Patent Publication Number: US-6341458-B1

Title: Extruded composite corners for building construction

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The present invention relates generally to composite materials for buildings and the like. More specifically, this invention relates to thermoplastic polymer based composite corner members, such as trim strips or posts for building construction. The composite material may be comprised of cellulosic material, such as cementitious based cellulose reinforced material. 
     Corner posts are typically used at the vertical intersection of two side walls, either on the inside (i.e., recessed corners) or outside (i.e., protruding corners) of the intersection. Often, the exterior of the side walls is covered with planking, siding, or stucco. Newer materials such as fiber-containing concrete are also being used to cover building exteriors. Many of these materials leave openings or improperly sealed junctions at the intersection. These openings may allow moisture or insects to pass behind the exterior covering, thereby causing rot, crumbling, or other resultant damage. Exterior corners are also desirable to provide relative ease of installation of the wall intersections. It is therefore desirable to use a strong, durable corner or covering to create an appropriate seal at the exterior corner. It is also desirable that the corner or covering be aesthetically pleasing on the exterior of the building. 
     Similarly, recessed corners (on the exterior of buildings) are susceptible to many of the same problems as the protruding corners. Even with the addition of caulking material on the adjacent seams, protection can only be obtained for a short time. Eventually, the caulking material will dry and become brittle, allowing water and is insects to penetrate the wooden or other components. 
     It is therefore an object of the present invention to develop durable, water-tight corner posts for building construction that are easy to install, relatively inexpensive, and aesthetically pleasing. 
     The present invention comprises an extruded composite outside corner post for building construction. The outside corner post is preferably formed of a thermoplastic wood composite material. The corner post comprises perpendicular first and second elongated faces. These first and second faces are connected so as to form a right angle. The post has first and second elongated lips. The first elongated lip is located at the edge of the first elongated face, opposite the second elongated face. The first elongated lip extends into the region of the right angle, and is perpendicular to the first elongated face. The second elongated lip is located at the edge of the second elongated face opposite the first elongated face. The second elongated lip extends into the region of the right angle, and perpendicular to the second elongated face. 
     The post also comprises first and second angled extensions extending into the region of the right angle. The first angled extension is connected to the first face between the second face and the first lip. The first angled extension has a first extension portion that is parallel to but shorter than the second elongated face, and a first nailing flange that is parallel to the first elongated face and extends from the end of the first extension portion. The second angled extension is connected to the second face between the first face and the second lip. The second angled extension has a second extension portion parallel to but shorter than the first elongated face, and a second nailing flange that extends from the end of the second extension portion and is parallel to the second elongated face. 
     The first lip and first nailing flange of the first angled extension are preferably adapted to sufficiently contact the front and back faces, respectively, of an exterior building material when an end of the building material is placed in contact with the first extension portion of the first angled extension. The second lip and the second nailing flange of the second angled extension are preferably adapted to sufficiently contact the front and back faces, respectively, of an exterior building material when an end of the building material is placed in contact with the second extension portion of the second angled extension. The building material may be any material appropriate for exterior walls, such as extruded composite siding, vinyl siding, aluminum siding, fiber cement siding, and wood planking. The nailing flanges of the post may comprise openings adapted to allow passage of construction fastening devices. These fastening devices, such as nails or screws, may be used to rigidly affix the exterior building materials to the corner post. 
     The present invention also includes an extruded composite inside corner post for building construction, formed of a thermoplastic wood composite. The inside corner post comprises first and second elongated inner portions, the first and second inner portions connected so as to define a right angle. The post also has first and second nailing flanges. The first nailing flange extends from the end of the first elongated inner portion away from and parallel to the second inner portion. The second nailing flange extends from the end of the second elongated inner portion away from and parallel to the first inner portion. The post also comprises first and second elongated supports. The first elongated support extends from the first elongated inner portion, near the intersection of the first and second elongated inner portions and parallel to the first nailing flange. The second elongated support extends from the second elongated inner portion near the intersection of the first and second elongated inner portions, parallel to the first nailing flange. 
     The post also comprises first and second elongated lips. The first elongated lip extends from the end of the first elongated support parallel to and in the direction of the first elongated inner portion. The second elongated lip extends from the end of the second elongated support parallel to and in the direction of the second elongated inner portion. 
     The first lip and first nailing flange are preferably adapted to sufficiently contact the front and back faces, respectively, of a planar building material when an end of the building material is placed in contact with the first elongated inner portion. The second lip and second nailing flange are preferably adapted to sufficiently contact the front and back faces, respectively, of a planar building material when an end of the building material is placed in contact with the second elongated inner portion. The planar building material may be any appropriate exterior wall construction material, such as extruded composite planking, exterior building panels, and wood planking. 
     The inside corner post may additionally comprise openings in the first and second nailing flanges through which construction fastening devices may be passed. The post may also comprise openings in the first and second elongated inner portions through which construction fastening devices may be passed. These openings may facilitate the fastening of the post to a corner post of a building. 
     In addition to the novel features and advantages mentioned above, other objects and advantages of the present invention will be readily apparent from the following descriptions of the drawings and preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an end view of an exterior corner that may be used in accordance with the present invention. 
     FIG. 2 is an end view of an interior corner that may be used in accordance with the present invention. 
     FIG. 3 is a perspective cutaway view of a corner member of the present invention installed on a building structure. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) 
     The present invention is directed to interior and exterior corner posts for buildings and the like. FIG. 1 shows a preferred embodiment of an exterior corner post of the present invention. The exterior corner post  1  is shown from one end of the post. The post has a first elongated face  2  and a second elongated face  3 . The faces are formed perpendicular to one another so as to form substantially a right angle. The elongated faces may be of any appropriate width, but in this selected embodiment are each approximately 4 ¼″ wide. The posts may be of any appropriate length, such as posts of 6, 8, 10, 12, or 20 feet. 
     The post has a first elongated lip  4  and a second elongated lip  5 . The first elongated lip  4  is located at the edge of the first elongated face  2 , opposite the second elongated face  3 . The first elongated lip extends into the region of the right angle and is perpendicular to the first elongated face. The distance from the inside of the first elongated lip to the outside of the first elongated face may be any appropriate distance, in this embodiment preferably about 0.525″. The second elongated lip  5  is located at the edge of the second elongated face  3  opposite the first elongated face  2 . The second elongated lip extends into the region of the right angle, preferably the same distance as the first elongated lip, and is perpendicular to the second elongated face  3 . 
