MAGNETIC ATTACHMENT ASSEMBLY FOR ATTACHING A FIRST OBJECT TO A SECOND OBJECT
20190177983 ยท 2019-06-13
Inventors
Cpc classification
E04F2015/02072
FIXED CONSTRUCTIONS
F16B5/128
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E04F19/0472
FIXED CONSTRUCTIONS
E04F15/02044
FIXED CONSTRUCTIONS
International classification
E04F13/08
FIXED CONSTRUCTIONS
E04F19/04
FIXED CONSTRUCTIONS
E04F15/02
FIXED CONSTRUCTIONS
Abstract
A magnetic attachment assembly for attaching a first object to a second object includes a first and second ferromagnetic devices possessing an attractive magnetic property pulling each toward one another. The first ferromagnetic device is attached to the first object and an adhesive layer on the second ferromagnetic device is for attaching the second ferromagnetic device to the second object. A removable separator is initially positioned intermediate the first ferromagnetic device and the second ferromagnetic device and is frictionally held in place prior to attachment of the second ferromagnetic device to the second object. During installation, the user pushes the attachment assembly onto the second object, pulls the first ferromagnetic device away from the second ferromagnetic device, removes the separator, and then pushes the first ferromagnetic device back to the second ferromagnetic device thereby attaching the first object to the second object.
Claims
1. A magnetic attachment assembly for attaching a first object to a second object, the magnetic attachment assembly comprising: a first ferromagnetic device for attachment to the first object; a second ferromagnetic device adjacent the first ferromagnetic device, the first ferromagnetic device and the second ferromagnetic device in combination possessing an attractive magnetic property pulling each toward one another; an adhesive layer affixed on a side of the second ferromagnetic device that faces away from the first ferromagnetic device, the adhesive layer for attaching the second ferromagnetic device to the second object; and a removable separator intermediate the first ferromagnetic device and the second ferromagnetic device; wherein the removable separator holds the second ferromagnetic device a predetermined distance away from the first ferromagnetic device; the predetermined distance does not prevent the attractive magnetic property from overcoming forces of gravity on the second ferromagnetic device; and prior to attaching the second ferromagnetic device to the second object, the second ferromagnetic device is magnetically held in an initial position adjacent the first ferromagnetic device with the removable separator frictionally held therebetween.
2. The magnetic attachment assembly of claim 1, wherein: after attaching the adhesive layer of the second ferromagnetic device to the second object, the removable separator is removed from between the first ferromagnetic device and the second ferromagnetic device such that the second ferromagnetic device is held in a second position adjacent the first ferromagnetic device by the attractive magnetic property; and while in the second position, the second ferromagnetic device is closer to the first ferromagnetic device by the predetermined width of the removable separator no longer intermediate the first ferromagnetic device and the second ferromagnetic device.
3. The magnetic attachment assembly of claim 1, wherein: the first ferromagnetic device is attached within a recess on the first object; and the predetermined thickness of the removable separator is such that the side of the second ferromagnetic device upon which the adhesive layer is affixed extends past a forward edge of the first object only when the removable separator is held in place between the first ferromagnetic device and the second ferromagnetic device.
4. The magnetic attachment assembly of claim 3, wherein, after removing the removable separator from between the first ferromagnetic device and the second ferromagnetic device, the side of the second ferromagnetic device upon which the adhesive layer is affixed is substantially flush with the forward edge of the first object.
5. The magnetic attachment assembly of claim 1, wherein: at least one of the first ferromagnetic device and the second ferromagnetic device includes a permanent magnet; and at least one of the first ferromagnetic device and the second ferromagnetic device includes a magnet conductor.
6. The magnetic attachment assembly of claim 1, wherein the removable separator is a non-ferromagnetic device that does not experience the attractive magnetic property between the first ferromagnetic device and the second ferromagnetic device.
7. The magnetic attachment assembly of claim 1, wherein: the first ferromagnetic device is mounted on an insert; and the first ferromagnetic device is attached to the first by object by inserting the insert into an insert-holding slot on the first object.
8. The magnetic attachment assembly of claim 7, wherein the insert-holding slot on the first object has a depth greater than a height of the insert such that the first ferromagnetic device is moveable toward and away from the second ferromagnetic device while the insert is inserted within the insert-holding slot.
