Note: Descriptions are shown in the official language in which they were submitted.
CA 02696099 2010-11-05
TITLE: CROWN MOULDING
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0002] The present invention relates to architectural
mouldings used in interior and exterior residence and commercial
applications and in particular relates to lineal crown mouldings
used in residential and commercial construction.
DESCRIPTION OF THE PRIOR ART
[0003] Installing architectural moulding inside a room or to
a building exterior is an increasing trend in building construction
and renovation. When tastefully designed, it adds a degree of
elegant decoration that enhances the esthetics of the business or
residence, and potentially increases property values. Crown
mouldings are typically fashioned as an elongated strip of
decorative material installed at an angle at the juncture between
walls and ceilings, ledges or overhanging roofing but can find
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other applications including capping walls, pilasters, cabinets,
cornice assemblies or door and window hoods. Crown mouldings can
be manufactured in a variety of materials. Historically crown
mouldings were milled from wood or cast in plaster. Today crown
mouldings are available in plaster, solid wood, finger joint wood
construction, medium density fibre board (MDF), polyurethane, PVC,
fiberglass, polystyrene and plaster-coated foam mouldings.
[0004] Conventional lineal crown moulding are an elongated
piece of material having a front surface with a decorative profile
and a generally flat back surface. Crown mouldings that are cast
or extruded have a front surface with a decorative profile but the
back surface is more likely to be non-planar to reduce the amount
of material used to form the moulding.
[0005] Regardless of the material of construction, the entire
front surface is decorative and serves no functional purpose. The
crown moulding is typically applied against a ceiling and a wall
at an angle. Crown moulding typically comes in three different
spring angles: 38 , 45 and 52 . The spring angle is the "tilt"
at which the crown moulding sits on the wall. The different spring
angles are a way to show off the moulding detail better at different
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wall heights. For example on a lower ceiling you want the crown
moulding to tilt up towards the eye for better viewing. In the same
way crown moulding set into a high ceiling looks best when it's
tilted down.
[0006] The spring angle or tilt is accomplished by providing
a top chamfer portion on the back surface which is placed against
the ceiling ("ceiling seat") and a bottom chamfer portion on the
back that is placed against the wall ("wall seat"). With a 38
spring angle, the moulding is titled at an angle of 38 relative
to the wall and at an angle of 52 relative to the ceiling with
the wall seat flat against the wall and the ceiling seat flat
against the ceiling. This provides a crown moulding mounted further
down the wall.
[0007] With a 52 spring angle, the moulding is tilted at an
angle of 52 relative to the wall and at an angle of 38 relative
to the ceiling with the wall seat flat against the wall and the
ceiling seat flat against the ceiling. This provides a crown
moulding mounted further along the ceiling.
[0008] With a 45 spring angle, the moulding is tilted at an
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angle of 45 relative to the wall and at an angle of 45 relative
to the ceiling with the wall seat flat against the wall and the
ceiling seat flat against the ceiling. This provides a crown
moulding mounted equi-distant down the wall and along the ceiling.
[0009] Because crown moulding is mounted at an angle between
the wall and ceiling, as opposed to flat against either the wall
or the ceiling, it is difficult to cut. Further installation, in
a room or other space, typically can be time consuming in order
to have the mouldings fit together in or around corners or other
objects as seamlessly as possible. The possibility of errors is
high and there is a significant amount of waste material. When
cutting crown moulding to fit an inside or outside corner, to form
the angles required to install crown molding with a mitred corner,
the moulding must be cut in two directions at once; first it must
be beveled and second it must be mitered. There are two different
methods commonly used: vertically nested or flat.
[0010] The vertically nested method can be undertaken with
either a mitre saw or compound mitre saw and is applicable to crown
moulding regardless of the materials of construction or design of
the moulding provided the saw has sufficient vertical stroke to
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accommodate the crown vertically nested on the saw table. Large
sizes of crown mouldings, where the height of the moulding
precludes vertical nesting, must be cut flat. Typically wood and
MDF crown moulding is cut and installed using either a mitre saw
or compound mitre saw. With moulding made from materials that are
easier to cut than solid hardwoods or MDF, a mitre box and hand
saw can be used. With a mitre saw or mitre box and hand saw, the
blade remains perpendicular to the saw table or base of the mitre
box but the blade is positioned to cut at an angle relative to the
fence of the mitre saw or back wall of the mitre box.
[0011] Cutting crown moulding flat requires a compound mitre
saw and crown moulding with a flat back surface. This is
particularly true for large sizes where the vertical stroke of the
saw is not sufficient to permit cutting using the vertical nesting
method. With a compound mitre saw not only can the blade and table
be rotated horizontally relative to the fence, the vertical angle
of the blade can also be adjusted.
[0012] When cutting crown moulding using the vertically nested
method, the moulding is placed with the wall seat on the bottom
of the back surface of the moulding resting squarely against the
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fence or back wall of the mitre box and with the ceiling seat on
the top of the back surface of the moulding resting squarely on
the base of the saw or mitre box. Placing the moulding on the saw
at the same angle as it will be installed creates the right bevel.
