Patent Publication Number: US-6910307-B1

Title: Architectural molding

Description:
BACKGROUND OF THE INVENTION 
   This invention relates to architectural molding installed at the base, mid-portion or top of an architectural wall and, in particular, to a molding composed of flexible plastic foam. 
   Decorative moldings are routinely used in architecture to provide decoration and to cover various raw edges and imperfections. Such moldings are most commonly made of wood, but other rigid materials have been employed. In general, such materials are relatively expensive and installation of the molding has required substantial skill as a workman. 
   U.S. Pat. No. 5,496,512 shows thin molded plastic (e.g., polystyrene) molding strips for application to walls. The molding strips rely on thinness to provide flexibility and are either vacuum or pressure molded. A central portion of the molding is attached to the wall and one or more of the edges of the molding are resiliently flexed into snug engagement with the wall. The molding is installed using overlapped joints. There is a need for more effective architectural molding and architectural molding which is easier to install. 
   SUMMARY OF THE INVENTION 
   An architectural molding includes an extruded flexible plastic foam member having a front side, a rear side and a cross sectional profile. Also included is a layer of pressure sensitive adhesive affixed to at least a portion of the rear side and a release strip releasibly adhered to the layer of pressure sensitive adhesive. 
   A method for installing the architectural molding to a structure includes providing the molding; removing a portion of the release strip to expose a portion of the pressure sensitive adhesive; adhering the exposed portion to the structure; flexing a portion of the molding not yet adhered to the structure away from the structure and removing an additional portion of the release strip to expose an additional portion of the pressure sensitive adhesive; and adhering the additional portion to the structure. 
   A tool for the application of an architectural molding between a wall and a ceiling, where the molding has a front side, a rear side and a cross sectional profile. The tool includes a ceiling following surface; a wall following surface; a profile following surface; and a handle, the handle providing a manual grip for sliding the tool along a wall and ceiling intersection and the profile following surface providing pressure resistive support to a central portion of the profile, while permitting respective outer portions of the profile to be pressed against the wall and the ceiling. 
   A method for installing the architectural molding between a wall and a ceiling using the tool is also provided. The method includes placing the tool against the intersection; removing a portion of the release strip to expose a wall portion and a ceiling portion of the pressure sensitive adhesive; placing the central portion against the profile following surface and adhering the wall portion to the wall and the ceiling portion to the ceiling; flexing a portion of the molding not yet adhered to the wall or ceiling away from the wall or ceiling, respectively, and removing an additional portion of the release strip to expose an additional portion of the pressure sensitive adhesive; sliding the tool to cooperate with the flexed portion; and adhering the additional portion of the pressure sensitive adhesive to the wall or ceiling. 
   An architectural molding adapter includes an elongate sheet of plastic material having a back side and a front side; a plurality of longitudinal fold grooves in the sheet; a pressure sensitive adhesive affixed to longitudinal peripheral portions of the back side; and a release strip releasibly adhered to the pressure sensitive adhesive, the adapter being adapted to provide an intermediate attachment point for multiple rows of crown molding when the adapter is folded along a plurality of the fold grooves into a generally rectangular cross section structure when attached to a wall and ceiling. 
   A method for installing multiple rows of pressure sensitive adhesive backed crown molding using the adapter is also provided. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a cross sectional perspective view of an installed molding according to the invention for a top portion of a wall. 
       FIG. 2  is a cross sectional perspective view of an installed molding according to the invention for a mid-portion of a wall. 
       FIG. 3  is a cross sectional perspective view of an installed molding according to the invention for a base portion of a wall. 
       FIG. 4  is a perspective view of a package containing a molding according to the invention. 
       FIG. 5  is a cross sectional longitudinal elevation view of nested layers of molding according to the invention. 
       FIG. 6  is a longitudinal elevation view (with many elements shown in cross section) showing a tool in use for installing molding according to the invention. 
       FIG. 7  is a perspective view showing a tool in use for installing molding according to the invention. 
       FIG. 8  is a longitudinal elevation view or end view of an adapter for installing multiple rows of molding according to the invention. 
       FIG. 9  is a cross sectional longitudinal elevation view of the adapter of  FIG. 8  in use with moldings according to the invention. 
       FIG. 10  is a cross sectional view of a molding according to the invention. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
   When a range such as 5-25 is given, this means preferably at least 5 and preferably not more than 25. 
   Referring to  FIG. 1 , an architectural molding  10  is shown installed between a top portion of a wall  12  and the edge of a ceiling  14 . Moldings at this location are often referred to as crown moldings. The molding  10  includes an extruded flexible plastic foam member  16  having a cross section or cross sectional profile  18  and a rear side or surface  20  and a front side or surface  22 . The front side or surface  22 , when viewed in cross section (such as looking down the longitudinal length of the molding), determines the front surface profile of the molding. Correspondingly, the rear side or surface  20  determines or defines a rear surface profile. In the preferred embodiment, the cross sectional profile  18  is constant along the longitudinal direction of the member  16 ; that is, if you look at the cross sectional profile  18  every few feet as you travel down the length of member  16 , the profile  18  will remain the same. 
