Note: Descriptions are shown in the official language in which they were submitted.
CA 02528573 2005-11-30
MODULAR MOULDING WITH FITTED SPLINE
JOINERY SYSTEM
TECHNICAL FIELD
The present invention relates generally to modular ornamental mouldings. In
particular, the present invention relates to a modular moulding with a fitted
spline joinery
system.
BACKGROUND OF THE INVENTION
Ornamental wood mouldings have long been employed to enhance the look of
furniture, cabinetry, architectural interiors, and the like. Current options
include employing a
skilled carpenter or woodcrafter to create a unitary custom moulding or
selecting a standard
stock moulding to fit into a specific length and application.
With the explosion of demand for high-end, custom-look cabinetry in kitchens,
bathrooms, and other previously pure utility spaces, ornamental legs and faux-
leg wood
mouldings are in higher demand than ever before. However, a furniture or
cabinet maker
either has to stock many various unitary ornamental legs or faux-leg
mouldings, manufacture
their own mouldings, or utilize modular component ornamental mouldings and
tack and/or
glue each piece into place to create a unit that looks like a turned furniture
leg.
Although the latter option is used with more frequency, it adds to labor costs
as it is
time-consuming to line up modular pieces of adjoining mouldings, such as
center spools,
elongated column pieces, base spools, and base blocks to create the look of a
turned leg.
These individual components are generally tack nailed to furniture, cabinets,
or the like, and
then filled in with wood putty to patch any visible crevices. The result
provides a unitary
columnar ornamental moulding look, but is time consuming to assemble. Further,
unless the
assembler has great skill and patience, the end result may not comport with
highly discerning
homeowners and contractors as the resulting moulding may contain visible gaps
or carpenter
tacks, and/or the individual moulding pieces may be unevenly aligned.
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SUMMARY OF THE INVENTION
The present invention is directed to a unique modular ornamental moulding
system
that employs a spline and groove joinery method. Each ornamental moulding
unit, such as
an elongated column member, a base block, a base spool, or a center spool, has
a
substantially planar back surface and a front ornamental surface, with the
front surface
intended to be visible. Each moulding unit is designed to align with each
other to form a
unitary columnar moulding, that looks like a one-piece turned leg, with the
back surfaces all
in substantial planar alignment and the top surface forming a unitary columnar
ornamental
moulding. Each substantially planar back surface has a groove (or slot) that
is longitudinally
aligned of each piece, such that when each moulding piece is laid end-to-end
and the
ornamental features of each moulding piece are in a desired arrangement, at
least portions of
the groove are aligned with portions of the groove adjacent mouldings.
According to one
aspect of the present invention, the groove is continuous and straight when
each moulding
unit is aligned end-to-end.
An elongated spline of a shape to be fitted within the now longitudinally
aligned
groove is positioned at least by and between each two adjacent and contacting
moulding
pieces. The spline may be rounded with a substantially circular cross
sectional shape or may
be partially rounded with a planar lower surface. The spline lower surface is
either
preferably planar to conform to the planar surface of the back of each
moulding piece or
positioned below the planar back surface to not protrude beyond the overall
substantially
planar back surface of the assembled columnar ornamental moulding.
The present invention also includes a method of applying a plurality of
modular
ornamental moulding pieces to a piece of furniture, or the like, that provides
the appearance
of a unitary columnar ornamental moulding. Moreover, the modular pieces are
assembled
and adhered or otherwise affixed to a furniture surface without the need for
tack pins or glue
for each individual piece. The method includes providing a plurality of
modular ornamental
moulding units with a substantially planar back surface and a top surface that
forms the
ornamental moulding and that each unit has a groove aligned longitudinally of
the planar
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surface. At least one spline is fitted within the longitudinally-positioned
groove at least by
and between adjoining sections of adjacent moulding units. In this way, the
moulding units
form a columnar ornamental moulding with a substantially planar back surface
and an
ornamental top surface. The resulting assembled columnar ornamental moulding
is adhered,
such as by wood glue, or otherwise affixed, to a desired location on a piece
of furniture, or
the like, via the substantially planar surface.
In addition to the great flexibility that furniture and cabinet makers will
have by
stocking fewer ornamental moulding pieces and the ability to provide customers
with greatly
enhanced number of ornamental options, the current modular moulding invention
and
method provides cost-saving ease of installation and improved aesthetics
(e.g., virtually no
gaps and no misalignment).
