Abstract:
A modular trim kit including a number of modular trim pieces and a number of connectors which can be utilized to secure a first trim module to a second trim module to allow the modules to be assembled in a shape matching a cutout in a wall pad. In certain exemplifications of the present disclosure, a single trim module may be utilized to trim the cutout. In configurations in which the cutout is formed with angled corners to define a polygonal cutout, the kit may include corner trim modules sized and shaped to accommodate trimming at the vertices of the polygonal cutout.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to a trim kit for trimming a cutout in a panel, and more particularly, to a modular trim kit adaptable to trim a cutout in a padded wall panel. 
       BACKGROUND 
       [0002]    Padded wall panels, which are sometimes simply referred to as wall pads, are routinely utilized to cushion hard surfaces which may be encountered by people. Wall pads can be placed over the solid wood and/or concrete walls of a sporting venue. For example, wall pads can be placed over outfield walls in baseball stadiums and over the walls of a gymnasium, e.g., adjacent a basketball goal. 
         [0003]    Wall pads are typically constructed of three materials:
       1) A backing, which can be made of any rigid material (e.g., oriented strand board (OSB) or other types of waferboard);   2) A thick layer of shock absorbing foam (e.g, polyurethane foam, bonded foam, polychloroprene foam, etc.) padding covering the backing, and   3) A covering (e.g., a vinyl cover) positioned over the foam and secured to the backing.       
 
         [0007]    In certain circumstances, it is desirable to place a wall pad over a wall including a functional aspect, such as e.g., an electrical outlet, a water fountain or a window opening. In such circumstances, it is also desirable to continue to allow access to the functional aspect after the wall pad is operatively positioned over the wall. Because the size, shape and location of the functional aspect cannot always be predetermined, prefabricated wall panel openings accommodating these situations cannot easily be manufactured. 
       SUMMARY 
       [0008]    To accommodate access to functional aspects of varying size, shape and location, standard wall pads may be modified to allow for a cutout in the wall pad of appropriate size and shape to allow access to the functional aspect, with the wall pad protecting the wall adjacent to the functional aspect. Simply cutting a standard wall pad to provide a cutout to accommodate access to the functional aspect would leave the wall pad with unfinished edges and potentially allow access to and removal of the protective foam of the wall pad. To obviate these issues, the present disclosure provides a modular trim kit which may be utilized to trim the rough edge of the wall pad formed by creating the cutout. 
         [0009]    The modular trim kit of the present disclosure generally includes a number of modular trim pieces and a number of connectors which can be utilized to secure a first trim module to a second trim module to allow the modules to be assembled in a shape matching the cutout in the wall pad. In certain exemplifications of the present disclosure, a single trim module may be utilized to trim the cutout. For example, a single elongate trim module may have its opposite ends joined together to form a ring to trim a ring-shaped cutout. In configurations in which the cutout is formed with angled corners to define a polygonal cutout, the kit may include corner trim modules sized and shaped to accommodate trimming at the vertices of the polygonal cutout. 
         [0010]    In an exemplification thereof, the present disclosure provides a modular trim kit for trimming a panel. The modular trim kit of this exemplification including: at least one elongate trim module, the at least one elongate trim module having an elongate trim module longitudinal axis, the at least one elongate trim module having an elongate trim module finished surface and an elongate trim module reception channel sized for receipt of a thickness of the panel, the elongate trim module finished surface positioned opposite the elongate trim module reception channel along the first elongate trim module longitudinal axis, whereby, with a thickness of the panel positioned in the first elongate trim module reception channel, the finished surface is exposed opposite the panel. In this exemplification of the present disclosure, the modular trim kit further includes at least one connector sized and shaped to selectively connect to the at least one elongate trim module, the at least one connector having a connector longitudinal axis, with the connector connected to the at least one elongate trim module, and the thickness of the panel positioned in the at least one elongate trim module reception channel, at least a segment of the at least one connector spanning the width of the at least one connector is obscured from view. 
         [0011]    In another exemplification thereof, the present disclosure provides a trim module including a plurality of selectively interconnectable trim modules, at least one of the plurality of interconnectable trim modules comprising a corner trim module. In this exemplification of the present disclosure, the corner trim module includes a first leg, the first leg having a substantially linear first leg longitudinal axis running along a length of the first leg, the first leg having a first leg finished surface and a first leg reception channel, the first leg finished surface positioned opposite the first leg reception channel; and a second leg extending from the first leg, the second leg having a substantially linear second leg longitudinal axis running along a length of the second leg, the second leg having a second leg finished surface and a second leg reception channel, the second leg finished surface positioned opposite the second leg reception channel, the first leg longitudinal axis intersecting the second leg longitudinal axis to form an angle, so that the corner trim module can be positioned over a corner of a panel to trim the corner. 
