Patent Abstract:
An apparatus and method for covering a corner with trim includes a trim section. The trim section includes a resilient corner section having, a first and second generally-planar surfaces intersecting at an angle on the back of the resilient corner section and first and second tabs having a cross-sectional thickness less than a cross-sectional thickness of the corner section. The method for installing a molding system includes mounting the corner piece of trim to a wall corner defined by two walls intersecting at an angle with respect to each other and mounting a tab associated with the corner piece or trim to the wall, wherein an angled corner defined by the walls is covered by the corner piece of trim, and the angled corner is fitted to a surface on the corner piece of trim complementing the angled corner.

Full Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to molding (often referred to as trim or wall base) that is located at the base of interior walls. More particularly, the present invention relates to a corner section of trim and a method for attaching it to a corner defined by two interior walls, the corner section may be used in accordance many types of wall base as well as a stackable trim molding system where the molding is made of a resilient man-made material.  
       BACKGROUND OF THE INVENTION  
       [0002]     Molding (or trim) is often placed at a base section of a wall, where the wall meets the floor. The molding receiving proposed modifications and improvements is commonly referred to as wall base, cove base, base board, base molding, mop board, trim, and/or skirting. Molding is used whether a floor be hardwood, carpet, or resilient flooring to provide a transition between the wall and the flooring. The trim can provide several useful functions. For example, if the wall is painted, the painting can extend to nearly the floor and then be covered by trim creating a clean, crisp line between the trim and the paint. The same can be true for when the wall is wallpapered. However, if a wall is to be repainted, to achieve a crisp line between the end of the wall, the trim must be taped prior to painting, a slow and steady approach to carefully painting the wall but not contacting the trim must be adopted or the trim must be removed before the paint is applied. These methods are laborious. In the case of removing the trim, often the act of removing the trim causes it to be destroyed, and new trim must be applied after the wall is repainted. These methods can be time-consuming and costly.  
         [0003]     Other problems with existing trim is that the trim is susceptible to damage. For example, often trim is made of wood, which can crack or break, or be gouged which necessitates the trim being repaired or replaced. Another problem associated with trim is that if a floor surface is to be replaced, whether it be replacing the carpet, or adding carpet over an uncarpeted floor, or any other type of floor replacement, often the trim must be replaced. The trim often needs replacement because the new flooring will have a different height than the old flooring, or the act of removing the flooring will cause the trim to crack and break. Wood trim can be expensive and labor intensive to be treated whether by painting or being stained, or otherwise given a surface treatment in order to preserve the wood. Further, wood trim must be machined in order to give the trim contours such as beveled edges or other contours that are often desirable. The need to work the wood trim of course, can increase its costs.  
         [0004]     Another problem encountered when installing trim systems is how to apply a wall base to a corner defined by the intersection of two walls. The problem is compounded by the fact that corners can be inside or outside corners, and each type of corner must be dealt with differently.  
         [0005]     Currently, when wall base or other trim is installed at a location having a corner, a variety of methods are employed. Some methods require cutting and fitting on site where the installers, giving the primary responsibility of altering some of the existing base material to create the corner. This usually ends up with mixed results, depending upon the experience and ability of the particular installer.  
         [0006]     In some of these cases, the wall base material is grooved on the back and wrapped around the corner where the point of the corner coincides with the groove. In this instance, some portions of the wall base may be permanently distorted and sometimes discolored at the apex of the corner due to stress on the wall base material.  
         [0007]     In many cases, the resilient wall base inherently is biased to return to a straight position. This biasing feature of the wall base may result in the base pulling away from the wall when bent around a corner and, leaving an unsightly gap.  
         [0008]     Recently, the marketplace has seen an increase of resilient base material that is too thick for either of these installation methods. In such an instance, an installer is required to miter cut and fit the wall base on site. In many cases, this requires the abilities that may be outside the realm of many flooring and trim installers.  
         [0009]     In some instances, corner blocks or other factory-produced materials are used to cover corners. This approach can result in a dissimilar material used at the corner that does not match the wall base material. The corner blocks may be rigid and may be prone to be knocked loose by pedestrian traffic or floor maintenance equipment.  
         [0010]     Accordingly, it is desirable to provide a trim molding system and method that can overcome some of the problems associated with traditional trim systems. For example, it would be desirable to provide corner pieces for use in a trim system to alleviate the need for installers to spend significant time and effort to customized wall base or other types of trim at corners. Further, it would be desirable to provide corner pieces of trim to give a finished, good workmanship type appearance at corner installations.  
       SUMMARY OF THE INVENTION  
       [0011]     The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus and method is provided to provide corner pieces for use in a trim system to alleviate the need for installers to spend significant time and effort to customized wall base or other types of trim at corners. An aspect of some embodiments of the invention is to provide corner pieces of trim to give a finished, good workmanship type appearance at corner installations.  
