Compound structural material cover and intermediate trim strip

Abstract

A trim strip (10) includes an anchoring flange (16). A structural material cover (18) is coupled to the anchoring flange (16). The structural material cover (18) includes an upper cover member (20) and a lower cover member (22). The upper cover member (20) covers a portion of an exposed structural material layer (25). The lower cover member (22) has a structural material flush mounting surface edge (26) and covers a portion of a structural material sub-layer (28). A method of forming a multiple layer structure (15) includes applying a compound structural material cover and intermediate trim strip (10) to a peripheral edge (64) of the sub-layer (28) and applying the exposed structural material layer (25) to the sub-layer (28) and to the compound structural material cover and intermediate trim strip (10).

Description

TECHNICAL FIELD

[0001] The present invention relates generally to trim strips for various construction surfaces, and more particularly to an apparatus for covering and providing a transitional mating intermediate for multiple structural material surfaces.

BACKGROUND OF THE INVENTION

[0002] In typical residential and commercial construction projects various structural materials, such as tile, plywood, sheetrock, concrete, cement board, adhesives, and the like are utilized. These materials may be applied to wall surfaces, floor surfaces, shelves, stairs, access panels, doors, as well as other known surfaces. The materials may also be applied in layers; for example, a structural floor may include a first sub-floor layer of plywood material, a second sub-floor layer of concrete or cement board material, and an exposed layer formed of tile. At peripheral edges of structural layers or at transitional joints between different structural materials, the exposed material edges are typically not of a suitable finish quality such that installation of a trim strip or the like is commonly required.

[0003] Using tile installations as a prime example, tiles are often laid on a rigid sub-platform on which a layer of a suitable mastic adhesive or tile cement has been placed. After the tiles have adhesively bonded to the sub-platform, a suitable grouting material is filled into the gaps between adjacent tiles to maintain spaced alignment and complete the installation process. However, at the peripheral edges of an installation area, exposed tile edges can be unsuitable to satisfy finish quality standards, thus requiring installation of a trim strip.

[0004] A common trim strip that is used is referred to as a “schluter strip” that is used to separate a tiled floor section from an adjacent floor section having a different floor covering or structural material for establishing a decorative delineation therebetween, while covering the exposed tile edges. Conventional strips typically include an elongated anchoring flange segment that is secured to a sub-platform. The tiles are then placed on the anchoring flange segment such that the exposed edges abut a vertical flange segment of the trim strip. A corner or edge of the strip between the anchoring flange and the vertical flange provides an aesthetically pleasing finished flush appearance between the sub-flooring and the tiles and between the tiles and the adjacent flooring.

[0005] However, in tiling of stair treads the above-mentioned trim strip is not capable of covering the stair treads themselves. Exposed edges of tile and of stair treads are generally considered unsightly such that an additional finishing step is routinely required for presenting a more acceptable aesthetic appearance at the stair edge. Various methods and trim strips exist for tile installations over stair treads, in which the covering of the tile layer edges and stair tread edges is desired.

[0006] For example, tiles having a rounded edge may be laid so as to cover the edge of the stair tread. However, rounded tiles are typically expensive and have specific uses which limit their versatility, thereby increasing both the material and labor costs associated with their installation. Alternatively, vertical tiles may be mounted to a riser such that the exposed edge of the stair tread may be covered. This alternative generally requires overlapping of a vertical tile covering the stair riser with a horizontal tile extending over the edge of the stair tread. However, because a portion of the horizontal tile overhangs the stair tread, it is readily susceptible to undesirable cracking from the weight normally borne by the stair thread. In addition, such a tile alternative is not practical in those situations where the stair tread overhangs the stair riser.

[0007] As an alternative to the above-noted tiled stair edges, a trim member may be installed onto the tread edge to cover exposed edges of the tiles. Installation of the trim member can require an elongated slot to be routered into the exposed edge of the stair tread to facilitate installation. Such an installation requirement is not only time consuming but also requires a high degree of precision since misalignment of the routered slot relative to the final exterior tiled floor surface may result in an undesirable raised lip being created.

[0008] The above-mentioned methods and existing trim strips also do not account for multiple structural material layer exposure and transitioning between multiple structural layers. Tile installations typically have at least one additional layer over other forms of installation, due to the need for a concrete or cement board sub-platform layer. For example, a tile wall installation typically includes three layers: a sheetrock layer, a cement board layer, and a tile layer. When a transition exists between a single sub-layered structure, such as between an adjacent drywall layer and a concrete sub-layer with an exposed tile layer, peripheral edges of the tile layer are exposed. In other applications, such as access panels or shelves, peripheral edges of both the cement board and the tile layers are exposed.