To cut the crown moulding to create the mitre to fit an inside mitred
corner, for the left side of the corner, set the saw angled to the
right to half the exact angle of the first corner, schematically
illustrated as \. Whether cutting for an inside or outside corner,
few rooms have a perfectly square corner. In order to quickly find
the exact degree of the corner, use an angle finder.
[00131 Save the piece of moulding to the right of the saw - the
piece to the left of the saw is scrap. For the right side of the
corner, reset the saw angled to the left to half the exact angle
of the first corner, schematically illustrated as /. Save the piece
of moulding to the left of the saw - the piece to the right of the
saw is scrap.
[0014] To cut the crown moulding to fit an outside mitred corner,
for the left side of the corner, set the saw angled to the left
to half the exact angle of the first corner, schematically
illustrated as /. Save the piece of moulding to the right of the
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saw - the piece to the left of the saw is scrap. For the right side
of the corner, reset the saw angled to the right to half the exact
angle of the first corner, schematically illustrated as \. Save
the piece of moulding to the left of the saw - the piece to the
right of the saw is scrap. Holding the moulding in place
consistently at the proper angle while cutting can be difficult
and various jigs have been developed to try and make it easier.
If the two mitre cuts are off slightly the two pieces of moulding
will not form a perfect mitred corner.
[0015] A compound mitre saw makes it possible to make the bevel
and mitre cuts at the same time with the flat back surface of the
crown moulding lying flat on the saw table. The angles for crown
mouldings are very precise and difficult to set exactly. Since
the mouldings can shift slightly and very few rooms have perfectly
square corners, typically all saw settings are first tested on
scrap pieces. Charts have been developed providing appropriate
mitre-bevel settings for mouldings with 52 /38 , 38 /52 and
45 /45 ceiling to wall seat angles for a wide range of corner
angles. For example:
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Angle 52 /38 Crown Moulding 45 /45 Crown Moulding
Between
Mitre Bevel Mitre Bevel
Walls
Setting Setting Setting Setting
86 33.43 35.19 37.17 31.14
87 32.97 34.86 36.69 30.86
88 32.52 34.53 36.21 30.57
89 32.07 34.20 35.74 30.29
90 31.62 33.86 35.26 30.00
91 31.17 33.53 34.79 29.71
92 30.73 33.19 34.33 29.42
93 30.30 32.85 33.86 29.13
[0016] To cut the crown moulding to create the mitre to fit an
inside mitred corner, using crown moulding with a spring angle of
52 /38 , for the left side of the corner, place the moulding with
the back side flat against the table and the top edge of the moulding
against the fence. Check the charts for a 90 corner (or other angle
for the corner as measured) and set the mitre angle of the saw blade
to the right, schematically illustrated as \, at 31.62 and the
bevel angle at 33.86 . The piece to the left of the saw is the
good piece the piece to the right of the cut is scrap. For the
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right side of the corner, place the moulding with the back side
flat against the table and the bottom edge of the moulding against
the fence. Re-set the mitre angle of the saw blade to the left,
schematically illustrated as / at 31.62 and the bevel angle at
33.86 . The piece to the left of the saw is the good piece, the
piece to the right of the cut is scrap. Trying to cut the moulding
face down is problematic with a non-planar profile that has uneven
thicknesses and may have a tendency to rock.
[0017] To cut the crown moulding to fit an outside mitred corner,
for the left side of the corner, place the moulding with the back
side flat against the table and the bottom edge of the moulding
against the fence. Check the charts for a 90 corner and set the
mitre angle of the saw to the left, schematically illustrated as
/ at 31.62 and the bevel angle at 33.8 6'. The piece to the right
of the saw is the good piece the piece to the left of the cut is
scrap. For the right side of the corner, place the moulding with
the back side flat against the table and the top edge of the moulding
against the fence. Re-set the mitre angle of the saw blade to the
right, schematically illustrated as \ at 31.62 and the bevel angle
at 33.86 . The piece to the right of the saw blade is the good piece
the piece to the left of the cut is scrap.
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[0018] For moulding with a different spring angle or for corners
other than 90 , the mitre angles and bevel angles will be different.
[0019] From the foregoing it is evident that cutting and
installing crown moulding takes considerable skill. In some cases
a jig may be required. Further it is time consuming to set the
saw, measure, cut a piece, re-set the saw, measure and cut a second
piece to finish one corner. In addition there is a significant
amount of waste as only the piece on one side of the saw blade
after each cut can be used and the piece on the other side of the
saw blade is scrap. Also the frequency of an error in setting the
saw and cutting the piece for one side of the corner is relatively
high resulting in additional waste of time and materials.
[0020] To avoid having to mitre-cut the crown moulding to fit
precisely into inside corners or around outside corners,
pre-mitred corners have been manufactured to fit a 90 inside
corner or outside corner. The pre-mitred corners are made from
short sections of crown moulding , usually about six to eight inches
and are made with the most common profiles. By installing the
pre-mitred corners in the room the installer then only has to cut
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the crown moulding to the correct length to butt up against the
ends of the pre-mitred corners. It is important that the profile
on the pre-mitred corners match exactly the profile of the lineal
crown moulding. The Wood Moulding & Millwork Producers Association
have standardized a number of different profiles and different
sizes.