         [0012]     In accordance with one embodiment of the present invention, a trim section is provided. The trim section includes: a resilient corner section having a front and back; a first and second generally planer surfaces intersecting at an angle on the back of the resilient corner section; and first and second tabs connecting to the resilient corner section having a cross sectional thickness less than a cross sectional thickness of the corner section.  
         [0013]     In accordance with another embodiment of the present invention, a method for installing a molding system is provided. In some embodiments of the invention, the method includes: mounting the corner piece of trim to a wall corner defined by two wall intersecting at an angle with respect to each other; and mounting a tab associated with the corner piece of trim to a wall, wherein an angled corner defined by the walls is covered by the corner piece of trim and the angled corner is fitted to a surface on the corner piece of trim complimenting the angled corner.  
         [0014]     In accordance with yet another embodiment of the present invention, a trim section is provided. The trim section includes: a resilient corner section; a first and second generally planer surfaces intersecting at an angle on the corner section; and means for securing the resilient corner section to a wall, wherein the means for securing the resilient corner section to a wall forms a substantially planner surface with the at least one of the first and second generally planer surfaces.  
         [0015]     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
         [0016]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
         [0017]     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]      FIG. 1  is a perspective view illustrating a resilient trim system and covering apparatus for an inside corner according to an embodiment of the invention.  
         [0019]      FIG. 2  is a top view of a resilient corner section.  
         [0020]      FIG. 3  is a side view of the resilient corner section shown in  FIG. 2 .  
         [0021]      FIG. 4  is a rear view of the resilient corner section shown in  FIG. 2 .  
         [0022]      FIG. 5  is a perspective view illustrating a resilient trim system and cornering apparatus for an outside corner, according to an embodiment of the invention.  
         [0023]      FIG. 6  is a top view of a resilient corner section for an outside corner.  
         [0024]      FIG. 7  is a side view of the resilient corner section shown in  FIG. 6 .  
         [0025]      FIG. 8  is a rear view of the resilient corner section shown in  FIG. 6 .  
     
    
     DETAILED DESCRIPTION  
       [0026]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.  
         [0027]     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides an apparatus and method for covering a corner with a resilient base (trim) using a corner piece of wall base. Some embodiments of the invention may be useful for covering an outside corner and other embodiments of the invention may be useful for covering an inside corner.  
         [0028]      FIGS. 1-4  illustrate one embodiment of the invention that includes a corner piece  12  configured for attaching to an inside-type corner. The term, “inside”, refers to the fact that corner piece  12  is fit inside a space defined by the corner as shown in  FIG. 1 .  FIGS. 5-8  will illustrate another embodiment of the invention where a corner piece  12  is fit to an outside corner. The term, “outside corner”, refers to the fact that the corner piece  12  is placed in a space outside of the corner defined by the walls  20 ,  22  as shown in  FIG. 5 . In addition, corners having angles of less than equal to and greater than 90° may be covered using apparatus described herein.  FIGS. 1-4  will be explained first and then  FIGS. 5-8  will be explained.  
         [0029]     An embodiment of the present inventive apparatus is illustrated in  FIG. 1 .  FIG. 1  illustrates a resilient (flexible) molding system  10 . A flexible molding system  10  shown in  FIG. 1  includes a corner piece  12 , a wall base  14 , a base shoe  16 , and a top trim piece  18 . The flexible molding system also includes an adhesive  19  which adheres the flexible molding system to walls  20 ,  22 . The flexible molding system  10  is attached to the base of the walls  20 ,  22 , and is adjacent to and sits upon a floor  24 .  
         [0030]     The corner piece  12  is suited to be used with elements of a flexible molding system and method as shown and described in U.S. patent application Ser. No. 10/991,502, titled Stackable Trim Molding System and Method, filed Nov. 19, 2004, which is incorporated herein by reference in its entirety. However, the corner piece  12 , or other apparatus and methods in accordance with the invention are suitable for use with other trim systems, molding systems and wall base systems and are in no way limited to specific systems described in the application mentioned above.  
         [0031]     As shown in  FIG. 2 , the corner piece  12  includes a main section  26 . The main section  26  has a front  28  and a back  30 . For the purposes of this document, the term “front”  28  refers to the part of the corner piece  12  that will be exposed when the corner piece  12  is installed at a corner, and the back  30  is the part of the corner piece  12  that will be butted up against and adhered to the walls  20 ,  22 , defining the corner.  
