Title:
EXTERIOR TRIM PIECES WITH WEATHER STRIPPING AND COLORED PROTECTIVE LAYER
Kind Code:
A1


Abstract:
Exterior trim pieces for use on exteriors of buildings. The exterior trim pieces include outside corner trim pieces, inside corner trim pieces, and framing trim pieces for providing an aesthetically pleasing appearance to an exterior of a building. Each of the trim pieces include a body and at least one flange extending from the body to define a concealing space for hiding siding ends and the like. Each of the trim pieces also includes at least one weather strip to assist in sealing the trim pieces to the exterior to prevent the intrusion of water and other elements behind the trim pieces. Each body of the trim pieces is preferably formed from co-extruded rigid cellular PVC and an acrylic-based protective layer. The rigid cellular PVC and the protective layer are formed in matching colors to yield colored-through trim pieces.



Inventors:
Taylor, Christopher M. (Hilliard, OH, US)
Hoffmann, Stephen O. (Lebanon, OH, US)
Application Number:
12/188833
Publication Date:
02/12/2009
Filing Date:
08/08/2008
Assignee:
TAPCO INTERNATIONAL CORPORATION (Wixom, MI, US)
Primary Class:
International Classes:
E04B2/00
View Patent Images:
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Primary Examiner:
CHAPMAN, JEANETTE E
Attorney, Agent or Firm:
QUINN IP Law (Northville, MI, US)
Claims:
What is claimed is:

1. A trim piece for use on an exterior of a building, comprising: a body defining a face for abutting against the exterior of the building, said body including a flange with a concealing space defined beneath said flange; and a flexible weather strip disposed on said body in spaced relation to said flange and extending outwardly from said body, said weather strip configured for sealing to the exterior of the building.

2. A trim piece as set forth in claim 1 wherein said face of said body is flat.

3. A trim piece as set forth in claim 2 wherein said weather strip includes a second face for abutting the exterior of the building, said second face extending from said face of said body at an obtuse angle for enhancing sealing of said weather strip to the exterior of the building.

4. A trim piece as set forth in claim 1 wherein said weather strip includes a base disposed on said body and extends outwardly from said base to an end, said weather strip tapering from said base to said end.

5. A trim piece as set forth in claim 1 wherein said weather strip is formed of flexible PVC.

6. A trim piece as set forth in claim 1 wherein said weather strip is less rigid than said body.

7. A trim piece as set forth in claim 1 wherein said body is formed of rigid cellular PVC having a shore D hardness of from 50 to 90 and said weather strip is formed of flexible PVC having a shore A hardness of from 50 to 90.

8. A trim piece as set forth in claim 1 wherein said body includes a first side portion and a second side portion disposed perpendicularly to said first side portion.

9. A trim piece as set forth in claim 1 wherein said body includes a pair of abutment portions configured for abutting the exterior of the building such that an air pocket is defined between said body and the exterior of the building when said body is mounted to the exterior.

10. A trim piece for use on an exterior of a building, comprising: a body formed of a color and defining at least one face for abutting against the exterior of the building, said body including a flange with a concealing space defined beneath said flange; and a protective layer disposed on said body for providing weather resistance to said trim piece, wherein said protective layer is formed in said color to match said body such that wear of said protective layer is less visibly noticeable.

11. A trim piece as set forth in claim 10 wherein said protective layer is formed of acrylonitrile styrene acrylate.

12. A trim piece as set forth in claim 10 wherein said protective layer has a thickness of 0.1 inches or less.

13. A trim piece as set forth in claim 12 wherein said protective layer has a thickness of from 0.02 to 0.1 inches.

Description:

RELATED APPLICATION

This patent application is a non-provisional and claims the benefit of U.S. Provisional Patent Application No. 60/954,832, filed on Aug. 9, 2007, the advantages and disclosure of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to exterior trim pieces used in decorating exteriors of buildings. More specifically, the present invention relates to exterior trim pieces formed from rigid cellular polyvinyl chloride (PVC) that are configured for concealing siding and providing an aesthetically pleasing finished appearance to an exterior of a building. The present invention also relates to exterior trim pieces having protective layers. Examples of such exterior trim pieces include trim pieces used on or around doors, garages, windows, inside wall corners, outside wall corners, and the like.

