GB2609228A

GB2609228A - A corner bead cover

Info

Publication number: GB2609228A
Application number: GB2110638.0A
Authority: GB
Inventors: Brown Garry
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-07-23
Filing date: 2021-07-23
Publication date: 2023-02-01
Anticipated expiration: 2041-07-23
Also published as: GB202110638D0; GB2609228B

Abstract

Damaged, pre-existing metal corner beads located within corners of walls are prone to oxidisation, and consequent rusting. The present invention provides a corner bead cover 10 for covering a damaged bead and restoring or repairing the corner. The corner bead cover 10 comprises two wings 20, 30 meeting together 10 at an apex 25, a ridge 40 projecting from the apex, wherein an outer surface 21, 31 of each wing comprises a textured surface configured, in use, to provide an attachment surface for a filler material, wherein the corner bead cover 10 is impermeable to moisture and oxygen, such that, in use, the corner bead cover 10 is configured to seal the damaged, pre-existing bead and provide a barrier between the wall and the filler material when applied 15 to outer surfaces 21, 31 of the wings 20, 30. A sealing layer may be applied to the wings, which may have apertures in them, and may include foil, bitumen or knotting solution. The wings may extend between 10 mm and 200 mm and the ridge between 0.1 mm and 5 mm. The wings may taper away from the apex and be between 0.05 mm and 5 mm thick. The bead cover may be of a polymer or plastics material.

Description

A corner bead cover The present invention relates generally to a corner bead cover and a method of covering a damaged, pre-existing bead and finds particular, although not exclusive, utility in covering damaged, pre-existing beads located within a corner of a wall.

Comer beads are commonly used on the corners of building walls to provide protection against impacts, as well as to provide a continuous straight edge to produce an aesthetically pleasing finish to a wall. The beads are attached to the corner of a wall to be plastered, and then the wall is covered with plaster, using the bead to fhtin the straight edge.

A problem with metal beads is that they are prone to damage during construction of a building. In particular, tools and mishandling can cause a galvanised layer of the metal bead to be scratched off or removed. This may allow oxygen and/or moisture from the air or within the wall to contact the metal below the galvanised layer, resulting in oxidisation and consequently rust. A rusting corner bead m2iy cause a displeasing discolouration of the corner of the wall, and may also be detrimental to the structural integrity of the wall if the rust causes significant damage.

Two main methods are commonly employed to overcome the problem of rusting metal comer beads. The first method is to simply paint over the rust as it appears. This is a temporary fix, and will have to be repeated frequently as the metal bead continues to rust. The second method is to cut out the comer bead and replace it. This is costly and labour intensive. Additionally, if a new metal bead is damaged during the installation, the new bead also may be prone to rusting.

It is desirable to address this problem.

In a first aspect, the present invention provides a corner bead cover for covering a damaged, pre-existing bead located within a corner of a wall, the corner bead cover comprising two wings meeting together at an apex, thus forming an L-shape cross-section, and a ridge projecting from the apex, wherein an outer surface of each wing comprises a textured surface configured, in use, to provide an attachment surface for a filler material, wherein the corner bead cover is impermeable to moisture and oxygen, such that, in use, the corner bead cover is configured to seal the damaged, pre-existing bead and provide a barrier between the wall and the filler material when applied to outer surfaces of the wings.

Tn this way, a rusting pre-existing metal comer bead may he covered to hide any discolouration, and additionally may be prevented from oxidising further. By providing a barrier between the wall and filler material, moisture and oxygen may be prevented from reaching the pre-existing bead from outside of the wall. Starving metal of moisture and oxygen may prevent further oxidisation and rusting. The barrier between the wall and filler material also prevents discolouration and rust from contacting the filler material and causing an undesirable surface finish of the corner of the wall.

The corner bead cover may provide a more permanent solution than simply painting over the pre-existing bead, and also may not require the labour-intensive process of cutting out the pre-existing bead and replacing it with a new bead.

The comer of the wall may be located on any protruding comer of a building or may be located on an outer edge of a window alcove or doorway. The comer of the wall may be located on the interior or exterior of the building.

A pre-existing bead may comprise any metal bead currently present within the corner of the wall, such that the corner bead cover is retrofitted to the corner of the wall.

A damaged bead may comprise any metal bead that has been subject to oxidisation, such that the metal bead comprises rust.