9. The magnetic attachment assembly of claim 8, further comprising a removing tool comprising a third ferromagnetic device possessing a stronger attractive magnetic property in order to pull the first ferromagnetic device away from the second ferromagnetic device in the insert-holding slot when the removing tool is held adjacent an opposing side of the first ferromagnetic device away from second object.
10. The magnetic attachment assembly of claim 7, wherein the insert and the insert-holding slot are dovetail-shaped.
11. The magnetic attachment assembly of claim 5, wherein at least one of the first ferromagnetic device and the second ferromagnetic device includes a steel plate positioned adjacent the permanent magnet on a side of the permanent magnet away from an adjacent one of the first ferromagnetic device and the second ferromagnetic device.
12. The magnetic attachment assembly of claim 11, wherein the steel plate has a width of substantially a same width of the permanent magnet.
13. The magnetic attachment assembly of claim 1, wherein at least one of the first ferromagnetic device and the second ferromagnetic device includes a steel plate positioned adjacent a row of permanent magnets on a side of the permanent magnets away from an adjacent one of the first ferromagnetic device and the second ferromagnetic device.
14. The magnetic attachment assembly of claim 13, wherein the steel plate runs lengthwise under the row of the permanent magnets and has a width of substantially a same width of the permanent magnets.
15. The magnetic attachment assembly of claim 1, wherein at least one of the first ferromagnetic device and the second ferromagnetic device includes a plurality of steel plates each positioned adjacent a respective one of a plurality of rows of permanent magnets on a side of the permanent magnets away from an adjacent one of the first ferromagnetic device and the second ferromagnetic device.
16. The magnetic attachment assembly of claim 15, wherein each of the steel plates runs lengthwise under its respective row of the permanent magnets and has a width of substantially a same width of the permanent magnets in its respective row.
17. The magnetic attachment assembly of claim 1, wherein: at least one of the first ferromagnetic device and the second ferromagnetic device includes a row of screw holes with an aluminum plate running lengthwise adjacent the row of screw holes; and the screw holes pass through the aluminum plate for attaching the at least one of the first ferromagnetic device and the second ferromagnetic device to at least one of the first object and the second object.
18. The magnetic attachment assembly of claim 1, wherein the first object is a trim board and the second object is a wall.
19. (canceled)
20. The magnetic attachment assembly of claim 1, wherein at least one of the first ferromagnetic device and the second ferromagnetic device is provided on a clip for attaching the at least one of the first ferromagnetic device and the second ferromagnetic device to at least one of the first object and the second object.
21. A method of attaching a first object to a second object, the method comprising: attaching a first ferromagnetic device to the first object; providing a second ferromagnetic device adjacent the first ferromagnetic device with a removable separator intermediate the first ferromagnetic device and the second ferromagnetic device, wherein the first ferromagnetic device and the second ferromagnetic device in combination possess an attractive magnetic property pulling each toward one another, the removable separator holds the second ferromagnetic device a predetermined distance away from the first ferromagnetic device, the predetermined distance does not prevent the attractive magnetic property from overcoming forces of gravity on the second ferromagnetic device, and prior to attaching the second ferromagnetic device to the second object, the second ferromagnetic device is magnetically held in an initial position adjacent the first ferromagnetic device with the removable separator frictionally held therebetween; pushing the first object toward the second object such that an adhesive layer affixed on a side of the second ferromagnetic device that faces away from the first ferromagnetic device is pushed against the second object, the adhesive layer thereby attaching the second ferromagnetic device to the second object; pulling the first object away from the second object to thereby overcome the attractive magnetic property and pull the first ferromagnetic device away from the second ferromagnetic device attached to the second object; after the first ferromagnetic device is pulled away from the second ferromagnetic device, removing the removable separator from between the first ferromagnetic device and the second ferromagnetic device; and pushing the first object toward the second object such that attractive magnetic property pulls the first ferromagnetic device against the second ferromagnetic device thereby attaching the first object to the second object.
