PANEL TRIM AND RELATED METHOD OF MANUFACTURE
A panel trim including a cover and a base joined at opposite ends of a flange to form channels on opposite sides of the flange. The channels are adapted to receive panels, with the cover adapted to conceal the gap between the panels. The panel trim can include at least one ramp joined with the base. The panel trim can also include a flex region to enable independent flexing of opposite sides of the cover as panels are inserted into respective channels. The panel trim can be modified to accommodate linearly aligned panels, as well as panels that are at an angle to one another.
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The present invention relates to panel systems, and more particularly, to panel trim that conceals a gap between adjacent panels.
Panel systems are frequently used to aesthetically or functionally enhance existing structures, such as walls. Most panel systems include large panels that come in a variety of thicknesses, depending on the application. To install the panel systems, a user cuts or shapes the panels to a desired configuration or dimension. Sometimes, the panels come pre-cut so that the user need not further modify them. The user then joins the panels, usually one-by-one, with a wall via adhesives or fasteners until the wall is sufficiently covered with the panels to the user's satisfaction.
Typically, the panels are joined with the wall in a side-by-side configuration so that the edge of one panel is adjacent or abutting the edge of another panel. This configuration usually produces a visible gap or void between the panels. In some applications, this gap is acceptable. In most applications, however, it is not, as it provides a visual break in the wall, and can provide a location between the panels where dust and other debris can collect.
Manufacturers of panel systems have accordingly developed a variety of trim pieces adapted to cover the gap between panels. A simple trim piece is an “H” shaped construction, where one panel edge fits within one side of the H, and another panel edge fits within the other side of the H. While this construction conceals the gap, it is usually difficult to attach to a wall, and requires a variety of different dimensioned trim pieces to accommodate panels of varying thickness.
Another conventional trim piece is similar to the H trim piece above, but slightly modified. As shown in
First, the trim piece requires the construction of two separate components, that is, the base and the cover piece. This increases cost of manufacture as different molds or extrusion dies are required for each piece. It also increases labor during installation, as the user must spend time cutting the two pieces to the same length, and connecting the two pieces. Second, the construction of the cover piece can make it difficult to join with the base after the panels are joined in place with the trim. For example, as shown in
The present invention provides a panel trim including a cover and a base joined at opposite ends of a flange. These components form channels on opposite sides of the flange. The channels can be configured so that panels nest therein, with the cover covering a gap between the panels.
In one embodiment, the cover can be one piece, with all of the components, for example, the cover, the flange and the base formed as a monolithic structure. Optionally, this structure can be formed using extrusion techniques.
In another embodiment, the panel trim can include one or more flex regions that enable portions of the cover to flex and/or move relative to other portions of the cover so that the other portions do not obstruct the positioning of panels within the channels. Generally, the portion on one side of the flange can flex substantially independently of a cover portion on the opposite side of the flange with the flex region. Optionally, the flange can include a portion of a flex region to facilitate the desired amount of flex.
In another embodiment, the flex regions can be grooves, recesses, slots, apertures or material voids defined by the cover and/or flange that enable a portion of the cover, for example, that portion extending beyond the flange, to flex upwardly and away from the base without causing another portion of the flange, for example, the part on the opposite side of the flange, to bend toward the base on the opposite side of the flange.
In yet another embodiment, the flex regions can be produced by co-molding or co-extruding different materials at the flex regions so that these regions are more flexible than other regions of the cover and/or flange. The term “co” is used to refer to the combination of two or more different materials with different durometer values, and is not intended to limit the scope of the invention to just two different materials. For example, the term “co” may refer to the combination of three materials with different durometer values.
In a further embodiment, the base of the panel trim can include one or more ramps that increase in height as they approach the flange. Optionally, the ramps can include a ramp base (where the ramp begins), which is positioned at a location that is under or concealed by the cover.
In yet a further embodiment, each ramp can be reinforced with a support rib extending along a portion of the width of each ramp. The support rib can be utilized when it is desirable to have a hollowed, yet structurally reinforced, ramp so that panels engaging the ramp do not deform the ramp. Optionally, the support rib can extend from the underside of the ramp to a location that is substantially coplanar with another portion of the base that engages a surface against which the trim is positioned.
In another, further embodiment, a method of making the panel trim is provided, the method including: forming panel trim including a base and a cover connected by a flange; forming a panel accepting channel between the cover and the base; and forming flex regions in at least one of the cover and the flange. Optionally, the method includes forming a ramp in the base, the ramp being generally hollow, except for a structural support rib on its underside. Further optionally, the panel trim is formed by extruding or molding techniques.
