Abstract:
An elongated horizontal transitional trim product includes an elongated, molded, horizontally-positionable stiffening block. The block has a flat, vertical back surface; a flat, horizontal top surface; a flat, horizontal bottom surface; and a front surface. The front surface extends between an outer edge proximate to the top surface and an outer edge proximate to the bottom surface, and has a cross-sectional profile that includes a plurality of interconnected curved and vertical and horizontal flat surfaces. The stiffening block is capable of being secured directly to a flat, vertical surface of a building. The trim product further includes an elongated deformable metallic sheet terminating in respective upper and lower end sections located above and below a central section. The central section of the metallic sheet includes a plurality of interconnected, continuous surfaces in its cross-sectional profile which mate and snugly fit with the cross-sectional profile of the stiffening block. The metallic sheet is capable of being mounted onto the stiffening block by utilizing the shape of the central, upper, and lower end sections of the sheet to support and maintain the sheet on the stiffening block prior to installing other support means.

Description:
This application is a continuation of application Ser. No. 09/714,322, filed Nov. 16, 2000 now U.S. Pat. No. 6,837,020. 

   FIELD OF THE INVENTION 
   The present invention relates to the field of building construction materials, and more particularly to building architectural trim products. 
   BACKGROUND OF THE INVENTION 
   The architectural distinctiveness of a house or other building is often attributable to the trim that provides a finishing touch to an otherwise common shape. Trim distinctiveness has, through the years, evolved from Greek, Roman, Gothic, and Victorian to contemporary and modernistic. Each style has various characteristic details and shapes that sets it apart from the others. 
   Parallel changes have come about through the development of building materials, especially those materials that form the visible surface of a house or building. Common exterior surface materials in use today are wood, brick, vinyl, and aluminum. Vinyl and aluminum have the advantage of being supplied from the factory with its final color applied, and need no more than minimum maintenance. With each of these exterior surface materials, the trim portions of the building, e.g., the crosshead piece over a door or window, the fascia below the roofline, the transition frieze, or molding, between a wall and ceiling, are almost always made of wood. The reason for wood being used for this purpose is that wood can be efficiently formed into attractive shapes that are distinctive to a particular style. Forming similar shapes of plastic requires complex molds, and shapes of metal or concrete have traditionally been heavy. Even where the exterior siding of a building is made of vinyl or aluminum, modern siding materials that are mass produced with their surface colors applied at the factory, the trim has generally been made of wood. However, wood has the drawback of requiring periodic maintenance in the form of scraping and painting to prevent degradation. 
   One known exception is a line of architectural trim products made of plastic resin from Style-Mark, Inc. of Archbold, Ohio. These known plastic trim products require substantial molding investment and capacity to produce, and involve either a substantial inventory or a significant delivery delay to obtain. In addition, in order to keep inventory within reason, these trim products are available in white only; if another color is desired, the parts must be painted at the construction site. 
   A process and apparatus exists for forming factory painted aluminum sheet into rain gutters. The aluminum is supplied in roll form and is drawn as a sheet through a mechanism having complementary convex and concave rollers to form the profile gutter shape. Forming aluminum rolled sheet into gutters at the site of installation has the advantage of permitting a seamless, continuous length of gutter to be installed across the entire edge of a house&#39;s roof, without the need to transport long gutter sections, e.g. 10 meter (39 feet), over the roads to the building site. 
   While forming aluminum sheet into gutters is known, the objective has been to achieve long, continuous sections, as described above. Furthermore, gutters are typically of a simple and functional cross sectional contour with an upwardly open channel. In the design of architectural trim products, a degree of flexibility is necessary since the style of the building will dictate the style and the width of the trim. 
   Therefore, it is an object of the present invention to provide an architectural trim product that can be economically produced in a variety of shapes and styles. 
   It is another object of the present invention to provide an architectural trim product that can be produced in a variety of colors without the need for painting at the construction site. 
