WO2005124054A1

WO2005124054A1 - A device and method for flush mounting air duct grates, electrical switch plates, electrical receptacle plates, electrical light fixtures and other drywall aperture covers on drywall surfaces using drywall bead

Info

Publication number: WO2005124054A1
Application number: PCT/CA2005/000922
Authority: WO
Inventors: William George Lennox; Llyod Murray Lennox; Jeffery Todd Williams
Original assignee: William George Lennox; Llyod Murray Lennox; Jeffery Todd Williams
Priority date: 2004-06-15
Filing date: 2005-06-15
Publication date: 2005-12-29
Also published as: CA2471528A1

Abstract

A device system and method for flush mounting aperture covers with finished drywall surfaces and which may be used to flush mount hot air exhaust grates, cold air intake grates, electrical light and receptacle boxes, light fixtures and access panel covers. The invention includes a bead plate or frame each side thereof having a sectional profile of a piece of corner bead comprising a bead along at least the front surface of the bead plate immediately adjacent the aperture opening and transitioning into edges of corner bead, substantially at 90° angles to each other. The corner bead may be attached to the corner bead is affixed to the outside surface of the drywall in typical fashion and is feathered into the surface of the drywall in typical fashion. The interior walls of the bead plate form a receptacle for an aperture cover, preferably with stops to aid in mounting the front surface of the aperture cover flush with the outside surface of a piece of drywall. The bead plate may be fixedly or removably attached to a piece of duct work, electrical box or other chamber.

Description

A Device for Flush Mounting Drywall Aperture Covers on Drywall Surfaces

Field of the Invention:

This invention relates generally to the finishing of apertures in drywall surfaces. In particular, the

invention relates to the finishing of an aperture in a drywall surface to accept a flush mounted cover

or insert therein.

Background of the Invention:

Since the construction of interior walls in homes and buildings with lathe and plaster became

virtually obsolete, the preferred material for the construction of walls, ceilings and other structures has been drywall. Drywall is typically sold in 4 x 8, 4 x 10, or 4 x 12 foot sheets, often in 3/8, y₂ and 5/8 inch thicknesses. The drywall sheets substantially comprise an outer paper or cardboard

cover and a gypsum interior making the drywall sheets significantly fire resistant. As the gypsum

in the centre of drywall sheets is substantially brittle the cardboard covering on one side of a sheet

of drywall may be scored with utility knife or other tool at which point the drywall can be bent along

the score thus breaking the inner drywall material, more or less along the line of the score. Once the

drywall has been broken into more or less the shape desired the paper or cardboard covering on the

opposite side of the sheet of drywall initially scored may be cut through with a utility knife or other

tool thus severing the sheet of drywall into two or more separate pieces.

Once drywall is cut into desired shapes and sizes, the drywall is typically attached to wooden studs or rafters in residential construction and to metal studding in commercial and industrial applications.

Drywall is usually attached to the substrate by special screws known as drywall screws. The sheets

of drywall which are usually sold flat provide the flat surfaces for the construction of rooms and the

like, which surfaces may be painted or otherwise finished with wall paper and/or the like and once

fully installed. The drywall screws typically hold the drywall firmly against the studding.

Once the drywall is securely in place, seams exist between sheets of drywall which are installed to

abut one another. Furthermore, there is the issue of covering drywall seams along edges such as ceilings, door frames, window frames and other openings. In order to make the surface of a wall,

ceiling or other surface appear continuous, drywall compound known in the trade as "mud" is applied to the cracks between the abutting sheets of drywall and between the end surfaces of drywall

and any surfaces against which the sides of drywall abut. Drywall tape is typically applied onto the joints where pieces of drywall abut while the drywall compound is still wet. The wet drywall compound holds the drywall tape in place, which drywall tape is substantially made of paper.

Alternatively, self adhesive drywall tape may be applied to the drywalls without drywall compound

being applied before application of the adhesive drywall tape. A additional layer or layers of drywall

compound is typically applied on top of the drywall tape once the original application has

substantially dried and "feathered" over both edges of abutting drywall sheets. When dry the

drywall compound may be sanded flat, thus providing a continuous surface from one drywall sheet

or surface to another. Drywall sheets thus finished may ultimately be primed and painted or

otherwise finished. However, drywall tape is typically not used alone to finish the outside corner of a joint formed by

two pieces of drywall typically abutting at a 90° angle. No matter how the abutting edges of the

drywall are broken or cut, a straight seam is rarely obtained. Accordingly, even if drywall tape is

used along an outside corner of a typically 90° angle the joint forming the substrate onto which the

tape must be applied may be uneven when finished. Furthermore, the edges of unreinforced drywall

tape is subject to significant tearing, bending and denting when the room in which the drywall is

located is in use. This is especially so when the drywall is along vertical outside edges, such as the

vertical outside edges of a doorway constructed of drywall where a multitude of objects may come

into contact with the outside comer of a typical 90° vertical drywall joint.

Accordingly, the use of what is known as "corner bead" developed in order to reinforce the edge of

drywall joined at an angle, typically 90°. A typical metal corner bead would be constructed of galvanized tin and longitudinally would have the profile of a 90° angle, with each of the sides of the

angle being approximately one inch, further comprising an outwardly projecting substantially

circular arc from each of the edges, such projecting arc being referred to as "bead".

