Patent Publication Number: US-4545162-A

Title: Moldings

Description:
This invention relates to moldings which are adapted as shafts to be fastened to sub-structure of a building and be revealed to extents as trim along with finish structure of a building, and the invention also relates to building structures which are characterized by the molding being a component thereof. 
     An object of the present invention is the provision of structurally worthwhile moldings which are readily produced and easily installed and which for trim introduce a reveal including the interior of a channel, and are well suited for use with any of a variety of finish materials, such as paneling or board or wet applied settable plaster, available in the trade for covering sub-structure of a building, and which moldings in the instance of use with wet applied settable plaster may serve as a ground for the wet plaster, or which in the instance of dry paneling or board may serve as a ground for the dry paneling or board, having the moldings in either instance offer a reveal for trim. 
     A further object herein is that of providing moldings of the character indicated wherein the channel thereof is accompanied by coves formed in the molding with the rear of the channel, such as to allow wet plaster or the like to enter either or both of the coves, as the case may be, and take set, having a cleat in the cove. 
     Another object of this invention is to provide moldings of the character indicated having the channel situated forwardly in the molding so that a reveal represented by the interior of the channel is relatively easy to clean, and is visible in full depth of the channel from a wider angle of view, because of the channel being relatively shallow. 
     Other objects of this invention in part will be obvious and in part pointed out more fully hereinafter. 
     As conducive to a clearer understanding of certain features of the present invention, it is noted at this point that in the field of architectural trim and building construction it has become desirable to have moldings at hand which satisfactorily serve as grounds for finish material which at least in part is to be added after the moldings have been secured to sub-structure of a building, and moldings which furthermore ornamentally present a reveal when the molding is in place and is partially concealed by the finish material through treating the molding as a ground. 
     Moldings of the character indicated are for example in demand for use with finish material either or both of a dry pre-formed type or of a fluent settable grade which is to be added outside sub-structure of the building to opposite sides of the already installed molding as a ground on the sub-structure, thereafter to have the molding intermediately serve as trim. In other instances, demands reach into situations where a segment of the finish material has already been put into place on sub-structure of the building, allowing the molding thereafter to be installed on the sub-structure with one side of the molding against the segment, and then to have the molding on the opposite side serve as a ground for supplemental finish material to be added for covering the sub-structure. Fluent settable materials, such as plaster, of course are fluent when first brought against the molding and later take set, while so-called dry finish materials, such as panels or boards, in being used with the molding, are bodily put into place. 
     Frequently, moldings are needed for corner environments differing with whether the sub-structure of the building calls for about a 90° or about a 270° coverage measured outside the confronted faces of the sub-structural corner. To illustrate further, the corner environment may involve a side wall to side wall situation, a side wall up to a ceiling situation or a side wall down to a soffit situation. In other than corner environments, moldings also are sometimes required to serve as trim between first and second finished areas within, say, a wall or a ceiling outside the sub-structure of a building, and in all it has become desirable to have moldings of the character referred to available in varieties to select from in order to satisfy one or more specialized needs. 
     In accordance with the present invention, moldings which are well suited for the dual purpose of being grounds for finish material, and affording trim, are provided, and the molding is a shaft formed such as by extrusion, being made for example of an aluminum base alloy of any satisfactory type or, if desired, made of any other suitable material such as from an opaque grade of synthetic resin. 
     The molding shaft comprises, a reveal wall structure which intermediately of first and second lateral terminal ends thereof includes first and second side walls, and a web having first and second junctions with those side walls and forming an interiorly revealed channel with those side walls. Lead wall structure in the molding shaft introduces a stub wall having junction at a first end of the lead wall structure with the rear of the channel web marginally inwardly from the junctions of the channel side walls with the web. The stub wall is between first and second coves behind the channel web. 
     The lead wall structure is further characterized by including lead wall means providing a second end of the lead wall structure and being adapted to lead along sub-structure of a building and be fastened to that sub-structure in contact therewith. At least a portion of the lead wall means includes a lead wall forming a lead angle with the stub wall so as to have the stub wall offset the channel from the lead wall. 
