Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
     The present invention claims the benefit of U.S. provisional application Ser. No. 60/987,900, filed Nov. 14, 2007, which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to decorative trim, and, more particularly, to decorative trim for a house or similar building. 
     BACKGROUND OF THE INVENTION 
     Decorative trim, trimwork, or scrollwork is typically cut from wood and used to decorate the exterior of dwelling structures such as houses. Because of wide variations in home exteriors, such as roof pitch, porch construction, roof fascia, soffit design, and the like, wooden trimwork is often customized by skilled workers off-site after measurements are taken, and then is brought to the site for final installation and customization. This creates added expense and delays in construction, amongst other problems. 
     SUMMARY OF THE INVENTION 
     The present invention provides a decorative trim system made up of readily customizable standard pieces that are easily joined to one another and adapted to fit most any structure without requiring skilled woodworkers to perform the installation or assembly. 
     In one form, the present invention provides a decorative trim assembly including first and second trim modules. Each of the trim modules has a decorative portion and a rail portion coupled to the decorative portion. The rail portion has an end portion and defines a channel. The channel has a first height and a first width, and the end portion has a second height and a second width not greater than the first height and the first width of the channel. The channel of the first trim module receives the end portion of the second trim module for assembling the first and second trim modules together. 
     In one aspect, the first trim module is substantially identical to the second trim module. Optionally, a third trim module is mountable at one of the first and second trim modules. The third trim module has a decorative portion and a rail portion coupled to the decorative portion. The rail portion has a third height and a third width not greater than the first height and the first width of the channel. The rail portion of the third trim module is adapted to be received into the channel. 
     In another aspect, the decorative trim assembly includes a screw block at the channel. The screw block receives a screw when the third trim module is fastened to either the first or second trim module with the screw. 
     In yet another aspect, the decorative trim assembly includes a rail finish cap, a corner bracket, a pendant, a gable post, a gable end, or an angle adapter, any of which may be coupled to either the first or second trim module. 
     According to another form of the present invention, a decorative trim assembly is provided for a building exterior and includes an emblem member and a trim module for receiving the emblem member. The emblem member has an outer perimeter. The trim module has an aperture for receiving the outer perimeter of the emblem member, which is removable therefrom. The trim module has at least one wall defining the aperture that receives the emblem member. The wall that defines the aperture has first and second pluralities of snap-fit ramped surfaces. The first plurality of snap-fit ramped surfaces are spaced longitudinally from one another and arranged in a first plane. The second plurality of snap-fit ramped surfaces are also spaced longitudinally from one another and are arranged in a second plane that is parallel to the first plane. The first plurality of snap-fit ramped surfaces are arranged in an alternating manner with the second plurality of snap-fit ramped surfaces so that the perimeter member can be snap-fit at the aperture and releasably retained thereat by the first and second pluralities of snap-fit ramped surfaces. 
     In one aspect, the trim module is a corner bracket module or a pendant module. Both the outer perimeter and the aperture may be circular. The decorative trim assembly may be made of polyvinylchloride, and may include a stabilizer that resists ultraviolet radiation. 
     In another form of the present invention, a method is provided for installing a decorative trim assembly. The method includes providing a first trim module and a second trim module for attachment to a building exterior. A rail portion is provided at each of the first trim module and the second trim module. The first trim module is attached to the building exterior. A screw block is inserted into the rail portion of the first trim module. The second trim module is attached to the first trim module by inserting the rail portion of the second trim module into the rail portion of the first trim module and driving a fastener through one of the rail portions and into the screw block. 
     According to yet another form of the present invention, a decorative trim assembly is provided for a building exterior gable. The assembly includes a gable post, a gable end, and at least one gable module. The gable post has a top end, a bottom end, a front flange, and a rear flange. The gable end receives the bottom end of the gable post. The gable module has a decorative portion and a rail portion, and engages both the gable post and the building exterior gable. The front flange and the rear flange of the gable post receive therebetween the decorative portion of the gable module, and the rail portion abuts the building exterior gable. 
     According to one aspect, the decorative portion of the gable module is fastened to the gable post with a first fastener, and the gable end is fastened to the gable post with a second fastener. 
     According to another aspect, a rail finish cap is provided to receive an end of the rail portion of the gable module and to span between the rail portion and the top end of the gable post. 
