Ornamental plaster crown molding

• US 6,228,507 B1
• Filed: 08/24/1998
• Issued: 05/08/2001
• Est. Priority Date: 08/24/1998
• Status: Expired due to Fees

• Current Assignee: Richard D.W. Hahn
• Original Assignee: Richard D.W. Hahn
• Inventors: Hahn, Richard D. W.
• Primary Examiner(s): Loney, Donald J.
• Application Number:
  US09/138,852
• Time in Patent Office: 988 Days
• Field of Search: 52/255, 52/254, 52/287.1, 52/316, 52/742.1, 52/742.12, 52/717.01, 52/716.1, 52/311, 428/192, 428/167, 428/537.7, 442/367, 442/348, 442/386, 442/327
• US Class Current: 428/542.2
• CPC Class Codes: B28B 1/29 by profiling or strickling the material in open moulds or on moulding surfaces in rotary moulds B28B1/02; by means of profiled rollers B28B3/12, B28B3/123
• CPC Class Codes: B28B 1/522 for producing multi-layered articles B28B1/526, B28B1/527 take precedence
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B28B 7/0064 Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces B28B7/36 takes precedence; producing decorative effects B44C; designs of stone surfaces B44F
• CPC Class Codes: E04F 19/0436 between ceiling and wall
• CPC Class Codes: E04F 2019/0431 of two or more materials
• CPC Class Codes: E04F 2019/0454 with decorative effects
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]
• CPC Class Codes: Y10T 442/665 Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]

Abstract

A prefabricated crown molding strip designed to facilitate one-person installation and composed of plaster that is reinforced by two layers of fiber reinforcement, one of bulk fiberglass intermixed throughout the outer portion of the strip and the ornamentation thereon and a second of a sheet of fiberglass netting generally centrally located as a spine in the strip and substantially coextensive therewith. Two side surfaces of the strip are disposed generally in perpendicular planes for engagement with a wall and a ceiling, and have patterns of longitudinally extending ribs and grooves of predetermined depths for facilitating adhesive mounting of the strip, and also facilitating selective removal of plaster to accommodate irregularities on supporting surfaces. Pre-formed nail holes are molded in preselected nailing locations. Also the method of making crown molding strips in steps providing the above characteristics, in a sequence of pours of plaster in fluid state, the addition of the reinforcing fiber, and formation of the patterns of ribs and grooves.

Claims

1. A prefabricated ornamental plaster crown molding strip for installation in a room space along the juncture of a ceiling and a wall, said strip comprising:

an elongated body composed primarily of plaster and having;

an outer decorative surface for facing into the room space and including raised decorative ornamentation thereon, said decorative surface having first and second edges for extending, respectively, along the ceiling and the wall,

first and second side edge surfaces for engagement with the ceiling and the wall, respectively,

one longitudinal edge portion of said body being offset to form a cornice along one edge of the body,

and an inside surface substantially parallel to the outer surface and extending between said side edge surfaces,

said body being of a predetermined thickness along its length between said outer surface and said inside and side edge surfaces, apart from said raised ornamentation;

a first reinforcing layer of lightweight fabric in the form of netting embedded in said plaster in predetermined spaced relation with said outer surface and with said inside and side surfaces, said netting having side edges close to the side edges of said outer surface;

and a second reinforcing layer of lightweight non-woven, long-fiber material intermixed throughout the outer portion of the plaster between said netting and said decorative surface;

said first and second side surfaces comprising patterns of alternating longitudinal grooves and ridges, the grooves being of preselected depths less than the spacing of said first reinforcing layer from said first and second side surfaces.

2. A prefabricated ornamental plaster crown molding strip as defined in claim 1 wherein said first and second reinforcing layers are fiberglass netting and bulk fiberglass, respectively.

3. A prefabricated ornamental plaster crown molding strip as defined in claim 1 wherein said patterns of grooves and ridges cover said first and second side surfaces except for said one longitudinal edge portion, said ridges comprising unreinforced plaster.

4. A prefabricated ornamental plaster crown molding strip as defined in claim 3 wherein said patterns comprise spaced first grooves of preselected depth and second grooves shallower than said preselected depth.

5. A prefabricated ornamental plaster crown molding strip as defined in claim 3 wherein said predetermined thickness of said body is in the range of eight to thirteen millimeters, and said first reinforcing layer is spaced from said outer surface in the range of approximately one-half to two-thirds of the thickness of the body.

6. A prefabricated ornamental plaster crown molding strip as defined in claim 3 wherein said predetermined thickness is approximately eleven millimeters and said first reinforcing layer is spaced from said outer surface approximately seven millimeters and from the remaining surfaces by approximately four millimeters.

7. A prefabricated ornamental plaster crown molding strip as defined in claim 6 wherein said first grooves are of a maximum depth in the range of one to three millimeters.

8. A prefabricated ornamental plaster crown molding strip as defined in claim 7 wherein said first and second grooves are of varied depth ranging from less than one millimeter to more than two millimeters.