     The post also comprises first  30  and second  40  angled extensions extending into the region of the right angle. The first angled extension  30  is connected to the first elongated face between the second elongated face  3  and the first lip  4 , preferably about 0.875″ from the outside edge of the first lip to the outside edge of the extension  30  as it begins from the first face  2 . The first angled extension  30  has a first extension portion  6  that is parallel to but shorter than the second elongated face  3 , preferably about 1.575″ in length from the outside edge of the first elongated face to the end of the first extension portion. The first angled extension  30  also has a first nailing flange  7  that is parallel to the first elongated face  2  and extends from the end of the first extension portion  6 . The first nailing flange  7  may be of any appropriate length, preferably about 2.125″. 
     The second angled extension  40  is connected to the second face  3  between the first face  2  and the second lip  5 . The second angled extension has a second extension portion  8  parallel to but shorter than the first elongated face  2 , again preferably about 1.575″ in length from the outside edge of the second elongate face to the end of the first extension portion. The second angled extension preferably also has a second nailing flange  9  that extends from the end of the second extension portion  8  and is parallel to the second elongated face  3 . The second nailing flange  9  may be of any appropriate length, preferably about 2.125″. 
     The first lip  4  and the first nailing flange  7  of the first angled extension are preferably adapted to sufficiently contact the front and back faces, respectively, of an exterior building material when an end of the building material is placed in contact with the first portion  6  of the first angled extension. The spacing between the lip  4  and the first nailing flange  7  of the first angled extension may be any width appropriate for receiving a given building material, preferably about 0.850″. Caulking or any other appropriate sealant may be placed in the pocket created by the lip and angled extension before inserting the building material, so as to create an enhanced water-tight seal. The second lip  5  and the second nailing hange  9  of the second angled extension are preferably similarly adapted. 
     The building material to be inserted into the outside corner may be any material appropriate for exterior walls, such as extruded composite siding, fiber cement siding, vinyl siding, aluminum siding, and wood planking. Such building material is installed in conventional manner onto the building, and ends of the building material, located at the corners, are received in the pocket created by the lips and the nailing flanges. 
     The post may additionally comprise openings  10  in the nailing flanges  7 ,  9 , these openings adapted to allow passage of construction fastening devices. These fastening devices, such as nails or screws, may be used to rigidly affix the post to the building frame. The openings  10  may be of any size and shape appropriate for the fastening devices. The openings are preferably of an elongated or oval shape, preferably about 1.0″ in length. 
     The exterior corner  1  may be molded in any appropriate color so as to match the appearance of a building exterior. The extruded corner may also have a pattern or texture formed on the outside faces so as to match the texture of pattern of a building material held in place by the corner. 
     As shown in FIG. 2, the present invention also includes an extruded composite inside (recessed) corner post  11  for building construction, preferably formed of a vinyl based cellulose reinforced composite. The inside corner post  11  comprises a first elongated inner portion  12  and a second elongated inner portion  13 , the first and second inner portions connected so as to define a right angle. The inner portions may be of any appropriate width, preferably equal widths. In a preferred embodiment, the width of each inner portion is approximately 1.3″ to 1.6″. 
     The post also has a first nailing flange  14  and second elongated nailing flange  15 . The outer portions may be of any appropriate width, preferably of equal widths. In a preferred embodiment, the width of each outer portion is approximately 2.1″ to 2.4″. The first elongated flange  14  extends from the end of the first elongated inner portion  12  away from and parallel to the second inner portion  13 . The second elongated flange  15  extends from the end of the second elongated inner portion  13  away from and parallel to the first inner portion  12 . 
     The post also comprises a first elongated support  16  and a second elongated support  17 . The elongated supports may be of any appropriate width, preferably of equal widths. In a preferred embodiment, the width of each support is approximately 0.9″ to 1.1″. The first elongated support  16  extends from the first elongated inner portion  12 , near the intersection of the first and second elongated inner portions and parallel to the first elongated nailing flange  14 . The second elongated support  17  extends from the second elongated inner portion  13  near the intersection of the first and second elongated inner portions, parallel to the second elongated nailing flange  15 . 
     The post also comprises a first elongated lip  18  and a second elongated lip  19 . The lips may be of any appropriate width, preferably of equal widths. In a preferred embodiment, the width of each lip is approximately 0.5″ to 0.6″. The first elongated lip  18  extends from the end of the first elongated support  16  parallel to and in the direction of the first elongated inner portion  12 . The second elongated lip  19  extends from the end of the second elongated support  17  parallel to and in the direction of the second elongated inner portion  13 . 
     As shown in FIG. 3, the first lip  18  and first elongated nailing flange  14  define an area for receiving an exterior building material  50  when an end of the exterior building material is placed in the receiving area. The second lip  19  and second elongated outer  15  portion likewise define an area for receiving an exterior building material. The planar building material held in place by a corner may be any appropriate exterior wall construction material, such as extruded composite planking, fiber cement siding, interior building panels, and wood planking. Caulking or any other appropriate sealant may be placed in the pocket created by the lip and elongated extension before inserting the building material, so as to create an enhanced water-tight seal. 
     The recessed corner post  11  may additionally comprise openings  20  in the first and second elongated nailing flanges,  14  and  15  respectively, through which construction fastening devices may be passed to secure the corner  11  to the building frame. The openings  20  may be of any size and shape appropriate for the fastening devices. The openings are preferably of an elongated or oval shape, preferably about 1.0″ in length. 
     The space  70  created between the exterior building material component (that resides between the lip and the nailing flange) and the elongated face of the corner post, serves as a weep path (or escape path) for moisture droplets and/or rain drops that may become otherwise trapped between the materials at the corner. It also allows for air circulation behind the exterior building material that may enhance the life and long lasting appearance characteristics of the invention and the exterior building material. 
     The extruded corner  11  may have a pattern or texture formed on the faces  16 ,  17  of the supports so as to match the texture or pattern of a building material being used. 
     The extruded composite used in forming the corners of the present invention may be any appropriate polymer based cellulose reinforced composite. In a preferred embodiment, the corners are formed of a cellulosic composite comprising: (a) at least one cellulosic material present in an amount in the range of from about 20% to about 60% by weight of the composite, and (b) at least one thermoplastic polymer material present in an amount in the range of from about 20% to about 70% by weight of the composite. 
     It is preferred that the cellulosic material(s) is/are present in an amount in the range of from about 30% to about 55% by weight of the composite. It is also preferred that the cellulosic material(s) be selected from wood saw dust, seed husks, ground rice hulls, newspaper, kenaf, coconut shells, bagasse, corn cobs, and peanut shells, and mixtures thereof. 
     It is preferred that the thermoplastic polymer material(s) be present in an amount in the range of from about 25% to about 60% by weight of the composite. 
     The composite thermoplastic compound may consist of rigid PVC dryblend compound, polyethylene, polypropylene or ABS combined with relatively high loadings of cellulose reinforcement. 
     An example PVC material for use in the present invention may include: 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                   
                 Preferred Range 
               
