WO2003076732A1 - Improved apparatus for forming a corner of a wall - Google Patents

Improved apparatus for forming a corner of a wall Download PDF

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Publication number
WO2003076732A1
WO2003076732A1 PCT/US2003/006804 US0306804W WO03076732A1 WO 2003076732 A1 WO2003076732 A1 WO 2003076732A1 US 0306804 W US0306804 W US 0306804W WO 03076732 A1 WO03076732 A1 WO 03076732A1
Authority
WO
WIPO (PCT)
Prior art keywords
central portion
right lateral
lateral portions
sheets
corner
Prior art date
Application number
PCT/US2003/006804
Other languages
French (fr)
Inventor
Mark Spurlock
Rick Chamberlain
Original Assignee
Mark Spurlock
Rick Chamberlain
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mark Spurlock, Rick Chamberlain filed Critical Mark Spurlock
Priority to AU2003216529A priority Critical patent/AU2003216529A1/en
Publication of WO2003076732A1 publication Critical patent/WO2003076732A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • E04F13/06—Edge-protecting borders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • E04F13/06—Edge-protecting borders
    • E04F13/068—Edge-protecting borders combined with mesh material or the like to allow plaster to bond therewith
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • E04F13/06—Edge-protecting borders
    • E04F2013/063—Edge-protecting borders for corners

