AU2013100288B4 - Architectural moulding and method of joining same - Google Patents

Abstract

An improved architectural moulding 10 for use on a building construction is disclosed. The moulding 10 comprises a body 12 having a length defined by opposed peripheral ends 14, 16. The present invention resides in the inclusion of joining means 20 disposed at one or both of the peripheral ends 14, 16 which are useful for improving the structural integrity of a length of architectural moulding 10 composed of multiple individual mouldings 10 joined to one another. The joining means 20 comprises a recessed portion 40 defined at least in part by a rebate surface 12. In use the recessed portion 40 abuts a recessed portion 40 of an adjacent moulding 10 providing a volume for receiving a reinforcing element 42 and an adhesive filler 44 thereby bonding the adjacent mouldings 10 to one another.

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A INNOVATION PATENT (Original) APPLICATION NO: LODGED: COMPLETE SPECIFICATION LODGED: ACCEPTED: PUBLISHED: RELATED ART: NAME OF APPLICANT: Build Technologies Holdings Pty Ltd ACTUAL INVENTOR: Mr Matthew Valantine De Pledge ADDRESS FOR SERVICE: LORD AND COMPANY, Patent and Trade Mark Attorneys, of PO Box 530, West Perth, Western Australia, 6872, AUSTRALIA. INVENTION TITLE: "ARCHITECTURAL MOULDING AND METHOD OF JOINING SAME" DETAILS OF ASSOCIATED PROVISIONAL APPLICATION NO'S: Australian Provisional Patent Application Number 2012900998 filed on 13 March 2013 The following Statement is a full description of this invention including the best method of performing it known to me/us: TITLE "ARCHITECTURAL MOULDING AND METHOD OF JOINING SAME" TECHNICAL FIELD [0001] The present invention relates to an architectural moulding and a method of joining same for use on a building construction. BACKGROUND [0002] It is known in the art to use architectural mouldings, particularly cornices, to improve an aesthetic appearance of a building construction. Prior art architectural mouldings are made in a variety of cross sectional shapes and sizes and come in lengths having a uniform cross section along the length which are then installed by fixing adjacent lengths together and mounting them in position. [0003] Prior art methods of joining architectural mouldings together include the use or combination of adhesives and fixtures. Regardless of how well adjacent prior art architectural mouldings are joined together there always exists a visible seam indicating a line of connection between the two mouldings. The seam can be minimised through good craftsmanship including further finishing procedures and the use of putties, fillers and paints applied to the architectural mouldings in order to produce a seamless and aesthetic finish. [0004] Problems arise in the event of thermal expansion and contraction which causes adjacent architectural mouldings to move relative to one another and which results in unsightly cracks appearing along the seam or abutting edges of adjacent architectural mouldings over time. Cosmetic maintenance of such cracks can be carried out through patching up and painting however such maintenance requires time consuming and costly additional steps. 2 [0005] The present invention attempts to overcome at least in part the aforementioned disadvantages of previous architectural mouldings and methods of joining same. [0006] An object of the present invention is to provide an architectural moulding comprising a plurality of joined individual mouldings having an improved structural integrity. [0007] A further object of the present invention relates to an architectural moulding comprising a portion of reduced cross-sectional area for abutting and joining together with an adjacent and complementary architectural moulding. [0008] A further object of the present invention relates to a method of joining architectural mouldings to provide a seamless join between adjacent architectural mouldings. SUMMARY OF INVENTION [0009] In accordance with one aspect of the present invention there is provided an architectural moulding for use on a building construction, the architectural moulding comprises an elongate body having a longitudinal axis, the elongate body having a first peripheral end and an opposed second peripheral end and at least a portion having a profiled surface disposed between the first and second peripheral ends, wherein the elongate body comprises joining means disposed proximal at least one peripheral end. [0010] In accordance with a further aspect of the present invention there is provided a method of joining architectural mouldings in accordance with the present invention, the method comprising the steps of 1. Providing a rebate surface proximal at least one peripheral end of one or more architectural mouldings to be joined together. 3 2. Aligning the adjacent mouldings end to end such that a recessed portion is formed by the one or more rebate surfaces of abutting peripheral ends. 3. Applying a filler material to the recessed portion. 4. Shaping the filler material to conform with a profiled surface of the architectural mouldings. 5. Fitting the architectural moulding in place to the building construction. [0011] Preferably the joining means comprises a portion providing a rebate surface having substantially proportional dimensions to the profiled surface. [0012] Preferably the architectural moulding comprises a step of 0.5-10 mm from the profiled surface to the rebate surface. [0013] Preferably the joining means comprises a width of 50-100 mm. [0014] Preferably the step is disposed to run along a line orientated to be substantially perpendicular to the longitudinal axis of the architectural moulding. [0015] Preferably a reinforcing element is disposed across the abutting joining means of adjacent architectural mouldings which is used in combination with the filler material to improve a strength characteristic of the join. BRIEF DESCRIPTION OF DRAWINGS [0016] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a foam core used in the manufacture of an architectural moulding according to one embodiment of the present invention; Figure 2 shows a perspective view of a pair of foam cores in accordance with a preferred embodiment of the present invention; Figure 3 shows the foam cores of Figure 2 in an abutted position; 4 Figure 4 is a perspective view of a preferred embodiment of the present invention showing complementary first and a second architectural mouldings spaced apart; Figure 5 is a perspective view of the mouldings of Figure 4 with the joining means abutting one another; Figure 6 is a perspective view of the mouldings of Figure 4 showing a reinforcing element disposed across the adjacent joining means for connecting the first and the second architectural mouldings in accordance with the method of present invention; Figure 7 is a perspective view of the first and second architectural mouldings of Figure 6 bonded together; and Figure 8 is a schematic plan view of a plurality of joined architectural moulding having a mitred end configuration. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0017] Referring to the Figures 4-7, there is shown an architectural moulding 10 for use with a building construction in accordance with the present invention. The architectural moulding 10 comprises a body 12 having a longitudinal axis and a first and a second peripheral end 14, 16. The architectural moulding 10 is configured to provide a profiled surface 18 extending between the peripheral ends 14, 16. It should be understood that the profiled surface may take on any suitable configuration as desired for the aesthetic qualities of the building construction. [0018] As seen in Figure 4 two respective architectural mouldings 10 are shown next to one another with the body 12 of each moulding 10 further comprising joining means 20 disposed proximal to at least one peripheral end 14, 16. [00191 It should be understood that the present invention may provide an architectural moulding 10 having one joining means 20 as seen in Figure 4 or alternatively an architectural moulding 10 (not shown) may be provided having joining means disposed at both ends 14, 16. The configuration of the architectural moulding 10 may 5 be variable and should be considered in the context of the finished product. For example where an architectural moulding 10 is to be joined at both ends with other mouldings 10 it will be arranged to have joining means 20 disposed at each peripheral end 14, 16 