         [0032]     On the back  30  of the corner piece  12 , is a first surface  32  and a second surface  34 . The first and second surfaces  34  intersect with each other in some embodiments at substantially a right angle. Because the corner piece  12  is flexible and resilient, it may accommodate corners where the walls  20  and  22  do not meet to form a right angle. However, if the angle varies too far from a 90° angle, then corner pieces  12  may be manufactured where the first  32  and second surface  34  come together at a different angle to accommodate a corner having an obtuse or acute angle defined by the walls  20 ,  22 .  
         [0033]     The first surface  32  and the second surface  34  are generally flat although they may include ridges or grooves, be scored, or have other type of surface phenomena in order to provide a desired surface for facilitating adhesion of an adhesive  19  between the corner piece  12  and the walls  20 ,  22 .  
         [0034]     A first tab  36  and second tab  38  are located on and attached to the corner piece  12 . The first tab  36  is attached to the main section  26  of the corner piece  12  to provide a generally continuous surface with the first surface  32 . Likewise, the second tab  38  is attached to the main section  26  of the corner piece  12  to provide a generally continuous surface with the second surface  34 . Again, the tabs  36  and  38  may include grooves or ridges, scoring any other surface phenomena in order to facilitate adhesion to the walls  20 ,  22 .  
         [0035]     The front  28  of the main section  26  may be contoured in a decorative manner in order to enhance the visual appearance of the corner piece  12 .  
         [0036]      FIG. 3  is a side view of the corner piece  12  shown in  FIGS. 1-4 .  FIG. 3  illustrates the back  30  and front  28  sides of the corner piece  12 . Tabs  38  and  36  and the bottom surface  42  of the corner piece  12  are also visible in  FIG. 3 .  
         [0037]     In some embodiments of the invention, in order to size the corner piece  12  to a desired height, an installer may cut with a saw or other suitable means, the corner piece  12  near the bottom end  42 .  
         [0038]     Some embodiments of the invention include angled portions  40  of the tabs  38  and  36  as seen in  FIGS. 1, 3  and  4 . In some embodiments of the invention, angled portions  40  are used on the tabs  38 ,  36  to help in reducing the likelihood of a gap forming between a walls  20 ,  22  and a top piece  18  (or wall base  16  when top trim is not used) due to the tab  36  or  38  existing between top piece of trim  18  or wall base  16  and the walls  20 ,  22 . An unsightly gap may be avoided by connecting the top trim  18  directly to the walls  20 ,  22  without having, or at least minimally having a portion of the tab  36  in between the top trim  18  and the walls  20 ,  22 .  
         [0039]     Thus, the angled portions  40  are incorporated in some embodiments to reduce the likelihood of creating a gap between the top trim  18  (or wall base  14 ) and the walls  20 ,  22 .  
         [0040]     With reference now to  FIG. 4 , the back side  30  of the corner piece  12  is shown. As shown in  FIG. 4 , the first surface  32 , including a back surface of the tab  36 , creates a generally plainer surface, and is ready for application of an adhesive  19 .  
         [0041]     In some embodiments of the invention, the adhesive  19  may be a latex adhesive, similar to adhesives commonly used for installing other types of trim. Other ways of installing the corner piece  12  to a wall  20 ,  22  can include glue (perhaps factory applied) that can be applied to the back  30  of the corner piece  12 . The glue may be protected until installation by a removable release paper that is removed to expose the glue prior to installation. In other embodiments of the invention, a double-faced scrim-reinforced tape is used. The tape is carried on a release paper. It is attached to the back  30  of the corner piece  12 , then the paper is removed, and the corner piece  12  is placed where desired.  
         [0042]     In other embodiments of the invention, the corner piece  12  may be adhered to the walls  20 ,  22  by use of any suitable adhesive or fastener in accordance with the present invention. As shown in  FIGS. 1 and 5 , mechanical fasteners  39  may also be used. Mechanical fasteners can include nails, screws, staples or any other mechanical-type fastener. Mechanical fasteners  39  may extend through the tabs  36 ,  38  and through the walls  20 ,  22  to attach the corner piece  12  to the walls  20 ,  22 . Some embodiments of the invention may include adhesives and mechanical fasteners. Optionally, the corner piece may be fastened to the floor  24  (see  FIG. 1 ) by adhesive and/or mechanical fastener.  
         [0043]      FIG. 5  is an illustration of an apparatus in accordance with one embodiment of the present invention where a corner piece  12  is fitted to an outside corner defined by walls  20 ,  22 . The corner piece  12  has a front side  28  and a back side  30 . The back side  30  attaches to a corner defined by two walls  20 ,  22 , as shown.  