22-40. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will be described in greater detail with reference to the accompanying drawings which represent preferred embodiments thereof:
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DETAILED DESCRIPTION
[0093] Embodiments are disclosed herein for use in mounting material, such as trim or molding to a surface such as a wall and/or ceiling, for use in mounting fence boards to a fence frame, for mounting decking to deck joists and in any other suitable situation. In some embodiments a plurality of axially spaced-apart magnets are affixed to either the material or to the surface and a magnetic conductor is mounted to the opposing surface or material.
[0094] Disclosed is an apparatus and kit for installing molding such as baseboards and crown molding to a structure. The molding is attached to the structure using magnets by securing the molding to the structure using the magnetic bond between a magnetic conductor and magnet. The installed molding is easily removed without damaging the molding or the structure simply by breaking the magnetic bond.
[0095] In some embodiments, the magnet is secured to the trim and the conductor is secured to the structure. In other embodiments, the magnet and conductor combination can reside substantially flush within a recess in the trim and are secured using an adhesive layer. An additional embodiment includes a kit providing a magnet and magnetic conductor and a trim piece configured to house each to facilitate the installation of the trim. The present magnetic apparatus provides ease of initial installation of the removal and replacement of the trim when painting and installing flooring.
[0096] In greater detail, the removable and remountable trim molding secured by a magnetic bond to a structure includes various embodiments. The magnetic attachment assembly includes both a magnet and magnetic conductor which can be assembled in various configurations to bond a molding trim to a structure. The term trim is inclusive such trim moldings as baseboards, crown moldings, window and door trim and door jams and the like. The term structure includes the walls and ceilings of most any building or dwelling where trim may be applied.
[0097] The term magnetic conductor is inclusive of any material attracted to a magnet to form a magnetic bond. By way of example and not limitation, the term may include most any suitable metal, such as in a thin sheet or even a wire mesh. Additionally, some metallic paints may have sufficient bonding potential. Other magnets may be utilized as magnetic conductors in some embodiments. The term magnet is inclusive of any material or object that produces a magnetic field. In an embodiment, the magnet is a permanent magnet or a material that creates its own persistent magnetic field. An embodiment includes a metallic permanent magnet. Embodiments include rare-earth magnets or may include plastic materials which are formulated to be magnetic.
[0098] In one embodiment, the magnetic attachment assembly includes the trim molding having a magnet attached to the trim and the magnetic conductor attached to the structure to which the molding is applied. However, such an arrangement may be reversed. For example, the magnetic conductor may be attached to the molding trim and the magnet to the structure.
[0099] The magnet can reside within a recess in the trim molding to help the molding sit flush with the wall or ceiling of the structure. The recess is sized such that the trim piece is substantially flush with a surface of a structure when the magnetic attachment assembly comprising the combination of the magnet and magnetic conductor reside with the recess. The term substantially flush includes the appearance of unity between wall or structure and the trim, but allows for some gap between the trim and wall that does not detract from appearance. In an embodiment, the gap formed between the trim and wall surface may be such that caulking may be used as in some traditional installations if so desired by the installer.
[0100] Additionally, it is contemplated that, in an embodiment, the magnet may extend substantially the length of the trim molding. The conductor may also extend the same by being substantially the length of the trim molding to be attached to the structure. However, both do not need to extend the substantial length together. For example, the magnetic conductor may extend the length of the trim, but the magnet component may be spaced apart and attached to the trim, with the reverse also being true.
[0101] The present apparatus also includes a kit for removable and remountable trim molding. The kit includes a magnet and a magnetic conductor. The magnet includes a first surface and the magnetic conductor includes the same where an adhesive layer is attached to at least one of the first surfaces of either the magnet or magnetic conductor. The second surfaces of the magnet and magnetic conductor operatively align to form a magnetic bond.
[0102] It is contemplated that the kit includes the magnetic attachment assembly being provided having both the first surfaces of the magnet and magnetic conductor having an adhesive layer. Typically, the adhesive layer further includes a release paper preserving the adhesive. The term paper is used generally and includes most any material including plastics. The adhesive may be a contact or pressure sensitive adhesive. In embodiments, the adhesive is stronger than the bond created between the magnet and the magnetic conductor.
[0103] The kit can further include any tool useful in creating a recess within the molding such that the magnetic attachment assembly can reside therein and enable the trim to sit substantially flush with the wall or ceiling of the structure. Such tools can include a router or bit, by way of example and not limitation.
