Apparatus and method for forimng fascia molding

Abstract

An apparatus (10) includes internal mechanisms (18, 20, 24) for advancing, guiding and roll forming fascia molding (30, 30a) from sheet material (14) fed from coil stock (16) or in precut sheets (72). The fascia molding (30, 30a) includes a roll formed curved profile (32) in between angled top and bottom portions.

Description

TECHNICAL FIELD

The present invention relates generally to roll forming, and more particularly to a new and unique method and apparatus for forming fascia molding in continuous lengths.

BACKGROUND OF THE INVENTION

Various types of trim pieces are used in the construction industry to complete the exteriors of buildings. For example, fascia is typically used underneath the eaves and at the gable ends of houses. Fascia generally serves two purposes. Primarily, it serves to cover and close the intersection between the upper end of the wall and the outside end of the adjacent roof edge. However, such fascia also serves to provide a neat and finished appearance to the building, which is also important.

In the past, such fascia has typically been made from pieces of solid material, such as wood, shaped to the desired cross-sectional profile, cut to length and then separately fastened to the building. These of course are exposed to the weather and elements, requiring maintenance, the frequency of which depends upon the location of the building. Such maintenance is time consuming, difficult and expensive.

Various building products such as siding and roofing, have been available heretofore for reducing building maintenance. However, there has not been available a fascia molding formed from substantially maintenance-free materials which can be manufactured in continuous lengths.

Similarly, various machines have been available heretofore for manufacturing gutters, siding, soffit panels and the like. However, there has not been available an apparatus for roll forming fascia molding in continuous lengths from substantially maintenance-free material.

A need has thus arisen for an apparatus and method for forming fascia molding in continuous lengths from substantially maintenance-free material in order to reduce the costs associated with the fascia of the prior art.

SUMMARY OF THE INVENTION

The present invention comprises an apparatus and method for-forming fascia molding which overcomes the foregoing and other difficulties associated with the prior art. In accordance with the invention, the leading end of a strip of suitable material from a roll or coil is fed into one end of an enclosure or housing, which includes a drive mechanism for advancing it along a predetermined feed path. A predetermined arrangement of various guides and rollers define the feed path. As the material advances along the feed path, it is progressively formed by the guides and rollers into a unique fascia molding in continuous lengths, which can be cut to the desired length by a shear or cutting mechanism as it exits the other end of the enclosure. The fascia molding can then be applied to a building, thus avoiding the difficulties and unnecessary costs associated with the prior art.

BRIEF DESCRIPTION OF DRAWING

A better understanding of the invention can be had by reference to the following Detailed Description in conjunction with the accompanying Drawing, wherein:

FIG. 1 is a perspective view of an apparatus for forming fascia molding in continuous lengths in accordance with the present invention;

FIGS. 2-9 are schematic profiles illustrating the various steps in forming the fascia molding herein;

FIG. 10 is a schematic profile of a modification to the fascia molding herein; and

FIGS. 11 and 12 are schematic illustrations showing two typical installations of the fascia molding herein.

FIG. 13 is a perspective view of a modified apparatus for forming fascia molding in preselected lengths in accordance with the present invention;

FIG. 14 is a plan view of a section of material with holes preformed along its opposite edges before forming; and

FIG. 15 is a plan view of a section of material precut across its opposite ends in order to facilitate forming a mitre joint.

DETAILED DESCRIPTION

Referring now to the Drawing, wherein like reference numerals designate like or corresponding elements throughout the views, and particularly referring to FIG. 1, there is shown an apparatus for forming fascia molding 10. The apparatus 10 includes an elongate housing or enclosure 12 having opposite front and back ends. Apparatus 10 can be supported on legs 13 as shown, in a fixed position, or carried on a mobile platform (not shown) such as a trailer or within a truck for transportation to/from a work site.

Strip material 14 from a roll or coil of stock 16 is fed into the front end of the enclosure 12. The flat strip material 14 can comprise sheet metal, such as aluminum, which may be coated on one side 14a and uncoated on the other side 14b. Material 14 comprises bendable or malleable sheet material like that used in forming gutters and the like. In the preferred embodiment, the material 14 comprises aluminum about 12 to 15 inches wide and about 0.027 or 0.029 inch thick, coated with paint or vinyl on side 14a and uncoated in mill finish on the opposite side 14b. Any suitable material or coatings can be used.

The coil of stock 16 can be supported on a stand (not shown) in front of the enclosure 12, or mounted on top of the enclosure. In the preferred embodiment, the stock coil 16 is supported so that the material 14 is fed into the enclosure 12 with the coated side 14a facing up, as shown.

Within the enclosure 12 of the apparatus 10 are a motor and drive mechanism 18 and a guide and roller arrangement 20 defining a feed path for advancing the material 14 through the machine. A shear or blade mechanism 22 is located at the front end of enclosure 12 for cutting the fascia molding 30 to length as it comes out. The shear mechanism 22 is manually actuated by handle 24.

