Patent Publication Number: US-2019186156-A1

Title: Skirting and architrave installation system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     See Application Data Sheet. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT 
     Not applicable. 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB) 
     Not applicable. 
     STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the installation of skirting and architraves and in particular to a skirting and architrave installation system that eliminates the need for skilled tradesmen to perform the work. 
     The invention has been developed primarily for the carpentry and building industries and will be described hereinafter with reference to these applications. 
     The disclosure of Australian patent application number 2013200949 FASTENER and PCT/AU2016/000186 are incorporated herein by reference. Patent application number 2013200949 has been invented to secure pre-finished skirting and architraves to the building without penetrating the pre-finished surface. 
     2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98 
     Skirting boards and architraves are used as decorative items that frame the junction of wall and floor, and provide a frame around windows and doors. In order to achieve a neat and tidy finish, skilled tradesmen are required to accurately cut and skillfully install these decorative items. However, this method of installation is time consuming as there is no margin for error. 
     Furthermore, skirting and architraves are installed via nails or screws, therefore a painter is required to patch the nail/screw holes prior to applying a finishing coat of paint, which in order to achieve a high quality finish, is also time consuming and expensive. 
     In recent years pre-finished skirting and architraves have been available however installation is more time consuming and difficult due to inefficient installation solutions offered. 
     Corner moulds and covers have been offered as an alternative to cutting of mitre joints, however cutting accurate lengths is still required as the skirting and architraves essentially but up to the corner moulds. 
     There is thus a need for a skirting and architrave installation system that eliminates the need for skilled tradesmen, thereby reducing installation time and associated costs. This will allow the use pre-finished skirting and architraves to be used, with further finishing work not being required. 
     The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative. 
     It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country. 
     BRIEF SUMMARY OF THE INVENTION 
     According to a first aspect, the present invention provides a connector piece to cover the gap between two skirting profiles disposed at an angle to each other, the connector piece comprising:
         a body having a bend to correspond to the angle, the body having a front portion, a rear portion, and a cavity between the front portion and the rear portion, the cavity having end portions for receiving respective end sections of the skirting profiles,   wherein the front portion forms the exposed decorative contour of the connector piece, and   wherein the rear portion comprises an engagement means for engaging a respective rear surface of the skirting profiles when the end sections of the skirting profiles are received into the cavity       

     Preferably, the connector piece is for a corner and the front portion comprises a substantially 90° bend therein corresponding to the corner of the wall. 
     Preferably, the corner is an internal corner or an external corner. 
     Preferably, the front portion matches an exposed decorative contour of the skirting profiles. 
     Preferably, the front portion extends from the floor when mounted in use. 
     Preferably, the engagement means of the rear portion comprises an inserting tab which extends downwardly from the front portion. 
     Preferably, the inserting tab has a bend and follows the shape of the front portion. 
     Preferably, the inserting tab comprises a curved lead at its lower end portion that are biased towards a rear face of the skirting profiles. 
     Preferably, the front portion extends from the floor in use and tightly matches the exposed decorative contour of the skirting profiles. 
     Preferably, the connector piece comprises strengthening ribs between the front portion and the rear portion. 
     Preferably, the side extremities of the front portion are wider than the side extremities of the rear portion. 
     Preferably, side leading edges of the front portion are splayed inwardly to contact front faces of the skirting profiles in use. 
     Preferably, the rear portion extends to a mid-portion of the front portion. 
     Preferably, the front portion has front face sections facing in perpendicular directions towards or away from each other. 
     The present invention also provides a skirting profile comprising a front face and a rear face, wherein the rear face in cross-section comprises upper and lower notches which engage a wall in use, the notches spacing the rear face from the wall providing a rebate between the rear face and the wall. 
     Preferably, the rebate is at least 3 mm in depth. 
     Preferably, the skirting profile comprises a top face and a bottom face and the rebate extends from adjacent a top face to adjacent the rear face. 
     The present invention also provides an assembly comprising two skirting profiles and the connector piece of claim  1 . 
     The present invention also provides an architrave connector block having a top face and side walls, wherein at least two side walls comprise rebates shaped to correspond to architrave profiles. 
     Preferably, the block comprises a raised decorative feature extending from the top face. 
     Other aspects of the invention are also disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings. 
         FIG. 1  shows a side cross-sectional view of a skirting profile with an increased rebate mounted against a wall. 
         FIG. 2  shows a side cross-sectional view of the skirting profile of  FIG. 1 , with its top notch removed. 
         FIG. 3  shows a schematic view of a skirting connector piece in position above the skirting profile. 
         FIG. 4  shows a schematic view of the skirting connector piece partly engaged with the skirting profile. 
         FIG. 5  shows a schematic view of the skirting connector piece completely engaged with the skirting profile. 
