Abstract:
The present invention extends an interior corner piece to create flange portions of a ceramic or porcelain molding. The structure of the invention can provide a sanitary transition between a wall and a floor by smoothing out and raising the surface away from a sharp corner or crevice. The invention also moves edges of the corner piece farther away from the inside corner. This can improve sanitation and allow for easier cleaning. This structure can promote a smoother installation and more uniform molding scheme by possibility improving the stability of the design to allow the molding piece to lie flush in the corner. The features of the invention may promote easier installation, better sanitation, and a pleasing appearance to the molding scheme.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application relates to, and claims the benefit of the filing date of, co-pending U.S. provisional patent application Ser. No. 60/864,862 entitled SANITARY COVE MOLDING, filed Nov. 8, 2006, the entire contents of which are incorporated herein by reference for all purposes. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to floor and wall coverings and, more particularly, to sanitary ceramic or porcelain cove moldings to be used in transition from floor to wall coverings. 
         [0004]    2. Description of Related Art 
         [0005]    Ceramic or porcelain moldings are used for various purposes. Molding does not only increase the aesthetic value of the environment in which it is used, but impervious molding may also improve sanitation and cleanliness. Dirt and germs often become trapped in the corners between the walls and the floor, and within the grout between individual tiles. Molding is often used to raise and smooth out those crevices and corners, and may decrease the amount of exposed grout. 
         [0006]    However, the typical inside corner molding existing on the market today has several disadvantages. First, installation of this molding may present challenges. The current corner molding lacks stability and it is difficult to install in isolation without support from the neighboring baseboard molding pieces. Furthermore, if corner moldings are installed last to improve the stability, variations in the lengths of the baseboard moldings may create gaps which may result in an increase of exposed grout. Both these situations may greatly decrease uniformity throughout the scheme and negatively impact the aesthetic value of the molding. Secondly, an increase in the amount of grout exposed may make sanitation more difficult and the presentation of the molding more abrasive, as does an increase in the number of seams existing between the various molding pieces. 
         [0007]    Therefore, there is a need in this market for an inside corner molding unit that increases stability, eases the difficulty of installation, and promotes uniformity by reducing the number of seams between molding pieces and decreasing the amount of exposed grout in the molding design scheme. There is also a need to improve the aesthetic value of the molding while improving sanitation and cleanliness of such molding schemes. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention achieves these and other objectives through its design and structure. It can provide a sanitary transition between a wall and a floor by smoothing out and raising the surface away from a sharp corner or crevice, to allow for easier cleaning. The invention also may decrease the number of seams and the amount of exposed grout by moving the grout joint and edges of the molding piece farther away from the inside corner. This also improves cleanliness. The structure of the invention can provide for a smoother installation and more uniform molding scheme by improving the stability of the design with the use of a right-angle, rather than a triangle or point, to allow the molding piece to lie flush in the corner. All of the features of the invention may promote easier installation, better sanitation, and a pleasing appearance to the molding scheme. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following Detailed Description taken in conjunction with the accompanying drawings, in which: 
           [0010]      FIG. 1  is a perspective view of a prior art sanitary cove molding system; 
           [0011]      FIG. 1A  is an elevation of a component of a sanitary cove molding system installed in a tile floor and wall; 
           [0012]      FIG. 2  is a perspective view of a first component of a sanitary cove molding system; 
           [0013]      FIGS. 3A and 3B  are an end views of a first component of a sanitary cove molding system; 
           [0014]      FIGS. 4A and 4B  are nother end views of a first component of a first component of a sanitary cove molding system; 
           [0015]      FIG. 5  is a perspective view of a first component of a sanitary molding system in a vertical orientation; 
           [0016]      FIG. 6  is a front perspective of an extended inside corner component of a sanitary cove molding system; 
           [0017]      FIG. 7  is a top plan view of an extended inside corner component of a sanitary cove molding system; 
           [0018]      FIG. 8  is a rear perspective of an extended inside corner component of a sanitary cove molding system; 
           [0019]      FIG. 9  is a perspective view of a sanitary cove molding system using an extended inside corner component; 
           [0020]      FIG. 10  is an exploded view of a sanitary cove molding system using an extended inside corner component; and 
           [0021]      FIGS. 11A-11C  are perspective and side views of an outside corner component of a sanitary cove molding system. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    The entire contents of Provisional Patent Application Ser. No. 60/864,862, entitled: “SANITARY COVE MOLDING” filed on Nov. 8, 2006, including appendices, are incorporated herein by reference for all purposes. 