[0009] A combination schluter and nosing strip is suggested in U.S. Pat. No. 5,433,986 (Moscatello) for covering of a tile edge and a stair tread. The trim strip of Moscatello includes a bar segment, an anchoring flange, and a nosing segment. The bar segment is designed for covering a tile edge, the anchoring flange is designed for coupling between a tile layer and stair tread, and the nosing segment is designed for covering and overhanging a stair tread. Unfortunately, Moscatello is primarily limited to stair tread applications and although providing ease of installation, does not account for transitioning between multiple structural layers. Additionally, since the trim strip of Moscatello is designed to overhang a stair tread, it is not feasible for use in flush mount type applications where an aesthetically pleasing finished flush appearance between a trim strip and a sub-platform or between a trim strip and an adjacent surface is desired.

[0010] It is therefore desirable to provide an apparatus that overcomes the numerous functional and installation-related shortcomings associated with conventional trim strips, and provide an apparatus and system which are capable of covering multiple structural layers, providing an transition between structural layers and adjacent surfaces, are aesthetically pleasing and cost effective, and are relatively easy to incorporate in various material installations.

SUMMARY OF THE INVENTION

[0011] The present invention provides an apparatus and system for covering and providing a transitional mating intermediate for multiple structural material surfaces. A trim strip is provided that includes an anchoring flange. A structural material cover is coupled to the anchoring flange. The structural material cover includes an upper cover member and a lower cover member. The upper cover member covers a portion of an exposed structural material layer. The lower cover member has a structural material flush mounting surface edge and covers a portion of a structural material sub-layer. A method of forming a multiple layer structure is also provided that includes applying a compound structural material cover and intermediate trim strip to a peripheral edge of a sub-layer. The method also includes applying an exposed structural material layer to the sub-layer and to the compound structural material cover and intermediate trim strip.

[0012] One of several advantages of the present invention is that it provides a trim strip that serves as both a multiple layer edge cover and as an intermediate between adjacent structural material layers.

[0013] Another advantage of the present invention is that it provides a flush aesthetically desirable trim piece and mating edge for mating with sub-layers and adjacent layers.

[0014] Furthermore, the present invention is application versatile in that it may be applied in structural material construction applications, using various materials, and having any number of structural material layers.

[0015] Moreover, the present invention provides rigidity, strength, and durability to a compound joint and to a periphery cover area.

[0016] The present invention itself, together with further objects and attendant advantages, will be best understood by reference to the following detailed description, taken in conjunction with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] For a more complete understanding of this invention reference should now be had to the embodiments illustrated in greater detail in the accompanying figures and described below by way of examples of the invention wherein:

[0018] FIG. 1 is a perspective view of a compound structural material cover and intermediate trim strip in accordance with an embodiment of the present invention;

[0019] FIG. 2 is a cross-sectional view of the compound structural material cover and intermediate trim strip installed in a tiled floor application in accordance with an embodiment of the present invention;

[0020] FIG. 3 is a cross-sectional view of a compound structural material cover and intermediate trim strip installed in a single sub-layer tiled wall application in accordance with another embodiment of the present invention;

[0021] FIG. 4A is a cross-sectional view of the compound structural material cover and intermediate trim strip, of FIG. 1, having a single anchoring flange installed in a multiple sub-layer tiled wall application in accordance with another embodiment of the present invention;

[0022] FIG. 4B is a cross-sectional view of a compound structural material cover and intermediate trim strip having a pair of anchoring flanges installed in a multiple sub-layer tiled wall application in accordance with another embodiment of the present invention;

[0023] FIG. 5 is a perspective view of the compound structural material cover and intermediate trim strip, of FIG. 1, installed in a shelving application in accordance with another embodiment of the present invention;

[0024] FIG. 6 is a cross-sectional view of the compound structural material cover and intermediate trim strip, of FIG. 1, installed in an access panel application in accordance with another embodiment of the present invention; and

[0025] FIG. 7 is a logic flow diagram illustrating a method of forming a multiple layer structure in accordance with multiple embodiments of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0026] In the following figures the same reference numerals will be used to refer to the same components. While the present invention is described with respect to an apparatus for covering and providing a transitional mating intermediate for multiple structural material surfaces, the present invention may be adapted and applied to various trim applications known in the art. The present invention may be applied to wall surfaces, floors surfaces, shelves, stairs, access panels, doors, as well as other surfaces or trim applications.

[0027] In the following description, various operating parameters and components are described for one constructed embodiment. These specific parameters and components are included as examples and are not meant to be limiting.

