Note: Descriptions are shown in the official language in which they were submitted.
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DECORATIVE MOLDING SYSTEM
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Provisional Application Serial
No.
60/797,500, filed May 4, 2006, entitled "Decorative Molding System," the
entire disclosure of
which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to the field of decorative moldings and,
in particular,
to a selectively removable crown molding system.
2. Description of Related Art
[0003] Applying "crown molding" is the process by which a decorative molding
is
applied to the top edge of walls, cabinets, or other furniture. The process of
applying crown
molding is typically done along the seams where a ceiling meets a vertical
wall. Generally
speaking, crown molding is difficult to apply because it is applied at an
angle defined by an
inside edge on the backside of the crown molding and either the ceiling or the
vertical wall.
These pairs of angles are typically on the order of 55-degrees by 35-degrees,
52-degrees by 38-
degrees, or 45-degrees by 45-degrees. As such, extremely precise cutting and
positioning of the
molding needs to be made in order to achieve an installation that looks clean
and professional.
[0004] In typical crown molding parlance, the wall surface behind the molding
is referred
to the rise and the ceiling surface behind the molding is referred to the run.
With reference to
FIG. 11 (prior art), a cross-sectional view of a piece of crown molding
abutting the wall and
ceiling surfaces is shown. Wall surface 1110 is the rise and ceiling surface
1112 is the run.
Surface 1120 is the decorative surface of the molding and surface 1122 is the
rear-facing, non-
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visible surface of the molding. Two edge surfaces 1124, 1126 sit flush on the
ceiling and wall,
respectively. Nails 1140 are driven into the wall and ceiling as necessary to
fit the molding in
place.
[0005] With this background, the process of applying crown molding requires
positioning the crown molding so that one edge surface 1126 sits flush on a
vertical wall and
another edge surface 1124 sits flush on the ceiling. As such, the crown
molding spans and,
covers the seam 1130 between the vertical wall and the ceiling. Because wall
and ceiling
structures in most homes are uneven in that the surfaces of a vertical wall
and ceiling do not
create a 90-degree angle, the problems associated with installation of crown
moldings are
exacerbated. Moreover, room corners, where two vertical walls meet a ceiling,
require complex
"compound miter" cuts requiring both a bevel cut and a miter cut, or difficult
to apply coping
cuts. In order to carry out such cutting, a great deal of experience and
expensive and
complicated tools such as compound miter saws, coping saws, or air-driven or
battery powered
finish nailers are needed in order to effectively install the crown molding.
These conditions
make the prospect of installing crown molding both daunting and expensive for
an average
homeowner requiring expertise that most "do-it-yourself' homeowners do not
possess.
Therefore, there is a need for a crown molding system, and process of applying
such crown
molding, that allows a user to relatively easily apply crown molding without
having a great deal
of woodworking experience, or without requiring the use of expensive or
complicated tools.
[0006] Additionally, in traditional crown molding systems, the crown molding
is attached
using nails, screws, glue, or other attachment means designed to permanently
attach the crown
molding to the wall and ceiling surfaces. With the increase of wired
technologies permeating the
home environment, such as wiring for home theaters and wired Ethernet
networks, there is an
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increased need for minimally invasive wiring options that eliminate or reduce
the need for in-
wall wiring. Because traditional crown molding is permanently mounted,
opportunities for
wiring in the space behind crown molding are generally limited to pre-
installation wiring.
Because media, theater, or network components, for example, may be added or
deleted by choice
or as new products become available, there is a desire and need for removable
crown moldings
that permit post-installation wiring options. The various embodiments of the
present invention
satisfy the foregoing, as well as other needs.
SUMMARY OF THE INVENTION
[0007] In an embodiment of the present invention, a decorative molding system
and
method of installation includes a pair of removably engagable molding
components.
