Note: Descriptions are shown in the official language in which they were submitted.
CA 02534001 2012-11-05
TITLE: MULTI PIECE CURVED MOLDINGS
FIELD OF THE INVENTION
[0001] The present invention relates to curved moldings and more particularly
relates to
multi piece curved moldings, collapsible multi piece curved moldings and
methods of
joining curved molded sections.
DESCRIPTION OF THE PRIOR ART
[0002] Referring now to FIGS. 41 through 44 which depict prior art curved
moldings
which are also known in the art as arched sections which typically are used
for trimming
around windows and doorways, both interior and exterior applications and in
various
other applications requiring trim moldings
[0003] Currently today arched molding sections are generally manufactured in
one piece.
FIG. 41 depict a typical prior art curved molding section known as laminated
arch 502 in
which numerous wood strips 504 are jointed together with glue joints 507 to
form a glued
arch 508 having a cross section appearance as in 506. This is a one piece
solid wood arch
which is made out a number of wood strips 504. The profile is then milled into
one
surface of the glued arch 508. The reader will note that this a highly labour
intensive,
slow and expensive process.
[0004] The other prior art arch, method of making curved moldings and arches
is shown
as block arch 510 which is made out of a number of wood blocks 512 which are
glued
together at glue joints 514. Once the wood blocks have been securely glued
together, an
arch. is milled out of the wood block section, creating milled arch 516 shown
in dashed
lines in FIG. 43. Curved moldings are also milled out of fibre board, plywood,
particle
board and other composite materials. In each case the arch or curved molding
is a one
piece construction.
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[0005] The other type of prior art curved molding and/or arched sections which
is
commercially available is a rubber molding 520 shown in FIG. 44. This is a
semi-flexible
continuous piece of a vinyl rubber type material which can be applied as a
curved
molding or arch. The reader will appreciate that this type of molding is not
suitable, when
a natural wood finish is desired. In addition the installation of the rubber
molding 520
shown in FIG. 44 is limited to over a very narrow temperature range and
therefore, it
difficult to use this type of rubber moldings under certain conditions,
particularly in cold
weather for exterior applications. In preferred embodiments.
[0006] Historically the difficulty with the one piece curved molding or arch
construction
shown in FIGS. 41 to 43 is storing and transporting the large cumbersome
curved
molding arch sections. In particular, breakage and damage does occur
frequently in
storage or transport which is undesirable. Secondly on installation, these
arches have very
little to no flex or give to them which makes it difficult to install them
particularly if the
arch way which has been pre-constructed or roughed in by previous carpenters
is not
perfectly matched to the arch section that has been milled.
[0007] In regard to the laminated arch 502, the laminating lines can be seen
which is
undesirable in natural wood type constructed curved moldings or arches.
[0008] Therefore, there is a need for a curved molding and/or arch system
which can be
shipped in sections and/or preferably is collapsible and can be shipped in a
compact form
and then placed into an extended position in which the arch is ready for
installation.
There is also a need for a method of attaching smaller curved sections
together so that the
connection of these curved sections can be accomplished at the job site
thereby enabling
the manufacturer to ship the curved moldings and/or arch section in smaller
pieces.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will now be described by way of example only with
reference to the
following drawings in which:
[0010] FIG. 1 is a top plan view of the present invention, foldable molding.
[0011] FIG. 2 is a side elevational view of the present invention, multi piece
curved
molding shown in FIG. 1.
[0012] FIG. 3 is a bottom plan view of the present invention, multi piece
curved molding.
[0013] FIG. 4 is a side elevational view of the multi piece curved molding
shown in FIG.
3.
[0014] FIG. 5 is a top plan view of two curved sections butting each other.
[0015] FIG. 6 is a side elevational view of the curved section shown in FIG.
5.
[0016] FIG. 7 shows the two curved sections in the folded position as well as
in the
partially foldable positions in dashed lines.