         [0023]    In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. Additionally, for the most part, details concerning installation procedures, materials, and the like, have been omitted to the extent that such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the understanding of persons of ordinary skill in the relevant art. 
         [0024]    Turning now to  FIG. 1 , the reference numeral  100  generally indicates a sanitary cove molding system comprising a sanitary cove molding straight piece  102 , a sanitary inside cove inside corner piece  104 , and a sanitary outside cove outside corner piece  106 . Straight pieces  102  can be used to cover the straight-edge transitions between floors and walls, and to cover the straight-edge transitions between two walls. Corner pieces  104 ,  106  can be used to cover 90-degree corners and 270-degree corners, respectively. Straight pieces  102  can be extruded in the desired shape, while corner pieces  104 ,  106  can be pressed into their desired shapes. Straight and corner pieces  102 ,  104 ,  106  are shaped to have edges of substantially the same thickness as adjacent floor and wall tile pieces, and are curved to provide a substantially seamless transition between a tile-covered floor and an adjacent tile-covered wall or between two adjacent tile-covered walls. The pieces of the sanitary cove molding system fit so as to provide a substantially continuous, flush surface extending between a tile-covered floor and an adjacent tile-covered wall, or between two adjacent tile-covered walls, with substantially no sharp corners or edges upon which dirt and microbes can accumulate. The resulting corners are easily cleaned with a wet mop, reducing the need for certain cleaning agents. 
         [0025]      FIG. 1  illustrates straight piece  102  installed in a corner adjacent a first edge  204  of floor tile piece  202 . Inside corner piece  104  is shown installed at one end of straight piece  102  and at one corner  205  of floor tile piece  202 . Outside corner piece  106  is shown installed adjacent corner piece  104  and adjacent a second edge  206  of floor tile piece  202 . Turning now to  FIG. 1A , straight piece  102  is shown installed in a corner and adjacent a surface tile  202  along a first planar surface such as a floor, and adjacent a surface tile  210  installed along a second planar surface such as a wall. The view representing a corner between two adjacent walls would be substantially the same as shown in  FIG. 1A , as the same technique applies. The customary gaps between the pieces can be filled with grout  208 A,  208 B, forming a substantially continuous, flush surface extending between a tile covered floor and an adjacent tile-covered wall, or between two adjacent tile-covered walls. 
         [0026]    The pieces of the sanitary cove molding system can be fabricated from suitable materials such as ceramic, porcelain, synthetic stone, or other rigid, stone-like materials. The pieces of the sanitary cove molding system can be finished with a coat or glaze, as required, to obtain or further enhance certain desired properties of the sanitary cove molding pieces. One desired property of the sanitary cove molding pieces is imperviousness to microbial life. The substantially impervious sanitary cove molding pieces tend not to support microbial life, in part because the water absorption rate of the pieces is too low to permit introduction of microbes into the material of the cove molding pieces. The pieces meet the ASTM standard for impervious materials in which the rate of water absorption is less than 0.5 percent. This can be accomplished by utilizing an appropriate process for forming the body of each piece, and by careful selection of the material and or finish applied to each of the sanitary cove molding pieces. The pieces can be fired in such a way as to remove substantially all porosity from the material, thereby reducing the water absorption rate of the material and making the body of each piece substantially impervious to microbial life. The surface of each piece can be coated or glazed to impart a desired color to the piece and to seal the exposed surfaces of the pieces, thereby reducing the water absorption rate at the exposed surface of each piece and making the exposed surface of each piece substantially impervious to microbial life. 
         [0027]    The pieces of the sanitary cove molding system can be used with a flooring system such as described in the attached Appendix A, describing a Porcelain Flooring System delivering a high performance, anti-microbial and easily maintained surface. 
         [0028]    Turning now to  FIG. 2 , the straight piece  102  has length L and width W, and has edges  108 A,  108 B of substantially the same thickness as an adjacent floor or wall tile piece (not shown). A curved surface  110  extends transversely to the length L, and across width W, thereby interconnecting edge  108 A and  108 B. The exposed curved surface  110  and the edges  108 A,  108 B can be finished with a coating or glazing as described above to impart a color to the piece and to seal the surface against water absorption. End surfaces  112 A,  112 B and rear surface  114  need not be coated or glazed if these surfaces are generally not exposed when the piece  102  is installed in a tile flooring system. Similarly, corner pieces  104 ,  106  have exposed outer surfaces that can be coated or glazed to seal the surfaces against water absorption, and also have end surfaces and rear surfaces that need not be glazed if those surfaces are generally not exposed when the pieces  104 ,  106  are installed in a tile flooring system. 