[0021] A difficulty in practical terms is that most rooms
consist of inside corners, rather than outside corners. With
pre-mitred corners two SKUs are required per profile and size of
moulding, one for inside corners and a second for the outside
corners. About 4 to 5 inside corners are sold for every outside
corner. Therefore there is an extensive amount of additional shelf
or bin space required for two SKUs and a extensive amount of waste
of outside corners which eventually cannot be sold and are scraped.
In addition the pre-mitred corners are commonly made for 90 inside
corners or outside corners. But as noted above most rooms are not
perfectly square with 90 corners. In situations where the corners
are not 90 use of pre-mitred corners is precluded.
[0022] Another way to avoid having to cut mitred corners
involves the use of corner boxes. Corner boxes have a decorative
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and functional purpose. One type of corner box to fit an inside
corner has two flat pieces of material joined at their ends to form
a right angle. The pieces are wider than the height of the crown
moulding so when the top edge of the flat pieces rests against the
ceiling, the end of the crown moulding butts against the flat piece.
A decorative element depends from the bottom side of the flat pieces.
The decorative element is typically formed of pieces of flat back
crown moulding formed as an outside corner but do not have to match
the profile of the crown moulding being installed. Alternatively
the corner block can be made of one solid piece of material. The
corner blocks for an outside corner are a notched square box larger
than the height of the crown moulding so when the top edge of the
box rests against the ceiling, the end of the crown moulding butts
against the flat side of the box. A decorative element depends from
the bottom of the box. The decorative element is typically formed
of pieces of flat back crown moulding formed as outside corners
but do not have to match the profile of the crown moulding being
installed. Alternatively the corner block can be made of one solid
piece of material. Use of the corner blocks eliminates the need
to make mitred inside or outside corners when installing the crown
moulding.
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[0023] In an effort to make cutting the crown moulding easier
numerous jigs to hold the crown moulding in position on the saw
have been developed. See for example US Patent Nos. 7,360,476;
6,782,782; 6,422,117; 5,730,434; 4,907,482 and 4,875,399.
[0024] The invention described herein provides a solution to
the difficulty in cutting and installing crown moulding and doing
so in less time and with less waste than with products currently
available.
SUMMARY OF THE INVENTION
[0025] The present invention provides lineal crown mouldings
for use in residential and commercial applications that can be used
to create mitred corners by setting the saw once, cutting once to
form both the required bevelled and mitred cut. The two pieces
on opposite sides of the cut can be joined to form either an inside
or outside corner or where a longer piece of moulding is required,
another piece of the lineal crown moulding cut without re-setting
the saw and joined with the first piece to form either an inside
or outside corner.
[0026] The lineal crown mouldings of the present invention
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comprise an elongated moulding with a front surface having a top
front chamfer portion, a bottom front chamfer portion and a front
non-planar decorative profile portion positioned between said top
front chamfer portion and said bottom front chamfer portion and
a back surface having a top back chamfer portion and a bottom back
chamfer portion and a back non-planar decorative profile portion
positioned between said top back chamfer portion and said bottom
chamfer portion. The front surface and the back surface have
substantially identical configurations inverted relative to each
other about a vertical centre line from a top edge of said crown
moulding to a bottom edge of said crown moulding.
[0027] The lineal crown moulding of the present invention has
a uniform cross-section along its length, the cross section having
an upper half and a lower half having substantially identical
configurations reversed 180 degrees relative to each other about
a horizontal centre line through a mid point of said cross section.
[0028] In another aspect the present invention provides a
method of cutting with a mitre saw the lineal crown moulding of
the present invention to create either an inside or outside corner
with one cut.
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[0029] In a further aspect the present invention provides a
method of installation of the lineal crown moulding of the present
invention in less time and with less waste than conventional crown
moulding.
[0030] For the purposes of this specification the term "lineal
crown moulding" means a long, generally straight piece of
decorative moulding as opposed to curved mouldings such as arches,
corner blocks, plinth blocks, rosettes etc. The terms "top
"bottom", "upper", "lower", "front", "back" and "height" used in
conjunction with the description of the crown moulding of the
present invention are referenced to crown moulding orientated with
its longitudinal axis horizontal.
[0031] Further features of the invention will be described or
will become apparent in the course of the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In order that the invention may be more clearly
understood, embodiments thereof will now be described in detail
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by way of example, with reference to the accompanying drawings,
in which:
[0033] Figure 1 is a front perspective schematic of a prior art
lineal crown moulding having a front surface with a decorative
profile and a generally flat back surface.
[0034] Figure 2 is a back perspective schematic of the prior
art lineal crown moulding shown in Figure 1.
[0035] Figure 3 is a front perspective view of one embodiment
of the lineal crown moulding of the present invention having a front
surface with a decorative front profile portion and having a back
surface with a decorative back profile portion with the decorative
front profile portion and decorative back profile portion having
substantially identical configurations inverted relative to each
other about a vertical centre line of the crown moulding..
[0036] Figure 4 is a back perspective view of the lineal crown
moulding of Figure 3.