         FIG. 6  is an enlarged schematic view of the inserting tabs of the skirting connector piece showing flexing of the tabs. 
         FIG. 7  shows a plan sectional view of an external skirting connector. 
         FIG. 8  shows a top plan view of the external skiting connector. 
         FIG. 9  shows an end elevation view of the external skirting connector. 
         FIG. 10  shows an isometric view of the external skirting connector of  FIGS. 7, 8, and 9 . 
         FIG. 11  shows a plan sectional view of an internal skirting connector. 
         FIG. 12  shows a top plan view of an internal skirting connector. 
         FIG. 13  shows an end elevation view of the internal skirting connector. 
         FIG. 14  shows an isometric view of the internal skirting connector of  FIGS. 11, 12, and 13 . 
         FIG. 15 . Shows an exploded isometric view of an example assembly mounted against a wall comprising cut skirting sections joined by the connector pieces above. 
         FIG. 16  shows an isometric view of the  FIG. 15  assembly with connector pieces fitted. 
         FIG. 17  shows a top plan view an architrave connector block. 
         FIG. 18  shows an end elevation view of the architrave connector block. 
         FIG. 19  shows an isometric view of the architrave connector block. 
         FIG. 20  shows a schematic view of architrave profiles cut square, with an outline of the architrave connector block. 
         FIG. 21  shows a schematic view of the architrave connector block fitting over the architrave profiles. 
         FIG. 22  shows an isometric view of  FIG. 20 . 
         FIG. 23  shows an isometric view of  FIG. 21 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features. 
       FIG. 1  shows a cross-section of a skirting profile  100  in accordance with a preferred embodiment of the present invention. The skirting profile  100  comprises a front face  110 , a top face  114  and a feature splay  112  that extends between the front face  110  and the top face  114 , which together form the exposed decorative contour  1   16  of the skirting profile  100 . A rear face  120  of the skirting profile  110  comprises upper and lower notches  140  which meet/engage the wall  132  in use. The notches  140  space the rear face  120  from the wall providing a rebate  130 , being a gap between the rear face  120  and the wall. 
       FIG. 2  shows the skirting profile  100  with the upper notch  140  removed (indicated as  150 ) from adjacent the top face  114  to form an opening to the rebate  130 . 
       FIG. 3  shows the skirting profile  100  at the junction of the wall  132  and floor  134  with connector piece  200 / 300  above, meeting with the skirting face  110 . The connector piece  200 / 300  is either an external corner connector piece  200  or internal corner connector piece  300  as further described below. 
     In use, the skirting profiles  100  are disposed at the junction between the wall  132  and the floor  134 . As shown in  FIGS. 15 and 16 , the connector pieces  200 / 300  are shaped to extend and cover the gap between skirting profiles  100  that are disposed substantially at 90° to each other. That is, skirting profiles  100  at internal and external corners of the wall. The connector pieces  200 / 300  are thus shaped to have a generally right angle shaped body. 
     Each connector piece  200 / 300  comprises a front portion  205 / 305  and a rear portion  215 / 315 . The front portion  205 / 305  comprises a front face  210 / 310 , an ornamental/decorative splay  212 / 312 , and a top face  214 / 314  which together form the exposed decorative contour of the connector piece  200 / 300 , and which matches the exposed decorative contour  116  of the skirting profile  100 . The front portion  205 / 305  comprises a substantially 90° angle/bend therein corresponding to the corner of the wall. 
     The rear portion  215 / 315  comprises an inserting tab  220 / 320  which extends downwardly from the top face  214 / 314 . The inserting tab  220  follows the shape of the front portion  205 / 305  and comprises a substantially 90° angle/bend therein corresponding to the corner of the wall. In end view, the inserting tab  220  comprises a curved lead  240  at its lower end portion that is slightly proud of the rebate  130 . That is, the curved lead  240  is biased towards the rear face  120 . 
     A cavity  235  is formed between the front portion  205 / 305  and the rear portion  215 / 315  which receives an end section of the skirting profile  100  in use. The inserting tab  220  is inserted and received in the rebate  130 . 
       FIG. 4  shows an end portion of a connector piece  200 / 300  partly engaged over the skirting profile  100  with front face of connector piece  210 / 310  fitting adjacent to the front face  110  of the skirting profile  100 . As the connector piece  200 / 300  is inserted from above, the inserting tab  220  flexes as the curved lead  242  is pressed against the rear face  120  of the skirting profile  100 . 
       FIG. 5  shows the connector piece  200 / 300  being fully installed over the skirting profile end section. The front portion  205 / 305  extends from the floor  134  and covers and tightly matches the exposed decorative contour of the skirting profile  100 . The pressure of the flexing of the inserting tab  242  provides positive engagement to hold the connector piece  200 / 300  tightly against the rear face  120  of the skirting profile. 
