U.S. patent application number 11/566001 was filed with the patent office on 2007-07-05 for trim components and methods for manufacturing same.
Invention is credited to John Pace, Shawn Petras.
Application Number | 20070151180 11/566001 |
Document ID | / |
Family ID | 38110576 |
Filed Date | 2007-07-05 |
United States Patent
Application |
20070151180 |
Kind Code |
A1 |
Pace; John ; et al. |
July 5, 2007 |
TRIM COMPONENTS AND METHODS FOR MANUFACTURING SAME
Abstract
Trim components incorporating a nail flange and/or one or more
siding receiving spaces/slots. A single-piece corner trim component
of board construction defining a seamless outer surface and a pair
of siding receiving spaces/slots. A method of manufacturing a
single-piece corner trim component by forming first and second
siding receiving spaces along first and second edges, respectively,
of an inner surface of a board, the first and second siding
receiving spaces being substantially parallel to each other;
forming a substantially V-shaped groove in the inner surface of the
board, the V-shaped groove is disposed substantially parallel to
each of the first and second siding receiving spaces and is defined
by a first slanted edge, a second slanted edge and a skin disposed
between the vertex of the V-shaped groove and an outer surface of
the board, and joining together the first and second slanted edges
so that the skin defines a seamless outer corner.
Inventors: |
Pace; John; (Cranberry Twp.,
PA) ; Petras; Shawn; (Freeport, PA) |
Correspondence
Address: |
THORP REED & ARMSTRONG, LLP
ONE OXFORD CENTRE
301 GRANT STREET, 14TH FLOOR
PITTSBURGH
PA
15219-1425
US
|
Family ID: |
38110576 |
Appl. No.: |
11/566001 |
Filed: |
December 1, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60741964 |
Dec 2, 2005 |
|
|
|
Current U.S.
Class: |
52/287.1 |
Current CPC
Class: |
E04F 19/04 20130101;
E04F 19/02 20130101; E04F 2019/0422 20130101; A47B 2096/203
20130101; E04F 2019/0427 20130101; E04F 2019/0413 20130101; E04F
19/0495 20130101 |
Class at
Publication: |
052/287.1 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. An elongated corner trim component comprising a single-piece
board construction comprising first and second sides defining a
seamless outer surface and a siding receiving space defined by an
edge of each of said first and second sides.
2. The elongated corner trim component of claim 1 wherein a joint
between said first and second sides comprises a first slanted edge
of said first side and a second slanted edge of said second
side.
3. The elongated corner trim component of claim 2 further
comprising a skin that is an integral part of both said seamless
outer surface and an outer corner of said elongated corner trim
component.
4. The elongated corner trim component of claim 2 wherein said skin
is contiguous with each of said first and second slanted edges.
5. The elongated corner trim component of claim 2 wherein said skin
has a thickness of about 0.003 inches to about 0.008 inches.
6. The elongated corner trim component of claim 2 wherein a
protruding portion defined by one of said first and second slanted
edges is disposed within a recess defined by the other of said
first and second slanted edges.
7. The elongated corner trim component of claim 1 wherein the
single-piece board construction comprises a polymer.
8. The elongated corner trim component of claim 3 further
comprising tape disposed on said outer corner.
9. The elongated corner trim component of claim 1 wherein the
single-piece board construction comprises polyvinyl chloride.
10. The elongated corner trim component of claim 1 wherein each
siding receiving space has a substantially equal leg "L" shaped
cross-section.
11. An elongated trim component comprising outer and inner surfaces
wherein said inner surface defines a nail flange.
12. The elongated trim component of claim 11 wherein said inner
surface also defines a siding receiving space.
13. The elongated trim component of claim 11 comprising a
single-piece board construction of PVC material.
14. An elongated trim component of single-piece board construction
comprising outer and inner surfaces wherein said inner surface
defines a siding receiving space.
15. An elongated corner trim component comprising: a single-piece
construction comprising: a first side having an edge that defines a
first siding receiving space; a second side having an edge that
defines a second siding receiving space; and an interior joint
between said first and second sides comprising a first slanted edge
of said first side and a second slanted edge of said second side;
wherein said first and second sides define a seamless outer surface
comprising a skin as an integral part of said seamless outer
surface and said skin defines an outer corner of said elongated
corner trim component.
