US20070234661A1 - Multi piece curved moldings - Google Patents

Multi piece curved moldings Download PDF

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Publication number
US20070234661A1
US20070234661A1 US11/307,081 US30708106A US2007234661A1 US 20070234661 A1 US20070234661 A1 US 20070234661A1 US 30708106 A US30708106 A US 30708106A US 2007234661 A1 US2007234661 A1 US 2007234661A1
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Prior art keywords
curved
hinge
wafer
abutting
molding
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US11/307,081
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Ed Vaes
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Ed Vaes
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Priority to US64741705P priority Critical
Priority to US59479605P priority
Application filed by Ed Vaes filed Critical Ed Vaes
Priority to US11/307,081 priority patent/US20070234661A1/en
Publication of US20070234661A1 publication Critical patent/US20070234661A1/en
Abandoned legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/006Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings of curvilinear outline
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/06Interconnection of layers permitting easy separation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/12Uniting ornamental elements to structures, e.g. mosaic plates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/04Borders; Finishing strips, e.g. beadings; Light coves for use between floor or ceiling and wall, e.g. skirtings
    • E04F19/0495Plinths fixed around wall openings or around corners of walls
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/05Separate connectors or inserts, e.g. pegs, pins, keys or strips
    • E04F2201/0594Hinge-like connectors

Abstract

The present invention is a multi piece curved molding including at least two curved sections adapted to butt together at an abutting joint. It further includes a flexible hinge for connecting the curved sections together at the joint for operably folding and unfolding the curved sections. Preferably it also includes a wafer for connecting two abutting curved sections at an abutting joint.

Description

  • This application claims priority from previously filed U.S. Provisional Applications, first application, Application No. 60/647,417 filed Jan. 28, 2005, titled: FOLDABLE MOLDINGS, Applicant: Ed Vaes. Second Application, Application No. 60/594,796 filed May 6, 2005, titled: FOLDABLE MOLDINGS, Applicant: Ed Vaes.
  • FIELD OF THE INVENTION
  • The present invention relates to curved moldings and more particularly relates to multi piece curved moldings, collapsible multi piece curved moldings and methods of joining curved molded sections.
  • SUMMARY OF INVENTION
  • Referring now to FIGS. 41 through 44 which depict prior art curved moldings which are also known in the art as arched sections which typically are used for trimming around windows and doorways, both interior and exterior applications and in various other applications requiring trim moldings.
  • Currently today arched molding sections are generally manufactured in one piece. FIG. 41 depict a typical prior art curved molding section known as laminated arch 502 in which numerous wood strips 504 are jointed together with glue joints 507 to form a glued arch 508 having a cross section appearance as in 506. This is a one piece solid wood arch which is made out a number of wood strips 504. The profile is then milled into one surface of the glued arch 508. The reader will note that this a highly labour intensive, slow and expensive process.
  • The other prior art arch, method of making curved moldings and arches is shown as block arch 510 which is made out of a number of wood blocks 512 which are glued together at glue joints 514. Once the wood blocks have been securely glued together, an arch. is milled out of the wood block section, creating milled arch 516 shown in dashed lines in FIG. 43. Curved moldings are also milled out of fibre board, plywood, particle board and other composite materials. In each case the arch or curved molding is a one piece construction.
  • The other type of prior art curved molding and/or arched sections which is commercially available is a rubber molding 520 shown in FIG. 44. This is a semi-flexible continuous piece of a vinyl rubber type material which can be applied as a curved molding or arch. The reader will appreciate that this type of molding is not suitable, when a natural wood finish is desired. In addition the installation of the rubber molding 520 shown in FIG. 44 is limited to over a very narrow temperature range and therefore, it difficult to use this type of rubber moldings under certain conditions, particularly in cold weather for exterior applications.
  • Historically the difficulty with the one piece curved molding or arch construction shown in FIGS. 41 to 43 is storing and transporting the large cumbersome curved molding arch sections. In particular, breakage and damage does occur frequently in storage or transport which is undesirable. Secondly on installation, these arches have very little to no flex or give to them which makes it difficult to install them particularly if the arch way which has been pre-constructed or roughed in by previous carpenters is not perfectly matched to the arch section that has been milled.
  • In regard to the laminated arch 502, the laminating lines can be seen which is undesirable in natural wood type constructed curved moldings or arches.