Basic corner bead may be of metal, usually galvanized tin, or may be of a plastic. Metal comer bead

is usually held in place by drywall screws whereas plastic bead is typically held in place by glue or

contact cement. Once the corner bead is applied to the outside edge of a 90 ° drywall joint drywall

compound may be "feathered" over the joint from the crest of the bead over each of the flanges

continuing to and over the adjacent drywall surface. Each application of drywall compound is

typically sanded with additional coats of drywall compound being applied in order to fill in voids, cracks or otherwise provide for a smooth transitional plane from the adjoining drywall surface over

each of the bead corner bead flanges to the crest of the bead on the comer bead.

Typically several layers of drywall compound are applied over the installed corner bead, typically

at least three. A first coat is often made with a drywall compound known as setting compound

which is currently available under brand names such as "Durabond"™. Subsequent coats of drywall

compound are usually of a type referred to as finishing compound or topping compound which is

readily available under brand names such as "Synko"™ or "CGC³^. Thus finishing an outside

corner of a drywall joint in the indicated manner is quite time consuming especially while waiting

for each coat of drywall compound to dry before applying a fresh coat. This is in addition to the time required to sand each of the coats of drywall compound substantially flush with the outer surface of thedrywall surfaces being joined. Accordingly, such applications are usually only undertaken where finished surfaces are required.

Before drywall is installed air ducts are typically installed in walls and ceilings for the provision of

warm air from, and the return of cool air to, a furnace and/or air conditioner. Duct work is installed

in virtually all applications, the preferred method of heating being forced air heating. Duct work

would typically be installed by heating and cooling contractors.

Before drywall is applied, electrical boxes are also typically located throughout the walls, ceilings

and other surfaces. The electrical boxes are fed with the required type of electrical wiring for the

type of construction involved with the potentially live ends of the wire being capped off and left in empty electrical boxes. The electrical boxes could be for light or other switches. Electrical outlets,

connecting boxes to which light fixtures may be attached or potentially for utility boxes only

maintaining additional wiring for future use, if needed. Access holes are often cut in drywall as well

in order to have access to water valves and other equipment necessary to maintain a building.

Drywall is typically applied over the entirety of a room with holes being cut in the drywall either

before or after the drywall is attached to the studs, rafters or other supporting material. Given the

way in which the apertures in the drywall are created, and the composition of drywall itself, the

edges of the aperture in drywall adjacent air duct openings, electrical boxes and the like are not

easily finished. Furthermore, even if such edges could be finished, the aperture must be covered in

a manner accommodating the function of the covering.

Accordingly, the practise of the trade is to have the aforementioned apertures roughed out without

the edges being finished, the apertures being roughly the size of the air duct openings, electrical box

openings or other necessary openings. Air duct grills, switch plates, receptacle plates and utility

cover plates without apertures are typically then installed over the apertures on top of drywall

surfaces with the edges of the aperture covers concealing the rough edges of the drywall forming the

aperture. The aperture covers would typically be installed with screws.

Although a variety of aperture openings are commercially available in the marketplace either with

its own finish, or being capable of being painted, the aperture covers projecting from the walls,

ceilings or the like spoil the smooth surface of the walls, thus detracting from the look of the room to be finished. Although smaller apertures may exist in the aperture coverings such as for the flow of air or the projection of an electrical light switch or an electrical receptacle, the projection of the aperture covering is substantially more intrusive. Thus far, there has been no practical way to avoid protruding aperture covers on drywall surfaces.

Summary of the Invention:

It is therefore an object of the invention herein to provide a finished drywall aperture which may optionally accept a variety of fixed or removable aperture inserts such that the outer surface of the aperture inserts are substantially flush with the outer surface of the sheet or sheets of drywall through which the aperture is located.

Tn general fsp i&tTThe invention provides that cόriier bead be installed along the outer edges of the aperture to be partially or fully covered. Inside surfaces of comer bead are attached to outside surfaces of the drywall immediately surrounding the aperture in the usual manner used in the trade. Drywall compound is feathered from the crest of the comer bead over the edges of the comer bead and onto the adjacent surface of the drywall. As an angle from the surface of the finished drywall to the crest of the drywall bead is slight, the drywall surface finished with drywall compound from the crest of the comer bead, as feathered onto the adjacent drywall surfaces past the end of the bead flanges appear to be substantially flat.

Preferably, the co er bead bounding the outside edges of the aperture are integral or attached to one another to maintain a uniform bead height relative to each portion of comer bead bounding the aperture to be covered. Preferably the flange transitioning from one edge of the bead and to be

inserted into the drywall aperture forms a substantially rigid frame to maintain a consistent shape

to receive an insert of predetermined dimensions. Preferably the frame should also be sufficiently

rigid to maintain a substantially cavity for an insert. Although the insert may be made to any height

below or above the surface of the drywall in a room, the outside surface of the insert is preferably

flush with the outside surface of the finished drywall aperture. Preferably the frame comprises stops

preventing the insert from being inserted too far into the frame, thus aligning the front surface of the

insert with the outer surface of the finished drywall aperture. The aperture insert may be fixedly

attached but is preferably removably attachable. The insert may be fixedly held in the frame by any

traditional means including, but not limited to, welding, rivetting and glueing. The insert may be removably attachable by any usual means including, but not limited to, screws, bolts, clips, friction

fits, springs, magnets, hinges, etc.