16. The elongated corner trim component of claim 15 wherein said
skin is contiguous with each of said first and second slanted
edges.
17. The elongated corner trim component of claim 15 wherein said
skin has a thickness of about 0.003 inches to about 0.008
inches.
18. The elongated corner trim component of claim 15 wherein said
skin has a thickness of about 0.005 inches.
20. The elongated corner trim component of claim 15 wherein a
protruding portion defined by one of said first and second slanted
edges is disposed within a recess defined by the other of said
first and second slanted edges.
21. The elongated corner trim component of claim 15 further
comprising tape disposed on said outer corner.
22. The elongated corner trim component of claim 15 comprising a
PVC material.
23. A method of manufacturing an elongated corner trim component of
single-piece construction comprising: forming first and second
siding receiving spaces along first and second edges, respectively,
of an inner surface of a board, wherein said first and second
siding receiving spaces are substantially parallel to each other;
forming a substantially V-shaped groove in said inner surface,
wherein said V-shaped groove is disposed substantially parallel to
each said first and second siding receiving spaces and said
V-shaped groove is defined by a first slanted edge, a second
slanted edge and a skin of board material disposed between a vertex
of said V-shaped groove and an outer surface of the board, and
joining together said first and second slanted edges to form said
corner trim component wherein said skin defines a seamless outer
corner of said elongated corner trim component.
24. The method of claim 23 wherein said skin has a thickness of
about 0.003 inches to about 0.008 inches.
25. The method of claim 23 wherein all of said forming steps are
performed by one or more cutting processes.
26. The method of claim 23 wherein all of said forming steps are
performed by milling.
27. The method of claim 23 wherein an adhesive is used in joining
together said first and second slanted edges.
28. The method of claim 23 wherein heat welding is used in joining
together said first and second slanted edges.
29. The method of claim 23 wherein ultrasonic welding is used in
joining together said first and second slanted edges.
30. The method of claim 23 further comprising applying an adhesive
to an inner corner joint formed by the joining together of said
first and second slanted edges.
31. The method of claim 30, further comprising blowing air into
contact with said adhesive to accelerate the curing of said
adhesive.
32. The method of claim 23 further comprising applying a
reinforcement element over said outer corner of said elongated
corner trim component.
33. The method of claim 32 wherein said reinforcement element
comprises a tape.
34. The method of claim 23 further comprising: forming a protrusion
on one of said first and second slanted edges; and forming a recess
on the other of said first and second slanted edges, wherein said
protrusion is disposed in said recess after the joining together of
said first and second slanted edges.
35. The method of claim 34 wherein all of said forming steps are
performed by one or more cutting processes.
36. A method of trimming a building structure comprising: supplying
one or more trim components selected from the group consisting of:
(i) an elongated trim component of a single-piece board
construction defining a nail flange and a siding receiving space;
(ii) an elongated trim component of a single-piece board
construction defining a siding receiving space; (iii) an elongated
trim component of a single-piece board construction defining a pair
of siding receiving spaces; (iv) an elongated trim component of a
single-piece board construction defining a nail flange and (v) an
elongated, corner trim component of a single-piece board
construction defining a seamless outer surface and a pair of siding
receiving spaces; and installing the one or more selected trim
components on a building such that at least one end of one or more
pieces of siding installed on the building is received within a
siding receiving space of, or abuts against one of, the one or more
selected trim components installed on the building.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from provisional
application Ser. No. 60/741,964 filed Dec. 2, 2005 and entitled
Trim Components And Method For Trimming A Building, the entirety of
which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to trim components
for building structures and to methods for manufacturing such trim
components and for trimming a building structure.
[0003] U.S. Pat. No. 4,827,683 discloses a corner post formed of
two elongated members, which may be molded plastic, each member
having a decorative ridge on the front face, a part of one ridge on
one of the members lying along an edge thereof and defining a
flange having an inner face which abuts an adjacent edge of the
other member and covers the joint between the members. The ridge on
the other member is spaced from its edge, the same distance as the
first ridge is spaced from the front face of the other member and
additional symmetrically spaced ridges are also disclosed.