     Therefore, the decorative trim assembly of the present invention provides a set of decorative modules that are easily customized for a given application at a work site. The assembly is readily assembled with conventional tools and once installed, requires little or no maintenance. The assembly resists discoloration, swelling or shrinking, rot, mildew, cracking, and the formation of gaps. Further, the assembly may include customizable modules that can receive a variety of decorative inserts by snap-fitting emblems or other inserts into or out of the customizable modules. 
     These and other objects, advantages, purposes, and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a front elevation of a house having a decorative trim assembly in accordance with the present invention; 
         FIG. 1B  is another front elevation of another house with a decorative trim assembly of the present invention; 
         FIG. 2  is an exploded front view of portions of the decorative trim assembly of the present invention; 
         FIG. 3A  is a perspective view of a pair of spandrels prior to assembly; 
         FIG. 3B  is a perspective view of the pair of spandrels of  FIG. 3A  assembled together; 
         FIG. 4  is an end elevation of a spandrel and a pendant assembled together; 
         FIG. 5A  is a perspective view of the spandrel and pendant of  FIG. 4 ; 
         FIG. 5B  is a perspective view of the spandrel and pendant of  FIG. 5A  having a screwblock in rail portions of the spandrel and pendant; 
         FIG. 6A  is an exploded front elevation of a gable portion of the decorative trim assembly; 
         FIG. 6B  is an enlarged front elevation of an upper portion of a gable portion of the decorative trim assembly; 
         FIG. 7A  is a perspective view of a gable post and gable end prior to assembly; 
         FIG. 7B  is a side elevation of the gable post and gable end assembled together; 
         FIG. 7C  is an end elevation of a gable post; 
         FIG. 8A  is a perspective view of a gable module and a gable extension module; 
         FIG. 8B  is an enlarged perspective view of the section labeled VIIIB in  FIG. 8A ; 
         FIG. 9  is a perspective view of a corner bracket and angle adapter installed at a vertical post and header; 
         FIG. 10  is a top plan of the corner bracket, adapter, and vertical post of  FIG. 9 ; 
         FIG. 11A  is a perspective view of a bracket angle adapter as shown in  FIGS. 9 and 10 , taken from the front and side thereof; 
         FIG. 11B  is a perspective view of the bracket angle adapter of  FIG. 11A , taken from the back and opposite side thereof; 
         FIG. 12  is a front elevation of another corner bracket including a selected emblem assembled therewith in accordance with the present invention; 
         FIGS. 13A-13C  are sectional views taken along lines  13 A- 13 C in  FIG. 13 ; and 
         FIG. 14  is a side sectional view of a portion of a gable module prior to attachment at a roof overhang. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings and the illustrative embodiments depicted therein, a decorative trim assembly  10  is provided for beautifying or decorating the exterior of a building such as a house  12  ( FIGS. 1A and 1B ). Assembly  10  includes various elements or modules that may be joined together and/or joined to the exterior portions of house  12  to decorate the house as desired by a user. The various modules include, for example, spandrel modules  14 , pendant modules  16 , corner bracket modules  18 , gable modules  20 , gable extension modules  22 , gable post modules  24 , and gable end modules  26  ( FIGS. 2 and 6A ). Also included for joining and finishing purposes are bracket angle adapter  28 , rail finish caps  30 , and screw blocks  32 . Each module  14 ,  16 ,  18 ,  20 ,  22 ,  24 , and  26  includes at least one rail portion generally referred to by the suffix a or a′ (e.g. spandrel rail  14   a  or  14   a ′), and a decorative portion generally referred to by the suffix b (e.g. spandrel decorative portion  14   b ). 
     As best seen in  FIG. 2 , a plurality of modules, such as spandrels  14 , pendant  16 , and corner bracket  18 , may be joined together to form a trim subassembly  34 . To build trim subassembly  34 , one or more spandrels  14  may be placed or assembled end-to-end and fastened to the underside of a header  36  ( FIGS. 1B and 9 ), as will be described in greater detail below. Pendant  16  and corner bracket  18  are attached to rails  14   a ′ on the lower edge of spandrels  14  using fasteners  38  and screw blocks  32 . Corner bracket  18  is attachable to rail  14   a  and to post  40  ( FIGS. 1B ,  9 , and  10 ) and is typically placed at one end of spandrel  14 . 