[0028] Referring now to FIGS. 1 and 2, a perspective view of a compound structural material cover and intermediate trim strip 10 and a cross-sectional view of the trim strip 10 installed in a tiled floor application, are shown, in accordance with embodiments of the present invention. The trim strip 10 may be applied to a peripheral edge 12 of an installation area 14 of a multiple layer structure 15, as shown in FIG. 2. The trim strip 10 includes one or more anchoring flanges 16 (only one is shown in FIGS. 1 and 2). A structural material cover 18 is coupled to the anchoring flanges 16 and includes an upper cover member 20 and a lower cover member 22. The upper cover member 20 covers at least a portion of an exposed structural material layer edge 24 of an exposed structural material layer 25. The lower cover member 22 has a structural material flush mounting surface edge 26 and covers at least a portion of one or more structural material sub-layers 28 (only one is shown in FIG. 2).

[0029] The anchoring flanges 16 may include, multiple adhesive apertures 30, which may be ornamental in design, and multiple fastener apertures 32, as shown. The adhesive apertures 30 allow adhesive 34, such as cement, mastic compound, or other known adhesive compounds to pass therethrough for adhesively securing the anchoring flanges 16 to the structural material layers 25 and 28. The adhesive 34 is applied to an outermost sub-layer surface 35 to adhesively secure the exposed layer 25 to the sub-layer 28. The fastener apertures 32 provide an additional method of securing the anchoring flanges 16 to one or more sub-layers, such as sub-layer 28. Fasteners 36, which may be, for example, screws or nails, can extend through the fastener apertures 32 and fasten to the sub-layer 28. The fasteners 36 may also include cement board screws, drywall screws, drywall nails, or other fasteners known in the art. The size and shape of the fastener apertures 32 may correspond to a particular application and the type and size of fasteners being utilized in that application.

[0030] The upper cover member 20 includes a first ridge 38 that is adapted to be in contact or close proximity with the exposed layer 25. The ridge 38 forms a first channel 40 with the anchoring flange 16 and the upper cover member 20 for adhesion therein. A first gap 42 exists between an upper member inner surface 44 and the edge 24. The gap 42 may be filled with the adhesive 34 during construction and allow the upper member 20 to be adhesively securely to the exposed layer 25. The upper member 20 may be curved or arced, as shown, to provide an aesthetically desirable smooth transition between the exposed layer 25 and the sub-layer 28 and between adjacent surfaces, such as adjacent surface 46. Of course, the upper member 20 may have various shapes and sizes.

[0031] The lower cover member 22 is an intermediate structural mating member that covers sub-layer edges, such as edge 48, and may also mate sub-layer edges with adjacent structural material layers, such as adjacent layer 50. The lower member 22 includes a first mating surface 52 that mates to the sub-layer 28 and a second mating surface 54 that is in contact with or mates to the adjacent layer 50. The first mating surface 52 may be contoured to mate with a contour of the sub-layer 28. For example, cement board typically has an outer peripheral edge 56 that is circular or arced, as shown in FIG. 3; the first mating surface 52 may also be circular or arced to correspond and mate with the peripheral edge 56.

[0032] The lower cover member 22 includes a second ridge 58 that is adapted to be in contact or in close proximity with the sub-layer 28. The ridge 58 forms a second channel 60 with the anchoring member 16 and the lower member 22 for adhesion therein. A second gap 62 may exist between the first mating surface 52 and a second side edge 64 of the sub-layer 28. The second gap 62 is similar to the first gap 42, in that the second gap 62 may be filled with adhesive during construction and allow the lower member 22 to be adhesively securely to the sub-layer 28.

[0033] The lower member 22 may have a height 66 that is substantially equal to thickness 68 of the sub-layer 28. For example, cement board is commonly produced to have a thickness of approximately 0.5 inches; the lower member height 66 may be approximately equal to 0.5 inches to precisely cover the cement board and allow the flush edge 26 to mate with or reside on a sub-layer below the cement board.

[0034] The anchoring flanges 16 and the structural material cover 18 may be integrally formed together as a single unit. Also, the trim strip 10 may be formed using various methods known in the art including various extrusion processes.

[0035] The trim strip 16 may be formed of various material including aluminum, steel, plastic, or other materials known in the art. The trim strip 16 may be utilized over peripheral edges of various installation areas involving various structural materials. For example, the exposed layer 25 may include structural materials such as tile, grout, stone, wood, linoleum, as well as other material known in the art. Also, sub-layers, such as sub-layer 28, may include structural materials, such as plywood, wood, concrete, cement board, backer board, greenboard, as well as other structural materials known in the art.

