U.S. patent application number 09/255079 was filed with the patent office on 2002-05-23 for method and kit for repairing a construction component.
Invention is credited to HAGEL, RICHARD C..
Application Number | 20020059772 09/255079 |
Document ID | / |
Family ID | 22966747 |
Filed Date | 2002-05-23 |
United States Patent
Application |
20020059772 |
Kind Code |
A1 |
HAGEL, RICHARD C. |
May 23, 2002 |
METHOD AND KIT FOR REPAIRING A CONSTRUCTION COMPONENT
Abstract
The present invention is a method and kit for repairing a
construction component that has a damaged portion. First, the
damaged portion is removed from the construction component. Next, a
durable portion is provided that is preferably comprised of a
cellulosic/polymer composite material which is moisture, decay, and
insect resistant. The durable portion preferably has about the same
shape as the damaged portion. The durable portion is then connected
to the construction component to replace the damaged portion. The
materials for repairing the construction component may be provided
in a single kit.
Inventors: |
HAGEL, RICHARD C.;
(NACOGDOCHES, TX) |
Correspondence
Address: |
STANDLEY & GILCREST LLP
495 METRO PLACE SOUTH
SUITE 210
DUBLIN
OH
43017
US
|
Family ID: |
22966747 |
Appl. No.: |
09/255079 |
Filed: |
February 19, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09255079 |
Feb 19, 1999 |
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09130160 |
Aug 6, 1998 |
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09130160 |
Aug 6, 1998 |
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08837776 |
Apr 22, 1997 |
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08837776 |
Apr 22, 1997 |
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08612757 |
Mar 8, 1996 |
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Current U.S.
Class: |
52/656.4 |
Current CPC
Class: |
E04G 23/0277 20130101;
E06B 1/06 20130101; E06B 1/32 20130101; E06B 1/6092 20130101; E06B
3/984 20130101; E04G 23/02 20130101; E06B 1/52 20130101 |
Class at
Publication: |
52/656.4 |
International
Class: |
E04C 002/38 |
Claims
What is claimed is:
1. A method for repairing a wooden component, said method
comprising: removing a desired portion of said wooden component;
providing a durable portion comprised of a cellulosic/polymer
composite material which is moisture, decay, and insect resistant,
said durable portion having approximately the same shape as said
desired portion; and connecting said durable portion to said wooden
component to replace said desired portion.
2. The method of claim 1 wherein said desired portion of said
wooden component is deteriorating.
3. The method of claim 1 wherein said desired portion of said
wooden component is damaged.
4. The method of claim 1 wherein said durable portion is connected
to said wooden component by a finger joint.
5. The method of claim 1 wherein said durable portion is connected
to said wooden component by at least one dowel.
6. The method of claim 1 wherein said durable portion is connected
to said wooden component by an adhesive.
7. The method of claim 1 wherein said durable portion is connected
to said wooden component by mechanical means.
8. The method of claim 1 wherein said durable portion is an
extruded product.
9. The method of claim 1 wherein said durable portion is a molded
product.
10. The method of claim 1 wherein said wooden component is a member
of the group consisting of a door, a door frame, a window frame, a
deck plank, a garage door, a garage door frame, a porch post, a
casing, and a brickmold.
11. A method for repairing a construction component that is
comprised of fibrous material, said method comprising: removing a
desired portion of said construction component; providing a durable
portion comprised of a cellulosic/polymer composite material which
is moisture, decay, and insect resistant, said durable portion
having approximately the same shape as said desired portion; and
connecting said durable portion to said construction component to
replace said desired portion.
12. The method of claim 11 wherein said desired portion of said
construction component is harmed by moisture, decay, or
insects.
13. A kit comprising the combination of: a durable member of
predetermined shape; means for connecting said durable member to a
preexisting structure; and means for instructing a user of said kit
how to install said durable member.