  • Therefore, there is a need for a curved molding and/or arch system which can be shipped in sections and/or preferably is collapsible and can be shipped in a compact form and then placed into an extended position in which the arch is ready for installation. There is also a need for a method of attaching smaller curved sections together so that the connection of these curved sections can be accomplished at the job site thereby enabling the manufacturer to ship the curved moldings and/or arch section in smaller pieces.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The invention will now be described by way of example only with reference to the following drawings in which:
  • FIG. 1 is a top plan view of the present invention, foldable molding.
  • FIG. 2 is a side elevational view of the present invention, multi piece curved molding shown in FIG. 1.
  • FIG. 3 is a bottom plan view of the present invention, multi piece curved molding.
  • FIG. 4 is a side elevational view of the multi piece curved molding shown in FIG. 3.
  • FIG. 5 is a top plan view of two curved sections butting each other.
  • FIG. 6 is a side elevational view of the curved section shown in FIG. 5.
  • FIG. 7 shows the two curved sections in the folded position as well as in the partially foldable positions in dashed lines.
  • FIG. 8 is a top plan view of an alternate embodiment of the present invention, multi piece curved molding.
  • FIG. 9 is a side elevational view of the multi piece curved molding shown in FIG. 8.
  • FIG. 10 is a bottom plan view of the second embodiment of the present invention, multi piece curved molding.
  • FIG. 11 is a side elevational view of the multi piece curved molding shown in FIG. 10.
  • FIG. 12 is a bottom plan view of two curved sections of the multi piece curved molding shown in FIG. 8 with the elastic hinge shown in the stretched position.
  • FIG. 13 is a side elevational view of the multi piece curved molding shown in FIG. 12.
  • FIG. 14 shows two curved sections of the multi piece curved molding in a folded position as well as in partially folded positions in dashed lines.
  • FIG. 15 is a top plan view of a third embodiment of the present invention, the multi piece curved molding.
  • FIG. 16 is a side elevational view thereof.
  • FIG. 17 is a bottom plan view of the third embodiment of the present invention.
  • FIG. 18 is a side elevational view thereof.
  • FIG. 19 is a side elevational view of the third embodiment, multi piece curved molding shown in the extended position.
  • FIG. 20 is a side elevational view of the third embodiment of the multi piece curved molding shown in the partially folded position.
  • FIG. 21 is a side elevational view of the third embodiment of multi piece curved molding shown in the more partially folded position.
  • FIG. 22 shows the third embodiment of the multi piece curved molding in the closed position.
  • FIG. 23 shows the third embodiment of the present invention, multi piece curved molding shown in the folded position within the interior of a shipping box.
  • FIG. 24 is a top plan view of a fourth embodiment of the present invention, multi piece curved molding.
  • FIG. 25 is an end view of FIG. 24.
  • FIG. 26 is a side elevational view thereof.
  • FIG. 27 is a top plan view of the other half of the fourth embodiment of the present invention, multi piece curved molding.
  • FIG. 28 is an end view thereof.
  • FIG. 29 is a side elevational view thereof.
  • FIG. 30 is a top plan schematic assembly view of the fourth embodiment of the present invention, multi piece curved molding.
  • FIG. 31 is a side elevational view thereof.
  • FIG. 32 is a top plan view of the left half of the fourth embodiment of the present invention, multi piece curved molding.
  • FIG. 33 is aside perspective view of multi piece curved molding in the folded position.
  • FIG. 34 is a side elevational view of foldable molded in the folded position.
  • FIG. 35 is a side elevational view of flexible hinge.
  • FIG. 36 is a side elevational view of flexible hinge in a partially folded condition.
  • FIG. 37 is a top perspective view of flexible hinge.
  • FIG. 38 is a bottom perspective view of flexible hinge.
  • FIG. 39 is a side perspective view of flexible hinge in the partially folded condition.
  • FIG. 40 is an elevation view of a window opening shown in a wall together with a piece of graph paper taped thereon for drawing of a framed outline.
  • FIG. 41 is an elevated plan view of a prior art one piece laminated arch.
  • FIG. 42 is a cross sectional view of the laminated arch shown in FIG. 41.
  • FIG. 43 is a prior art one piece block arch.
  • FIG. 44 is a perspective schematic view of a prior art one piece rubber molding arch.
  • FIG. 45 is a perspective schematic view of a wafer shown in exploded fashion.
  • FIG. 46 is a schematic perspective view of the assembled wafer.
  • FIG. 47 is a schematic perspective view of the assembled wafer showing the peel off back coming off.