Definitions

  • This invention is related to the forming of a corner of a wall, particularly a wall made of sheet rock, also known as gypsum board.
  • the wall frames are often covered with sheets of a gypsum material known as sheet rock. After the panels are mounted on the wall, the seams are taped and spackled and the corners finished with a tape or a corner forming member. If using a corner forming member, it can be very difficult to accurately place the corner member and retain it in place while it is spackled into place. A need therefore remains for an apparatus that reliably and easily defines a corner when building a wall.
  • the present invention is embodied in an improved corner member that can be readily and easily placed and retained on a "raw" corner, and then spackled with a joint compound to permanently bond the corner member to the wall and form a smooth finished surface.
  • One preferred embodiment of the invention is shown in the accompanying drawings, and generally comprises a central member formed into the shape of a finished corner, i.e., either round or squared.
  • each vertical edge of the central member Extending from each vertical edge of the central member is a strip of mesh.
  • an adhesive that temporarily bonds the corner member to the wall boards until the joint compound is applied and dried.
  • the mesh rests on the surface of the adjacent wall board panel, and is embedded in the joint compound to permanently bond the corner member to each adjacent wall board.
  • the adhesive is selected to remain tacky after initial application to the corner member, and to adhere to the underlying wallboard.
  • the corner members are preferably formed of a polymeric material such as a thermoplastic.
  • the mesh strip is preferably formed of commercially available polymeric mesh. In a preferred embodiment, the mesh strip and the central member are co-extruded to embed the mesh in the central portion of polymeric material.
  • the mesh strip is permanently embedded in the central member.
  • the mesh strip is inset from the upper surface of the central member to provide a surface and space for the joint compound to meet smoothly with the central member.
  • the mesh is adhered to the central member by adhesive, welding or any other suitable means.
  • the corner members are provided in precut lengths that correspond to standard wall heights, facilitating ready corner formation without the need for unnecessary trimming, and contributing to higher production rates when utilizing the invention.
  • Some preferred embodiments are pre-formed to common architectural angles such as 90 ° and 135°, but any suitable angle can be selected.
  • the central portion is flat, and is formable to essentially any angle for use in ceiling peaks for example.
  • Fig. 1 is a perspective view of a first embodiment of the invention and for use in forming a 90° square corner.
  • Fig. 2 is a perspective view of a second embodiment of the invention and for use in forming a rounded 90° corner.
  • Fig. 3 is a perspective view of a second embodiment of the invention and for use in forming a 135° corner.
  • Fig. 4 is a perspective view of a second embodiment of the invention and for use in forming a rounded 135° corner.
  • Fig. 5 is a cross-sectional view of the embodiment shown in Fig. 1.
  • Fig. 6 is a cross-sectional view of the embodiment shown in Fig. 1, and attached to the sheets of building material.
  • Fig. 7 is a cross-sectional view of another preferred embodiment in which the central portion is flat, and is bendable to conform to nearly any angle Detailed Description of the Preferred Embodiments
  • Central portion 12 is preferably formed from a molded thermoplastic material, although any other suitable material could also be used.
  • central portion 12 is formed at a right angle to define a right angle corner of a wall.
  • the corner can be a rounded 90° corner (Fig. 2), or an angled or rounded 135° corner (Fig.'s 3 and 4 respectively).
  • Other corner profiles and angles are also possible and are only limited by the architect's needs and imagination.
  • Lateral portions 14 and 16 are preferably formed of a fiberglass mesh and are attached to central portion 12 by being molded into or co- extruded with the central portion as it is being manufactured.
  • a mold (not shown) is provided with a central void defining the finished shape of the central portion 12. Adjacent the central void in the mold are left and right recesses sized to receive the precut mesh lateral portions. The inner edge of each precut mesh lateral portion extends into the central void. When molten material is introduced into the mold the edge of the precut mesh lateral portions is engulfed by molten material and permanently embedded there as the molten material cools and hardens.
  • a mesh strip is co-extruded through a die and embedded in the central portion 12 as it is extruded through an extrusion die.
  • the mesh is a single strip that protrudes from each edge of the central body 12.
  • Fig. 5 is a cross-sectional view of the embodiment shown in Fig. 1 , and including central portion 12 and lateral portions 14 and 16.
  • the outer surfaces 18 and 20 of lateral portions 14 and 16 respectively are recessed from the outer surface 22 of central portion 12 to form a recess into which spackling 25 (joint compound) is placed to finish the joint.
  • spackling 25 joint compound
  • Fig. 6 shows the finished corner in cross section, • including the left and right sheets of building material 28 and 30, central portion
  • each of the lateral portions 14 and 16 is filled with a spackling compound (joint compound) 34 that covers the seams and forms a finished outer surface between the central portion 12 and the sheets of building material.
  • this invention includes embodiments that form any desired angle between adjacent sheets, and any corner profile, e.g. rounded, squared, oblique, etc.
  • the central portion 12 is formed in a flat configuration and includes the protruding mesh lateral portions 14 and 16 as described above.
  • the mesh 35 is a single piece with a first portion 35 embedded in central portion 12 and lateral portions 14, 16 extending from the central portion.
  • Central portion 12 is flexible and can therefore be bent to nearly any desired angle to accommodate installation along roof peaks and other areas that do not conform to normal 90° or 135 ° angles.
  • a notch 38 is formed in central portion 12 to enhance the flexibility of the central portion.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

A corner forming device having a central portion and left and right lateral portions for forming a wall corner. The left and right lateral portions are preferably a mesh material permanently bonded to the central portion, and slightly recess from the central portion to form a recess spackling compound is placed to finish the corner.