[0037] Figure 5 is an enlarged cross sectional view of the
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lineal crown moulding of Figure 3 and 4.
[0038] Figure 6 is a front plan view of the front surface of
a short piece of the lineal crown moulding of Figure 3 showing a
mitre and bevel cut with the front surface denoted as A and the
back surface denoted as B.
[0039] Figure 7 is a left piece portion of the crown moulding
of Figure 6 mitred and cut away from the right piece shown in Figure
8.
[0040] Figure 8 is a right piece portion of the crown moulding
of Figure 6 mitred and cut away from the left piece shown in Figure
7.
[0041] Figure 9 shows in perspective view the left piece of the
crown moulding shown in Figure 7 in the process of being assembled
to the right piece of the crown moulding shown in Figure 8 along
the mitre cut to form an inside corner shown in Figure 10 and/or
the outside corner shown in Figure 11.
[0042] Figure 10 is a perspective view of the left piece and
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the right piece of the crown moulding of the present invention
assembled to form an inside corner.
[0043] Figure 11 is a perspective view of the inside corner of
Figure 10 turned over to form an outside corner.
[ 0044 ] Figure 12 is a cross sectional view of the lineal crown
moulding shown deployed at the intersection of the ceiling and wall
at an angle of 45 degrees with the front surface facing away from
the wall and ceiling.
[0045] Figure 13 is a cross sectional view of the lineal crown
moulding shown deployed at the intersection of the ceiling and wall
at an angle of 45 degrees turned around and inverted with the back
surface facing away front-the wall and ceiling.
[0046] Figure 14 is a cross sectional view of the lineal crown
moulding shown deployed at the intersection of the ceiling and wall
at an angle of 38 degrees to the ceiling and 52 degrees to the
wall with the front surface facing away from the wall and ceiling.
[0047] Figure 15 is a cross sectional view of the lineal crown
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moulding shown deployed at the intersection of the ceiling and wall
at an angle of 52 degrees to the ceiling and 38 degrees to the wall
with the front surface facing away from the wall and ceiling.
[0048] Figure 16 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention having
a front surface with a decorative front profile portion and having
a back surface with a decorative back profile portion with the
decorative front profile portion and decorative back profile
portion having substantially identical configurations inverted
relative to each other about a vertical centre line of the crown
moulding.
[0049] Figure 17 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention.
[0050] Figure 18 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention.'
[0051] Figure 19 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention.
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[0052] Figure 20 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention.
[0053] Figure 21 is an end plan view of another embodiment of
a lineal crown moulding according to the present invention.
[0054] Figure 22 is a perspective view of a piece of the lineal
crown moulding of Figure 3-5 ready to be cut vertically nested on
a mitre saw.
[0055] Figure 23 is a schematic end plan view of the lineal crown
moulding, saw table and saw fence of Figure 22.
[0056] Figure 24 is a perspective view of a piece of the lineal
crown moulding of Figure 3-5 ready to be cut flat on a compound
mitre saw.
[0057] Figure 25 is a schematic end plan view of the lineal crown
moulding, saw table and saw fence of Figure 24.
[0058] Figure 26 is a schematic end plan view of another
embodiment of lineal crown moulding according to the present
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invention, compound mitre saw table and saw fence where the height
of the crown moulding is greater than the width of the saw table.
[0059] It will be appreciated that for purposes of clarity and
where deemed appropriate, reference numerals have been repeated
in figures to indicate corresponding features, and that the various
elements in the drawings have not necessarily been drawn to scale
in order to better show the features of the invention.
DETAILED DESCRIPTION
[0060] Referring to Figures 1 and 2, prior art lineal crown
moulding made from wood or MDF, generally indicated at 100, is
illustrated. The crown moulding 100 has a front surface 102 with
a decorative non-planar profile, generally indicated at 106 and
a generally flat back surface 104. As noted above the entire front
surface is decorative and serves no functional purpose. The crown
moulding is typically applied against a ceiling and a wall at an
angle. Crown moulding typically comes in three different spring
angles, 38 , 45 and 52 . The spring angle is the "tilt" at which
the crown moulding sits on the wall. The different spring angles
are a way to show off the moulding detail better at different wall
heights. For example on a lower ceiling you want the crown moulding
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to tilt up towards the eye for better viewing. In the same way crown
moulding set into a high ceiling looks best when it's tilted down.
[0061] The spring angle or tilt is accomplished by providing
a top chamfer portion 110 on the flat back surface 104 which is
placed against the ceiling ("ceiling seat") and a bottom chamfer
portion 112 on the back surface that is placed against the wall
("wall seat") . With a 38 spring angle, the flat back surface 104
of the moulding is titled at an angle of 38 relative to the wall
and at an angle of 52 relative to the ceiling with the wall seat
112 flat against the wall and the ceiling seat 110 flat against
the ceiling.