Specifically, a base piece includes a run member hingeably connected to a rise
member, such
that an approximately 90-degree angle can be created between the run and rise
members. Each
of the run and rise members include an engagement hook at their respective
ends. The base
piece is mounted to vertical wall and ceiling surfaces by attaching the run
member to the ceiling
and the rise member to the wall, such that the hinge portion connecting the
run and rise members
sits approximately in the intersection between the vertical wall and ceiling.
A molding piece
having a decorative surface generally of a profile known in the art for crown
moldings includes
upper and lower engagement surfaces. Each of the upper and lower engagement
surfaces
includes a protrusion for engagement with the engagement hooks on the base
piece. In this way,
the molding piece can be removably engaged to the base piece to give an
appearance similar to
traditional crown molding, but with an ease of installation unavailable with
traditional crown
molding.
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[0008] In this embodiment, the base piece and crown piece are removably
engagable to
each other and can be flush mounted to the ceiling. In another embodiment, the
system is
adapted to provide mounting that is not flush with the ceiling for decorative
and visual effect,
and possibly to be combined with a secondary visual element. In this
embodiment, the hinge
connecting the run and rise members is designed such that its rotation about
an axis passing
through the hinge will not rotate substantially past a point creating an angle
smaller than
approximately 90-degrees between the run and rise members. As such, the base
piece can be
fixed to a vertical wall via the rise member without attachment of the run
member such that the
molding can be attached to provide a space between the ceiling and top of the
molding. The base
piece may further include vents or a channel in the surface of the run member
enabling the
routing of accent lighting.
[0009] In yet another embodiment, either or both of the base and crown pieces
can be
provided in a form, such as but not limited to a roll, that enables a user of
the system to cut the
respective pieces required for a specific length to avoid splicing together
separate pieces to cover
a given wall space. In this embodiment, the system may be extruded or formed
using plastic so
that it can be coiled or rolled during the forming process. Therefore, the
user is not limited to
any specific length or span and the need for "splicing" two spans together is
rendered obsolete.
The base piece of the system may be mounted to a wall or ceiling surface using
any of a number
of fasteners, including but not limited to nails, screws, adhesives, adhesive
tapes, and the like.
The base piece may also include at one or more secondary hingeable portions
disposed on either
or both of the run and rise members to facilitate bending of the base piece to
conform to the
contour of the juncture of a wall and ceiling thereby improving installation
on walls and ceilings
that may be out of square.
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[0010] Additionally, in some embodiments, the crown molding systems are
significantly
lighter as a result of the thickness of the crown profile and the materials
from which the molding
pieces are formed. Furthermore, in accordance with at least one embodiment,
the system
requires only a standard utility knife and fastener. Specifically, the ends of
the crown piece can
be mitered using a utility knife to form the corners.
[0011] Crown molding is manufactured in many different styles, shapes and
dimensions;
while a standard style is illustrated herein, and those skilled in the art
will recognize the present
invention applies to crown moldings of all conceivable styles, shapes and
dimensions (whether
milled from wood, extruded from plastic materials or molded from plastic
materials). The
materials used in its manufacturing can range from wood, plastic, fiberglass,
clay, plaster and
any others known to those having skill in the art.
[0012] Additional features and advantages of the present invention are
described further
below. This summary section is meant merely to illustrate certain features of
the embodiments
of the inventions, and is not meant to limit the scope of the invention in any
way. The failure to
disclose a specific feature or embodiment of the invention, or the inclusion
of one or more
features in this summary section, should not be construed to limit the
invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A further understanding of the present invention can be obtained by
reference to the
embodiments set forth in the illustrations of the accompanying drawings. The
drawings are not
intended to limit the scope of this invention but merely to clarify and be
illustrative of
embodiments of the invention.
