Patent Publication Number: US-6340264-B1

Title: Coupling assembly, connecting member and articles manufactured therefrom

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a coupling arrangement for attaching first and second members. More particularly, the invention relates to a dovetail type coupling arrangement for securing molding to a support surface. 
     2. Description of the Prior Art 
     It is often desirable to place a transition molding between adjacent rooms of flooring. This is especially common where the flooring material changes from room to room. For example, as a decorative laminate hallway transitions into a tile kitchen, a transition molding is commonly positioned between the two rooms. 
     In many instances the molding is simply nailed to the underlying subfloor. As anyone who has installed molding with nails knows, attaching the molding to the support surface is very difficult, and the nail heads are almost impossible to hide. Surface scarring is also encountered when individuals install chair rails, crown molding, shoe molding and a variety of other moldings throughout a home or office. Moldings scarred in this manner are aesthetically undesirable, and attempts have been made to provide attachment mechanisms which reduce the likelihood that the molding will be scarred as a result of the installation process. 
     Aluminum tracks are commercially used for the installation of flexible molding, such as vinyl molding. This includes the installation of expansion and transition molding, end caps and reducer strips. In accordance with the prior methods, the molding is an extruded length of flexible vinyl, or other polymer, including a downwardly extending connecting member with outwardly extending ribs. The connecting member is shaped for positioning within the track. 
     In practice, the aluminum track is affixed to the floor and the connecting member on the back of the flexible molding is interlocked between a pair of flanges extending from the upper surface of the track. Ribs extending along the connecting member and the interior surfaces of the flanges interlock to resist the removal of the rib from the flanges. In this way, the molding is “pinched” in position by the track. 
     Others have also attempted to develop systems for attaching rigid molding to a support surface. For example, one prior art technique for attaching wood molding employs a recess in the molding and a rib projection on the track member to secure the molding to a support surface. Specifically, a recess with parallel walls is formed in the molding. The recess is shaped and dimensioned to fit over a single ribbed flange extending upwardly from the track member. The ribbed flange includes outwardly extending ribs on opposite sides. The ribs engage the parallel walls of the molding&#39;s recess to securely mount the molding on the support surface. Unfortunately, movement of the recess along the ribbed flange saws away at the recess wall, ultimately resulting in the loosening of the molding. 
     As discussed above, prior connecting assemblies exhibit many shortcomings. For example, they commonly loosen over time as pressure is applied to the molding during normal use. In addition, prior connecting assemblies require that specific ribs be integrally formed with the molding and are often cumbersome to install. In fact, where such ribs are used in conjunction with wood-based molding, the simple act of installing the rib between the flanges commonly results in the shearing off of the rib and the soon to follow loosening of the molding. 
     After studying prior connecting assemblies, it is clear that a versatile, convenient, and reliable coupling assembly is needed for attaching molding to a support surface. The present invention provides such a coupling assembly, as well as articles manufactured with the coupling assembly and a connecting member for use with the coupling assembly. 
     SUMMARY OF THE INVENTION 
     It is, therefore, an object of the present invention to provide a coupling assembly for securely attaching moldings to a support surface. The coupling assembly includes a track member having first and second upwardly extending flanges defining a channel. The coupling assembly also includes a connecting member shaped and dimensioned for secure attachment within the channel defined by the upwardly extending flanges. The connecting member includes first and second expansion members which move outwardly as the connecting member is forced downwardly within the channel to securely couple the connecting member within the track member and to force the first and second upwardly extending flanges outwardly into engagement with the molding such that the molding is securely coupled to the track member. 
     It is also an object of the present invention to provide a connecting member adapted for coupling molding to a track member secured to a support surface. The connecting member includes a central spike, a first expansion member extending from one side of the central spike and a second expansion member extending from an opposite side of the central spike. In use, the first expansion member and the second expansion member move outwardly as the central spike is forced downwardly within the channel to securely couple the connecting member within the track member and to force the first and second upwardly extending flanges outwardly into engagement with the molding such that the molding is securely coupled to the track member. 