       FIG. 6  shows an enlarged detail of the curved lead inserting tab being in a natural state  240  (shown via dashed lines) and flexing  242  against the rebate  120 . 
       FIGS. 7 to 10  show the external corner connector piece  200 . 
       FIG. 7  shows a top sectional view of the external corner connector piece  200 , having strengthening ribs  230  between the front portion  205  and the rear portion  215 . The inserting tabs  220  have the curved lead  240  for easier inserting into the rebate. The extremities of the front face  210  are wider than the edges of the rear portion  215 , and contain leading edges  250  that are splayed inwardly to ensure the front face  210  of the connector piece is always in contact with the front face of the skirting profile  1   10  in use. 
       FIG. 8  is an overhead view of the external corner connector piece  200  having the front face  210 , the ornamental/decorative splay  212 , and the top face  214 . The angle of the corner of the front portion  205  is less than 90 degrees to accommodate walls that are not truly square. The front portion  205  has front face sections  210  facing in perpendicular directions away from each other. 
       FIG. 9  is an end view of the external corner connector piece  200  showing the inserting tab  220  with a curved lead  240 . The front face  210  and ornamental/decorative profile  212  are compatible to the profile of skirting  100 . The reinforcing rib  230  provides strength to the external corner connector piece  200 . The front portion  205  is dimensioned to cover the entire end section of the skirting profile  100  in use from the floor  134 . The rear portion  215  extends to a mid-portion of the rear face  120  of the skirting profile  100 . 
       FIG. 10  is an isometric view of the external corner connector piece  200  having the front face  210 , the ornamental/decorative face  212 , top face  214  and the leading edge  250 . Inserting tabs  220  incorporate a curved lead  240 . 
       FIGS. 11 to 14  show the internal corner connector piece  300 , which is similarly formed as the external corner connector piece  200 . The internal corner connector piece  300  however has a front portion  305  with front face sections  310  facing in perpendicular directions towards each other. 
       FIG. 11  shows a top sectional view of the internal corner connector piece  300 , having strengthening rib  230 . The inserting tabs  220  have a curved lead  240  for easier inserting into the rebate. The extremities of the front face  310  contain leading edges  250  that are splayed to ensure the front face  310  of the connector piece is always in contact with the front face of the skirting profile  110 . 
       FIG. 12  is an overhead view of the internal corner connector piece  300  having a front face  310  an ornamental/decorative splay  312 , and a top face  314 . The angle of the corner is more than 90 degrees to accommodate walls that are not truly square. 
       FIG. 13  is an end view of the internal corner connector piece showing the rear inserting tab  220  with a curved lead  240 . The front face  310  and ornamental/decorative profile  312  are compatible to the profile of skirting  100 . The reinforcing rib  230  provides strength to the external corner connector piece  300 . 
       FIG. 14  is an isometric view of the internal corner connector piece  300  having a front face  310 , an ornamental/decorative face  312 , top face  314  and a leading edge  250 . Inserting tabs  220  incorporate a curved lead  240 . 
       FIG. 15  shows an isometric view of an example assembly with an internal and external corner. The assembly comprises skirting  100  with cutting  160  that are not required to be accurate. At the top face  114 , the end sections are notched  150  to expose the rebate  130  for insertion of the inserting tabs  220  of the connector pieces  200 / 300 . The connector pieces  200 / 300  are inserted from above with the inserting tabs  220  and curved lead  240  providing a tight pressed fit against the front portion of the skirting profile  100 . 
       FIG. 16  shows an isometric view of installed skirting  100  with connector pieces  200 / 300  corresponding to the profile of the skirting. The profiles  210 / 310  tightly fit against the front face  110  of the skirting profile  100  via leading edges  250  of the connector pieces  200 / 300 . 
       FIGS. 17 to 19  shown an architrave connector block  400  which is generally a square block shape with perimeter walls  420  and a top face  410 . 
       FIG. 17  shows an overhead view of the architrave connector block  400  having an ornamental/decorative feature  412  incorporated into the top face  410 . The underside houses a recessed base  430  that is slightly higher than the perimeter walls  420 , and corner pod  440 . 
       FIG. 18  shows an end view of the architrave connector block  400  having a raised ornamental/decorative feature  412  extending from the top face  410 . A recessed base  430  has a rebate shape  422  that corresponds to the architrave profile, and is housed within the perimeter walls  420  and corner pod  440 . 
       FIG. 19  shows an isometric view of the architrave connector block  400  with clearer view of the recess  430  within the profile rebate  422 . The corner pod  440  and perimeter walls  420  are defined by the architrave profile  500 . The corner pod  440  also provides the cutting tolerance for the architrave. 