     The lead wall structure and the channel are disposed and extend in the molding shaft relatively to one another, for the lead wall means to be accessible for being fastened in place against the building sub-structure and the channel to be interiorly revealed upon the lead wall means being fastened in place. Still further, the lead wall structure and the channel are disposed and extend relatively to one another in the molding shaft, for finish material, upon being disposed outside each of first and second extents of the sub-structure of the building and contiguous, outside the channel, respectively to the first and second lateral terminal ends of the reveal wall structure, to conceal the first and second extents of the sub-structure, the first and second coves, and the outside faces of the first and second side walls of the channel and, with regard to entering the spaces inside the first and second coves, be at farthest closely outside the first and second coves, while the interior of the channel remains revealed and the lead wall means still is fastened in place. 
     Molding shafts in accordance with the present invention not only serve as grounds for various finish materials, but as trim. Where the finish material is of a fluent settable type and is applied prior to setting, the material in being worked to the molding shaft for a ground, preferably is in depth to enter the related cove behind the channel and eventually set with a cleat in that cove. It will also be appreciated that the molding shafts have utility as grounds and trim for dry finish materials and that the dry finish materials such as paneling or board can be presented contiguous to the molding shaft without entering the cove, or if desired in certain instances the paneling or board may be provided with a tongue which is entered into the cove. 
     Further aspects are that the molding shafts, by having the channel offset in the molding shaft in a forward lateral direction, are characterized by the channel being relatively shallow, considering the extent of the offset. Accordingly the reveal afforded as trim by the interior of the channel, in also being relatively shallow, is more easily cleaned. The channel web portion of the reveal in the relatively shallow channel moreover is visible with a resulting ornamental effect from a wider angle of view than would be the case for a deeper channel. 
    
    
     In the accompanying drawings representing several illustrative embodiments of this invention which are presently preferred: 
     FIG. 1 is an isometric fragmentary view of a molding shaft; 
     FIGS. 2, 3 and 4 provide transverse cross sectional views of the molding shaft in FIG. 1 and in addition represent different environments wherein the molding shaft is associated with building sub-structure and finish materials; 
     FIGS. 5, 6 and 7 are views similar to the latter three figures, but involve modified forms of molding shafts and exemplify their use; and 
     FIGS. 8, 9, 10 and 11 are isometric fragmentary views representing longitudinally curved molding shafts, having reference to the FIG. 7 embodiment. 
    
    
     Referring now more particularly to the embodiment represented in FIG. 1, a molding shaft, designated in general by the reference numeral 10, is characterized by including on the length thereof a forwardly laterally open channel 11, and lead wall structure 12 rearwardly of the channel 11 in the molding shaft 10. Channel 11 as shown in FIG. 1 is defined by a web laterally straigt 15 and by laterally straight first and second side walls 13 and 14, there being junctions 16 and 17 of the channel web 15 with the first and second side walls 13 and 14, respectively. A stub wall 18, which is a portion of the lead wall structure 12, co-extends longitudinally with the channel web 15 and has a junction 19 at the rear of the channel web 15 with first and second portions 15a and 15b of the channel web 15. The first and second side walls 13 and 14 of the channel 11 and the stub wall 18 laterally form approximately right angles with the channel web 15, having the junction 19 disposed marginally inward from the junctions 16 and 17, and junction 19 leads longitudinally substantially parallel with the junctions 16 and 17 with the molding shaft 10 meanwhile being in the longitudinally straight condition indicated in FIG. 1. Approximaltely right angle coves 20 and 21 are laterally produced behind the channel 11 by the stub wall 18 with the first and second portions 15a and 15b of the channel web 15. 