[0062] Crown mouldings may be manufactured from plaster, solid
wood, finger joint wood construction, medium density fibre board
(MDF), polyurethane, PVC, fiberglass, polystyrene and
plaster-coated foam mouldings in a wide variety of sizes from small
sizes about an inch high to about seven inches to larger sizes
(custom profiles can be any height) and profiles. See for example
"WM/Series Wood Moulding Patterns", "HWM/Series Hardwood Moulding
Patterns" and "WMDF Series Wood Moulding Patterns", all published
by the Wood Moulding & Millwork Producers Association, which
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describe standard profiles for flat back lineal crown mouldings
made from wood or MDF and are incorporated herein by reference.
[0063] Referring to Figures 3 to 5, one embodiment of a lineal
crown moulding, generally indicated at 200, according to the
present invention is illustrated. Figures 3 and 4 illustrate an
end of the lineal crown moulding of indefinite length. As shown
in Figures 3-5, the lineal crown moulding 200 includes a front
surface 202, a back surface 204, a front decorative profile portion
206, a back decorative profile portion 208, a top front chamfer
210, a bottom front chamfer 212, a top back chamfer 214 and a bottom
back chamfer 216. In Figures 3 and 4, the front surface 202 is
denoted with the letter A and the back surface 204 is denoted with
the letter B for future cross referencing.
[0064] Referring now to Figure 5, and enlarged cross-section
of the lineal crown moulding of Figures 3 and 4, in the embodiment
illustrated, the lineal crown moulding 200 has three distinct
portions: (1) a first portion generally indicated at 218 includes
the top front chamfer 210, as well as the top back chamfer 214,
(2) a second portion 220 which includes the front decorative
profile portion 206 and the back decorative profile portion 208
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and (3) a third portion 222 which includes the bottom front chamfer
212 and the bottom back chamfer 216.
[0065] The front surface 202 and the back surface 204 of the
crown moulding 200 of the embodiment shown in Figures 3-5 have
substantially identical configurations but are not mirror images
of each other. The configuration of the front surface 202 and back
surface 204 are inverted (rotated 180 degrees) relative to each
other about a vertical centre line 224 from a top edge 225 of said
crown moulding to a bottom edge 226 of said crown moulding in order
to be able to utilize both sides of the crown and obtain the mitring
advantages as described herein. In the embodiment illustrated in
Figure 5, the vertical centre line 224 runs from the point of
intersection 213 of the top front chamfer 210 and top back chamfer
214 to the point of intersection 215 of the bottom front chamfer
212 and bottom back chamfer 216.
[0066] The lineal crown moulding of the present invention has
a uniform cross-section along its length, the cross section having
an upper half and a lower half having substantially identical
configurations reversed 180 degrees relative to each other about
a horizontal centre line through a mid point of said cross section.
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[0067] Crown moulding 200 is useful when there is a non planar
decorative profile portion defined by the crown moulding 200 which
is pleasing to the eye. The present device has no significance
if for example the crown moulding is simply a rectangular piece
of moulding where there is non-planar decorative profile portion.
The present invention has a decorative profile portion 220 that
is non-planar, meaning that there is a decorative contour with one
or more curved sections defined within the non-planar decorative
profile portion 220 which in fact is other than simply straight
parallel sides as for example in a simple four sided dressed piece
of lumber.
[0068] The crown moulding 200 of the present invention is of
indefinite length and is normally referred to as lineal crown
moulding which will be sold/purchased in pre-selected lengths such
as 8, 12, 14, 16 and at times 20 foot lengths not dissimilar to
the lengths of flat back crown moulding that has been previously
available.
[0069] The lineal crown moulding 200 is shown deployed in Figure
12 with the top back chamfer 214 on the back surface 204 adjacent
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ceiling 230 and the bottom back chamfer 216 on the back surface
204 adjacent wall 232. The top and bottom back chamfers 212 and
216 act as landings or mounting areas upon which the lineal crown
moulding 200 rests and is positioned against the wall and ceiling.
In Figure 12 the decorative front profile 206 is facing away from
the wall 232 and ceiling 230. The top back chamfer 214 acts as the
ceiling seat and the bottom back chamfer 216 acts as the wall seat.
[0070] Due to the configuration of the lineal crown moulding
200 of the present invention, in Figure 13, the lineal crown
moulding 200 is turned over and inverted end to end with decorative
back profile 208 facing away from the wall 232 and ceiling 230.
The bottom front chamfer 212 acts as the ceiling seat and the top
front chamfer 210 acts as the wall seat.
[0071] The crown moulding of the present invention can be
installed with either the front surface 202 being exposed and
visible or the back surface 204 being exposed and visible.
Regardless of the side chosen, crown moulding 200 can be selected
to provide the same appearance.
[0072] As shown in Figure 12, the crown moulding 200 installed
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with the front surface 202 exposed results in top back chamfer 214
and the bottom back chamfer 216 making contact with the ceiling
and wall respectively. As shown in Figure 13, the crown moulding
200 installed with the back surface 204 exposed results in bottom
front chamfer 212 and the top front chamfer 210 making contact
with the ceiling and wall respectively. The spring angle of the
lineal crown moulding 200 of the present invention (the angular
relationship of the lineal crown moulding 200 relative to the wall
or ceiling) is determined by the slope of chamfers 210, 212, 214
and 216. The lineal crown moulding of the present invention
installed at the juncture of a ceiling and a wall at the same common
spring angles as for the prior art flat back lineal mouldings are
shown in Figures 12-15.