[0004] U.S. Pat. No. 4,189,885 discloses trim components for siding
construction, the principal trim component of which is a trim strip
having a J-shaped channel and a smaller adjacent C-shaped channel
opening substantially perpendicular to each other. Two of such trim
strips together with a corner cap form an outside corner assembly.
The principal trim strip of U.S. Pat. No. 4,189,885 is also
disclosed as being useful for covering soffits and window and door
trim.
[0005] The trim components of the above-mentioned patents include
either extraneous decorative elements or complicated J-shaped or
C-shaped channels which increase the cost and complexity of the
processes for manufacturing and installing such items.
[0006] The present invention in its various preferred embodiments
described herein overcomes the shortcomings of such prior art
components by providing highly aesthetic, yet efficient and
cost-effective trim components and methods for manufacturing and
installing the same.
SUMMARY OF THE INVENTION
[0007] One aspect of the present invention relates to an elongated
corner trim component comprising a single-piece board construction
comprising first and second sides defining a seamless outer surface
and a siding receiving space defined by an edge of each of the
first and second sides. A joint between the first and second sides
may comprise a first slanted edge of the first side and a second
slanted edge of the second side. The elongated corner trim
component of the present invention may further comprise a skin that
is an integral part of the seamless outer surface where the skin
defines an outer corner of the elongated corner trim component.
Preferably, the skin is contiguous with each of the first and
second slanted edges and has a thickness of about 0.003 inches to
about 0.008 inches, and most preferably a thickness of about 0.005
inches. A protruding portion defined by the first slanted edge is
disposed within a recess defined by the second slanted edge to help
secure together the first and second sides of the elongated corner
trim component. The outer corner of the elongated corner trim
component of the present invention may also be reinforced with
tape. The elongated corner trim component of the present invention
preferably is made from a cellular polyvinyl chloride (or
polychloroethene under IUPAC nomenclature, hereinafter "PVC")
material, but also may be fabricated from other materials including
other polymers, wood, wood/polymer composites, steel, aluminum and
other metals.
[0008] Another aspect of the present invention relates to an
elongated trim component preferably comprising a PVC resin material
having first and second sides wherein the second side has a first
portion removed to define an L-shaped nail flange and a second
portion removed to define a siding receiving space.
[0009] A further aspect of the present invention relates to an
elongated trim component comprising a substantially flat board
having first and second sides wherein the second side has first and
second portions removed to define first and second siding receiving
spaces, respectively.
[0010] A further aspect of the present invention relates to a
method of manufacturing an elongated corner trim component of
single-piece board construction comprising: forming first and
second siding receiving spaces along first and second edges,
respectively, of an inner surface of a generally rectangular board,
wherein the first and second siding receiving spaces are
substantially parallel to each other; forming a substantially
V-shaped groove in the inner surface of a board, wherein the
V-shaped groove is disposed substantially parallel to each the
first and second siding receiving spaces and the V-shaped groove is
defined by a first slanted edge, a second slanted edge and a skin
of board material of about 0.003 inches to about 0.008 inches thick
disposed between the vertex of the V-shaped groove and an outer
surface of the board, and joining together the first and second
slanted edges to form the corner trim component wherein the skin
defines an outer corner of the elongated corner trim component.
Preferably, all of the forming steps are performed by one or more
cutting processes including without limitation milling and an
adhesive is used in joining together the first and second slanted
edges. In addition, the method may further comprise applying an
adhesive to an inner corner joint formed by the joining together of
the first and second slanted edges and blowing air into contact
with the adhesive to accelerate its curing. Further, the method may
also comprise applying, temporarily or permanently, a reinforcement
element, such as tape, over the outer corner of the elongated
corner trim component. Also, the method may comprise forming a
protrusion on the first slanted edge and a recess on the second
slanted edge, wherein the protrusion is disposed in the recess
after the joining together of the first and second slanted edges.
