Abstract:
An improved architectural trim device constructed from cellular polyvinylchloride. The process employs manufacturing dimensionalized cellular PVC architectural components from a single sheet of plastic that can achieve both linear and radius shapes without using heat bending techniques. The process strengthens the cellular PVC, giving it more structural integrity than other products made strictly of cellular PVC. These techniques enable the manufacture of components with tighter tolerances than traditional heat bending techniques which distort the size and shape of the material making accurate and precise assembly difficult.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    In accordance with 37 C.F.R. §1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. Accordingly, the present invention claims priority as a continuation-in-part of U.S. patent application Ser. No. 14/534,890, entitled “METHOD OF MANUFACTURING ARCHITECTURAL COMPONENTS”, filed Nov. 6, 2014. The contents of the above referenced application is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention is directed to the field of architecture and, in particular, to improved architectural trim components constructed from cellular polyvinylchloride and the method of manufacture. 
       BACKGROUND OF THE INVENTION 
       [0003]    Architectural trim components are traditionally constructed from wood. Unfortunately, wood is susceptible to decay, and the most common wood decay is dry rot. Dry rot is caused by certain fungi which grow when sufficient moisture is present, allowing the fungi to grow and digest the wood, causing the wood to shrink, show a brown discoloration, and crack into pieces. There are many species of fungi that can cause dry rot. For instance, fungus such as serpula lacrymans, armillaria, or lignicolous can cause dry rot wood decay. Some fungi secrete an enzyme that breaks down cellulose in wood, which can also lead to discoloration and cracking known as soft rot. These include fungus such as chaetomium, ceratocystis and kretzschmaria deusta fungi. White rot fungi, common in hardwoods used outdoors, breaks down lignin in wood, leaving lighter colored cellulose behind. 
         [0004]    Plastics, including composites made of plastic and wood, have been recognized as a substitute for architectural trim structures. Plastic has weather resistant qualities, can be treated to resist ultraviolet radiation, and has a surface porosity that accepts painting. However, simply substituting plastic for a wood trim structure is not as desirable since plastic possesses poor structural capabilities. Further, a large chunk of plastic creates both a weight and a cost disadvantage. And, while plastic may be a beneficial substitute for small trim components, the trend has been to develop lighter, stronger, and more durable products. 
         [0005]    Heating plastic to form curves and bends is well known, but includes the inherent problems caused by the heat changing the structure of the plastic. Fiber reinforced thermoset plastics, such as fiberglass, also provide desirable weather resistant performance qualities, but lack the look and feel of traditional wood trim components. Further, fiber reinforced plastics are difficult to shape, modify, or otherwise work with in the field. 
         [0006]    What is lacking in the art are architectural trim components, and the method of constructing them, that can substitute for wood architectural trim components. The components should be constructed of plastic or a composite of plastic and wood, the preferable material being cellular polyvinylchloride, to produce trim components that are light weight, easily manufactured and installed, and are imperious to weather. 
       SUMMARY OF THE INVENTION 
       [0007]    Disclosed is an improved architectural trim and method of manufacturing architectural trim components from plastic or a wood-plastic composite. In the preferred embodiment, a single piece of cellular polyvinylchloride (“PVC”) is employed to form a trim component. By way of example, the trim component is drawn on a CAD system to form the cutting steps for left, right and front trim members using guidelines and machining layers. The CAD drawing is preferably imported into an AlphaCAM system with an NC code output directed to a CNC router. The CNC router operates to prepare the trim member, wherein the sides are adjoined to a frontal piece by a living hinge. The living hinge eliminates the need for aligning the sides for assembly. Assembly is with an accelerated PVC adhesive. A reactive resin, filled or unfilled, can be used to fill any gaps between the assembled side and front component. Exposed reactive resin is sanded, and the architectural trim component is then primed for painting. The architectural trim can be painted before or after installation, with the result providing a weather resistant product having superior properties to conventional wood. 
         [0008]    The process employs manufacturing dimensionalized cellular PVC architectural trim components from plastic sheets to produce both linear and radius shapes without heating to provide enhanced structural integrity. In lieu of the structural weakening of the plastic caused during heating, the instant process strengthens the structure. 
         [0009]    An objective of the invention is to provide a process wherein architectural trim components of varying designs and sizes can go from a design stage to manufacturing in a matter of minutes. 
         [0010]    Another objective of the invention is to provide assembled trim components interconnected with a living hinge to provide tight tolerances between side walls and eliminate structural distortion. 
         [0011]    Another objective of the invention is to provide a method of creating architectural components that can be repeated quickly and accurately. 
         [0012]    Still another objective of the invention is to provide architectural trim components that can be manufactured using materials and techniques that create a product that is weather resistant and will not rot, crack, or warp. 
         [0013]    Still another objective of the invention is to provide an architectural trim component formed from a single piece of plastic with prepared hinge lines to eliminate misalignment during assembly. 
         [0014]    Yet still another objective of the invention is to provide an architectural trim that is hollow, making it lighter and easier to install versus wood or solid plastic trim. 