[0073] If a spring angle of 45 degrees is desired each of the
chamfers 210,212,214 and 216 are at an angle of 45 degrees to the
straight lines 240,241 through the two outermost points on the
decorative front and back profiles 206,208 respectively. A line
through the two outermost points on the decorative front and back
profiles 206,208 is used in order the have the proper spring angle
when the lineal crown moulding is cut flat (as described
subsequently in this text).
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[0074] For example in Figure 5 line 240 is formed by the straight
line through end points 242,243 of the top front chamfer 210 and
bottom front chamfer 212. The angle 246 of the top front chamfer
210 to line 240 is 45 degrees. Similarly the angle 247 of the bottom
front chamfer 212 to line 240 is 45 degrees. The angle 248 of the
top back chamfer 214 to line 241 is 45 degrees. Similarly the angle
249 of the bottom back chamfer 216 to line 241 is 45 degrees.
[0075] In another embodiment of the lineal crown moulding 300
shown in Figure 16 a different profile for the front surface 302
and back surface 304 is illustrated. In this embodiment lineal
crown moulding 300 includes a front surface 302, a back surface
304, a front decorative profile portion 306, a back decorative
profile portion 308, a top front chamfer 310, a bottom front chamfer
312, a top back chamfer 314 and a bottom back chamfer 316. The front
surface 302 and the back surface 304 of the crown moulding 300 of
the embodiment shown in Figure 16 have substantially identical
configurations inverted relative to each other about a vertical
centre line 324 of said crown moulding in order to be able to utilize
both sides of the crown and obtain the mitring advantages as
described herein. In the embodiment illustrated in Figure 16, the
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CA 02696099 2010-01-29
vertical centre line 324 runs parallel and midway between straight
lines 340,341 through the two outermost points 342,343 and 344,345
on front and back surfaces 302,304 respectively. The angle 346 of
the top front chamfer 310 to line 340 is 45 degrees. Similarly the
angle 347 of the bottom front chamfer 312 to line 340 is 45 degrees.
The angle 348 of the top back chamfer 314 to line 341 is 45 degrees.
Similarly the angle 349 of the bottom back chamfer 316 to line 341
is 45 degrees.
[0076] There are other orientations used and some of these are
listed as follows:
Angle to Ceiling Angle to Wall
38 degrees 52 degrees (see Figure 14)
52 degrees 38 degrees (see Figure 15)
30 degrees 60 degrees (not shown)
60 degrees 30 degrees (not shown)
[0077] In Figure 5, the angles 248, 249 add up to substantially
90 degrees as do the angles 246, 247 for installation between a
perpendicular oriented wall and ceiling. The two angles 248, 247
must be substantially the same in order to be able to orient the
lineal crown moulding with either the front surface 202 or back
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CA 02696099 2010-01-29
surface 204 exposed and obtain the mitring advantages as described
herein. The two angles 246, 249 must also be substantially the
same in order to be able to orient the lineal crown moulding with
either the front surface 202 or back surface 204 exposed and obtain
the mitring advantages as described herein.
[0078] The top front chamfer 210, the bottom front chamfer 212
and the top back chamfer 214 and the bottom back chamfer 216 are
required in order to ensure the proper orientation of the lineal
crown moulding 200 against a ceiling 230 and wall 232 as depicted
in Figures 12-13. These are not decorative features but rather
structural elements required to obtain the advantages of the
current invention.
FORMING MITRED INSIDE OR OUTSIDE CORNERS
[0079] An advantage of the lineal crown moulding of the present
invention is that an inside or outside corner can be created with
one cut, without the need to reset the position of the saw or cutting
multiple pieces of moulding.
[0080] Referring now to Figures 6 through to 11, we will now
CA 02696099 2010-01-29
describe how inside and outside corners are created.
[0081] Figure 6 illustrates a piece of lineal crown moulding
cut in two directions at once; beveled and mitered. There are two
different methods described hereafter for cutting the lineal crown
moulding either vertically nested or flat to create the required
cut. Figure 6 shows the piece of crown moulding with the profile
of the embodiment in Figures 3-5 and having a definite length.
[0082] In Figures 6 -11, the front surface 202 of the piece of
lineal crown moulding is denoted with capital A' s whereas the back
surface 204 is denoted with capital B's (in dashed lines in Figure
6 indicating that this is on the back side not seen in the top plan
view of Figure 6). The piece of lineal crown moulding is mitre
and bevel cut along line 280 as shown to create a left piece 282
depicted in Figure 7 and a right piece 283 depicted in Figure 8.