[0013] Figure 1 depicts a device in accordance with an embodiment of the
present
invention;
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[0014] Figure 2 depicts a crown piece in accordance with an embodiment of the
present
invention;
[0015] Figure 2A depicts an extruded profile view of the crown piece shown in
Figure 2
in accordance with an embodiment of the present invention;
[0016] Figure 3 depicts a base piece in accordance with an embodiment of the
present
invention;
[0017] Figure 3A depicts an extruded profile view of the base piece shown in
Figure 3 in
accordance with an embodiment of the present invention;
[0018] Figure 4 depicts a base piece of Figure 3 in accordance with an
embodiment of
the present invention;
[0019] Figure 5 depicts a system in accordance with an embodiment of the
present
invention;
[0020] Figure 6 depicts a system in accordance with an embodiment of the
present
invention;
[0021] Figures 6A and 6B depict expanded side views of a base piece in
accordance with
one embodiment of the present invention;
[0022] Figure 6C depicts an expanded view of a hinge on a base piece in
accordance with
one embodiment of the present invention;
[0023] Figure 7 depicts a corner piece in accordance with an embodiment an
embodiment
of the present invention;
[0024] Figure 8 depicts a corner pieces in accordance with an embodiment of
the present
invention;
[0025] Figure 8A depicts a side view of the comer piece of Figure 8;
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[0026] Figure 9 depicts a connector piece in accordance with an embodiment of
the
present invention;
[0027] Figure 10 depicts a system in accordance with an embodiment of the
present
invention; and
[0026] Figure 11 depicts a prior art crown molding arrangement.
DETAILED DESCRIPTION OF THE CERTAIN EMBODIMENTS
[0028] The present invention generally relates to a decorative molding system
and a
process of installing such a system, along with certain secondary decorative
or functional items.
In the following description, for purposes of explanation, specific numbers,
materials and
configurations are set forth in order to provide a thorough understanding of
the invention. It will
be apparent, however, to one having ordinary skill in the art that the
invention may be practiced
without these specific details. In some instances, well-known features may be
omitted or
simplified so as not to obscure the present invention.
[0029] Certain embodiments of the present invention will now be discussed with
reference to the aforementioned figures, wherein like reference numerals refer
to like
components. It should be noted that reference in the specification to phrases
such as "one
embodiment" or "an embodiment" means that a particular feature, structure or
characteristic
described in connection with the embodiment is included in at least one
embodiment of the
invention. The appearances of phrases such as "in one embodiment" in'various
places in the
specification are not necessarily all referring to the same embodiment.
[0030] Now referring to Figures 1-10, in accordance with various embodiments
of the
present invention, a crown molding system 2 includes at least a crown piece 10
and base piece
20. Crown piece 10 preferably has a decorative profile (as shown at least in
Figure 1). Crown
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piece 10 generally includes bottom and top attachment devices 12 and 14,
respectively, base
facing surface 16 and front surface 18. Base piece 20 includes bottom and top
attachment
devices 26 and 28 for engagement to attachment to devices 12 and 14. Base
piece 20 may
comprise a fixed L-shape adapted to fit the contour of a ceiling-wall
juncture, or may be
provided with a hingeable portion 22 and/or 24 for adapting a flat base piece
20 to conform to
such a contour. Hingeable portions 22 or 24 may be formed in any way known to
those having
skill in the art, such as but not including by a score line formed in a
plastic or resin sheet that
facilitates bending of the sheet at the score line, or weakening the portion
of the base piece 20 to
be hinged. In an embodiment, the hinge can be oriented such that open wedge
portion of the
hinge is in a ceiling facing position, as opposed to the orientation of hinge
22. In another
embodiment, where the material of the base piece is a harder material, such as
wood, base piece
20 can comprise two separate pieces, one for contacting a wall and the other
for contacting a
ceiling, joined by a hinge. In an embodiment in which the system is engineered
from PVC
plastics, the system is adapted to be coiled or rolled during the extrusion
process. In such
embodiments, user is not limited to any specific length or span and the need
for "splicing" two
spans together is obsolete, as further described below.
