SE543501C2

SE543501C2 - Method for manufacturing a corner bead

Info

Publication number: SE543501C2
Application number: SE1851269A
Authority: SE
Inventors: Arne Jöneman; Kristian Brauner
Original assignee: Vaeggmaterial I Sverige Ab
Priority date: 2018-10-17
Filing date: 2018-10-17
Publication date: 2021-03-09
Also published as: US20210355692A1; EP3867460A1; WO2020081001A1; SE1851269A1; EP3867460A4

Abstract

The present invention relates to a method for manufacturing a corner bead (5) configured for mounting on an internal or external corner (4) of a building construction (1), comprising: providing a first flange (6) and a second flange (7); and arranging the first flange (6) and the second flange (7) in a configuration having a longitudinal extension and with a generally L-shaped cross-section. Furthermore, the method comprises: forming said first flange (6) with a first surface (8) which is configured for facing said building construction (1); forming said second flange (7) with a second surface (9) which is also configured for facing said building construction (1); coating at least one of said first surface (8) and said second surface (9) at least partially with an adhesive element (10) in the following manner: applying said adhesive element (10) in the form of a hot melt adhesive (10) on a protective layer (11); and applying said protective layer (11) on said at least one of said first surface (8) and said second surface (9) which is thereby coated with said hot melt adhesive (10).

Description

ln the field of building constructions, it it is previously known to arrange interior walls byfastening sheets of gypsum wallboards to a support structure. Such interior walls aresometimes arranged so that they define outside corners. These outside corners are in an exposed position and can be easily damaged, which is a disadvantage. ln order to protect such an outside corner from potential damage, it is previously known touse so-called corner beads. A corner bead is a relatively thin and longitudinally extendingreinforcement structure having two flanges forming an L-shaped cross-section and beingconfigured for mounting along such an outside corner. A corner bead can bemanufactured from a suitable plastics material and will act as a reinforcement of theoutside corner. ln this manner, any potential damage to the outside corner can beminimized or even eliminated. Also, the corner bead contributes to a clean and even surface of the building construction including the corner.

According to known technology, a corner bead is mounted on an outer corner before anyfurther surface treatment, such as painting, is carried out. A conventional way of attachinga corner bead is by gluing it to the outside corner and then applying compound on the wall element including the corner bead.

Furthermore, a previously known corner bead of the above-mentioned type is known fromthe patent document US 2006/283115. Even though the article disclosed in US2006/283115 fulfills the basic requirements regarding a corner bead for mounting on abuilding construction, there is a need for further improvements of such devices. Firstly,there is a requirement for a simple Way of attaching the corner bead to the buildingconstruction and a need for a secure attachment of the corner bead on different types ofsurfaces of the building construction. Also, there is a desire to provide a cost-efficient process for manufacturing such corner beads.

Consequently, there is a need for further improvements within the relevant field of technology.

SUMMARY OF THE INVENTION ln accordance with the present disclosure, there is provided an improved method formanufacturing a corner bead having the purpose of solving the above-mentioned problems related to prior art within this field. ln accordance with the disclosure, this object is obtained by means of a method formanufacturing a corner bead configured for mounting on an internal or external corner ofa building construction, comprising: providing a first flange and a second flange; andarranging the first flange and the second flange in a configuration having a longitudinalextension and with a generally L-shaped cross-section. Furthermore, the methodcomprises the following steps: forming said first flange with a first surface which isconfigured for facing said building construction; forming said second flange with a secondsurface which is also configured for facing said building construction; coating at least oneof said first surface and said second surface at least partially with an adhesive element inthe following manner: applying said adhesive element in the form of a hot melt adhesive on a protective layer; and applying said protective layer on said at least one of said first surface and said second surface which is thereby coated with said hot melt adhesive According to the disclosure, certain advantages are obtained. Firstly, an efficient processfor manufacturing corner beads at a low production cost is obtained. Also, the corner beadwhich is manufactured according to the disclosure can be securely attached to buildingconstructions having different types of surfaces, even surfaces being coated with dust anddirt. Furthermore, ï the corner bead can be handled by aperson in an easier and quicker way during mounting on a corner. Also, the choice ofadhesive element can be adapted to different temperatures, which simplifies the mounting of the corner bead.

