Patent Grant
7748179
1. Field of the Invention
The subject invention relates to decorative exterior trim assembly for use in a surround for openings of residential or commercial structures, and more particularly to a decorative molding apparatus for heading a doorway, window, patio door, garage door opening, etc. of a residential or commercial structure.
2. Description of the Related Art
Molding assemblies are used in a variety of applications to frame or head opening such as doorways, windows, patio doors, garage doors etc., to provide a decorative, aesthetically appealing look for an opening of a structure. Such assemblies typically include a mantel extending along a longitudinal axis between ends for mounting against a mounting plane above the opening in the building to present a decorative face spaced forwardly from the mounting plane a decorative distance.
In recent years, these decorative molding assemblies have been manufactured from plastics such as high-density polyurethane. In general, plastics provide significant advantages over natural wood. For example, decorative molding assemblies or components thereof manufactured from plastic are low in maintenance when compared with natural wood molding assemblies. Plastic molding assemblies are not susceptible to moisture and therefore will not decay, warp or splinter like natural wood. However, there is still a need to divert water away from the opening and structure.
Advantageously, plastic decorative molding assemblies or components thereof can be sawed, drilled, glued or nailed just like natural wood. Still further, during the manufacture of plastic molding assemblies, plastic can be tinted with dyes or other materials to provide molding assembly components which are of desired colors, thus obviating the need for painting prior or subsequent to installation on a structure.
Many lengths of the mantel are required to accommodate various opening sizes. The mantels are cut to provide the desired length and end covers are placed over the cut ends to conceal the open end and to maintain the decorative and aesthetic appearance of the mantel. These end-covers were made specifically for each end, i.e., a left or right end. The requirement for left and right end-covers increases the number of components to the assembly and the manufacturing tooling required for producing the assembly.
The invention provides for the end cover having a top and a bottom and presenting a front corner extending between the top and the bottom and being symmetrical from the front corner whereby the end cover may be disposed over either end of the mantel.
The subject invention provides a mantel or header molding having a mounting base, decorative cover or mantel and end-cover. The mounting base and decorative mantel can be formed to many lengths, ultimately allowing the user to cut the mantel molding to a desired length, after which the single end cover of the subject invention may be added to either end.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
An exterior trim assembly for use in a surround of an opening in a building and is generally shown in
The exterior trim assembly is made from a plastic material, such as high density polyurethane. The mantel 20 and base 22 are of such geometry to allow for ease of manufacturing by a molding process, such as extrusion, to a standard length. The standard length, of the mantel 20 and the base 22, reduces the tooling required to manufacture the exterior trim, thereby reducing the manufacturing and processing expense allowing the user cut the mantel 20 and base 22 to the desired length.
The mantel 20 defines a rear mounting plane and a decorative face 24 spaced forwardly from the plane a decorative distance (X). More specifically, the mantel 20 includes a ledge 26 extending from the decorative face 24 rearwardly to a lip 28 defining the rear mounting plane, i.e., the surface of the building adjacent the base 22 engages the lip 28 to define the mounting plane. The decorative face 24 extends downwardly from the ledge 26 in an irregular pattern having different distances from the mounting plane. The ledge 26 defines the widest part of the mantel 20 as the decorative face 24 of the mantel 20 decreases in distance from the mounting plane downwardly from the ledge 26, i.e, in the fashion of a crown molding. In addition, the mantel 20 includes protrusions 30 spaced in a line along the decorative face 24 and between the ends thereof, the protrusions 30 being spaced rectangles formed integrally with the decorative face 24. The ledge 26 can be sloped downward to allow for drainage away from the structure. However, it is appreciated that those skilled in the art would recognize other ways to drain water off of the ledge 26 of the mantel 20.
The invention includes an end cover 32 for disposition over an end of the mantel 20 that includes a top defined by an upper wall 34 and a bottom defined by a lower wall 36. The end cover 32 presents a front corner 38 extending between the upper wall 34 and the lower wall 36 and is symmetrical rearwardly from the front corner 38 whereby the end cover 32 may be disposed over either end of the mantel 20. The end cover 32 includes two front surfaces 40 extending from the front corner 38 to a respective pair of side edges 42. The distance perpendicular to either of the front surfaces 40 from the front corner 38 to a position aligned with either of the edges being equal to the decorative distance (X). The upper wall 34 at the top of the end cover 32 extends between the front surfaces 40 and the side edges 42 and the lower wall 36 at the bottom extends between the front surfaces 40 and the side edges 42. The upper wall 34 and the lower wall 36 each has the shape of a parallelogram with equal sides. As illustrated, each parallelogram defines a square, albeit, squares of different areas between the top and bottom. The end cover 32 has a symmetry that allows the end cover 32 to be used on either end, i.e., the left or right end. The universal use of the end cover 32 reduces the number of components and allows the end user to cut the mantel 20 and base 22 to the desired length, and conceal the cut with the end cover 32. The reduction in parts reduces the manufacturing and processing thereby lowering the cost to manufacture and process the trim assembly. The end cover 32 is made from a plastic material, such as high density polyurethane, and may be manufactured utilizing various molding techniques or machining the end cover 32 from a solid. One skilled in the art would appreciate that the end cover 32 could be used on both ends of the mantel 20 to possibly simply the molding process of the mantel 20, allow the user to cut on both ends of the mantel 20 and base 22 or create a symmetrical appearance with end covers on both ends of the mantel 20.
The front surfaces 40 of the end cover 32 are defined by front walls 44 having interior surfaces complementary to the irregular pattern of the decorative face 24 of the mantel 20, as best shown in
In the modification of
In the modification of
In the modification of
A mechanical attachment is included for attaching the end cover 32 to the mantel 20. Such attachments may take many forms but are illustrated here as snap together devices. The end cover 32 includes a tab 52, as shown in
The foregoing invention has been described in accordance with the relevant legal standards; thus, the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiments may become apparent to those skilled in the art and do come within the cope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims. In addition, the reference numerals in the claims are merely for convenience and are not to be read in any way as limiting.
This application claims the benefit of U.S. provisional application Ser. No. 60/536,927 filed Jan. 16, 2004.
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