   It is a further object of the present invention to provide an architectural trim product that does not require periodic maintenance. 
   These and other objects of the present invention will become apparent through the disclosure of the invention to follow. 
   SUMMARY OF THE INVENTION 
   The present invention provides an architectural trim product fabricated of sections formed out of aluminum sheet material. The sections have a cross sectional profile shape that includes curved portions and right angle bends. The sections are optionally used as a fascia, a frieze in lengths matching the length of a wall-to-soffit joint, crosshead trim over a window or door or other trim uses. In the crosshead application, the horizontal section piece is mitered at each end and the ends are each closed with a short piece of similar miter-cut section, giving the appearance of a three-dimensional solid. An attaching bolster, or stiffening block, is formed in a shape to fit behind the contour of the trim section to support it to a wall while minimizing the tendency of the aluminum to bend. In all forms, the method of mounting the trim product of the invention to the building structure provides secure attachment with no visible nails, screws, or adhesive. 
   The sections of architectural trim are made from aluminum sheet pieces that have been cut to length and then bent. The curves are formed first by pressing the sheet between two shaped components, for example pipe segments. After forming the curves, the right-angle bends are made on a conventional brake, or the like. An alternate forming process uses a set of matching rollers to form the aluminum sheet into a contour-shaped trim piece. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In order for the invention to become more clearly understood it will be disclosed in greater detail with reference to the accompanying drawings, in which: 
       FIG. 1  is a front elevation view of a building wall having a window over which a crosshead architectural trim product according to the invention is mounted. 
       FIG. 2  is a perspective view of a section of formed sheet material for making an architectural trim product of the invention. 
       FIG. 3  is a perspective view of the crosshead trim product according to  FIG. 1 . 
       FIG. 4  is a side elevation view of the architectural trim product according to  FIG. 3 , further showing a bolster support piece therewithin. 
       FIG. 4A  is a perspective view of the bolster support piece of  FIG. 4 . 
       FIG. 4B  is a side elevation view of the architectural trim product according to  FIG. 3 , further showing a J-hook and a block as mounting pieces therewithin. 
       FIG. 5  is a side elevation view of a second embodiment of the invention as mounted to a building wall with a mounting clip. 
       FIG. 5A  is a side elevation view of the embodiment of  FIG. 5  showing the steps involved in mounting the trim product to the mounting clip. 
       FIG. 5B  is a side elevation view of an alternate shape trim product of the embodiment of  FIG. 5 . 
       FIG. 6  is a side elevation view of a portion of a building to which a frieze with a concave curve portion according to the invention has been mounted. 
       FIG. 6A  is a side elevation view of a portion of a building to which a frieze with a convex curve according to the invention has been mounted. 
       FIG. 6B  is a side elevation view of a portion of a building to which a frieze with concave and convex curve portions according to the invention has been mounted. 
       FIG. 6C  is a side elevation view of a portion of a building to which a frieze with a convex curve according to the invention has been mounted by means of a J-hook. 
       FIG. 7  is a front elevation view of a portion of a building roofline to which a fascia trim product according to the invention is mounted. 
       FIG. 7A  is an enlarged cross sectional view taken in the direction of line  7 A— 7 A of  FIG. 7  and depicting a fascia of a first contour. 
       FIG. 7B  is an enlarged cross sectional view taken in the direction of line  7 A— 7 A and depicting a fascia of a second contour. 
       FIG. 8  is an end elevation view of a press die set having curved and angular portions for creating curved and angular contour portions in a sheet of bendable materials. 
       FIG. 9  is a perspective view of a pair of engageable die rollers having surfaces formed with curved and angular portions for creating curved and angular contour portions in a sheet of bendable material. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The architectural trim product of the present invention is an economical and versatile component for enhancing the appearance of the interior or exterior of a building. The trim product can be formed to emulate the appearance of most of the building trim products that are currently available in wood or molded plastic resin, in an efficient and attractive way. Examples of types of trim products to which the present invention pertains include, but are not limited to, crosshead trim over windows and doors, friezes between an exterior wall and an adjacent soffit, cove molding between an interior wall and a ceiling, and fireplace mantles. In all embodiments of the invention, the component that will remain in view covers the wall-mounting component and any fasteners. 