         [0015]    Another objective of the invention is to provide an architectural trim product that looks the same as traditional architectural trim made from wood, yet eliminates all the problems associated with wood. 
         [0016]    Yet still another objective of the invention is to provide an architectural trim product that requires minimal maintenance in even the harshest of climates. 
         [0017]    Still another objective of the invention is to provide a process that allows manufacturing of cellular PVC components to create an unlimited combination of shapes and sizes from sheet goods of varying thicknesses. 
         [0018]    Other objectives and further advantages and benefits associated with this invention will be apparent to those skilled in the art from the description, examples and claims which follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a front inside view of a one piece architectural component; 
           [0020]      FIG. 2  is a perspective view thereof; 
           [0021]      FIG. 3  is the front inside view with a left side of the architectural component folded into position; 
           [0022]      FIG. 4  is the front inside view with the left and right side view folded into position; 
           [0023]      FIG. 5  is the front inside view with the left side, right side, and end pieces placed into position; 
           [0024]      FIG. 6  is a perspective view of the assembled component; 
           [0025]      FIG. 7  is a pictorial view of a mounting structure; 
           [0026]      FIG. 8  is a pictorial view of an architectural trim installation; 
           [0027]      FIG. 9  is a pictorial view of an architectural trim installation; 
           [0028]      FIG. 10  is a perspective view of two pieces of architectural trim attached together; 
           [0029]      FIG. 11  is an exploded view of the two pieces of architectural trim illustrated in  FIG. 10 ; 
           [0030]      FIG. 12  is a perspective view of the attachment of two components of an architectural trim component; and 
           [0031]      FIG. 13  is a perspective view of an alternative attachment of two components of an architectural trim component. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0032]    Referring to the Figures in general, disclosed is an example of the invention used for architectural trim from cellular polyvinylchloride (“PVC”). One architectural trim component  100  disclosed in the  FIGS. 1-6  is a decorative trim component placed beneath a soffit  60  commonly used in early construction and now used to assimilate early construction techniques and appearance. The method of manufacturing such decorative trim components employs a CAD software program for drawing the architectural trim component design, which is then cut from a single PVC sheet. By way of example, the Applicant&#39;s trim component  8  has a left side component  10 , a right side component  12  forming a mirror image of the left side component  10 , and a frontal component  14 . The left side component  10  has a substantially uniform wall thickness, and is further defined by a rear edge  16  having a front contoured edge  18  that extends from a proximal end  20  to a distal end  21 . A lower portion of the front contoured edge  18  is attached to the frontal component using a living hinge, wherein the contoured edge  18  is constructed and arranged to match a contoured edge  22  of the frontal component, allowing the left component  10  to be folded into a  90  degree position as depicted in  FIG. 3 . The outer edge  23  is not contoured, and provides a flat surface when folded to allow flush mounting against a house soffit. 
         [0033]    Similarly, the right side component  12  has a substantially uniform wall thickness, and the design is defined by a rear edge  24  and a front contoured edge  25  that extends from a proximal end  26  to a distal end  27 . A lower portion of the contoured edge  25  is attached to the frontal component  14  using a living hinge, wherein the contoured edge  25  is constructed and arranged to match a contoured edge  26  of the frontal component, allowing the right component to be folded into a  90  degree position as depicted in  FIG. 4 . The rear edge  24  is not contoured, and provides a flat surface when folded to allow flush mounting against a house soffit. 
         [0034]    The frontal component  14  is rectangular shaped having a thickness with the first side edge  22  having a reciprocal angular shape to the contoured edge  18  of the left side component  10 , and a second side edge  26  having a reciprocal shape to the contoured edge  25  of the right side component  12 . The CAD drawing of the trim component is imported into a CAD/CAM program having a programmed algorithm for applying machining styles to layers along the length of the frontal component  14 . In particular, the numerical control output code for operating a CNC router for cutting the trim shapes from a plastic sheet and positioning guidelines includes machine lines  30  that allow for the ease of bending the plastic section around curve. Expansion layer  32  is between a base section  35  and the machine line section  30 . The machine lines  30  are cut into and decrease the thickness of the frontal component  14 , allowing a portion of the frontal component  14  to bend conjugate along contoured edge  37  of left side  10  and contoured edge  38  of right side  12 . The machine lines  30  allow the section to follow the shape of the left and right side curvatures, which may be made of most any curvature design. In addition, a concave reverse cut  34  along expansion section  32  allows convex positioning of the frontal element. The reverse cut  34  allows for a step as further illustrated in  FIG. 6 . The machine lines  30  are v-shaped cuts into the inner face of the frontal component  14 , where decreasing the distance between cuts and increasing the depth of the cuts allows for a smaller curvature radius. This process allows the cellular PVC to bend along a contoured edge without the decrease in structural integrity associated with the heating and bending of plastics. 