Each wing may comprise a substantially planar portion being rectangular in shape, such that the length of each wing may be substantially greater than the width. It will be appreciated that other wing shapes are also contemplated. For example, the wings may be pentagonal, or may comprise an arcuate edge. the wings may be different shapes to each other.

Each wing may comprise a first edge. Each first edge may comprise a substantially straight edge, such that the first edge of each wing meets together to form the apex. The apex may define a longitudinal axis, and each wing may extend behveen 10mm and 80mm from the apex in a direction perpendicular to the longitudinal axis. The apex may be considered as a central portion of the corner bead cover. Dimensions outside of this range are also contemplated. Each wing may comprise a second edge, substantially parallel to the first edge. The second edges may be substantially straight, or may be curved, jagged, or undulating. The wings and apex may be manufactured as one piece.

The thickness of each wing may be continuous along its width and/or length. The thickness of each wing may be between 0.05mm and 2mm, preferably 1mm. Thicknesses outside of this range are also contemplated. Alternatively, at least one of the wings may taper from the apex towards a distal end of the at least one wing, wherein the distal end is substantially parallel to the apex. The distal end may be the second edge of the wing. In this way, filler material may lie applied over the corner bead cover such that there is no noticeable step indicating the edge of the corner bead cover under the filler material. the maximum thickness of each wing at a point proximate the apex may be between 0.05mm and 2mm, preferably imm, and this may taper to less than 0.05mm at the distil end. thicknesses outside of this range are also contemplated.

The wings may have different dimensions to each other, or may have the same dimensions. Furthermore, only one wing may comprise a tapered portion.

In use, the corner bead cover may be positioned such that the longitudinal axis defined by the apex is substantially parallel to the axis of the corner of the wall.

The L-shape cross-section formed by the two wings may comprise an angle of approximately 90 degrees. Alternatively, the L-shape cross-section may comprise an angle less than 90 degrees, such that the corner bead cover may clamp to the corner of the wall when it is attached.

The outer surface of each wing may be defined as the surface on the outside Of the L-shape.

The ridge may project out of the planes defined by the outer surfaces of the wings a sufficient distance to enable a minimum thickness of filler material to be applied to the wings. The minimum thickness may be the minimum thickness required to completely cover the surface of each wing. the ridge may project between 0.1mm and 5mm, more preferably 2mm to 3mm, from the apex in a direction away from the inside of the L-shape cross-section. The ridge may project in a direction parallel to the plane of the outer surface of either wing, or may project in a direction in-between the planes of the outer surface of either wing. The corner bead cover may be symmetrical, wherein the line of symmetry passes through the corner of the L-shape.

In use, the ridge may define a new corner point of the wall. The ridge may comprise a cross-section having a curved edge.

The ridge may comprise a tapered cross-section, such that the ridge tapers from the apex. In this way, the new corner point may comprise a substantially square edge after the filler material has been applied. Alternatively, the ridge may comprise a V-shape cross-section such that the new corner point comprises a substantially square edge.

The wings mid ridge may comprise plastics.

The textured surface may comprise rough or coarse portions, grooves, keyed portions, bumps, undulating portions, or indents, thereby providing a larger surface area per unit area. Tii this way, the filler material may be more securely bonded to the outer surfaces of the wings.

The term "impermeable" may define a property of the material wherein fluid cannot pass through the material. 'the fluid may comprise gas (for example oxygen) or liquid (for example water). The fluid may comprise vapourised or condensed liquid.

Sealing the damaged, pre-existing bead may comprise preventing moisture or liquid from passing through the corner bead cover and contacting the pre-existing bead.

The corner bead cover may be flush against the wall and/or pre-existing bead such that there is no gap or space therebetween. In this way, oxygen and/or moisture may not be trapped within the gap or space, thereby preventing continued oxidation of the pre-existing bead.

The filler material may comprise any material suitable for, when in a viscous form, plastering to the corner bead cover, before drying to form a solid layer. The filler material may also comprise a waterproofing agent.

Each wing may include holes therethrough to provide the textured surface, and art impermeable layer located on the inside of the I,-shape. 'this may provide a keying surface. In this way, the filler material may adhere to both the wings and the impermeable layer, providing a stronger bond to the corner bead cover.