     Spandrel rails  14   a ,  14   a ′ have a narrowed or reduced-size step or shoulder region  42  at one end, and a corresponding carve-out or recessed region  44  at an end of spandrel rail  14   a ,  14   a ′ opposite shoulder region  42  ( FIG. 3A ). Regions  42 ,  44  correspond in shape and size to one another so that they may be nested together with the outer surfaces of rails  14   a ,  14   a ′ substantially flush and continuous when joined in this manner. Thus, rails  14   a ,  14   a ′, shoulder region  42 , and recessed region  44  are generally U-shaped and configured such that narrowed regions  42  of one spandrel module are cooperatively received at recessed regions  44  of an adjacent spandrel module ( FIG. 3B ). 
     Fastener holes  46  in rails  14   a  ( FIGS. 3A ,  3 B,  8 A, and  8 B) facilitate the connection of spandrels  14  to header  36  with fasteners  38  that are driven through holes  46 . Thus, as many spandrels as are desired may be assembled end-to-end with regions  42 ,  44  on rails  14   a ,  14   a ′ nested together to form a continuous spandrel assembly. Expansion spaces or joints  48  ( FIG. 3B ) may be left where narrowed regions  42  are received in recessed regions  44  to permit the expansion and contraction of spandrels  14  in various weather and temperature conditions. Expansion joint  48  is a slider joint that exposes a greater or lesser amount of shoulder region  42  when spandrel modules  14  contract and expand, such as in cold and hot weather, respectively. Preferably, when assembly  10  is installed in hot weather, a relatively small amount of shoulder region  42  is left exposed to permit contraction in cold temperatures, and when assembly  10  is installed in cold weather, a relatively large amount of shoulder region  42  is left exposed to permit expansion in warm temperatures. 
     Pendant  16  and corner bracket  18  may be used independently or in combination with spandrels  14 . Pendant rail  16   a  and corner bracket rail  18   a  are sized to be received within rails  14   a ′ of spandrels  14  (FIGS.  2  and  4 - 5 B). As best seen in  FIG. 4 , rails  16   a ,  18   a  have a width that is approximately equal to or less than the inner width of rails  14   a ′ of spandrel  14  so that rails  16   a ,  18   a  may be inserted within or slid into rails  14   a ′. Rails  14   a ′ form generally U-shaped channels for receiving rails  16   a ,  18   a . Rails  16   a ,  18   a  form generally U-shaped channels for receiving screw blocks  32 . Rails  16   a ,  18   a  are formed with finished ends  50  that close off the ends of rails  16   a ,  18   a  to hide the channels and present a finished look. In order to improve the fastenability of pendant  16  and corner bracket  18  to spandrels  14 , screw blocks  32  may be inserted into the U-shaped channels of rails  16   a ,  18   a  so that fasteners  38  (which may be threaded screws or the like) may be driven into screw blocks  32  from rails  16   a ,  18   a , and also from rails  14   a ′, without the pointed tips of fasteners  38  protruding from any of the rails ( FIGS. 2 ,  5 A, and  5 B). 
     A gable subassembly  52  may be assembled at a gable  54  ( FIG. 6A ) in a similar manner as trim subassembly  34  is installed at header  36  and post  40 . Gable subassembly  52  includes at least one gable module  20 , gable post module  24 , and gable end module  26 . Gable subassembly  52  may also include one or more gable extension modules  22  for extending gable subassembly  52  along gable  54 . Gable extension rail  22   a  and gable rail  20   a  are substantially similar and include elongated narrow regions  56  at one end and finished ends  58  opposite elongated narrow regions  56 . It will be appreciated that finished ends  58  may be substantially identical to finished ends  50  of pendant  16  and corner bracket  18 . Elongated narrow regions  56  of rails  20   a ,  22   a  are elongated narrowed portions of rails  20   a ,  22   a  and have closed ends. As best seen in  FIG. 6B , rail finish caps  30  have substantially the same size and shape as rails  16   a ,  18   a ,  20   a , and  22   a , and are complimentarily sized to receive elongated narrow regions  56  of rails  20   a ,  22   a  in a nesting manner, similar to the manner in which shoulder regions  42  are received in recessed regions  44  of spandrel rails  14 , described above. 
     As best seen in  FIG. 8B , elongated narrowed region  56  may be assembled at rail  22   a  or  20   a , by first cutting off or removing finished end  58  from the rail of the adjacent module and inserting narrowed region  56  into rail  22   a  or  20   a . The modules are attached to gable  54  via fasteners  38  inserted through fastener holes  46 . Gable post  24  is cut at a top end  60  to match the apex angle of gable  54  ( FIGS. 6A and 6B ), and may be cut at a lower end  62  to a desired overall length. One or more fasteners  38  may be driven through top end  60  of gable post  24  and into gable  54 . Preferably, at least two fasteners  38  are driven from one side of gable post  24  and at least one fastener  38  is driven from the other side to stabilize post  24  in proper alignment ( FIG. 6A ). 
