Two-part composite molding and trim with raceway

Abstract

A two-part molding fabricated to include one or nonmetallic components and a wiring raceway. The molding includes a base attachable to a wall or other surface, and a face fabricated of the nonmetallic component, such as a wood polymer composite. The face is easily removably attachable to the base and it and the base are formed such that when they are joined together, the raceway is established between them. The face may be formed by extrusion or other means into a selectable shape, and is suitable for painting, staining, printing, or other surface treatment to give a desired appearance. The two-part arrangement of the molding allows painting of the wall to which it is attached without unintended to the visible surface of the molding. The face includes an interior miter channel for receiving a miter plate to ensure tight fit of the molding around comers.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] The present application claims the priority benefit of U.S. provisional patent application Ser. No. 60 / 625,764, filed Nov. 8, 2004, entitled “EXTRUDED WOOD POLYMER COMPOSITE “FACE” MOLDING PROFILES” of the same named inventor. The entire contents of that prior application are incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to molding and trim products. More particularly, the present invention relates to molding to be applied to any of walls, door frames, and window frames. The present invention is directed to a two-part composite molding including a wiring raceway. For purposes of description of the present invention, the word molding refers to any of molding, trim, casing, mopboard or the like that is applied to the perimeter of walls, doors, and windows. [0004] 2. Description of the Prior Art. [0005] Traditionally, solid wood has been used for interior m...

AI Technical Summary

Benefits of technology

[0012] It is an object of the present invention to provide molding that is easy to install. It is also an object of the present invention to provide molding that is easy to surface treat and has a useful life at least as comparable as that of wood, MDF, or FJP. Further, it is an object of the present invention to provide molding that is relatively easy to fabricate and comparably priced in relation to wood, MDF, FJP, and extrusions. Yet further, it is an object of the present invention to provide molding that may be employed to hide wiring while allowing for access to the wiring when desired.

[0015] Unlike the base, the exterior surface of the face of the molding is to be seen. Therefore, it is fabricated of material or treated in a manner suitable to conform to consumers' expectations of the appearance of traditional molding products. The face material is preferably of a material capable of being surface treated, such as by painting, staining, or printing. That material may be a nonmetallic material. The face may be surface treated when fabricated or after an initial installation. An advantage of the molding of the present invention over traditional one-piece molding relates to re-painting or re-staining the molding after it has been installed. The face of the molding of the present invention may be easily removed from the wall, placed flat and surface treated away from the wall, and then re-attached to the base. Similarly, a re-painting of the wall may be done without unintentional painting of the molding by first removing the face from the base, painting the wall, and then re-attaching it to the base.

[0016] As indicated, the face of the molding is preferably fabricated of a nonmetallic material. The nonmetallic material may be a polymeric material, such as polystyrene, polyethylene, polypropylene, or co-polymers thereof, or other polymeric materials with structural characteristics sufficient for the expected environment of the molding. Alternatively, the nonmetallic material may be something other than a polymeric material including for example a wood-based product and more particularly, a wood polymer composite. While various combinations of materials may be used to form the composite, the face of the molding is preferably fabricated of a composite comprising about 70% post industrial wood fiber, about 20% corn starch and about 10% polymer. The Fasalex® composite available from Fasalex GmbH of Austria is suitable for this application. The composite is stronger, lighter and more environmentally efficient than recent wood substitutes. The composite may be extruded to any selectable shape, thereby enabling the fabrication of complex and ornate shapes as desired by the consumer, without extensive machining or waste material generation. Product not within specification can be ground up and introduced back into the process. The composite molding of the present invention is price competitive with MDF. The composite can be painted, stained, printed or profile wrapped without any prior treatment. The exterior surface of the face may optionally be printed with a wood grain, eliminating the need for any decorative finish, and conforming to expectations of the traditional appearance of molding.

Problems solved by technology

Scarcity has driven up the price for stain grade wood molding.

There are no time savings with one product as compared to the others.

Installing and finishing interior moldings is labor intensive.

More so, painting or papering walls around trim also adds significant labor.

Also, as a wood product, FJP can crack, split and dent.

Additionally, although MDF is more dimensionally stable than wood based products, there are limitations associated with it.

Many professional carpenters don't like working with it.

It is heavy, dusty and difficult to nail.

Even in small amounts, the formaldehyde can cause serious health problems.

However, extruded styrene is lightweight and dents easily.

The paper or foil used to wrap the extrusion is not a convincing substitute for wood and cannot be repaired or painted like wood.

In addition, wood products manufacturing tends to be labor intensive.

The number of extruded molding profiles commercially available is limited.

For the most part, little advancement has been made in the technology of much of the molding products used in the building industry.

They are also difficult to access when necessary.

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