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[0001]     The present application claims priority under 35 U.S.C. § 119(e), and any other applicable laws, to U.S. Provisional Application No. 60/741,467, entitled “Trim Molding System”, filed Dec. 2, 2005, which is incorporated herein by reference in its entirety. 
     
    
     FIELD  
       [0002]     Embodiments of the present invention relate generally to construction materials and, more particularly, to trim molding.  
       BACKGROUND  
       [0003]     The trim molding system and apparatus described by the embodiments shown herein has been conceived and created to address, among other things, a current limitation of trim pieces for walls having a “bullnose” or rounded corner. Embodiments can also be applicable to trim pieces installed at angled corners and for splicing trim pieces to be installed along a flat surface.  
         [0004]     At the present time, builders installing interior rounded corner bead on drywall corners, can typically use mitering on a plurality of trim pieces, for example, two 22 and ½ degree miters, to wrap various trim molding around corners. Multiple mitering can represent a difficult and time consuming process. Further, the results of the finished trim work can not be aesthetically or visually desirable because of a choppy trim transition around an otherwise rounded corner.  
         [0005]     The invention of the “corner cap” (as shown in PCT Application No. PCT/US2004/031961, also by the present inventor) can make transitioning trim molding around a bullnose corner easier and more visually appealing by reducing or eliminating mitering and can give the trim molding a smoother transition around the corner, providing an improved visual appearance that is more consistent with a rounded corner aesthetic. However, during development and application of embodiments of the corner cap invention, it has proven difficult to consistently match the profile of the injection molded plastic corner cap (which can be produced with very consistent dimensions) to the wood trim molding boards. Because construction suppliers can typically obtain trim molding from multiple manufacturers, some of which can use different tolerances and machines to produce the “same” molding profile, the trim boards can have variations in dimensions. These variations can be in thickness, height and/or location of profile lines and make it difficult to get a consistent match between the plastic corner cap and the wood trim board.  
       SUMMARY  
       [0006]     Embodiments can address the above-referenced problem of aligning a molded plastic corner cap with a milled wood trim board, among other things. The inventor has discovered that a potential solution to this profile matching problem can include molding both the corner cap and the trim molding pieces from the same or similar material, for example,. ABS plastic or similar material, thereby producing trim pieces having similar dimensional tolerances. In addition to potentially solving the profile matching issue, embodiments can also allow for an improved connection between trim molding pieces and the corner cap, or between trim molding pieces, by providing a “tab” and “keyway” system that joins two components together.  
         [0007]     At least one embodiment can include a trim molding system comprising a first trim piece, a second trim piece, and a corner cap. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening an a side of the second trim piece. The corner cap can include a top, bottom, front, back, a first side, and a second side. The corner cap can have a first tab extending from the first side and a second tab extending from the second side. The first tab can be configured to fit into the first keyway of the first trim piece and the second tab can be configured to fit into the second keyway of the second trim piece. Thus, the first and second trim pieces can be joined with the corner cap. Further, the first trim piece, the second trim piece, and the corner cap can each have a matching trim profile that is substantially continuous when the first trim piece and the second trim piece are joined to the corner cap. The phrase “substantially continuous,” as used herein, means an outward surface of at least one side of a trim piece is flush with the corresponding outward surface of a mating piece.  
         [0008]     At least one further embodiment can include a trim molding system comprising a first trim piece, a second trim piece, and a splice tab. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening on a side of the second trim piece. The splice tab can be configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece are spliced together. Further, the first trim piece and the second trim piece can each have a matching trim profile that is substantially continuous when the first trim piece and the second trim piece are spliced using the tab.  
         [0009]     At least another embodiment can include a trim molding system having a first trim piece, a second trim piece, and an angled corner tab. The first trim piece can include a front, a back, a top, and a bottom. A first keyway can be formed in the first trim piece, the first keyway having an opening on a side of the first trim piece. The second trim piece can include a front, a back, a top, and a bottom. A second keyway can be formed in the second trim piece, the second keyway having an opening on a side of the second trim piece. The angled corner tab can be configured to fit into the first keyway and the second keyway, such that, when assembled, the first trim piece and second trim piece meet at an angle corresponding to the angled corner tab.  