     Rail finish cap  30  has substantially the same dimensions of gable extension rail  22   a  and gable rail  20   a , and may be cut and/or trimmed to fill any gap between top end  60  of gable post  24  and gable extension module  22  or gable module  20  ( FIG. 6B ). Rail finish cap  30  is configured to cover at least a portion of elongated narrow region  56  of rail  22   a  or  20   a . Decorative portion  20   b ,  22   b  of gable module  20  and gable extension module  22  may be fastened to gable post module  24  with fasteners  38  to stabilize and support gable subassembly  52 . Further, a portion of decorative portions  20   b ,  22   b  may be received in a channel  65  of gable post  24 , as will be described in greater detail below. 
     Gable end module  26  is attachable at lower end  62  of gable post module  24  in order to present a finished look for gable subassembly  52 . Gable post  24  is configured as an I-beam with an additional intermediate flange  63   a  between front and rear flanges  63   b ,  63   c  ( FIG. 7C ). Intermediate flange  63   a  may be narrower in width than front flange  63   b  and rear flange  63   c  to form channel  65  so that a portion of decorative portions  20   b ,  22   b  may be inserted into channel  65  such that decorative portions  20   b ,  22   b  abut intermediate flange  63   a  and frictionally engage inner facing surfaces of front flange  63   b  and rear flange  63   c . This arrangement permits gable module  20  and/or gable extension module  22  to be angularly adjusted relative to gable post  24 , as indicated by a double arrow in  FIG. 6B , to match any roof pitch angle at gable  54 . Thus, decorative portion  20   b ,  22   b  engages channel  65  with a portion of the decorative portion&#39;s curved periphery, which portion is somewhat or slightly different as the angle of modules  20 ,  22  changes for gables of different pitches. Decorative portion  20   b ,  22   b  is fastened with fastener  38 , which is driven through the curved portion that engages post  24 , and into post  24  for a clean, custom appearance regardless of the roof pitch at gable  54 . 
     As best seen in  FIGS. 7A and 7B , bottom end  62  of gable post  24  is received in gable end module  26  by a plurality of spaced flanges or tabs  64  that project inwardly from inner surfaces of a pair of front/back panels  66 , which are joined by a web  68 . A fastener  38  ( FIG. 6A ) may be driven through either of front/back panels  66  and into any of flanges  63   a ,  63   b ,  63   c  to hold gable post module  24  to bottom end  62  of gable post  24 . 
     Gable subassembly  52  may be further customized for house  12 , such as by trimming gable module rail  20   a  to form a notch  132  along its entire length ( FIG. 14 ). Notch  132  permits rail  20   a  to receive a fascia projection  134  that extends below a bottom surface of a soffit  136  forming a roof overhang at gable  54 . It will be appreciated that the various modules of assembly  10  may be trimmed or custom-fit at the work site, in the described manner or in a similar manner, to fit the needs of the particular application. 
     Decorative trim assembly  10  may be made of any moldable material that is preferably strong, readily cut with saws or other tools, possesses a low coefficient of thermal expansion, is colorfast, and is resistant to weather and embrittlement. Preferably, assembly  10  is made of a material that is somewhat compliant or resilient to facilitate assembly and to permit fastening the assembly without cracking or deforming. For example, assembly  10  may be made of polyvinyl chloride (PVC) with ultraviolet (UV) stabilizers, and may be tinted or colored as desired. 
     Referring now to  FIGS. 9-11B , bracket angle adapter  28  has a bracket-facing side with a flange  70  for receiving rail  18   a  of corner bracket module  18 . Adapter  28  includes a pair of side panels  72  connected via a plurality of webs  74 . As best seen in  FIGS. 9 and 10 , bracket angle adapter  28  may be angle-cut at its back side, opposite flange  70 , so that corner bracket module  18  may be placed against post  40  without a gap when post  40  has a face  76  set at an angle to corner bracket rail  18   a.    
