Modular molding system
20250341103 ยท 2025-11-06
Inventors
- Joshua E. DeWitt (Westfield, IN, US)
- Thomas P. Hicks (Lafayette, IN, US)
- Donald E. DeWitt (Syracuse, IN, US)
Cpc classification
E04F19/0463
FIXED CONSTRUCTIONS
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A modular molding system is provided for mounting at a wall-ceiling interface in a structure, such as an RV, and around a window opening in the structure. The system includes a mounting component and a trim component removable mountable to the mounting component. The mounting component is configured in one embodiment to be mounted to the wall-ceiling interface and in another embodiment to be mounted around a window opening. The molding system includes a functional component separate from the function of the molding system. In one embodiment, the functional component is an LED lighting strip and, in another embodiment, the functional component is a guide channel for a screen or sunshade of a window valence. A snap-fit engagement is provided between the mounting component and the trim component. The mounting component and the trim component are extruded plastic so that that the components can be cut to size as desired.
Claims
1. A modular molding system for providing an aesthetic feature to a wall and/or ceiling structure, comprising: a mounting component including; an elongated base track defining at least one fastener panel configured to be fastened to a wall and/or a ceiling surface; and at least one functional component providing a function different from the aesthetic feature of the molding system; a trim component including an elongated trim panel sized to conceal the mounting component when the trim panel is engaged to the mounting component and the mounting component is fastened to the wall and/or ceiling surface; and a removable snap-fit connection between the base track and the trim panel.
2. The modular molding system of claim 1, wherein the removable snap-fit connection includes: a pair of retention arms defined by the base track and projecting outward from said fastener panel; and at least one pair of resilient prongs projecting from an inner surface of the trim panel, said resilient prongs configured to be deflected relative to each other upon engagement with the pair of retention arms, thereby exerting a spring force to hold the prongs in engagement with the retention arms.
3. The modular molding system of claim 2, wherein the trim panel includes a first pair of resilient prongs and a second pair of resilient prongs spaced apart along the inner surface of the trim panel from the first pair, each of said first and second pair of resilient prongs configured for selective snap-fit engagement with the pair of retention arms of the mounting component.
4. The modular molding system of claim 3, wherein: said base track is configured to be seated at the interface between a vertical wall surface and a ceiling surface, including a vertical fastener panel configured to engage said vertical wall surface and a horizontal fastener panel configured to engage said ceiling surface; said trim component has a width along the elongated trim component; said trim component includes an end panel at each opposite edge of said width, each end panel extending inward and generally perpendicularly from the trim panel; said first pair of resilient prongs is arranged so that the end panel at a first one of said opposite edges is in contact with said vertical wall surface when the first pair of resilient prongs are engaged with the pair of retention arms, and the end panel at a second one of said opposite edges is spaced apart from said ceiling surface to define a first gap; and said second pair of resilient prongs is arranged so that the end panel at a second one of said opposite edges is in contact with said ceiling surface when the second pair of resilient prongs are engaged with the pair of retention arms, and the end panel at said first one of said opposite edges is spaced apart from said vertical wall surface to define a second gap.
5. The modular molding system of claim 4, wherein: the base track defines at least two mounting surfaces separate from the fastener surface, a first one of said mounting surfaces arranged to align with said first gap, and a second one of said mounting surfaces arranged to align with said second gap; and the functional component includes an LED lighting strip configured to be mounted on any of said at last two mounting surfaces, said LED lighting strip configured to generate light to pass through one of said first gap and said second gap depending on the arrangement of the trim component on the mounting component.
6. The modular molding system of claim 1, wherein: the base track defines a mounting surface separate from the fastener surface; and the functional component includes an LED lighting strip configured to be mounted on said mounting surface.
7. The modular molding system of claim 6, wherein said base track defines a wiring channel for receiving wiring associated with said LED lighting strip.
8. The modular molding system of claim 7, wherein: said elongated base track defines two fastener panels; said elongated base track defines an elongated fastener channel extending from each of said two fastener panels, each elongated fastener channel configured to guide an elongated fastener to said fastener panel; and said fastener channels and said fastener panels defining said withing channel.
