Abstract:
Devices and methods for preventing baseboard tilt associated with fastening a baseboard to a wall panel having a recessed edge. A baseboard support includes a corner bracket having first and second upright base members and having one or more flaps extending from an upright edge a base member. Each flap forms a flap angle with an adjacent portion of the bracket. Each flap is attached to the bracket at a resilient flap corner, or flap hinge. The baseboard support can be positioned in a corner in an upright position. A first baseboard can be positioned so that the baseboard end engages the first upright base member. A second baseboard can be positioned to engage the second upright base member, forming a mitered joint between the two baseboards. The baseboard support provides a stop that prevents each baseboard from tilting away from its corresponding wall panel and creating an unsightly gap. The flap or flaps allow the baseboard support to stand freely in the interior corner prior to baseboard positioning. Each flap may also provide a resilient force against a baseboard end to further prevent tilting. Methods of installing a baseboard and preventing baseboard tilt are also provided.

Description:
BACKGROUND 
     1. Technical Field 
     The present invention relates generally to construction materials and more particularly to devices and methods for installing baseboards. 
     2. Background Art 
     Conventional drywall panels of the types used in residential and commercial buildings for walls are typically fastened to underlying studs or beams. Multiple drywall panels can be mounted adjacent one another vertically and/or horizontally to form a wall. Standard drywall panels commonly include one or more tapered edges. When two drywall panels are positioned adjacent each other, a filler material such as a tape, plaster or mud can be applied to the tapered region between the panels to cover a seam or crack that may exist between the two panels. The tapered edges of the drywall panels provide a recess that can be filled with a filler material such as tape, plaster, mud or another suitable filler material without creating a bulge or protrusion from the plane of the wall. 
     When a conventional drywall panel is positioned adjacent a floor or a subfloor, the lower tapered edge running parallel to the floor creates a recess in the region where the panel approaches the floor or subfloor. The recess, or cavity, can extend back away from the wall surface a few millimeters or up to greater than a centimeter in some applications. Such a recess adjacent a floor is generally not necessary for accommodating a filler material as there is no panel joint nearby, but is necessarily present due to the tapered longitudinal edges found on conventional drywall panels. 
     Following drywall panel installation, baseboards are typically installed. When a baseboard is positioned against the lower edge of a drywall panel in the region near the floor or subfloor for fastening in place, a cavity is generally formed behind the baseboard between the baseboard and the tapered region of the drywall. An inflection position on the drywall panel where the tapered region meets the plane of the panel is typically located between the top edge of the baseboard and the bottom edge of the baseboard. Thus, the baseboard hides the tapered region, but the tapered region exists behind the baseboard. The inflection position acts as a tilting fulcrum against the baseboard when the baseboard is fastened to the drywall panel. The bottom edge of the baseboard has a tendency to be pushed into the cavity formed between the baseboard and the tapered region of the drywall panel. This can be referred to as baseboard tilt, wherein the top edge of the baseboard is pushed outward away from the wall, creating an undesirable gap between the top edge of the baseboard and the drywall panel. Such a gap is generally unacceptable in construction and must be corrected. When such gaps are formed, either the baseboard must be removed and reinstalled, or the gap must be filled with a material such as a caulking. Caulking is not an acceptable solution in many applications because the caulk has a tendency to shrink or crack over time, thereby revealing the gap and requiring further caulking. 
     Others have attempted to solve the problems associated with installing baseboards against tapered regions of drywall panels by placing small shims or supports between the back of the baseboard and the drywall panel. However, such shims are often merely scrap pieces of wood or cardboard and do not precisely fit the dimensions of the cavity between the drywall panel and the baseboard. 
     Thus, there is a continuing need in the art for improvements in devices and methods for installing baseboards. 
     BRIEF SUMMARY 
     One aspect of the present invention provides an apparatus for supporting a baseboard. The apparatus includes a corner bracket having first and second upright base members attached at a base member corner. A first flap extends from the first upright base member in some embodiments. The first flap prevents the bracket from falling over. The first flap is operable to resiliently engage the baseboard. 
     A further aspect of the present invention provides an apparatus for supporting a baseboard against a tapered region of a wall panel, the wall panel having a wall panel thickness. A corner bracket includes a first upright base member and a second upright base member interconnected at a base living hinge. A first flap is attached to the first upright base member at a first flap living hinge. A second flap is attached to the first upright base member at a second flap living hinge. 