     A lead wall 22, being a further portion of the lead wall structure 12, forms on the length of the molding shaft 10 a junction 23 with an outer end of the stub wall 18 rearward of the junction 19. As represented in FIG. 1, junction 23 leads longitudinally substantally parallel with junction 19 in the molding shaft 10 in the longitudinally straight condition of the molding shaft 10, meanwhile having the lead wall 22 and channel web 15 substantially coincident with parallel planes and having the lead and wall 22 and the stub wall 18 form approximately a right angle with one another. The lead wall 22 extends laterally outwardly in the molding shaft 10 past and thus beyond the second side wall 14 of the channel 11 and is adapted to contact sub-structure of a building and be fastened to that sub-structure. Notably, too, the stub wall 18 offsets the channel 11 forwardly from the lead wall 22 and, as compared with the depth of the molding shaft 10, the forwardly open channel 11 is relatively shallow as presented forwardly of the coves 20 and 21. In the present embodiment, the junction 19 substantially coincides with the longitudinal center line of the channel web 15 so as to have the ratio of lateral reach from junction 16 into cove 20 to junction 19, to lateral reach from junction 17 into cove 21 to junction 19, be approximately 1:1. If desired, in practice still in accordance with the present invention, any one of a number of other ratios for lateral reaches respectively corresponding to those just expressed may be introduced, instead of the aforementioned approximately 1:1 ratio referred to for the molding shaft 10, in producing molding shafts otherwise similar to the molding shaft 10. The ratio selected for this purpose is preferably in the range of about 3:1 to and including the ratio of approximately 1:1 already mentioned. In the present embodiment, the molding shaft 10 further includes a flange 10a joined to the forward end of the second side wall 14 of the channel 11 and reaching laterally outwardly of the channel 11 a short distance at about a right angle to the second side wall 14, thus laterally being substantially parallel with the lead wall 22 and providing an extension of the reveal surface introduced by the forwardly open channel 11 and being available to conceal the end of finish material which is to be placed immediately behind the flange 10a so as to have the latter afford a terminal end of the reveal. In certain embodiments, the flange 10a is omitted, calling for the finish material to be more closely abutted against the channel 11 second side wall 14, thus laterally terminally ending the reveal at the forward end of the second side wall 14. 
     Turning to examples of installations in accordance with the present invention and of how the molding shaft 10 may be interrelated with building materials, it will be noted with reference to FIG. 2 that the molding shaft 10, therein represented as installed, is associated with first and second building side wall sub-structural extents 25 and 26 and with first and second side wall finish materials 27 and 28 which may be substantially alike or of different composition applied to conceal the sub-structural side wall extents 25 and 26 in a building corner environment. In the course of finishing the corner, the first finish material 27, such as fluent settable plaster or dry wall paneling, is for example first applied to the sub-structural extent 25, following which the lead wall 22 of the molding shaft 10 is placed against the sub-structural extent 26 and secured as by nails 29 to the sub-structural extent 26 having the first side wall 13 of the channel 11 abutted against the first finish material 27. Thereafter, the second finish material 28 is applied against the second side wall 14 of the channel 11, thereby concealing the side wall 14 exteriorly of the channel 11, the cove 21, the lead and contact wall 22 and the sub-structural extent 26, and leaving the interior of the channel 11 revealed forwardly as trim. Where the second finish material 28 used is a fluent settable material, the cove 21 becomes accessible for the second finish material 28 to enter and produce a cleat, meanwhile having the flange 10a available to serve for a working ground along with the second side wall 14 of channel 11. 
     In certain practices, still in accordance with the present invention, and which practices also can be understood by again referring to FIG. 2, the molding shaft 10 is installed against the second sub-structural extent 26 before application of the first finish material 27 outside the first sub-structural extent 25, and allowance is made either to slide dry paneling, or the like, as the first finish material 27 into position within a gap between the first side wall 13 of the channel 11 and the sub-structural extent 25 so as to be outside the channel 11 and against the first side wall 13, or to apply fluent settable finish material to enter the gap between the first side wall 13 and the first sub-structural extent 25 and be contiguous to the cove 20, such as to enter that cove, using the first side wall 13 for a working ground. 