14. The kit of claim 13 further comprising at least one shim.
15. The kit of claim 13 further comprising sandpaper.
16. The kit of claim 13 further comprising tool means for removing
a damaged portion from said preexisting structure, wherein said
durable member is adapted to replace said damaged portion of said
preexisting structure.
17. The kit of claim 13 further comprising tool means for
installing said durable member.
18. The kit of claim 13 further comprising means for marking said
preexisting structure such that a desired portion of said
preexisting structure may be removed and replaced by said durable
member.
Description
[0001] This is a continuation-in-part of U.S. application Ser. No.
09/130,160, filed Aug. 6, 1998. U.S. application Ser. No.
09/130,160 is a continuation of U.S. application Ser. No.
08/837,776, filed Apr. 22, 1997, now U.S. Pat. No. ______. U.S.
application Ser. No. 08/837,776 is a continuation of U.S.
application Ser. No. 08/612,757, filed Mar. 8, 1996, now U.S. Pat.
No. 5,661,943.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates generally to a method and kit
for repairing a construction component, and more particularly, to a
method and kit for repairing a construction component that has a
deteriorating or damaged portion. The present invention is
particularly useful for repairing wooden construction components
that have been harmed by moisture, decay, or insects. However,
those skilled in the art should recognize that the present
invention may be utilized to repair practically any type of damage
that may be caused to a construction component.
[0003] A portion of a construction component may be damaged while
the remainder of the construction component remains substantially
undamaged. For one example, repeated mopping of a floor may cause
deterioration of the bottom portions of wooden doors and door
frames which come into contact with the mop. For another example, a
portion of a deck plank may be damaged by termites.
[0004] In light of this problem, a need exists for a method for
replacing only a damaged portion of a construction component.
Another need exists for a method for repairing a construction
component to prevent the same type of damage in the future. Yet
another need exists for a method for repairing a construction
component which results in a desired physical appearance.
[0005] The present invention satisfies some or all of these needs.
One embodiment of the present invention provides a method for
repairing a wooden component. First, a desired portion is removed
from the wooden component. The desired portion may be damaged,
deteriorating, discolored, or in practically any state of
disrepair. Next, a durable portion is provided that is preferably
comprised of a cellulosic/polymer composite material which is
moisture, decay, and insect resistant. The durable portion
preferably has about the same shape as the desired portion. The
durable portion is then connected to the wooden component to
replace the desired portion.
[0006] Another embodiment of the present invention provides a
method for repairing a construction component that is comprised of
fibrous material. In this method, a desired portion is removed from
the construction component. The desired portion may be damaged,
deteriorating, discolored, or in practically any state of
disrepair. A durable portion is then provided which preferably has
about the same shape as the desired portion that was removed from
the construction component. The durable portion may be comprised of
a cellulosic/polymer composite material which is moisture, decay,
and insect resistant. The durable portion is then connected to the
construction component to replace the desired portion.
[0007] The methods of the present invention may be used to repair
practically any type of construction component that is comprised of
fibrous material. For example, the methods of the present invention
may be used to repair doors, door frames, window frames, deck
planks, garage doors, garage door frames, porch posts, fence posts,
casings, brickmolds, and other similar types of components. It
should also be recognized that the methods of the present invention
may be used to repair other types of components, whether or not
comprised of a fibrous material, that have a damaged portion that
may be removed.
[0008] In addition to the novel features and advantages mentioned
above, other objects and advantages of the present invention will
be readily apparent from the following descriptions of the drawings
and preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a door frame that has been
damaged by repeated mopping of the surrounding floor;
[0010] FIG. 2 is a perspective view of the door frame of FIG. 1
after the damaged portions have been removed according to a
preferred method of the present invention;
[0011] FIG. 3 is a perspective view of the door frame of FIG. 1
after the damaged portions have been replaced with durable portions
according to a preferred method of the present invention; and
[0012] FIG. 4 is a flow diagram of a preferred method of the
present invention for repairing a construction component.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)
[0013] The present invention is directed to a method and kit for
repairing a construction component that has a portion which is
deteriorating, damaged, discolored, or in a state of disrepair. The
present invention is particularly useful for repairing damage to a
construction component that is caused by moisture, decay, or
insects. However, it is believed that the patentability of the
present invention is not dependent on the cause or type of
damage.