   Referring now to  FIG. 1 , a wall of building  10  is illustrated with typical window  12  located therein. Window  12  may be of the type having a plurality of individual frames (as shown) or of the type with a single frame for each of its upper and lower sections. A first side trim  16   a  is mounted in vertical orientation on the left side of window  12  and a second side trim  16   b  is mounted similarly on the right side thereof. Side trims  16   a  and  16   b  preferably are formed of a bendable sheet material. A crosshead  18  is mounted above window  12  and extends laterally to slightly overlap each of side trims  16   a  and  16   b  for architectural interest. The particular shape of crosshead  18  as illustrated is stepped from its bottom surface (as shown), of length L 1 , to its top surface of length L so that its top surface overhangs side trims  16   a  and  16   b  by a greater amount than does its bottom surface. Each end of crosshead  18  is closed by a short piece of the same profile shape of which the central portion of crosshead  18  is made with the central portion and the end portions cut at a complementary shape with their mutual joint sealed with a pliant material, for example caulking compound. 
     FIG. 2  illustrates, in perspective view, a length of formed sheet material  20  that has been bent to create a desired profile for being assembled to make crosshead  18  as described above. Formed sheet  20  is formed by making a number of curved and square bends in an elongate sheet of material of the type that is able to retain a shape to which it is bent. A sheet material that has been found to be satisfactory is aluminum sheet of 0.56 mm (0.022 inch) thickness. Such aluminum sheet material is available with one surface painted during the manufacturing process, and is available from a variety of suppliers, for example, Aluminum Corporation of America. Alternate materials that provides the requisite characteristics of retaining a bent shape are, for example, copper sheet and galvanized steel sheet. Formed sheet material  20  comprises a series of linear bends oriented parallel to the elongate linear edges of sheet  20 , including vertically oriented rear lip  22 , horizontally oriented top panel  24 , vertically oriented top face  26 , horizontal return  28 , curved portion  30 , vertically oriented middle face  34 , horizontally oriented middle return  36 , vertically oriented skirt  40 , horizontally oriented bottom return  42 , and angularly oriented grip  44 . As will be apparent to those skilled in the trade, formed sheet material  20  may incorporate various arrangements of right angle, curved, and angled bends. Any curved portions formed may be either concave or convex and either circular or another form of curve, e.g. parabolic. Additionally, more than one curved portion may be formed to achieve a different appearance. 
   Referring now to  FIG. 3 , crosshead  18  is shown in perspective view including front panel  58  and end cap  60 . Length L of crosshead  18  is substantially greater than width  1  thereof. Front panel  58  and end cap  60  are each cut from a length of formed sheet material  20  (see  FIG. 2 ). Front panel  58  and end cap  60  are cut along their mating edges at complementary miter angles to be assembled to each other and form a three-dimensional component. For mounting crosshead  18  over window  12 , as illustrated in  FIG. 1 , the opposite end of front panel  58  and a second end cap (not shown) are similarly prepared and assembled. Upper tab  60   a  and lower tab  60   b  are configured to securely engage the mating end of front panel  58 . When end cap  60  is assembled to front panel  58 , a weather resistant sealant, e.g. silicone caulk, is applied to the rear of the mating edge, preferably in a color to match the exposed surfaces of crosshead  18 . 
