Abstract:
The invention is a joint cover assembly for covering a gap adjacent an edge of a panel that covers a sub-surface, and a method of covering such a gap. The assembly includes a molding having a flange, a first bar, and a second bar. The flange is positioned along a longitudinal axis, and the first bar extends generally orthogonally from the flange. The second bar extends generally orthogonally from the flange. A tab depends generally orthogonally from the first panel engaging surface. At least one of the tab and the flange engage the edge in order to tightly fit within the gap. The method includes the steps of placing the flange in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the flange to cooperate to retain the molding in the gap when the assembly is in an installed condition.

Description:
FIELD OF INVENTION  
         [0001]    The invention is a joint cover assembly that includes a molding, similar to a T-Molding, for covering a gap that may be formed adjacent a panel in a generally planar surface, such as a floor or wall.  
         BACKGROUND OF THE INVENTION  
         [0002]    Wood or laminate flooring has become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels. The differing types of panels that have developed, of course, may have differing depths and thicknesses.  
           [0003]    It is necessary to provide a smooth transition or edge to the floor, such as at the corner of a wall. The edges near a wall are commonly known as edge or corner moldings.  
           [0004]    Additionally, one may desire to floor adjacent areas with different types of material. One instance where this may be desired, for example is in the differing rooms of a home. Specifically, one may desire to have one type of flooring in a kitchen, and a different appearance in an adjacent living room, and an entirely different look in an adjacent bath. In order to accomplish this, became necessary to develop a type of molding accomplish this, became necessary to develop a type of molding or seal that could be used as a transition from one type of flooring to another.  
           [0005]    A problem is encountered, however, when one desires to use flooring materials that are dissimilar in shape or texture. For example, when one desires to have a hard floor adjacent a carpet, problems are encountered with the edge moldings of the prior art. Additionally, the prior art moldings encountered difficulty in covering the gap that may be formed between flooring of differing height or thickness.  
           [0006]    Moreover, for purposes of reducing cost, it is important to be able to have a molding that is versatile; meaning it could be used to cover a gap between relatively coplanar surfaces, as well as surfaces of differing thicknesses.  
         SUMMARY OF THE INVENTION  
         [0007]    The invention is a joint cover assembly for covering a gap adjacent an edge of a panel, such as that covers a sub-surface. The assembly includes a body having a flange positioned along a longitudinal axis, and a first bar extending generally orthogonally from the flange, and bearing a generally planar first panel engaging surface. The assembly also has a second bar extending generally orthogonally to the flange, and bearing a second generally planar panel engaging surface. A tab is on the first panel engaging surface and displaced from the flange, depending orthogonally from the first panel engaging surface.  
           [0008]    The assembly may also include a rail positioned adjacent the edge, wherein the flange is configured to be slidingly retained within the rail. In a preferred embodiment, the rail is coupled directly to the subsurface that is covered by the panel.  
           [0009]    The outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both bars. This outward-facing surface may be treated, for example, covered with a laminate or a paper, such as a decor, impregnated with a resin, in order to increase its aesthetic value, or blend, match, or contrast with the panels.  
           [0010]    A shim may be placed between the flange and the subfloor. In a preferred embodiment, the shim may be positioned on the underside of the rail; however, if a rail is not used, a shim may be positioned between the flange and the subfloor. Additionally, the shim may be adhered to either the flange or subfloor using an adhesive or any known fastener (such as a nail or screw).  
           [0011]    The assembly may also include a reducer positioned between the first arm and the subfloor. The reducer has a top that engages the first panel engaging surface, and a bottom that engages the subfloor, as well as a channel formed in the top and configured to engage and receive the tab. The reducer is configured to keep the first arm, second arm, and an outward facing surface of the panel relatively coplanar when an edge of a material thinner than the panel is positioned beneath the first arm. The material may comprise any of a carpet, laminate flooring, ceramic or wood tile, linoleum, turf, paper, natural wood or veneer, vinyl, wood, ceramic or composite finish, or any type of covering. The reducer facilitates one to use coverings having varying thicknesses are desired to cover a subfloor. The reducer helps the molding not only cover the gap, but provide a smoother transition from one surface to another.  
           [0012]    Alternatively, the tab may be positioned and configured to slidingly engage the edge of a panel. A lip may be positioned and configured on the tab in order to slidingly engage a protuberance adjacent an upper edge of the rail in order to retain the assembly in its installed position.  