         [0012]    In a further exemplification thereof, the present disclosure provides a protective wall panel including a protective wall panel segment and a modular trim kit for trimming a perimeter defining a cut-out in the protective wall panel segment. In this exemplification of the present disclosure, the protective wall panel segment includes a cut-out sized and shaped to allow access to a functional aspect positioned behind the protective wall panel segment. In this exemplification of the present disclosure, the modular trim kit includes at least one elongate trim module and at least one connector, the at least one elongate trim module covering at least a portion of the perimeter defining the cut-out in the protective wall panel, the at least one elongate trim module including a face flange extending over a face of the protective wall panel segment intersecting the perimeter defining the cut-out, the at least one connector selectively connectable to the at least one elongate trim module. 
         [0013]    In yet a further exemplification thereof, the present disclosure provides a method of sizing a protective wall panel including the steps of: removing a portion of the protective wall panel to form a cut-out in the protective wall panel; and trimming the cut-out with a modular trim kit. In this exemplification of the present disclosure, the step of trimming the cut-out with a modular trim kit includes the steps of: selecting at least one of a plurality of interconnecting trim modules, each of the plurality of interconnecting trim modules having a reception channel sized for receipt of a thickness of the wall panel and a finished surface; forming a shape corresponding to a perimeter defining the cut-out in the protective wall panel with the at least one of the plurality of interconnecting trim modules; and position the at least one of the plurality of interconnecting trim modules about the perimeter defining the cut-out, with the thickness of the wall panel occupying the reception channel of the at least one of the plurality of trim modules. 
         [0014]    In a still further exemplification thereof, the present disclosure provides a modular trim kit for trimming a panel, the modular trim kit including at least one elongate trim module, the at least one elongate trim module having an elongate trim module longitudinal axis, the at least one elongate trim module having an elongate trim module finished surface and an elongate trim module reception channel sized for receipt of a thickness of the panel, the elongate trim module finished surface positioned opposite the elongate trim module reception channel along the first elongate trim module longitudinal axis, the elongate trim module reception channel including a perimeter surface and a face flange; and at least one connector sized and shaped to selectively connect to the at least one elongate trim module, the at least one connector having a connector longitudinal axis, the at least one elongate trim module having a connector channel formed in the perimeter surface, the connector channel defined by a connector channel wall and sized to frictionally receive the at least one connector. 
         [0015]    The above-mentioned and other features of the invention and the manner of obtaining them, will become more apparent and the invention itself will be better understood by reference to the following description of exemplary embodiments of the invention taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a perspective view of a pair of adjacent wall pads showing the outline of a to-be-formed cutout in the two adjacent wall pads; 
           [0017]      FIG. 2  is a perspective view of the wall pads of  FIG. 1  with a cutout formed therein and trimmed by a modular trim kit of the present disclosure; 
           [0018]      FIG. 3  is an exploded view of the arrangement illustrated in  FIG. 2 ; 
           [0019]      FIG. 3 a    is an enlarged, partial exploded view of the trim kit utilized in  FIGS. 2 and 3 ; 
           [0020]      FIG. 4  is a perspective view of the wall pads shown in  FIG. 1 , after the cutout has been made, but before the trim kit is secured in place to trim the cutout; 
           [0021]      FIG. 5  is a partial sectional view taken along line  5 - 5  of  FIG. 2 ; 
           [0022]      FIG. 6  is a first perspective view of an interior corner trim module; 
           [0023]      FIG. 7  is a second perspective view of the interior corner trim module of  FIG. 6 ; 
           [0024]      FIG. 8  is a perspective view of an exterior corner trim module; 
           [0025]      FIG. 9  is a perspective view of a connector utilized to connect a first trim module of the trim kit to a second trim module of the trim kit; 
           [0026]      FIG. 10  is a perspective view of a straight trim module of the present disclosure; and 
           [0027]      FIG. 11  illustrates an exemplary method for removing a portion of a protective wall panel to form a cutout in the protective wall panel. 