[00311 Figures 2A and 3A show an extruded profile view of the crown piece 10
and base
piece 20 shown in Figures 2 and 3, respectively. As can be seen in Figure 2A;
a crown piece
contains bottom attachment device 12 which connects to attachment device 22 of
base piece 20
and top attachment device 14 which connects to attachment device 26 of base
piece 20.
Attachment devices 12 and 14 can comprise a bead for engaging attachment
devices 26 and 28 of
base piece 20, which comprise hooks or sockets, forming a pressure fit ball
and socket type
engagement. The opposite arrangement (not shown) can also be employed wherein
sockets 26
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and 28 are formed on molding piece 10 and beads 12 and 14 are formed on base
piece 20. Other
attachment embodiments for the present invention include tab-slot arrangements
and any other
suitable attachment arrangement known to those having skill in the art. In an
embodiment of the
present invention, beads 12 and 14 are releasably attachable to sockets 26 and
28.
[0032] As can be seen in Figures 5 and 6, base piece 20 is adapted to be
fastened flush to
a wall and either flush mounted to a ceiling or positioned below and away from
the ceiling
surface. In an embodiment, as shown in Figure 6, back portion 21 of base piece
20 includes
hinge 22. As further shown in the expanded view of Figure 6A, hinge 22 is
preferably formed as
a generally triangular slot in face 23 of base piece 20. The slot includes
faces 22a and 22b,
which are preferably separated when base piece 20 is laid open, as shown in
Fig. 6A, by an angle
of approximately 90-degrees. As such, when base piece 20 is rotated to be
positioned on a wall
surface, faces 22a and 22b are each rotated approximately 45-degrees such they
contact one
another preventing the angle between the rise and run of base piece 20 from
rotating to an angle
more acute than approximately 90-degrees, as shown in Figure 6B. This feature
advantageously
provides additional support to base piece 20 when being mounted in a position
that is not flush
with a ceiling.
[0033] It should be understood that although a triangular profile for the slot
of hinge 22 is
preferred, other profiles may be used consistent with present invention. It
should also be
recognized that devices and systems in accordance with the present invention
may be employed
in homes, offices, restaurants and the like wherever it is desirable to have
crown molding. The
present inventions may be employed with hard fixed ceiling structures, with
standard drop
ceilings, or placed partially up a wall not abutment with a ceiling for
decorative purposes.
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[0034] With reference back to Figure 6, the system of the present invention
may also
include lighting disposed between the portion 21a of base piece 20 and a
ceiling. Lighting may
comprise rope lighting, fluorescent light fixtures or other light fixtures
(not limited to
fluorescent) of any color, as well as decorative lighting, which may include
colors or effects for
ornamentation purposes. It should be appreciated that because the system is
comprised of a base
piece which is fastened to a wall, and a crown piece which is in turn secured
to the base piece,
the crown piece is preferably adapted to be removable, allowing a user the
option to use the
combination of the base piece and crown piece as a non-combustible housing or
conduit for
various wires (i.e. electrical, telephone, speaker, cable/satellite etc.).
While the figures depict a
"two" piece "system," with regard to the base and crown pieces, additional
decorative pieces as
desired by the user to can be installed onto the crown piece to enhance the
look of the molding
once assembled.
[0035] In an alternate embodiment, as shown in Figure 6C, the run 620 of base
piece 20
may include one or more openings 630 such that lighting can be routed in the
space formed
between the base piece 20 and crown piece 10, as opposed to being positioned
above run 620, as
shown in Figure 6. Openings 630 are preferably of sufficient size and number
as to allow an
even distribution of light to emanate out of the top of the base piece.
Openings are preferably
generally oval in shape and sized so as to retain the structural rigidity of
the run of base piece 20.
How large openings 630 may be made relative to the width of run 620 is
dependent in large part
of the material used to form base piece 20. Alternatively, openings 630 may be
covered by a
light diffuser including a plurality of light reflecting facets, such as the
plastic material
commonly found on fluorescent light housings. In addition, base piece 20 may
be formed from a
translucent material so as to avoid the need for openings.