[0036] Although, in the preceding FIG. 2 and in the following FIGS. 3-5 the present invention is described and illustrated in respect to multiple tile applications, the present invention may be applied to various other structural material applications known in the art.

[0037] Referring now to FIG. 3, a cross-sectional view of a trim strip 10′ installed in a single sub-layer tiled wall application in accordance with another embodiment of the present invention is shown. The trim strip 10′ is horizontally adhered between a cement board sub-layer 70 and an exposed tile layer 72. Although, the trip strip 10′ is shown as being adhered horizontally, it may be adhered vertically or at any other angle. The cement board layer 70 is directly fastened to a support structure 74, such as a framed wall 76 having studs 78. An adjacent layer 50′, which in an embodiment of the present invention is formed of a drywall material, mates to the trim strip 10′ at a second mating surface 54′.

[0038] Referring now to FIGS. 4A-B, cross-sectional views of the trim strip 10 having a single anchoring flange 80 and of a trim strip 10″ having a pair of anchoring flanges 82 both of which being installed in multiple sub-layer tiled wall applications are shown in accordance with other embodiments of the present invention. In FIG. 4A, the lower cover member 22 covers a cement board sub-layer 84, whereas in FIG. 4B a lower member 22′ covers not only a first sub-layer 86 but also a second sub-layer 88 that resides behind the first sub-layer 86.

[0039] For the embodiment of FIG. 4A, the framed wall 76 is covered by a greenboard layer 90. The greenboard layer 90 acts as a second sub-layer with respect to an exposed layer 91. The cement board layer 84 is fastened through the greenboard layer 90 to the studs 78. Adhesive may be applied between the cement board layer 84 and the greenboard layer 90 for additional strength and support. The flush edge 26 resides on the greenboard layer 90.

[0040] In FIG. 4B, a first anchoring flange 92 is secured between an exposed tile layer 94 and the first sub-layer 86. A second anchoring flange 98 is secured between the first sub-layer 86 and the second sub-layer 88. Flush edge 26′ of the lower member 22′ resides on an adjacent layer 102. In one embodiment of the present invention the adjacent layer 102 is formed of drywall, the first sub-layer 86 is formed of cement board, and the second sub-layer 88 is formed of greenboard. Although, the trim strip 10″ is shown as having a pair of anchoring flanges, any number of anchoring flanges may be used. The lower member 22′ may vary in height to cover one or more sub-layers.

[0041] Referring now to FIG. 5, a perspective view of the trim strip 10 installed in a shelving application in accordance with another embodiment of the present invention is shown. The trim strip 10 may cover a shelf periphery 103 of a shelf 104. The trim strip 10 provides an aesthetically pleasing and finished edge to the shelf 104.

[0042] Referring now to FIG. 6, a cross-sectional view of the trim strip 10 installed in an access panel application in accordance with another embodiment of the present invention is shown. The trim strip 10 may cover a panel periphery 105 of a pair of access panels 106 that overlaps over exposed tile layers 108. When the access panels 106 are in a closed position, as shown, the flush edge 26 may reside on the exposed adjacent tile layers 108 surrounding the access panels 106, providing an aesthetically pleasing access panel configuration. The trim strip 10 is versatile in that it may be used in various applications, the above-stated applications being just a few examples.

[0043] Referring now to FIG. 7, a logic flow diagram illustrating a method of forming a multiple layer structure in accordance with multiple embodiments of the present invention is shown.

[0044] In step 120, one or more sub-layers are applied to a support structure. As shown in FIGS. 4A and 4B, the greenboard sub-layers 90 and 100 and the cement board sub-layer 84 and 88 may be fastened to a stud wall 76.

[0045] In step 122, an adhesive compound, such as compound 34 is applied to the outer most sub-layer, such as sub-layers 28, 70, 84, and 88. The adhesive material 34 may be applied to both an outer most surface of the sub-layers, such as surface 35 and to a peripheral edge of the sub-layers, such as edge 64.

[0046] In step 124, using the embodiment of FIG. 2, the trim strip 10 is applied to the peripheral edge 64. The anchoring member 16 is adhered to the outer most sub-layer 28. When multiple sub-layers exist, lower members and additional anchoring flanges may be adhesively secured to sub-layers other than the outer most sub-layer, such as in the embodiment of FIG. 4B. In step 126, continuing from the example of FIG. 2, the trim strip 10 may be further fastened to the sub-layer 28 via the fasteners 36 extending through the fastener apertures 32. In step 128, the exposed layer 25 is applied to the sub-layer 28 and to the trim strip 10. The anchoring member 16 is adhered to the exposed layer 25. The upper cover member 20 covers and adheres to the edge 24.