  • FIG. 48 is a schematic perspective view of the wafer showing the transverse and longitudinal direction.
  • FIG. 49 is a side elevational view of the wafer which has been distorted and or displaced in the longitudinal direction.
  • FIG. 50 is a schematic perspective view of the wafer shown compressed.
  • FIG. 51 is a side elevational view of the wafer shown compressed.
  • FIG. 52 is a partial cut away assembly view of two curved sections together with a wafer shown mounted in recessed wafer pockets.
  • FIG. 53 is a schematic perspective view of the wafer showing the peel off backing being taken off prior to being placed into a recessed wafer pocket.
  • FIG. 54 is a schematic perspective view showing the wafer installed on a recessed wafer pocket.
  • FIG. 55 is a schematic perspective view of a wafer.
  • FIG. 56 is a top plan view of a curved section together with a wafer installed in one end and showing the recessed wafer pocket in the other end.
  • FIG. 57 is a schematic perspective view of a curved section showing wafers being installed in recessed pockets in both ends of a curved section.
  • FIG. 58 is a schematic perspective view of a multi layered hinge in exploded fashion.
  • FIG. 59 is a schematic perspective view of multi layered hinge shown in an assembled fashion with the peel off backing shown partially pulled back.
  • FIG. 60 is a perspective schematic view of a flexible hinge.
  • FIG. 61 is a top plan view of a curved section showing hinge pockets at each abutting end.
  • FIG. 62 is a schematic perspective view of curved section showing a hinge installed in a hinge pocket on the left side.
  • FIG. 63 is a curved molding and/or arch section showing four curved sections connected together with flexible hinges on the left side and right side and a wafer in the middle.
  • FIG. 64 is a side elevational view of the arch shown in 63, wherein the curved sections on each end are in the partially folded position.
  • FIG. 65 shows the arch in FIG. 62 in front elevational view in the extended position.
  • FIG. 66 shows the arch shown in FIG. 63 in the folded position.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • FIGS. 1 through 7 depict the first embodiment of the present invention, multi piece curved molding shown generally as 100. Multi piece curved molding 100 includes the following major components, namely molding 102 having a molding profile 110, which is comprised of curved sections 104, separated by abutting joints 106 at abutting ends 107 and attached together with a flexible hinge 108. Molding 102 has a top surface 112 and a bottom surface 114 and defines an inner radius 116 and an outer radius 118 as depicted in FIG. 1. Multi piece curved molding 100 is shown in the extended position 150 in FIGS. 1, 2, 3, 4, 5 and 6 and can be folded from the extended position 150 to the folded position 120 as shown in FIG. 7, wherein abutting or adjacent curved sections 104 are folded onto each other in the manner shown in FIG. 7. In folded position 120 one of the curved sections 104 is pivoted through partially folded positions 122 as shown in dashed lines in FIG. 7, until two curved sections 104 are folded onto each other into folded position 120. Flexible hinge 108 shown in FIG. 6 and also FIGS. 2 and 3, hold abutting curved sections 104 together when in the extended position. By physically rotating one curved section 104 towards the other curved section 104 as shown in FIG. 7, flexible hinge 108 is put into the folded flexible hinge position 124 shown in FIG. 7.
  • A second embodiment of the present invention is shown as Multi piece curved molding 200. Multi piece curved molding 200 includes the following major components, namely molding 202, curved sections 204, elastic hinge 206. Elastic hinge 206 in FIGS. 8, 10 and blown up in FIG. 12 is shown in the stretched position 230, wherein the abutting curved section 204 are pulled apart in lateral direction 218, thereby stretching elastic hinge 206 into the stretched position 230. In stretched position 230, a gap 207 results between abutting curved sections 204 and by rotating or folding adjacent curved section 204, one can place the abutting curved sections 204 into the outside folded position 220 as show in FIG. 14. As one rotates curved section 204, they rotate through partially folded positions 222 until it is entirely in the outside folded position 220. The curved section 204 is rotated along fold direction 240 as shown in FIG. 14. Molding 202 has a mold profile shown as 210 in cross-sectional view.
  • Yet a third embodiment of the present invention, a Multi piece curved molding as shown generally as 300 includes the following major components, namely molding 302, curved sections 304, flexible top hinge 308, flexible bottom hinge 309. Molding 302 has a molding profile 310 and adjacent curved sections 304 abut each other at abutting joints 306.