     It is a further object of the present invention to provide a multi-component article including the present coupling assembly connecting a first member to a second member. 
     Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross sectional view of the present coupling assembly. 
     FIG. 2 is a top view of the track member and connecting members positioned within a doorway. 
     FIGS. 3,  4  and  5  are cross sectional views showing the steps associated with the installation of molding in accordance with the present invention. 
     FIG. 6 is a perspective view of the connecting member. 
     FIG. 7 is a perspective view of the molding. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The detailed embodiment of the present invention is disclosed herein. It should be understood, however, that the disclosed embodiment is merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limited, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention. 
     With reference to FIGS. 1-7, a coupling assembly  10  securely coupling molding  12  to a support surface  14  is disclosed. The coupling assembly  10  includes a track member  16  and a connecting member  18 . The connecting member  18  is shaped and dimensioned for secure attachment to the track member  16 . 
     The track member  16  is preferably formed from extruded aluminum, although other materials may be used without departing from the spirit of the present invention. The connecting member  18  is injection molded and formed from high density polyethylene, although other materials and manufacturing techniques may be employed without departing from the spirit of the present invention. 
     The track member  16  is an elongated member which is cut to a desired length before use. The track member  16  includes a base  20  with a top surface  22  and a bottom surface  24 . The bottom surface  24  of the track member  16  is provided with longitudinally extending grooves  26  enhancing the secure attachment of the track member  16  to a support surface  14 . The top surface  22  includes first and second upwardly extending flanges  28 ,  30  defining a channel  32 . 
     The top surface  22  further includes longitudinally extending recesses  34   a ,  34   b  on opposite sides of the first and second flanges  28 ,  30 . The recesses  34   a ,  34   b  provide space allowing the heads  36  of the securing nails  38  to lie substantially flush with the top surface  22  of the track member  16 . A longitudinal groove  40   a ,  40   b  is formed within the center of each recess  34   a ,  34   b . The groove  40   a ,  40   b  is designed to guide the tip of a nail  38  as it is fastened to the track member  16 . 
     The first and second upwardly extending flanges  28 ,  30  are substantially mirror images of each other. As such, each flange includes an exterior surface  42   a ,  42   b  and an interior surface  44   a ,  44   b . The exterior surface  42   a ,  42   b  is substantially smooth, although it may include texturing, serrations or other variations, without departing from the spirit of the present invention. For reasons that will be better appreciated based upon the following disclosure, the smooth exterior surface  42   a ,  42   b  prevents movement of the molding  12  relative to the track member  16  from wearing away and loosening the molding  12 . 
     The interior surface  44   a ,  44   b  of each flange  28 ,  30  is provided with inwardly directed ribs  46   a ,  46   b  shaped and dimensioned to engage the connecting member  18  in a manner that will be discussed below in greater detail. In addition, the base  48   a ,  48   b  of each flange  28 ,  30  includes a relieved section allowing the flange  28 ,  30  to flex outwardly for reasons discussed in greater detail below. Specifically, the exterior surface  42   a ,  42   b  of each flange  28 ,  30  includes a recessed section  50   a ,  50   b  adjacent the base  48   a ,  48   b  of the flange  28 ,  30 . The recessed section  50   a ,  50   b  provides additional flexibility at the base  48   a ,  48   b  of the flange  28 ,  30 , permitting the flange  28 ,  30  to flex outwardly for the retention of molding  12  thereon. 
     The connecting member  18  is shaped and dimensioned for secure attachment within the channel  32 . Each connecting member  18  is approximately ¾ inch long, although this length may be varied without departing from the spirit of the present invention. As will be discussed in greater detail below, the connecting members  18  are positioned at one foot intervals along the track member  16  during the installation process. 
     In practice, the connecting member  18  is designed to expand outwardly as it is forced downwardly within the channel  32 . The connecting member  18  includes a central spike  52  with a first expansion member  54  extending from one side of the central spike  52  and a second expansion member  56  extending from an opposite side of the central spike  52 . First and second frangible joints  58 ,  60  couple the first and second expansion members  54 ,  56  to the central spike  52 . 