[0014] FIG. 1 shows an example of a door frame 10 that has been
damaged by repeated mopping of a floor 20. In particular, portions
12, 14 of the door frame 10 have deteriorated due to excessive
contact with a wet mop. In order to repair the door frame 10
according to a preferred method of the present invention, the
portions 12, 14 are removed from the door frame 10. The portions
12, 14 may be removed from the door frame 10 by any conventional
means including, but not limited to, cutting, sawing, chopping,
sanding, and other suitable wood, plastic, and metal processing
techniques.
[0015] FIG. 2 shows the door frame 10 after the portions 12, 14
have been removed. Before, during, or after the removal of portions
12, 14, the edges 16, 18 of the door frame 10 may be shaped,
finished, and contoured to facilitate the formation of joints
between the door frame 10 and the durable portions that replace the
portions 12, 14. The edges 16, 18 may be shaped, finished, and
contoured by any conventional means including, but not limited to,
cutting, sawing, chopping, sanding, and other suitable wood,
plastic, and metal processing techniques.
[0016] FIG. 3 shows the door frame 10 after the durable portions
32, 34 have been connected to the door frame 10 according to a
preferred method of the present invention to replace the portions
that were removed from the door frame 10. The durable portions 32,
34 are preferably moisture, decay, and insect resistant, and the
durable portions 32, 34 are preferably resistant to the type of
damage sustained by portions 12, 14. The durable portions 32, 34
may be comprised of practically any material that may be shaped or
formed into a desired shape. For example, the durable portions 32,
34 may be comprised of wood, treated wood, plastic, vinyl, metal,
or combinations that include any of these materials such as
material composites including, but not limited to, polyvinyl
chloride (PVC) formulations, high density polyethylene (HDPE)
formulations, cellulosic/polymer composites, and other similar
material composites. As known in the art, cellulosic/polymer
composites may be sawed, sanded, shaped, turned, fastened,
finished, painted, and stained in the same or similar manner as
natural woods. Examples of extrudable cellulosic/polymer composites
that may be utilized in preferred embodiments of the present
invention include TIMBERTECH.RTM., ERT.RTM., TREX.RTM., and the
like.
[0017] A cellulosic/polymer composite material may be comprised of
one or more raw materials including, but not limited to, cellulosic
materials, thermoplastic materials, inorganic fillers,
cross-linking agents, process lubricants, accelerators, inhibitors,
enhancers, compatibilizers, blowing agents, and other suitable
materials. Examples of cellulosic materials include sawdust,
newspapers, alfalfa, wheat pulp, wood chips, wood fibers, wood
particles, ground wood, wood flour, wood flakes, wood veneers, wood
laminates, paper, cardboard, straw, cotton, rice hulls, coconut
shells, peanut shells, bagass, plant fibers, bamboo fiber, palm
fiber, kenaf, and other fibrous materials. The thermoplastic
materials may include multilayer films, HDPE, polypropylene, PVC,
low density polyethylene (LDPE), CPVC ABS, ethyl-vinyl acetate,
other suitable polyethylene copolymers, other suitable
thermoplastic materials, and formulations that incorporate any of
the aforementioned materials. Examples of inorganic fillers include
talc, calcium carbonate, kaolin clay, magnesium oxide, titanium
dioxide, silica, mica, barium sulfate, and other suitable inorganic
materials. Cross-linking agents may include polyurethanes such as
isocyanates, phenolic resins, unsaturated polyesters, and epoxy
resins. Combinations of the aforementioned agents are also known
examples of cross-linking agents. In addition, lubricants such as
zinc stearate and wax may be used to aid the shaping process.