         [0044]     Attached to the corner piece  12  are a first tab  36  and a second tab  38 . The tabs  36  and  38  are connected to walls  20 ,  22 , respectively. The tabs  36 ,  38  may be connected to the walls  20 ,  22 , by an adhesive  19  such as those described above, or by mechanical fasteners  39  as previously described. An adhesive may also be applied to the main section  26  of the corner piece  12  as well as the tabs  36 ,  38 . A wall base  14  is adhered to a wall  20  and butts up against the main section  26  of the corner piece  12 . Optionally, a base shoe  16  is located below the wall base  14 .  
         [0045]     In some embodiments of the invention, the base shoe  16  may include a carpet notch  46  which permits carpet to be placed in the notch  46  in order to provide a smooth transition between carpet and the base shoe  16 . An optional trim piece  18  is mounted above the wall base  14 . The top trim piece  18  abuts against the main section  26  of the corner piece  12 . The wall base  14 , the base shoe  16  and the corner piece  12  may be the same or different colors and have different contours in order to improve the aesthetic view of the trim system. The corner piece  12  may also be decoratively contoured and/or colored.  
         [0046]     The surface finish on the corner piece  12  wall base  14 , base shoe  16  and top trim  18  may be one that will permit paint to be applied to it.  
         [0047]     In some embodiments of the invention, the corner piece  12  is also equipped with a carpet notch  44  in order to allow carpet to be placed in the notch  44  to provide a smooth transition between carpet and the corner piece  12 . While the carpet notches  44 ,  46  are illustrated in embodiments where the corner piece  12  is adjusted to fit an outside corner, certainly carpet notches  44 ,  46  are not limited to such embodiments but may be also used in or be found in embodiments adapted for inside corners as well.  
         [0048]      FIG. 6  is a top view of the corner piece  12  according to an embodiment of the invention used for outside corners. The corner piece  12  includes a front side  28  that is rounded to soften the edges of the corner defined by the walls  20 ,  22 . On the back  30  side of the corner piece  12 , there is a first surface  32  and a second surface  34 , which are extended from the  26  by the first tab  36  and the second tab  38 .  
         [0049]      FIG. 7  is a side view of the corner piece  12  illustrated in  FIG. 6 . The front side  28  is visible in  FIG. 7 , and the front side of tab  36  is also illustrated. The angle portion  40  of tab  36  is shown descending from the main section  26  of the corner piece  12  to the end of tab  36 . The bottom surface  42  is substantially flat and configured to rest on a floor  24 , shown in  FIG. 5 .  
         [0050]      FIG. 8  is a rear view of the corner piece  12 , shown in  FIG. 6 . In the rear view, tabs  36 ,  38  are shown. The first surface  32  is shown to be substantially flat and contiguous with the back surface of tab  36 . Tab  38  is also illustrated and shows a substantially flat surface contiguous with the second surface  34 .  
         [0051]     The installation of a corner piece  12  will now be described according to some embodiments of the invention. In some embodiments of the invention, corner piece  12  is used as part of the system that includes a wall base  14 , an optional base shoe  16 , and an optional top trim piece  18 , as illustrated in  FIGS. 1 and 5 . An adhesive is applied to the back  30  of the corner piece  12 , particularly to the first and second surfaces  32 ,  34  (including back of the first and second tabs,  36 ,  38 ). Alternatively, the adhesive can be applied to the walls  20 ,  22 , and then the corner piece  12  can be fitted so that a corner defined by the walls  20 ,  22  fit around a corner defined by the intersection of the first and second surfaces  32 ,  34 , on the corner piece  12 . In some optional embodiments of the invention, mechanical fasteners may be used to secure the corner piece  12  in place. Any suitable method of securing the corner piece  12  in place is within the scope of the invention.  
         [0052]     In some embodiments of the invention, the corner piece  12  may be trimmed by cutting the corner piece to a desired size before its installation. In some embodiments of the invention, the corner piece  12  may be trimmed by cutting the bottom  42  of the corner piece  12 . In other embodiments of the invention, the corner piece can be trimmed at the top, and then the corner piece  12  can be applied to the walls  20 ,  22 , as described.  
         [0053]     Once the corner piece  12  is installed, an adhesive may be applied to the back part of the tabs  36 ,  38 , and then a wall base  14  can be applied as well as a base shoe  16  and top trim piece  18  (optionally the adhesive may be applied to the back of the wall base  14 , the optional base shoe  16  and optional top trim  18 ).  
         [0054]     In some optional embodiments of the invention, a carpet notch  44  may be found in the corner piece  12 . Carpet notches may also be found in some optional embodiments of the invention in the base shoe  16  or, alternatively, wall base  14 . In embodiments of the invention, which include carpet notches  44 ,  46 , the carpet notches provide a place for carpet to be located once the corner piece  12  and the base shoe  16  have been installed.  
         [0055]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Technology Classification (CPC): 4