     FIGS. 4 and 4B  show side elevation views of alternate means of mounting a length of formed sheet  20  to a building wall  62 .  FIG. 4  shows bolster  50  fastened to wall  62  by multiple fasteners N, such as nails, screws, or adhesive. Bolster  50  is preferably formed in a profile shape that is established to substantially follow the interior profile of formed sheet material  20 . Bolster  50 , in the preferred embodiment, is made by cutting a sheet of bendable material, e.g. aluminum, to an appropriate profile shape. Preferably, the profile shape of bolster  50  is cut in two mirror image flaps  56  and  57  that are separated by a flat area extending from extended top tab  52  to extended bottom tab  54 , as shown in perspective in  FIG. 4A . Bolster  50  serves to mount formed sheet  20  to wall  62  and also to minimize bending of formed sheet  20  if it is hit by an object. Bolster  50  is secured to wall  62  with a fastener N through top tab  52  and a second fastener N through bottom tab  54 . Top fastener N is hidden by rear lip  22 . Second fastener N through bottom tab  54  will be subsequently hidden by exterior siding panels (not shown) when they are assembled to wall  62 . Thus, the finished trim product will have no visible means of attachment to wall  62 . The parallel profile provision of two flaps  56  and  57  enhances the resistance of bolster  50  to bending. Grip  44  (see  FIG. 4 ) maximizes the security of mounting formed sheet  20  to bolster  50  through pressure and sharp edge engagement, with a sharp edge existing at the bottom of rear lip  22  to engage the top portion of bolster  50  and a sharp edge at the end of grip  44  to engage the bottom portion of bolster  50 . 
   Referring now to  FIG. 4B , formed sheet  20  is shown mounted to wall  62  by means of block  64  and J-hook  66 . Block  64  is a substantially elongate member having a substantially rectangular cross section, for example wood or plastic foam. J-hook  66  is formed of a strip of bendable material, e.g., aluminum, that has been bent in the general shape of a “J” so that when the upper straight portion thereof is fastened to wall  62  by fastening means N, for example nails or screws, the lower portion of the “J” is facing upwards. Block  64  is fastened to wall  62  by fastening means N at a height so that when rear lip  22  of formed sheet  20  is placed in the lower portion of J-hook  66 , and the bottom of formed sheet  20  is brought toward wall  62 , grip  44  grippingly engages the bottom surface of block  64  to secure formed sheet  20  in place. 
   Referring now to  FIG. 5 , a third embodiment of the invention is illustrated in side elevation view. A mounting clip  70  is formed with a substantially planar central portion, a bottom lip  72 , and a top lip  74 . The central planar portion of mounting clip  70  is affixed to wall  62  by any convenient means, e.g. fasteners N, and bottom lip  72  and top lip  74  are not anchored. Bottom lip  72  is formed with its lowermost part spaced from wall  62 . Top lip  74  is formed with its uppermost part slightly spaced from wall  62  with an angularly oriented planar portion leading toward its uppermost part. 
   Continuing with  FIG. 5 , face trim  76  is formed to mount onto mounting clip  70 . Face trim  76  has bottom hook  78 , formed to engage bottom lip  72  of mounting clip  70 . Face trim  76  also has top hook  80 , formed to engage top lip  74  of mounting clip  70 . 
   The assembly of face trim  76  to mounting clip  70  is illustrated in sequential steps in  FIG. 5A . After bottom hook  78  of face trim  76  has been placed in engagement with bottom lip  72  of mounting clip  70  (see  FIG. 5 ), top hook  80  is placed against the angled portion of top lip  74  as seen as dashed line A. Pressure is exerted against top hook  80  in the general direction indicated by arrow X, causing top hook  80  to bend upwardly relative to the body of face trim  76  (see  FIG. 5A ), moving from position A (dashed lines) to position B (dashed lines). As top hook  80  approaches the uppermost end of top lip  74 , its extreme end snaps over and into place between top lip  74  and wall  62  as indicated at position C (solid lines). Once in this mounted position, depending on the length of top hook  80  that enters behind top lip  74 , removal of face trim  76  is difficult, if not impossible, without substantial distortion. 
   Referring now to  FIG. 5B , a further profile shape of this second embodiment of the invention is shown. In this profile shape, mounting clip  70  is formed similarly to that discussed and shown above, but face trim  76 ′ has a more exaggerated profile. Top hook  80 ′ and bottom hook  78 ′ securely hold face trim  76 ′ to mounting clip  70 . In this manner, differing architectural styles can be accommodated using the mounting principles described above. 