         [0029]    Turning now to  FIG. 3A , a straight piece  102  is shown viewed from one end thereof, illustrating the edges  108 A,  108 B and the concave curved surface  110  extending therebetween. The piece  102  as shown rests on the rear, unexposed surface  114  of the straight piece  102 , which can be shaped with small protruding areas  115 A,  115 B along rear surface  114  to enhance adhesion to a subsurface of a wall or floor during installation. The straight piece  102  has a cross-sectional profile that lends itself to extrusion fabrication techniques, having substantially the same cross section along the entire length of the piece  102 . 
         [0030]    Turning now to  FIG. 3B , a straight piece  102 ′ is shown viewed from one end thereof, illustrating the edges  108 A′,  108 B′ and the concave curved surface  110 ′ extending therebetween. The piece  102 ′ as shown rests on the rear, unexposed surface  114 ′ of the straight piece  102 ′, which can be extruded with serrated longitudinal grooves  115 ′ to substantially increase adhesiveness important in securing the strait piece to a subsurface of a wall or floor during installation. 
         [0031]    Turning now to  FIG. 4A , the straight piece  102  is shown viewed from one end thereof, illustrating the edges  108 A,  108 B and the concave curved surface  110  extending therebetween. The piece  102  rests on corners between the edges  108 A,  108 B and exposed curved surface  110  of the straight piece  102 . The profile of rear surface  114  can be seen to have generally planar surfaces  116 A,  116 B, which contain small protruding areas  115 A,  115 B, adjacent the edges  108 A and  108 B, respectively. The piece  102  can also have a substantially planar surface  118  interconnecting generally planar surfaces  116 A,  116 B. 
         [0032]    Turning now to  FIG. 4B , the straight piece  102 ′ is shown viewed from one end thereof, illustrating the edges  108 A′,  108 B′ and the concave curved surface  110 ′ extending therebetween. The piece  102  rests on corners between the edges  108 A′,  108 B′ and exposed curved surface  110 ′ of the straight piece  102 ′. The profile of rear surface  114 ′ can be seen to have a generally planar surfaces  116 A′,  116 B′ adjacent the edges  108 A′ and  108 B′, respectively. The piece  102 ′ can also have a substantially planar surface  118 ′ interconnecting generally planar surfaces  116 A′,  116 B′. The straight piece can be manufactured to include serrated longitudinal grooves  115 A′,  115 B′,  115 C′ on the surfaces of  116 A′,  116 B′,  118 ′ to enhance adhesion to subsurface wall or floor during installation. A hollow center  111  can also be incorporated to reduce weight and amount of material used in manufacturing. 
         [0033]    Turning now to  FIG. 5 , the straight piece  102  is shown standing vertically upon on an end surface  112  and in a corner between two adjacent walls, illustrating the fit of the piece in a vertical configuration. 
         [0034]    Turning now to  FIG. 6 , an extended interior corner piece  300  is shown from the front with a view of exposed surfaces. Flange portions  302 A and  302 B extend outward for a substantial, non-trivial, distance from a central portion  303  and move edges  308 A and  308 B away from the corner between two walls behind the sanitary cove molding system. The flange portions  302 A and  302 B can serve several purposes. First, flange portions  302 A and  302 B may extend far enough from the central portion  303  to alter a center of gravity  320  of the extended interior corner piece  300  in such a way that a vertical axis  322 , as shown in  FIG. 6 , through the center of gravity  320  is substantially normal to a plane  324  of the bottom surface. The axis  322  and the plane  324  can form a substantially 90-degree right angle. This may be true no matter how the extended corner piece  300  is situated. This structure can also provide additional stability to the extended interior corner piece  300 , and this stability may make installation easier by allowing the corner piece  300  to lie flush against the floor and the walls without additional support. Second, by moving the edges  308 A and  308 B farther from the central portion  303 , the extended interior corner piece  300  can become easier to clean during and after installation because the seams and edges  308 A and  308 B are not crowded within a small corner area where dirt and microbes may accumulate. Flange portion  302 A may extend away from central portion  303  in a first direction along a first horizontal axis  326 . Flange portion  302 B may extend away from central portion  303  in a second direction along a second horizontal axis  328 . The concave surfaces  310 A,  310 B and  310 C may provide a smoother, continuous transition from floor to wall and wall to wall permitting cleaning utensils to reach previously tight areas. Finally, the extended interior corner piece  300  may allow for better planning in the installation process because, due to its improved stability, the corner molding piece  300  can be placed before the adjacent straight molding pieces. This can reduce the number of grout seams and gaps in the molding system altogether and improve the aesthetic value of the finished system. The exposed concave surfaces  310 A,  310 B,  310 C, and upper edge  304 A,  304 B,  304 C, and inner edge  306 A,  306 B of the extended corner piece  300  can be finished with a coat or glaze as described above to attain the desired coloring and to seal the surface against water absorption. 