Again, such forming steps preferably are performed by one or more
cutting processes including without limitation milling.
[0011] Yet another aspect of the present invention relates to a
method of trimming a building structure comprising: supplying one
or more trim components selected from the group consisting of: (i)
a first elongated, substantially flat trim component defining a
nail flange and a siding receiving space; (ii) a second elongated,
substantially flat trim component defining a pair of siding
receiving spaces; and (iii) an elongated, corner trim component of
single-piece board construction defining a seamless outer surface
and a pair of siding receiving spaces; and installing the one or
more selected trim components on a building such that at least one
end of one or more pieces of siding previously or subsequently
installed on the building is received within a siding receiving
space of the one or more selected trim components installed on the
building.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For the present invention to be clearly understood and
readily practiced, the present invention will be described in
conjunction with the following figures which are incorporated into
and constitute a part of the specification, wherein:
[0013] FIG. 1 is a cross-sectional view of a intra-wall or window
trim component of the present invention having a nail flange and a
siding receiving space which preferably is used for new
construction applications;
[0014] FIG. 2 is a cross-sectional view of an end-wall or window
trim component of the present invention having a siding receiving
space which preferably is used for remodeling around an existing
window;
[0015] FIG. 3 is a cross-sectional view of a end-wall or window
trim component of the present invention having a nail flange which
preferably is used for new construction applications where the
siding or exterior covering material butts against the trim;
[0016] FIG. 4 is a cross-sectional view of a corner trim component
of the present invention having a single-piece board construction,
a seamless outer surface and a pair of siding receiving spaces;
[0017] FIG. 5 is a cross-sectional view of a substantially flat
trim component of the present invention having a pair of siding
receiving spaces;
[0018] FIG. 6 is a cross-sectional view of an intermediary of the
corner trim component of FIG. 4 made in accordance with a method of
the present invention; and
[0019] FIG. 7 is a cross-sectional view of a starter trim component
of the present invention having a front-facing siding receiving
space.
DETAILED DESCRIPTION
[0020] It is to be understood that the figures and descriptions of
the present invention have been simplified to illustrate elements
that are relevant for a clear understanding of the present
invention, while eliminating, for purposes of clarity, other
elements that may be well known. Those of ordinary skill in the art
will recognize that other elements are desirable and/or required in
order to implement the present invention. However, because such
elements are well known in the art, and because they do not
facilitate a better understanding of the present invention, a
discussion of such elements is not provided herein. The detailed
description of the present invention and the preferred
embodiment(s) thereof are set forth in detail below with reference
to the attached drawings.
[0021] Referring now to the drawings, wherein like reference
numerals designate corresponding structure throughout the views,
FIG. 1 illustrates a preferred embodiment of an intra-wall or
window trim component 10 of the present invention comprising a
front face 12 and a rear face 14. A portion 16 of rear face 14 is
preferably cut out as shown to create nail flange 11 having an
L-shaped upper profile. The cut-out portion 16 and flange 11 are
sized as needed to accommodate window nail flanges and/or other
construction components disposed on a wall of a building structure
away from an end thereof. The cut-out portion 16 and flange 11
allow the trim component 10 to be mounted over a window nail flange
(not shown) while maintaining a level or flush relationship with
respect to other trim components being used to trim the walls of a
building and/or the window itself. The trim component 10 also
defines a siding receiving space 18 for receiving the ends of the
pieces of siding abutting a window (not shown) or other intra-wall
structure (not shown) around which strips of the trim component 10
have been installed for functional and aesthetic purposes. All of
the cut-out portion 16, nail flange 11 and siding receiving space
18 are preferably sized as required for a given application. Also,
the cut-out portion 16 is more preferably 17/8 inches wide by about
1/8 to 5/32 inches deep to accommodate window nail flanges commonly
used in building construction. Likewise, siding receiving space 18
is preferably 3/4 of an inch wide by 3/4 of an inch deep to
accommodate commonly used siding products without requiring any "J"
channels against the trim component 10 or the use of excessive
caulking to seal the joint between the trim and the siding.