In another aspect the flange is extending off the bead along each edge of the drywall aperture are

oriented slightly downwardly such that the interior angle of the comer bead is less than a right angle.

Preferably the comer bead flanges is extending outwardly from the drywall aperture to be covered

are not joined at each comer thus allowing the flanges to be mounted on the outside surfaces

surrounding the drywall aperture to separate at the comers when the frame further comprising the

perimeter bead and outwardly directed flanges to independently flex outwardly as the frame is

pushed inwardly into the drywall aperture thus permitting more accurate and easier installation of

the comer bead against a surface containing a drywall aperture, which surface is not completely flat.

Of course, the outwardly directed flanges to be attached to the outer surfaces of the drywall may be attached although this embodiment may not work as well.

In one aspect one or more pieces of comer bead may be installed against in a drywall aperture such

that the laterally extending flanges of the comer bead are finished in drywall fashion against the

outer surface of the drywall bounding the drywall aperture and with the remaining flange of the

comer bead having a lateral profile of substantially 90°, extending into the drywall aperture and

adapted to form a frame or cavity for a variety of inserts. The frame preferable comprises stop

means to align the front surface of an insert with the finished outer drywall surface bounding the

drywall aperture. The inserts may be fixedly attached or removably attachable depending on application. While the frame further comprising the outwardly extending bead and laterally

extending flanges may be used for any number of general applications they are particularly useful

for substantially all apertures which would be required in a drywall surface or to recess items which would ordinarily not be flushed with a drywall surface. These applications would include hot and cold forced air grates, electrical switch plates, electrical receptacle plates, utility box plates, access

panels, control panels, telephone jack plates, cable tv, jack plates, central vacuum cover plates,

thermostat recess plates, alarm and security recess plates, and the like. In this aspect, the frame and

bead flanges collectively referred to a bead plate may be constructed to accept various inserts of

standard pre-determined sizes, including length, width and depth or with respect to custom inserts

also a predetermined dimensions including length, width and depth.

In another aspect, the bead plate may be integral with or fixedly or removably attachable to apparatus

which would otherwise be separately mounted in, through, behind or approximate the drywall surface. These apparatus include hot and cold air duct openings, the electrical switch boxes,

electrical receptacle boxes, electrical utility boxes, telephone wiring boxes, ceiling or wall fans, pot

lights, light fixtures, control panel boxes, wiring boxes, etc.

Most commercially available comer bead may be used for the within embodiments, but plastic

comer bead is preferred due to pliability except where surrounding heat would require metal comer

bead such as around the opening of a pot light or other electric light fixtures.

The applications set out above and the embodiments referred to herein are intended to be illustrative only and are not intended to limit the scope of the invention in anyway.

Brief Description of the Drawings:

FIG. 1 is a longitudinal view of a typical piece of galvanized tin comer bead.

FIG 1 A is a fragmented side view of the piece of galvanized tin comer bead of FIG 1.

FIG.2 is a longitudinal view of a piece of plastic "L" bead with a bead projecting from the plane of only one side of the comer bead.

FIG. 2A is a fragmented side view of the piece of plastic L bead of Fig. 2.

FIG. 34s a longitudinal view of a piece of "J" bead.

FIG. 3 A is a fragmented side view of the J bead of Fig. 3.

FIG 4 is a longitudinal view of a piece of metal comer bead overlapped with drywall tape (paper

bead)..

FIG. 4A is a fragmented side view of the paper bead of Fig. 4. FIG 5 is a longitudinal view of a metal piece of comer bead with a stop edge and a safety edge. FIG. 5 A is a fragmented side view of the comer bead of Fig. 5.

FIG. 6 is a longitudinal view of a piece of paper bead showing the bead along only one edge of the comer bead with an overlay of drywall tape wrapped around one of the edges. FIG. 6A is a fragmented side view of the paper bead of Fig. 6.

FIG. 7 is a front view of a drywall aperture with comer bead along the four edges thereof. FIG. 8 is a sectional side view of the drywall aperture containing the comer bead of FIG. 7. FIG. 9 is a rear view of a bead plate with a frame. «_*.

FIG. 10 is a front view of a bead plate installed on a flat drywall surface. FIG. 10a is a longitudinal view of the preferred comer bead and related measurements. FIG. 11 is a rear view of a moulded or welded bead plate with frame reinforcement. TIG712 is a front view of a bead plate with an air grate insert. FIG. 13 is a side view of the bead plate and air grate insert of Fig. 12. FIG. 16 is a prior art hot air discharge boot. FIG. 16a is a prior art air duct cover assembly. FIG. 17 is a hot air discharge boot with integral bead plate. FIG. 18 is an alternate orientation of a prior art boot.

FIG. 19 is a front perspective view of a boot with removably attachable bead plate and insert stops. FIG. 20 is an alternate orientation of a hot air discharge boot with fixed or removably attachable bead plate.

FIG. 20a is a sectional top view of the boot of Fig. 20 with lateral insert stops. FIG. 21- is a front view of a bead plate for covering an electrical box and for mounting a receptacle or switch therein with a smaller than standard cover plate.