       
    
    
       [0028]    Additional illustrations of straight trim modules, interior corner trim modules and exterior corner trim modules useable with the teachings of the present disclosure can be found in Design Patent Applications bearing attorney docket numbers DRA-0038-02-US-E; DRA-0038-03-US-E and DRA-0038-04-US-E, each of which is entitled TRIM MODULE, assigned to the assignee of the present application and filed on even date herewith, the entire disclosures of which are hereby expressly incorporated by reference herein. 
         [0029]    Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the invention. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner; and 
       DETAILED DESCRIPTION 
       [0030]    The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. 
         [0031]      FIG. 1  illustrates first wall panel  20  and adjacent second wall panel  22 . First wall panel  20  and adjacent wall panel  22  may be secured together as a unit or may be completely discrete, separate wall panels which will be positioned adjacent to one another over a wall. If secured together as a unit, panels  20 ,  22  may be considered a single panel. In this instance, cutout  24  is spaced from an outer perimeter of the wall panel. Similarly, if panels  20 ,  22  are separable, each includes a cutout intersecting an outer perimeter of the panel.  FIG. 1  further illustrates the outline for cutout  24 . Referring to  FIG. 2 , cutout  24  is trimmed with trim kit  26  to provide finished edges within cutout  24 .  FIG. 5  illustrates a sectional view of part of second wall panel  22 . As illustrated, the second wall panel  22  is formed of three layers: 1) backing  52 ; 2) foam layer  54 ; and 3) covering  56 . Backing  52  may be formed of any rigid material, e.g., a 7/16 inch OSB or other type of waferboard. Foam layer  54  may be a 2 inch layer of shock absorbing foam such as polyurethane foam, bonded foam, polychlorprene foam, etc. Covering  56  may be a vinyl covering. First wall panel  20  shares the same construction as second wall panel  22 . 
         [0032]    To remove a portion of first wall panel  20  and second wall panel  22  to define cutout  24 , the method illustrated in  FIG. 11  may be implemented. In step  62  of method  78 , the cutout shape for cutout  24  is selected. The shape for cutout  24  will generally correspond to the perimeter of the functional aspect to which access is desired. Method  78  then progresses to step  64  at which the backing layer is sawed along the line corresponding to the cutout shape selected in the preceding step. Step  64  may be implemented in a number of ways. For example, if first wall panel  20  and second wall panel  22  are joined prior to implementation of method  78 , then a hole saw or drill may be utilized to initially form an aperture through backing  52  into which the blade of a saw, such as a jigsaw may be positioned. If first wall panel  20  and second wall panel  22  are separable, then step  64  may be implemented merely by applying a saw blade directly to backing  52  at an exterior surface of the corresponding panel  20 ,  22 intersecting the cutout shape selected in step  62 . In an exemplification, backing  52  is cut in step  64  to a depth of backing  52 , i.e., stopping short of cutting foam layer  54 . After step  64  is complete, method  78  progresses to step  66  at which a segment of backing  52  defined by the saw line is removed. Method  78  then progresses to step  68  at which the cutout shape formed in backing  52  by steps  64  and  66  is utilized as a jig to guide cutting foam layer  54  along a line corresponding to the cutout shape. Specifically, an electric carving knife can be used to cut foam layer  54 . In an exemplification, foam layer  54  is cut to a depth of foam layer  54 , i.e., stopping short of cutting covering  56 .Method  78  then progresses to step  72  at which a segment of foam layer  54  corresponding to the shape of cutout  24  is removed. To this point in the method, covering  56  is left undisturbed. Method  78  continues at step  74 , with covering  56  cut into a plurality of covering segments. For example, covering  56  may be cut into segments  80  and  82 , as illustrated in  FIG. 1 . Segments  82  are interior segments that will be discarded, while segments  80  will be pulled through the cutout and secured to backing  52 , as illustrated in  FIG. 5 . This step of the method is illustrated at step  76  in  FIG. 11 . Step  76  of method  78  ensures that covering  56  remains taut over first wall panel  20  and second wall panel  22 . Securing segments  80  to backing  52  may be done with staples  58  inserted through covering  56  and into cutout wall segments  28  as illustrated in  FIG. 4 , or by stapling covering  56  to the back of backing  52  with staple  58 , as illustrated in  FIG. 5 . 