[0022] The window trim component 10 of the present invention
preferably is used primarily for new construction applications
where the perimeter trim overlies the window nail flanges. Before
installing the window trim component 10, the window area should be
properly prepared to accept it. The window should be installed
square, true and plumb with the area where the window is to be
installed covered with house wrap. A large bead of sealant is
preferably applied around the rough window opening. The window is
inserted into the opening pressing the flanges into the bead of
sealant. Once in place, the entire nail flange of the window is
covered with a rubberized asphalt flashing, such as Grace Vycor or
equivalent. The flashing should extend 4 to 6 inches from the frame
of the window. The flashing is preferably applied to the bottom of
the window first, then to the jambs and finally across the head of
the window overlapping the flashing at the four corners. At the
window header, the flashing is folded over and onto the top of the
window to keep stray rainwater from getting behind the window.
Typical window nailing flanges are approximately 1/8'' thick
creating an irregular surface for the casing boards or window trim
making the approximately 17/8''.times. 3/16'' nail flange cut-out
portion 16 of the window trim component 10 ideal for this
condition.
[0023] Having measured the window, the required lengths of window
trim component 10 are miter cut to create a picture frame look when
the trim components 10 are installed around the window. Before such
installation, an elongated bead of sealant preferably is applied on
the face 14 just inside the 3/4.times.3/4 siding receiving space
18. The purpose of this sealant bead is to provide a positive seal
of the trim component 10 against the wall of the house, as well as
a dam which will prevent water or wind driven moisture from working
its way behind the trim component 10. The window trim component 10
is then pressed onto the side of the building around the perimeter
of a window and nailed into place, preferably without nailing
through the portions of exterior faces 12 that overlie the siding
receiving spaces 18 which are generally only about 1/4'' thick and
thus may break if struck with a hammer or nail gun. Stainless steel
galvanized fasteners designed for wood trim and siding using
fasteners with thin shanks, blunt points, and full round heads are
preferred for installing the window trim components 10. Such
fasteners preferably are long enough to penetrate the substrate a
minimum of 1 inch and are preferably spaced a maximum of 24 inches
on center and, more preferably, 16 inches on center in order to
minimize any expansion or contraction of the window trim components
10 after installation. Preferably the mitered corners of the window
trim components are also glued together using a compatible PVC
adhesive.
[0024] Since the window trim component 10 installed across the
window header is likely to pond water, an elongated piece of light
gage aluminum having a J-shaped cross-section preferably may be
placed into the horizontally oriented upper siding receiving space
18 such that the ends of the J-shaped aluminum piece are bent
downward and extend about an inch into the siding receiving spaces
18 of the vertically oriented window trim components 10 installed
around the window. The J-shaped aluminum piece of such construction
will channel rain water out of the horizontally oriented upper
siding receiving space 18 and into the vertically oriented siding
receiving spaces 18 disposed on the vertical sides of the
window.
[0025] FIG. 2 shows a preferred embodiment of an end-wall or window
trim component 20 of the present invention having a front face 21
and a rear face 22 which defines a siding receiving space 23 for
receiving the ends of the pieces of siding abutting a window (not
shown) or other intra-wall structure (not shown) around which
strips of the trim component 20 have been installed for functional
and aesthetic purposes. The siding receiving space 23 is preferably
sized as required for a given application. More preferably, siding
receiving space 23 is 3/4 of an inch wide by 3/4 of an inch deep to
accommodate commonly used siding products.
[0026] FIG. 3 shows a preferred embodiment of an end-wall or window
trim component 24 of the present invention having a front face 25
and a rear face 26 having a cut-out portion 27 removed to define
nail flange 28 having an L-shaped upper profile. The cut-out
portion 27 and nail flange 28 allow the trim component 24 to be
mounted over a nail board (not shown) disposed adjacent to a window
or an end of a wall while maintaining a level or flush relationship
with respect to other trim components being used. The cut-out
portion 27 and nail flange 28 are preferably sized as required for
a given application. Also, the cut-out portion 27 is more
preferably 17/8 inches wide by about 1/8 to 5/32 inches deep to
accommodate window nail flanges commonly used in building
construction.