FIG. 21 a is a smaller than standard switch plate and switch plate cover.

FIG. 21b is a side view partially in section showing the switch and plate of FIG. 21a.

FIG. 21 c is a typical modem prior art electrical receptical.

FIG. 22 is a fragmented sectional top view of FIG. 21 showing environment.

FIG.23 is a bead plate to cover an electrical box and for inserting a receptacle or switch therein and

a standard sized switch or cover plate.

FIG. 24 is a sectional top view of the bead plate of FIG. 23 showing environment.

FIG. 26 is a front view of a combination bead plate and electrical box.

FIG. 27 is a rear view of the combination bead plate and electrical box of FIG. 26.

FIG. 28 is a bead plate for a circular pot light.

FIG. 29 is a side view of a combination bead plate and pot light.

FIG. 30 is a bead plate for a square or rectangular ceiling light.

FIG. 31 is a sectional fragmented side view of the bead plate of FIG. 30 and optional combination

light fixture.

FIG. 32 is a sectional top view showing a bead plate in use with abutting tiles.

Detailed Description of the Preferred Embodiments of the Invention:

The preferred embodiments will now be described with reference to the figures. FIG. 1 is a typical

prior art comer bead 36 typically made from galvanized tin with bead 37 and flanges 38. FIG. 1 a

shows a series of smaller holes 40 typically used to accept drywall screws and a series of larger holes

along the length of the flanges which are typically used to aid with retention of drywall compound

typically feathered from the crest of bead 37 over flange 38, past the flange edge 40a and smoothly transitioning into the outside surface of drywall 44a. Alternatively, the comer bead may be attached

to drywall by means of nails, glue, contact cement, staples or the like.

FIG.2 shows another typical prior art comer bead often made from plastic. Bead 43 is substantially

arc shaped from edge 42 such that the plane along flange 42 does not have portions of the bead on

both sides of the said plane. Flange 44 is installed against a drywall surface with drywall compound

being feathered from the crest 43a of bead 43 over flange 44 and onto the drywall substrate to which

the comer bead is attached. Edge 42 typically covers the end 42a of drywall sheet 44a.

FIG. 2a shows a plurality of holes to help adhere flange 44 to the surface of drywall 44a by collecting glue or spray contact cement used to adhere the lower surface of flange 44 to the outer surface 44a of a heated drywall. Hole 45 is also used to accumulate and hold drywall compound as

well.

FIG. 3 is another prior art comer bead 46 having a substantially semicircular bead 49 arching from

flange 50 and roundly transitioning into flange 48 whereby no part of bead 49 falls on both sides of

the plane created by flange 48. The end of flange 48 comprises a heal 47 resulting in a U shaped

cavity 49a which may be used to form a smooth edge over a piece of drywall typically sealing the

gypsum centre of a drywall panel between flange 50 and heel 47.

FIG. 3a shows flange 50 with a series of off set elongated slots for attaching the comer bead to

drywall and for catchment of excess glue or contact cement alternatively used for mounting the corner bead on drywall and for providing edges for gripping the drywall compound to be applied

over the comer bead and feathered over flange 50 and onto the face of the drywall sheet to which

the comer bead is being attached.

FIG. 4 shows an alternate comer bead 52 with a metal bead 56 comprising metal flanges 55 and 54,

which may be of different lengths. In this form of co er bead a drywall tape surface is placed over

the outside surfaces of the metal comer bead with the drywall tape surfaces extending past the edges

of the metal comer bead within. Drywall tape 53 over the comer be'ad is typically applied with wet

drywall compound over a comer surface and allowed to dry. A further layer of drywall compound

is used to tape edges 53 and feather the surface to be created by the drywall compound from bead 56 over the tape covering 53 and onto the adjacent drywall surface. FIG.4a shows bead 56 in side view showing paper flange 53 overlying metal flange 55.

FIG. 5 shows another prior art comer bead 57 wherein flange 59 has no bead extending from its

surface and does not intended to be feathered with drywall compound. Comer bead 57 has flange

59 which comprises a safety edge or bend to prevent users from injuring themselves against a sharp

edge which would otherwise be exposed. Bead 60 arcs into flange 61. Flange 61 is intended to be

feathered with drywall compounds over flange 61 and into the drywall surface. FIG. 5a shows

comer bead 57 with apertures 62 which again may be used to hold drywall screws and/or to act as

a gripping surface for drywall compound.

FIG. 6. shows an alternate form of comer bead 63 with metal flanges 66 and 65, often of differing depths. Flanges 65 and 66 are covered by paper covering 67 which wraps around the end of flange

65 with the end of paper covering 69 not being wrapped around the back of flange 66. Paper flange

69 is intended to be feathered from bead 68 over paper flange 69 onto the surface of the adjoining

drywall surface.

FIG. 7 shows an assembly of prior art comer bead 71 arranged to provide a substantially square or

rectangular aperture 73 into which an optional aperture insert 73 a may be placed. In this

embodiment metal comer bead is held in place preferably

of drywall screws

72, which are screwed into the drywall through apertures 39a. Alternatively, plastic or vinyl comer

bead may be used and held in place by glue or contact cement. Drywall comer bead 71 is then feathered from the crest of bead 37 over flanges 71a and onto the adjacent drywall surface. Interior flanges 38 forming a substantially square or rectangular cavity within which to place a full or partial

aperture cover over aperture 73 such that the optional aperture cover 73a, may be manually placed

flush with the drywall surface created by the said feathering.

