Patent Publication Number: US-2018044926-A1

Title: Crown moulding

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to the moulding components. In particular, the present disclosure relates to crown moulding strips and other similar trim and/or finishing strips. 
     DESCRIPTION OF RELATED ART 
     Commonly, crown mouldings comprise decorative plaster or wooden trim installed where walls meet ceilings. In some cases, crown moulding components are manufactured from plastic, foam, or engineered wood products such as medium-density fibreboard. Crown moulding may typically be installed at an angle to both the wall and the ceiling surfaces, leaving a void behind the moulding and between the moulding, wall, and ceiling that has essentially a triangular cross-sectional shape. 
     Because the crown moulding is not typically installed flush against the wall or the ceiling, installation can present challenges, both for novice do-it-yourselfers and for experienced installers. Typically, the installer must figure out the height where the moulding strip would abut the wall, which may be dependent upon the intended crown angle and the width of the crown moulding strip. Such problems may increase the time and/or cost of crown moulding installation. Miscalculations by the installer may lead to wasted materials, lost time to correct errors and/or redo installation steps, and misaligned moulding pieces. 
     Some crown moulding installations include a layered crown design, where multiple strips are stacked to provide a more complex appearance than a single moulding strip. In such installations, the aforementioned difficulties in installing a crown moulding are exacerbated by the number of layers to be built up. 
     SUMMARY 
     In one embodiment, a method of installing a crown moulding is disclosed. The method includes affixing an anchor strip along a wall, inserting a portion of one of the anchor strip and a moulding strip into a notch, and affixing the moulding strip to the anchor strip. 
     In another embodiment, a method of installing a crown moulding is disclosed. The method includes providing an anchor strip having a cross-sectional profile, providing a moulding strip having a cross-sectional profile, wherein one of the anchor strip cross-sectional profile and the moulding strip cross-sectional profile has a notch along its length, affixing the anchor strip to a wall, and inserting a portion of one of the anchor strip and the moulding strip into the notch, thereby abutting the moulding strip to the anchor strip. 
     In another embodiment, crown moulding components are disclosed. The crown moulding components include an anchor strip and a moulding strip. One of the anchor strip and the moulding strip has a notch along its length. A portion of one of the anchor strip and the moulding strip is adapted to be seated in the notch. 
     The present disclosure will now be described more fully with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred or particular embodiments specifically discussed or otherwise disclosed. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only so that this disclosure will be thorough, and fully convey the full scope of the disclosure to those skilled in the art. Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  depicts a cross-sectional view of a crown moulding installation with a moulding strip having a notch according to an embodiment of the present disclosure; 
         FIG. 2  depicts a cross-sectional view of a moulding strip having a notch being fitted to an anchor strip according to an embodiment of the present disclosure; 
         FIG. 3  depicts a cross-sectional view of a crown moulding installation with a moulding strip having a notch and an anchor strip having an elongated profile according to an embodiment of the present disclosure; 
         FIG. 4  depicts a cross-sectional view of a crown moulding installation with a 45 degree spring angle according to an embodiment of the present disclosure; 
         FIG. 5  depicts a cross-sectional view of a crown moulding installation with an anchor strip having a curved surface according to an embodiment of the present disclosure; 
         FIG. 6  depicts a cross-sectional view of a crown moulding installation with a moulding strip having a relatively shallow notch according to an embodiment of the present disclosure; 
         FIG. 7  depicts a cross-sectional view of a crown moulding installation with an anchor strip having a notch according to an embodiment of the present disclosure; and 
         FIG. 8  depicts a cross-sectional view of a moulding strip being fitted to an anchor strip having a notch according to an embodiment of the present disclosure. 
     
    
    
     Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure. 
     DETAILED DESCRIPTION 
     In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the spirit and scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense. 
     Reference throughout this specification to “one embodiment,” “an embodiment,” “one example,” or “an example” means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “one example,” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it should be appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale. 
     Embodiments of the present disclosure comprise crown moulding components and methods of installing the same. In the present disclosure, reference to crown moulding component may include moulding strips, also commonly known as molding or coving, or other types of finishing strips and/or millwork components. Such millwork components may be manufactured from wood, reformed or engineered wood, plastic, plaster, foam, composites thereof, or other materials. 
     In various embodiments, a crown moulding installation according to the present disclosure includes an anchor strip affixed to a wall and a moulding strip affixed to the anchor strip. In one embodiment, a notch or cut-out along a length of the moulding strip receives a portion of the anchor strip, thereby providing a relatively easy fitment process and essentially flat nailing surface. In other embodiments, a notch along a length of the anchor strip receives a portion of the moulding strip. In various embodiments, various planar surfaces of the anchor strip abut corresponding planar surfaces of the moulding strip to provide a stable and secured install. In other embodiments, one or more curved surfaces of the anchor strip abut corresponding curved surfaces of the moulding strip to provide a stable and secured install. In various embodiments, anchor strips and/or moulding strips may be manufactured in milling or shaping operations already known in the art or not yet known in the art. 