   The face trim products shown in  FIGS. 5 ,  5 A, and  5 B and described above are adaptable for a variety of interior and exterior construction components. In addition to the exterior components of crosshead, fascia, and frieze described in relation to the first embodiments of the present invention, this second embodiment is useful as crown molding, window or door casings, baseboards, and mantle pieces. 
   As briefly described above, a frieze, being a building component that is installed as a transitional trim between a vertical wall and a ceiling or soffit, is typical of a further embodiment of the present invention. A side elevation view of a frieze  88 , mounted between an exterior wall of building  10  and a soffit  84 , is illustrated in  FIG. 6 . Frieze  88  has single concave curve section  90  and a number of alternating inwardly and outwardly oriented right angle bends. Anchor  92  is formed at an upper end of frieze  88  and configured to engage an adjacent edge of soffit  84 . The lower edge of frieze  88  is typically secured to building wall  10  by fastening means N prior to the application of exterior siding. Stiffening block  95  is made to substantially conform to the contour of and provide reinforcement for frieze  88 . Stiffening block  95  is preferably formed of foamed plastic resin. As shown in  FIG. 6 , the stiffening block  95  includes an upper ledge  97  that engages the rearwardly extending anchor  92 . 
     FIG. 6A  illustrates a side elevation view of a frieze  94  which is a variation of the frieze contour shown in  FIG. 6  and described above. Frieze  94  comprises a convex curve section  96 , as differing from concave curve section  90  described above. Stiffening block  95   a  is similar to stiffening block  95  described above. 
     FIG. 6B  illustrates a side elevation view of a frieze  98  that incorporates concave curve section  100  and convex curve section  102 . Additional variations, for example, curved sections positioned at the center or the lower end of the frieze, multiple concave or multiple convex sections, and parabolic or elliptical curves are also obtainable. Stiffening block  95   b  is similar to stiffening block  95  described above. 
     FIG. 6C  depicts frieze  104  which is similar in contour to frieze  94  of  FIG. 6A . Frieze  104  is formed with an anchor portion for engagement with an inside edge of soffit  84  as described above. The visible face area of frieze  104  may be formed with a variety of convex or concave curves and one or more square bends. Stiffening block  95   c  is positioned between frieze  104  and the structure of house  10  to reduce the chance of frieze  104  being dented or bent after installation. Frieze  104  terminates with an upwardly facing edge  108  that engages J-hook  106 , assembled to house  10  in inverted orientation by fastener N. Fastener N may be screws, nails, or adhesive, e.g. silicone caulk material. 
   Referring now to  FIG. 7 , a portion of a roofline of a building  10  is shown in front elevation view. Fascia  112  is positioned at the forward surface of the eave with roofing material  110  above. 
     FIG. 7A  is a cross sectional view of fascia taken in the direction of line  7 A— 7 A of  FIG. 7  configured with a first contour. Block  128   a  is mounted to the side of rafter  116  by adhesive or other fastener means. J-hook  118  is mounted in inverted orientation beneath block  128   a . Fascia  112   a  is then placed with its lower end  122   a  engaging J-hook  118  and its upper edge  124   a  engaging roof sheathing  114 . Upper edge  124   a  may optionally be affixed to sheathing  114  by means of an adhesive such as, for example, silicone caulk material. Exterior roofing material, e.g. shingles,  110  is applied last. Fascia  112   a  is configured to mount with edges P, Q, and R in contact with block  128   a , thus affording sufficient stiffening to avoid bending or minor denting. 