Where comer bead is not designed to be feathered in two perpendicular planes the edge with the

bead projecting therefrom to be feathered from the crest of said bead over the said edge is referred

to as the fill edge. The edge of the comer bead which has no bead projecting outwardly from the

plane formed by the surface of the second edge is referred to as a stop edge. In the embodiments referred to herein comer bead with one fill edge and one stop edge is preferred in most applications herein as a smooth surfaces may be provided for the insertion of an insert. Comer bead atop each edge can be useful for seating retaining clips, risilient, spring loaded or otherwise. The comer bead shown in FIG. 7 is shown in sectional side view in FIG. 8. FIG. 8 shows drywall

screws 74 holding metal comer bead 71 in place for feathering. FIG. 8 shows a potential

configuration for heating duct 77 installed such that the heating duct work is extends substantially

to the outside surface of the drywall 75. Interior comer bead flange 38 is placed inside the duct work

in this embodiment allowing sheet metal screws 74a to further secure the comer bead by applying

said drywall screws or sheet metal screws through flange 38 and into the sheet metal surface of duct

77.

FIG. 9 shows another embodiment in which an integral frame 80a or bead plate 80 is created from one or more lengths of comer bead. Preferably one length of comer bead 57 as shown in FIG. 5 is

used to create the bead plate 80. Bead plate 80 is constructed by cutting through flange 61 from the edge of flange 61 to and through the entirety of bead 60. From the end of a length^~δf comer bead 57 at least four cuts through flange 60 are required to allow comer bead 57 to be bent to allow

interior flanges 59 of comer bead 57 to be bent along seams 78 resulting in a square or rectangular

frame 80a.. In this embodiment which contemplates bending flanges 59 metal comer bead would

be preferable as it tends to be more capable of maintaining flanges 59 at right angles at bends 78 .

At the time of making the fourth cut through flange 61 an additional length of flange 59 may be

retained before the material constituting frame 80a is cut from the rest of the comer bead by cutting

through flange 59. The tab may be bent along bend 78a allowing tab 79 to be fastened to flange 59a.

Tab 79 may be fastened to flange 59a by screws 81a or in any other traditional means such as

bolting, snapping, welding, gluing or other known means.

FIG. 1 Oshows frame 287 holding solid access panel 286 by means of a friction fit, such frame being bounded by bead 284 on all four sides of frame 287, frame 287 being permanently formed by stop

edges of comer bead joined at interior comers 288. Bead 284 and fill edges (flanges) 281 are

preferably not joined at comer edges 282 creating comer gaps 283 when bead 284 and fill edges are

attached to a flat drywall surface. Bead plate 280 is preferably made of plastic and comprise fill holes

285. _. _

FIG. 10a shows a preferred piece of comer bead 290 with bead 291 , fill edge 292, and stop edge 293

OH the overall height is preferably 114 inch but may be primarily useful from 3/16 inch to 5/8 inches

. BH bead height is preferably 1/16 inch but may be primarily useful from 1/16 inch to 1/8 inches. ER edge rise is preferably 3/16 inch but may be primarily useful from 1/8 inches to V% inches..

FIG. 11 shows another embodiment 80b of the bead plate of FIG. 9. While the bead plate of FIG. - 9 has the advantage of being able to be pre-manufactured with a bead plate with a fixed aperture

sized to avoiding the tedious and inaccurate installation of several pieces of comer bead along

different sides of a drywall opening, the bead 60 of each flange 51 of bead plate 80 do not mate at

bends78 resulting in an installer having to take some additional care at the comers. Furthermore,

the angles between each of the flange portions 59 may not be right angles without the installer '

bending the frame 80a accordingly during installation and securing flanges 61 only after the installer

has ensured that the comers of aperture 82 formed by flange portions 59 are in fact at right angles. ^'

Bead plate 81b overcomes some of the disadvantages of bead plate 80 by providing a substantially

continuous flange border of flanges 61 by cutting individual sections of comer bead outwardly and diagonally at approximately 45° angles along flange 61 and at 90° angles from the bead along

flanges 59. Flanges 61 would meet in an unstressed state but slightly spread when pressed flat and

adhered to a flat surface surrounding the drywall border. The seams 81 may alternately then be

welded along seams 81 and along seams 78 forming rigid aperture 82, however free flange ends .

generally mount better against an imperfectly flat drywall surface. The interior angles of said

aperture 82 are usually right angles. If Flanges 61 are not desired to be welded or otherwise joined

the frame formed by joining flanges 59 may be reinforced with triangle shaped supports, preferably

by welding for metal comer bead and by moulding for plastic corner bead. Alternatively, other

materials may be used.. Triangular supports 78a may also be placed strategically along the depth of the frame comprising flanges 59 to provide a stop which when an insert is placed into the frame the outer plane of the insert is aligned with the outer surface of the drywall aperture. Holes may also

be made in triangular support pieces to accept screws or bolts to hold an insert in place within a frame, from which bead and fill edges extend outwardly.