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[0036] Illustrative materials from which the pieces of the system may be made
include
but are not limited to acrylic, polymer, plastic, wood, metal, rubber and
composite materials
similar to what is employed for example in TREXTM decking material. In a
preferred
embodiment, materials employed for the crown 10 and base 20 pieces are PVC. In
an
embodiment, additives such as but not limited to pigments, dyes, "sparkling"
elements, iridescent
elements and the like may be added to the material employed as is well known
to those having
skill in the art in the fabrication of the devices in accordance with the
present invention for
ornamental effect. The additives may be added to provide patterns, such as but
not limited to
faux marble patterns. The devices in accordance with the invention can be
provided with
varying degrees of translucency. In other embodiments, devices can be provided
with matte or
textured surfaces to enhance the three dimensional appeal of the device.
[0037] Illustrative fasteners include but are not limited to staples, screws,
nails,
adhesives, adhesive tapes such as but not limited to double-sided adhesive
tapes and other
fasteners suited for fastening decorative materials to walls as are well known
to those having
skill in the art.
[0038] In an embodiment of the present invention, base piece 20 is provided in
a roll of a
desired length; preferably of sufficient length to mount molding on the walls
of a room in single
lengths. As shown in Figure 5, base piece 20 is bent along hinge 22 to
approximately 90-degrees
to fit the space between a ceiling and wall in a flush mount application. Base
piece 20 is then
fastened onto a wall using fasteners 27 which can include staples, nails,
screws, adhesive,
adhesive tape or the like. Crown piece 10 may likewise be provided in roll
form extruded from
plastic and cut to a desired length. It is preferable to cut the crown piece
10 to substantially the
same length as base piece 20, and more preferable to a length substantially
the same as the length
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of the wall being covered. However, skilled artisans will recognize there may
be some
applications wherein the respective lengths of the crown 10 and base 20 pieces
are not identical.
Crown piece 10 may then be attached to the base piece using the attachment
devices 12, 14, 26
and 28, the ends of the crown piece 10 may be mitered using a utility knife to
form the corners.
[0039] The installation process of installing crown molding using corner
pieces 700,
according to an embodiment of the present invention, will now be discussed in
more detail.
When installing the crown molding whether flush to the ceiling or below the
ceiling, an inside
corner piece 700, as shown in Figure 7, and outside corner piece 800, as shown
in Figure 8, can
be used to avoid the need to miter the ends of crown piece 10.
[0040] With reference to Figure 7, inside corner piece 700 includes a main
body 710 with
a pair of tabs 702 extending therefrom. Main body 710 of inside corner piece
700 preferably
includes a pair of wall surfaces 712 and 714 positioned substantially
perpendicular to one
another and designed to fit into a corner between two abutting wall surfaces.
Main body 710
also preferably includes a pair of side walls 716, 718 that each extend
substantially
perpendicularly from a respective one of the wall surfaces 712, 714. Side
walls 716, 718 are
joined at corner 720. In the embodiment shown in FIG. 7, side walls 716 and
718 slope
gradually upward from the bottom walls 712, 714, respectively, such that the
side profile of the
side walls 716, 718 generally match the side profile of a molding piece (not
shown in Figure 7).
Decorative surface 730 is also preferably designed to match the look of the
decorative surface of
a molding piece.