           [0013]    The tab may be frustum-shaped with a large base distal the first panel engaging surface. Additionally, the tab may be lobe shaped, having a bulbous end distal the first panel engaging surface. Of course, any suitable shape would suffice, provided the tab is sufficiently sturdy, and may facilitate any of the functions set forth in the preceding paragraphs.  
           [0014]    The assembly may be used to cover gaps between tongue-and-groove type panels, such as the so-called glue-free laminate floors. In addition to the uses mentioned above, the tab may also engage the edge of one of the panels, or may actually fit within a grooved edge. In order to better accommodate this type of gap, a second tab may be positioned to depend from the second panel engaging surface.  
           [0015]    The assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even on stairs. The detachment of the first bar may increase the suitability for this purpose.  
           [0016]    An adhesive, such as a glue, a microballoon adhesive, contact adhesive, or chemical adhesive, may be positioned on the tab, the flange, the first panel engaging surface, and/or the second panel engaging surface. Of course, such an adhesive is not necessary, but may enhance or supplement the snap-type fit of the assembly into the gap. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.  
           [0017]    The inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of dissimilar surfaces. For example, when installing floors into a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, carpet, or turf.  
           [0018]    The invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface. The method includes myriad steps, including, inter alia, the steps of placing the flange in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the flange to cooperate to retain the molding in the gap when the assembly is in an installed condition.  
           [0019]    These and other objects, uses, and functions of the above-referenced invention will become apparent from the following written description, taken together with the accompanying drawings and appended claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is an exploded view of a preferred embodiment of the joint cover assembly, according to the principles of the invention  
         [0021]    [0021]FIG. 2 is a perspective view of one embodiment of the joint cover assembly, according to the principles of the invention, shown in an installed condition.  
         [0022]    [0022]FIGS. 3 and 3A are a comparative perspective views of respective preferred embodiments of the retainer, according to the principles of the invention.  
         [0023]    [0023]FIG. 4 shows the underside of a molding portion of a preferred embodiment of the joint cover assembly.  
         [0024]    [0024]FIGS. 5 and 5A are a comparative perspective views of respective preferred embodiments of the retainer, according to the principles of the invention.  
         [0025]    FIGS.  6 - 16  show comparative cross-sectional views of various embodiments of the molding portion of the joint cover assembly, according to the principles of the invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]    [0026]FIG. 1 shows an exploded view of the various parts of the inventive joint cover assembly  10 . The joint cover assembly includes a T-like molding  11 , having a flange  16  formed so that it can fit between the gap  20  formed adjacent an edge  27  of a panel  24 .  
         [0027]    As shown in FIG. 1, the panels  24  are the tongue-and-groove type, having a groove  27  positioned near the gap  20 ; however, the tongue and groove type of panel is not necessary.  
         [0028]    A first bar  12  extends generally orthogonal to the flange from adjacent a first end of the flange  16 , and a second bar  12  extends generally orthogonally from adjacent the first end of the flange  16 . As shown, the flange  16 , first bar  12 , and second bar  14  from a general T-shape. This T-shape, while a preferred embodiment, is not mandatory, of course.  
         [0029]    The joint assembly  10  is best used for covering a gap  20  formed between adjacent edges of adjacent panels, such as coverings for a subfloor  22 . the various coverings for the subfloor  22  may be panels  24 , as shown, but may also be tile, linoleum, turf, or carpet, wood, vinyl, ceramic or composite finish, or other materials as mentioned herein. In order to increase aesthetics, the upper surface  34  of the molding  11  may be selected to match or blend with the decor of the panels  24 .  
         [0030]    The molding  11  may be formed of any suitable, sturdy material, such as wood, polymer, wood, or even a wood/polymer composite. Due to the growing popularity of wood and laminate flooring and wood wall paneling, however, many prefer a natural or simulated wood-grain appearance on the outward facing surface  34 . Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the surface  34  with a laminate having a decor sheet that simulates wood. Alternatively, the decor can simulate stone, brick, inlays, or even fantasy patterns.  