[0027] FIG. 4 shows a preferred embodiment of a corner trim
component 30 of the present invention having a pair of sides 31, 33
that have outer or front faces 32 and 34, respectively, that define
the outer seamless surface of the corner trim component 30
including corner 51. Side 31 has a slanted inner edge 35, a rear or
inner face 36 and an outer edge 53. The inner face 36 and outer
edge 53 of side 31 define siding receiving space 37, while the
inner slanted edge 35 defines recess or groove 42. Side 33 has a
slanted inner edge 40, a rear or inner face 38 and an outer edge
54. The inner face 38 and outer edge 54 of side 33 define siding
receiving space 39, while the inner slanted edge 40 defines the
protruding tongue 41 having a triangular cross-section. The corner
trim component 30 is preferably made from a single-piece board
construction as more fully described below, but can also be made
from two or more pieces. As shown in FIG. 4, the respective mitered
ends 35, 40 preferably are locked together with the triangular
tongue 41 and groove 42, and/or glue or other method such as heat
welding or ultrasonic welding as required.
[0028] Preferably, an elongated strip of the corner trim component
30 is disposed on a corner of a building such that its siding
receiving spaces 37, 39 are aligned on the respective walls
emanating from such building corner to receive the ends of siding
strips installed on the respective walls. Each of the siding
receiving spaces 37, 39 is preferably sized as required for a given
application. More preferably, each of the siding receiving spaces
37, 39 is 3/4 of an inch wide by 3/4 of an inch deep to accommodate
commonly used siding products. The 3/4'' by 3/4'' siding receiving
spaces 37, 39 can receive the ends or sides of nearly all siding
products and work especially well with fiber cement siding and
vinyl siding.
[0029] Before installing a corner trim component 30, the corner of
the building or house should be prepared to accept it. The corner
of the house or building should be square, true and plumb and
covered with some form of barrier such as house wrap, or asphalt
felt. The protective barrier should extend 4 to 6 inches beyond the
outside edges of the corner trim component 30. An elongated bead of
sealant is preferably applied prior to installation along the
length of each of the inner faces 36, 38 near the respective siding
receiving spaces 37, 39. The purpose of the sealant bead is to
provide a positive seal as well as a dam which will prevent water
or wind driven moisture from getting behind the corner trim
component 30. The corner trim component 30 is then pressed onto the
corner of the building and nailed into place preferably without
nailing through the portions of exterior faces 32, 34 that overlie
the siding receiving spaces 37, 39 which are generally only about
1/4'' thick and thus may break if struck with a hammer or nail gun.
Stainless steel fasteners designed for wood trim and siding using
fasteners with thin shanks, blunt points, and full round heads are
preferred for installing the corner trim components 30. Such
fasteners preferably are long enough to penetrate the substrate a
minimum of 1 inch and are spaced a maximum of 24 inches on center
and, more preferably, 16 inches on center in order to minimize any
expansion or contraction of the corner trim components 30 after
installation.
[0030] FIG. 5 illustrates a preferred embodiment of a band trim
component 60 of the present invention having a front face 62, a
rear face 64 and a pair of siding receiving spaces 66 and 68
defined by rear face 64. Preferably, an elongated strip of the band
trim component 60 is disposed around the perimeter of a two-story
building, such as a single-family home, at the juncture between the
first and second floors. The siding receiving spaces 66, 68 of the
band component 60 receive the elongated top or bottom sides, as the
case may be, of siding strips installed on the sides of the
building. Each of the siding receiving spaces 66, 68 is preferably
sized as required for a given application. More preferably, each of
the siding receiving spaces 66, 68 is about 3/4 of an inch wide by
about 3/4 of an inch deep to accommodate commonly used siding
products. The 3/4'' by 3/4'' siding receiving spaces 66, 68 can
receive the ends or sides of nearly all siding products and work
especially well with fiber cement siding and vinyl siding.