[0017] FIG. 8 is a top plan view of an alternate embodiment of the present
invention,
multi piece curved molding.
[0018] FIG. 9 is a side elevational view of the multi piece curved molding
shown in FIG.
8.
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[0019] FIG. 10 is a bottom plan view of the second embodiment of the present
invention,
multi piece curved molding.
[0020] FIG. 11 is a side elevational view of the multi piece curved molding
shown in
[0021] FIG. 12 is a bottom plan view of two curved sections of the multi piece
curved
molding shown in FIG. 8 with the elastic hinge shown in the stretched
position.
FIG. 12.
[0023] FIG. 14 shows two curved sections of the multi piece curved molding in
a folded
position as well as in partially folded positions in dashed lines.
[0024] FIG. 15 is a top plan view of a third embodiment of the present
invention, the
multi piece curved molding.
[0025] FIG. 16 is a side elevational view thereof
[0025] FIG. 17 is a bottom plan view of the third embodiment of the present
invention.
[0027] FIG. 18 is a side elevational view thereof
molding shown in the extended position.
[0029] FIG. 20 is a side elevational view of the third embodiment of the multi
piece
curved molding shown in the partially folded position.
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[0030] FIG. 21 is a side elevational view of the third embodiment of multi
piece curved
molding shown in the more partially folded position.
[0031] FIG. 22 shows the third embodiment of the multi piece curved molding in
the
closed position.
[0032] FIG. 23 shows the third embodiment of the present invention, multi
piece curved
molding shown in the folded position within the interior of a shipping box.
[0033] FIG. 24 is a top plan view of a fourth embodiment of the present
invention, multi
piece curved molding.
[0034] FIG. 25 is an end view of FIG. 24.
[0035] FIG. 26 is a side elevational view thereof.
[0036] FIG. 27 is a top plan view of the other half of the fourth embodiment
of the
present invention, multi piece curved molding.
[0037] FIG. 28 is an end view thereof.
[0038] FIG. 29 is a side elevational view thereof.
[0039] FIG. 30 is a top plan schematic assembly view of the fourth embodiment
of the
present invention, multi piece curved molding.
[0040] FIG. 31 is a side elevational view thereof.
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[0041] FIG. 32 is a top plan view of the left half of the fourth embodiment of
the present
invention, multi piece curved molding.
[0042] FIG. 33 is aside perspective view of multi piece curved molding in the
folded
position.
[0043] FIG. 34 is a side elevational view of foldable molded in the folded
position.
[0044] FIG. 35 is a side elevational view of flexible hinge.
[0045] FIG. 36 is a side elevational view of flexible hinge in a partially
folded condition.
[0046] FIG. 37 is a top perspective view of flexible hinge.
[0047] FIG. 38 is a bottom perspective view of flexible hinge.
[0048] FIG. 39 is a side perspective view of flexible hinge in the partially
folded
condition.
[0049] FIG. 40 is an elevation view of a window opening shown in a wall
together with a
piece of graph paper taped thereon for drawing of a framed outline.
[0050] FIG. 41 is an elevated plan view of a prior art one piece laminated
arch.
[0051] FIG. 42 is a cross sectional view of the laminated arch shown in FIG.
41.
[0052] FIG. 43 is a prior art one piece block arch.
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[0053] FIG. 44 is a perspective schematic view of a prior art one piece rubber
molding
arch.
[0054] FIG. 45 is a perspective schematic view of a wafer shown in exploded
fashion.
[0055] FIG. 46 is a schematic perspective view of the assembled wafer.
[0056] FIG. 47 is a schematic perspective view of the assembled wafer showing
the peel
off back coming off.
[0057] FIG. 48 is a schematic perspective view of the wafer showing the
transverse and
longitudinal direction.
[0058] FIG. 49 is a side elevational view of the wafer which has been
distorted and or
displaced in the longitudinal direction.
[0059] FIG. 50 is a schematic perspective view of the wafer shown compressed.