According to an embodiment, the method comprises positioning the surface or surfaces which are coated with said hot melt adhesive along a further surface which is free from said hot melt adhesive; and arranging said protective laver generallv across the combined width of the hot melt adhesive and said further surface.

According to an embodiment, the method comprises arranging said first flange and said second flange with an angle in relation to each other which is between 85° and 95°.

According to an embodiment, the method further comprises: providing a third surface on said first flange which is not facing said building construction; providing a fourth surface on said second flange which is not facing said building construction; and covering at least one of said third surface and said fourth surface with an absorbing surface laver which is configured for absorbing compound.

According to an embodiment, the method further comprises: providing a pattern of perforations on at least one of said first flange and said second flange, said perforations extending generallv along the longitudinal direction of said flange or flanges.

According to an embodiment, the method further comprises manufacturing said corner bead at least partlv from a biodegradable plastic material.

Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in greater detail below with reference to the figures shown in the appended drawings.

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 shows a perspective view of a building construction on which a corner bead according to the disclosure is mounted; shows a perspective view of a part of the corner bead; shows a further perspective view of a part of the corner bead according to Figure 2; is a cross-sectional view of the corner bead according to Figures 2 and3; and is a view of the corner bead showing in particular a pattern of perforations of the corner bead.

DESCRIPTION OF EMBODIMENTS Different aspects of the present disclosure will now be described more fully with referenceto the enclosed drawings. The embodiments disclosed herein can, however, be realized inmany different forms and should not be construed as being limited to the aspects described below.

With initial reference to Fig. 1, there is shown a perspective view from above of a buildingconstruction 1 comprising a number of wall elements 2, suitably in the form of gypsum orplasterboard wallboard elements which are attached to a support structure 3. The buildingconstruction 1 as such is well-known and is for this reason not described in further detail here.

The building construction 1 is designed with an outwardly facing corner 4, i.e. extendingalong a corner where two wall elements 2 meet. As mentioned initially, it is known thatsuch an outside corner 4 may be exposed to damage. ln order to provide reinforcement ofthe outside corner 4, and to make the outside corner 4 look tidy and of high quality, acorner bead 5 is mounted on the outside corner 4. This is done prior to further surface treatment such as painting or attaching wall-paper.

E corner bead 5 which is manufactured bv means of the method according to the disclosure is formed as alongitudinally extending element having a first flange 6 and a second flange 7 which areconfigured generally with an L-shaped cross-section. As further disclosed in Fig. 2, whichis a perspective view of an end section of the corner bead 5 the first flange 6 has a first inner surface 8 and the second flange 7 has a second innersurface 9. The first and second inner surfaces 8, 9 are intended to face the buildingconstruction 1 when the corner bead 5 is mounted by attaching it as intended on the corner 4, and as shown in Fig. 1.

With particular reference to Fig. 2, the first inner surface 8 and the second inner surface 9are both covered with an adhesive element, suitably in the form of a hot melt adhesive 10.According to alternative embodiments, the adhesive element 10 can be applied on eitherone of the first inner surface 8 or the second inner surface 9. Also, the hot melt adhesive can be of a type which comprises ethylene-vinyl acetate (EVA), resin and wax. lt should be noted that although the embodiment in Figs. 1 and 2 is directed to a cornerbead 5 which is configured for mounting on an outside corner 4, the disclosure alsoincludes embodiments involving a corner bead 5 which can be mounted on an inner, orinternal, corner 4' as indicated in Fig. 1. ln such case, an adhesive element is applied on the reverse side of each flange.

Furthermore, with reference to Fig. 3, which is a perspective view of the corner bead 5from a different angle as compared with Fig. 2, there is shown an embodiment in which aprotective layer 11 is used for applying and supporting the adhesive element 10. Moreprecisely, an adhesive element such as a layer of hot melt adhesive 10 is first applied onthe protective layer 11. The protective layer 11 is subsequently applied on the secondinner surface 9. ln this manner, the second inner surface 9 will be coated with the hot meltadhesive 10. Also, the protective layer 11 should be peeled away and removed before attaching the corner bead 5 to a corner 4 of a building construction 1.

Fig. 3 is a simplified drawing which shows only one protective layer 11, i.e. which ispositioned along the second flange 7. lt should be noted that a further protective layer withan adhesive element can be applied on the first inner surface 8 in a similar manner as described above.