BACKGROUND OF THE INVENTION

Exterior trim pieces are well known in the art for finishing exteriors of buildings to provide an aesthetically pleasing finished appearance. Traditionally, wood has been used to form these trim pieces. One particular example of this is seen in older clapboard houses in which wood trim provides a finished appearance to wood clapboards. Unfortunately, wood is subject to degradation from insects, wind, rain, sun, and other environmental elements. PVC or vinyl siding was eventually developed as a substitute for wood. Vinyl siding was found to be durable and weather resistant. To compliment the use of vinyl siding, exterior trim pieces were also developed that were similarly durable and weather resistant. Often such pieces are used to finish around doors or windows or to finish inside and outside wall corners of a building that has been covered in vinyl siding. Examples of such trim pieces are shown in U.S. Pat. No. 5,090,174 to Fragale and U.S. Pat. No. 5,542,222 to Wilson et al.

Conventional exterior trim pieces are typically formed of two components including an outside metal or PVC layer and an inner substrate that insulates the trim pieces and/or provides support to the trim pieces. However, joining the inner substrate to the outside layer can be difficult and time consuming. For this reason, building product manufacturers have begun to offer integrated exterior trim pieces that combine the advantages of an aesthetically pleasing outer layer with an insulative or supportive inner substrate. These exterior trim pieces are formed of rigid cellular PVC. This material can be manufactured in a manner to resemble actual wood trim, while providing the highly weatherable characteristics of PVC.

One example of exterior trim pieces formed from rigid cellular PVC is shown in U.S. Patent Application Publication No. 2007/0151180 to Pace et al. The trim pieces include spaces configured for receiving and concealing siding. The trim pieces are preferably nailed to the exterior similar to nailing wood trim to an exterior. Before nailing, a sealant is applied to an inner surface of the trim piece to help seal the trim piece to the exterior. The trim pieces can be painted to provide multiple colors as desired.

Even with these advancements in exterior trim pieces, there still remains a need in the art for features that better assist in sealing the trim pieces to the exterior of the building to prevent the intrusion of water or other elements behind the trim pieces. Furthermore, there is a need in the art for exterior trim pieces that include features for weather resistance and that are formed in a variety of colors to suit a variety of applications.

SUMMARY OF THE INVENTION AND ADVANTAGES

The present invention provides exterior trim pieces for mounting to an exterior of a building to create an aesthetically pleasing appearance to the exterior. The trim piece includes a body defining a face for abutting against the exterior of the building. The body includes a flange with a concealing space defined beneath the flange. A flexible weather strip is disposed on the body in spaced relation to the flange. The weather strip extends outwardly from the body. The weather strip is configured for sealing to the exterior of the building to prevent the intrusion of water or other elements behind the trim piece.

The present invention also provides a trim piece having a protective layer for use on an exterior of a building to create an aesthetically pleasing appearance to the exterior. This trim piece includes a body formed of a color. The body defines at least one face for abutting against the exterior of the building. The body includes a flange with a concealing space defined beneath the flange. The protective layer is disposed on the body for providing weather resistance to the trim piece. The protective layer is formed in the same color as the body to match the body such that wear of the protective layer is less visibly noticeable.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a front perspective view of a building having a plurality of siding panels covering an exterior of the building with an outside corner trim piece of the present invention covering an outside corner of the building and window trim pieces of the present invention framing a window of the building;

FIG. 1A is a partial perspective view of a building having a plurality of siding panels covering the exterior of the building with an inside corner trim piece of the present invention covering an inside corner of the building;

FIG. 2 is a cross-sectional view of an outside corner trim piece installed on the exterior of the building;