[0060] FIG. 51 is a side elevational view of the wafer shown compressed.
[0061] FIG. 52 is a partial cut away assembly view of two curved sections
together with a
wafer shown mounted in recessed wafer pockets.
[0062] FIG. 53 is a schematic perspective view of the wafer showing the peel
off backing
being taken off prior to being placed into a recessed wafer pocket.
[0063] FIG. 54 is a schematic perspective view showing the wafer installed on
a recessed
wafer pocket.
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[0064] FIG. 55 is a schematic perspective view of a wafer.
[0065] FIG. 56 is a top plan view of a curved section together with a wafer
installed in
one end and showing the recessed wafer pocket in the other end.
[0066] FIG. 57 is a schematic perspective view of a curved section showing
wafers being
installed in recessed pockets in both ends of a curved section.
[0067] FIG. 58 is a schematic perspective view of a multi layered hinge in
exploded
fashion.
[0068] FIG. 59 is a schematic perspective view of multi layered hinge shown in
an
assembled fashion with the peel off backing shown partially pulled back.
[0069] FIG. 60 is a perspective schematic view of a flexible hinge.
[0070] FIG. 61 is a top plan view of a curved section showing hinge pockets at
each
abutting end.
[0071] FIG. 62 is a schematic perspective view of curved section showing a
hinge
installed in a hinge pocket on the left side.
[0072] FIG. 63 is a curved molding and/or arch section showing four curved
sections
connected together with flexible hinges on the left side and right side and a
wafer in the
middle.
[0073] FIG. 64 is a side elevational view of the arch shown in 63, wherein the
curved
sections on each end are in the partially folded position.
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[0074] FIG. 65 shows the arch in FIG. 62 in front elevational view in the
extended
position.
[0075] FIG. 66 shows the arch shown in FIG. 63 in the folded position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0076] FIGS. 1 through 7 depict the first embodiment of the present invention,
multi
piece curved molding shown generally as 100. Multi piece curved molding 100
includes
the following major components, namely molding 102 having a molding profile
110,
which is comprised of curved sections 104, separated by abutting joints 106 at
abutting
ends 107 and attached together with a flexible hinge 108. Molding 102 has a
top surface
112 and a bottom surface 114 and defines an inner radius 116 and an outer
radius 118 as
depicted in FIG. 1. Multi piece curved molding 100 is shown in the extended
position
150 in FIGS. 1, 2, 3, 4, 5 and 6 and can be folded from the extended position
150 to the
folded position 120 as shown in FIG. 7, wherein abutting or adjacent curved
sections 104
are folded onto each other in the manner shown in FIG. 7. In folded position
120 one of
the curved sections 104 is pivoted through partially folded positions 122 as
shown in
dashed lines in FIG. 7, until two curved sections 104 are folded onto each
other into
folded position 120. Flexible hinge 108 shown in FIG. 6 and also FIGS. 2 and
3, hold
abutting curved sections 104 together when in the extended position. By
physically
rotating one curved section 104 towards the other curved section 104 as shown
in FIG. 7,
flexible hinge 108 is put into the folded flexible hinge position 124 shown in
FIG. 7.
[0077] A second embodiment of the present invention is shown as Multi piece
curved
molding 200. Multi piece curved molding 200 includes the following major
components,
namely molding 202, curved sections 204, elastic hinge 206. Elastic hinge 206
in FIGS.
8, 10 and blown up in FIG. 12 is shown in the stretched position 230, wherein
the
abutting curved section 204 are pulled apart in lateral direction 218, thereby
stretching
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elastic hinge 206 into the stretched position 230. In stretched position 230,
a gap 207
results between abutting curved sections 204 and by rotating or folding
adjacent curved
section 204, one can place the abutting curved sections 204 into the outside
folded
position 220 as show in FIG. 14. As one rotates curved section 204, they
rotate through
partially folded positions 222 until it is entirely in the outside folded
position 220. The
curved section 204 is rotated along fold direction 240 as shown in FIG. 14.