The impermeable layer may comprise foil and/or bitumen. For example, the impermeable layer may comprise bitumen paper with a foil backing. The impermeable layer may be located inside the L-shape of the corner bead cover such that the foil backing is in contact with a surface of the wings located inside the L-shape. The impermeable layer may be affixed adhesively to each wing.

The corner bead cover may further comprise a layer of knotting solution applied to the impermeable layer. The knotting solution may be applied to the inside of the impermeable layer, such that is on the inside of the L-shape. The knotting solution may be applied to the bitumen paper.

In a second aspect, the invention provides a method of covering a damaged, pre-existing bead located within a corner of a wall, the method comprising the steps of: providing the corner bead cover; attaching the corner bead cover device to the corner of the wall via adhesive such that the damaged, pre-existing bead is covered and sealed; and applying filler over the second layer of the corner bead cover device.

The method may further comprise the step of applying knotting solution to the inside of the impermeable layer.

The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.

Figure 1 is a cross-sectional side view of the corner bead cover.

Figure 2 is a perspective view of the corner bead cover.

Figure 3 is a cross-sectional view of the corner bead cover attached to a corner of a wall.

The present invention will be described with respect to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. Each drawing may not include all of the features of the iiveritiori and therefore should not necessarily be considered to be an CtilbOdirIltilt of the invention. Tn the drawings, the srze of some of the elements may be exaggerated and not drawn to scale for illustrative purposes. 'the dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.

Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein. Likewise, method steps described or claimed in a particular sequence may be understood to operate in a different sequence.

Moreover, the terms top, bottom, over, under and the like in the description and the claims arc used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other orientations than described or illustrated herein.

Tt is to be noticed that the term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. it is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B. Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or 1 5 aspects. Furthermore, the particular features, structures or characteristics of any one embodiment or aspect of the invention may be combined in any suitable manner with any other particular feature, structure or characteristic of another embodiment or aspect of the invention, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments or aspects.

Similarly, it should be appreciated that in the description various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual drawing or aspect should not necessarily be considered to be an embodiment of the invention. Rather, as the following claims reflect, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art For example, in the following claims, any of the claimed embodiments can be used in any combination.

Tn the description provided herein, numerous specific details arc set forth. TIowevcr, it is understood that embodiments of the invention may be practised without these specific details, in other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

in the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The use of the term "at least one" may mean only one in certain circumstances.

The use of the term "any" may mean "all" and/or "each" in certain circumstances. The principles of the invention will now be described by a detailed description of at least one drawing relating to exemplary features. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept or technical teaching, the invention being limited only by the terms of the appended claims.

Figure 1 shows a cross-sectional side view of the corner bead cover 10. The corner bead cover 10 includes a first wing 20 and a second wing 30. First edges of the first and second wings 20,30 are joined together at an apex 25, such that the cross-section of the corner bead cover 10 forms an L-shape. Area A defines the "inside" of the L-shape, and area B defines the "outside" of the L-shape. The first and second wings 20, 30 extend from the apex 25 at approximately 90 degrees to each other. It will be appreciated that other angles are contemplated, for example 80 degrees. The first and second wings 20, 30 comprise outer surfaces 21,31 located on the outside of the L-shape, wherein the outer surfaces 21, 31 comprise a textured surface (not shown). The corner bead cover 10 may be substantially rigid, and may comprise plastics.

The first and second wings 20, 30 taper From the apex 25 towards respective distal ends 22, 33 of the first and second wings 20, 30. T Towever, it will be appreciated that one or both of the wings 20, 30 may not taper, and instead may have a continuous thickness.

The corner bead cover 10 further comprises a ridge 40 projecting from the apex 25 in a direction away from the inside of the L-shape. The ridge 40 comprises a cross-section comprising a curved portion 41. the centre point of the curved portion 41 is aligned with the corner point of the L-shape. the ridge 40 further comprises projections 42 projecting over the outer surfaces 21, 31 of the first and second wings 20, 30 and away from the inside of the L-shape.

The corner bead cover 10 further comprises an impermeable layer 50 located inside the L-shape. The impermeable layer 50 may comprise bitumen paper backed with foil (not shown), and the impermeable layer may be adhesively affixed to the inside of the first and second wings 20, 30 such that the foil is in contact with the first and second wings 20, 30.