  • The third embodiment, Multi piece curved molding 300 is shown in the extended position 350 in FIG. 19 is shown in a partially folded position 352 in FIG. 20 and a more partially folded position 354 in FIG. 21.
  • The third embodiment, namely Multi piece curved molding 300 is shown in the completely accordion folded position 356 in FIG. 22 and wherein the molding in the accordion folded position 356 is shown packaged within a box 360 schematically in FIG. 23. By using a flexible top hinge 308 and flexible bottom hinge 309, in alternating sequences shown in FIG. 19, one is able to fold the Multi piece curved moldings 300 from the extended position 350 to the accordion folded position 356 in accordion style as shown in sequence in FIGS. 19 through 22.
  • A person skilled in the art will note that difficulty with producing curved moldings as shown in 102, 202 and 302 is the problem with packaging and shipping large curved molding pieces without having them damaged in transit. In order to overcome the transit and damage problem, it is desirable that one is able to fold molding 102, 202 or 302 into a box 360 as depicted in FIG. 23 in order to provide for a more compact shipping container and also to ensure that damage to the contents of the container are minimized.
  • In order to be able to fold moldings 102, 202 and 302, various solutions have been depicted and described above, including using flexible hinge 108 shown in the first embodiment using the elastic hinges 206 as shown in the second embodiment and/or using top and bottom flexible hinges 308 and 309 as shown in the third embodiment. In this manner by simply pivoting or folding adjacent curved sections 104, 204 or 304 onto each other, one is able to reduce the size of the curve molding for shipping purposes.
  • The recipient of the package will receive molding 102, 202 or 302 in the folded position 120, outside folded position 220 or accordion folded position 356 and the end user simply needs to unfold the folded curved sections into the extended positions wherein the curved sections abut each other at the abutting joints as depicted in FIGS. 1, 8 and 15.
  • Flexible hinges allow one to fold adjacent curved sections so that they fold onto each others backside 114 as depicted in FIG. 7. By utilizing an elastic hinge, one is able to fold adjacent curved sections onto their front side as shown in FIG. 14. By utilizing a series of elastic and/or flexible hinges as shown in FIG. 15, one can fold curve molding in accordion style onto front side and backside surfaces as depicted in FIGS. 19 through 22.
  • A person skilled in the art will note that there are other variations which are possible, including hinges which in fact have the more traditional hinge pin type hinge arrangement which are generally found on doors, wherein it likely would be necessary to recess the hinge into the back or the bottom surface 114 of the molding in order to ensure that the hinge itself does not get in the way of the installation of the molding 102.
  • It has been contemplated by the inventors that the flexible hinge 108 and/or the elastic hinge 206 would be extremely thin and not have any material effect upon the installation of the molding 102.
  • Multi piece curved molding 100 are shown as molding 102 could be used for any application requiring a curved molding including, for cap molding or casing around circular windows having radius of different types.
  • FIGS. 24 through 39 inclusive depict a fourth embodiment of the present invention multi piece curved molding 400.
  • The fourth, embodiment is used in the same manner as described above for embodiments one, two and three. The major differences between the fourth embodiment with the previously described embodiments is the method of hinging.
  • In the fourth embodiment flexible hinge 408 includes a left member 464 and a right member 462 which are connected at a hinge portion 460 as preferably shown in FIGS. 37 and 38. Flexible hinge 408 is preferably made from a flexible plastic material so that it can easily be bent along hinge portion 460. However other hinge designs not depicted may work equally as well. Flexible hinge 408 is attached to adjacent curved sections 404 as it is secured to each half of curved sections 404 in hinge pockets 450. Flexible hinge 408 can be used with almost any type of molding 402, provided that adjacent curved sections 404 can be adapted to accommodate flexible hinge 408. each curved section includes a front side 411, a back side 413, and a profile 415.
  • In order to save space and to avoid damage of multi piece curved moldings 400, the multi piece curved moldings 400 are folded as depicted in the various drawings to minimize packaging space and also to minimize damage in transit.