Molding 202
has a mold profile shown as 210 in cross-sectional view.
[0078] Yet a third embodiment of the present invention, a Multi piece curved
molding as
shown generally as 300 includes the following major components, namely molding
302,
curved sections 304, flexible top hinge 308, flexible bottom hinge 309.
Molding 302 has
a molding profile 310 and adjacent curved sections 304 abut each other at
abutting joints
306.
[0079] The third embodiment, Multi piece curved molding 300 is shown in the
extended
position 350 in FIG. 19 is shown in a partially folded position 352 in FIG. 20
and a more
partially folded position 354 in FIG. 21.
[0080] The third embodiment, namely Multi piece curved molding 300 is shown in
the
completely accordion folded position 356 in FIG. 22 and wherein the molding in
the
accordion folded position 356 is shown packaged within a box 360 schematically
in FIG.
23. By using a flexible top hinge 308 and flexible bottom hinge 309, in
alternating
sequences shown in FIG. 19, one is able to fold the Multi piece curved
moldings 300
from the extended position 350 to the accordion folded position 356 in
accordion style as
shown in sequence in FIGS. 19 through 22.
[0081] A person skilled in the art will note that difficulty with producing
curved
moldings as shown in 102, 202 and 302 is the problem with packaging and
shipping large
curved molding pieces without having them damaged in transit. In order to
overcome the
CA 02534001 2012-11-05
transit and damage problem, it is desirable that one is able to fold molding
102, 202 or
302 into a box 360 as depicted in FIG. 23 in order to provide for a more
compact
shipping container and also to ensure that damage to the contents of the
container are
minimized.
[0082] In order to be able to fold moldings 102, 202 and 302, various
solutions have been
depicted and described above, including using flexible hinge 108 shown in the
first
embodiment using the elastic hinges 206 as shown in the second embodiment
and/or
using top and bottom flexible hinges 308 and 309 as shown in the third
embodiment. In
this manner by simply pivoting or folding adjacent curved sections 104, 204 or
304 onto
each other, one is able to reduce the size of the curve molding for shipping
purposes.
[0083] The recipient of the package will receive molding 102, 202 or 302 in
the folded
position 120, outside folded position 220 or accordion folded position 356 and
the end
user simply needs to unfold the folded curved sections into the extended
positions
wherein the curved sections abut each other at the abutting joints as depicted
in FIGS. 1,
8 and 15.
[0084] Flexible hinges allow one to fold adjacent curved sections so that they
fold onto
each others backside 114 as depicted in FIG. 7. By utilizing an elastic hinge,
one is able
to fold adjacent curved sections onto their front side as shown in FIG. 14. By
utilizing a
series of elastic and/or flexible hinges as shown in FIG. 15, one can fold
curve molding in
accordion style onto front side and backside surfaces as depicted in FIGS. 19
through 22.
[0085] A person skilled in the art will note that there are other variations
which are
possible, including hinges which in fact have the more traditional hinge pin
type hinge
arrangement which are generally found on doors, wherein it likely would be
necessary to
recess the hinge into the back or the bottom surface 114 of the molding in
order to ensure
that the hinge itself does not get in the way of the installation of the
molding 102.
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[0086] It has been contemplated by the inventors that the flexible hinge 108
and/or the
elastic hinge 206 would be extremely thin and not have any material effect
upon the
installation of the molding 102.
[0087] Multi piece curved molding 100 are shown as molding 102 could be used
for any
application requiring a curved molding including, for cap molding or casing
around
circular windows having radius of different types.
[0088] FIGS. 24 through 39 inclusive depict a fourth embodiment of the present
invention multi piece curved molding 400.
[0089] The fourth, embodiment is used in the same manner as described above
for
embodiments one, two and three. The major differences between the fourth
embodiment
with the previously described embodiments is the method of hinging.