Description

Improved Apparatus for Forming a Corner of a Wall
Cross-Reference to Related Application
This application is a continuation-in-part of U.S. provisional patent application, serial No. 60/361,848, filed on March 4, 2002. The priority of the prior application is expressly claimed and its disclosure is hereby incorporated by reference in its entirety. Background of the Invention
This invention is related to the forming of a corner of a wall, particularly a wall made of sheet rock, also known as gypsum board.
When finishing the interior of a building, the wall frames are often covered with sheets of a gypsum material known as sheet rock. After the panels are mounted on the wall, the seams are taped and spackled and the corners finished with a tape or a corner forming member. If using a corner forming member, it can be very difficult to accurately place the corner member and retain it in place while it is spackled into place. A need therefore remains for an apparatus that reliably and easily defines a corner when building a wall. Summary of the Invention
The present invention is embodied in an improved corner member that can be readily and easily placed and retained on a "raw" corner, and then spackled with a joint compound to permanently bond the corner member to the wall and form a smooth finished surface. One preferred embodiment of the invention is shown in the accompanying drawings, and generally comprises a central member formed into the shape of a finished corner, i.e., either round or squared.
Extending from each vertical edge of the central member is a strip of mesh. On the inner surface of the central member and/or the mesh strips is an adhesive that temporarily bonds the corner member to the wall boards until the joint compound is applied and dried. The mesh rests on the surface of the adjacent wall board panel, and is embedded in the joint compound to permanently bond the corner member to each adjacent wall board. The adhesive is selected to remain tacky after initial application to the corner member, and to adhere to the underlying wallboard. The corner members are preferably formed of a polymeric material such as a thermoplastic. The mesh strip is preferably formed of commercially available polymeric mesh. In a preferred embodiment, the mesh strip and the central member are co-extruded to embed the mesh in the central portion of polymeric material. As the heated and softened polymeric material cools and hardens, the mesh strip is permanently embedded in the central member. In a preferred embodiment, the mesh strip is inset from the upper surface of the central member to provide a surface and space for the joint compound to meet smoothly with the central member. In other embodiments, the mesh is adhered to the central member by adhesive, welding or any other suitable means.
The corner members are provided in precut lengths that correspond to standard wall heights, facilitating ready corner formation without the need for unnecessary trimming, and contributing to higher production rates when utilizing the invention. Some preferred embodiments are pre-formed to common architectural angles such as 90° and 135°, but any suitable angle can be selected. In another preferred embodiment, the central portion is flat, and is formable to essentially any angle for use in ceiling peaks for example.
These and other features of the invention will be described in detail by reference to the drawings. Brief Description of the Drawings
Fig. 1 is a perspective view of a first embodiment of the invention and for use in forming a 90° square corner.
Fig. 2 is a perspective view of a second embodiment of the invention and for use in forming a rounded 90° corner.
Fig. 3 is a perspective view of a second embodiment of the invention and for use in forming a 135° corner.
Fig. 4 is a perspective view of a second embodiment of the invention and for use in forming a rounded 135° corner.
Fig. 5 is a cross-sectional view of the embodiment shown in Fig. 1.
Fig. 6 is a cross-sectional view of the embodiment shown in Fig. 1, and attached to the sheets of building material.
Fig. 7 is a cross-sectional view of another preferred embodiment in which the central portion is flat, and is bendable to conform to nearly any angle Detailed Description of the Preferred Embodiments