[0018] Each of the durable portions 32, 34 may have practically any
shape which enables it to be connected to the door frame 10 to
replace the respective portion that was removed from the door frame
10. It is preferred that the durable portions 32, 34 have shapes
that are about the same as the respective shapes of the portions
that each will replace to repair the door frame 10. Herein, when it
is stated that a durable portion has approximately the same shape
as the portion which it will replace, it is referring to the shape
of the portion prior to any damage which may have been sustained by
the portion.
[0019] The durable portions 32, 34 may be shaped or formed using
conventional techniques. For example, if the durable portions 32,
34 are comprised of thermoplastic or cellulosic/polymer composite
materials, the durable portions 32, 34 may be extruded or molded to
obtain final net shapes. In addition, other conventional wood,
plastic, and metal processing techniques including, but not limited
to, cutting, sawing, chopping, and sanding may be utilized to
achieve the final net shapes of the durable portions 32, 34.
[0020] The durable portions 32, 34 may be connected to the door
frame 10 utilizing conventional techniques, and the joints between
the durable portions 32, 34 and the door frame 10 may be of any
suitable type. For maximum aesthetic appeal, it is preferred that
edges of the durable portions 32, 34 are adapted to mate with the
respective edges 16, 18 of the door frame 10. FIG. 3 shows examples
of glued finger joints 42, 44 between edges of the durable portions
32, 34 and the respective edges 16, 18 of the door frame 10.
Another example of a joint may be formed by adhesively bonding a
substantially flat edge of a durable portion to a substantially
flat edge of a component that is being repaired. In addition to
adhesives such as glues, epoxies, and other suitable adhesives, a
durable portion may be connected to a construction component by at
least one dowel, by mechanical means such as a brace, a bracket, a
hinge, pins, nails, screws, clamps, or other mechanical fastening
devices, or by fastening the durable portion and the construction
component to a common support structure (e.g., a wall) using
adhesives, dowels, or any of the aforementioned mechanical
means.
[0021] The materials for repairing the construction component may
be provided in a single kit. The kit may include one or more
durable portions, sandpaper, shims, adhesives, mechanical fastening
means, tools for removing the damaged portion(s) and/or installing
the durable portion(s) (e.g., a saw, a utility knife, a
hand-operated cutting tool, a router, a plane, and/or a chisel), a
form or pattern that enables a user to mark the construction
component so that a desired portion of the construction component
may be removed, written or pictorial instructions for repairing the
construction component using the kit, and any other suitable
materials that may facilitate the repair of the construction
component. One example of a form or pattern is a molded piece that
generally conforms to the shape of the construction component so
that the construction component may be easily marked or cut. FIG. 4
is a flow diagram of a preferred set of instructions for repairing
a door frame that has a damaged portion. As used therein,
FrameSaver.TM. End refers to a durable portion of the present
invention that may be used to repair a door frame, and
FrameSaver.TM. TrimEnd refers to a durable portion of the present
invention that may be used to repair the trim of a door frame.
[0022] The items in each kit are preferably adapted to repair a
particular shape and type of construction component such as a
particular door or window frame. For example, the durable portion
may have a predetermined shape, length (e.g., 8 or 10 inches), and
edge. In addition, the form or pattern may have a predetermined
shape, length, and edge so that the shape of the portion to be
removed from the construction component is approximately the same
as the shape of the durable portion.
[0023] The preferred embodiments herein disclosed are not intended
to be exhaustive or to unnecessarily limit the scope of the
invention. The preferred embodiments were chosen and described in
order to explain the principles of the present invention so that
others skilled in the art may practice the invention. Having shown
and described preferred embodiments of the present invention, those
skilled in the art will realize that many variations and
modifications may be made to affect the described invention. Many
of those variations and modifications will provide the same result
and fall within the spirit of the claimed invention. It is the
intention, therefore, to limit the invention only as indicated by
the scope of the claims.
* * * * *