9. A prefabricated ornamental plaster crown molding strip as defined in claim 1 further including preformed nail-hole indentations in selected nailing locations in said outer surface.

10. A prefabricated ornamental plaster crown molding strip for installation in a room space along the juncture of a ceiling and a wall, said strip comprising:

an elongated body composed primarily of plaster and having;

an outer decorative surface for facing into the room space and including raised decorative ornamentation thereon, said decorative surface having first and second edges for extending, respectively, along the ceiling and the wall,

first and second side surfaces substantially parallel to said outer surface for engagement with the ceiling and the wall, respectively,

and an inside surface extending between said side surfaces,

said body being of a predetermined uniform thickness between said outer surface and said inside and side surfaces, apart from said raised ornamentation and having one longitudinal edge portion that is offset to form a cornice;

a first reinforcing layer of lightweight open mesh fabric embedded in said plaster in predetermined spaced relation with said outer surface and with said inside and side surfaces, said fabric having side edges close to the side edges of said outer surface;

and a second reinforcing layer of lightweight non-woven, fiber material intermixed throughout the outer portion of the plaster between said fabric and said decorative surface.

11. A prefabricated ornamental plaster crown molding strip as defined in claim 10 further including a layer of unreinforced plaster between said first and second reinforcing layers, said fabric being embedded in said layer of plaster.

12. A prefabricated ornamental plaster crown molding strip as defined in claim 10 wherein said predetermined uniform thickness of said body is in the range of eight to thirteen millimeters, and said first reinforcing layer is spaced from said outer surface in the range of one-half to two thirds of the thickness of the body.

13. A prefabricated ornamental plaster crown molding strip as defined in claim 10 wherein said thickness is approximately eleven millimeters and said first reinforcing layer is spaced from said outer surface approximately seven millimeters and from the remaining surfaces by approximately four millimeters.

14. A prefabricated ornamental plaster crown molding strip as defined in claim 10 wherein said first and second side surfaces comprise patterns of alternating grooves and ridges, the grooves being of preselected depths less than the spacing of said first reinforcing layer from said first and second side surfaces.

15. A prefabricated ornamental plaster crown molding strip as defined in claim 10 wherein said fabric is fiberglass netting and said long-fiber material is bulk fiberglass.

16. A prefabricted ornamental plaster crown molding strip as defined in claim 10 further including preformed nail-hole indentations in selected nailing locations in said outer surface.

17. In a prefabricated molded ornamental strip of predetermined length, thickness and width having an outer surface including raised decorative ornamentation thereon, and first and second side surfaces for engagement with angularly disposed supporting surfaces, the improvement comprising:

first and second layers of fiber reinforcement embedded in the strip, the first layer being a sheet of open mesh fabric slightly narrower in width than the strip and positioned a predetermined distance inwardly from said outer surface, and

said second layer being non-woven bulk fibers intermixed in the outer portion of the strip between the first layer and said outside surface.

18. The improvement defined in claim 17 wherein said first and second reinforcing layers are fiberglass netting and bulk fiberglass, respectively.

19. The improvement defined in claim 18 wherein said strip has at least one side surface formed with a pattern of spaced first grooves of preselected depth with bottoms close to said first reinforcing layer and separated by a plurality of second grooves of a different preselected depth between each pair of first grooves.

20. The improvement defined in claim 17 further including preformed nail-hole indentations in selected nailing locations in said outer surface.

21. A prefabricated ornamental plaster crown molding strip for installation in a room space between a wall and a ceiling, comprising

an elongated body composed primarily of plaster and having:

an outer decorative surface for facing into the room space and including raised decorative ornamentation integrally joined to the body;

an inside surface parallel to said outside surface for facing the wall, said elongated body being of uniform thickness, apart from said ornamentation, along its length, and

a patterned cornice decoration integral with the remainder of the body extending along one edge portion of the body and having an upper edge for engaging the ceiling, said cornice decoration being offset from the remainder of the body to extend into the room space, and being of the same thickness as the remainder of the body;

a first reinforcing layer of open-mesh fabric embedded in the body and in said cornice and having side edges close to the edges of the body, said fabric being spaced from said inside and outside surfaces;

and a second reinforcing layer of non-woven fiber material intermixed in the plaster between said fabric and said outside surface to reinforce the outer portion of the body adjacent said outside surface.

22. A prefabricated ornamental crown molding strip as defined in claim 21 wherein said inside surface comprises a pattern of alternating longitudinal grooves and ridges.

23. A prefabricated ornamental crown molding strip as defined in claim 21 wherein the thickness of said body is in the range of eight to thirteen millimeters, and said first layer is spaced from the outside surface by one-half to two-thirds the thickness.

24. A prefabricated ornamental crown molding strip as defined in claim 21 wherein said cornice decoration has a concave curvature on its inner side forming the offset from the remainder of the body, and a flat upper edge for engagement with the ceiling.

25. A prefabricated ornamental crown molding strip as defined in claim 21 wherein said decorative cornice has a concavely curved inner side, a decorated outside surface following the curvature of said inner surface, and a flat upper edge, said first and second layers extending into said decorative cornice.