   The member  16  is provided with one or more layers of pressure sensitive adhesive. For example, pressure sensitive adhesive layers  24 ,  26  may be affixed on the rear side  20  on outer or edge portions of the molding  10  that will contact the wall or ceiling. Referring to  FIG. 7 , a release strip  28 ,  29  is initially adhered to each area or layer of pressure sensitive adhesive to protect the adhesive until installation of the molding  10 . 
   The member  16  is extruded in continuous lengths having a constant cross sectional profile  18 . The extrusion process ordinarily results in a constant, unchanging cross sectional profile.  FIG. 1  illustrates a compound cove crown molding (see the front surface profile). Other types of moldings having a continuously constant or uniform cross section and front surface profile can be utilized, such as, the following types of molding (these being determined by the front surface profile): crown, cove, fillet and fascia, torus, reeding, cavetto, scotia, conge and beak. Various front surface profiles for crown and cove moldings can be used, such as those illustrated in molding catalogues from Hiland Wood Products, Walnut Creek, Ohio and American Hardwood, Columbia Station, Ohio, which are known in the art and which are incorporated herein by reference. The member  16  is preferably a low density, closed cell, thermoplastic flexible foam that is resiliently compressible and resiliently flexible. The flexible plastic foam preferably has a density of 1.6-3, more preferably about 2, lbs. per cubic foot, preferably less than 9, 7, 6, 5, 4 and 3 lbs./cu. ft. The flexible foam is resilient and can be easily bent and compressed and will then return to its original shape. The flexible plastic foam is preferably polyethylene, rubber latex, polypropylene, polyurethane, polyvinyl chloride or polyolefin flexible plastic foam, more preferably polyethylene flexible plastic foam, preferably made with an isobutane blowing agent. The extruded flexible plastic foam is preferably polyethylene, less preferably substantially or principally or predominantly polyethylene or the major proportion of which is polyethylene. Such polyethylene foams are available as Nomafoam from Nomaco, Inc., Zebulon, NC. 
   The layer of pressure sensitive adhesive  24 ,  26  may be applied to the member  16  either while member  16  is being made or at a later time. In the preferred embodiment, the adhesive may be, for example, a hot melt pressure sensitive adhesive applied hot (such as 350° F.) to the member  16  and becoming affixed thereto as the adhesive cools. A suitable adhesive is available from H. B. Fuller Company, St. Paul, Minn., as HL-8209 DR. Preferably, the pressure sensitive adhesive is high heat resistant, permanent grade with a 180 degree peel (60 sec./75 F, 1 mil.) of at least 5, more preferably at least 6 or 7, lbs./inch, polyken tack of at least 1500 grams, loop tack of at least 50, 70 or 90 ounces. The release strips  29 ,  28  are releasibly adhered to the adhesive  24 ,  26 , respectively. It is also possible to affix the adhesive in other ways, such as applying the adhesive to the release strip and then applying the adhesive/release strip from web-like rolls. 
   The member  16  may be pre-colored to desired colors by adding coloring to the plastic foam material prior to extruding. This produces a front side  22  suitable for use without further painting, coating, etc. 
   One may also apply a primer to the front side  22  either during manufacturing (pre-primed) or at the job site to make the molding  10  paintable (including techniques such as “wood-graining”). A primer such as Chil-Perm CP-30 from Childers Products Company may be used. The primed surface may then be painted. 
   It is also possible to treat the front surface  22  with corona charge for corona treatment. This electrostatic treatment allows paint to adhere directly to the surface  22  without a primer coating. Alternatively the front surface can be treated with corona charge in-line at the manufacturing facility, and a flexible and quick dry paint or primer can also be applied in-line. 
   In the preferred embodiment, the molding  10  is produced, packaged and sold in at least 30 foot lengths and, typically, in lengths of at least 50, 75, 100 and 120 feet. The profile  18  is typically in the range of {fraction (3/16-3/4)}, more preferably {fraction (1/4-1/2)}, more preferably about ⅜, inch in thickness (and 2 to 8 or 3 to 6 or about 4.5 inches wide, that is, from the tip near layer  24  to the tip near layer  26 ). This thickness allows segments of the molding  10  to be joined with either butt or mitered joints. The molding  10  can be accurately cut with a cutting guide such as a miter guide with a hand-held serrated knife. The thickness of the molding  10 , when cut, provides a wide attachment face or bonding surface for butt or miter joints to product precise uniform attachments. The thickness also may be chosen to provide sufficient strength to span the space between the wall  12  and the ceiling  14 . The resilience of the molding  10  promotes tight joints. The joints may be glued with a suitable adhesive (e.g., FD-8133 manufactured by H. B. Fuller Company) or heat bonded. 