     Molding shaft 10 also readily lends itself to use in building side wall and ceiling corner or soffit environments such as is represented in FIGS. 3 and 4. In the FIG. 4 ceiling corner environment, the lead wall 22 is fastened, as by nailing, to a sub-structural ceiling extent 30, and is thereafter covered by ceiling finish material 32, with the first side wall 13 of the channel 11 being against building side wall finish material 33 applied to a side wall sub-structural extent 31. The installation in FIG. 3 has the molding shaft 10 in a soffit situation wherein there is an upper sub-structural corner 34 with the lead wall 22 of the molding shaft 10 fastened, as by nailing, to a horizontal underside of the sub-structural corner 34. Meanwhile, the first side wall 13 of the channel 11 is disposed against the side of a vertically downwardly projecting end 36 of dry wall finish material which above covers the vertical side of the sub-structural corner 34. 
     In the FIG. 5 embodiment, a molding shaft 10&#39;, similar to the molding shaft 10 in FIG. 1, includes a second lead wall 22&#39; supplementing the first lead wall 22. Lead wall 22&#39; extends laterally outwardly past and appreciably beyond the first side wall 13 of the channel 11 from a junction 23&#39; in common with the stub wall 18 and the first lead wall 22, both lead walls 22&#39; and 22 being substantially within a plane in common for a longitudinally straight condition of the molding shaft 10&#39;. It will be appreciated from FIG. 5 that the molding shaft 10&#39; has utility such as to situate the channel 11 between dry finish type panels, or between sections of fluent settable plaster type finish materials, or between one of each of the two types of materials, this with the materials being substantially within a plane in common, and which materials in any event are designated by the reference numerals 39 and 40, and cover both of the lead walls 22&#39; and 22 which are secured to the sub-structure 38 as by nailing. It will be seen, too, that a second flange 10b, similar to the flange 10a for the second side wall 14 has been added to the outer end of the first side wall 13 of the channel 11 and reaches laterally outwardly at about a right angle relatively to the first side wall 13 of the channel 11 a short distance for being associated in a manner similar to the flange 10a with the corresponding finish material. For use in a similar environment, a molding shaft 10 according to FIG. 1 may instead be provided and installed with or without the addition of the flange 10b as suggested from FIG. 5. 
     Referring now to the FIG. 6 embodiment, a molding shaft 50 is suited to present a decorative channel reveal in a bevel sense across a finished sub-structural corner, and also serves as a ground for the finish material. Molding shaft 50 includes a lead wall 51 and an allocating wall 52 co-extending with one another longitudinally of the molding shaft 50 and with a channel 55 and a stub wall 53. Laterally, the walls 51 and 52 are disposed at about a right angle relatively to one another so as to receive against their inner surfaces a sub-structural corner 66 of a building when the molding shaft 50 is being installed. 
     The stub wall 53 has a first junction 54 at rearward end in common with the walls 51 and 52 and forms substantially 135° outside angles with the walls 51 and 52. At forward end, the stub wall 53 has a second junction 56 with first and second portions 57a and 57b of a web 57 of the channel 55 and introduces approximately right angle coves 60 and 61 with the web portions 57a and 57b behind the channel web 57. First and second side walls 58 and 59 of the channel 55 for a longitudinally straight condition of the molding shaft 50 are substantially concurrent with first and second substantially perpendicular planes which intersect the walls 51 and 52, at about right angles, rearwardly laterally in the molding shaft 50 of the stub wall junction 54 and intersect one another along an axis x behind the stub wall junction 54. 
     The stub wall junction 56 with the first and second portions 57a and 57b of the channel web 57 is laterally removed substantially equidistantly from junctions 62 and 63 of the channel web 57 with the first and second side walls 58 and 59 of the channel 55, and these side walls 58 and 59 form about 135° angles with the channel web 57 inside the channel 55. The molding shaft 50 further comprises a pair of flange walls 64 and 65 integral with the forward ends of the channel side walls 58 and 59 and directed laterally outwardly in the molding shaft 50 at about right angles to the channel side walls 58 and 59 respectively, and terminating with a shorter lateral reach than the lead wall 51 and the allocating wall 52. The flange walls 64 and 65 afford lateral terminal ends for the reveal wall structure. 