FIG. 2A is a blown-up view of the weather strip illustrating an angled orientation of the weather strip prior to installation;

FIG. 3 is a cross-sectional view of another outside corner trim piece installed on the exterior of the building;

FIG. 4 is a cross-sectional view of an inside corner trim piece installed on the exterior of the building;

FIG. 5 is a cross-sectional view of a trim piece installed on the exterior of the building around the window of the building;

FIG. 6 is a cross-sectional view of another trim piece installed on the exterior of the building around the window of the building;

FIG. 7 is a blown-up view of any of the trim pieces shown with an added protective layer and sealant used to seal the trim piece to the exterior; and

FIG. 8 is a schematic view of the process used to form the trim pieces of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, trim pieces for use on the exterior 10 of a building 12 are generally shown at 20, 40, 60, 80, and 100. The trim pieces 20, 40, 60, 80, 100 provide an aesthetically pleasing appearance to the exterior 10 of the building 12. The trim pieces 20, 40, 60, 80, 100 are configured to hide ends of siding panels 14 arranged on the exterior 10 of the building 12. The trim pieces 20, 40, 60, 80, 100 include an outside corner trim piece 20, an alternative outside corner trim piece 40, an inside corner trim piece 60, a framing trim piece 80, and an alternative framing trim piece 100.

Referring to FIG. 2, the outside corner trim piece 20 is shown mounted to the exterior 10 of the building 12. The outside corner trim piece 20 comprises an elongated body 22 preferably formed of rigid cellular PVC. In one embodiment, the rigid cellular PVC is created by Celuka, a foaming extrusion process that creates tiny air bubbles within the body 22, resulting in a density less than half that of regular PVC. Cellular PVC may have a tensile strength of 2,000 to 5,000 psi and resist deflection up to 150° F.

The body 22 is formed in one-piece such that there are no joint lines in the body 22. The body 22 comprises a first elongated side portion 24 and a second elongated side portion 26 arranged generally perpendicular to one another. Of course, other versions of the outside corner trim piece 20 could have the side portions 24, 26 arranged at other angles to one another to accommodate outside corners of exterior walls that meet at various angles to one another.

A first flange 28 extends from the first side portion 24 such that outer surfaces of the first flange 28 and the first side portion 24 are continuous. A second flange 30 extends from the second side portion 26 such that outer surfaces of the second flange 30 and the second side portion 26 are continuous. Concealing spaces S are defined beneath each of the flanges 28, 30 for receiving and concealing the siding panels 14. The spaces S preferably have a depth D of from 0.5 inches to 2.0 inches, more preferably from 0.9 inches to 1.1 inches, and most preferably about 1.0 inches. The spaces S also have a width W of from 0.6 inches to 2.0 inches, more preferably from 0.7 inches to 1.1 inches, and most preferably about 0.9 inches. The spaces S are sized to accommodate various sizes of conventional siding panels 14.

A first abutment 32 extends generally perpendicularly from the first side portion 24 to abut the exterior 10 of the building 12. A second abutment 34 extends generally perpendicularly from the second side portion 26 to abut the exterior 10 of the building 12. Each of the abutments 32, 34 extend the length of the trim piece. Each of the abutments 32, 34 have a flat face 33, 35 configured to squarely rest on the exterior 10. This configuration provides an air pocket between the body 22 and the exterior 10. In alternative embodiments (not shown), the abutments 32, 34 are removed such that the side portions 24, 26 rest directly on the exterior 10 of the building 12. The outside corner trim piece 20 is secured to the exterior 10 by securing fasteners F (e.g., nails or screws) through the side portions 24, 26 and abutments 32, 34 into the exterior 10. The outside corner trim piece 20 could also be secured with an adhesive applied to the flat faces 33, 35 of the abutments 32, 34. Additional abutments (shown by hidden lines in FIG. 2) may be added in all embodiments.