9. The modular molding system of claim 1, wherein said elongated base track defines an elongated fastener channel extending from each of said at least one fastener panel, said elongated fastener channel configured to guide an elongated fastener to said fastener panel.
10. The modular molding system of claim 1, in which the system is configured for mounting around a window opening of a recreational vehicle in which the window opening includes a window assembly and valence supporting at least one window covering extendable over the window opening, wherein said functional component includes at least one channel defined in said base track, said at least one channel configured to receive an edge of said at least one window covering therein to guide said at least one window covering as it is extended over said window opening.
11. The modular molding system of claim 1, in which said valence supports a screen and a sunshade and said at least one channel includes a separate channel to receive an edge of said screen and said sunshade.
12. The modular molding system of claim 1, wherein: said base track is configured to be seated at the interface between a vertical wall surface and a ceiling surface, including a vertical panel configured to engage said vertical wall surface and a horizontal panel configured to engage said ceiling surface; and said base track defines a pair of fastener guide channels, each configured to receive an elongated fastener therethrough, and one of said guide channels intersecting said vertical panel and the other of said guide channels intersecting said horizontal panel.
13. A modular molding system for providing an aesthetic feature to a wall and/or ceiling structure, comprising: a mounting component including an elongated base track defining a fastener panel configured to be fastened to a wall and/or a ceiling surface; a trim component including an elongated trim panel sized to conceal the mounting component when the trim panel is engaged to the mounting component and the mounting component is fastened to the wall and/or ceiling surface; and a removable snap-fit connection between the base track and the trim panel, wherein the removable snap-fit connection includes: a pair of retention arms defined by the base track and projecting outward from said fastener panel; and a first pair of resilient prongs and a second pair of resilient prongs spaced apart along the inner surface of the trim panel from the first pair, each of said first and second pair of resilient prongs configured for selective snap-fit engagement with the pair of retention arms of the mounting component.
14. The modular molding system of claim 13, wherein: said base track is configured to be seated at the interface between a vertical wall surface and a ceiling surface, including a vertical panel configured to engage said vertical wall surface and a horizontal panel configured to engage said ceiling surface; said trim component has a width along the elongated trim component; said trim component includes an end panel at each opposite edge of said width, each end panel extending inward and generally perpendicularly from the trim panel; said first pair of resilient prongs is arranged so that the end panel at a first one of said opposite edges is in contact with said vertical wall surface when the first pair of resilient prongs are engaged with the pair of retention arms, and the end panel at a second one of said opposite edges is spaced apart from said ceiling surface to define a first gap; and said second pair of resilient prongs is arranged so that the end panel at a second one of said opposite edges is in contact with said ceiling surface when the second pair of resilient prongs are engaged with the pair of retention arms, and the end panel at said first one of said opposite edges is spaced apart from said vertical wall surface to define a second gap.
Description
DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0020] For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains.
[0021] A modular molding system 5 shown in
[0022] The fastener can have a self-tapping tip T that is configured to pierce the associated fastener panel 12a, 12b of the base track 12, and to be driven into a wall frame or stud F behind the wall W, or similar structure behind the ceiling C. It is also contemplated that the fastener S could be configured to engage a conventional wall anchor behind the wall W or ceiling C. A plurality of fasteners S can be used to fasten the base track to the ceiling/wall joint, as shown in
[0023] It is contemplated that the fastener guide channels 14, fastener surface 15 and guide notch 16 extend continuously along the length of the elongated base track. This configuration allows positioning a fastener at any desired location along the length of the base track when installing the modular molding system 5. Alternatively, a discrete number of fastener guide notches 16 can be provided at predetermined locations along the length of the guide track. In that instance, it is further contemplated that the guide notches are in the form of discrete holes through the fastener surface 15, to accommodate a fastener without a self-tapping tip. The guide notch hole can be aligned with a corresponding hole in the fastener panels 12a, 12b of the base track, or the hole can be formed by drilling through the base track and into the ceiling or wall.
[0024] The base track 12 further defines an interior channel 17 along its length. As described herein, the channel can receive wiring for integrating a lighting system into the molding system 5. The base track can also define ancillary channels 18 that are separated from the main channel 17 by the fastener guide channel 14. The ancillary channels can be purely structural, although they could be used to receive additional wiring.