FIGS. 12 and 13 show another embodiment in which bead plate 83a retains a flush air grating 87

comprising air passages 89 and air passage dividers 88. Air grate 87 is held in place by means of

friction fit but may alternatively be held in place by screws, nuts and bolts, clips, springs or other

means which would preferably allow the air grate to be removable. Interior flanges 91 are provided

with a tab at the outer edge of flanges 91 which align the front surface of air grate 87 of

predetermined depth with the outer drywall surface created by feathering drywall compound from

the crest of bead 85 over flange 83 and smoothly positioning into the adjoining drywall surface.

Again, for further security, interior flange 91 may be equipped with drywall screws to attach same to duct work 94. Standard drywall screws or the like are preferable as screws with raised heads may

provide an obstruction for the insertion of air grate 87.

FIG. 16 shows prior art hot air discharge vent 105 for attachment to duct work in a hot air heating

system, such discharge vent 105 being commonly referred to as a "boot". Boot 105 typically has

a cylindrical intake aperture 107 a rectangular discharge aperture 106, sides 109 and a transition

body to convert the round air intake to the rectangular outlet. Typically boot 105 is mounted in a

ceiling, wall or floor with at least edges 109 being tacked to sur ounding studding, typically by

screws. Drywall is typically installed over top of discharge aperture 106 such that the drywall aperture is substantially the same size as discharge aperture 106.

FIG. 16a shows a typical cold air return cavity with surface mounted grill 201. Ducting is not always provided for cold air returns and often a hollow chamber between opposing inside drywall

surfaces 203, separated by studding 202 provides a channel 204 for the return of cold air to the

heating system through drywall aperture 199. A surface mounted grate 201 is then typically screwed into the drywall and preferably into the studding 202.

FIG. 17 shows modified boot 110a. with integral or attached bead plate 110b comprising four

flanges 111 and four beads 112. Preferably stops 117 are installed in all four interior comers of

aperture 106 at the required depth.so that the air grill is flush with the outer drywall surface in which the boot 110a is mounted. Boot 110a would typically be installed by providing round hot air discharge duct work, with a male

end in proximity to where an air duct boot is to be installed. Boot 110a is then installed through the

drywall aperture which the widest part of the boot may pass ,but which opening is not wide enough

for flanges 111 to pass. Inlet aperture 107 would be fed through the aperture in the drywall and

would be slid over the duct work for the supply of hot air, such connection preferably to be by

means of a friction fit. Once collar 110 containing aperture 107 is placed over the duct work to

supply the hot air, that portion of the back of the boot farthest from the round inlet collar is pushed

into the aperture in the drywall while continuing to urge the inlet cellar 110 of the boot 110a onto

the hot air supply ducting until the back side of flanges 111 are resting against the drywall against which the boot is to be secured. Back wall 109a is angled toward the inlet collar from abutting flange 111 sufficiently to allow back edge 115 to pivot through the aperture in the drywall without

making the aperture in the drywall wider than required.. Preferably the angle from the bottom surface 115a ofboot 110a to the plane created by rear wall 109a ofboot 110a is preferably 120°, but may be between 105° to 135°. Alternatively, edge 115 maybe rounded, preferably having a

radius of 2 inches.

FIG. 18 depicts another prior art boot 119showing an air intakel21, an air discharge 121a, and

discharge sides 122, but with the air intake 121 at the bottom of the boot 119 rather than a side.

FIG. 19 shows modified boot 130 comprising a bead plate 130a comprising flanges 123 and bead

129 and interior flanges 128. Bead plate 130a can either be permanently attached to boot 130 if

same is to be installed after drywall is installed or may be removably attachable to the boot if the boot without the bead plate is to be installed before the drywall is to be installed. Inside flanges 128

may be attached to sides 122 of boot 130, or to sides 109 of boot 105 or to sides 142 of boot 135.

FIGS .21 and 22 show another embodiment of bead plate 150 used for the mounting of an electrical

switch or an electrical receptacle together with a smaller than standard flush cover plate 160a. Bead

plate 150 contains a recess 160 configured to be deep enough to allow the front surface of a cover

plate to be flush with the surrounding drywall surface. Recess 160 is bounded by a bead 152 on all

four (4) sides which is feathered into the surrounding drywall in the*s|ated fashion. Recess back 161

is formed by upper and lower shoulders 156 and side shoulders 158. Between opposite side shoulders 158 and opposite top and bottom shoulders 156 is cavity 159 which provides access to a standard electrical box against which bead plate 150 is to be installed. Shoulders 156 each comprise

a shoulder recess 154 of sufficient depth to accept a mounting flange of a standard electrical switch or receptacle. This depth is approximately 3/64ths of an inch. Horizontal elongated slots 155 are provided through the bottom of the bead plate and are located to allow standard mounting bolts to

hold a switch or receptacle firmly against the shoulder recesses 154 through elongated slots 155 and

into threaded holes 163 of ears 168 of a standard receptacle box 164. Electrical box 164 is typically

mounted to stud 165 by screws 166. The gap 167 between electrical box 164 and the back of bead

plate 162 may be adjusted by changing the mounting depth of the box 164 and /or by selecting a

deeper bead plate 150.