     FIG. 7B  provides a cross sectional view of a fascia  112   b  that differs in contour and means of support from fascia  112   a  of  FIG. 7A . Fascia  112   b  is configured to extend further outwardly from rafter  116  at its top portion than at its bottom portion. To accommodate this greater extension of fascia  112   b , roof sheathing  114  is mounted to protrude a greater distance beyond rafter  116  than occurs in the illustration of  FIG. 7A . Stiffening block  128   b  substantially conforms to the interior dimensions of fascia  112   b  and is adhesively or otherwise mounted to rafter  116 . Fascia  112   b  is mounted with its lower edge engaging inverted J-hook  118  and its upper edge  124   b  engaging and adhered to roof sheathing  114 , thus supporting corners P′, Q′, and R′ and the surfaces between. As with prior described trim products, any nails, screws, or adhesive used for mounting the trim product or a supporting J-hook or other component are positioned to be totally hidden when the siding panels or other exterior parts are installed. In this way, a finished installation without visible fasteners is achieved. 
   Referring now to  FIG. 8 , a side elevation view is shown of a first embodiment set of forming dies  132 ,  136  according to the present invention. The solid line drawing shows forming dies  132  and  136  prior to closure with sheet  130  of bendable material in position with surface A painted and surface B unpainted. The dashed line drawing shows formed sheet  130 ′ after closure of forming dies  132 ,  136 . The lower part of the die set consists of lower die  132 , having a selected contour, for example including one or more curved sections and one or more angular sections, and is substantially elongate in a direction perpendicular to the plane of the drawing. Columns  134  support base  132 . Upper die  136  is made in a matching contour to the contour of base  132 . Form  136  is supported above base  132  by ram  138 . Rear lip  22 , bottom return  42 , and grip  44  (see  FIG. 2 ) are formed in a subsequent bending operation. 
   In operation, bendable sheet  130  is placed substantially flat on lower die  132  and a downwardly directed force F is applied to upper die  136  through ram  128  to bend sheet  130  to become, after forming, sheet  130 ′, shown in dashed lines. According to the desired configuration of sheet  130 ′, different combinations and relationships of curved and angular portions create differing architectural effects. 
   Referring now to  FIG. 9 , an alternate device employing base die roller  140  and form die roller  144  is disclosed for the continuous formation of contours in a sheet  130  of bendable material. A cross sectional view through base die roller  140  and form die roller  144  is substantially equal to the elevation view of forming dies  132 ,  136  shown in  FIG. 8 . By forming a set of dies as rollers, longer continuous lengths of formed sheet are possible than with a fixed length set of opposed dies. Base die roller  140  mounts on shaft  142  and is driven in the rotational direction indicated by arrow Y. Form die roller  144  mounts on shaft  146  and is driven in the rotational direction indicated by arrow Y′. Both base die roller  140  and form die roller  144  have matching areas of curvature and a number of alternating inwardly and outwardly oriented right angle bends to form a sheet of bendable material  130  similarly when die rollers  140  and  144  are brought together in the direction of arrows K and rotated and sheet  106  moves in the direction of arrow Z. As will be readily understood, the result will be similar whether base die roller  140  moves up or form die roller  144  moves down, or both move toward each other. Depending on the length of sheet material supply and the length of formed sheet required, transverse cuts are made at selected intervals along the formed sheet. As noted above in respect to forming dies  132  and  136  of  FIG. 8 , rear lip  22 , bottom return  42 , and grip  44  (see  FIG. 2 ) are formed in a separate bending operation. 
   In each of the disclosed embodiments of the present invention, a sheet of material is bent to obtain a selected cross sectional profile between linear edges thereof. The architectural trim products thus formed are mounted to a building with both of the linear edges in contact with a building surface and with all fasteners, e.g. nails or screws, positioned to be subsequently masked by other trim components or siding. Thus, no fasteners of the trim products of the invention are visible in the finished building. 
   The above detailed description of a preferred embodiment of the invention sets forth the best mode contemplated by the inventor for carrying out the invention at the time of filing this application and is provided by way of example and not as a limitation. Accordingly, various modifications and variations obvious to a person of ordinary skill in the art to which it pertains are deemed to lie within the scope and spirit of the invention as set forth in the following claims.