As will be described below, the corner bead 5 can be attached to an outside corner 4 of abuilding construction 1 (see Fig. 1) by means of the adhesive element. After attaching thecorner bead 5 to the building construction 1, compound will be applied in one of morelayers so as to produce an even surface of the building construction 1 including the corner4. After applying compound, the wall elements in question can then be painted or be provided with wallpaper, in a manner which is well-known as such.

According to an embodiment, the protective layer 11 is in the form of a paper strip whichis coated with a thin surface layer of silicone. According to an alternative embodiment, the protective layer can be in the form of a thin sheet of plastic material.

Furthermore, according to the embodiment shown in Fig. 3, the second inner surface 9 isconfigured in a manner so that the hot melt adhesive 10 covers generally the entire second inner surface 9 with the exception of a further surface 12. This further surface 12 is formed as a relatively narrow and longitudinally extending strip which is free fromadhesive and which suitable extends along the inner corner of the corner bead 5, i.e.where the first flange 6 and the second flange 7 meet. The width of the further surface 12is suitably a few millimetres, as compared with the width of the entire second innersurface 9, which is suitably within the interval 30-50 mm. lt should be noted that theprotective layer 11 extends across the entire second inner surface 9, i.e. generally acrossthe combined width of the hot melt adhesive 10 and the above-mentioned further surface12. The part of the protective layer 11 which is located on top of the further surface 12 willdefine a “finger grip” part of the layer 11. ln this manner, a process of peeling off andremoving the protective layer 11 before attaching the corner bead 5 to the building construction 1 can be further simplified.

According to an embodiment, the corner bead 5 is configured so that the first flange 6 andthe second flange 7 are arranged with an angle in relation to each other which is within aninterval between 85° and 95°. ln the event that the corner bead 5 is used in an internalcorner 4', the angle between the first and second flanges is preferably within an interval of93° and 95°.

Also, the corner bead 5 is also suitably provided with a slightly rounded corner strip 13,i.e. a so-called “nose”, which extends generally along the entire length of the corner bead5. The provision of such a corner strip 13 simplifies the process of applying compound on the corner bead 5 after attaching it to the building construction 1.

Furthermore, the first flange 6 is formed with a third surface 14 which is not facing saidbuilding construction and the second flange 7 is formed with a fourth surface 15 which isnot facing said building construction. At least one of the third surface 14 and the fourthsurface 15 is covered with an absorbing surface layer 16 which is configured forabsorbing compound during the process of preparing an even wall element after attachingthe corner bead 5. According to an embodiment, the absorbing surface layer 16 coversgenerally the entire third surface 14 and fourth surface 15, i.e. it extends over the cornerstrip 13. An advantage of using the absorbing surface layer 16 is that the corner bead 5 will be tightly attached to the building construction in question after applying compound.

Furthermore, as indicated in Figs. 2 and 3, the first flange 6 and the second flange 7 are provided with a pattern of perforations 17. This pattern extends generally along the entire length of the corner bead 5. By providing this pattern of perforations 17, the corner bead 5can be attached more securely to the surface of the building construction 1 sincecompound will more easily penetrate through the corner bead 5 and reach the surface of the corner 4, while also covering the corner bead 5.

According to an embodiment, the corner bead 5 is manufactured from a plastics materialsuch as ABS plastics. According to a further embodiment, the corner bead 5 ismanufactured from a biodegradable plastic material, which is an advantage from anenvironmental point of view. Such a material can be based on a composition comprisingbiodegradable polyester, starch, a filler material and a binding agent, in suitableproportions. As regards the filler material, such material can according to an embodimentcomprise dolomite in the form of particles with a polished surface. A further advantage ofusing a biodegradable material for the corner bead 5 is that it can be manufacturedslightly thinner than the embodiment involving an ABS plastics material. This will simplifythe process of applying compound and also means that less compound material has to be used, which is a further advantage.

Fig. 4 shows a cross-sectional view of the corner bead 5 according to an embodiment ofthe disclosure. As indicated, the corner bead 5 comprises a first flange 6 and a secondflange 7 on which a layer of adhesive material 10 is applied. A protective layer 11 isprovided on top of the adhesive material 10. lt should be noted that Fig. 4 shows anembodiment in which both the first flange 6 and the second flange 7 supports a layer of adhesive material 10 and a protective layer 11.