Elongated weather strips WS are secured to the abutments 32, 34 to form an extension of the flat faces 33, 35 of the abutments. The weather strips WS are preferably formed of flexible PVC (fPVC). In one embodiment, the fPVC may be formed with plasticizers to provide it with more flexibility relative to conventional PVC or rigid cellular PVC. In one embodiment, the fPVC has a Shore A hardness of from 50 to 90, while the rigid cellular PVC has a Shore D hardness of from 50 to 90. The weather strips WS can be secured to the abutments 32, 34 by an adhesive, ultrasonic welding, or by extruding the fPVC onto the abutments 32, 34.

Referring to FIG. 2A, each of the weather strips WS has a base 37 fixed to the abutment 32, 34 and preferably tapers from the base 37 to a tapered end 38. More specifically, each weather strip WS tapers from the base 37 initially along a radius R to the tapered end 38. Each weather strip WS has a strip width SW (see FIG. 2) of from 0.1 to 1.0 inches, more preferably from 0.3 to 0.7 inches, most preferably from 0.4 to 0.5 inches. In any event, the strip width SW is preferably less than the width W of the spaces S to prevent interference with the siding 14. Each weather strip WS has an average thickness along its taper of preferably less than 0.1 inches, more preferably less than 0.075 inches, most preferably from 0.040 to 0.055 inches. The weather strips WS act as seals against the exterior 10 of the building 12. Given the configuration of the weather strips WS, sealant is not required.

The weather strip WS is preferably fixed to the abutment 32 at an obtuse angle A with the flat face 33 of the abutment 32. Thus, the angle between the flat face 33 of the abutment 32 and the face (not numbered) of the weather strip WS designed for facing the exterior 10 of the building 12 is less than 180 degrees. The purpose of this angle A is to provide a better seal against the exterior 10. During installation, the weather strip WS flexes from this angled configuration to a flat or 180 degree configuration against the exterior 10 such that the face of the weather strip WS and the face 33 of the abutment 32 form a continuous surface in the same plane. By flexing the weather strip WS from the angled configuration, a small biasing force remains to assist in keeping the weather strip WS against the exterior 10 thereby further preventing the intrusion of water and other elements behind the outside corner trim piece 20.

Optionally, a sealant 39 (see FIG. 7) can be applied to an underside of the weather strips WS prior to mounting the outside corner trim piece 20 to the exterior 10 and/or a sealant 39 can be applied along the seam created between the weather strips WS and the exterior 10. The weather strips WS, when mounted vertically along the exterior 10, channel water down along the weather strips WS in the space S, to the ground. By channeling the water away from the exterior 10, moisture damage can be reduced.

The outside corner trim piece 20 may be manufactured in various sizes depending on the particular application. Convenient widths (measured along one side portion/flange) are from 2 inches to 8 inches, more preferably from 4 to 6 inches. The outside corner trim piece 20 may be cut from stock provided in various lengths, e.g., 10 ft, 12 ft, 14 ft, 16 ft, 18 ft, and so on. Biscuit holes (not shown) may be provided in ends of the trim piece 20 to receive biscuits (not shown) used to connect adjacent pieces together.

Referring to FIG. 3, the alternative outside corner trim piece 40 is shown mounted to the exterior 10 of the building 12. The alternative outside corner trim piece 40 comprises an elongated body 42 preferably formed of rigid cellular PVC. The body 42 is formed in one-piece such that there are no joint lines in the body 42. The body 42 comprises a first elongated side portion 44 and a second elongated side portion 46 arranged generally perpendicular to one another. Of course, other versions of the alternative outside corner trim piece 40 could have the side portions 44, 46 arranged at other angles to one another to accommodate outside corners of exterior walls that meet at various angles to one another.

A first flange 48 extends from the first side portion 44 such that outer surfaces of the first flange 48 and the first side portion 44 are continuous. A second flange 50 extends from the second side portion 46 such that outer surfaces of the second flange 50 and the second side portion 46 are continuous. The concealing spaces S, similar to those described above, are defined beneath each of the flanges 48, 50 for receiving and concealing the siding panels 14.