The panel trim of the present invention provides a simple and efficient construction that is easy to install and accommodates different thickness panels. Where the trim includes a cover having one or more flex regions, this enables portions of the cover to flex independently of other portions, and enables a user to insert a first panel within the channel on one side without tilting the cover about the flange thereby diminishing the channel dimensions on the opposite side of the flange. Accordingly, a user can easily insert a second panel in the other channel. The flex regions also facilitate insertion of a single panel within the channel of the trim, as their flexure minimizes the amount of force needed to insert the panel within the channel. Further, after insertion of a panel in the channel, the flex regions can urge the cover into engagement with the panel, providing a cleaner seal between the trim and the panel. Where the panel trim includes a ramp, it can accommodate a variety of different thickness panels. Upon insertion of thinner panels in to the channel having a ramp, the ramp “lifts” the panel into engagement with the cover so that the interface between the cover and the panel is tight and clean. Where the panel trim includes a hollow ramp, the underside of the ramp can include a reinforcing rib. With the ramp being hollow and supported by a reinforcing rib, rather than being of a solid, filled configuration, the panel trim can be efficiently manufactured using extrusion techniques.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
A current embodiment of the panel trim of the present invention is shown in
The following terms will have the definitions presented. As used herein, “panel” refers to any material that forms a surface, including but not limited to composite, plastic (natural or fiber), or wood sheets, rolls, webs, boards, or other construction materials. These materials may be configured to enhance that existing structure aesthetically or functionally.
As used herein, “wall” refers to any surface to which trim or panel may be joined including, but not limited to, surfaces constructed from drywall, composites, plastics, wood, fiber, concrete, brick, or other material.
II. ComponentsReferring to
The trim can also include a base 40, which can include guides 42 and 44, ramps 46 and 48, and a central region of the base 50. The guides 42 and 44 can be configured so that when the trim is attached to a wall, they are generally parallel to the wall. Alternatively or additionally, the guides can be generally parallel to the panels, but adopted to flex or change configuration during the insertion of the panels (
The upper ramp surface can be at a predetermined angle α or β to the guide 42 or 44. The lower ramp surface can be substantially parallel with the upper surface. The ramp angles α and β can be selected to prevent binding of a panel as it engages a ramp 46, while still moving the panel upward, toward the cover 30 to provide a tight, aesthetically pleasing seal between the cover 30 and upper surface of the panel. The ramp angles α or β can vary from about 5 degrees to about 30 degrees, optionally about 10 degrees to about 20 degrees, and optionally about 14 degrees.
The ramps can further define recesses or voids. Where there is a recess 53, 55 defined adjacent the bottom ramp surface 47 and 51, the ramps can be structurally reinforced with structural support 72 and 74. These supports can be located on the lower surface 47 and 51 of the ramp to prevent or limit the deformation of the ramp 46 and 48 during insertion of the panels. The structural support can extend from the lower ramp surface to a location substantially coplanar with the guides 42 and 44 and/or the wall 150. Accordingly, the supports 72 and 74 can contact the wall on which the panels are mounted and provide further structural support for the ramps 46 and 48, thereby preventing the ramps from buckling when an inserted panel exerts force on it. The structural supports 72 and 74 can be located at the midpoint of the lower surface of the ramps 46 and 48, but may be placed at virtually any location along the lower surface of the ramps. Alternatively, the ramps 46 and 48 can be solid or hollow structures, with material extending from the upper ramp surface down to a plane generally coplanar with the guides 42 and 44, and then the wall 150, having no voids therebetween. In the case of such a solid or hollow ramp, there may be no need for the structural supports 72 and 74 because the ramp itself can be strong enough to prevent deformation during insertion of the panels.
The central region of the base 50 can generally include a lateral member 57 that can be substantially coplanar with the wall 150. The central region of the base 50 can also generally include vertical members 59 and 61 that connect the ramps 46 and 48 to the lateral member 57. The vertical members 59 and 61 can be substantially perpendicular to the lateral member 57.
The trim 25 can further include a flange 52 extending from the base 40. This flange 52 can be generally substantially perpendicular to the cover 30 and/or the base 40, as desired, or at other selected angles as the application requires. The flange 52 can include a first flange end 54 joined with the cover 30 and a second flange end 56 joined with the central region of the base 50. Alternatively, the second flange end 56 can be offset from the central region as desired. The flange can also include opposing first and second flange sides 58 and 60 that define the innermost portions of channels 66 and 68. The flange sides 58 and 60 can be adjacent to the flex region 70 as desired. Indeed, the sides 58 and 60 can terminate at or near, or transition to the flex regions 70 as desired.