         [0010]     For example, various embodiments can include trim molding pieces, corner caps, splice tabs, or angled corner tabs made of an extruded ABS, other plastic or similar material suitable for use as trim molding. An exemplary trim molding piece can include a female “keyway” molded into the interior of the trim molding piece and disposed toward the back surface of the trim molding piece. A tab can be inserted into the keyway in order to, for example, splice trim pieces, join trim pieces at a corner, or join trim pieces to a corner cap. The tab and keyway system can thus provide for a joint between trim pieces that is self-aligning and produces a trim profile that is aligned and/or produces a continuous trim profile around a bullnose corner bead. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  provides a side elevation view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;  
         [0012]      FIG. 2  provides an orthogonal view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;  
         [0013]      FIG. 3  provides a perspective view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;  
         [0014]      FIG. 4  provides a front elevation view of a portion of an exemplary trim molding piece in accordance with at least one embodiment;  
         [0015]      FIG. 5  provides an orthogonal view of exemplary trim pieces, including two trim boards and a corner cap, in accordance with the with at least one embodiment;  
         [0016]      FIG. 6  provides an orthogonal view of an exemplary trim splice tab in accordance with at least one embodiment;  
         [0017]      FIG. 7  provides an orthogonal view of an exemplary trim angled corner tab in accordance with at least one embodiment;  
         [0018]      FIG. 8  provides an orthogonal view of an exemplary embodiment of the present invention in which two trim boards are to be spliced using a splice tab in accordance with at least one embodiment;  
         [0019]      FIG. 9  provides an orthogonal view of an exemplary embodiment of the present invention in which two trim boards are to be joined at an inside corner using an angled corner tab in accordance with at least one embodiment; and  
         [0020]      FIG. 10  provides an orthogonal view of at least one embodiment in which two trim boards are to be joined at an outside corner using an angled corner tab. 
     
    
     DETAILED DESCRIPTION  
       [0021]      FIGS. 1 and 2  each show a portion of an exemplary trim molding piece in accordance with various embodiments. In particular, a trim molding piece  10  can comprise a front surface  12 , a partially open back  14 , a top  16 , a bottom  18 , and a keyway  20 . The keyway  20  can comprise a top keyway slot  22  and a bottom keyway slot  24 . The top keyway slot  22  and bottom keyway slot  24  can, for example, be about ⅛ inch wide and the keyway  20  can be dimensioned in height according to the trim molding piece. Further, the location of the keyway  20  relative to the back  14  of the trim molding piece  10  can vary. It should be appreciated that the dimensions and placement of the keyway  20  can vary according to a contemplated use and by taking into account various considerations, such as, for example, a particular trim type, shape and size, among other things, without departing from the spirit and scope of the present invention.  
         [0022]     Still referring to  FIGS. 1 and 2 , the top  16  of the trim molding piece  10  can include a top portion  26  and a bottom portion  28 , which both substantially contact a surface, such as a wall, when the trim molding is installed. The top portion  26  of the back  14  of the trim molding piece  10  can have a thickness  27 . The bottom portion  28  of the back  14  of the trim molding piece  10  can have a thickness  29 . The thicknesses  27  and  29  can be, for example, about ⅛ inch for typical trim molding applications. However, it should be appreciated that the thicknesses  27  and  29  can vary according to a contemplated use and by taking into account, for example, a particular trim type, shape and size, among other things, without departing from the spirit and scope of the present invention. The front  12  of the trim molding piece  10  can include a trim profile  30  that gives the trim an ornamental or decorative visual appearance. While the back  14  is shown partially open, it should be appreciated that the back  14  can be formed fully open or fully closed.  
         [0023]      FIGS. 3 and 4  each show a portion of an exemplary corner cap in accordance with various embodiments. In particular, a corner cap  32  can comprise a front  34 , a profile  30 , a back  36 , a top  38 , a bottom  40  and a tab  42 . The tab  42  can include a front tab surface  44 , a back tab surface  46 , a side tab surface  48 , a top  50 , and a bottom  52 . Further the tab  42  has a height  54 , a width  56 , a thickness  58  and corners  60 .  