A first abutment 52 extends generally perpendicularly from the first side portion 44 to abut the exterior 10 of the building 12. A second abutment 54 extends generally perpendicularly from the second side portion 46 to abut the exterior 10 of the building 12. Each of the abutments 52, 54 have a flat face 53, 55 configured to squarely rest on the exterior 10. In alternative embodiments (not shown), the abutments 52, 54 are removed such that the side portions 44, 46 rest directly on the exterior 10 of the building 12. The alternative outside corner trim piece 40 is secured to the exterior 10 by securing fasteners F (e.g., nails) through the side portions 44, 46 and abutments 52, 54 into the exterior 10. The alternative outside corner trim piece 40 could also be secured with an adhesive applied to the flat faces 53, 55 of the abutments 52, 54.

Elongated weather strips WS, similar to those described above, are secured to the abutments 52, 54 to form an extension of the flat faces 53, 55 of the abutments.

The alternative outside corner trim piece 40 may be manufactured in various sizes depending on the particular application. Convenient widths are from 2 inches to 6 inches, more preferably from 3 to 4 inches. The alternative outside corner trim piece 40 may be cut from stock provided in various lengths, e.g., 10 ft, 12 ft, 14 ft, 16 ft, 18 ft, and so on.

Referring to FIG. 4, the inside corner trim piece 60 is shown mounted to the exterior 10 of the building 12. The inside corner trim piece 60 comprises an elongated body 62 preferably formed of rigid cellular PVC. The body 62 is formed in one-piece such that there are no joint lines in the body 62. The body 62 comprises a first elongated side portion 64 and a second elongated side portion 66 arranged generally perpendicular to one another. Of course, other versions of the inside corner trim piece 60 could have the side portions 64, 66 arranged at other angles to one another to accommodate inside corners of exterior walls that meet at various angles to one another. A pair of elongated beveled faces 67, 67 forms an inside of the body 62 that faces the inside corner of the exterior 10.

A first flange 68 extends from the first side portion 64 such that outer surfaces of the first flange 68 and the first side portion 64 are continuous. A second flange 70 extends from the second side portion 66 such that outer surfaces of the second flange 70 and the second side portion 66 are continuous. Concealing spaces S, similar to those described above are defined beneath each of the flanges 68, 70 for receiving and concealing the siding panels 14.

A first abutment 72 extends generally perpendicularly from the first side portion 64 to abut the exterior 10 of the building 12. A second abutment 74 extends generally perpendicularly from the second side portion 66 to abut the exterior 10 of the building 12. Each of the abutments 72, 74 has a flat face 73, 75 configured to squarely rest on the exterior 10. The inside corner trim piece 60 is secured to the exterior 10 by securing fasteners F (e.g., nails) through the side portions 64, 66 and abutments 72, 74 into the exterior 10. The inside corner trim piece 60 could also be secured with an adhesive applied to the flat faces 73, 75 of the abutments 72, 74.

Elongated weather strips WS, similar to those described above, are secured to the side portions 64, 66 to form an extension of the flat faces 73, 75 of the abutments 72, 74.

The inside corner trim piece 60 may be manufactured in various sizes depending on the particular application. Convenient widths are from 2 inches to 8 inches, more preferably from 3 to 4 inches. The inside corner trim piece 60 may be cut from stock provided in various lengths, e.g., 10 ft, 12 ft, 14 ft, 16 ft, 18 ft, and so on.

Referring to FIG. 5, the framing trim piece 80 is shown mounted to the exterior 10 of the building 12. The framing trim piece 80 comprises an elongated body 82 preferably formed of rigid cellular PVC. The body 82 is formed in one-piece such that there are no joint lines in the body 82. The body 82 includes a generally rectangular portion 84.