[0104] The magnetic attachment assembly must have both the first surfaces of the magnet and the magnetic conductor in contact with the wall and/or trim to form the mechanical or chemical bond. The magnet and the magnetic conductor do not need to be in physical contact in an embodiment, only that a magnetic bond is formed between the second surfaces of the two to securely hold the trim to the wall. Such an arrangement will enable the trim to sit totally flush with the wall and aid in preventing the need to caulk the wall.
[0105] Furthermore, the kit can include the trim piece having a recess whereby the recess is operatively sized to house the magnet or conductor. Additionally, the trim piece may include a preinstalled magnetic assembly within the recess, such that only the first surface of one of the magnetic components requires an adhesive layer to attach to the wall or ceiling of the structure.
[0106] A further embodiment includes a method of securing the removable and remountable trim molding to a structure. The method includes providing both a magnet and conductor. The method then includes affixing the magnet to the trim molding and affixing the magnetic conductor to the structure. The magnet and magnetic conductor may be affixed chemically in one embodiment using an adhesive and in a further embodiment mechanically. Additionally, both methods for affixing may be used in combination. The affixation of the magnet and magnetic conductor may also be reversed in a further embodiment. The magnet and magnetic conductor are operatively aligned and secured to the trim and molding to the structure.
[0107] Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views, depicted are apparatuses and methods according to various embodiments of the present invention.
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[0112] Having reference to
[0113] As illustrated in
[0114] The strip of magnets 4 is then affixed to the surface 14 to which the target material 12 is to be mounted. The strip of magnets 4 can be affixed using conventional fasteners or can be affixed using an adhesive 8, such as an adhesive low in volatile organic compounds (low VOC). In some embodiments, the plastic material 5 on the strip of magnets 4 is generally a relatively flexible strip of polystyrene plastic which has an adhesive 8 applied to the back surface and a paper tape 16 removably covering the adhesive 8. The paper 16 is removed to adhesively bond the strip 7 to the surface. One such suitable adhesive 8 is 3M VHB tape.
[0115] In some embodiments, the slot 10 extends along the length of the target material 12, and the conductor 6 extends along the length of the slot 10. In alternate embodiments, the slot 10 is discontinuous, the conductor 6 being sized to fit the slot 10. In other embodiments, the slot 10 extends the length of the material 12; however, the conductor 6 is discontinuous and affixed at spaced intervals within the continuous slot 10.
[0116] In some embodiments, as shown in
[0117] As shown in
[0118] As shown in
[0119] In some embodiments such as shown in
[0120] In the embodiment shown in
[0121] Having reference to
https://www.kjmagnetics.com/calculator.asp.)
[0122] In some embodiments, a plurality of holes are made at spaced intervals along a strip of plastic, such as PVC or polystyrene styrene. The holes extend through the strip and have a stepped profile; a larger diameter portion adjacent a back side of the strip and a smaller diameter portion adjacent a front side of the strip. A piece of galvanized steel 120 is inset into the larger diameter portion and a magnet 4 is inset into the smaller diameter portion, thereabove and adhesively bonded thereto. A strip of double-sided adhesive tape 8, such as a polyethylene foam tape (PE foam tape), is affixed to the back side of the strip 5 to permit application to the surface 14.
[0123] In an alternate embodiment, shown in
[0124] Although the above embodiments have focused on the magnets 4 being located on a strip 5 that is secured to a target surface 14 while the magnetic conductor 6 is mounted within a slot 10 on the object material 12, it should be noted that in other embodiments these components locations may be reversed. In other words, the magnets 4 may be secured within the slot 10 on the object material 12 and the magnetic conductor 6 may be mounted on a strip 5 that is secured to a target surface 14. Generally speaking, both the magnets 4 and the magnetic conductor 6 are ferromagnetic devices that together possess an attractive magnetic property that pulls each toward one another. For instance, in the illustrated examples, the magnetic conductor 6 is a first ferromagnetic device that is attached to a trim board or other object 12 that is desired to be attached to a surface 14. The magnets 4 are second ferromagnetic devices that possess attractive magnetic properties pulling toward the first magnetic device (e.g., a steel conductor 6). In general, these two ferromagnetic devices 4, 6 experience magnetic forces pulling each other toward one another and may therefore be swapped in relative positions with each other in different embodiments.
