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Publication numberUS20070151180 A1
Publication typeApplication
Application numberUS 11/566,001
Publication dateJul 5, 2007
Filing dateDec 1, 2006
Priority dateDec 2, 2005
Also published asCA2569787A1
Publication number11566001, 566001, US 2007/0151180 A1, US 2007/151180 A1, US 20070151180 A1, US 20070151180A1, US 2007151180 A1, US 2007151180A1, US-A1-20070151180, US-A1-2007151180, US2007/0151180A1, US2007/151180A1, US20070151180 A1, US20070151180A1, US2007151180 A1, US2007151180A1
InventorsJohn Pace, Shawn Petras
Original AssigneeJohn Pace, Shawn Petras
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Trim components and methods for manufacturing same
US 20070151180 A1
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.
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Claims(35)
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

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

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.

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.

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.

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.

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

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.

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.

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.

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.

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

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:

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;

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;

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;

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;

FIG. 5 is a cross-sectional view of a substantially flat trim component of the present invention having a pair of siding receiving spaces;

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

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

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.

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 1⅞ inches wide by about ⅛ to 5/32 inches deep to accommodate window nail flanges commonly used in building construction. Likewise, siding receiving space 18 is preferably ¾ of an inch wide by ¾ 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.

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 ⅛″ thick creating an irregular surface for the casing boards or window trim making the approximately 1⅞″× 3/16″ nail flange cut-out portion 16 of the window trim component 10 ideal for this condition.

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 ¾×¾ 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 ¼″ 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.

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.

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 ¾ of an inch wide by ¾ of an inch deep to accommodate commonly used siding products.

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 1⅞ inches wide by about ⅛ to 5/32 inches deep to accommodate window nail flanges commonly used in building construction.

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.

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 ¾ of an inch wide by ¾ of an inch deep to accommodate commonly used siding products. The ¾″ by ¾″ 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.

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 ¼″ 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.

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 ¾ of an inch wide by about ¾ of an inch deep to accommodate commonly used siding products. The ¾″ by ¾″ 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.

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.

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″×4″, a nominal 5/4″×6″ or a nominal 5/4″×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″×11.0″ or nominal 5/4″×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″×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.

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.

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 14½″ 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 ¾″×¾″ 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.

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.

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.

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.

Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US8661751 *Apr 6, 2011Mar 4, 2014James Robert LawrieAlignment spacer for siding outside corner
US8707640 *Nov 21, 2011Apr 29, 2014Bosley WrightRemovable bulkheads for building fixtures
US8789336 *Feb 14, 2012Jul 29, 2014Oneday Wall AbEdge strip for mounting of a wall board
US8850775 *May 3, 2013Oct 7, 2014Garland Industries, Inc.Non-welded coping caps and transitions
US20120167498 *Nov 21, 2011Jul 5, 2012Bosley WrightRemovable Bulkheads for Building Fixtures
US20130291464 *May 3, 2013Nov 7, 2013Garland Industries, Inc.Non-welded coping caps and transitions
US20140245680 *May 16, 2014Sep 4, 2014Garland Industries, Inc.Non-welded coping caps and transitions
Classifications
U.S. Classification52/287.1
International ClassificationE04B2/00
Cooperative ClassificationE04F19/02, E04F19/04, E04F2019/0413, E04F19/0495
European ClassificationE04F19/02, E04F19/04
Legal Events
DateCodeEventDescription
Mar 13, 2007ASAssignment
Owner name: WOLFPAC TECHNOLOGIES, INC., PENNSYLVANIA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PACE, JOHN;PETRAS, SHAWN;REEL/FRAME:019006/0721
Effective date: 20070312