Referring now to Fig. 1 , a preferred embodiment of the invention is shown at 10, and includes central portion 12 and left and right lateral portions 14 and 16 respectively. Central portion 12 is preferably formed from a molded thermoplastic material, although any other suitable material could also be used. In this embodiment central portion 12 is formed at a right angle to define a right angle corner of a wall. In other embodiments the corner can be a rounded 90° corner (Fig. 2), or an angled or rounded 135° corner (Fig.'s 3 and 4 respectively). Other corner profiles and angles are also possible and are only limited by the architect's needs and imagination. Lateral portions 14 and 16 are preferably formed of a fiberglass mesh and are attached to central portion 12 by being molded into or co- extruded with the central portion as it is being manufactured. For example, in one method of forming the apparatus a mold (not shown) is provided with a central void defining the finished shape of the central portion 12. Adjacent the central void in the mold are left and right recesses sized to receive the precut mesh lateral portions. The inner edge of each precut mesh lateral portion extends into the central void. When molten material is introduced into the mold the edge of the precut mesh lateral portions is engulfed by molten material and permanently embedded there as the molten material cools and hardens. The mesh lateral portions 14 and 16 are thereby permanently mounted to the central portion 12. In another method of manufacturing the invention, a mesh strip is co-extruded through a die and embedded in the central portion 12 as it is extruded through an extrusion die. In this embodiment the mesh is a single strip that protrudes from each edge of the central body 12.
The corner forms of this invention are preferably precut to lengths corresponding to standard or common wall heights to minimize the trimming necessary during installation, although the invention is not limited to any specific dimension, and could also be provided in bulk roll form. Turning now to Fig.'s 5 and 6, the mounting of the apparatus to the sheets of building materials will be described in greater detail. Fig. 5 is a cross-sectional view of the embodiment shown in Fig. 1 , and including central portion 12 and lateral portions 14 and 16. In this embodiment, the outer surfaces 18 and 20 of lateral portions 14 and 16 respectively are recessed from the outer surface 22 of central portion 12 to form a recess into which spackling 25 (joint compound) is placed to finish the joint. On the inner surfaces 24 of the left and right lateral portions is a contact adhesive 26. Fig. 6 shows the finished corner in cross section, • including the left and right sheets of building material 28 and 30, central portion
12, and lateral portions 14 and 16. Lateral portions 14 and 16 are adhered to the respective left and right sheets of building material by adhesive 26. While in the preferred embodiment adhesive 26 is a contact adhesive, any suitable adhesive in any suitable form (tape, liquid, solid) can be used. The recess portion of each of the lateral portions 14 and 16 is filled with a spackling compound (joint compound) 34 that covers the seams and forms a finished outer surface between the central portion 12 and the sheets of building material.
As mentioned above, this invention includes embodiments that form any desired angle between adjacent sheets, and any corner profile, e.g. rounded, squared, oblique, etc. Referring to Fig. 7, in one such embodiment the central portion 12 is formed in a flat configuration and includes the protruding mesh lateral portions 14 and 16 as described above. In the illustrated embodiment the mesh 35 is a single piece with a first portion 35 embedded in central portion 12 and lateral portions 14, 16 extending from the central portion. Central portion 12 is flexible and can therefore be bent to nearly any desired angle to accommodate installation along roof peaks and other areas that do not conform to normal 90° or 135° angles. In the embodiment shown a notch 38 is formed in central portion 12 to enhance the flexibility of the central portion.
The invention has been described by reference to preferred embodiments. Those skilled in the art will appreciate that the invention as described can be modified in detail and material of construction without departing from the scope of the claimed invention.