  • FIG. 45 shows a connection device for connecting two adjacent curved sections 650 namely wafer 602 preferably made up of a number of layers, namely rigid plastic top layer 604, flexible foam intermediate layer 606, adhesive bottom layer 608 and peel off backing 610. FIG. 45 shows multi layered wafer 602 in exploded form namely with the various layers detached. FIG. 46 shows the wafer in its assembled condition and FIG. 47 shows part of the peel off backing being peeled off. This is only one of many possible constructions for wafer 602. Wafer 602 may in fact, just be made out of one solid piece of rigid plastic, rather than in multi layered form, however as will be shown in FIG. 48 through 51, it preferably is multi layered so that it provides for more flexibility of the curved molding. FIG. 48 shows transverse direction 622 and longitudinal direction 620 of wafer 602. The flexible foam intermediate layer 606 provides for a certain amount of flexibility. For example if wafer 602 is displaced in the longitudinal direction as shown in FIG. 49, the rigid plastic top layer 604 can be displaced relative to the adhesive bottom layer 608 as shown in FIG. 604 being displaced in an amount 626. Similarly multi layered wafer 602 can also be displaced in a transverse direction. Therefore, there is a certain amount of give or flexibility in the transverse and longitudinal directions that multi layered wafer 602 possess due to the flexible foam intermediate layer 606.
  • Shown in FIG. 50, multi layered wafer 602 can also be compressed by to a thickness shown as 628 as shown in FIGS. 50 and 51. In this manner, sheer forces as well as compression forces will result in a small amount of displacement of the rigid plastic top layer 604 relative to the adhesive bottom layer 608. Due to this inherent flexibility in wafer 602, the curved sections 650 can be somewhat displaced relative to each other along abutting joint 652. Referring now to FIGS. 52, 53 and 54, FIG. 52 shows multi layered wafer 602 placed into position in a recessed wafer pocket 612. Approximately ½ of wafer 602 is adhesively attached to the recessed wafer pocket 612 of once curved section and the other half of wafer 602 is adhesively bonded to the other recessed wafer pocket 612 of the adjacent curved section 650. As shown in FIG. 54, due to the flexibility of wafer 602, it is possible to obtain some movement of curved section 650 in the transverse direction 622 and the longitudinal direction 620 as shown in the figure.
  • FIGS. 55, 56 and 57 shows wafer 602 being installed into recessed wafer pocket 612 of each curved section 650 approximate abutting end 654.
  • Referring now to FIG. 58 which shows a multi layered hinge 700. Preferably multi layered hinge includes a rigid plastic top layer 702 which defines a left member 703, a right member 701 and a hinged portion 705. Two separate pieces of a flexible foam intermediate layer 704 is bonded to right member 701 and left member 703 respectively. On top of flexible foam intermediate layer 704 is adhesive bottom layer 706 having a peel off backing 708. In this manner multi layer hinge 700 is capable of hingeably moving about hinged portion 705 without flexible foam layer 704 and/or adhesive bottom layers 706 and/or peel off backing 708 interfering with the motion of the hinge. Similar to the description of wafer 602, multi layer hinge 700 also can be deformed in the longitudinal direction, the transverse direction as well as in compression. Therefore, the discussion above regarding FIGS. 48, 49, 50 and 51 equally apply to multi layered hinge 700. Multi layered hinge 700 allows some movement between adjacent curved sections 707 thereby giving the installer some opportunity to adjust the curved molding to the opening or archway it is to be installed in.
  • FIGS. 60, 61 and 62 show flexible hinge 408 and/or multi layered hinge 700 placed into hinge pocket 702 of curved section 706.
  • Hinged pocket 702 includes pocket side 720, a pocket back 722 and a pocket bottom 724. The adhesive bottom layer 706 is attached to pocket bottom 724 providing for an adhesive bonding between the right member 701 or the left member 703 and curved sections 707. Hinge pocket 702 is dimensioned in such a fashion that flexible hinge 408 and/or multilayered hinge 700 is recessed into the backside 714 of curved section 706. Each curved section 707 has a profile 712, a front side 710 and a back side 714.
  • FIG. 63 show the combination of using wafers and/or flexible hinges 408 and/or multi layered hinges 700. FIG. 63 shows four curved sections 706 connected together. The outer two sections are connected with a flexible hinge 408 or a multi layered hinge 700, such that the outer two curved sections 707 can fold onto the adjacent or abutting section as shown in FIG. 64. The inner two curved sections 707 are attached with a wafer 602, such that these two portions are simply connected by wafer 602, but cannot be placed into the folded position. A person skilled in the art will appreciate that this will dramatically reduce the size of the shipping container necessary to ship a large arch and if necessary it can be shipped in two pieces together with a separately included wafer 602 for connecting the hinged curved sections. In other words, the two curved sections connected with flexible hinge 408 for example, can be folded in half to provide for a compact curved sections folded onto it self and included within the shipping container can be a wafer 602, such that when the folded curved sections are unfolded, the installer can manually place the wafer 602 in position in order to attach the two folded curved sections together with wafer 602.