     Briefly, and as discussed in greater detail below, the first and second expansion members  54 ,  56  are releasably coupled to the central spike  52  such that the first expansion member  54  and the second expansion member  56  move outwardly as the central spike  52  is forced downwardly within the channel  32 . As the first and second expansion members  54 ,  56  are forced outwardly, they act upon the first and second upwardly extending flanges  28 ,  30  to force the upwardly extending flanges  28 ,  30  outwardly into engagement with the molding  12  such that the molding  12  is securely coupled to the track member  16 . 
     With this in mind, each expansion member  54 ,  56  includes a lower end  62   a ,  62   b  shaped and dimensioned for engagement with the floor  63  of the channel  32  as the central spike  52  is pushed downwardly within the channel  32 . Each expansion member  54 ,  56  includes an upper end  64   a ,  64   b  shaped and dimensioned for receipt within the ribs  46   a ,  46   b  formed along the interior surface  44   a ,  44   b  of each upwardly extending flange  28 ,  30 . 
     Collapse of the connecting member  18  within the channel  32  will now be described in detail. After the connecting member  18  is loosely inserted within the channel  32 , the lower ends  62   a ,  62   b  of the first and second expansion members  54 ,  56  contact the floor  63  of the channel  32 . Downward pressure is then applied to the central spike  52 , for example, by a piece of molding  12  placed over the track member  16  and the connecting member  18 . 
     As downward pressure is applied to the central spike  52 , the first and second frangible joints  58 ,  60  break. That is, the first and second expansion members  54 ,  56  are broken from the central spike  52 . The central spike  52  is then free to move downwardly within the channel  32 , and between the first and second expansion members  54 ,  56 . 
     As the central spike  52  moves downwardly between the first and second expansion members  54 ,  56 , the outwardly tapering shaft  66  of the central spike  52  is brought into contact with the upper ends  64   a ,  64   b  of the first and second expansion members  54 ,  56 , forcing the first and second expansion members  54 ,  56  to move outwardly and apply pressure to the upwardly extending flanges  28 ,  30 . This pressure causes each flange  28 ,  30  to bow outwardly approximately 2½° in the presently described embodiment. 
     The unique shape of the connecting member  18  securely binds the connecting member  18  within the channel  32  as it applies pressure to the upwardly extending flanges  28 ,  30 . Specifically, the lower end  62   a ,  62   b  of each expansion member  54 ,  56  includes interior recesses  68   a ,  68   b  shaped to respectively receive the remnant projections  69   a ,  69   b  remaining along the lower end  67  of the central spike  52  after it has split from the expansion members  54 ,  56 . In this way, the central spike  52  is prevented from moving up once the connecting member  18  is fully seated within the channel  32 . 
     In addition, the upper ends  64   a ,  64   b  of the expansion members  54 ,  56  are provided with dogs  72   a ,  72   b  which seat within the ribs  46   a ,  46   b  formed along the interior surfaces  44   a ,  44   b  of the first and second upwardly extending flanges  28 ,  30 . As with the lower end  67  of the central spike  52  seating within recesses  68   a ,  68   b  formed along the lower ends  62   a ,  62   b  of the expansion members  54 ,  56 , the dogs  72   a ,  72   b  prevent the connecting member  18  from moving up once it is fully seated within the channel  32 . 
     The outward flexing provided by the coupling assembly  10  is used to securely couple a first member to a second member with a dovetail joint. For example, and in accordance with the preferred embodiment of the present invention, the present coupling assembly  10  may be employed in attaching molding  12  to a support surface  14 . With reference to FIGS. 1-5, the track member  16  is first secured to the support surface  14 . Nails  38  are used to secure the track member  16  to the support surface  14  in accordance with the preferred embodiment of the present invention, although other attachment mechanisms, such as, glue, screws, double sided tape etc, may be employed without departing from the spirit of the present invention. 
     With reference to FIG. 2, once the track member  16  is properly secured to the support surface  14 , appropriate connecting members  18  are inserted, and spaced, within the channel  32  (for example, one connecting member every 12 inches). The molding  12  is then placed over the track member  16  and the connecting members  18 . 