As shown in
Turning to
In the embodiment shown in
As shown in
The trim 25 of the present invention can be made from a variety of materials using a variety of techniques. For example, the trim and its components can be constructed from plastics, composites, metals, fibers, natural materials or combinations thereof, depending on the application. When finished, the trim and its components can form a single, monolithic, unitary structure having a substantially uniform thickness throughout as desired. Construction can be achieved using an extrusion process, where material is passed through an extruder to form a linear, one-piece, monolithic panel trim including a base 40 having a ramp 46, a flange 52 joined with the base, and a cover 30 joined with the flange so that the cover and base cooperate to form opposing first and second channels 66 and 68 on opposite sides of the flange. In this extrusion process, the flex region can be formed as described in connection with the embodiments herein. With the trim extruded, it may be cut to desired lengths, trimmed and packaged for shipment. Where the trim 25 includes a generally hollow ramp with a support structure, this configuration can be conducive to such extrusion processes, as it produces a trim having components of a substantially uniform thickness. Optionally, the trim can be manufactured using other methods, such as injection molding, machining, and the like.
After being manufactured, the trim can be used by an end user. In general, a user can use the trim 25 to conceal the gap 213 between adjacent panels in the following manner. The user can place the base 40 adjacent a wall 150 and join the base with the wall 150, using fasteners such as glue, screws, or nails. As shown in
After the first panel 200 is inserted, the user can follow the same procedure for the second panel 210, in the opposite channel 68. Due to the cover portion 34 maintaining its original distance 64 and the channel retaining its original dimensions, the panel 210 is readily and easily inserted within the channel 68.
IV. Alternative EmbodimentsA first alternative embodiment is shown in
In a second alternative embodiment shown in
In a third alternative embodiment shown in
In a fourth alternative embodiment shown in
A variety of additional alternative embodiments are shown in
The above description is that of the current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.
Claims
1. A panel trim adapted for placement between adjacent first and second panels, the panel trim comprising:
- a base including a ramp;
- a flange joined with the base;
- a cover joined with the flange, the cover including a first cover portion and a second cover portion, the first cover portion and the base, and the second cover portion and the base, forming first and second channels on opposite sides of the flange, respectively, the cover including at least one flex region adjacent the flange so that the first cover portion flexes independently from the second cover portion without substantially altering the second channel,
- wherein the ramp extends upwardly toward the first cover portion, increasing in height as the ramp nears the flange.
2. The panel trim of claim 1 wherein the flex region is at least one of a groove, a recess, and a void defined by the cover adjacent the flange.
3. The panel trim of claim 1 wherein the cover is constructed from a first material having a first durometer, wherein the flex region is constructed from a second material having a second durometer that is less than the first durometer.
4. The panel trim of claim 1 wherein the ramp is raised at an angle between about 5 degrees and about 30 degrees relative to the base.
5. The panel trim of claim 1 wherein the ramp is located inward from the outer end of the cover portion so that the cover portion completely conceals the ramp from a viewer viewing along a line substantially parallel to the flange.
6. The panel trim of claim 1 wherein the ramp includes a panel engaging upper surface, a bottom surface opposite the upper surface, and a recess defined adjacent the bottom surface, wherein a structural support element is joined with the bottom surface of the ramp, the structural support extending downward from the bottom surface a distance so that the structural support element simultaneously engages a wall, to which the trim is joined, with the base.
7. A panel trim adapted for placement between first and second panels, the panel trim comprising:
- a base including a central region and opposing ends;
- a flange including a first flange end and a second flange end distal from the first flange end, the first flange end joined with the cover at the central region and extending substantially perpendicularly to the base, the flange including opposing first and second flange sides;
- a cover joined with the second flange end so that the cover, flange and base form opposing first and second channels, with the first channel adapted to receive the first panel and the second channel adapted to receive the second panel, the cover including a first cover portion extending from the flange on the first flange side, the first cover portion terminating at a free first flange end positioned a first distance from the base, the cover including a second cover portion extending from the flange on the second flange side, the second cover portion terminating at a free second flange end positioned a second distance from the base; and
- a flex region defined at least partially by the cover, the flex region being adjacent the flange and the first cover portion, the flex region enabling the first cover region to flex relative to the flange, and relative to and independently from the second cover portion,
- wherein the first panel is insertable by a user into the first channel without substantially moving the second cover portion so that the second distance remains substantially unchanged when the first panel is inserted into the first channel, whereby the second channel remains open and sized to receive the second panel,
- wherein the base includes at least one ramp positioned within the first channel, the ramp including a ramp base, the ramp base being located inward from the free first flange end, the ramp adapted to urge the first panel toward the first flange portion as a user inserts the first panel deeper into the first channel,
- wherein the base, cover and flange are integrally formed into a one piece panel trim,
- whereby the cover covers ends of the first and second panels when those ends are adjacent one another, thereby concealing a gap between the first and second panels.