These and other advantages will become more apparent upon review of the
Drawings,
the Best Mode for Carrying Out the Invention, and the Claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Like reference numerals are used to designate like parts throughout the
several views
of the drawings, wherein:
Fig. 1 is a pictorial front view of various ornamental modular moulding units
that can
be arranged to form a unitary columnar ornamental moulding;
Fig 2 is a back view of Fig. 1 illustrating the groove and spline joinery
system of the
present invention;
Fig. 3 is an enlarged pictorial view of an exemplar moulding piece or unit;
Fig. 4 is an end view of the unitary columnar ornamental moulding of Fig. 1
illustrating a first embodiment of the groove and spline joinery system;
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Fig. 5 is a cross-sectional view of the unitary columnar ornamental moulding
taken
substantially across lines 5 - 5 of Fig. 1 and illustrating the same groove
and spline joinery
embodiment of Fig. 4;
Fig. 6 is an end view like Fig. 4 except illustrating a second embodiment of
the
groove and spline joinery system;
Fig. 7 is a cross-sectional view like Fig. 5 except illustrating the second
embodiment
groove and spline joinery system of Fig. 6;
Fig. 8 is an end view like Fig. 4 except illustrating a third embodiment of
the groove
and spline joinery system;
Fig. 9 is a cross-sectional view like Fig. 5 except illustrating the third
embodiment
groove and spline joinery system of Fig. 8;
Fig. 10 is an end view like Fig. 4 except illustrating a fourth embodiment of
the
groove and spline joinery system;
Fig. 11 is a cross-sectional view like Fig. 5 except illustrating the fourth
embodiment
groove and spline joinery system of Fig. 10;
Fig. 12 is a perspective view illustrating assembly of the modular moulding
components to form a unitary columnar moulding;
Fig. 13 is a front view of an exemplar assembled unitary columnar moulding
having
two base blocks, two end spools, two elongated columns, and a center spool;
Fig. 14 is a back view of a unitary columnar moulding, similar to Fig. 13
except
illustrating another exemplar unitary ornamental moulding arrangement having
two base
blocks, two end spools, and a single elongated column;
Fig. 15 is a front view of Fig. 14;
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Fig. 16 is a perspective view of a piece of furniture to which one assembled
unitary
columnar moulding of the present invention is adhered to the furniture surface
and another is
about to be adhered; and
Fig. 17 is a perspective view of a framed minor to which a pair of assembled
unitary
columnar mouldings of the present invention is adhered to the frame portion.
BEST MODE FOR CARRYING OUT THE INVENTION
The present invention is directed to a modular ornamental moulding joinery
system to
achieve unitary columnar ornamental moulding for application to furniture,
cabinetry,
frames, and the like. Referring to Figs. 1-17, a unitary ornamental column
moulding 10 is
made up of individual modular moulding pieces 12. The individual modular
moulding pieces
12 may be elongated column members 14, base spools 16, base blocks 18, or
center spools
20.
Referring particularly to Fig. 3, each moulding piece 12 includes a first end
22 and a
second end 24 with a generally axially-aligned body portion 26 generated about
an imaginary
axis A - A positioned therebetween. At least one end of each moulding piece 12
has a
surface that conforms to an end of another moulding piece 12. According to one
embodiment, each end has a cross-planar surface 28 (or cut) essentially
perpendicularly to
axis A - A so as to be aligned end-to-end with an adjoining moulding piece 12,
although
other conjoining end shapes may be used but are not illustrated.
Each moulding piece 12 has a front surface 30 which when joined with at least
one
other moulding piece form a unitary columnar ornamental surface 32 that is to
be placed
front side up upon a desired surface on a piece of furniture or the like. The
various
illustrations in Figs. l, 13, and 15-17 are for illustrative purposes only and
not to be limited
to the designs that are shown. Hundreds, perhaps thousands, of design
permutations may be
had with minimal stocking, as opposed to having specialty moulding in stock or
resorting to
expensive custom orders.
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Each moulding piece's back surface 34 is substantially planar so that each
adjoining
moulding piece can better align, as discussed in further detail below, and
that once the
moulding pieces are aligned to form the unitary columnar moulding, the
substantially planar
back surface 34 can be readily adhered or otherwise fixed to a substantially
planar surface on
furniture and the like.
According to one aspect of the invention, each moulding piece 12 is
essentially a
cylindrical column or block that has been cut substantially one-half axially
along axis A -A.