         [0035]    Referring now to  FIG. 7 , the extended interior corner piece  300  may have several portions with different dimensions. Flange portions  302 A,  302 B have lengths LA, LB and widths WA, WB and edges  304 A,  304 B,  306 A,  306 B of substantially the same thickness as an adjacent floor or wall tile piece (not shown). Curved surfaces  310 A,  310 B extend transversely to lengths LA, LB and across widths WA, WB thereby interconnecting edge  304 A,  304 B and  306 A,  304 B. Lengths LA and LB may or may not be substantially the same and widths WA and WB may or may not be substantially the same. In an embodiment, the curved surface  310 C of central portion  303  rotates about a vertex  307  defined by the converging of inner edges  306 A and  306 B of the flange portions  302 . 
         [0036]    Turning now to  FIG. 8 , the extended interior corner piece  300  is shown from the bottom rear with a view of the surfaces  314 A,  314 B,  314 C,  312 A and  312 B, disposed opposite concave surfaces  310 , and configured to be fixed against the floor and walls. Bottom surfaces  312 A and  312 B may be substantially continuous horizontal surfaces corresponding to flange portions  302 A and  302 B, respectively, and adjacent to bottom front edges  306 A and  306 B, respectively. Rear surfaces  314 A,  314 B and  314 C may be substantially vertical contiguous surfaces corresponding to flange portions  302 A and  302 B, and central portion  303 , respectively, and adjacent to top edges  304 A,  304 B and  304 C, respectively. There can be a cut-back portion  316  represented by the surfaces  316 A,  316 B and  316 C along the length of the extended corner piece. Cut-back surfaces  316  may be substantially contiguous surfaces extending between and interconnecting bottom surfaces  312  and rear surfaces  314 , and can allow the extended corner piece  300  to lie flush against the walls and floor, promoting an easier install even if the inside corners are not “truly” ninety degrees. Any remaining gaps between the extended inside corner piece  300  and the walls can be filled with portland cement based mortar. Additionally, the greater surface area of the bottom side of the extended corner piece  300 , shown by the surfaces  312 A and  312 B, may substantially contribute to the improved stability and to the benefits of such stability discussed above. No coating or glaze should be applied to this side of the extended corner piece  300 , specifically surfaces  314 A,  314 B,  314 C, surfaces  312 A,  312 B, and surfaces  316 A,  316 B,  316 C, since it remains unexposed and requires a rougher texture for adhesion purposes. 
         [0037]    Turning now to  FIG. 9 , the sanitary cove molding system is illustrated from a perspective view as assembled with a floor piece  202 , two wall pieces  210 A and  210 B, a vertical straight piece  102 C, horizontal straight pieces  102 A and  102 B, an outside corner piece  106 , and an interior corner piece  300 . All molding pieces installed together can provide a smooth and continuous transition from floor to wall and wall to wall, and a polished inward curve rotating about the corner portion of the molding system. 
         [0038]    Turning now to  FIG. 10 , as in  FIG. 9 , the sanitary cove molding system is illustrated from an exploded perspective view showing the following components: a floor piece  202 , two wall pieces  210 A and  210 B, a vertical straight piece  102 C, two horizontal straight pieces  102 A and  102 B, an outside corner piece  106 , and an extended interior corner piece  300 . 
         [0039]    Turning now to  FIG. 11A-11C , a sanitary outside cove  106  may be configured as an L-Shaped unit with a top edge  120 , a front edge  122 , a bottom surface  124  and a back surface  126 . The back surface  126  lies adjacent to the top edge  120  and the bottom surface  124  lies adjacent to the front edge  122 . A concave surface  128  extends transversely from the front edge  122  to the top edge  120 . A rear cut-back  130  surface may be substantially contiguous surface portions extending between and interconnecting bottom surface portions  124  and rear surface portions  126 . As described above with respect to sanitary inside cove inside corner piece  300 , the cut-back portions allow the outside corner piece to lie flush against a wall and a floor without obstruction. The top and front edges  120 ,  122  and the concave surface  128  are exposed and can be treated with a coating or glaze to achieve the desired color and to seal the surface against water absorption. 
         [0040]    Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.