         [0035]    The frontal component  14  is assembled with the left and right trim components  10 ,  12  wherein the frontal component  14  bends conjugate to the reciprocal front contoured edges  22 , formed on the left and right side of each individual component  10 ,  12 . The frontal component may include a step formed by a reverse cut  34  allowing section  32  to span a large distance followed by a curvature using the machine lines  30  and extending to the distal ends  21  and  27 . 
         [0036]    Preferably, the components are permanently fastened together using an accelerated PVC adhesive. While proper machining all but eliminates any spacing between components, space that may still exist is permanently filled with a two part epoxy. Once dry, excess epoxy and any uneven corner edge is sanded to form a uniform and seamless corner edge, giving the appearance of a single solid piece of trim. The architectural trim can then be primed and painted. Alternatively, the architectural trim can be primed, mounted to a building structure, and then painted, or mounted and then primed and painted. 
         [0037]    The architectural trim  100  is fabricated from a single piece of sheet material  102  with said front member  14  having an inner surface  61  and an outer surface  63  with a thickness therebetween. The front member is further defined by a rectangular shaped rigid base section  35  coupled to a rectangular shaped curvature section  47  by a first living hinge  33 . The curvature section  47  is formed from a plurality of ridge shaped machine line cuts  30  placed parallel to each other, allowing the curvature section  47  to bend. The left side member  10  has a first rigid base  41  coupled to a first edge  22  of the rigid base  35  of the front member  14  by a living hinge formed between the frontal member and the left side member. The left side member  10  includes a first curved end  43  extending from the first rigid base  41  to a left side distal tip or end  21 ; the first curved end  43  including a first beveled surface  37  for receiving a first edge  45  of the front member curvature section  37 . 
         [0038]    The right side member  12  has a second rigid base  65  coupled to a second edge  26  of the rigid base  35  of the front member  14  by a third living hinge formed between the frontal member and the right side member. The right side member  12  includes a second curved section  67  extending from the first rigid base  65  to a right side distal tip or end  27 ; the second curved section  67  including a second contoured edge  38  which is formed from a beveled surface for receiving a second edge  69  of the front member curvature section  47 . The ridge shaped machine line cuts  30  permits the curvature section  47  to bend conjugate to and interface with the left side member  10  and the right side member  12 , which are then held in position with adhesive. 
         [0039]    The beveled edges between the left side member and the front member are constructed and arranged to position the two members at a  90  degree angle. Similarly, the right side member and the front member are constructed and arranged to position the two members at a  90  degree angle as depicted in  FIG. 6 . 
         [0040]      FIG. 7  illustrates an installation having a top mounting support  40  securable to soffit  60 , and a side mounting support  42  securable to a wall  62  of a building. Preferably, the mounting supports  40  and  42  are made out of the similar PVC material; however, since the mounting supports  40  and  42  will fit within the back surface of the architectural trim and are thereby hidden permanently, other suitable materials may be used. The mounting supports  40  and  42  can be secured to the soffit and wall by conventional fasteners  44  such as screws or nails. Additionally, the mounting supports  40  and  42  can be formed as two separate pieces, or as one piece with a machined v-cut allowing for the angled bend. An architectural trim component  51  can be placed over the mounting supports and fastened by screws, nails or the like. The use of PVC mounting material further provides an option of attaching the architectural trim component  51  by adhesive. As seen in  FIG. 8 , architectural trim components  52  can be placed in series along a building soffit  66  and abutting frieze board  68 , giving the appearance of classical architectural.  FIG. 9  illustrates how multiple pieces of architectural trim can be incorporated into the outer wall of a building where the architectural trim of the instant invention provides components  50 ,  54 , and a louver trim component  64 . Additionally, as seen in  FIGS. 9-11 , multiple architectural trim components  50 ,  54  can be joined together and affixed to the building exterior. This combination of two architectural trim components  50  and  54  can also be seen in  FIG. 10 , where the components are shown from a rear side angle.  FIG. 11  is an exploded view of  FIG. 10 . Left side component  55 , right side component  56 , front component  57 , and back component  58  of trim component  54  are depicted in this exploded view. 
         [0041]      FIGS. 12-13  show how the pieces of cellular PVC can be adhered together. In  FIG. 12 , a frontal component  14  and a right side component  12  are shown cut at angles so that the mounting surfaces of each meet at a corner of the architectural trim component  50 .  FIG. 13  depicts a top mounting support  40  attached to a right side component  12  so that the mounting support is hidden from view when the architectural trim component  50  is mounted to the building exterior.  FIGS. 12 and 13  are illustrative and not limiting, as other mounting connections can be used to bond the two pieces of cellular PVC. Tongue-and-groove, lock mitre, and curved edges are examples of other connections which can be used to increase the surface area of mounting surface where the two PVC pieces are joined, where an increase in surface area on the mounting surfaces can increase the strength of the bond between the two components. 
         [0042]    The method of forming architectural trim from cellular polyvinylchloride allows for unlimited radius forms, wherein the machining technique eliminates the need for heat bending or laminating. While a detailed embodiment of the instant invention directed to Applicant&#39;s Outlook pattern is disclosed herein, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms and include most any radius form. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
         [0043]    One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.