[0025] In one feature of the modular molding system 5, a resilient and removable snap-fit engagement is provided between the mounting component 10 and the trim component 30. For the mounting component, the snap-fit engagement is provided by a pair of retention arms 20 projecting outward from the fastener surface 15 of the base track 12. In one embodiment, the arms 20 are opposing and spaced apart, defining a channel that is generally centered along an axis bisecting the right-angle bracket configuration of the base track. In other words, the arms 20 and resulting channel are generally equidistant from each panel 12a, 12b of the base track. Each retention arm 20 includes a guide surface 22 on the facing surfaces of the opposing arms. The opposing guide surfaces diverge slightly from each other toward the ends of the respective arms. An engagement notch 24 is formed at an inboard end of each guide surface. In one embodiment, the engagement notch is near the midpoint of the length of each arm 20. The notch can be generally triangular in shape, as shown in
[0026] The base track can be provided with generally flat mounting surfaces 28a, 28b. The surfaces can be used to mount functional elements, such as the functional elements 100 shown in
[0027] The modular molding system 5 further includes a trim component 30 that is configured to be adjustably and removably engaged to the base track. The trim component 30 includes an elongated trim panel 31 that is configured to be cut to a desired length relative to the length of the wall-ceiling joint that is receiving the molding system. As shown in
[0028] The trim component 30 has a width along the elongated length of the panel, with the width sized to conceal the mounting component when the trim component is mounted thereon. The trim component includes an edge panel 32a, 32b at the opposite edges of width of the trim panel. In one embodiment, the edge panels extend inward and generally perpendicularly from the trim panel. As shown in
[0029] The resilient snap-fit engagement for the trim component 30 is provided by at least one pair of resilient prongs 33 projecting inward from the trim panel 31. Each prong terminates in an engagement head 35 which defines a sloped ramp surface 36. The prongs 33 diverge apart from each other so that the ramp surfaces 36 of the engagement heads 35 contact the outermost end of the guide surfaces 22 of the mounting component 10. The ramp surfaces 36 and guide surfaces 22 are configured for sliding contact. As the trim component is pushed toward the mounting component, the resilient prongs 33 deflect toward each other as the ramp surfaces slide along the guide surfaces. The engagement heads include a locking surface 37 that clicks into the engagement notches 24 of the retention arms 20. The engagement notches 24 can also be angled inward so that the force required to push the resilient prongs further into the mounting component is prohibitive. The end of the retention arms 20 can also include a support foot 35 that can contact the inside surface of the trim panel 31 to hold the panel in position on the mounting component.
[0030] As shown in
[0031] The base track 52 of the mounting component 50 shown in
[0032] The modular molding system 5 of the present disclosure contemplates a mounting component 10/50 and a trim component 30/70 that can be cut to size to fit any wall-ceiling interface. It can be appreciated that the mounting component can extend almost the entire length of the wall-ceiling interface. However, at an interior corner, two mounting components meet at the corner, requiring one mounting component to shortened to avoid interference between the two components. At an exterior corner, the mounting components can both extend to the corner without interfering with each other. However, the 3-dimensional aspect of the trim components complicate the interface between adjacent trim components at an interior and exterior corner. Thus, the molding system 5 can include corner pieces that accommodate interior and exterior corners of the wall-ceiling interface, as shown in
[0033] In another aspect of the present disclosure, a modular molding system can be provided for locations in a building or vehicle other than at a wall joint. A modular molding system 105 is configured to be mounted around a window assembly, such the window assembly for an RV shown in
[0034] The present disclosure provides a window molding system 105 that encircles the side and bottom extents of the window opening O in the wall W, as best seen in
[0035] The outboard edge 115 of the base track 112 defines an edge hook used for mounting the trim component 130 as described herein. The inboard edge of the base track defines functional elements, and particularly elements used to align and guide the sunshade and screen components. Thus, in one embodiment, the inboard edge of the base track 112 defines a sunshade channel 122 that is arranged to face inward across the window opening so that the side edge of the sunshade SS can be seated and slide within the channel. The base track further defines a screen channel 125 between the sunshade channel 122 and the fastener panel 114. The screen channel 125 is arranged parallel to the sunshade channel so that the side edge of the screen SC can be seated and slide within the channel. Like the molding system 5, the window molding system 105 combines a separate functional element with the decorative trim component. In this embodiment, the functional component includes the guides for the window screen and shade.