[0125] Likewise, in other embodiments, two separate magnets may be utilized as first and second ferromagnetic devices as long as they are configured in the correct orientation such that they experience an attractive magnetic property, for instance, South-pole to North-pole or vice versa. Of course, two ferromagnetic devices such as steel plate magnetic conductors 6 would not experience any attractive magnetic property between them without the presence of an additional permanent magnet so two conductors 6 would not be sufficient to pull toward one another unless one is magnetised to a sufficient degree.
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[0130] As can be seen from
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[0133] To detach the trim board 12 from the wall surface 14, the magnets 56 of the removal tool 54 are held against the outer surface 58 of the trim board 12. The stronger magnets 56 of the removal tool 54 pull on the conductor plate 6 and the insert 24 shifts position away from the magnetic strip 5 and toward the magnets 56 of the removal tool 54. Because the conductor 6 is now further away from the wall strip magnets 4, the attractive magnetic force on the wall strip 5 is reduced.
[0134] In some embodiments, to ensure that attractive magnetic forces on the wall strip 5 are reduced, the polarity directions of the magnets 56 in the removing tool 54 are opposite those of the magnetic strip 5. In other words, a same pole of the magnets 4 in the wall strip 5 may face the same pole in the magnets 56 is the removing tool 54. In this way, the magnets 4, 56 will repel each other while the magnetic conductor moves toward the strong of the two, i.e., moves toward the removing tool 54.
[0135] As a result of the magnetic conductor 6 moving away from the wall strip magnets 5, the magnetic forces holding the trim board 12 to the wall are reduced. The user may start by holding the removing tool 54 near an end of the baseboard to reduce the holding strength at that end. The user can then manually peel back that end of the trim board 12 from the wall 14. Since the trim board 12 is no longer being strongly held at that end (as a result of the increased distance between the conductor 6 and the wall strip 5), the forces pulling on the wall adhesive 8 are correspondingly reduced. The user may then slide the removing tool down the trim board 12 while peeling the trim board 12 away from the wall. Benefits of the larger air gap 42 and the removal tool 54 in some embodiments include less strength being required by the user to remove the trim 12, less wear and tear on the adhesive 8 during the removal process, and reduced possibility of damage to the wall while removing the trim 12.
[0136] As shown in
[0137] Having reference to
[0138] In the case where wider material 12 is to be applied, such as 6 or 7 baseboard, more than one slot 10 can be provided and additional magnet strips 4 can be affixed to the surface 14 to ensure secure engagement therebetween over the width/height of the material 12. Further, where decor is changed and one wishes to use the wider material 12 instead of the narrower/lower material 12 that has already been installed, the narrow material 12 can simply be pulled from the magnet strip 4 and a second magnet strip 4 affixed to the surface 14 spaced thereabove to coincide with the second slot 10 on the wider/taller material 12.
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[0140] Any of the above-described methods may be employed including dovetail inserts 24 or adhesive, etc.
[0141] The magnet wall strip 5 is positioned adjacent the conductor 6 with the removable separator 60 intermediate the conductor 6 and the magnetic strip. The conductor 6 and the magnets 4 in the strip 5 in combination possess an attractive magnetic property pulling each toward one another. The removable separator 60 holds the magnetic strip 5 a predetermined distance D1 away from the conductor 6. The predetermined distance D1 does not prevent the attractive magnetic property from overcoming forces of gravity on the magnetic strip 5. In this way, prior to attaching the magnetic strip 5 to the wall 14, the strip 5 is magnetically held in an initial position adjacent the conductor 6 with the removable separator 60 frictionally held therebetween.
[0142] Once the magnetic attachment assembly 2 is configured in the position shown in
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[0144] After the conductor 6 is pulled away from the second ferromagnetic device, the user removes the separator 60 from between the magnetic strip 5 and the conductor 6. In some embodiments, the separator 60 is a non-ferromagnetic material such as plastic such that it will simply fall away when the trim board 12 is pulled away from the wall 14. The user may thereby easily reach between the trim 12 and wall 14 to grab the separator 60 for removal.