     Yet another aspect of the present invention provides a wall assembly including a wall panel having a tapered lower edge; a baseboard positioned adjacent the wall panel; a cavity defined between the baseboard and the tapered lower edge; and a baseboard support disposed in the cavity. The baseboard support further includes a corner bracket having a first upright base member and a second upright base member attached to the first upright base member. A first flap extends from the first upright base member, and a second flap extending from the second upright base member. 
     Numerous other objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the following disclosure when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of an embodiment of a baseboard support in accordance with the present disclosure. 
         FIG. 2  illustrates a partial cross-sectional view of Section 2-2 of an embodiment of the baseboard support of  FIG. 1 . 
         FIG. 3  illustrates a partial cross-sectional view of an embodiment of an interior wall corner having an embodiment of a baseboard support disposed therein. 
         FIG. 4  illustrates a partial cross-sectional view of an embodiment of an interior wall corner including the baseboard support of  FIG. 3  and a first baseboard engaging the first flap of the baseboard support. 
         FIG. 5  illustrates a partial cross-sectional view of the embodiment of an interior wall corner and baseboard support of  FIG. 4  including a second baseboard engaging the second flap of the baseboard support and forming a mitered baseboard joint with the first baseboard. 
         FIG. 6  illustrates a partial perspective view of an embodiment of a wall assembly including an interior wall corner. 
         FIG. 7  illustrates a prior art partial cross-sectional view of an embodiment of a baseboard engagement with a wall panel of Section 7-7 from  FIG. 6 . 
         FIG. 8  illustrates a partial cross-sectional view of the embodiment of a baseboard engagement with a wall panel of  FIG. 7  showing a baseboard gap  80 . 
         FIG. 9  illustrates a partial perspective view of an embodiment of a baseboard support positioned in an interior wall corner engaged by a baseboard. 
         FIG. 10  illustrates a partial cross-sectional view of an embodiment of a baseboard support positioned between a baseboard and a wall panel. 
         FIG. 11  illustrates a perspective view of an embodiment of a baseboard support blank. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings,  FIG. 1  illustrates a perspective view of an embodiment of an apparatus for supporting a baseboard, or baseboard support, designated by the numeral  10 . In the drawings, not all reference numbers are included in each drawing, for the sake of clarity. In addition, positional terms such as “upper,” “lower,” “side,” “top,” “bottom,” etc. refer to the apparatus when in the orientation shown in the drawing. A person of skill in the art will recognize that the apparatus can assume different orientations when in use. 
     As seen in  FIG. 6 , a conventional wall assembly in some embodiments includes an interior wall corner  72  formed between a first wall panel  54  and a second wall panel  56 . A plurality of wall studs  76  extend upward from one or more bottom plates  84  and support each wall panel  54 ,  56  from behind. Each wall panel  54 ,  56  can include a conventional drywall or sheet rock panel of the types typically used in residential and commercial construction. Each wall panel includes a tapered lower edge. For example, first wall panel  54  includes a first tapered lower edge  70   a , and second wall panel  56  includes a second tapered lower edge  70   b . A first baseboard  62  can be positioned against first wall panel  54  adjacent first tapered lower edge  70   a , and a second baseboard  64  can be positioned against second wall panel  56  adjacent second tapered lower edge  70   b . First and second baseboards  62 ,  64  meet at a mitered joint  66 . Each baseboard  62 ,  64 , generally rests against floor  68 . 
     Referring now to  FIG. 7 , a cavity  86  can be formed behind each baseboard due to the tape of the corresponding wall panel against which the baseboard is positioned. It is understood that, in some applications, cavity  86  can be formed not by a tapered region but by another irregularity in the underlying wall panel such as a void or a wall panel edge that ends before the edge meets floor  68 . During conventional baseboard installation procedures, baseboard  62  is positioned against wall panel  54  as seen in  FIG. 7 . A first baseboard fastener  78   a , such as but not limited to a finishing nail, can be nailed into the upper half of baseboard  62  to secure baseboard  62  to the wall panel  54 . First baseboard fastener  78   a  is generally aligned with one of the wall studs  76  in some applications. 
     A second baseboard fastener  78   b , such as but not limited to a second finishing nail, can be nailed into the lower half of baseboard  72 , as seen in  FIG. 8 . When the second baseboard fastener  78   b  is driven through baseboard  62 , the driving force may cause the baseboard  62  to move into cavity  86 , or tilt, thereby causing the top baseboard edge  82  to lever away from the wall panel  54 , creating a gap  80 . 