[0036] The base track 112 includes features for engaging the trim component 130. The edge hook 115 is one component of the engagement feature. Another component of the engagement feature is a retention arm 120 that is provided adjacent the inboard edge of the track. The retention arm 120 defines a guide bead 121 that combines with a guide bead 123 defined by the outboard end of the sunshade channel 122, as shown in
[0037] The trim component 130 includes an elongated trim panel 131 that can be cut to size, like the trim panel 31. The inboard edge of the trim panel 131 defines an engagement edge 131a that is bent inward to wrap around the inboard end of the sunshade channel 122. The outboard side of the trim panel 131 includes a side panel 132 that is angled inward, preferably at a perpendicular angle. The side panel 132 terminates in an edge hook 132a that is configured for mating engagement with the edge hook 115 of the base track. Like the trim panel 31, the trim panel 131 includes a pair of resilient prongs 133 projecting inward from the inner surface of the trim panel. The resilient prongs are arranged to be pressed between the guide bead 121 on the retention arm 120 and the guide bead 123 of the base track 112, to provide the resilient removable snap-fit connection between the mounting component and the trim component. In particular, the trim panel 131 is mounted on the base track by first engaging the edge hook 132a of the trim panel with the edge hook 115 of the base track. This engagement extends along the entire length of the trim panel and serves as a fulcrum point for pivoting the trim panel 131 toward the inboard end of the base track. As the trim panel is pivoted, the resilient prongs 133 contact the guide beads 121, 123, causing the prongs to deflect towards each other until the prongs are fully seated within the engagement channel 126. The resilient prongs 133 exert a spring force to push the prongs outward into frictional engagement with the engagement channel 126. The guide beads 121, 123 also help retain the prongs within the engagement channel. In this position, the engagement edge 131a of the trim panel wraps around the end of the sunshade channel 122 to provide a uniform appearance of the trim component, effectively concealing the mounting component 110.
[0038] The base track 112 can also define a T-slot 126 inboard of the screen channel 125. The T-slot can receive a guide 127 mounted to the lower end of the screen that can provide some rigidity to the screen.
[0039] As shown in
[0040] The base track 112 includes a surface 116 that can be used to support an additional functional component. For instance, the functional component can be an LED lighting strip, such as the lighting strip 100. Openings can be provided in the side panel 132 so that the lighting strip can add to the ambiance around the window system WS.
[0041] An alternative modular window molding system 205 is shown in
[0042] The molding system 205 further includes a trim component 230 that includes a trim panel 231 with a side panel 232. The trim panel 231 includes a pair of prongs 233 projecting form the inner surface of the panel. The prongs terminate in a bead 234 that is configured to bear against the end of the resilient retention arms 220 when the trim component is added to the system. Unlike the prior embodiments, the retention arms on the base track are resilient to flex towards each other as the prongs 233 are pushed toward the fastener panel 214, to form the removable snap-fit connection between the mounting component and the trim component. In another modification from the window molding system 105, the trim panel 231 is configured to extend across part of the window opening, rather than terminating at the sunshade and screen channels 222,225.
[0043] It is contemplated that the components of the modular molding systems disclosed herein can be extruded and provided in a range of conventional lengths. The components can be cut to length at the installation site. In one specific embodiment, the components are formed of a high-density polyethylene. The trim components can be provided in a range of colors for aesthetic appeal.
[0044] The functional component 100 for the molding systems disclosed herein provide a function in addition to the aesthetic function achieved by the trim component. Thus, in any of the molding systems disclosed the functional component can be a device or devices other than the LED lighting strip and sunshade/screen channels described above. For instance, the functional component can be a security system or even part of a sound system. The functional component could also be part of a motorized system to raise and lower the sunshade/screen in a window system.
[0045] The present disclosure should be considered as illustrative and not restrictive in character. It is understood that only certain embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.