         [0031]    A rail  26  is coupled to the subfloor  22  within the gap  20 . as shown, the rail may be coupled to the subfloor  22  by means of fasteners, such as screws (as shown); however, any known method of coupling would suffice. The rail  26  and the flange  16  are preferably cooperatively formed so that the flange  16  is slidingly retained within the rail  26  when the rail is installed.  
         [0032]    The rail may be formed of a sturdy, yet pliable material that will outwardly deform as the flange is inserted, but will retain the flange  16  therein. Such materials include, but are not limited to, plastic, wood/polymer composites, wood, polymers, etc.  
         [0033]    A tab  18  depends from the first bar. As shown in FIG. 1, the tab  18  depends downward from the first bar, and runs generally parallel to the flange  16 . As shown in FIG. 1, the tab may bear the shape of a frustum with its larger base distal the first bar  12 ; however, other suitable shapes are possible, as will be discussed hereinafter.  
         [0034]    As shown in FIG. 1, the assembly further includes a retainer  40  having a channel  42  that is formed to receive the tab  18 . When the molding  11  is required to cover a gap  20  between panels  24 ,  25  of differing heights, as is shown in FIG. 1, the retainer  40  is positioned between the first arm  12  and the subfloor  22 .  
         [0035]    Even though the assembly  10  may function without any type of glue or adhesive, an alternate embodiment includes the placement of adhesive  31  on the molding  11 . The adhesive may be placed on molding  11  at the factory (for example, pre-glued); alternatively, the glue may be applied while the panels are being assembled. As shown in FIG. 1, the adhesive is a strip-type adhesive, but any type of adhesive, such as glue, chemical or chemically-activated adhesives, contact cements, microballoon adhesives, etc. may be used. Additionally, while the embodiment in FIG. 1 shows the adhesive strips  31  attached to respective panel engaging surface  36 , the adhesive may also be attached to the tab  18 , flange  16 , the ridges  32 , or any suitable place. Preferably, adhesive should only be applied to one of the panel engaging surfaces  36 ,  38 , in order to allow accommodate some slight relative movement that may occur during changes of temperature, for example. Allowing a slight amount of movement may also eliminate unneeded material stresses as well, thereby reducing warping or deterioration of the material surface.  
         [0036]    [0036]FIG. 2 shows a preferred embodiment of the assembly  10  in an installed condition, wherein the panels  24 ,  25  are of differing thicknesses. Of course, the panel  24  may be of any type of covering, such as carpet, turf, tile, linoleum or the like. As shown in FIG. 3, the retainer  40  includes a bottom  46 , and a top  45  having a channel  42 , and an inner surface  44 .  
         [0037]    Referring now again to FIG. 2, note that the top  45  of the retainer firmly engages the panel engaging surface  36  of the first arm  12 , and the bottom  46  engages panel  25 . Note that the tab  18  is firmly held within the channel  42  of the retainer  40 . Viewing FIGS. 2 and 3 together, note that the inner surface  44  of the retainer  44  does not engage the flange, as shown. Generally, a small amount of clearance is preferred between the rail  26  or flange  16  and the inner surface  44 ; however, the inner surface  44  may optionally be configured to engage one of the rail  26  or flange  16 .  
         [0038]    The retainer  40  may be made of a composite, pliable material that has some “give” to it. For example, the tab  18  may be formed to be slightly larger than the opening of the channel  42 , thereby forcing the channel  42  to outwardly deform in order to accommodate the tab  18 , and therefore snap-fit together.  
         [0039]    As shown in FIG. 3, the outer surface  47  of the retainer  40  is generally treated to match or blend with the outer surface  34  of the molding, in order to improve aesthetics. Therefore, the outer surface  47  may be treated in the same way as the outward facing surface  47 , as discussed herein. Alternatively, the outer surface  47  can be treated to contrast with the outer surface  34 .  
         [0040]    [0040]FIG. 3 a  shows an alternate embodiment of the retainer  40 ′. Note that corresponding parts that perform analogous functions of this alternate retainer  40 ′ are afforded similar reference numbers, for clarity. The outer surface  47 ′ of this embodiment is configured generally orthogonal to the upper surface  44 ′ and the lower surface  46 ′ of the retainer  40 ′. This alternate configuration of the outer surface  47 ′ not only provides a different appearance, it also has been shown to be preferred when softer surfaces, such as carpet or turf, are positioned beneath the lower surface  46 ′ of the retainer  40 ′.  