[0041] With reference to Figure 8, outside corner piece 800 includes a main
body 810
with a pair of tabs 802 extending therefrom. Main body 810 of inside corner
piece 800
preferably includes a pair of wall surfaces 812 and 814 positioned
substantially perpendicular to
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one another and meeting at spine 815. Wall surfaces 812 and 814 are designed
to fit into a
corner between two abutting wall surfaces. Main body 810 also preferably
includes a pair of
side walls 816, 818 that each extend substantially perpendicularly from a
respective one of the
wall surfaces 812, 814. Decorative surface 830 is also preferably designed to
match the look of
the decorative surface of a molding piece. Figure 8A depicts a side view of
outside corner piece
800 showing a preferred embodiment of wall surface 812
[0042] With reference to Figure 9, connector piece 900 includes a main body
910 with a
pair of tabs 902 extending therefrom. Main body 910 of connector piece 900
preferably includes
a pair of side wall surfaces 912 and 914 positioned substantially parallel to
one another and
connected to an adjoining wall surface 913. In the embodiment shown in FIG. 9,
side walls 912
and 914 slope gradually upward from the wall surface 913, such that the side
profile of the side
walls 712, 714 generally match the side profile of a molding piece (not shown
in Figure 9).
Decorative surface 930, which preferable spans the outer edge of side walls
712, 714 is also
preferably designed to match the look of the decorative surface of a molding
piece.
[0043] The corner pieces are installed in the corners of the room where the
corner piece
can connect to the base piece 20 when installed on the wall. Each of the
corner pieces preferably
has a pair of flat tabs 702 and 802, respectively, that extend over base piece
20 when properly
installed. Each of the corner pieces may then be secured to the corner of the
room where the two
walls meet, by either screwing, stapling, nailing or gluing the corner piece
into the wall, or using
any other known attachment means to attach the corner piece to the wall.
[0044] In order to properly install the crown molding, an installer measures
the distance
between the two corners in the room and cuts a base piece 20 as shown in
Figure 4 to the desired
length. Next, the base piece 20 is crimped along its hinge (as shown in Figure
3) to be slid into
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the corner created between the ceiling and the wall. The base piece need not
be bent to a full
ninety-degree angle, and a more obtuse angle, such as 1I0-degrees may be
sufficient, although
the dimensions of the location being where the molding is being installed can
be a factor. Using
the hinge 24, the base piece 20 sits tightly against the wall where it is
stapled or screwed into
place using known attachment mechanisms. Once the base piece 20 has been
installed and
secured, the corner pieces 702 and 802 are secured at either end of the base
piece 20. A strip of
crown piece 18 is cut to match the size of length the base piece 20 between
the respective corner
pieces 702, 802, and the crown piece 18 is snapped onto the base piece 20
using attachment
devices 12 and 14 which connect to attachment devices 26 and 28 respectively
on the base piece.
In an embodiment of the present invention, a connector piece 900 as shown in
Figure 9 can be
installed at the end of the molding to additionally secure the base piece 20
to the crown piece 10.
Figure 10 shows a fully installed crown molding showing the outside corner
piece, the connected
crown molding including base piece 20 and crown piece 10, the inside corner
piece 700 and the
connector piece 900. In the situation where an installer wants to install the
crown molding below
the ceiling mount, measurements should first be taken below the ceiling mount
to establish the
correct placing for the securing of the base piece 20 and the corner pieces
700 and 800 (and the
connector piece 900) and the same installation process described above is used
at the location
below the ceiling mount that he or she wishes to install the molding.
[0045] Those skilled in the art will recognize that the method and system of
the present
invention has many applications, may be implemented in many manners and, as
such is not to be
limited by the foregoing exemplary embodiments and examples. While the
preferred
embodiments have been described and illustrated it will be understood that
changes in details and
obvious variations might be made without department from the spirit and
principle of the
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invention and therefore the scope of the invention is not to be construed as
limited to the
preferred embodiment. In this regard, any number of the features of the
different embodiments
described herein may be combined into one single embodiment and alternate
embodiments
having fewer than or more than all of the features herein described are
possible. Moreover, the
scope of the present invention covers conventionally known and features of
those variations and
modifications through the system and components described herein as would be
understood by
those skilled in the art. It is the intention, therefore, to be limited only
as indicated by the scope
of the claims appended hereto.
[0046] It is also to be understood that the following claims are intended to
cover all of the
generic and specific features of the invention herein described and all
statements of the scope of
the invention that, as a matter of language, might be said to fall
therebetween.
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