         [0024]     The tab  42  can function as a connecting means and can be formed so as to mate with the keyway  20  of a trim molding piece  10  when the corner cap  32  and the trim molding piece  10  are joined. The tab  42  can be formed as a part of the corner cap  32 , or as a separate element design for inserting into the corner cap  32 . In other words, the corner cap  32  can be formed with a keyway into which the tab  42  is inserted. The height  54  of the tab  42  is related to the height of the keyway  20  ( FIGS. 1 and 2 ) such that the tab  42  and the keyway  20  can be joined, for example using a press fit. Other methods of joining the tab  42  and the keyway  20  can be used including adhesives, fasteners, detents, interlocking members, or the like. For example, the thickness  58  of the tab  42  can be dimensioned such that the tab  42  engages the top keyway slot  22  and the bottom keyway slot  24  in a press fit arrangement. The width  56  of the tab  42  is such that it is sufficient to provide a sturdy joint between a trim molding piece  10  and a corner cap  32 . For example, the tab  42  can have a width of ½ inch to 1 inch for a typical trim molding piece application. It should be appreciated that the tab can be dimensioned according to a contemplated use of the invention by taking into account, among other things, a particular trim type, shape and size; a particular corner configuration, and/or the like.  
         [0025]      FIG. 4  also shows a top of tab to top of corner cap dimension  62  and a bottom of corner cap to bottom of tab dimension  64 , according to various embodiments. These dimensions can correspond to the positioning of the keyway  20  relative to the trim molding piece  10 . The tab  42  can be positioned relative to the back  36  of the corner cap  32  to correspond to the placement of the keyway  20  relative to the back  14  of the trim molding piece  10 . The placement and dimensions of the keyway and tab can depend on numerous factors including a particular trim type, shape and size, and can vary without departing from the spirit and scope of the present invention.  
         [0026]      FIG. 5  shows an exploded view of two exemplary trim molding pieces and an exemplary corner cap in accordance with various embodiments. In particular, a corner cap  32  is shown prior to being joined to two trim molding pieces  10 . When assembled, the tabs  42  on each side of the corner cap  32  can slide into the respective keyways  20  of the trim molding pieces  10 .  
         [0027]     This configuration of a trim molding system including trim molding pieces  10  and a corner cap  32  can provide for a smooth transition of the trim profile around a corner having a radius. In other words, the trim profile can be maintained substantially continuously around the corner.  
         [0028]      FIG. 6  shows an exemplary splice tab in accordance with various embodiments. A splice tab  66  can comprise a front  68 , a back  70 , a top  72 , a bottom  74 , a first side  76  and a second side  78 . The splice tab  66  can be configured to fit into keyways provided in the sides of two adjacent trim molding pieces in order to provide a splice, or butt joint. Thus, the splice tab  66  can be dimensioned, for example, to allow for a press fit into the keyways of trim molding pieces for which the splice tab has been constructed to splice together. When assembled, the splice tab  66  should preferably extend about halfway into a keyway of each adjacent trim molding piece. In other words about half of the splice tab  66  will be in one keyway and the other half of the splice tab  66  will be in the keyway of the adjacent trim molding piece. The splice tab can be provided with a notch, detent, or other feature to indicate a halfway point in order to aid in the splicing of trim pieces.  
         [0029]      FIG. 7  shows an exemplary angled corner tab in accordance with various embodiments. An angled corner tab  80  can comprise a first tab side  82 , a second tab side  84 , an angled corner  86 , a front  88 , a back  90  a top  92  and a bottom  94 . The angled corner tab can be configured to join two trim molding pieces in an angled corner arrangement. When assembled, the first side tab  82  can be inserted into one trim molding piece, and the second tab side  84  can be inserted into another trim molding piece such that the two trim molding pieces will meet at a joint angle θ determined by the angle of the angled corner  86  of the angled corner tab  80 . Further, the two trim molding pieces can be mitered according to the angle of the angled corner tab  80 . The angled corner tab can be provided at an inside or outside corner. It should be appreciated that the angled corner tab can be formed at various corner angles in accordance with a contemplated use.  
         [0030]      FIG. 8  shows two exemplary trim molding pieces and an exemplary splice tab prior to splicing the trim molding pieces with the splice tab. In particular two trim molding pieces  10  are shown prior to being sliced with a slice tab  66 . When assembled, the splice tab  66  will be inserted into the keyways  20  of the two trim molding pieces  10 . The splice tab  66  and keyways  20  (one of which is shown) can operate to align the trim pieces such that when attached to a surface, such as a wall, the trim pieces are aligned at the splice joint.  