In order to provide for a smaller switch plate the mounting flanges 171 and 171 a at the end of each

switch or receptacle assembly must be removed in order for same to fit between the opposite ends of shoulder recesses 154. As standard (unmodified) switch or receptacle mounting flanges would

accommodate a standard cover plate bolt pattern, a method of attaching a smaller than standard

cover plate to bead plate 150 is required. FIG.21a shows the approximate size of the smaller than

standard switch plate for use with bead plate 150. FIG.21 b is a side view of switch plate/receptacle

plate of FIG.21a showing clips 172 along the lower surface thereof. Clips 172 are inserted into slots

157 as shown on FIG. 21, which clips allow switch plate 160a to be snapped into cavity 160 and

removed from cavity 160 via light pressure such as provided by a tip of a screw driver. Cover plates

and cover plate bases sold under the brand LUTRON (tm) use a clip and slot system which could be used in this embodiment, an electrical box 164 is typically mounted in a wall against a stud via

nails or screws. Electrical box 164 may be flush mounted with the front surface of the stud to receive drywall or may be mounted slightly forward of same for protrusion into apertures to be created in the drywall for access to said electrical box 164. As electrical boxes may not be mounted with sides completely in alignment with vertical, the bead plate 150 may be manipulated slightly

so it be that the bead plate 150 may be rotated slightly to place the bead plate 150 vertically against

the drywall surface against which the bead plate 150is to be mounted even though the electrical box 164 is imperfectly mounted. The elongated slots 155 allow the bead plate 150 to be slightly rotated. Once the vertical position for the bead plate 150 is established the bead plate 150 may be held in

place by bolting the bead plate 150 onto the electrical box 164 through slots 155 with or without a

switch or receptacle being mounted against shoulder recesses 154. The bead plate can then be

attached to the drywall in the usual fashion and feathered from the crest of the bead 152 over flanges

151 into surrounding drywall. Alternatively, standard switch and recepticle fixtures may be used without removing the ends of the

supports by extending the shoulder recesses 154 vertically completely through the walls of cavity

1 0. Accordingly one side of a recepticle support can be slid through the opening at one end and

the other recepticle support may then be slid through the slot at the other end of cavity 160, at which

point the plug or switch can be centered' and installed with a portion of each support within opposing

slots in upper and lower slots of cavity 160.

FIGS.23 and 24 show bead plate 180 which is similar in function toΦead plate 150 except that bead plate 180 is designed to accept a standard sized switch or receptacle cover plate. Bead plate 180 is

also designed to accept a standard size switch assembly or a standard size receptacle assembly

including support flanges and wings 171 as in FIG. 21c. Bead plate 180 is provided with larger upper and lower shoulder recesses 185. The distance between the upper and lower opposing ends 185a of shoulder recesses 185 is between four and 1/8 inches and the height of theswitch/recepticle plate cavity . Preferably bead plate 180 includes side shoulders 183a of at least l/8th of an inch

wide and upper and lower shoulders 183 at least l/8th of an inch high in order to be large enough

to firmly seat a standard switch receptacle plate to prevent unwanted bending of switch and

receptacle plates during use or pressure which may result in breakage. The width of side shoulders

is preferably 3/8ths of an inch to Vi of an inch although the shoulders may be smaller or larger. If

the shoulders are narrower than approximately 3/8ths of an inch not only will the interior of a

standard electrical box be exposed through aperture 184 of bead plate 180 but the constraction

surrounding electrical box 164 will also be viewable and accessible through aperture 184. Upper

and lower shoulders also prevent a direct view into receptacle boxes or behind the bead plate 180. Upper and lower shoulders 183 also prevent a child or an individual from intentionally or

unintentionally inserting a thin object into the cavity of an electrical box.

Shoulder recesses 185 also equipped with apertures 187 which may accommodate standard spaced

switch plate bolts which hold a standard switch plate directly onto the surface of a switch assembly.

Standard switch plate bolts may come in varying lengths but are often approximately one (1) inch

long. Apertures 187 allow the cover plate flangel71d of a standard switch assembly to be

sufficiently engaged. Without an access aperture the end of standard plate bolts access could be

blocked by shoulder recess 185 preventing a standard switch plate from being snugly bolted to the

cover plate flange 171d of a standard switch or recepticle assembly. Aperture 187 is not required to be threaded in any way and is only intended to allow free passage of switch and recepticle plate

bolts.

Bead plate 180 also contains a slotted aperture 186, similar to that in bead plate 150 in order to allow

the bead plate to be oriented to true vertical, preferably with a spirit level, even though the electrical

box into which the bead plate must be bolted may be off vertical. This requires there to be some play

in aperture 186 through which the bolt attaches the switch assembly or receptacle assembly through

aperture 186 and into threaded holes 194 in the receptacle box.

FIGS. 26 and 27 disclose a further embodiment in which bead plate 205 further comprises an

attached electrical box 213. Flanges 206 comprise the border of the bead plate. The bead plate is

provided with recess 209 which may be sized to accept a standard or custom switch plate or receptacle plate . Recess 209 is bounded by side walls 208a which transition into bead 208 and in

rum transition into flange 206. Bead plate 205 also comprises upper and lower shoulders 218 and

side shoulders 218a. Upper and lower shoulders 218 and side shoulders 218a extend from recess

walls 208a to electrical box walls 212. An attached or integral electrical box 213 provide cavity 210

and wiring apertures 211. Electrical box 213 must have at least one aperture through which

electrical wires may pass into cavity 210 through the walls 212 or back 223 of electrical box 213.