A flange 88 extends from the rectangular portion 84 such that outer surfaces of the flange 88 and the rectangular portion 84 are continuous. A concealing space S, similar to those described above, is defined beneath the flange 88 for receiving and concealing the siding panels 14.

A first abutment 92 extends generally perpendicularly from the rectangular portion 84 to abut the exterior 10 of the building 12. A second abutment 94, spaced from the first abutment 92, extends generally perpendicularly from the rectangular portion 84 to abut the exterior 10 of the building 12. Each of the abutments 92, 94 have a flat face 93, 95 configured to squarely rest on the exterior 10. In alternative embodiments (not shown), the abutments 92, 94 are removed such that the rectangular portion 84 rests directly on the exterior 10 of the building 12. The framing trim piece 80 is secured to the exterior 10 by securing fasteners F (e.g., nails) through the rectangular portion 84 and abutments 92, 94 into the exterior 10. The framing trim piece 80 could also be secured with an adhesive applied to the flat faces 93, 95 of the abutments 92, 94.

An elongated weather strip WS, similar to those described above, is secured to the first abutment 92 to form an extension of the flat face 93 of the first abutment 92. As previously discussed, the weather strip WS, when mounted vertically along the exterior 10, channels water down along the weather strip WS in the space S, to the ground. Framing trim pieces 80 can also be mounted horizontally. For instance, several framing trim pieces 80 can be used to frame a window, door, or garage, with some positioned vertically and some positioned horizontally to create a frame around the window, door, or garage. In this case, the corners of the frames are mitered such that the weather strip WS of a horizontally positioned framing trim piece 80 meets the weather strip WS of a vertically positioned framing trim piece 80. As a result, water, which might otherwise collect on the weather strip WS of the horizontally positioned framing trim piece 80, is allowed to channel down the weather strip WS of the vertically positioned framing trim piece(s) 80.

The framing trim piece 80 could be used in a variety of applications to provide an aesthetically pleasing trim piece to any part of the exterior 10. The use of the framing trim piece 80 is not intended to limit the present invention. The framing trim piece 80 may be manufactured in various sizes depending on the particular application. Convenient widths are from 2 inches to 8 inches, more preferably from 5 to 6 inches. The framing trim piece 80 may be cut from stock provided in various lengths, e.g., 10 ft, 12 ft, 14 ft, 16 ft, 18 ft, and so on.

Referring to FIG. 6, the alternative framing trim piece 100 is shown mounted to the exterior 10 of the building 12. The alternative framing trim piece 100 comprises an elongated body 102 preferably formed of rigid cellular PVC. The body 102 is formed in one-piece such that there are no joint lines in the body 102. The body 102 includes a generally rectangular portion 104.

An elongated flange 108 extends from the rectangular portion 104 such that outer surfaces of the flange 108 and the rectangular portion 104 are continuous. A concealing space S, similar to those described above, is defined beneath the flange 108 for receiving and concealing the siding panels 14.

A first abutment 112 extends generally perpendicularly from the rectangular portion 104 to abut the exterior 10 of the building 12. A second abutment 114, spaced from the first abutment 112, extends generally perpendicularly from the rectangular portion 104 to abut the exterior 10 of the building 12. Each of the abutments 112, 114 have a flat face 113, 115 configured to squarely rest on the exterior 10. In alternative embodiments (not shown), the abutments 112, 114 are removed such that the rectangular portion 104 rests directly on the exterior 10 of the building 12. The alternative framing trim piece 100 is secured to the exterior 10 by securing fasteners F (e.g., nails, screws) through the rectangular portion 104 and abutments 112, 114 into the exterior 10. The alternative framing trim piece 100 could also be secured with an adhesive applied to the flat faces 113, 115 of the abutments 112, 114.

An elongated weather strip WS, similar to those described above, is secured to the first abutment 112 to form an extension of the flat face 113 of the first abutment 112.