         [0031]      FIG. 9  shows two exemplary trim molding pieces and an exemplary angled tab, in accordance with the present invention, prior to being joined on an inside corner. In particular, two trim molding pieces  10  are shown prior to being joined at a corner by an angled corner tab  80 . When assembled, the angled corner tab  80  will be inserted into the keyways (not visible in this figure) of the two trim molding pieces  10 . The angled corner tab  80  and keyways (not visible in this figure) can operate to align the trim pieces such that when attached to a surface such as a wall the trim pieces are aligned at the corner.  
         [0032]      FIG. 10  shows two exemplary trim molding pieces and an exemplary angled tab, in accordance with various embodiments, prior to being joined on an outside corner. In particular, two trim molding pieces  10  are shown prior to being joined at an outside corner by an angled corner tab  80 . The trim molding pieces  10  are shown with mitered edges  96 . When assembled, the angled corner tab  80  will be inserted in to the keyways (not visible in this figure) of the two trim molding pieces  10 . The angled corner tab  80  and keyways (not visible in this figure) can operate to align the trim pieces such that when attached to a surface such as a wall the trim pieces are aligned at the corner.  
         [0033]     The trim molding pieces can be attached to the wall surface, or other surface, by using fasteners, adhesives, or any other means of attachment suitable for attaching trim to a surface. The trim molding pieces  10  can be cut to any desired length and still allow for the connection of the corner cap tab  42  (as shown in  FIGS. 3 and 4 ), splice tab, or angled corner tab to the trim molding keyway  20  (as shown in  FIGS. 1 and 2 ). The tab  42  can aid in aligning the molding profile of the components and can provide a tight joint at the connection (see, for example,  FIG. 5 ).  
         [0034]     The “keyway” and “tab” according to various embodiments can be used for any molding types or profiles, for example: baseboard, chair rail, crown molding and/or any other trim moldings. Further, the keyway and tab according to various embodiments can be used for elements other than molding, such as wire or cable covers, and/or other structural or functional elements where it can be desirable to use a keyway and tab system and corner caps.  
         [0035]     Further, the “keyway” in the trim molding pieces can also allow for a connecting splice tab for splicing long runs of trim molding along a wall surface (see  FIG. 8 ), as well as for both inside and outside angled corners (e.g. ninety degree corners) (see  FIGS. 9 and 10 ). The tabs (splice, angled corner and corner cap) can also aid in aligning the molding profile and provide a tight joint at the connection. Although 90 degree corners are shown, it should be appreciated that the trim system can be used with other corner angles.  
         [0036]     The tabs and keyways are preferably joined with a press fit, but can also be joined using an adhesive or a fastener. An adhesive can have an advantage of providing additional strength to the joint.  
         [0037]     Embodiments of the trim molding pieces can be manufactured using a variety of materials and techniques, including, for example, extruded plastic. The extruded trim molding pieces can be attached to a wall or other surface using traditional fasteners such as nails or screws. The fasteners can be applied either manually (e.g. with a hammer) or automatically (e.g. pneumatic nail gun). Alternatively, the extruded trim molding pieces can be affixed to a wall or other surface using an adhesive. Depending on the material the trim pieces are made of, the trim pieces can be cut and sanded like traditional wood trim pieces.  
         [0038]     A joint between trim pieces or between a trim piece and a corner cap is preferably very small, but in the case where the joint is noticeable, the joint can be filled with putty, caulk, and adhesive and/or other material suitable for filling such joints. Further, the joints between trim pieces or between trim pieces and a corner cap can be glued with an adhesive suitable for use with the material comprising the trim pieces and corner cap.  
         [0039]     It is, therefore, apparent that there is provided in accordance with the present disclosure, a trim molding system. While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, applicants intend to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention.

Summary:
A trim molding system including trim pieces having a tab and corresponding keyway system. The tab fits into the keyway. Trim boards having keyways are configured to be joined to a corner cap having tabs to provide a trim system that is suitable for use with bullnose corner bead. Trim boards having are configured to be spliced using a splice tab that both joins and aligns the trim boards. Trim boards having keyways are configured to be joined at a corner using an angled corner tab that both joins and aligns the trim boards, and conforms to a corner angle of a surface such as a wall.