whereas a moulding 10 to be joined at only a single end 14, 16 may only have provision of a single joining means 20. A moulding 10 may be joined to an adjacent moulding 10 using existing methods where a mitred configuration is required as seen in Figure 8 [0020] As seen in Figure 4, in a preferred embodiment of the present invention the joining means 20 comprises a rebate surface 22 connected to and separated from the profiled surface 18 by a step 24. Regardless of the shape of a profiled surface 18 provided on a moulding 10 it is preferable that the rebate surface 22 be configured to be substantially parallel with the profiled surface 18. Accordingly, the rebate surface 22 is substantially arranged to have the same cross sectional profile as the profiled surface 18, with the rebate surface 22 appearing as a telescopic extension of the profiled surface 18 having a reduced cross sectional dimensions but similar proportions. [0021] It is to be understood that the rebate surface 22 may have any configuration desired provided that it does not extend laterally beyond the profiled surface 18. As outlined above it is preferable and an advantage of the present invention for the rebate surface 22 and the profile surface 18 to be similar in shape to assist the finishing procedures after bonding adjacent mouldings 10 to one another. [0022] It is an advantage of the present invention that the joining means 20 provides a space in which a join having a greater depth and width than known joins can be realised. Accordingly, the structural integrity of a finished architectural moulding 10 according to the present invention is improved over prior art architectural mouldings. [0023] As seen in Figure 5 a preferred embodiment of the moulding 10 the step 24 comprises a wall 26 of between 0.5 to 10 mm in height and preferably the wall 26 is disposed at a substantial right angle to the longitudinal axis although other heights are 6 possible. Alternate embodiments may comprise different angles between the step 24 wall and the rebate surface 22. The rebate surface 22 may have any width 'w' however in order to provide adequate bonding between adjacent mouldings 10, it is envisaged a width between 50-100 mm is preferable to provide a sufficient recessed volume to adequately bond adjacent mouldings 10. [0024] Alternate embodiments may provide a rebate surface 22 that is arranged to extend between a peripheral end 14, 16 and the profiled surface 18. In this embodiment the rebate surface 22 will be arranged at an acute angle with respect to the profiled surface 18 and the peripheral end 14, 16 and providing a recessed portion 40 having a substantially triangular configuration. [0025] It is a further advantage of the present invention that the moulding 10 may have provision of joining means 20 having a greater length than outlined above and which may be cut to size according to a custom requirement. Thus a working length of the moulding 10 of the present invention can be varied by providing a moulding 10 comprising an elongate joining means 20 which can be shortened by trimming one or more of the peripheral ends 14, 16 in order to suit the building construction dimensions. [0026] It is envisaged the architectural moulding 10 of the present invention will be constructed from an expanded polystyrene (EPS) foam core 30 with a hardened polymer external coating 36. Typically the external coating 36 comprises a polyurethane or polymer modified cement material of a thickness preferably between 1 to 12 mm. As can be seen in the embodiment shown in Figures 1-3 the foam core 30 is shaped to provide a profiled surface 18 as required. In one embodiment of the present invention the joining means 20 begins as a separate foam end portion 32 which is similarly shaped to the profiled surface 18 before being adhered to one of the peripheral ends of the foam core 30. As outlined above (not shown) both peripheral ends 14, 16 of the foam core 30 may be fitted with joining means 20. 7 [0027] It should be understood that the mounting surfaces 34 of the architectural moulding 10, which are typically a planar surface, are not arranged to have a step 24 between the architectural moulding 10 body 12 and the joining means 20. [0028] During one method of manufacture the foam end portion 32 and the foam core 30 are bonded or mechanically fastened together with the mounting surfaces 34 arranged to be coplanar and the profiled surface 18 arranged to be parallel with the rebate surface 22 as shown in Figure 2. [0029] In a preferred method of manufacture of the moulding 10 all the shape features including the profiled surface 18, wall 26, step 24, rebate surface 22 and peripheral ends 14, 16 are manufactured from a single and integral foam core 30. This may be achieved during the actual manufacture of the moulding 10 or alternatively may by a subsequent machining process prior to application of the polymer surface coating 36. Accordingly, the preferred method of manufacture does not require separate foam end portions 32 (as shown in Figure 1) and thus does not require the additional steps of aligning and bonding the end portions 32 to the core 30. The preferred method of manufacture results in the end portions 32 and the joining means 20 being integral with the moulding 10. [0030] The architectural moulding 10 may then be covered with the polymer surface coating 36 giving the moulding 10 the desired mechanical strength characteristics required for use. Preferably the polymer surface coating 36 is consistent in thickness along the length of the architectural moulding 10 with the joining means 20 distinguished at the peripheral ends 14, 16 of the architectural moulding 10 by the rebate surface 22. [0031] In use, one or more architectural mouldings 10 are measured out for use on a building construction. The rebate surface 22 of the present invention is long enough to permit trimming of a peripheral end 14, 16 if necessary and as required. 8 [0032] Alternatively measurements may be taken on site or from plans and the required mouldings 10 manufactured to precise lengths with the rebate surface 22 included. [0033] Alternative embodiments of a moulding 10 may be cut on site or manufactured to comprise an end 14, 16 having a mitred configuration as seen in Figure 8 for abutting an adjacent mitred end 14, 16 to form a square corner as is known in the art. [0034] It should be understood that trimming the ends 14, 16 of a moulding 10 may remove a portion of the polymer surface coating 36 and expose a portion of the foam core 30. Mouldings 10 may be adhered together using an expanding foam material in a seam line 38 or between adjacent end portions 14, 16. As the ends 14, 16 are joined with other mouldings 10 peripheral ends 14, 16 the finished product will have no exposed foam core 30. [0035] Once a correct length is determined the architectural mouldings 10 are typically arranged in longitudinal alignment with the mounting surfaces 34 co planar and the joining means 20 of respective mouldings 10 abutting as seen in Figures 5 and 6. A recessed portion 40 is formed on either side of the seam line 38 formed as the mouldings 10 are abutted. Preferably a reinforcing element 42 such as an alkaline resistant woven fibreglass mesh of any mesh size or gauze for example is laid into the recessed portion 40 and then as seen in Figure 7 the recessed portion 40 is filled with an adhesive filler material 44 such as a two part epoxy resin or other equivalent filler material as is known in the art including acrylic cement modified fillers. [0036] The filler material 44 is allowed to set and subsequently sanded back to conform with the profiled surfaces 18 of the respective mouldings 10 providing a continuous and seamless profiled surface 18 extending along the joined mouldings 10. The joined architectural mouldings 10 may then be lifted into position and fixed in place by known means. 9 [0037] In some instances the length of the joined architectural mouldings 10 may have an end to end finished length of 10 meters or more making them awkward to handle. In such cased the individual mouldings 10 may be separately fitted into position on a building construction by known means. Once in position the reinforcing element 42 and the filler material 44 may be applied to the respective mouldings 10 recessed portion 40 and allowed to set thereby. Final shaping and painting of the moulding 10 may then be performed. [0038] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. 10