[0031] FIG. 7 illustrates a cross-section of preferred embodiment
of an elongated starter trim component 80 of the present invention
having a front face 82, a rear face 84, a bottom edge 86 and a top
edge 88 that has a width of about a quarter of an inch. The starter
trim component 80 has a front wall 90 having a height of about an
inch and a ledge 92 that define an elongated siding receiving space
94. Preferably, the angle between the front wall 90 and ledge 92 is
greater than 90 degrees such that ledge 92 is slanted downward such
that the offset between the outermost point on the ledge 92 and the
innermost point of the ledge 92 is about one quarter of an inch.
Preferably, an elongated strip of the starter trim component 80 is
disposed around the perimeter of a building, such as a
single-family home, at grade level or at the juncture between the
first and second floors. The siding receiving space 94 of the
starter trim component 80 receives a bottom edge of the siding
installed on the building immediately above the starter trim
component 80. The starter trim component 80 including without
limitation front face 82 thereof are preferably sized as required
for a given application.
[0032] The trim components 10, 20, 24, 30, 60 and 80 disclosed
herein are preferably made from a cellular polymer material
selected specifically for the intended application or environment,
e.g., interior or exterior. More preferably, the trim components
10, 20, 24 and 30 are fabricated from either a nominal
5/4''.times.4'', a nominal 5/4''.times.6'' or a nominal
5/4''.times.8'' standard rectangular boards in lengths up to and
including 24'. The band trim component 60 preferably is fabricated
from either a nominal 5/4''.times.11.0'' or nominal
5/4''.times.14.50'' rectangular boards in lengths up to 20' and
including 10', 18' and 20'. The starter trim component 80
preferably is fabricated from a nominal 5/4''.times.8.0''
rectangular board in lengths up to 20' and including 18'. The trim
components 10, 20, 24, 30, 60 and 80, more preferably, are made
from a cellular PVC material comprising PVC resin of more than 70
percent by weight, calcium carbonate (less than 10 percent by
weight), titanium dioxide (less than 20 percent by weight) and/or
additional additives as required. The exterior sides of each of the
trim components 10, 20, 24, 30, 60 and 80 preferably may be made
smooth or textured to simulate other materials, such as wood. The
trim components 10, 20, 24, 30, 60 and 80, however, may be
fabricated from other materials including wood and/or other
polymers. Also, while the siding receiving spaces of trim
components 10, 20, 30, 60 and 80 are generally disclosed as having
a substantially equal leg "L" shaped cross-section, the trim
components 10, 20, 30, 60 and 80 are not limited to such
construction and may comprise siding receiving spaces having
cross-sections of various sizes and shapes including, without
limitation, substantially L-shaped, rounded, circular, ovular, and
triangular.
[0033] A preferred method of trimming a building structure
according to the present invention comprises (1) supplying or
selling, preferably to a building contractor, builder or carpenter,
one or more trim components selected from the group consisting of:
(i) an intra-wall or window trim component 10 defining a nail
flange 11, cut-out 16 and a siding receiving space 18; (ii) an
end-wall or window trim component 20 defining a siding receiving
space 23; (iii) an end-wall or window trim component 24 defining a
cut-out portion 27 and nail flange 28; (iv) a corner trim component
30 of single-piece board construction having a seamless outer
surface and a pair of siding receiving spaces 37, 39; and (v) a
band trim component 60 having a front face 62 and a rear face 64
defining a pair of siding receiving spaces 66 and 68; and (2)
installing the one or more selected trim components 10, 20, 24, 30
on a building or structure such that the end(s) of one or more
pieces of siding previously or subsequently installed on the
building abut(s) against, and/or are received within siding
receiving space(s) defined by, the one or more selected trim
components 10, 20, 24, 30 installed on the building or
structure.
[0034] A preferred method, which may be performed by hand or on a
fully or partially automated fabrication unit or line, for
fabricating the corner trim component 30 from a single, generally
rectangular board 29 will now be described with reference to FIGS.