   Referring to  FIG. 4 , the molding  10  may be packaged in rolls within a box  30  such as a cardboard box. An opening or slot  32  in the box  30  may be used to dispense the molding  10  as it is installed. For example, in the case of 4.5 inch wide crown molding, a 30×30×5 inch box can hold at least 120 feet of the molding  10 . The weight of such a package and molding combined would typically be less than  6  pounds. Preferably, the front side  22  of the molding  10  faces the inside of the roll (as shown in  FIG. 4 ) to facilitate installation. Preferably, the molding  10  comes out of the box “right-handed”, that is, as it comes out of the box you start on the right side of the wall and work to the left. During this process the molding comes out of the box properly oriented so that the top of the molding is against the ceiling and the bottom is against the wall. In this way the molding is coming out of the box “right-handed”.  FIG. 4  shows the molding  10  coming out of the box “left-handed”. 
   Referring to  FIG. 5 , the profile of the molding  10  may be advantageously chosen to provide nesting between the layers  10   a ,  10   b ,  10   c ,  10   d  of a roll of the molding  10 . This nesting maximizes the amount of the molding  10  in a given roll diameter and minimizes the likelihood of creases in the surface of the molding  10 . Preferably, nesting is achieved by providing a front surface profile which matches or substantially matches or matches in significant portions the rear surface profile. Typically this will result when the cross sectional profile  18  is of substantially or generally uniform thickness. 
   Referring to  FIGS. 1 and 7 , the molding  10  may be installed by removing a portion of the release strips  28 ,  29  to expose portions of the pressure sensitive adhesive  24 ,  26 . The exposed portions are then adhered to the ceiling/wall structure and a portion of the molding  10  that is not yet adhered to the structure is flexed away from the structure and more of the release strips  28 ,  29  are removed to expose an additional portion of the adhesive  24 ,  26 . The additional exposed portions are then adhered to the structure. 
   Typically, it may be desirable to apply an aesthetic coating such as paint to the molding  10  after it is adhered to the structure. 
   Referring to  FIGS. 6 and 7 , a tool  40  for easier installation of the molding  10  includes a ceiling following surface  42 , a wall following surface  44 , a profile following surface  46  and a handle  48 . In the preferred embodiment, the tool  40  is formed from an element  50  having a generally right angle cross section. The element  50  may be formed from, for example, a sheet of metal or rigid plastic and is preferably of constant width as shown in FIG.  7 . With reference to  FIG. 6 , the element  50  extends from the handle  48  upward to the curved portion  51  and across to near the tip  53  of the tool  40 . The element  50  has a first outside surface corresponding to the surface  42  and a second outside surface corresponding to the surface  44 . A block of plastic foam  52  (preferably flexible polyethylene foam.) attached to the inside surfaces of the element  50  provides the surface  46 . The surface  46  matches the contour of the central portion  54  of the rear side  20  of the profile  18 . Less preferably the portion of element  50  corresponding to surface  42  may be omitted and block  52  may be of other materials such as solid plastic. The tool  40  is shaped so that the two tips (one of which is tip  53 ) do not stick out far enough to contact the pressure sensitive adhesive  24 ,  26 . 
   The handle  48  is provided by an extension from the element  50 . The handle  48  is shown extending from the surface  44 , but it is also possible to extend from the surface  42 . 
   In use, the tool  40  is manually grasped by the handle  48  and the tool placed against the intersection of the wall  12  and the ceiling  14 . A portion of the release strips  28 ,  29  is removed to expose portions of the pressure sensitive adhesive  24 ,  26 . The central portion  54  is placed against the surface  46 . This guides the molding  10  into the correct position relative to the wall  12  and the ceiling  14  and provides pressure resistive support to the central portion  54  while allowing the manual pressing of the adhesive  24 ,  26  against the wall  12  and ceiling  14 , respectively. 
   The exposed portions are adhered to the wall  12  and the ceiling  14 , respectively, and a portion of the molding  10  that is not yet adhered to the wall or ceiling is flexed away from the wall or ceiling and more of the release strips  28 ,  29  are removed to expose additional portions of the adhesive  24 ,  26 . The tool  40  is slid and repositioned to cooperate with the flexed portion as the flexed portion is positioned by the surface  46  for adhering. The additional exposed portions are then adhered to the wall  12  and the ceiling  14 . In this manner the tool  40  is progressively slid along the top of the wall and a long continuous length of molding  10  is adhered in place. 