The drive mechanism 18, guide and roller arrangement 20 and cutter mechanism 22 of apparatus 10 are constructed and arranged in a new and unique combination from elements similar to those found in prior gutter machines. For example, see U.S. Pat. Nos. 3,529,461, 4,899,566, 5,551,272 and 6,931,903 to Knudson, the entire disclosures of which are hereby incorporated by reference herein.

FIGS. 2-9 illustrate the various steps in forming the flat material 14 into the fascia molding 30. The first step involves roll forming a longitudinal curved shape or profile 32 inward from one longitudinal edge 33. Reference numerals 33 and 36 designate the opposite side edges of profile 32. In the preferred embodiment as shown, the profile 32 is an oggee shape, although a crown profile, cove profile or other suitable profile of any desired shape can be used.

After the profile 32 has been formed, material 14 is then folded or bent in one direction upwardly along a longitudinal fold line 34 at one side of profile 32, as best shown in FIG. 3. The portion of material 14 thus folded or bent upwardly includes profile 32 and the flat portion adjacent to edge 33 between the profile and edge 33.

After the portion of material 14 inward from edge 33 has been folded in one direction upwardly, the material is bent downwardly in the other direction along longitudinal fold line 38 about 90 degrees to form an upper attachment flange 40 along the upper edge 33 of the fascia molding 30.

The portion of material 14 along the opposite edge 42 is also bent upwardly in one direction about 90 degrees along fold line 44 and then bent back downwardly in the other direction about 90 degrees along fold line 46, as best seen in FIGS. 4 and 5.

The flat and profile portions of material 14 inward from the edge 33 are then bent downwardly about 90 degrees along longitudinal fold line 48 and then bent back upwardly about 90 degrees along longitudinal fold line 50 to form the flat side of the fascia molding 30, as best seen in FIGS. 6 and 7.

The distance between fold lines 46 and 50, defining the flat side of the fascia molding 30, can vary depending upon the particular building application.

Meanwhile, the portion of material 14 along the opposite edge 42 is bent inwardly about 90 degrees along longitudinal fold line 52 and then bent back downwardly about 90 degrees along longitudinal fold line 54 to form a lower attachment flange 56 of the fascia molding 30, as best seen in FIG. 9.

FIG. 11 shows a typical installation the fascia molding 30. In the preferred embodiment, the lower attachment flange 56 is secured by fasteners 58 to wall sheathing 60, behind the upper edge of siding 62. The upper attachment flange 40 is secured by fasteners 64 to the outer edge of the roof sheathing 66.

FIG. 10 shows a modified fascia molding 30a, similar to fascia molding 30, except that the lower attachment flange 56 has been cut off along fold line 54, in order to provide support for soffit 68 under the roof eave, as shown in FIG. 12.

Although a particular sequence of steps have been shown and described herein for manufacturing the fascia molding 30, another sequence of steps in a different order could be used. Also, some steps could be combined and/or carried out simultaneously instead of sequentially, if desired.

If desired, longitudinally spaced-apart, holes or perforations (not shown) could be provided in the flanges 40 and 56 for receiving fasteners 64 and 58, respectively. Such holes or perforations would be elongated to allow for thermal expansion and contraction. Also, edges 33 and 42 could be folded back upon themselves for additional rigidity and reinforcement of flanges 40 and 56, respectively.

FIG. 13 shows an apparatus for forming fascia molding 70 incorporating a second embodiment of the invention herein. Since apparatus 70 incorporates components substantially similar to apparatus 10, the same reference numerals have been used, but with prime (′) notations for differentiation.

Instead of forming fascia molding 30 in continuous fashion from coil 16, which is then cut to length as desired with shear 24, apparatus 70 utilizes precut sheets 72 of material 14′ to form sections of fascia molding in precut lengths. Otherwise, the manufacturing steps are the same. In the preferred embodiment, the sheets. 72 of material 14′ are precut in any suitable length, such as 10, 12, or 16 feet long.

If desired, longitudinally spaced-apart, precut holes or perforations 74 can be provided along the opposite edges of each sheet 72 before forming the flanges 40 and 56 in fascia molding 30, as shown in FIG. 14.

Similarly, as FIG. 15 shows, one of both of the ends of each sheet 72 can be precut in a predetermined profile to facilitate joining two sections of fascia molding 30 together. For example, the ends of sheet 72 can be precut to facilitate making a mitre joint with and between two sections of fascia molding 30 during installation.