4 and 6. The raw boards 29 are typically about one inch thick and
range in width depending upon the desired width for the corner
component 30 being produced. Typical board widths are 7'', 11'' and
141/2'' for nominal 4'', 6'' and 8'' corners, respectively. The
first step in the process is the provision of a substantially flat,
raw board 29 preferably made from a compound comprising a cellular
polyvinyl chloride (PVC) resin of more than 70 percent by weight,
calcium carbonate (less than 10 percent by weight), titanium
dioxide (less than 20 percent by weight) and/or additional
additives as required. Next, a tape strip 45 optionally may be
applied to the centerline of the board. The tape strip 45 is used
to reinforce the skin 49 of board material created in subsequent
manufacturing steps described below. After the tape strip 45 has
been applied, the board proceeds through three cutter heads. The
center cutter head cuts a V-groove 47 substantially along the
longitudinal center line of the raw board as shown in FIG. 6, with
one slanted edge 40 of the V-groove preferably being cut to define
the elongated triangular tongue 41 and the other slanted edge 35 is
preferably cut to define a mating triangular groove 42. Such tongue
and groove construction may preferably comprise a variety of shapes
other than triangular, such as square, rectangular, etc., within
the scope of the present invention. Preferably, the V-groove 47 is
cut to a depth so that the remaining corner skin 49 of the PVC
material making up the raw board 29 (excluding the thickness of the
tape strip 45) remaining between the vertex or the bottom of the
V-groove 47 and the outer surface of the board 29 preferably ranges
in thickness from about 0.003 inches to about 0.008 inches and most
preferably is about 0.005 inches thick. The outside cutter heads
cut 3/4''.times.3/4'' square notches out of both edges of the board
to create the siding receiving spaces 37, 39 that run substantially
parallel to the V-groove 47 as shown in FIG. 6.
[0035] After the raw board 29 has been properly routed/milled, it
proceeds to a glue station where PVC adhesive or another applicable
adhesive is applied over the V-groove 47 including slanted edges
35, 40, the elongated triangular tongue 41 and the elongated
triangular groove 42. The notched edges 37, 39 are not coated with
PVC adhesive but are left to cool/dry. After the PVC adhesive is
applied, one side of the raw board 29, e.g., the side 31 defining
the elongated triangular groove 42, is rotated about 90 degrees
about a longitudinal axis running through, or tangential with a
surface of, the corner skin 49 such that the triangular tongue 41
is received within the triangular groove 42 and slanted edges or
faces 35, 40 are pressed together. It would also be within the
scope of the invention to rotate the other side 33 of the board 90
degrees in a similar manner or to bend or rotate each side 31, 33
of the board to some degree until the triangular tongue 41 is
received within the triangular groove 42 and slanted edges 35, 40
are pressed together. The raw board 29 is then held in this
position while the PVC adhesive cures to transform the raw board 29
into a corner trim component 30. To keep the corner at a true 90
degree angle while the white PVC glue fully cures, a bead of hot
melt adhesive (not shown) is injected over top of and into the
inside corner joint 50 (see FIG. 4) while the corner trim component
30 remains clamped together. The curing of the hot melt preferably
is accelerated by blowing a light stream of air onto the hot melt
after it has been applied to the inside corner joint 50. The newly
formed corner trim component 30 preferably is held clamped together
for about 2 to 3 minutes allowing further curing of the PVC
adhesive before it is unclamped and stacked for storage or
shipment. If a tape strip 45 was used, it preferably may be left in
place or removed, as desired, upon completion of the corner trim
component 30.
[0036] The relatively thin corner skin 49 having a preferred
thickness of about 0.003 inches to about 0.008 inches and a most
preferred thickness of about 0.005 inch thickness, forms a true,
sharp corner 51, but without any exposed seam or gap normally found
on mitered corners which can be unsightly and can collect dirt and
moisture. It has been found that if the remaining corner skin 49 is
too thick, it will not bend as easily when the one-piece corner
trim component 30 is formed and, therefore, will not produce a
corner which is a sharp as desired.
[0037] Although the invention has been described in terms of
particular embodiments in an application, one of ordinary skill in
the art, in light of the teachings herein, can generate additional
embodiments and modifications without departing from the spirit of,
or exceeding the scope of, the claimed invention. Accordingly, it
is understood that the drawings and the descriptions herein are
proffered by way of example only to facilitate comprehension of the
invention and should not be construed to limit the scope
thereof.
* * * * *