     As used herein, the term “anchor strip” may include a millwork component adapted to be affixed horizontally along a wall where crown moulding is to be installed. In embodiments, an anchor strip may be installed with a vertical offset from the ceiling, wherein the size of the vertical offset is dependent upon various parameters of the crown moulding installation. According to various embodiments, a crown moulding strip may be anchored to the anchor strip. Embodiments of anchor strips include a notch adapted to receive a portion of the crown moulding strip. In other embodiments, an anchor strip includes a portion that may be received by a notch on a crown moulding strip. 
     Referring now to  FIG. 1 , a cross-sectional view of installed crown moulding according to one embodiment is depicted. As shown in  FIG. 1 , a moulding strip  100  is affixed to an anchor strip  110 , which itself is affixed to a wall  120 . The moulding strip  100  spans a space between the anchor strip  110  and a ceiling surface  130 . Various embodiments of moulding components comprise one or more decorative profile faces  106 . Embodiments of anchor strips comprise a decorative profile face  116 . Profile faces  106 ,  116  may include similar or complementary design elements such that when moulding strip  100  is installed on anchor strip  110 , the combined anchor strip  110  and moulding strip  110  form a cohesive built-up appearance. 
     As shown in  FIG. 1 , embodiments of crown moulding strips  100  are installed with a spring angle of approximately 38 degrees. As used in the present disclosure, the term “spring angle” indicates an angle between the crown moulding and the wall on which the moulding is installed. Alternatively, the spring angle indicates the angle between the crown moulding and a vertical plane. The spring angle may also be known as a crown angle. 
     Referring to  FIG. 2 , moulding strip  100  further comprises a notch  105  comprising two adjacent surfaces at an angle to each other. In the embodiment depicted, the two adjacent surfaces comprise vertical and horizontal planar surfaces at a 90 degree angle to each other. In other embodiments, other orientations and/or angles of the adjacent surfaces may be utilized. In various embodiments, the surfaces that form the notch  105  comprise substantially flat surfaces. As shown in  FIG. 1 , the orientation of the notch  105  is such that when moulding strip  100  is placed on anchor strip  110  mounted to wall  120 , moulding strip  100  is at the spring angle relative to wall  120 . Further, in embodiments, top surface  107  is approximately parallel and adjacent to ceiling  130  due to the spring angle, width of moulding strip  100 , and angle of top surface  107 . 
     In alternative embodiments, a notch may comprise adjacent surfaces that intersect at angles other than 90 degrees. For example, some embodiments of the present disclosure include a notch formed by surfaces intersecting at an acute angle. Other embodiments include a notch formed by surfaces intersecting at an obtuse angle. Other embodiments include a notch formed by composite and/or curved surfaces. 
     Referring to  FIG. 3 , moulding strip  100  may be installed on anchor strip  112 . As shown in  FIG. 3 , the profile face of anchor strip  112  is elongated in comparison to anchor strip  110 . As would be understood by a person with ordinary skill in the art having the benefit of this disclosure, a group composed of a wide variety of anchor strips and moulding strips may have various shapes and sizes, and such components may be respectively interchangeable with other anchor strips and moulding strips, provided that the notch shape is substantially common across the group. As shown in  FIG. 1  and  FIG. 3 , moulding strip  100  has a spring angle of approximately 38 degrees, primarily due to the vertical placement of the respective top surfaces of anchor strip  110  or  112 , the horizontal offset of the notch from the wall  120  resulting from the thickness of anchor strip  110  or  112 , the width of moulding strip  110 , and the size and shape of the notch  105 . Thus, a variety of moulding strips may be compatible with a variety of anchor strips to result in a variety of spring angles, given the foregoing parameters are essentially kept constant within the group. 
     Referring to  FIG. 4 , an installed moulding strip  101  is shown having a spring angle of approximately 45 degrees. As shown in  FIG. 4 , the spring angle of moulding strip  101  results from a combination of the vertical position of anchor strip  110  (particularly, the vertical position of the top surface of anchor strip  110 ), the width of moulding strip  101 , the thickness of anchor strip  110 , and the size and shape of the notch of moulding strip  101 . Further, in embodiments, the top surface of moulding strip  101  is approximately parallel and adjacent to ceiling  130  due to the spring angle, width of moulding strip  101 , and angle of the top surface. 
     Referring to  FIG. 5 , moulding strip  102  is installed with anchor strip  113 . As shown in  FIG. 5 , moulding strip  102  has a notch with a curved surface  108  that interfaces with curved surface  118  of anchor strip  113 . Accordingly, moulding strip  102  and anchor strip  113  comprise one example of anchor strips and moulding strips that have corresponding cross-sectional shapes. In other embodiments, other curve radii or other various shapes may be selected for moulding strip and anchor strip matching pairs. 