[0047] The above-described steps are meant to be an illustrative example; the steps may be performed synchronously, sequentially, simultaneously, or in a different order depending upon the application.

[0048] The present invention provides a trim strip that may be applied to peripheral edges of various structural material layers. The present invention provides a compound trim strip that may be utilized to cover and transition between multiple structural layers. The present invention is simple in design, inexpensive to manufacture, easy to incorporate in various installations, and aesthetically desirable.

[0049] While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention, numerous modifications may be made to the methods and apparatus described without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. A trim strip comprising:

at least one anchoring flange; and

a structural material cover coupled to said at least one anchoring flange comprising;

an upper cover member covering at least a portion of an exposed structural material layer; and

a lower cover member having a structural material flush mounting surface edge and covering at least a portion of at least one structural material sub-layer.

2. A strip as in claim 1 wherein said at least one anchoring flange comprises at least one adhesive aperture.

3. A strip as in claim 1 wherein said anchoring member comprises at least one fastener aperture.

4. A strip as in claim 1 wherein said upper cover member comprises a ridge that is adapted to be in close proximity with said exposed structural material layer.

5. A strip as in claim 4 wherein said ridge forms a channel with said at least one anchoring member and said upper cover member for adhesion therein.

6. A strip as in claim 1 wherein said upper cover member has a curved configuration.

7. A strip as in claim 1 wherein said lower cover member is an intermediate structural mating member that mates said at least one structural material sub-layer with an adjacent structural material layer.

8. A strip as in claim 1 wherein said intermediate structural mating member comprises:

a first mating surface mating to said at least one structural material sub-layer; and

a second mating surface mating to said adjacent structural material layer.

9. A strip as in claim 1 wherein said lower cover member comprises a ridge that is adapted to be in close proximity with said at least one structural material sub-layer.

10. A strip as in claim 9 wherein said ridge forms a channel with said at least one anchoring member and said lower cover member for adhesion therein.

11. A strip as in claim 1 wherein said lower cover member comprises an inner surface that is contoured to mate with a surface of a sub-layer formed of a structural material selected from at least one of plywood, wood, concrete, cement board, backer board, and greenboard.

12. A strip as in claim 1 wherein said at least one anchoring flange is integrally formed with said structural material cover.

13. A strip as in claim 1 wherein the trim strip is formed by an extrusion process.

14. A strip as in claim 1 wherein said lower cover member has height substantially equal to thickness of a sub-layer formed of a structural material selected from at least one of plywood, wood, concrete, cement board, backer board, and greenboard.

15. A method of forming a multiple layer structure comprising:

applying at least one sub-layer to a support structure;

applying an adhesive compound to said at least one sub-layer;

applying a compound structural material cover and intermediate trim strip to a peripheral edge of said at least one sub-layer; and

applying an exposed structural material layer to said at least one sub-layer and to said compound structural material cover and intermediate trim strip.

16. A method as in claim 15 wherein applying a compound structural material cover and intermediate trim strip and applying an exposed structural material layer comprises;

covering at least a portion of said first sub-layer with a lower cover member of a structural material cover having a structural material flush mounting surface edge;

adhering at least one anchoring flange to said at least one sub-layer and said exposed structural material layer; and

covering at least a portion of said exposed structural material layer with an upper cover member of said structural material cover.

17. A method as in claim 16 further comprising fastening said at least one anchoring flange to said at least one sub-layer.

18. A compound structural material cover and intermediate trim strip comprising:

at least one anchoring flange adapted to adhere to multiple structural material layers;

a structural material cover coupled to said at least one anchoring flange comprising;

an curved upper cover member having a first ridge that is adapted to be in close proximity with an exposed structural material layer, said curved cover member covering a first exposed edge of said exposed structural material layer; and

a lower cover member covering a second exposed edge of at least one structural material sub-layer and comprising;

a structural material flush mounting surface edge; and

a second ridge that is adapted to be in close proximity with at least one structural material sub-layer.

19. A strip as in claim 18 wherein said first ridge and said second ridge form a pair of channels with said at least one anchoring member, said arced upper cover member, and said lower cover member for adhesion therein with said exposed structural material layer and said at least one structural material sub-layer.

20. A strip as in claim 18 wherein said lower cover member is an intermediate structural mating member that mates said at least one structural material sub-layer with an adjacent structural material layer, wherein said intermediate structural mating member comprises:

a first mating surface mating to said at least one structural material sub-layer; and

a second mating surface mating to said adjacent structural material layer.