   Referring to  FIG. 2 , a molding  10 ′ similar to the molding  10  of  FIG. 1  is shown installed on a mid-portion of the wall  12 . Moldings at this location are often referred to as chair rails. The rear side  20 ′ of the molding  10 ′ is generally flat and like the molding  10 , is provided with pressure sensitive adhesive (unshown) for adhering the molding  10 ′ to the wall  12 . The molding  10 ′ may be manufactured and packaged the same way as the molding  10  and installed similarly. In uninstalled form, the molding  10 ′ is also provided with at least one release strip. 
   A preferred chair rail or panel molding  74  is shown in  FIG. 10 , which is designed for convenient nesting. Molding  74  (preferably 1.5 inches from top to bottom) has a front surface  76  and a rear surface  78 , the lower flat portion of which is coated with a layer of pressure sensitive adhesive  80  for adhesion to a wall. 
   Referring to  FIG. 3 , a molding  10 ″ similar to the molding  10  of  FIG. 1  is shown installed on a base portion of the wall  12 . Moldings at this location are often referred to as base molding or baseboard molding. The rear side  20 ″ of the molding  10 ″ is generally flat and like the molding  10 , is provided with pressure sensitive adhesive (unshown) for adhering the molding  10 ″ to the wall  12 . Pressure sensitive adhesive may be applied along the entire rear side  20 ″, or in strips, such as strips along the top, middle and bottom of side  20 ″. Pressure sensitive adhesive may also be applied along the bottom surface  21  of molding  10 ″. The molding  10 ″ may be manufactured and packaged the same way as the molding  10  and installed similarly. In uninstalled form the molding  10 ″ is also provided with a release strip over each strip of pressure sensitive adhesive. Other front surface profiles for chair rail moldings and base moldings can be used, such as those illustrated in molding catalogues from Hiland Wood Products, Walnut creek, Ohio and American Hardwood, Columbia Station, Ohio, which are incorporated herein by reference. 
   Referring to  FIGS. 8 and 9 , an adapter or stepform  60  for applying multiple rows of the moldings  10  is shown. The adapter or stepform  60  is an elongate sheet, for example 6 to 18 inches wide, from {fraction (1/16)} to ½ , more preferably ¼ to {fraction (5/16)} or ⅜, inches thick and of any convenient length, such as at least 30, 50, 75, 100 or 120 feet. The adapter  60  is preferably of the same flexible plastic foam material as the member  16 , except preferably a little more dense; preferably having a density of 1.6-9, more preferably 2-6, more preferably 3-4, more preferably about 3, lbs. per cubic foot. Less preferably it is a plastic material which is resilient, flexible and coilable, such as solid or lightweight plastic. The adapter may be, for example 8 inches wide and ⅜ inch thick and have a series of longitudinal scoring or fold grooves  62 . The grooves  62  may be on either the front or back side or both, preferably the back. The grooves are spaced to provide convenient selection of spacing between folds, for example, ½ or ¾ inch to accommodate various combinations of molding sizes. The peripheral portions of the back side of the adapter  60  are provided with pressure sensitive adhesive  64 ,  66  and release strips  68 ,  70 , respectively. Other strips or layers of pressure sensitive adhesive (with release strips), such as illustrated at  71   a ,  71   b ,  71   c ,  71   d  and  71   e , may optionally be added longitudinally between each pair of adjacent grooves  62 . The adapter  60  is manufactured and packaged in rolls as described above and installed with a tool like tool  40  except that the profile following surface  46  is shaped to correspond to the shape of the adapter  60  as installed. 
   In use, the adapter  60  is folded on desired grooves  62  to form a generally rectangular cross section (in combination with the wall  12  and the ceiling  14 ), preferably 3.5×3.5 inches. Release strips  68 ,  70  are removed and, using a tool  40 , the adapter  60  is attached to the top portion of the wall  12  and to the edge portion of the ceiling  14 . Then as described above and using tool  40 , a crown molding or molding  10  is attached between the adapter  60  and the ceiling  14 . Another row of molding  10  is attached between the wall  12  and the adapter  60 . In this way, the adapter  60  serves as an intermediate attachment point for the rows of moldings and permits a much larger and more complex total molding surface to be installed. Note how a portion  61  of the adapter  60  forms a portion of the exposed molding surface. If the adapter  60  is folded further away from the adhesive (such as at location  63 ) so that a flat portion of adapter  60  between  64  and  63  is against the wall, the adapter  60  may also be stapled to the wall at location  65  for extra support. Alternatively, a layer of pressure sensitive adhesive, such as at  71   a ,  71   b ,  71   c ,  71   d  or  71   e , on the adapter  60  (with release strip removed) may serve the function of the staple. 
   The moldings disclosed herein are much less expensive than those of materials such as wood. Because the molding is light and flexible, it can be quickly installed with few tools. No unsightly nail holes are created and no sawing is required because the molding can be cut with a sharp knife. This also lowers the level of skill required for installation. 
   It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.