined angle to the wall 10, ceiling
20, or both.
[0030] 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 FIGS. 1 and 4, trim member 300 may have a first side
edge 312 that is substantially flush with the ceiling 20, and a
second side edge 314 that is substantially flush with the wall 10
when the trim member 300 is coupled with the retainer 200. In
exemplary embodiments, when the trim member 300 is coupled with the
retainer 200, there appears to be little or no gap between the
edges 312, 314 and the respective mounting surfaces 20, 10. In this
configuration, the trim member 300 may appear to be attached to the
corner 30, similar to conventional crown moulding trim. However,
unlike conventional crown moulding trim, trim member 300 of the
exemplary embodiments need not be directly fastened to the mounting
surface to remain flush with the mounting surfaces. In exemplary
embodiments, at least portions of the trim member 300 may compress
or flex to maintain consistent contact with the surface of the wall
10 or ceiling 20, along the length of the trim member 300. A more
flexible trim member 300 may remain flush to the underlying
mounting surface, regardless of imperfections in the mounting
surface. In exemplary embodiments, the trim member 300 may be
configured so that it remains substantially flush with the mounting
surface even after prolonged use.
[0031] 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.
[0032] 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 FIGS. 1-4 and 5A-5D, trim member 300 may have a male
portion of a mating fastening assembly, such as, for example, a
mounting flange 306 disposed on its inner surface 302 that may be
removably engaged with a female portion of a mating fastening
assembly, such as, for example, mounting receptacle 214 disposed on
the outer surface 208 of the retainer 200. In various exemplary
embodiments, the male/female mating fasteners may be reversed, such
that a male component is disposed on the retainer 200, and the
female component may be disposed on the trim member 300.
[0033] 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 FIGS. 5A and
5B, a snap interference fit may be provided by mating components
(214a/306a or 214b/306b) having engaging projections (220, 316),
that when engaged prevent the separation of the retainer 200 and
the trim member 300. Referring to FIG. 5C, a snap interference fit
may be provided by mating components (214c/306c), having
corresponding nesting ridges or contours or corrugations (216, 308)
on one or more surfaces that, when engaged, prevent the separation
of the retainer 200 and the trim member 300. Providing a plurality
of engaging members may enable a graduated degree of insertion of
the trim member 300 into retainer 200. Referring to FIG. 5D, a snap
interference fit may be provided by mating components (214d/306d)
having a ball and socket type of connector (222/318). Other known
or later developed mating mounting components or fastening
assemblies may be employed in the exemplary embodiments, consistent
with the embodiments described herein.
[0034] 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 FIGS. 1, 3, and 4, and 5C-5D, in exemplary
embodiments, mounting receptacle(s) 214 generally may be disposed
on the throat 212 portion of the retainer 200. However, in various
exemplary embodiments the mounting receptacle 214 may be disposed
in other suitable positions on the retainer 200. In exemplary
embodiments, the mounting receptacle(s) 214 may provide a groove or
slot opening toward the outer surface 208 of the retainer 200. The
groove or slot opening may be recessed into or integral with the
other portions of the retainer 200, or it may extend outwardly from
one or more portions of the retainer 200. For example, referring to
FIGS. 4 and 5A-5D, in an exemplary embodiment the mounting
receptacle 214 may be at least partially formed by one or more arms
218 that extend outwardly from the surface of the retainer 200,
providing a groove or slot. In the various exemplary embodiments
the mounting receptacle 214 may be configured in one or more shapes
suitable for mating with and operably coupling with the
corresponding mounting flange 306 of the trim member 300. For
example, the inner surfaces of arms 218 may have one or a plurality
of projections 220, ridges 216 or other surface contours that may
provide a snap interference fit with mounting flange 306.
[0035] 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 FIGS. 1, 2, 4 and 5A-5D, trim member 300 may include
one or more mounting flanges 306, disposed on the inward facing
surface 302 of the trim member 300. In exemplary embodiments, the
mounting flange(s) 306 may be centrally disposed along the width of
the trim member 300. However, the mounting portion(s) 306 may be
disposed in other suitable positions on the trim member 300, so
that the trim member 300 may be coupled with retainer 200. In the
various exemplary embodiments, the mounting flange 306 may be
configured in one or more shapes suitable for mating with and
operably coupling with the corresponding mounting receptacle 214 of
the trim member 300. For example, the sides of flange 306 may have
one or a plurality of projections 316, ridges 308 or other surface
contours that may provide a snap interference fit with mounting
receptacle 214.
[0036] 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 FIGS. 1 and
2, in various exemplary embodiments the mounting receptacle 214 or
mounting flange 306 may include one or more flexible flaps 310. The
flexible flaps 310 may be configured to resist removal of the
mounting flange 306 from the mounting receptacle 214. For example,
referring to FIG. 2, the flaps 310 may extend from the side edges
of the mounting flange 306, angled back toward the outer surface
304 of the trim member 300. In this configuration, the flexible
flaps 310 may flex inward as the mounting flange 306 is inserted
into the mounting receptacle 214, so as not to interfere with the
engagement of the two components. Once the mounting flange 306 is
fully inserted into the mounting receptacle 214, the flaps 310 may
flex back outward, with their distal ends abutting a portion of the
surface of the mounting receptacle 214, to resist removal of the
mounting flange 306 from the mounting receptacle 214. In various
exemplary embodiments, the mounting receptacle 214 may include one
or more surface features designed to engage with the flaps 310, to
increase the resistance necessary to remove the mounting flange 306
from the mounting receptacle 214. In exemplary embodiments, the
flexible flaps 310 may be more flexible than the materials used for
the elongated trim member 300, or the retainer 200. In exemplary
embodiments, other features, such as friction inducing substances
or contours, may be added to one or more interfaces of the
connectors to improve the engagement or interference between the
retainer 200 and trim member 300. In embodiments in which the trim
member 300 is extruded, such as extruded PVC, the flexible flaps
310 and/or other features may be formed integrally with the
elongated trim member 300, such as by coextruding the two materials
together. However, the flaps 310 and/or other features may be
separately formed, and then later attached to or coupled with trim
member 300.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
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