     With the molding shaft 50 fastened in place against the sub-structural corner 66, as represented in FIG. 6, first finish material 67 is applied exteriorly of the channel 55 against the channel first side wall 58, up to contiguously behind the flange wall 64, and against the sub-structural corner 66, so as to conceal the exterior face of the channel first side wall 58, the cove 60, the lead wall 51 and the related face of the sub-structural corner 66. Where the finish material 67 used is a dry wall panel presenting a square cut at the end adjacent to the channel first side wall 58, the panel end does not enter the cove 60 but merely closes off that cove from the outside; however, the panel may be provided with a tongue, if desired, to enter the cove 60. On the other hand, where the first finish material 67 is applied as a fluent settable material, the flange wall 64 is useful for a troweling ground, and the first finish material 67 can enter the cove 60 for cleating. Similar options are available in applying second finish material 68 relatively to the second side wall 59 of the channel 55 and the flange wall 65, for concealing the cove 61, the allocating wall 52 and the related surface of the sub-structural corner 66. 
     In certain embodiments, the allocating wall 52 is omitted from the structure of the molding shaft 50 with reliance accordingly being placed upon use of the lead wall 51 for placement and fastening of the molding shaft 50 against a sub-structural corner. The supplemental use of the allocating wall 52, though, is preferred, at least to facilitate allocation of the molding shaft 50 against the sub-structural corner, with or without the allocating wall 52 being used with fasteners for connecting the molding shaft 50 to the sub-structural corner. 
     A molding shaft 70 according to the FIG. 7 embodiment has utility for such purposes as with a sub-structural soffit. Lead wall structure in the molding shaft 70 comprises a stub wall 71 and first and second lead walls 72 and 73, the second lead wall 73 laterally forming a first lead wall angle with the first lead wall 72 and a second lead wall angle with the stub wall 71, both of these angles being approximately right angles. A first lateral end 72a of the lead wall structure is presented by an outer end of the first lead wall 72, and a second lateral end of the lead wall structure is presented at junction 71a of an end of the stub wall 71 with the web 77 of a channel 74. First and second side walls 75 and 76 of the channel 74 are joined at 75a and 76a with the outer ends of first and second portions 77a and 77b of the channel web 77 and are disposed at about right angles to the channel web 77 so as to have the channel 74 interiorly provide a forwardly open reveal. 
     The stub wall junction 71a is at the rear of the channel 74 and is at approximately the longitudinal center line of the channel web 77. Stub wall 71 serves as a boundary of first and second approximately right angle coves 78 and 79 which respectively have the web portions 77a and 77b for further boundaries, the stub wall 71 accordingly offsetting the channel 74 forwardly in the molding shaft 70 from the second lead wall 73 of the lead wall structure so as to have the ratio of lateral reach from junction 75a into cove 78 to junction 71a, to lateral reach from junction 76a into cove 79 to junction 71a, be approximately 1:1. If desired, in practices still in accordance with the present invention, any one of a number of other ratios for lateral reaches respectively corresponding to those just expressed may be introduced, instead of the aforementioned approximately 1:1 ratio referred to for the molding shaft 70, in producing molding shafts otherwise similar to the molding shaft 70. The ratio selected for this purpose is preferably in the range of about 1:3 to and including the ratio of approximately 1:1 already mentioned. 
     For a longitudinally substantially straight condition of the molding shaft 70, the first lead wall 72 and the first side wall 75 of channel 74 are substantially in alignment with one another by being substantially coincident with a plane in common thereto, and also in the present embodiment the molding shaft 70 is characterized by further including a ledge wall 80 which is connected at inner end outside the channel 74 with an outer end of the first side wall 75 of the channel 74 and projects laterally outwardly from the first side wall 75 to provide, forwardly, a reveal surface 80a extended from the interior reveal of the channel 74. Rearwardly, the ledge wall 80 has a surface 80b which is to be concealed. Channel 74 and the ledge wall 80 accordingly provide a reveal wall structure, and in the present embodiment this reveal wall structure is supplemented by a first flange 81 connected at about a right angle with the outer end of the ledge wall 80 and projecting rearwardly of the ledge wall 80 a small distance thus presenting an end 81a. A first lateral terminal end of the reveal wall structure accordingly is provided by the rearward end 81a of the first flange 81. A second flange 82 connected at about right angle with the outer end of the second side wall 76 of the channel 74 and projecting a small distance laterally outwardly of the second side wall 76 presents a second lateral terminal end 82a of the reveal wall structure. 