Claims (5)

1. An architectural moulding, for use on a building construction, the architectural moulding comprises an elongate body having a first peripheral end and a second peripheral end, the elongate body further comprises a portion having at least a profiled surface, and joining means disposed proximal at least one peripheral end, wherein the joining means provides a recessed portion defined at least in part by a rebate surface, wherein the recessed portion is configured to run substantially transverse to a length of the elongate body.

2. An architectural moulding according to claim 1 wherein the profiled surface substantially comprises the joining means, the rebate surface being spaced apart from, and connected to the profiled surface by a step.

3. An architectural moulding according to claim I or claim 2, wherein the rebate surface is a least in part substantially parallel with the profiled surface.

4. An architectural moulding according to any one of the preceding claims, wherein the rebate surface has a width of between 10 - 100 mm.

5. A method of joining a first architectural moulding to an adjacent second architectural moulding, each architectural moulding comprising an elongate body spacing apart and connecting together a first peripheral end and a second peripheral end, the method comprising the steps of: Arranging the first and second architectural mouldings such that a peripheral end of the first architectural moulding abuts with a corresponding peripheral end of the adjacent second architectural moulding; Providing a recessed portion disposed at one or more of the abutting peripheral ends, wherein the recessed portion is configured to run substantially transverse to a length of the elongate body; Filling the recessed portion with a filler and/or adhesive material thereby joining the first and second architectural mouldings together. 11