Furthermore, a thin strip corresponding to the above-mentioned further surface 12 isprovided, wherein the further surface 12 is free from adhesive material. Also, a cornerstrip 13, or “nose”, is provided where the first flange 6 and second flange 7 meet. The firstflange 6 has a third surface 14 facing away from the building construction in question (notshown in Fig. 4) and the second flange 7 has a fourth surface 15 facing away from thebuilding structure. An absorbing surface layer 16 is provided along the third surface 14and the fourth surface 15. Finally, a pattern of perforations 17 is arranged on the first flange 6 and the second flange 7.

Fig. 5 shows a view of the corner bead 5 in which the pattern of perforations 17 is shown in detail. According to an embodiment, the perforations 17 are provided in the form of a number of columns 18, for examples three columns 18 as shown in Fig. 5, which columns18 are sligthly offset in relation to each other. Also, the columns 18 of perforations 17 are concentrated to the outer section of the second flange 7. ln this manner, the corner bead can be securely fitted to a building construction while covering it by means of compound.

Fig. 5 shows a view which only discloses perforations 17 in the second flange 7. lt shouldbe noted, however, that according to an embodiment, a similar pattern of flanges is provided in the first flange 6 too.

According to the disclosure, there is alse provided a process for manufacturing a cornerbead 5 as described above. Such a manufacturing process is initiated by providing thefirst flange 6 and the second flange 7, and also arranging the first flange 6 and the secondflange 7 in a configuration having a longitudinal extension and with a generally L-shapedcross-section. Such a process step is carried out by extrusion of a suitable material, for example an ABS plastic material.

Furthermore, the adhesive element 10 is provided on the surfaces 8, 9 of the first flange 6and the second flange 7 which face the corner 4 of the building construction 1. This isachieved by first attaching the adhesive material 10 to the protective layer 11 and thenattaching the protective layer 11 on the above-mentioned surfaces 8, 9. This means that a certain amount of the adhesive material will adhere to said surfaces 8, 9.

Next, the absorbing surface layer 16 is attached to the outside of the corner bead 5, i.e. tothe third surface 14 and fourth surface 15 which do not face the building construction.According to an optional process step, the corner bead 5 is then marked with a suitablelogotype, product number etc., after which the above-mentioned perforation 17 are formed. Finally, the corner bead 5 is cut to a suitable length.

The invention is not limited to the embodiment but can be varied Within the scope of theappended claims. For example, the shape, length and thickness of the flanges 6, 7 mayvary. Also, other parameters such as the pattern of perforations and the area of the adhesive element may also vary. 11 Furthermore, the corner bead can be attached to both outside and inner corners. ln theevent that the corner bead is used in an internal corner, the adhesive element (with theprotective layer) and the absorbing surface layer must be positioned on the reverse sidesof the flanges as compared with the disclosure above, which describes a corner bead for an outside corner.

Claims

1. RX Datelïime 12 aug 2019 13255202 PJJÛ44/9 13:55 +463Û216705Westpatent +46302167D5 2019M18! 12 P10229SE2019-08-12 CLAiMS1.

2. A corner bead (5) for mounting on an lntemai or external comer of a buildingconstruction (1), said corner bead (5) comprising a ﬁrst ﬂange (6) and a second ﬂange (7)which are conflgured with a iongitudinai extension and a generally L-shaped cross-section. characterized in that said ﬁrst fianga (6) has a ﬁrst surface (8) intended forfacing sid building construction and said second ﬂange (7) has a second surface (9) alsointended for facing said building construction, wherein at least one of said ﬁrst surface (8)and said second surface (9) is at least partially coated with an adhesive element (10)_andr ' 'd adhesive ' ' the form f t esive 10 whi ' 'ed on a protective layer (11), which in tum i; applied on said at least egg gi said ﬁrst surface 8 and sal ds rface 9 wh' ' ereb coated wlths ' dhesive 10.