Thus, each moulding piece may look like a 1 /2 column moulding. Alternatively,
but not
shown, each moulding piece can be other shapes, e.g., 3/4 column, 1/3 column,
rectangular,
triangular, or other variation.
Referring particularly to Fig. 2 and also to Fig. 12, each substantially
planar back
surface 34 includes a longitudinally positioned groove 36 (or slot) that
aligns with each
moulding piece when positioned end-to-end. A spline 38 that is of a size and
shape to be
fitted within groove 36 is fitted within at least by and between adjoining
portions of abutting
and adjacent moulding pieces 12. In this way, the spline joins adjacent and
abutting
moulding pieces to form a unitary columnar moulding 10.
From a manufacturing standpoint a single elongated groove positioned
longitudinally
end-to-end of each moulding piece 12 is perhaps more pragmatic. In this
embodiment, the
resulting groove forms a unitary straight groove once the moulding pieces are
laid end-to-
end. However, it is not a necessary feature of the present invention that the
groove run the
entire longitudinal length of each modular piece, but merely at least at an
abutting end of
each modular member.
According to another aspect of the invention, the spline may be fitted, such
as friction
fit, within a groove that runs the full length of the unitary columnar
moulding 10 (not
illustrated).
Referring now to Figs. 4-11, the spline 38 may be a 1/2 rounded spline 40 with
a
planar surface 42 that, when placed into and fitted within the groove, is co-
planar with back
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surface 34. In the embodiment of Figs. 4 and 5, the groove may include a pair
of opposing
side walls 44 and an inverted "v-shaped" bottom 46 that aids in placement and
engagement
of the 1/2 rounded spline 40. The spline may be friction fit into the groove.
However, a
sealant, including glue, may be used to fit the spline within the groove as
illustrated in the
cross-sectional views of Figs. 5, 7, 9. and 11.
In another embodiment, as illustrated in Figs. 6 and 7, the groove may have a
rounded
bottom 48 that directly conforms to the shape of a rounded spline (whether
half round or
spherical, such as shown in Figs. 10 and 11 ). In yet another embodiment, as
illustrated in
Figs. 7 and 8, the groove 36/50 may be trapezoidal in shape for friction
fitting a 1/2 rounded
spline.
It is preferable that the back surface of the unitary columnar moulding 10 not
have
any outwardly protruding spline portions unless a corresponding groove is made
within the
surface to which the unitary columnar track is to be affixed. Although a
resulting smooth
planar surface of the combined spline and back surface may be had using a
spline with a
partially planar surface, the spline 38/52 may have a circular cross section,
as illustrated in
Figs. 10 and 11, or some other shape so as to fit within the groove such that
no spline portion
protrudes beyond the back surface of the moulding piece.
The present invention also includes a method of applying modular moulding
pieces in
order to obtain the look of expensive custom moulding without the need for
skilled
carpenters or stocking large amounts of pre-fabricated unitary ornamental
mouldings or
carpenter tacks. The method includes providing modular moulding pieces each
having front
surfaces and substantially planar surfaces. The method further includes
aligning desired
moulding pieces end-to-end such that the moulding pieces' substantially planar
surfaces align
and the front surfaces form an elongated ornamental moulding. Along the
substantially
planar surface of each moulding piece is a groove. A spline or portions of
spline are fitted
within the resulting elongated groove to join at least over portions of
adjacent and adjoining
moulding pieces to form a unitary columnar ornamental moulding. The back side
of the
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unitary moulding is adhered or otherwise affixed to a surface on a piece of
furniture,
cabinetry, or the like.
The present invention and method are primarily intended for the wood furniture
industry, with the moulding pieces being made of various types of woods.
However, the
present invention and its joinery system are not limited to wood mouldings and
may be used
on composite/man-made mouldings or even metal mouldings.
Advantages of the present invention include the ease and speed in which to
attain the
look of expensive custom moulding without the expense of unnecessary stock or
need for
highly skilled carpenters. Unsightly gaps between adjoining modular moulding
pieces or
misalignment are virtually eliminated in order that the highest quality
aesthetics are
maintained.
The illustrated embodiments are only examples of the present invention and,
therefore, are non-limitive. It is to be understood that many changes in the
particular
structure, materials, and features of the invention may be made without
departing from the
spirit and scope of the invention. Therefore, it is the inventors' intention
that their patent
rights not be limited by the particular embodiments illustrated and described
herein, but
rather by the following claims interpreted according to accepted doctrines of
claim
interpretation, including the Doctrine of Equivalents and Reversal of Parts.
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