         [0033]    With cutout  24  formed in first wall panel  20  and second wall panel  22 , trim kit  26  (see e.g.,  FIGS. 2 and 3 ) can be assembled to trim cutout wall segments  28  defining cutout  24 . In the exemplary embodiment, cutout  24  comprises a polygonal cutout formed by cutout wall segments  28  joined at cutout angles α and θ. To facilitate trimming such a polygonal cutout, trim kit  26  includes trim modules comprising interior corner modules  30  and exterior corner modules  50  as well as straight trim modules  60 . Corner modules  30 ,  50  are formed at angles α and θ as described below. 
         [0034]    Trim modules  30 ,  50  and  60  share similar features which allow them to be assembled as a continuous trim for cutout  24 . In this patent specification, these similar features are denoted with similar reference numerals having alternate letters appended thereto. Specifically, the shared features are denoted with a reference numeral having the alphabetic designator “i,” “e,” and “s” appended thereto, depending on whether they are a part of interior corner module  30 , exterior corner module  50  and straight module  60 , respectively. When referencing one of these shared features generically, i.e., as a part of any of the trim modules, no letter is appended to the reference numeral. 
         [0035]    Referring to  FIG. 6 , interior corner trim module  30  includes first leg  38   i  extending from second leg  40   i  with an angle α formed there between. Specifically, angle α is drawn between the finished surface  48   i  on each of first leg  38   i  and second leg  40   i  such that angle α does not intersect U-shaped channel  32   i  (described in detail herein below). Angle α is also defined between the longitudinal axis of first leg  38   i  and second leg  40   i.  In the exemplary embodiment, angle α is about 90 degrees, i.e. it is nominally 90 degrees. Interior corner module  30  may be formed with first leg  38   i  and second leg  40   i  separated by any angle less than 180 degrees. Referring to  FIG. 8 , exterior corner trim module  50  similarly includes first leg  38   e  extending from second leg  40   e  and forming an angle θ there between. Specifically, angle θ is drawn between the finished surface  48   e  on each of first leg  38   e  and second leg  40   e  such that angle θ does not intersect U-shaped channel  32   e.  Angle θ is also defined between the longitudinal axis of first leg  38   e  and second leg  40   e.  Exterior corner trim module  50  may be formed with first leg  38   e  and second leg  40   e  separated by any angle more than 180 degrees. Angles α and θ of interior corner trim module  30  and exterior corner trim module  50  correspond to angles α and θ formed by intersecting cutout wall segments  28  ( FIG. 3 ) such that interior corner trim module  30  and exterior corner trim module  50  are effective at trimming the corners formed at the vertices of polygonal cutout  24 . Referring to  FIG. 10 , straight trim module  60  does not include intersecting legs but rather is nominally formed with a linear longitudinal axis. 
         [0036]    Referring to  FIGS. 6 and 7 , interior corner trim module  30  includes finished surface  48   i  extending along both first leg  38   i  and second leg  40   i.  Finished surface  48   i  is a generally smooth surface free of sharp corners. Generally, finished surface  48   i  is an esthetically pleasing surface free of geometries that would likely cause harm to an individual forced against finished surface  48   i.  Opposite finished surface  48   i  extends U-shaped channel  32   i.  U-shaped channel  32   i  has as a base perimeter surfaces  46   i,  with face flange  42   i  and securement flange  44   i  extending upwardly from base perimeter surface  46   i  to complete U-shaped channel  32   i.  Formed below base perimeter surface  46   i  is connector channel  34   i,  which is defined by connector channel wall  36   i  which defines a slot beneath each perimeter surface  46   i.  U-shaped channel  32   i  extends opposite finished surface  48   i  along both first leg  38   i  and second leg  40   i.  Similarly, connector channel  34   i  is continuously formed below perimeter surface  46   i  along both first leg  38   i  and second leg  40   i.  For the sake of brevity, the corresponding parts of exterior corner trim module  50  and straight trim module  60  are not described. Generally, interior corner trim module  30 , exterior corner trim module  50 , and straight trim module  60  only differ in the angle between their finished surfaces  48 , i.e., less than 180 degrees (interior corner trim module  30 ), 180 degrees (straight trim module  60 ) and more than 180 degrees (exterior corner trim module  50 ). 