     In many applications, a baseboard support in accordance with the present disclosure can be utilized during baseboard installation to prevent baseboard tilting as illustrated in  FIG. 8 . Referring further to  FIG. 1 , an embodiment of a baseboard support  10  includes a corner bracket  14  having a first upright base member  16  and a second upright base member  18 . Each upright base member  16 ,  18  can include a substantially planar form in some embodiments. First and second upright base members  16 ,  18  are attached at a base member corner  20 . A first flap  22  extends from first upright base member  16 . 
     Base member corner  20  in some embodiments forms a base member corner angle  24 , seen in  FIG. 2 . In some embodiments, base member corner angle  24  is between about twenty and about one-hundred-eighty degrees. Baseboard support  10  is generally configured to be positioned on a floor or a subfloor in an upright position as seen in  FIG. 1  at an interior corner location between adjacent wall panels. Base member corner angle  24  is generally configured to correspond to the interior corner angle between the adjacent wall panels. For example, as seen in  FIG. 3 , a first wall panel  54  and a second wall panel  56  form an interior wall corner angle  58 . Interior wall corner angle  58  in many applications is about a ninety degree angle. However, in other applications, interior wall corner angle  58  can vary and can be greater than or less than ninety degrees. Base member corner angle  24  is generally chosen to correspond to interior wall corner angle  58 . In some embodiments, base member corner angle  24  is between about sixty degrees and about one-hundred-twenty degrees. In further embodiments, base member corner angle  24  is about ninety degrees. In additional embodiments, base member corner angle  24  is substantially equal to interior wall corner angle  58 . 
     In some embodiments, baseboard support  10  includes a polymer, a plastic or a vinyl material. In some embodiments, baseboard support  10  includes a polymer such as but not limited to polyvinyl chloride, polyethylene, polypropylene or mixtures thereof. Referring again to  FIG. 2 , in some embodiments, a base living hinge  60  is formed between first and second base members  16 ,  18 . Base living hinge  60  includes an integrally formed bridge between first and second base member  16 ,  18  and allows first and second base members  16 ,  18  to flex, or hinge, relative to each other along the intersection of first and second base members  16 ,  18  at living hinge  60 . During use, a user can manually force first and second base members  16 ,  18  closer together or further apart, thereby increasing or decreasing base member corner angle  24  to correspond more closely with interior wall corner angle  58 . As such, a single baseboard support  10  can include an initial base member corner angle  24  and can be manipulated to include a new base member corner angle that is larger or smaller than the initial base member corner angle  24 . Due to its flexible material composition, in some embodiments, baseboard support  10  may at least partially retain the new base member corner angle. 
     During use, in some embodiments, baseboard support  10  may be manipulated such that base member corner angle  24  is from about twenty degrees to about one-hundred-eighty degrees. When baseboard support  10  is configured such that base member corner angle  24  is about one-hundred-eighty degrees, baseboard support  10  may be used to support a scarf joint or other type of end-end joint between two baseboards along a wall panel. Additionally, when baseboard support  10  is configured such that base member corner angle  24  is about one-hundred-eighty degrees, baseboard support  10  may be used to provide an intermediate support along a length of a single baseboard. 
     A feature of the present invention is a baseboard support that is able to stand freely on a floor or subfloor surface. A simple bracket having only first and second upright base members has tendency to fall over away from the wall or tilt during baseboard installation. In some embodiments, the present invention provides one or more legs or flaps  22 ,  32 , seen in  FIGS. 1 and 2 , that extend from the upright base members  16 , 18  for preventing the baseboard support  10  from falling over when positioned on a floor or subfloor. Referring again to  FIG. 2 , in some embodiments a first flap  22  extends from the first upright base member  16  at a first flap corner  26 . First flap corner  26  defines a first flap corner angle  28 . In some embodiments, the first flap corner angle  28  is no greater than about ninety degrees. First flap corner angle  28  can include an acute angle. In a preferred embodiment, first flap corner angle  28  is less than about forty-five degrees. In a more preferred embodiment, first flap corner angle  28  is no greater than about thirty degrees. 
     First flap  22  provides a stand for hands-free placement of baseboard support  10  on a subfloor  68 , seen in  FIG. 3 , in an interior wall corner. First flap  22  generally keeps baseboard support  10  from falling over when placed in the interior wall corner. As such, while using baseboard support  10  in some applications, a worker may have both hands free to position and fasten the baseboard in place. 