In the case where we are making component parts such as an inside
corner and an outside corner, left piece 282 has a predetermined
length as shown in Figure 7 and right piece 283 has a predetermined
length as shown in Figure 8. The same technique applies to pieces
of lineal crown moulding, wherein left piece 282 has indefinite
lengths extending out to the left from what is shown in Figures
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CA 02696099 2010-01-29
6 and 7 and right piece 283 is also of indefinite length extending
to the right, outward from what is shown in Figure 6 and 8. Left
piece 282 includes a top right edge 286 and a bottom right edge
288. The right piece 283 includes a top left edge 290 and a bottom
left edge 292. In order to produce an inside corner as shown in
Figures 9 and 10 for example, right piece 283 is inverted or turned
over 180 degrees such that the back surface 204 is now visible and
denoted with a solid capital B. The mitred ends 289, 291 of the
left and right pieces 282, 283 are butted such that the top right
edge 286 of left piece 282 is adjacent the bottom left edge 292
of right piece 283 and the bottom right edge 288 of left piece 282
is adjacent the top left edge 290 of right piece 28.3. This creates
the inside corner shown in Figure 10 denoted as 294.
[0083] Referring now to Figure 11, the part depicted in.Figure
11 is an outside corner 296 which is the same part as inside corner
294 but simply turned over or rotated 108 degrees such that the
back surface 204 of the left piece 282 and the front surface 202
of the right piece 283 are visible.
[0084] Assembly of left piece 282 and the right piece 283, as
depicted in Figures 9 through 11, produces both an inside corner
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294 and an outside corner 296 by simply reorienting the parts.
[0085] With the present invention, with one cut and no waste
inside corners 294 and outside corners 296 are produced. In
addition as the same component part namely inside corner 294 is
the same component as outside corner 296, only one SKU needs to
be stocked by suppliers of the component parts 294,296 to function
as either an inside or outside pre-formed corner, making more
efficient use of bin or shelf space and eliminating the scrapping
of a substantial number of the outside corners produced - they can
be used as inside corners.
Cutting and Installation of lineal crown moulding of the present
invention
[0086] The first steps involved in installing crown moulding
in a room with mitred corners are the same whether using prior art
flat back crown moulding or the lineal crown moulding of the present
invention, namely:
1. Sketch the room you are about to crown.
Start in a corner and work your way around the room in a
clockwise direction, identifying each corner with a
number.
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2. Refer to a Crown Angle Chart for details on spring angle
and wall coverage. Use the moulding's respective wall
coverage measurement to mark its location on the wall.
3. Measure the length of each wall where you made your mark
and transcribe the measurements to your plan.
4. Measure the angle of each corner with a protractor and copy
the measurements to your plan resulting in a schematic
drawing of the room with the corners numbered, the length
of each wall and the corner angles marked on the drawing
[0087] The set up of the saw and cutting of the lineal crown
moulding of the present invention to create the bevel and mitre
cuts required in each corner of the room will vary depending on
if you have a mitre saw or compound mitre saw. It may be necessary
to use a compound mitre saw if the vertical stroke on the mitre
saw is not high enough to accommodate the size of the lineal crown
moulding being installed.
[0088] With a mitre saw (see Figures 22 and 23):
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CA 02696099 2010-01-29
5. Adjust the saw 450 to cut half of the measured angle
indicated on the plan. Note: Unless the angles of the other
corners are different, there is no need to readjust the saw
again. In the exemplified plan all the angles were 90
degrees so the saw is set to cut a mitre cut at 45 degrees.
6. Select a piece of lineal crown moulding 400 of the present
invention longer than the length of the wall from corner
1 to corner 2. Place the lineal crown moulding 400 to the
left of the saw blade 453 seated on the saw 450 as depicted
in Figures 22 and 23 with one of the chamfers 410,416 that
will form a wall seat against the fence 451 and the
corresponding chamfer 412, 414 that will form the ceiling
seat against the saw table 452. Note: if the wall is longer
than the length of lineal moulding available it will be
necessary to butt two or more pieces together to form the
required length. The butt joint between pieces should be
located where it is most esthetically appropriate and can
be formed without adjusting the saw.
7. Cut as close as possible to the right end of the lineal crown
moulding 400 to form the end that will fit in corner 1. The
little piece to the right of the blade is scrap.
CA 02696099 2010-01-29
Note whether you need inside corners or outside corners for your
next cut. In the exemplified plan corner 2 is an inside corner.
8. Turn the moulding over if going from an outside corner to
outside corner or inside corner to inside corner. In the
exemplified plane corner 2 is an inside corner so the
moulding is turned over. [If going from an outside corner
to an inside corner or inside corner to outside corner: Do
not turn the moulding over.]
Slide the moulding to the right. Mark to required length.
For an inside corner to an inside corner, measure from the
longest point of the moulding to the length indicated on
your plan. For an outside corner to an outside corner,
measure from the shortest point of the moulding to the
length indicated on your plan. If your next piece will be
for an inside corner to an outside corner or an outside
corner to an inside corner, measure from either (longest
or shortest) point to the length indicated on your plan
9. Align the right side of the blade with the edge of your mark
and cut to give you the moulding to extend from corners 1
to 2 with each end having the proper bevelled and mitred
cut.
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CA 02696099 2010-01-29
Repeat steps 6-9 until all of the pieces for each wall are
cut. Note: If angles vary between different corners of the
room, repeat step 2 before performing your cuts.