       FIG. 20  shows architrave profiles  500 , with front face  510  and decorative face  522  being square cut  530 , with outline of architrave connector block  400  shown as a dashed line. The distance ‘X’ between the architrave square cuts  530  and connector block  400  provides the cutting tolerance. 
       FIG. 21  shows architrave connector block  400  fitting over the architrave profile  500 , with the architrave cutting  530  being covered by the connector block  400 , eliminating the need for accurate cutting. 
       FIG. 22  is an isometric view of  FIG. 20  showing the architrave profiles  500  meeting at cuts  530 . 
       FIG. 23  is an isometric view of the connector block  400  fitted to the architrave profiles  500 , with rebate  422  corresponding to the decorative profile  522 . The corner pod  440  provides the cutting tolerance as the architrave profile sits within the recess. 
     Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described. 
     For example, decorative feature profiles can have any desired design, differently shaped features, size or thickness. Another variation having the decorative feature profile slightly recessed, with the corresponding connector pieces compatible 
     The skirting rebate is large and deep in depth and provides three advantages, it allows for the corner tab to slide behind the skirting, it provides clearance for the fastener head and allows for some material flex. The rebate also provides for tolerance if the wall and door jamb/window reveals are not perfectly in alignment. The rebate extends from adjacent the top face to adjacent the bottom face of the skirting and has a depth of at least 3 mm, preferably more than 5 mm. 
     The side leading edges  250  with a tapering in ensures the front face is the first most point of contact with the skirting face to eliminate gap between the two components. 
     The preferred embodiment in one aspect provides a skirting and architrave installation system comprising:
         a skirting rear profile with increased rebate,   an external corner skirting connector piece,   an internal corner skirting connector piece, and   an architrave connector block       

     Preferably, the rear profile rebate of the skirting is of sufficient depth to allow for space to house the inserting tab of the skirting connector pieces. 
     Preferably, the front surface or feature profile of the skirting can be of any ornamental design or decoration. 
     Preferably, the profile of the connector pieces corresponds to any ornamental design or decoration of the skirting feature profile. 
     Preferably, the skirting connector pieces are of a material that allows for slight deflection to conform to the angle of the corners, if the corners are not truly square. 
     Preferably, skirting connector pieces comprise of rear inserting tabs that lock between the skirting rear profile rebate and the building wall. 
     Preferably, each of the inserting tabs have a curved front surface that guides the connector piece in between the rear face of the skirting and wall. 
     Preferably, each of the inserting tabs is capable of flexing as the connector piece is inserted into the space between the rear of the skirting and the wall. 
     Preferably, the overall architrave connector block is slightly larger than the architrave profile, with an inner wall thickness that corresponds exactly to the size of the architrave profile. 
     Preferably, the inner wall thickness of the architrave connector block fits directly over the corresponding architrave profile for a tight connection. 
     Preferably, the architrave connector block houses a rebate profile that corresponds to a compatible architrave profile. 
     The embodiments provide a skirting and architrave installation system that uses pre-finished materials, and incorporates internal and external corner connector pieces to eliminate the need for accurate cutting and joining, thus allowing for quicker and easier installation. The top of the skirting is notched at the ends to receive the inserting tabs of the connector pieces, which are inserted from above the skirting. The inserting tabs have a curved lead that flexes between the wall and rear of skirting, providing a tight friction fit without the need for any nailing or adhesives. The outer most ends of the connector pieces have leading edges that are always in contact with the front face of the skirting profile. Architrave connector blocks incorporate a rebate to provide a cutting tolerance to the architrave profile which frame doors and windows, thus eliminating the need for tradesmen to skilfully install skirtings and architraves 
     The embodiments also provide a skirting and architrave installation system that comprises of:
         Skirting rear profile with depth of rebate,   External corner connector piece with rear inserting tabs,   Internal corner connector piece with rear inserting tabs,   Architrave connector block with profile rebates.       

     Preferably, the depth of rebate at the rear face of the skirting is such to accommodate the rear inserting tab of corresponding connector piece profiles. 
     Preferably, the internal and external corner connector pieces are inserted from above the skirting and incorporate rear inserting tabs with a curved sector that flexes to provide a tight friction fit between the wall and the rear face of the skirting. 
     Preferably, the outer most ends incorporate leading edges to ensure the outer most ends always are in contact with the front face profile of the skirting profile. 
     The embodiments also provide a skirting and architrave installation system that incorporates rebates within the architrave connector block that correspond with the architrave profile thus providing a cutting tolerance. 
     The embodiments also provide a skirting and architrave installation system that allows for quicker and simpler installation by eliminating the need for skilled tradesmen to accurately measure, cut and install skirting and architraves. 
     Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described. 
     The rear portion engagement means for engaging the rear surface of the skirting profile for example can comprise other shapes or other forms, such as a resilient metal or plastic clip or arm.