     Also seen in  FIGS. 1-5 , a second flap  32  extends from second upright base member  18 . Second flap  32  is attached to second upright base member  18  at a second flap corner  34 . Second flap corner  34  defines a second flap corner angle  36 . In some embodiments, the second flap corner angle  36  is no greater than about ninety degrees. In further embodiments, the second flap corner angle  36  is less than about forty-five degrees. In yet another embodiment, the second flap corner angle  36  is about thirty degrees. 
     In some applications, baseboard support  10  can be manually configured to adjust one or more angles between adjacent members. In some embodiments, corner bracket  14  includes a first upright base member  16  and a second upright base member  18  interconnected at a base living hinge  60 , seen in  FIG. 2 . Base living hinge  60  forms an integral joint between first and second upright base members  16 ,  18 . Similarly, a first flap living hinge  88  can be formed between first flap  22  and first upright base member  16 . First flap living hinge  88  forms an integral joint between first flap  22  and first upright base member  16 . First flap living hinge  88  allows first flap  22  to move toward first upright base member  16  when a baseboard is pressed against first flap  22 . Also, a second flap living hinge  90  can be formed between second flap  32  and second upright base member  18 . Second flap living hinge  90  forms an integral joint between second flap  32  and second upright base member  18 . Second flap living hinge  90  allows second flap  32  to move toward second upright base member  18  when a baseboard is pressed against second flap  32 . 
     In some embodiments, first flap  22  generally includes a first flap width  42 . First upright base member  16  includes a base member width  38 . In some embodiments, first flap width  42  is less than base member width  38 . As seen in  FIG. 1 , a flap opening  30  can be defined between first flap  22  and second flap  32 . Flap opening  30  generally allows insertion of a baseboard end between first flap  22  and second flap  32 . For example, as seen in  FIG. 3  and  FIG. 4 , a baseboard support  10  is positioned in an interior wall corner such that flap opening  30  generally faces away from the interior wall corner. A first baseboard  62  can be pressed against first flap  22  and slid toward second upright base member  18 . In some embodiments, second flap  32  includes a second flap end  46  that may engage the first baseboard  62  when first baseboard  62  is engaged with baseboard support  10 . Second flap end  46  in some embodiments can clip or secure baseboard support  10  to first baseboard  62 . In some embodiments, baseboard support  10  is configured to clip to a baseboard by providing a distance between second flap end  46  and first upright base member  16  that is equal to or slightly less than the thickness of first baseboard  62 . 
     Referring now to  FIG. 5 , a second baseboard  64  can be pressed against second flap  32 , thereby causing second flap  32  to hinge about second flap living hinge  90  toward second upright base member  18 . As such, a mitered baseboard joint  66 , or molding joint, can then be formed between first baseboard  62  and second baseboard  64 . 
     Referring now to  FIG. 9 , an embodiment of a baseboard support  10  is generally illustrated partially installed in an interior wall corner  72 . In this embodiment, second baseboard  64  can be positioned against second flap  32  while baseboard support  10  is installed in the corner between first and second wall panels  54 ,  56 . In this embodiment, second flap  32  can be partially or fully depressed by second baseboard  64 . In this embodiment, mitered edge  75  can be inserted into flap opening  30  between first and second flaps  22 ,  32 . From this position, second baseboard  64  is unable to tilt because first upright base member  16  engages floor  68 . 
     Referring now to  FIG. 10 , in some embodiments, a baseboard support  10  includes an apparatus for supporting a baseboard  62  against a wall panel  54 . Wall panel  54  includes a nominal wall panel thickness  98 . Baseboard support  10  includes a corner bracket  14 , seen in  FIG. 1 , including a first upright base member  16  and a second upright base member  18  interconnected at a base living hinge  60 , seen in  FIG. 2 . A first flap  22  is attached to the first upright base member  16  at a first flap living hinge  88 . In some embodiments, a second flap  32  is attached to the second upright base member at a second flap living hinge  90 . First flap  22  defines a first flap thickness  92 . First upright base member  16  defines a first upright base member thickness  94 . In some embodiments, first flap thickness  92  and first upright base member thickness  94  are substantially equal. In some embodiments, first flap thickness  92  and first upright base member thickness  94  are between about 0.15 to about 2.0 millimeters. 