               
                   
                 Range (per 100 
                 (per 100 parts of 
               
               
                 Ingredient 
                 parts of resin) 
                 resin) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 PVC resin (I.V. range of 0.6-1.0) 
                 100 
                 parts 
                 100 
                 parts 
               
               
                 Stabilizer 
                 2-8 
                 phr 
                 2-4 
                 phr 
               
               
                 Lubricants 
                 4-10 
                 phr 
                 4-6 
                 phr 
               
               
                 Process Aids 
                 1-4 
                 phr 
                 1-2 
                 phr 
               
               
                   
               
            
           
         
       
     
     Stabilizers may include tin, lead, barium and cadmium Common commercial lubricants known in the plastics processing industry, both internal and external, can be used. Examples of lubricants which can be used include calcium stearate, esters, paraffin wax, and amide wax. 
     Process aids such as acrylic modifiers for PVC aid fusion of the compound. 
     Additional components, for example foaming agents and compatibilizers, can be added if desired. 
     The cellulose material should be dried to between about 0.1%-3% in moisture content, preferably 0.1%-1.5% moisture by weight. 
     The dry blend may then be fed into an extruder e.g., a parallel, twin screw by Davis Standard. 
     The preferred embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The preferred embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. Having shown and described preferred embodiments of the present invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention. Many of those variations and modifications will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.