Claims

What is Claimed is:
1. An apparatus for forming a corner joining two sheets of building material comprising: an elongate body having a central portion and left and right lateral portions, the left and right lateral portions disposed at an angle relative to each other and to the central portion; the central portion having an outer surface in a predetermined shape that defines a boundary between adjacent sheets of building material; each left and right lateral portion having an inner surface shaped to overlay a portion of respective left and right sheets of building material, and having an outer surface that is adapted to receive a joint compound.
2. An apparatus according to claim 1 wherein the outer surfaces of the left and right lateral portions are recessed relative to the outer surface of the central portion.
3. An apparatus according to claim 1 wherein the left and right lateral portions are formed of a foraminous material.
4. An apparatus according to claim 3 wherein the foraminous material is a mesh material.
5. An apparatus according to claim 1 wherein the outer surface of the central portion defines an angled corner between the left and right sheets of building material.
6. An apparatus according to claim 1 wherein the outer surface of the central portion defines a rounded surface between the left and right sheets of building material.
7. An apparatus according to claim 1 which is formed from a moldable material.
8. An apparatus according to claim 1 wherein the angle between the left and right lateral portions is between about 22° and 150°.
9. A wall comprising: first and second adjacent sheets of building material; a corner member attached to the first and second sheets of building material, the corner member including an elongate body having a central portion and left and right lateral portions, the left and right lateral portions disposed at an angle relative to each other and to the central portion; the central portion having an outer surface in a predetermined shape that defines a corner between the adjacent sheets of building material; each left and right lateral portion having an inner surface overlaying a portion of respective left and right sheets of building material, and having an outer surface; and, a joint compound covering the left and right lateral portions and at least a portion of each of the left and right sheets of building materials.
10. An apparatus according to claim 9 wherein the outer surfaces of the left and right lateral portions are recessed relative to the outer surface of the central portion.
1 1. An apparatus according to claim 9 wherein the left and right lateral portions are formed of a foraminous material.
12. An apparatus according to claim 10 wherein the foraminous material is a mesh material.
13. An apparatus according to claim 9 wherein the outer surface of the central portion defines an angled corner between the left and right sheets of building material.
14. An apparatus according to claim 9 wherein the outer surface of the central portion defines a rounded surface between the left and right sheets of building material.
15. An apparatus according to claim 9 which is formed from a moldable material.
16. An apparatus according to claim 9 wherein the angle between the left and right lateral portions is between about 22° and 150°.
17. An apparatus according to claim 9 wherein at least a portion of the inner surface of the left and right lateral portions includes an adhesive.
18. An apparatus according to claim 9 wherein at least a portion of the inner surface of the left and right lateral portions includes an adhesive.
19. An apparatus according to claim 9 wherein the left and right lateral portions are a flexible mesh material, and wherein a portion of each the left and right lateral mesh portions are embedded in the central portion.
20. An apparatus according to claim 1 wherein the left and right lateral portions are formed of a flexible mesh material, and wherein a portion of each the left and right lateral flexible mesh portions are embedded in the central portion.
21. An apparatus according to claim 1 wherein the predetermined angle is 180°, and wherein the central portion is flexible to conform to a plurality of angles.
22. An apparatus according to claim 21 wherein the central portion includes an elongated notch defining a hinge axis.
23. An apparatus according to claim 9 wherein the predetermined angle is 180°, and wherein the central portion is flexible to conform to a plurality of angles.
24. An apparatus according to claim 23 wherein the central portion includes an elongated notch defining a hinge axis.
PCT/US2003/006804 2002-03-04 2003-03-04 Improved apparatus for forming a corner of a wall WO2003076732A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003216529A AU2003216529A1 (en) 2002-03-04 2003-03-04 Improved apparatus for forming a corner of a wall

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36184802P 2002-03-04 2002-03-04
US60/361,848 2002-03-04

Publications (1)

Publication Number Publication Date
WO2003076732A1 true WO2003076732A1 (en) 2003-09-18

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PCT/US2003/006804 WO2003076732A1 (en) 2002-03-04 2003-03-04 Improved apparatus for forming a corner of a wall

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AU (1) AU2003216529A1 (en)
WO (1) WO2003076732A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007116198A1 (en) * 2006-04-10 2007-10-18 Nigel Aulton Elongate abutment member of plaster
US12071763B2 (en) 2021-07-29 2024-08-27 Kelby Robinson Drywall inserts and methods

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1804564A (en) * 1930-05-31 1931-05-12 Mcchesney David Exterior corner connection for wall boards
USD457658S1 (en) * 2001-07-25 2002-05-21 Continuous Coating Corporation Right angle drywall bead with perforated flaps
US6539680B2 (en) * 2000-05-17 2003-04-01 Phillips Manufacturing Co. Paper bead and trim

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1804564A (en) * 1930-05-31 1931-05-12 Mcchesney David Exterior corner connection for wall boards
US6539680B2 (en) * 2000-05-17 2003-04-01 Phillips Manufacturing Co. Paper bead and trim
USD457658S1 (en) * 2001-07-25 2002-05-21 Continuous Coating Corporation Right angle drywall bead with perforated flaps

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007116198A1 (en) * 2006-04-10 2007-10-18 Nigel Aulton Elongate abutment member of plaster
EA015214B1 (en) * 2006-04-10 2011-06-30 Найджел Олтон Elongate abutment member of plaster
US8117791B2 (en) 2006-04-10 2012-02-21 Tony Baccarini Abutment member
US12071763B2 (en) 2021-07-29 2024-08-27 Kelby Robinson Drywall inserts and methods

Also Published As

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