3. 23. A corner bead (5) according to olaim _1_2, wherein said protective layer (11) isconstltuted by a siliconized paper strip. 3_

4. A corner bead (5) according to olaim lgLgjl-er-â, wherein the surface or surfaceswhich are coated with said hot melt adhesive (10) are positioned so as to deﬂne a furthersurface (12) which is free from said hot melt adhesive (10), and that said protective layer(11) extends generally across the combined width of the hot melt adhesive (10) and saidfurther surface (12). 1

5. A comer bead (5) according to any one of olaim J§_2-4, wherein said hot meltadhesive (10) comprises ethylene-vlnyi acetate (EVA), resin and wax. 5_

6. A comer bead (5) according to any one of the preceding ciaims, wherein said ﬁrstﬂange (6) and said second ﬂange (7) are arranged with an angle in relation to each otherwhich is between 85° and 95°. 6_¥. A comer bead (5) according to any one of the preceding clalms, wherein said cornerbead (5) is provided with a siightly rounded comer nosa (13) located where the ﬁrst ﬂange RX Dâtefïime 12 aug 2019 13255202 2Û19IÛBI12 13255 1-4630216705 P.ÛÛ5Westpatent + 4630216705 5/9P1 0229SE2019-05-122 (6) and the second fiange (7) meet, and extendlng generally along the entire length of thecomer bead (5). LS. A corner bead (5) according to any one of the preceding claims, wherein said firstﬂange (6) has a third surface (14) which is not facin said building construction (1) andsaid second fiange (7) has a fourth surface (15) which is not facing said buildingconstruction (1), wherein at least one of said third surface (14) and said fcurth surface(15) is covered with an absorbing surface layer (16) which is configured for absorbingcompound during attachment of the corner bead (5) to the building construction (1). §_8. A comer bead (5) according to any one of the preceding ciaims, wherein at least oneof said ﬁrst ﬂange (6) and said second ﬂange (7) is provided with a pattern of perforatlons(17) extending generally along the iongltudlnal direction of said ﬂange or ﬂanes. 1-19. A corner bead (5) according to any one of the preceding ciaims, said corner bead(5) being manufactured at least partly from a biodegradable plastic material. _1_q_-1-=i-. Method for manufacturing a corner bead (5) conﬁgured for mounting on an Internalor external comer (4) of a building construction (1), comprising: - providing a ﬁrst ﬂange (6) and a second ﬂange (7); and - arranging the ﬁrst fiange (6) and the second fiange (7) in a conﬁguratlon having aionitudinai extension and with a generally L-shaped cross-section, characterized in that the method further comprises: - forming said ﬁrst ﬂange (6) with a ﬁrst surface (8) which is oonflgured for facing saidbuilding construction (1): - forming said second fiange (7) with a second surface (9) which is also configured forfacing said building construction (1): and - coating at least one of said ﬁrst surface (8) and said second surface (9) at least partiilywith an adhesive element (10); id adhesive element in h layer (11) and- agglying said grotggjjyg layer (11) on said at least one gf said ﬁßt ggçfage (5) and saidsecond surfacg (Q) whiglg i§ theregy coated with ggig hg; mgit aghggiyg (]Q). -a ' otmeitadhesive 10 ona r iva RX Dateiïime 12 aug 2019 13:55:02 PJJÛE6/9 13:55 +46302167Û5Westpatent *4630216705 2019103112 P1 O229SE2019-08-12 1143. A method according to claim 1g-1-2, said method further comprising: - positioning the surface or surfaces (8; 9) which are coated with said hot melt adhesive(10) along a further surface (12) which is free from said hot malt adhesive (10); and - arranging said proteotlve layer (11) eneraliy across the combined width of the hot maltadhesive (10) and said further surface (12). 244. A method according to any one of clalms 10 951] 9-44, said method furthercomprising: - arrnging said ﬁrst fianga (2) and said second ﬂange (3) with an angle in relation to eachother which is between 85* and 95"”. _1146. A method accordin to any one of ciaims _1_E_2_44-44, said method furthercomprising: - providing a third surface (14) on said ﬂrst ﬂange (6) which is not facing said buildingconstruction (1); - providing a fourth surface (15) on said second ﬂange (7) whloh is not facing said buildingconstruction (1 ); and - coverlng at least one of said third surface (14) and said fourth surface (15) with anabsorbin surface layer (16) which is conﬁgured for absorbing compound. 3-16. A method according to any one of claims 1Q_-ﬁ_-1-1-1-5, said method furthercomprising: - providing a patiam of perforations (17) on at least one of said ﬁrst ﬂane (6) and saidsecond flange (7), said perforations (17) extending generally along the Iongitudinaldirection of said ﬂange or ﬂangas (6; 7). Ji-'l-ï. A method according to any one of claims 10-14 44-16, said method furthercomprising:~ manufacturing said comer bead (5) at least partly from a biodegradabie plastlc material.