[0090] In the fourth embodiment flexible hinge 408 includes a left member 464
and a
right member 462 which are connected at a hinge portion 460 as preferably
shown in
FIGS. 37 and 38. Flexible hinge 408 is preferably made from a flexible plastic
material
so that it can easily be bent along hinge portion 460. However other hinge
designs not
depicted may work equally as well. Flexible hinge 408 is attached to adjacent
curved
sections 404 as it is secured to each half of curved sections 404 in hinge
pockets 450.
Flexible hinge 408 can be used with almost any type of molding 402, provided
that
adjacent curved sections 404 can be adapted to accommodate flexible hinge 408.
each
curved section includes a front side 411, a back side 413, and a profile 415.
[0091] In order to save space and to avoid damage of multi piece curved
moldings 400,
the multi piece curved moldings 400 are folded as depicted in the various
drawings to
minimize packaging space and also to minimize damage in transit.
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[0092] FIG. 45 shows a connection device for connecting two adjacent curved
sections
650 namely wafer 602 preferably made up of a number of layers, namely rigid
plastic top
layer 604, flexible foam intermediate layer 606, adhesive bottom layer 608 and
peel off
backing 610. FIG. 45 shows multi layered wafer 602 in exploded form namely
with the
various layers detached. FIG. 46 shows the wafer in its assembled condition
and FIG. 47
shows part of the peel off backing being peeled off. This is only one of many
possible
constructions for wafer 602. Wafer 602 may in fact, just be made out of one
solid piece
of rigid plastic, rather than in multi layered form, however as will be shown
in FIG. 48
through 51, it preferably is multi layered so that it provides for more
flexibility of the
curved molding. FIG. 48 shows transverse direction 622 and longitudinal
direction 620 of
wafer 602. The flexible foam intermediate layer 606 provides for a certain
amount of
flexibility. For example if wafer 602 is displaced in the longitudinal
direction as shown in
FIG. 49, the rigid plastic top layer 604 can be displaced relative to the
adhesive bottom
layer 608 as shown in FIG. 604 being displaced in an amount 626. Similarly
multi
layered wafer 602 can also be displaced in a transverse direction. Therefore,
there is a
certain amount of give or flexibility in the transverse and longitudinal
directions that
multi layered wafer 602 possess due to the flexible foam intermediate layer
606.
[0093] Shown in FIG. 50, multi layered wafer 602 can also be compressed by to
a
thickness shown as 628 as shown in FIGS. 50 and 51. In this manner, sheer
forces as well
as compression forces will result in a small amount of displacement of the
rigid plastic
top layer 604 relative to the adhesive bottom layer 608. Due to this inherent
flexibility in
wafer 602, the curved sections 650 can be somewhat displaced relative to each
other
along abutting joint 652. Referring now to FIGS. 52, 53 and 54, FIG. 52 shows
multi
layered wafer 602 placed into position in a recessed wafer pocket 612.
Approximately 1/2
of wafer 602 is adhesively attached to the recessed wafer pocket 612 of once
curved
section and the other half of wafer 602 is adhesively bonded to the other
recessed wafer
pocket 612 of the adjacent curved section 650. As shown in FIG. 54, due to the
flexibility
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of wafer 602, it is possible to obtain some movement of curved section 650 in
the
transverse direction 622 and the longitudinal direction 620 as shown in the
figure.
[0094] FIGS. 55, 56 and 57 shows wafer 602 being installed into recessed wafer
pocket
612 of each curved section 650 approximate abutting end 654.
[0095] Referring now to FIG. 58 which shows a multi layered hinge 700.