     Referring to  FIG. 6 , a moulding strip  103  and anchor strip  110  installation is depicted. As shown in  FIG. 6 , moulding strip  103  comprises a relatively shallow notch  109 .  FIG. 6  thus illustrates that a variety of notch sizes and shapes fall within the scope of the present disclosure. 
     Various embodiments of the present disclosure may include crown moulding installed at virtually any spring angle. As set forth above, the spring angle of a crown moulding may be determined by a number of parameters including the notch shape and size, vertical position of the top surface of the anchor strip, the width of moulding strip  101 , the thickness of anchor strip  110 , and the size and shape of the notch. In particular, moulding strips may be designed for spring angles of approximately 38 degrees, 45 degrees, or 52 degrees. 
     Referring to  FIGS. 7 and 8 , embodiments of the present disclosure include moulding strip  104  and anchor strip  111 . As shown in  FIGS. 7 and 8 , this embodiment includes a notch  115  on anchor strip  111 , while moulding strip  104  has no such notch. Lower end  119  of moulding strip  104  is adapted to be received by notch  115 . Various embodiments of the anchor strip may have a wide variety of notch size and shapes to complement corresponding lower ends of moulding strips. 
     In operation, an anchor strip and a moulding strip may be installed on a wall to form a built-up appearance where the wall and a ceiling meet. The anchor strip and moulding strip may be selected for their appearance, size, spring angle, and other desired parameters according to one&#39;s particular preferences. In embodiments, the anchor strip can be affixed to a wall at a predetermined height. In embodiments, the predetermined height of the anchor strip can be measured as a distance from the ceiling. As set forth in greater detail above, the predetermined distance may be calculated according to various parameters such as moulding strip width, spring angle, anchor strip thickness, and size and/or shape of the notch. Accordingly, an installer may measure and then mark the predetermined anchor strip height, cut the anchor strip to length, and fix the anchor strip to the wall at the predetermined height. In one embodiment, an installer can mark the anchor strip height with a laser level or other light-based markers. In other embodiments, the installer can mark the anchor strip height with a chalk line, pencil, or other marking instruments. 
     Embodiments of the present disclosure include various methods of fixing the components to a wall, a ceiling, and/or each other. Such methods may include nails, staples, various types of glue or other adhesives, screws, other fasteners known in the art, or other fasteners not yet known in the art. In some embodiments, the anchor strip is installed by affixing to wall studs or other structural members. 
     Following installation of anchor strip, the installer may then cut the moulding strip to length, cope or miter the ends of the moulding strip (as called for by the crown moulding setting), and affix the moulding strip to the anchor strip. In embodiments where the moulding strip has a notch, the installer may place the moulding strip on the anchor strip by inserting the appropriate anchor strip portion into the notch so the moulding strip is seated on the anchor strip. In embodiments where the anchor strip has a notch, the installer may place the moulding strip on the anchor strip by inserting the appropriate moulding strip portion into the notch so the moulding strip is seated on the anchor strip. In embodiments, the moulding strip may span the length from the anchor strip to the ceiling at the desired spring angle when properly seated on the anchor strip. 
     In embodiments, the installer can affix the moulding strip to the anchor strip by driving nails through the moulding strip and into the anchor strip. In other embodiments, various types of fasteners and/or adhesives may be utilized to secure the moulding strip to the wall and/or anchor strip. In some cases, the installer may affix the moulding strip to a ceiling surface and/or ceiling joists with mechanical or adhesive fasteners. 
     Embodiments of the present disclosure may include moulding strips and/or anchor strips of virtually any desired thickness, width, and/or length. Embodiments of the present disclosure may be manufactured in a moulding machine or other type of milling or shaping operation. Embodiments may be coated with primer, paint, and/or other various coatings as would be understood by a person of ordinary skill in the art. In some embodiments, moulding strips and/or anchor strips are coated only in a primer or similar coating prior to installation. Following installation, the moulding strips and/or anchor strips may then be caulked and/or painted. In various embodiments, the installer can apply caulk to nail holes, joints, and/or seams. The installer may also sand the installed moulding strip and/or anchor strip and finish by applying coats of paint. 
     Embodiments of the present disclosure may present several advantages over prior art methods. For example, utilizing methods disclosed herein, crown moulding may be installed in less time than traditional techniques, which may result in reduced labor-related costs. Additionally, crown moulding installations may be easier to carry out for inexperienced installers, and may be more likely to be completed without unattractive defects. Crown moulding installations resulting from methods disclosed herein may benefit from a stable nailing surface provided by the abutted surfaces of the anchor strip and moulding strip at the notch. Additionally, crown moulding installations resulting from methods of the present disclosure may be more likely to have true (or near-true) corners compared to traditional installation methods due to the relative ease of installation. 
     Although the present disclosure is described in terms of certain preferred embodiments, other embodiments will be apparent to those of ordinary skill in the art, given the benefit of this disclosure, including embodiments that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the spirit and scope of the present disclosure.