From the foregoing, it will be appreciated that the present invention comprises an apparatus and method for forming fascia molding having several advantages over the prior art. One significant advantage is the ease of installation when the fascia molding can be made in continuous fashion and cut to length according to the particular building application, thus avoiding the seams and piecemeal approach characterized by the prior art. This results in efficiencies and cost savings in manufacturing, installation and maintenance. Other advantages will be evident to those skilled in the art.

Although particular embodiments of the invention have been illustrated in the accompanying Drawing and described in the foregoing Detailed Description, it will be understood that the invention is not limited only to the embodiments disclosed, but is intended to embrace any equivalents, modifications and/or rearrangements of elements falling within the scope of the invention as defined by the following Claims.

Claims

1. A method of manufacturing fascia molding, comprising the steps of:

a. providing a sheet of malleable material, said sheet having opposite longitudinal side edges, and opposite surfaces;

b. advancing said sheet along a predetermined feed path;

c. roll forming a predetermined longitudinal profile into said sheet, said profile being spaced inwardly between the side edges thereof;

d. roll forming a longitudinal first portion of said sheet between said profile and one adjacent side edge in one transverse direction;

e. roll forming said first portion and said profile in the opposite transverse direction; and

f. roll forming a second portion of said, sheet between said profile and the other side edge sequentially in both transverse directions to form inner and outer sections, the outer section adjacent said other side edge being substantially parallel to said first portion and spaced a predetermined distance away from the second portion by the inner section.

2. The method of claim 1, wherein the malleable material is aluminum in coil form.

3. The method of claim 1, wherein the malleable material is aluminum in precut flat sheet form.

4. The method of claim 1, wherein the longitudinal profile is an oggee.

5. The method of claim 1, wherein the angle between the inner and outer sections of said second portion is about a right angle.

6. The method of claim 1, wherein the angle between the inner and outer sections of said second portion is about a right angle.

7. The method of according to claim 6, wherein the angle between the inner section and said second portion is about a right angle.

8. The method of claim 1, further including the step of:

g. roll forming a third portion of said sheet between said profile and the said other side edge sequentially in both transverse directions to form inner and outer middle sections, the inner middle section being adjacent to said profile.

9. The method according to claim 8, wherein the angle between the inner and outer middle sections of said third portion is about a right angle.

10. The fascia molding manufactured according to the method of claim 1.

11. A method of manufacturing fascia molding, comprising the steps of:

a. providing a flat sheet of malleable material, said sheet having opposite longitudinal side edges, and opposite surfaces;

b. advancing said sheet along a predetermined feed path;

c. roll forming a predetermined longitudinal profile into said sheet, said profile being spaced inwardly between the side edges thereof;

d. roll forming a longitudinal first portion of said sheet between said profile and one adjacent side edge in one transverse direction;

e. roll forming said first portion and said profile in the opposite transverse direction;

f. roll forming a second portion of said sheet between said profile and the other side edge sequentially in both transverse directions to form inner and outer sections, the outer section adjacent said other side edge being substantially parallel to said first portion and spaced a predetermined distance away from the second portion by the inner, section, and

g. roll forming a third portion of said sheet between said profile and the said other side edge sequentially in both transverse directions to form inner and outer middle sections, the inner middle section being adjacent to said profile.

12. The method of claim 11, wherein the malleable material is aluminum in coil form.

13. The method of claim 11, wherein the malleable material is aluminum in precut flat sheet form.

14. The method of claim 11, wherein the longitudinal profile is an oggee.

15. The method according to claim 14, wherein the oggee is offset relatively closer to said one side edge.

16. The method of claim 11, wherein the angle between the inner and outer sections of said second portion is about a right angle.

17. The method of claim 11, wherein the angle between the inner and outer sections of said middle portion is about a right angle.

18. The fascia molding manufactured according to the method of claim 11.

19. Apparatus for manufacturing fascia molding from malleable sheet material, which comprises:

an elongate, generally rectangular enclosure having front and back ends;

means for feeding the sheet material into the front end of said enclosure;

means for advancing said material along a predeterminded feed path within said enclosure;

means positioned along the feed path for progressively roll forming said material into fascia molding by the steps of:

a. roll forming a predetermined longitudinal profile into said sheet, said profile being spaced inwardly between the side edges thereof;

b. roll forming a longitudinal first portion of said sheet between said profile and one adjacent side edge in one transverse direction;

c. roll forming said first portion and said profile in the opposite transverse direction;

d. roll forming a second portion of said sheet between said profile and the other side edge sequentially in both transverse directions to form inner and outer sections, the outer section adjacent said other side edge being substantially parallel to said first portion and spaced a predetermined distance away from the second portion by the inner section, and

e. roll forming a third portion of said sheet between said profile and the said other side edge sequentially in both transverse directions to form inner and outer middle sections, the inner middle section being adjacent to said profile.

20. The apparatus of claim 19, further including:

means associated with the back end of said enclosure for selectively cutting said fascia molding to length.