     Referring further to  FIG. 10 , in some embodiments, first upright base member  16  includes an upper base member edge  15 . Upper base member edge  15  is aligned with a location on tapered region  70  of wall panel  54 . Tapered region  70  defines a local tapered region thickness  96  aligned with upper base member edge  15 . In some embodiments, the sum of first flap thickness  92  plus the first upright member thickness  94  is substantially equal to the difference between the wall panel thickness  98  and the local tapered region thickness  96 . As such, first flap  22  is pressed against first upright base member  16  when baseboard  62  engages baseboard support  10 . 
     In a further embodiment, the sum of the first flap thickness  92  plus the first upright member thickness  94  is less than the difference between the wall panel thickness  98  and the local tapered region thickness  96 . In such embodiments, first flap  22  does not fully engage first upright base member  16  when baseboard  62  engages baseboard support  10 . First flap  22  may resiliently engage baseboard  62  when baseboard  62  is fully engaged with baseboard support  10 . It is appreciated that some flexing may occur in baseboard support  10  to conform to the specific geometry of the interior wall corner and baseboards. This feature includes one advantage of the present invention, as irregular geometries may be accommodated by baseboard support  10 . 
     In some embodiments, baseboard support  10  includes a single piece of injection molded plastic with three folds. A first fold is positioned between the first and second base members  16 ,  18 . A second fold is positioned between the first flap  22  and the first base member  16 . A third fold is positioned between the second flap  32  and the second base member. 
     Another feature of the baseboard support  10  in some embodiments provides a device that can be readily modified by a worker using a tool such as shears or a knife. Baseboard support  10  in some embodiments includes a polymer or a plastic material that can be custom shaped by a worker to fit a particular application. For example, a flap can be cut off, or an indentation can be cut in an upper or lower edge of a base member or a flap to accommodate an existing structure. In some applications, when a baseboard is pressed against a flap on baseboard support  10 , the flap may contact its corresponding base member and may create a support that is too thick for the baseboard to rest flush against the wall support. In such applications, baseboard support  10  is configured such that one or both flaps may be cut off by a user using a simple tool such as a knife or shears. 
     In some embodiments, baseboard support  10  includes a height between about one and about two inches. In further embodiments, baseboard support  10  includes a height of about one and three-eighths inches. In some embodiments, one or both base member widths can be about one and one-fourth inches. 
     After installation of baseboard support  10 , the device may be left in place permanently behind the baseboard or molding. Baseboard support  10  is generally compatible with a variety of floor coverings including carpet, hardwood flooring, laminate flooring, tile, etc. 
     In a further embodiment, the present disclosure provides a method of installing a baseboard. The method includes the steps of: (a) placing a baseboard support in an interior corner, the baseboard support including first and second base members interconnected at a living hinge, a first flap extending from the first base member and a second flap extending from the second base member; (b) positioning a first baseboard against the first flap; and (c) positioning a second baseboard against the second flap. 
     Referring now to  FIG. 11 , a further embodiment of the present invention provides a baseboard support blank  100  having a blank height  102  at least twice first upright base member width  38 , seen in  FIG. 2 . Baseboard support blank  100  generally includes an elongated version of a baseboard support  10 . Baseboard support blank  100  provides a blank that can be cut to a user&#39;s particular needs. For example, a blank  100  can be cut at a first cut location  49 , producing a first baseboard support  10   a . Blank  100  can be subsequently cut at a second cut location  50 , producing a second baseboard support  10   b . Blank  100  can then be cut at a third cut location  52 , producing third and fourth baseboard supports  10   c ,  10   d.    
     Baseboard blank  100  can include thermosetting or thermoforming polymer material and can be formed by various material processing techniques known in the art, including but not limited to injection molding or extrusion. Baseboard blank  100  generally includes a first blank base member  104  attached to a second blank base member  106  at a first blank joint  114 . In some embodiments, first blank joint  114  is a living hinge. A first blank flap  108  is attached to first blank base member  104  at a second blank joint  116 . Second blank joint  116  in some embodiments is a living hinge. A second blank flap  110  is attached to second blank base member  106  at a third blank joint  118 . In some embodiments, third blank joint  118  is also a living hinge. As such, first and second blank flaps  108 ,  110  are resiliently repositionable relative to first and second blank base members  104 ,  106 , respectively. 
     Thus, although there have been described particular embodiments of the present invention of a new and useful Baseboard Support Device and Methods, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.