Upper and lower shoulders 218 further comprise shoulder recesses^ 17 and switch and receptacle threaded mounting holes 216 and switch plate mounting bolt access apertures 215. FIG.27 is a back view of bead plate 205 more precisely showing support 214 comprising switch and receptacle

assembly threaded mounting holes 216.

Preferably bead plate 205 is moulded together with the electrical box but the electrical box may be attached in other ways known in the trade. The bead plate as well as the electrical box may be made

of metal and may be held together by welding, bolting, screwing, rivetting, gluing and/or the like. It is, of course, to be understood that a metal electrical box could be attached to a plastic bead plate

and vice versa.

FIG. 28 shows a round bead plate providing a round cavity for pot lights and the like. A pot light

may be installed above round bead plate 230 and inner flange 234. Alternatively, inner flange 234

can be made to nest inside or outside of a round wall of a pot light. Flange 234 may be permanently

or removably attached to the circular wall of a pot light. Bead 232 immediately abuts and encircles pot light cavity 235. Drywall compound is feathered from the crest of bead 232 outwardly from cavity 235 over flange 231, partially into compound receiving holes 233 and continuingly being feathered outwardly from centre cavity 235 past edge 236 onto the adjacent drywall surfaces surrounding bead plate 230.

Alternately, as shown in FIG. 29, bead plate 240 may be integral with or attached to the circular edges 234a of pot light 237. Lateral flanges 231 join partial bead 232 which comprises a second flange 234 substantially at a right angle to lateral flange 231 whereb^flange 234 is integral with or attached to pot light wall 234a. Optionally, springs 239a are flexibly or removably attachable to pot light wall 234a and which rest against upper surface of drywall 236a for added support. Typical pot light 237 includes bulb 238, electrical socket mounting assembly 239 and electrical power cable

-239a.

FIG. 30 shows another embodiment namely, bead plate 250 which is adapted to be nested with a ceiling light fixture or made integral with or attached to ceiling light fixture 249. Flanges 241 form the border of the bead plate. Bead 242 is outwardly abutted by flanges 241 and inwardly abutted by tabs 246 resulting in lateral recesses 246a and main recess 247a. With reference to FIGS.30 and 31 , flanges 241 are held in place by drywall screws 245 through drywall screws apertures 245a. Optionally, light fixture 249 may be fixedly or removably attached or integral with vertical flanges 241a.

FIG.32 illustrates another embodiment in which bead plate 260 is mounted over a plane or substrate 261 upon which drywall 262 is mounted on the outer surface of substrate 261 creating drywall cavity

268. Flange 264 is mounted on the outer surface of the edges of the drywall aperture with bead 265

immediately forward of the front of the drywall surfacie and abutting the drywall aperture. Interior

flange 266 travels all or a portion of the depth of drywall panel or panels 262 terminating in a rear

wall or stop 267 providing for the depth of the cavity between the crest of the bead and the said stop.

Said cavity 268 may be permanently filled with ceramic or other tiles 263, the surface of such tiles

which may be flush mounted with the crest of bead 265.

Claims

1. A duct opening for flush mounting on drywall surfaces comprising: a duct tube (narrow from end to end) drywall mounting flanges extending outwardly from the sides of the tube along the perimeter of one end of the tube; and a drywall bead along the perimeter of said one end of the tube connecting said one end of said tube to said extending drywall mounting flanges.

2. The duct opening of claim 1 wherein each wall of the tube is integral with the drywall mounting flange extending therefrom and integral with the bead along each wall of the perimeter.

3. The duct opening of claim 1 wherein the bead comprises a drywall angle bead wherein one edge of the angle bead comprises a drywall mounting flange and the edge is fastened to the duct opening.

-4. - - The duct opening of claim 3 wherein the means for affixing the second edges of the angle bead to the duct opening comprises one of the group of riveting, screwing, bolting, welding, gluing, friction, fitting and snapping.

5. The duct opening of claims 3 - 4 wherein the angle bead along more than one side of the perimeter of the duct opening is formed from one piece of angle bead comprising (relief) cuts through the drywall mounting flanges and bead at the comers of the duct opening.

6. The duct opening of claims 3 - 5 wherein one or more than one side of the duct opening comprises a separate piece of angle bead.

7. The duct opening of claim 6 wherein the duct opening comprises a separate piece of angle bead for each side of the perimeter of the duct opening.

8. The duct opening of claim 7 wherein each drywall mounting flange portion of angle bead is sized to form a substantially continuous drywall mounting flange around the perimeter of the duct opening.

9. The duct opening of claim 8 wherein the pieces of angle bead_^are joined at the corner of the duct opening at 45° angles.

10. The duct opening of claims 8 - 9 wherein the separate pieces of angle bead are connect by joining means. -_

11. The duct opening of claim 10 wherein the joining means comprises one of the group of welding.

12. The angle bead of claims 3 - 11 wherein the angle bead is along each side of the perimeter of the duct opening is formed into one piece.

13. The angle bead of claims 1 - 12 wherein the drywall mounting flanges and beads are made of one of the group consisting of plastic or metal.