         [0041]    [0041]FIG. 4 shows yet another alternate embodiment of the retainer  140 . In the illustration of this alternate embodiment, the analogous parts have been assigned referenced numbers that are increased by one-hundred, for clarity purposes. For example, the retainer  140  (as in FIG. 4) is analogous to the retainer  40  and  40 ′ of FIGS.  1 - 4 .  
         [0042]    As shown in FIG. 4, the retainer may be positioned between a first arm  112  of the molding  111  and the panel  125 . In this embodiment of the assembly  110 , the tab  118  engages the inner surface  144  of the retainer  140 .  
         [0043]    [0043]FIG. 5 shows an embodiment of a retainer  140  that may be used in the assembly shown in FIG. 4. Specifically, note that the retainer  140  in FIG. 5 has a solid, uninterrupted upper surface  145 —there is no need for a channel because the tab ( 118 , as in FIG. 4) will engage the inner surface  44  instead of the top surface  145 .  
         [0044]    [0044]FIG. 5A shows other embodiment of a retainer  140 ′ that can be incorporated into the assembly shown in FIG. 4. Similar to the embodiment of FIG. 3A, the embodiment shown in FIG. 5A has a front surface  1461  that will be generally orthogonal to the floor  122  (as shown in FIG. 4) when the retainer  140 ′ is installed. This perpendicular configuration of the front surface  147 ′ not only provides a different appearance, it has also been found to be preferred with softer surfaces, such as carpet or turf.  
         [0045]    [0045]FIG. 6 shows an underside view of the molding  11 . The molding  11  has a first panel engaging face  36  on the first bar  12 , and a second panel engaging face  38  on the second bar  14 . Preferably, panel engaging surface  36  bears an adhesive  31  positioned to adhere to a surface of a panel or retainer (not shown in FIG. 6, but viewable in FIG. 1, for example).  
         [0046]    FIGS.  7 - 15  show various cross-sectional views of the molding  11 . These figures show comparative configurations for the arms  12 ,  14 , the tab  18 , and the upper surface.  
         [0047]    In FIG. 7, the tab  18  is selected to be an outward-facing hook having a pointed end facing away from the flange. This particular selection for a tab may be used to engage an edge or groove of an adjacent panel. Additionally, note that FIG. 5 shows a shim  48  positioned between the flange  16  and the subfloor  22 . The shim  48  is generally selected of a pliable and flexible, yet durable material. The shim  48  may also be used in combination with the rail  26  as well.  
         [0048]    FIGS.  8 - 15  show comparative cross-sections of other embodiments of the molding  11 . The configurations of the moldings are very similar, except for the shape of the tab. The differing tabs have been assigned decimal numbers beginning with  18 , for clarity purposes. The tab  18 . 1  of the embodiment shown in FIG. 8 is a depending bulbous shape, having a large end distal the first panel engaging surface  36  of the first bar  12 .  
         [0049]    [0049]FIG. 9 shows a cross-section of another embodiment of the molding  11 . The tab  18 . 2  of this embodiment is shown to be a hook-shape with a point facing the flange  16 .  
         [0050]    [0050]FIG. 10 shows the cross-section of yet another embodiment of the molding  11 . In this embodiment, the tab  18 . 3  is shown to be a frustum-shape, similar to the shape of the tab  18  shown in FIG. 2.  
         [0051]    The purpose of the various-shaped tabs ( 18 - 18 . 8 ) is multi-fold. Primarily, the tab  18  serves to engage the channel  42  of the retainer  40 , which is used when covering of differing thickness is used. Alternatively, the respective tab ( 18 - 18 . 8 ) may engage an edge of a panel, carpet, turf, or other type of floor covering. As shown herein, the respective tab ( 18 - 18 . 8 ) may even be configured to engage a retainer.  
         [0052]    [0052]FIG. 16 shows an embodiment of the molding  11  having arms  12 ,  14  extending opposed to a central flange  16 ; note that this embodiment does not include a depending tab. Preferably, this embodiment of the molding  11  includes an adhesive on the underside of one of the arms  12 ,  14 .  
         [0053]    Having described the invention in detail, the examples herein discussed are set forth for illustrative purposes only, and not for limitation. It will be support to those skilled in the art that the disclosure can be modified without departing from the scope and spirit of the invention.