Preferably
multi layered hinge includes a rigid plastic top layer 702 which defines a
left member
703, a right member 701 and a hinged portion 705. Two separate pieces of a
flexible
foam intermediate layer 704 is bonded to right member 701 and left member 703
respectively. On top of flexible foam intermediate layer 704 is adhesive
bottom layer 706
having a peel off backing 708. In this manner multi layer hinge 700 is capable
of
hingeably moving about hinged portion 705 without flexible foam layer 704
and/or
adhesive bottom layers 706 and/or peel off backing 708 interfering with the
motion of the
hinge. Similar to the description of wafer 602, multi layer hinge 700 also can
be
deformed in the longitudinal direction, the transverse direction as well as in
compression.
Therefore, the discussion above regarding FIGS. 48, 49, 50 and 51 equally
apply to multi
layered hinge 700. Multi layered hinge 700 allows some movement between
adjacent
curved sections 707 thereby giving the installer some opportunity to adjust
the curved
molding to the opening or archway it is to be installed in.
[0096] FIGS. 60, 61 and 62 show flexible hinge 408 and/or multi layered hinge
700
placed into hinge pocket 702 of curved section 706.
[0097] Hinged pocket 702 includes pocket side 720, a pocket back 722 and a
pocket
bottom 724. The adhesive bottom layer 706 is attached to pocket bottom 724
providing
for an adhesive bonding between the right member 701 or the left member 703
and
curved sections 707. Hinge pocket 702 is dimensioned in such a fashion that
flexible
hinge 408 and/or multilayered hinge 700 is recessed into the backside 714 of
curved
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section 706. Each curved section 707 has a profile 712, a front side 710 and a
back side
714.
[0098] FIG. 63 show the combination of using wafers and/or flexible hinges 408
and/or
multi layered hinges 700. FIG. 63 shows four curved sections 706 connected
together.
The outer two sections are connected with a flexible hinge 408 or a multi
layered hinge
700, such that the outer two curved sections 707 can fold onto the adjacent or
abutting
section as shown in FIG. 64. The inner two curved sections 707 are attached
with a wafer
602, such that these two portions are simply connected by wafer 602, but
cannot be
placed into the folded position. A person skilled in the art will appreciate
that this will
dramatically reduce the size of the shipping container necessary to ship a
large arch and if
necessary it can be shipped in two pieces together with a separately included
wafer 602
for connecting the hinged curved sections. In other words, the two curved
sections
connected with flexible hinge 408 for example, can be folded in half to
provide for a
compact curved sections folded onto it self and included within the shipping
container
can be a wafer 602, such that when the folded curved sections are unfolded,
the installer
can manually place the wafer 602 in position in order to attach the two folded
curved
sections together with wafer 602.
[0099] In this manner a kit can be shipped which can be partially unfolded and
partially
connected together with wafers and flexible hinges and/or multi layered
hinges.
[0100] FIG. 64 shows the curved section in a partially folded position 770.
FIG. 65 shows
the curved sections in a fully extended position 772. FIG. 66 shows the curved
section in
the folded position 777 in which a wafer 602 has been placed at the factory
and the two
outer curved sections 707 have been folded onto each other at hinge 700 or
408.
[0101] It should be apparent to persons skilled in the arts that various
modifications and
adaptation of this structure described above are possible without departure
from the spirit
CA 02534001 2013-02-28
of the invention. While the principles of the invention have been shown and
described in
connection with specific embodiments, it is to be understood that such
embodiments are
by way of example and are not limiting As is evident from the foregoing
description,
certain aspects of the present invention are not limited by the particular
details of the
mouldings illustrated in the drawings. Other modifications and applications,
or
equivalents, will occur to those skilled in the art. The terms -having-,
"comprising" and
"including" and similar terms as used in the foregoing specification are used
in the sense
of "optional" or may include" and not as "required". Reference to an element
in the
singular is not intended to mean one and only one" unless specifically so
stated , but
rather one or more. Many changes, modifications, variations and other uses and
applications of the present construction will, however, become apparent to
those skilled
in the art after considering the specification and attached drawings. All
structural and
functional equivalents to the elements of the embodiment described throughout
the
disclosure that are known to those of ordinary skill in the art are intended
to be
encompassed herein.
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