Figure 2 shows a perspective view of the corner bead cover 10. The first and second wings 20,30 are substantially rectangular, and the apex 25 is formed at the meeting of a longitudinal edge of each wing 20, 30. The outer surface 31 of the second wing 30 comprises a textured surface comprising holes 33 extending completely through the second wing 30. In this way, filler material (not shown) applied to the corner bead cover 10 may be secured to the second wing 30 and the impermeable layer 50. It will be appreciated that the outer surface 31 may comprise other textured features such as grooves or coarse portion (not shown) in addition to, or instead of, the holes 33. Although not shown, the first wing 20 may also comprise a textured surface having holes therethrough. Again, it will be appreciated that other textured features are contemplated in addition to, (Jr instead of, the holes.

Figure 3 shows a cross-sectional view of the corner bead cover 10 attached to a corner of a wall 100. The wall 100 comprises a pre-existing metal corner bead 110, located on the peripheral corner of the wall 100. In use, the corner bead cover 10 is placed around the corner of the wall 100 over the pre-existing metal corner bead 110. The corner bead cover 10 may be adhesively attached to the corner of the wall 100 such that it does not move prior to the application of the filler material.

Once the corner bead cover 10 has been placed on the corner of the wall 100, filler material 120 is applied to the outer surfaces 21, 31 of the first and second wings 20, 30. The filler material 120 is applied such that it completely covers the outer surfaces 21, 31 of the first and second wings 20, 30 and tills a space created between the projections 42 and the outer surfaces 21, 31. TIowever, the tiller material 120 does not cover the arcuate portion 41 of the ridge, and instead the tiller material 120 is be applied such that its outer surface is flush with the arcuate portion 41 of the ridge.

The filler material 120 may be applied such that it tipers from the apex 25 to a point on the wall 100 beyond the distil ends 22, 32 of the first and second wings 20, 30.

in this way, the corner bead cover 10 is configured to seal a pre-existing metal corner bead 110 and provide a barrier between the wall 100 and the filler material 120 when applied to outer surfaces 21, 31 of the first and second wings 20, 30. As a result, the pre-existing metal comer bead 110 may be starved of moisture and oxygen, thereby preventing further oxidisation and rusting.

Claims

CLAIMS 1. 2. 3. 4. 5. 6. 7. 8.A corner bead cover for covering a damaged, pre-existing bead located within a corner of a wall, the corner bead cover comprising two wings meeting together at an apex, thus forming an L-shape cross-section, and a ridge projecting from the apex, wherein an outer surface of each wing comprises a textured surface configured, in use, to provide an attachment surface for a filler material, wherein the corner bead cover is impermeable to moisture and oxygen, such that, in use, the corner bead cover is configured to seal the damaged, pre-existing bead and provide a barrier between the wall and the filler material when applied to outer surfaces of the wings.
The corner bead cover of claim 1, wherein each wing includes holes therethmugh to provide the textured surface, and an impenneable layer located on the inside of the L-shape.
The corner bead cover of claim 2, wherein the impermeable layer is affixed adhesively to each wing.
The corner bead cover of either of claims 2 and 3, wherein the impermeable layer comprises foil and/or bitumen.
The corner bead cover of any of claims 2 to 4, further comprising a layer of knotting solution applied to the impermeable layer.
The corner bead cover of any of preceding claim, wherein the wings and ridge comprise plastics.
The comer bead cover of any preceding claim, wherein the apex defines a longitudinal axis, and each wing extends 10mm and 200mm from the apex in a direction perpendicular to the longitudinal axis.
The corner bead cover of any preceding claim, wherein at least one of the wings tapers from the apex towards a distal end of the at least one wing, wherein the distal end is substantially parallel to the apex.
9. The comer bead cover of any preceding claim, wherein the maximum thickness of each wing at a point proximate the apex is between 0.05mm and 5mm.
10. The corner bead cover of any preceding claim, wherein the ridge projects between 0.1mm and 5mm from the apex in a direction away from the inside of the L-shape cross-section.
11. A method of covering a damaged, pre-existing bead located within a corner of a wall, the method comprising the steps of: providing the corner head cover of any preceding claim; attaching the corner bead cover device to the corner of the wall via adhesive such that the damaged, pre-existing head is covered and sealed; and applying filler over the second layer of the corner bead cover device.