8. The panel trim of claim 7 wherein the flex region includes at least one of a groove, a recess, and a void defined by the cover adjacent the flange.
9. The panel trim of claim 7 wherein the cover is constructed from a first material having a first durometer, wherein the flex region is constructed from a second material having a second durometer that is less than the first durometer.
10. The panel trim of claim 7 wherein the ramp is raised at an angle between about 5 degrees and about 30 degrees relative to the base.
11. The panel trim of claim 7 wherein the ramp includes a panel engaging upper surface, a bottom surface opposite the upper surface, and a recess defined adjacent the bottom surface, wherein a structural support element is joined with the bottom surface of the ramp, the structural support extending downward from the bottom surface a distance so that the structural support element simultaneously engages a wall, to which the trim is joined, with the base.
12. The panel trim of claim 7 wherein the central region of the base includes a member substantially parallel to the flange and a member substantially perpendicular to the flange.
13. The panel trim of claim 7 wherein the upper and lower surfaces of the cover are substantially parallel, wherein the upper and lower surfaces substantially define a portion of a curve.
14. A panel trim adapted for placement between adjacent first and second panels, the panel trim comprising:
- a base including a ramp;
- a flange joined with the base, the ramp increasing in height as it nears the flange;
- a cover joined with the flange so that the cover and base cooperate to form opposing first and second channels on opposite sides of the flange, the second channel having first dimensions, at least one of the cover and the flange including a defined flex region so that a portion of the cover adjacent the first channel flexes independently from the second cover portion, wherein the second channel retains the first dimensions as a first panel is inserted by a user into the first channel.
15. The panel trim of claim 14 wherein the flex region includes at least one of a groove, a recess, and a void defined by the cover adjacent the flange.
16. The panel trim of claim 14 wherein the cover is constructed from a first material having a first durometer, wherein the flex region is constructed from a second material having a second durometer that is less than the first durometer.
17. The panel trim of claim 14 wherein the ramp is raised at an angle between about 5 degrees and about 30 degrees relative to the base.
18. The panel trim of claim 14 wherein the ramp includes a ramp base, wherein the cover extends laterally outward past the ramp base.
19. The panel trim of claim 14 wherein the ramp includes a panel engaging upper surface, a bottom surface opposite the upper surface, and a recess defined adjacent the bottom surface, wherein a structural support element is joined with the bottom surface of the ramp, the structural support extending downward from the bottom surface a distance so that the structural support element simultaneously engages a wall, to which the trim is joined, with the base.
20. A method for making panel trim, comprising:
- extruding a material through an extruder to form a linear, one-piece, monolithic panel trim including a base having a ramp, a flange joined with the base, and a cover joined with the flange so that the cover and base cooperate to form opposing first and second channels on opposite sides of the flange, the second channel having first dimensions, and
- forming a flex region in at least one of the cover and the flange adjacent the first channel, wherein the base, the base ramp, flange and cover are of a substantially uniform thickness.
21. A panel trim adapted for installation over an edge of a panel, the panel trim comprising:
- a base including a ramp to accommodate panels of different thicknesses;
- a flange joined with the base;
- a cover joined with the flange, the cover including a cover portion spaced apart from the base to define a channel, the cover including at least one flex region adjacent the flange so that the first cover portion flexes with respect to the flange; and
- wherein the ramp extends upwardly toward the cover portion, increasing in height as the ramp nears the flange.
Type: Application
Filed: Oct 8, 2008
Publication Date: Apr 8, 2010
Applicant: ISO-TRUDE, INC. (Grand Haven, MI)
Inventor: Michael J. Meulemans (North Muskegon, MI)
Application Number: 12/247,604
International Classification: E04F 13/07 (20060101); E04B 2/88 (20060101);