     Referring now to FIGS.  12  and  13 A- 13 C, a customizable corner bracket module  118  includes a rail portion  118   a  and a decorative portion  118   b . Decorative portion  118   b  includes a passageway or aperture  120  bounded by an inner perimeter wall  122 . In the preferred embodiment of  FIG. 12 , aperture  120  is circular in shape, although other shapes, such as polygons, are possible. A decorative insert  124  has a perimeter projection  126  along or around an entire perimeter wall  128  of decorative insert  124 . Perimeter wall  128 , as shown in FIGS.  12  and  13 A- 13 C, is circular and of complimentary size to aperture  120 , although other complimentary shapes are possible and vary with the size and shape of the aperture in the decorative portion of the customizable module. 
     Inner perimeter wall  122  includes a series of alternating ledges or ramped surfaces  130   a ,  130   b , each ramped surface having a ridge or shoulder  132   a ,  132   b  for engaging a corner  134   a ,  134   b  of perimeter projection  126  of decorative insert  124 . Ramped surfaces  130   a  are formed along inner perimeter wall  122  and spaced circumferentially apart from one another with ramped surfaces  130   b  interspersed between ramped surfaces  130   a  so that at any given point along inner perimeter wall  122 , only one ramped surface ( 130   a  or  130   b ), is formed. Shoulders  132   a ,  132   b  are thus oppositely-facing. Optionally, and as shown in  FIG. 13B , no shoulder is formed in the circumferential area between ramped surfaces  130   a  and ramped surfaces  130   b.    
     Accordingly, decorative insert  124  may be snap-fit to decorative portion  118   b  at inner perimeter wall  122  from either side of customizable corner bracket module  118 . For example, and with reference to  FIGS. 13A-13C , decorative insert  124  may be inserted into aperture  120  in a direction indicated by downwardly-pointing arrows. When inserted in this direction, corner  134   a  of perimeter projection  126  moves or slides along ramped surfaces  130   b  ( FIG. 13C ) until corner  134   b  snaps past or over shoulder  132   b . In the regions of inner perimeter wall  122  having ramped surfaces  130   a , corner  134   a  moves or slides along inner perimeter wall  122  until corner  134   a  encounters shoulder  132   a  ( FIG. 13A ), which prevents further movement of decorative insert  124  in the direction of insertion indicated by the arrows. 
     Thus, when decorative insert  124  is fully inserted into aperture  120 , shoulders  132   a  of ramped surfaces  130   a  prevent further movement of insert  124  in the direction of insertion, and shoulders  132   b  of ramped surfaces  130   b  prevent the removal of insert  124  in a direction opposite to the direction of insertion. Decorative insert  124  is thus held centered in place by oppositely facing shoulders  132   a ,  132   b . It will be appreciated that decorative insert  124  may be inserted into aperture  120  from either side of customizable corner bracket module  118  until corners  134   a ,  134   b  engage shoulders  132   a ,  132   b , respectively. Because decorative insert  124  and corner bracket module  118  are made of somewhat resilient materials, the application of a force somewhat greater than the force required for insertion of decorative insert  124  into aperture  120  may be applied to urge corners  134   a  or  134   b  over and past shoulders  132   a  or  132   b  for removal or replacement of decorative insert  124 . 
     It will be appreciated that an even number of ramped surfaces  130   a ,  130   b  are desirable to evenly distribute insertion and removal forces of decorative insert  124  into aperture  120 . At least four ramped surfaces  130   a ,  130   b  are preferred for preventing decorative insert  124  from twisting or rotating out of aperture  120 . However, it is envisioned that a greater or fewer number of ramped surfaces may be used to hold the decorative insert in the aperture of the decorative portion of the corner bracket module without departing from the spirit and scope of the present invention. The decorative insert may include any number of letters, numerals, insignia, patterns, or decorations, and it will further be appreciated that such inserts may be applied to other types of trim modules, such as pendants, gables; spandrels, and the like. 
     Accordingly, decorative trim assembly  10  provides a low maintenance decorative system for a house or other building that can be custom-fit and assembled at the work site. On-site fitting and assembly of decorative trim assembly  10  thus may be performed with only minor cutting and trimming during the assembly process to fit the various modules together and to attach them to one another and to the building. 
     Decorative trim assembly  10  is easily customized at the job site with conventional tools, such as hand saws or miter saws, and does not require ongoing maintenance tasks such as scraping and repainting to preserve its appearance. Decorative trim assembly  10  resists rot, mildew, wood-eating organisms, and, further, resists expansion and contraction in the presence of moisture, heat, and humidity alternating with colder temperatures and dryness. Thus, the trim assembly  10  resists forming unsightly gaps between adjacent pieces of trim, loosening of the trim from the building, and cracking or splitting of the trimwork itself. 
     Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.

Technology Category: 7