  • In this manner a kit can be shipped which can be partially unfolded and partially connected together with wafers and flexible hinges and/or multi layered hinges.
  • FIG. 64 shows the curved section in a partially folded position 770. FIG. 65 shows the curved sections in a fully extended position 772. FIG. 66 shows the curved section in the folded position 777 in which a wafer 602 has been placed at the factory and the two outer curved sections 707 have been folded onto each other at hinge 700 or 408.
  • It should be apparent to persons skilled in the arts that various modifications and adaptation of this structure described above are possible without departure from the spirit of the invention the scope of which defined in the appended claim.

Claims (27)

1. A collapsible multi piece curved molding comprising; at least two curved sections adapted to butt together at an abutting joint to form a contiguous curved molding;
and a means for hinging together the curved sections such that the curved sections are operably foldable between a folded position and an extended position.
2. The collapsible multi piece curved molding claimed in claim 1 wherein the hinging means including at least one flexible hinge joined to the curved sections proximate abutting ends for joining the curved sections at the abutting joint.
3. The collapsible multi piece curved molding claimed in claim 1 wherein the hinging means including at least one flexible hinge including a left member, a right member and a hinge portion, such that the left member adapted to be received in one hinge pocket and the right member adapted to be received in a second hinge pocket defined in the abutting curved sections, wherein the flexible hinge for joining abutting curved sections at the abutting joint.
4. The collapsible multi piece curved molding claimed in claim 3 wherein the hinge including a one piece rigid plastic construction having a left member, a right member and a hinge portion such that the left member adapted to be received in one hinge pocket and the right member adapted to be received in a second hinge pocket defined in the abutting curved section.
5. The collapsible multi piece curved molding claimed in claim 3 or 4 wherein the hinge including a multi layered hinge wherein the left and right members including a rigid plastic top layer, a flexible foam intermediate layer and an adhesive bottom layer such that the adhesive layer makes contact with the hinge pocket thereby adhesively connecting the hinge to the curved section.
6. The multi piece curved molding claimed in claim 1 wherein the connecting means including at least one elastic hinge joined to the curved sections proximate the abutting ends wherein the elastic hinge for operably folding and unfolding the curved sections selectively into an inside folded position or an outside folded position or an extended position.
7. A multi piece curved molding comprising at least two curved sections adapted to butt together at a joint to form a contiguous curved molding; and a means for connecting together the curved sections.
8. The multi piece curved molding claimed in claim 7 wherein the connecting means including at least one planar wafer, such that portions of the wafer are joined to each of the curved sections proximate abutting ends, the wafer for operably joining the curved sections such that they abut together at the abutting joint.
9. The multi piece curved molding claimed in claim 8 wherein substantially one half of the wafer is received within a recessed wafer pocket of one curved section and the other half of the wafer is received in a recessed wafer pocket of the abutting curved section thereby operably joining the curved sections at the abutting joint.
10. The multi piece curved molding claimed in claim 8 or 9 wherein the wafer including a one piece rigid plastic construction.
11. The multi piece curved molding claimed in claim 8 and 9 wherein the wafer including a multi layered wafer including a rigid plastic top layer, a flexible intermediate foam layer and an adhesive bottom layer such that the adhesive layer makes contact with the wafer pocket thereby adhesively connecting the hinge to the curved section.
12. A partially collapsible multi piece curved molding comprising; at least three curved sections adapted to butt together at abutting joints to form a contiguous curved molding; a means for hinging together at least two curved sections such that the curved sections are operably foldable between a folded position and an extended position; a means for connecting together at least two of the curved sections.
13. The partially collapsible multi piece curved molding claimed in claim 12 wherein the hinging means including at least one flexible hinge joined to the curved sections proximate abutting ends for joining the curved sections at the abutting joint.
14. The partially collapsible multi piece curved molding claimed in claim 13 wherein the hinging means including at least one flexible hinge including a left member, a right member and a hinge portion, such that the left member adapted to be received in one hinge pocket and the right member adapted to be received in a second hinge pocket defined in the abutting curved section, wherein the flexible hinge for joining abutting curved sections at the abutting joint.