     It will further be understood that in the FIG. 7 embodiment the molding shaft 70 has the first lead wall 72 adapted to be secured to a substantially vertical portion of a sub-structural soffit corner 85 of a building such as by means of nails 86, and meanwhile have the second lead wall 73 in position against a substantially horizontal portion of the sub-structural soffit corner 85 with the stub wall 71 leading downward substantially vertically. With the first lead wall 72 thus securely in place, first finish material 87 thereafter is applied outside the molding shaft 70 and contiguous to the first lead wall 72, the first side wall 75 of the channel 74 and still further contiguous to the rearward face 80b of the ledge wall 80 and the inner side of flange 81 for the first finish material 87 thereafter to afford a substantially vertical external face outside the sub-structural soffit corner 85, with the exterior face of the flange 81 initiating a reveal of the molding shaft 70 for the soffit. A second finish material 88 is applied endwise contiguous to the second side wall 76 of the channel 74 and the rearward side of the flange 82 so as to have the flange 82 terminate the reveal of the molding shaft 70 for the soffit and the second finish material 88 thereafter to afford a substantially horizontal exposed face of the soffit. Under the latter conditions, the first and second finish materials 87 and 88 conceal the sub-structural soffit corner 85, the lead wall structure inclusive of the first and second lead walls 72 and 73 and the stub wall 71, the coves 78 and 79 and the outside faces of the first and second side walls 75 and 76 of the channel 74 along with the rearward face 80b of the ledge wall 80. 
     The first and second finish materials 87 and 88, referred to, may of course in composition be similar or different, and either of these materials may be of a fluent settable type or of a dry wall type. Where the material is applied as a fluent settable material, the related cove 78 or 79 is available to receive cleating of the material and the first and second flange 81 or 82, as the case may be, is present as a guide for troweling or screeding, or in the instance of a pre-formed panel or board the inner flange face is available as an abutment. 
     In practice in accordance with the present invention, the molding shafts in the embodiments hereinbefore disclosed, aside from being produced and used in a substantially longitudinally straight condition, are instead produced and used in a longitudinally curved condition to satisfy certain needs. For the longitudinally straight condition as compared with the longitudinally curved condition of a molding shaft so produced, the transverse cross section of the longitudinally straight molding shaft may be similar to that of the longitudinally curved molding shaft, such as by derivation from the same extrusion die or from similar extrusion dies. To provide examples of longitudinal curvatures given to molding shafts in accordance with the present invention, reference is had to the molding shaft 70 in the FIG. 7 embodiment, and to FIGS. 8, 9, 10 and 11 wherein a variety of longitudinal curvatures which introduce curvature two-dimensionally as distinguished from three-dimensionally are presented for selection. The longitudinal curvatures represented for molding shaft 70 are respectively a bow laterally to the left in FIG. 8, a bow laterally to the right in FIG. 9, a forward arching in FIG. 10 and a rearward arching in FIG. 11, this in terms of the molding shaft 70 being viewed toward the front thereof, and thus in an upward direction from below in FIGS. 8, 9, 10 and 11. The molding shafts in the other embodiments herein are also provided and used either in a longitudinally straight condition or in a longitudinally curved condition, and with the longitudinal curvatures being similar for example to any one of those aforementioned with reference to FIGS. 8, 9, 10 and 11. 
     As the invention lends itself to many possible embodiments and as many possible changes may be made in the embodiments hereinbefore set forth, it will be distinctly understood that all matter described herein is to be interpreted as illustrative and not as a limitation.