Coating processes – With post-treatment of coating or coating material – Solid treating member or material contacts coating
Reissue Patent
1999-09-27
2001-11-06
Bareford, Katherine A. (Department: 1762)
Coating processes
With post-treatment of coating or coating material
Solid treating member or material contacts coating
C427S403000, C118S125000, C264S171130, C264S271100, C264S275000, C264S279000, C264S299000
Reissue Patent
active
RE037436
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to decorative moldings of the type used in the construction industry to adorn walls and ceilings.
BACKGROUND OF THE INVENTION
Decorative moldings have been used for some time in the construction industry. The moldings used typically had a flat surface on one side and a decorative surface on the other. A visually appealing design, usually in three dimensions, is formed on the decorative surface of the molding, while the flat surface is configured to fit against the wall or ceiling. The molding is mounted to the wall such that the decorative surface is exposed to view, The molding is attached to the wall by applying an adhesive to the flat surface of the molding and then pressing the glued surface to the wall.
Traditionally, moldings have been made of plaster. Due to the relative weight and inflexibility of plaster, traditional moldings could not be used with all wall surfaces, especially on the exterior of a building. Wooden moldings have become popular for some applications due to their relative flexibility and lightness. The cost of wooden moldings can be high, and wooden moldings tend to deteriorate if exposed to the elements.
Recently, exterior moldings have been made of foam. The foam moldings are often composed of an expanded polymer such as polystyrene or polyurethane. The foam molding may be used as is, but in most cases the decorative surface of the molding is covered with mesh and then a coating of either plaster or cement. The coating is applied by hand by either spraying or trowelling. The coating is done after the foam molding is attached to the wall.
The application of the coating to the foam molding has been done by hand. This is a one consuming business and the quality of the finished product is not always consistent In some cases the finished decorative surface is sloppy or the coating is of uneven thickness. The unevenness of the coating may make the molding more rigid in some places than in others. The unevenness of the coating tends to make the coating crack and delaminate over time.
SUMMARY OF THE INVENTION
The invention is a method of manufacturing an elongated decorative molding having a decorative surface and a desired cross-sectional profile, comprising the steps of applying a first coating material to a moulded core and then passing the moulded core through the opening of a first die. Once hardened, the coated profile is again coated with a second coating material and then passed through a second die.
The moulded core has a flat surface on one side, a decorative surface on another side and a cross sectional profile. The cross sectional profile of the moulded core is proportionally smaller than the desired cross sectional profile of the finished decorative molding. The coating material is applied to the decorative surface of the core and the profile of the die opening is proportionally larger than the cross-sectional profile of the core such that the decorative surface of the core is spaced from the die as it passes through the die opening.
The invention also comprises a device for coating a molding core comprising a coating means for applying the coating material to the molding core, a die for removing the excess coating material from the molding core and a feeding means for pushing the molding core through the coating means and through the die.
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patent: 658427 (1900-09-01), Cermak
patent: 3084662 (1963-04-01), Badger
patent: 3428024 (1969-02-01), Oita et al.
patent: 5672391 (1997-09-01), Santarossa
patent: 2804326 A1 (1979-08-01), None
patent: 3932573 A1 (1991-04-01), None
888804 Ontario Limited
Bareford Katherine A.
Kusner Mark
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