If the length of moulding to the left of the saw after step
9 is sufficiently long to cover the wall between corners
2 and 3 it is not scrap. Repeat steps 8 and 9 to give you
the moulding to extend from corners 2 to 3 with each end
having the proper bevelled and mitred cut.
10. You can either install the moulding as you go or if you are
going to stain or paint the moulding before installation
you can cut all the pieces first. To install, place the
moulding to the wall along the appropriate wall.
11. Ensure both edges are flush against the wall and ceiling
and that they align with your marks.
Secure with finishing nails.
[0089] With a compound mitre saw (see Figures 24 and 25):
5. Refer to a Crown Angle Chart for mitre and bevel settings.
Note: Unless the angles of your other corners are different,
you won't need to readjust your saw again.
6. Select a piece of lineal crown moulding 500 of the present
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invention longer than the length of the wall from corner
1 to corner 2. The lineal crown moulding 500 is placed to
the left of the saw blade 551 seated on the saw 550 as
depicted in Figures 24 and 25 with an edge 513 against the
fence 552 and the front or back surface 502, 504 flat on the
saw table 553.
7. Cut as close as possible to the right end of the lineal crown
moulding 500 to form the end that will fit in corner 1. Note
whether you need inside corners or outside corners for your
next cut. In the exemplified plan corner 2 is an inside
corner.
8. Turn the moulding over if going from an outside corner to
outside corner or inside corner to inside corner. If going
from an outside corner to an inside corner or inside corner
to outside corner: Do not turn the moulding over.
Slide the moulding to the right. Mark to required length.
For an inside corner to an inside corner, measure from the
longest point of the moulding to the length indicated on
your plan. For an outside corner to an outside corner,
measure from the shortest point of the moulding to the
length indicated on your plan. If your next piece will be
for an inside corner to an outside corner or an outside
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CA 02696099 2010-01-29
corner to an inside corner, measure from either (longest
or shortest) point to the length indicated on your plan.
9. Align the right side of the blade with the edge of your mark
and cut to give you the moulding for corners 1 to 2 with
each end having the proper bevelled and mitred cut.
Repeat steps 6-9 until all of the pieces for each wall are
cut. Note: If angles vary between different corners of the
room, repeat step 2 before performing your cuts.
If the length of moulding to the left of the saw after step
9 is sufficiently long to cover the wall between corners
2 and 3 it is not scrap. Repeat steps 8 and 9 to give you
the moulding to extend from corners 2 to 3 with each end
having the proper bevelled and mitred cut.
10. You can either install the moulding as you go or if you are
going to stain or paint the moulding before installation
you can cut all the pieces first. To install, place the
moulding to the wall along the appropriate wall.
[0090] If the lineal crown moulding 600 is wider than the saw
table 653 as illustrated schematically in Figure 26 it is important
in order to get the proper spring angle after cutting that the two
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outermost points 633, 634 on the front 602 and 635, 636 back surfaces
604 are spaced so they rest on the saw table 653. If not some form
of table extension or jig may be required.
[0091] Figures 17 through 21, illustrate in cross-section the
profile of other embodiments of the lineal crown moulding of the
present invention. In each case the lineal crown moulding has a
front surface and a back surface having substantially identical
configurations inverted relative to each other about a vertical
centre line from a top side of said crown moulding to a bottom side
of said crown moulding. Other sizes, profiles and materials of
construction fall within the scope of the present invention.
[0092] In developing the front non-planar decorative profile
portion and back non-planar decorative profile portion the design
of the resulting lineal crown moulding, if using the same nominal
thickness as for flat back crown moulding, standard profiles as
shown in the Wood Moulding & Millwork Producers Association
publications need to be modified. When developing the new
non-planar decorative profiles for the lineal crown moulding of
the present invention you should ensure that, when viewed in cross
section, thin sections between the front non-planar decorative
profile portion and back non-planar decorative profile portion
CA 02696099 2010-01-29
have sufficient structural integrity and strength to be used in
long lengths. For example for lineal crown moulding according to
the present invention made from MDF the modulus of elasticity (MOE)
and modulus of rupture (MOR) at the center of the crown moulding
should be optimized for example by increasing the amount of resin
to fiber, utilizing more refined fiber or changing the press cycle.
[0093] In Figures 17, 19-21 the angle of the chamfers is shown
as 44 degrees as opposed to 45 degrees in order to accommodate
slight imperfections in the wall or ceiling. Figure 18 shows angles
of 52 degrees for the top front chamfer and bottom back chamfer
and 38 degrees for the bottom front chamfer and top back chamfer.
[0094] The lineal crown moulding of the present invention:
(a) Cut frustration. Simply turn the moulding over and cut using
the same saw angle because both sides of the present invention have
a matching decorative profile.
(b) Cut time. All corners (inside and outside) can be cut without
repositioning the saw.
(c) Cut Waste. Since the saw stays locked in the same position
for all your cuts, you make fewer mistakes when cutting.
(d) The present invention makes installing crown moulding quick,
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easy and economical.
[0095] Having illustrated and described embodiments of the
invention and certain possible modifications thereto, it should
be apparent to those of ordinary skill in the art that the invention
permits of further modification in arrangement and detail. All such
modifications are covered by the scope of the invention
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