     In accordance with the preferred embodiment of the present invention, the molding  12  includes an underside  74  with a longitudinal recess  76  which is slightly larger than the exterior spacing between the upwardly extending flanges  28 ,  30  of the track member  16 ; that is, a female dovetail joint member. The recess is, however, formed such that the base  78  of the recess  76  is slightly wider than the open end  80  of the recess  76 . That is, the walls  82   a ,  82   b  of the recess  76  taper in slightly, for example, by approximately 2½° each, as they extend from the base  78  of the recess  76  to the open end  80  of the recess  76 . 
     As the molding  12  is pressed downwardly, pressure is applied to the central spike  52  breaking the first and second frangible joints  58 ,  60 . That is, the first and second expansion members  54 ,  56  are broken from the central spike  52 . The central spike  52  is then free to move downwardly within the channel  32 , and between the first and second expansion members  54 ,  56 . 
     As the central spike  52  moves downwardly between the first and second expansion members  54 ,  56 , the outwardly tapering shaft  66  of the central spike  52  is brought into contact with the upper ends  64   a ,  64   b  of the first and second expansion members  54 ,  56 , causing the first and second expansion member  54 ,  56  to expand outwardly and apply pressure to the upwardly extending flanges  28 ,  30 . This pressure causes each flange  28 ,  30  to bow outwardly approximately 2½°. 
     It should be appreciated that the tapered shaft  66  should not begin forcing the upper ends  64   a ,  64   b  of the expansion members  54 ,  56  outwardly until the open end  80  of the molding  12  is at least approximately half way down the flanges  28 ,  30 . In this way, outward bowing of the flanges  28 ,  30  does not impede the movement of the molding  12  over the track member  16 . If the flanges  28 ,  30  were to begin bowing outwardly too early, the underside  74  of the molding  12  adjacent the recess  76  will contact the upper end of the flanges  28 ,  30  and damage the molding  12 , the flanges  28 ,  30 , or both. 
     The bowed flanges  28 ,  30  engage the walls  82   a ,  82   b  of the recess  76  formed in the underside  74  of the molding  12  to form a dovetail joint securely bind the molding  12  to the track member  16 , and the support surface  14 . That is, the combination of the outwardly bowed flanges  28 ,  30  and the tapered recess  76  form a dovetail joint which very securely binds the molding  12  to the track member  16 . 
     The combination of the connecting members  18  bowing the flanges  28 ,  30  outwardly and the recess  76  (that is, female dovetail joint member) of the molding  12  forms a dovetail joint without the need for 90° insertion of adjacent members of a dovetail joint assembly. In this way, the present coupling assembly  10  provides a substantially permanent attachment mechanism for joining adjacent articles. In fact, once the molding  12  is properly secured to the track member  16 , the molding  12  must be physically damaged to facilitate removal from the track member  16 . 
     As discussed above, the unique shape of the connecting member  18  securely binds the connecting member  18  within the channel  32  as it applies pressure to the upwardly extending flanges  28 ,  30 . In fact, the dogs  72   a ,  72   b  along the upper ends  64   a ,  64   b  of the first and second expansion members  54 ,  56  are designed to sequentially engage the ribs  46   a ,  46   b  formed along the interior surface  44   a ,  44   b  of the flanges  28 ,  30  as the molding  12  and connecting member  18  settle downwardly in relation to the track member  16 . Specifically, as the connecting member  18 , and the molding  12 , move downwardly during settling, the dogs  72   a ,  72   b  move down and engage the next lower set of ribs to securely bind the connecting member  18  in position. 
     The prior discussion has primarily focused on the use of the present coupling assembly for securing transitional moldings to a floor surface. However, those skilled in the art will readily appreciate the wide range of uses for which the present invention may be employed. For example, the present coupling assembly could be used in the assembly of furniture or the construction of cabinets. In addition, the present coupling assembly may be used in the attachment of chair rails, crown molding, shoe molding and a variety of other moldings installed throughout a home or office. 
     While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims.