The present invention relates generally to building materials, and more specifically to an apparatus for aesthetically-pleasing trim and certain load-bearing applications using, for example, trimboard composed of a laminate polyvinyl product.
In home construction finishing, wood is often used due to its workability, economy, structural strength and desired appearance. However, wood is susceptible to a number of potential dangers that may shortly degrade its structural fitness and aesthetic appearance. For example, the effects of moisture, changing temperatures, UV light and insects may cause wood used in a visible location to swell, rot, split, cup, craze or weaken.
Recently developed cellular polyvinyl chloride (PVC) materials are being marketed for use as trimboards, cornerboards and/or beadboards. Some examples include KOMA™ trimboards (U.S. Pat. No. 4,141,944), marketed and distributed by Kömmerling Kunststoff GmbH (Huntsville, Ala.), and AZEK™ trimboards manufactured by Vycom Corp. (Moosic, Pa.). Such materials have desirable characteristics including water resistance, insect resistance, fire retardance, and workability with the same tools as would be used with wood. However, such materials have not been employed in applications requiring more structural support.
Thus, what is needed is a material having the durability of PVC-based trimboards that can be used in simple structures (e.g., railings, fences), where the structural strength requirements have necessitated use of alternative building materials.
It is also desirable to be able to provide further mechanical support for such structures in applications where a load will be borne by the laminate structures.
It is additionally desirable to provide mechanisms for seamlessly applying any type of trimboard to corners, posts or columns, or windows in a manner that hides fasteners, such as nails, screws and/or bolts, from view.
The inventor has developed additional implementations and accessories for the laminates described in PCT Application PCT/US2004/015287 filed May 14, 2004 entitled, “Synthetic Resin Structures and Mountings for such Structures”, which claims priority to U.S. Provisional Application Ser. No. 60/470,552 entitled “Laminate Structural Material and Method of Manufacture Thereof”, filed May 14, 2003, both of which are incorporated herein by reference in its entirety. Those applications describe (a) inventive methods for producing a plastic product meeting the needs described above, and (b) structural assemblies that enable use in structures such as, for example, pergolas, picket fences, railings, gazebos, etc. Such plastics can be assembled on site using low-level labor or ordinary consumer skills, and structures having enhanced aesthetics can be easily disassembled and reassembled.
In one aspect, the present invention provides a method of producing a laminate material that is highly durable, aesthetically pleasing, and suitable for construction projects wherein no screws or nails are externally visible. In this embodiment, the invention makes use of PVC-based trimboard materials to form a multilayer laminate comprised of multiple layers of the trimboard. Various means of adhering the trimboards may be employed. The laminate exhibits increased stiffness and strength, as well as an improved resistance to microcracking after a prolonged period of use in the field. The composite structure also generally exhibits increased longitudinal shear strength. The structure also exhibits increased axial load strength proportional to the thickness and number of trimboard layers employed. After formation, the composite laminate may then be employed as workable components in a wide range of assemblies.
In another aspect, the present invention provides various means of using the laminate in structures such as railings for increased structural support. In one embodiment, sections of laminate intended to be used as handrail supports are reinforced with segments of rigid material such as aluminum.
In another aspect, the present invention provides a reinforcing core for a hollow post, such as may be used in decking. The hollow post may have any cross-sectional shape, but is preferably square or rectangular. The reinforcing core may be used with posts formed of the inventive laminate so as to show no external screws or nails, or may be used more generally with other building materials. The reinforcing core makes use of a plurality of symmetrically disposed positioning screws to properly orient the post it is reinforcing. The reinforcing core also includes a bottom plate for securing the reinforcing core to a floor, ground or deck surface.
In yet another aspect, the present invention provides various means for attaching trimboards composed of any material, advantageously the inventive laminates but not limited to said laminate materials, to external surfaces, corners or windows in a manner in which no fasteners (e.g., nails or screws) are externally visible. These embodiments employ rigid clip mechanisms that allow use of trimboards in both new constructions and retrofits, and provide increased stability to structures, such as windows, compared to existing window trim installations, which typically merely abut the window.
For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawing and detailed description, wherein:
a is a cross-sectional view of a laminate sheet that has been mitered to create preferred shaped grooves in accordance with the present invention;
b is an illustration of a solid post that may be created by folding mitered sections of a laminate sheet, such as shown in
c is an illustration of a square hollow column that may be created by folding mitered sections of a laminate sheet, such as shown in
d is an illustration of a hexagonal hollow column that may be created by folding mitered sections of a laminate sheet, such as shown in
e is an illustration of a rectangular hollow collar for a post that may be created by folding mitered sections of a laminate sheet, such as shown in
a is a perspective view of the hollow column of
b is a perspective view of the hollow column of
a, 9b, 9c and 9d show the steps of assembling the railing assembly using the components of
a and 10b are side and top views of a first trim clip of the present invention;
c is a view of the first trim clip of the present invention for mounting corner trim;
d is a view of the first trim clip of the present invention for mounting window trim;
a is a perspective view of a second trim clip of the present invention;
b and 11c are views of the second trim clip of the present invention for mounting flat trim;
a and 12b are schematic illustrations of a window trim mounting assembly in accordance with the present invention; and
c, 12d, and 12e are illustrations of the window trim mounting assembly of
Preferred embodiments of the present invention will now be described with reference to the several figures of the drawing.
In one aspect, the present invention provides a method of producing a laminate material that is highly durable, aesthetically pleasing, and suitable for construction projects wherein no screws or nails are externally visible.
The invention makes use of PVC-based trimboard materials, such as those described above, in their commercially available sizes (i.e., up to 1″ thick) to create a multilayer laminate comprised of multiple layers of the trimboard. With reference to
In
A composite laminate structure 10 prepared in accordance with this invention exhibits an increased stiffness and strength in a direction normal to the planar interface between trimboards, as well as an improved resistance to microcracking after a prolonged period of use in the field. The composite structure also generally exhibits increased longitudinal shear strength. The structure also exhibits increased axial load strength proportional to the thickness and number of trimboard layers employed.
a shows a cross-sectional view of a laminate sheet that has been mitered to exhibit shaped grooves 112. While various shaped grooves (e.g., more curved or displaying more angled features) may be used, the pattern illustrated is particularly useful in allowing a single piece of laminate to be folded into a variety of shapes that exhibit nearly seamless combination. As shown, the grooves 112 do not go all the way through the laminate, but are cut sufficiently deep so as to allow for folding of the laminate sheet. When the sheet is folded, adhesives, glues or epoxies as described above are applied to the contact surfaces 114 to assure mechanical strength.
b-e illustrate a sample of the structures that can be formed by adjusting the groove angles 116 and spacings 118 between the grooves.
After formation, the composite laminate may then be employed as workable components in a wide range of assemblies. One such assembly, a railing system, is now described with the assistance of
With reference to
With reference to
a provides a side view of a bracket or clip 146 having a plurality of flanges 148 that are dimensioned to snap-fit snugly into a corresponding plurality of mitered kerfs 142 in the back side of a section 140 of trimboard. The flanges 148 may have tined ends 150 to further secure the flange within the kerfs 142. The clip 146 is formed of a rigid, durable material such as, for example, aluminum, and has one or more holes 144.
c illustrates a corner trim application of the clips, wherein the assembly of trimboard 140 and two clips 146 is positioned at the desired corner of a house with the clip 146 flush with the exterior wall surface and fasteners (e.g. nails, not shown) are inserted through the hole 144, securing the assembly to the house. As shown in
a-c show an alternative embodiment of a clip 190 for mounting the trimboard 140. Before installation, a groove 192 can be cut in the side surface 141 of trimboard 140 using a standard #20 biscuit saw blade. In most applications, side surface 141 is generally orthogonal to the mounting surface (not shown) to which the trimboard is to be secured. Clip 190 has an L-shaped flange 194 comprised of two sections, one of which is intended to be fully received tightly within a groove 192, the other has a surface substantially conforming to the trim board side surface 141. The distal end of the section received by the groove 192 may terminated in a feature such as, for example, a semicircular shaped protrusion 195 on the designed to further provide a tight fit of the section into groove 192. The other end of the clip has a hole 196 for receiving fasteners 198 to secure the trim 140 to the exterior of the house.
The present invention also provides a means for installing new or retrofitting any type of trim around windows in a more secure manner, and in a manner that overcomes limitations of conventional window trim. Conventional window trim is limited to configurations that abut the window. If an installer wishes to more tightly secure the trim to a window, the installer of conventional trim will most likely have to drill into the window, having the undesirable economic consequence of voiding the window manufacturer's warranty. Additionally, installers are currently limited to installing only the trim provided by the window manufacturer. The present invention allows installation of any style and/or quality of trim to any window.
With reference to
Once the window trim mounting assembly has been secured, with perhaps multiple pairs or clips judiciously disposed about the perimeter of the window (
Although the invention has been described with respect to certain specific embodiments, it should be realized this invention is also capable of a wide variety of further and other embodiments within the spirit and scope of this invention.
This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 60/541,656, filed Feb. 4, 2004 and International Application PCT/US2004/015287, filed May 14, 2004, which in turn additionally claims priority to Provisional Application Ser. No. 60/470,552, the contents of each is incorporated herein by reference in their entirety.
Number | Date | Country | |
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60541656 | Feb 2004 | US | |
60470552 | May 2003 | US |
Number | Date | Country | |
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Parent | PCT/US04/15287 | May 2004 | US |
Child | 11051048 | Feb 2005 | US |