The alternative framing trim piece 100 may be manufactured in various sizes depending on the particular application. Convenient widths are from 2 inches to 8 inches, more preferably from 5 to 6 inches. The alternative framing trim piece 100 may be cut from stock provided in various lengths, e.g., 10 ft, 12 ft, 14 ft, 16 ft, 18 ft, and so on.

Referring to FIG. 7, each body 22, 42, 62, 82, 102 of the trim pieces 20, 40, 60, 80, 100 preferably includes a protective layer P covering the rigid cellular PVC. FIG. 7 illustrates only the body 22 of the outside corner trim piece 20 for illustrative purposes. However, it is to be understood that the protective layer P shown in FIG. 7 applies equally to all of the trim pieces 20, 40, 60, 80, 100. The protective layer P is preferably an acrylic-based protective layer that is co-extruded onto the rigid cellular PVC of the body 22, 42, 62, 82, 102. This is also referred to as a capstock. The protective layers P of the trim pieces 20, 40, 60, 80, 100 can be formed in multiple colors (using suitable dyes, etc.) such that the trim pieces 20, 40, 60, 80, 100 are available in a variety of colors for a variety of applications. The protective layer P is most preferably formed of ASA (acrylonitrile styrene acrylate). ASA is a highly weatherable compound designed to have long lasting color retention.

The protective layer P has a preferred thickness of less than 0.1 inches, more preferably in the range of from 0.005 inches to 0.1 inches, most preferably from 0.008 inches to 0.012 inches. The protective layer P thickness is preferably uniform across the profile of the trim pieces 20, 40, 60, 80, 100. In one embodiment, the rigid cellular PVC forms a white core surrounded by the colored protective layer P. This prevents heat build-up in the trim pieces 20, 40, 60, 80, 100. In yet other embodiments, the rigid cellular PVC may be formed in colors (using suitable dyes, etc.) that match the colors of the protective layer P to provide a colored-through trim piece. This has the advantage that when the trim pieces 20, 40, 60, 80, 100 are cut to desired lengths during installation, a non-matching core is not exposed. Otherwise, the non-matching core requires painting to match the color of the protective layer P.

Referring to FIG. 8, a process line for manufacturing the trim pieces 20, 40, 60, 80, 100 is generally shown at 200. The process line 200 comprises conventional extrusion/die equipment 202 for co-extruding the protective layer P onto the rigid cellular PVC into the shape of the body 22, 42, 62, 82, 102 desired. A variety of dies (not shown) are used to provide the desired shapes shown in FIGS. 2-6. The process line 200 is preferably a continuous process, but could be arranged as a batch process as well.

After co-extruding the protective layer P onto the rigid cellular PVC into the desired shape, the co-extruded mass 204 enters a cooling tank 206 of water and then passes through a dryer 208. From the dryer 208, the mass 204 passes through one or more rollers 210 that can be embossed with wood grain or any other desired pattern to impart an aesthetic appearance to the surfaces of the trim pieces 20, 40, 60, 80, 100 that are viewable when installed.

Once imprinted with the desired pattern, the mass 204, which is now relatively cool, passes through another extruder/die 212 through which the weather strip(s) S are secured to the mass 204. This is preferably accomplished by extruding the weather strip(s) S onto the mass 204 of rigid cellular PVC/ASA by heating pellets (stored in hopper 214) of the fPVC to a temperature of from about 280° to 340° Fahrenheit. The heat causes the fPVC to soften and adhere to the mass 204. Once adhered, the mass 204a (now including the weather strip(s) WS) is further cooled by a submerged water tank 216. A cutter 218 then cuts the mass 204a into desired lengths, which are stacked for shipping. Prior to shipping the trim pieces 20, 40, 60, 80, 100, a protective adhesive film may cover the surfaces intended for outside viewing and exposure so as to protect those surfaces from scratches, dust, etc., prior to installation.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. For instance, in the illustrated embodiments, the flanges and abutments of each trim piece extend the entire length of each trim piece and are integrally formed as a unitary body. In other embodiments, the abutments and/or flanges could be separate components. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.





 
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