         [0037]    Trim kit  26  further includes a plurality of connectors  70  ( FIG. 9 ). Connectors  70  are sized to provide a mild interference fit in connector channel wall  36  formed in each of the trim modules. Therefore, connector  70  can be positioned in connector channels  34  of two adjacent trim modules to secure the two trim modules one to the other to provide a continuous finish surface  48  and a continuous U-shaped channel  32  spanning the adjacent trim modules. Connectors  70  are obscured from view when connecting adjacent trim modules, as connector channels  34  are positioned opposite finished surface  48  (i.e., on the panel side of the trim modules). When trimming cutout  24 , a pair of corner modules to be joined by a straight trim module  60  can first be positioned in their respective corners of cutout  24 , with a connector  70  inserted in an interference fit in the connector channel  34  of each corner module and extending therefrom. In this position, a first end of a straight trim module  60  can be inserted over connector  70  such that connector  70  occupies connector channel  34   s  in straight trim module  60  and straight trim module  60  abuts the corner module from which connector  70  extends. Because straight trim module  60  is sized to span the two corner modules, the installer may bow straight trim module  60  slightly to allow for insertion of a connector  70  extending from a second corner trim module to be inserted into connector channel  34   s  at the opposite end of straight trim module  60  before straightening straight trim module  60  to provide a continuous finished surface between the two corner modules. This procedure will be utilized to complete trimming of cutout  24 , with straight trim modules  60  being cut to size to span corner modules separated by a cutout wall segment  28  which does not include a corner. Straight trim modules  60  are sufficiently flexible to accommodate the installation method described above and are also sufficiently flexible to follow a contour of a cutout wall segment  28  between adjacent corners. As such, trim modules  60  may be used to trim linear sections of cutout  24 , curved sections of cutout  24 , spline sections of cutout  24 , and other non-linear profiles of cutout  24 . Furthermore, straight trim modules  60  may be joined by a connector  70  end-to-end to form a ring to trim a ring shaped cutout. The ring so formed need not fit into a circular cutout only, as the flexibility of straight trim module  60  will accommodate other arcuate shapes. The ring of this form of the present disclosure will provide a trim extending along the longitudinal axis of the trim module through 360 degrees and will flexibly conform to an arcuate and possibly undulating cutout wall segment. 
         [0038]    As illustrated in  FIG. 5 , U-shaped channels  32  are sized to accommodate a thickness of a wall panel  22  positioned therein. With U-shaped channels  32  occupied by a wall panel  22 , a staple or other connector may be inserted through securement flange  44  of a respective trim module to secure the trim module in place. Adhesive may also be applied to the interior surfaces of the trim module which will abut the wall panel to facilitate securement of the trim modules to the wall panel. If adhesive is used to secure the trim modules in place, then securement flange  44  may be rendered superfluous. Therefore, trim modules of alternative embodiments may incorporate an L-shaped channel formed by face flange  42  and perimeter surface  46 , while eliminating securement flange  44 . 
         [0039]    At times, a pair of corner trim modules will be utilized with no straight trim module  60  positioned there between. In these circumstances, corner trim modules, e.g.,  30 ,  50  can be cut to size to accommodate the geometry of cutout  24 . An example of such a configuration is shown with exterior corner trim module  50  illustrated in  FIGS. 2 and 3  immediately adjacent to an interior corner trim module  30  to the right. In this configuration, interior corner module  30  is first fit to second wall panel  22  with a connector  70  frictionally engaged in connector channel  34   i  and extending therefrom. In this position, exterior corner trim module  50  may be slid over connector  70  with connector  70  frictionally occupying connector channel  34   e.    
         [0040]    First wall panel  20  and second wall panel  22  are nominally formed as 2 foot by 6 foot rectangular pads, with backing  52  comprising a 7/16 inch thick waferboard and foam layer  54  comprising a  2  inch thick polyethylene foam and covering  56  comprising a 14 ounce per square yard solid vinyl coated polyester fabric with a breaking strength of 350 psi and a tear resistance of 65 pounds. Covering  56  is resistant to rot, mildew and ultraviolet light. Trim modules  30 ,  50  and  60  are, in an exemplary embodiment thereof, made of polyvinyl-chloride (PVC) with a durometer hardness SHORE A 75-80. 
         [0041]    Although cutout  24  is shown as spanning first wall panel  20  and second wall panel  22 , in one embodiment, cutout  24  is completely contained within a perimeter envelope of first wall panel  20 . In another embodiment, cutout  24  extends into the first wall panel along a first portion of its perimeter and has as a second portion of its perimeter formed of a side of the second wall panel. 
         [0042]    While this invention has been described as having exemplary designs, the present invention may be further modified with the spirit and scope of this disclosure. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.