15. The partially collapsible multi piece curved molding claimed in claim 12 further including a connecting means for connecting together curved sections, the connecting means including at least one planar wafer, such that the wafer being joined to each of the curved sections proximate abutting ends, the wafer for operably joining the curved sections such that they abut together at the abutting joint.
16. The partially collapsible multi piece curved molding claimed in claim 15 wherein substantially one half of the wafer is received within a recessed wafer pocket of one curved section and the other half of the wafer is received in a recessed wafer pocket of the abutting curved section thereby operably joining the curved sections at the abutting joint.
17. The partially collapsible multi piece curved molding claimed in claim 16 wherein the hinge including a multi layered hinge wherein the left and right members including a rigid plastic top layer, a flexible foam intermediate layer and an adhesive bottom layer such that the adhesive layer makes contact with the hinge pocket thereby adhesively connecting the hinge to the curved section.
18. The partially collapsible multi piece curved molding claimed in claim 17 wherein the wafer including a multi layered wafer including a rigid plastic top layer, a flexible intermediate foam layer and an adhesive bottom layer such that the adhesive layer makes contact with the wafer pocket thereby adhesively connecting the hinge to the curved section.
19. A kit including parts for assembling a multi piece curved molding, the kit including; a plurality of curved sections adapted to butt together at abutting joints to form a contiguous curved section; and a means for hinging together the curved sections such that the curved sections are operably foldable between a folded position and an extended position.
20. A kit including parts for assembling a multi piece curved molding, the kit including; a plurality of curved sections adapted to butt together at abutting joints to form a contiguous curved section; and means for connecting together the curved sections proximate abutting ends.
21. The kit claimed in claim 20 further including a means for hinging together the curved sections such that the curved sections are operably foldable between a folded position and an extended position.
22. The kit claimed in claim 21 wherein the hinging means including at least one flexible hinge joined to the curved sections proximate abutting ends for joining the curved sections at the abutting joint.
23. The kit claimed in claim 21 wherein the hinging means including at least one flexible hinge including a left member, a right member and a hinge portion, such that the left member adapted to be received in one hinge pocket and the right member adapted to be received in a second hinge pocket defined in the abutting curved section, wherein the flexible hinge for joining abutting curved sections at the abutting joint.
24. The kit claimed in claim 23 wherein the hinge including a multi layered hinge wherein the left and right members including a rigid plastic top layer, a flexible foam intermediate layer and an adhesive bottom layer such that the adhesive layer makes contact with the hinge pocket thereby adhesively connecting the hinge to the curved section.
25. The kit claimed in claim 20 wherein the connecting means including at least one planar wafer, such that portions of the wafer are joined to each of the curved sections proximate abutting ends, the wafer for operably joining the curved sections such that they abut together at the abutting joint.
26. The kit claimed in claim 25 wherein substantially one half of the wafer is received within a recessed wafer pocket of one curved section and the other half of the wafer is received in a recessed wafer pocket of the abutting curved section thereby operably joining the curved sections at the abutting joint.
27. The kit claimed in claim 26 wherein the wafer including a multi layered wafer including a rigid plastic top layer, a flexible intermediate foam layer and an adhesive bottom layer such that the adhesive layer makes contact with the wafer pocket bottom thereby adhesively connecting the hinge to the curved section.
US11/307,081 2005-01-28 2006-01-23 Multi piece curved moldings Abandoned US20070234661A1 (en)

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US20070151180A1 (en) * 2005-12-02 2007-07-05 John Pace Trim components and methods for manufacturing same
US20070220729A1 (en) * 2006-03-27 2007-09-27 Ed Vaes Method of manufacturing multi piece curved molding from planar material
US20090241446A1 (en) * 2008-03-25 2009-10-01 Scott Gittleman Concealed reinforcement member and joint reinforcement system for trim molding
US20100139203A1 (en) * 2008-03-03 2010-06-10 Brady Todd A Back plate bracketing system

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US20070220729A1 (en) * 2006-03-27 2007-09-27 Ed Vaes Method of manufacturing multi piece curved molding from planar material
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US8141319B2 (en) * 2008-03-03 2012-03-27 Brady Innovations, Llc Back plate bracketing system
US20090241446A1 (en) * 2008-03-25 2009-10-01 Scott Gittleman Concealed reinforcement member and joint reinforcement system for trim molding
US7832164B2 (en) * 2008-03-25 2010-11-16 Scott Gittleman Concealed reinforcement member and joint reinforcement system for trim molding

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