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[0146] Another benefit of the above-described installation process including the use of the separator 60 is to facilitate a strong bond of the adhesive 8 to the correct position on the wall 14. As illustrated in
[0147] The distance D1 corresponds to the width of the separator 60 in this embodiment. Thus, after the separator 60 is removed and the trim board 12 is attached to the wall 14 in the finished configuration as shown in
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[0151] Embodiments taught herein are not only useful for attaching trim and moldings to walls and ceilings, as noted above, they are also suitable for affixing decking to a substructure, such as a plurality of spaced apart deck joists.
[0152] Having reference to
[0153] Decking boards 40, whether wood, composite decking material such as TREX, available from TREX Company Inc., Winchester, Va., USA or AZEK, available from AZEK Building Products Inc., Scranton, Pa., USA, polyvinyl chloride (PVC) composite or wood-plastic composite (WPC) or other suitable materials, is used. Each decking piece or length 40 comprises one or more elongated slot(s) 10 formed therein, along an undersurface leaving the top surface of the board 40 unmarred. The slot 10 may similar to as shown in the above examples where the target material 12 to mount was baseboard trim such as illustrated in
[0154] As will be understood by those of skill in the art, a jig can be used for appropriately spacing the strapping 36 to provide suitable gaps between the decking pieces 40 to allow for any expansion of the materials, such as due to heat, moisture and the like.
[0155] In some embodiments, as shown in
[0156] The deck clip 72 comprises a generally U-shaped body having a flat upper surface and two opposing legs 78, 80 forming an open bottom. One or more magnets 74 are retained on the top surface of the clip 72, such as by adhesive. The opposing legs 78, 80 are angled inwardly for gripping the joist 76 therebetween. A bottom of each leg 78, 80 is flared outwardly for engagement, such as by a tool, to facilitate removal of the clip 72 from the joist 76, if required.
[0157] Wickers or protrusions 82 are formed on an inner surface of each of the legs 78, 80 for securely engaging the clip 72 with the joist 76 and to withstand upward movement of the clip 72 when decking 40 magnetically bonded thereto is lifted to release from the magnetic bonding for removal from the joists 76. The wickers or protrusions 80 may be formed by punching the material of the legs of the clip 78, 80, typically galvanized steel, to form one or more inwardly and upwardly extending prongs.
[0158] Optionally, holes 84 are provided in the legs 78, 80 of the clip 72 to permit fastening of the clips 72 to sides of the joists 76, such as with screws and the like, when positioned thereover. However, the system does not necessarily require the optional fasteners as the clips 72 may securely engage the joists 76 without the need for the optional fasteners in some embodiments.
[0159] As will be appreciated, fascia boards and shaped trim can be applied using the concepts taught herein to finish an edge of the deck.
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[0162] In addition to trim, baseboards, and decking, embodiments herein may also be utilized in fencing applications.
[0163] Having reference to
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[0167] Steal plates 128 are mounted under each row of magnets 4. Screw holes 132 are provided for mounting the board to a surface 14 or joists 36, 76. A row of screw holes runs down the center in this embodiment, and the screw holes 130 pass through an alumni plate 130 in order to provide additional strength to the board. In some embodiments, the strapping board 126 is extrusion moulded plastic and the aluminum plate 130 helps provide strength to the board and avoid the screws splitting the board.
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[0169] Although the invention has been described in connection with preferred embodiments, it should be understood that various modifications, additions and alterations may be made to the invention by one skilled in the art. For instance, in a further embodiments, the trim, deck, and/or fence board material 12 itself is extrusion molded and has the slot formed therein in any of the configurations described above or any other suitable configuration for retaining the conductor therein. One such composition that can be used for extrusion molding of the inserts or for manufacture of the entire material itself is polyvinyl chloride (PVC) or cellular PVC, commonly used to replace standard wood millwork, trims and the like. For aesthetic purposes, the material can be wrapped with other materials such as wood, metal and the like to provide different finishes. Alternatively, the PVC or cellular PVC can be colored to any desired color to complement the aesthetics of the project. Functions of single modules may be separated into multiple units, or the functions of multiple modules may be combined into a single unit. All combinations and permutations of the above described features and embodiments may be utilized in conjunction with the invention.