Static structures (e.g. – buildings) – Processes – Fabrication of member – module – etc.
Reexamination Certificate
2000-01-11
2001-05-15
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Processes
Fabrication of member, module, etc.
C052S745100, C052S489100, C052S489200, C052S344000
Reexamination Certificate
active
06230469
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to preparing non-beveled wallboard panel edges before installation in any axis to create a beveled edge when installed and to the installation for adjoining the prepared edges to form substantially a recessed flush butt-joint after tape and compound is applied.
BACKGROUND OF THE INVENTION
Wallboard has become an expensive commodity especially since energy costs have risen in recent years. Wastage factors start at ten percent for standard bi-level homes to fifteen percent for custom-built contemporary homes and ten percent or more for commercial buildings. A big factor in causing this waste is the undesirability of “butt-joints”. Butt-joints are non-beveled end joints of wallboard requiring compound to seal the joints, and this compound is noticeable to the end user and is most unsightly and very undesirable. Unfortunately, the resulting joint is very difficult to conceal and even a highly skilled professional has a difficult time hiding such a joint. Also, tons of material is thrown out each year because it is too short and this is not at all economical as the cost of disposing of waste is escalating.
Furthermore, building materials expand or contract as the temperature and humidity inside a building change. As the building materials move, tension builds up against the wallboard panels causing ridging or bulging. The tension is relieved as the panels bend outward, usually at the joint. This so-called ridging can occur in regular tapered edge seams, but it is much more common in non-beveled recess butt-joints. Consequently, there is a great need for an economical solution to the aforementioned problems.
There have been numerous attempts within the prior art to resolve the problems associated with creating an aesthetically pleasing, economical and functional recess flush butt-joint but each have inherent disadvantages and drawbacks which the present invention addresses and resolves in a novel, unique manner heretofore not taught.
For example, U.S. Pat. No. 4,920,651 entitled “WALLBOARD BEVELING APPARATUS” teaches a tool having a handle with a rotary blade. This tool is used after the wallboard has been installed and allows a worker to slide the tool along the recess flush butt-joint and bevel the material along the seam. Unfortunately, this is not acceptable because the tool also removes the bonded paper coating leaving the wallboard exposed and this causes many problems. For example this decreases the manufacturer's intended structural strength. Also, it is unlikely that this method or tool would comply with today's strict building and fire codes.
Further prior art includes U.S. Pat. No. 5,079,042 entitled “DRYWALL JOINT FINISHING SYSTEM”. Wherein they teach the use of multiple compounds and monofilament fibers which are used to fill in a recess formed within the panel edges. This system is much too costly, is very time consuming and the resultant seam must be covered with a very large amount of finishing compound.
U.S. Pat. Nos. 5,799,458 and 3,675,383 teach a method known as back-blocking which again is not feasible, as this is much to costly and time consuming.
Within all of the known prior art, the resultant seam is very difficult to conceal, thus a large amount of compound is necessary to provide a feathered flush appearance, this becomes most costly and wasteful and is a major disadvantage which the present method addresses and resolves.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a new method for beveling the edge of a non-beveled wallboard panel which can be easily performed on the job-site by any typical wallboard worker.
Another object of the present invention is to provide a new method for beveling the edge of a non-beveled wallboard panel which is extremely fast, and is therefore not time-consuming.
Yet another object of the present invention is to provide a new method for beveling the edge of a non-beveled wallboard panel which does not mar or damage the bonded paper coating on the wallboard panel in any manner.
Yet another object of the present invention is to provide a new method for installing wallboard panels to create a recessed flush butt-joint which is very easy for the worker to perform.
Still a further object of the present invention is to provide a new method for installing wallboard panels to create a flush butt-joint which is very fast and efficient.
Also another object of the present invention is to provide a new method of installing wallboard panels to create a recessed flush butt-joint which uses much less tape and compound than previous methods and this greatly eliminates unnecessary waste. Thus, this method is extremely economical.
Yet another object of the present invention is to provide a new method of installing wallboard panels to create a recessed flush butt-joint which is aesthetically pleasing as it is substantially seamless in appearance when finished and requires no feathering.
Also another object of the present invention is to provide a new method for installing the wallboard panels to create a recessed flush butt-joint that is strong and will not interfere with the integrity of the wallboard.
Still another object of the present invention is to provide a new method for installing the wallboard panels to create a recessed flush butt-joint which can be installed in different positions having different axes, such as when the wallboard panels are used for ceilings, or the like.
Yet another object of the present invention is to provide a new method for installing the wallboard panels which will not cause unacceptable air pockets as this causes blistering.
A further object of the present invention is to provide a new method of installing wallboard panels to create a recessed flush butt-joint which requires minimal additional tools, other than those typically used within the trade.
Still another object of the present invention is to provide a new method of installing wallboard panels to create a recessed flush butt-joint which reduces drying time when compared to the known prior art.
Also another object of the present invention is to provide a new method of installation which reduces undesirable spalling which is typically incurred within the known prior art and traditional installation of butt-joints.
A very important object of the present invention is to provide a new method of installing wallboard panels to create a recessed flush butt-joint which will comply with today's strict building, safety, and fire codes.
Still another important object is to provide a new method of installing wallboard panels wherein the worker slices a slot within the panel, thus removing some of the gypsum material therein. However, when tape and compound is applied, this slot is filled with compound and replaces the gypsum material which was removed, thereby increasing the overall strength and integrity of the panel which is most advantageous.
Other objects and advantages will be seen when taken into consideration with the following specification and drawings.
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Sandstrom Wayne R.
Santa Cruz Cathy D.
Friedman Carl D.
McDermott Kevin
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