Static structures (e.g. – buildings) – Conduit – trim – or shield member at corner
Reexamination Certificate
1998-11-09
2001-12-25
Yip, Winnie S. (Department: 3635)
Static structures (e.g., buildings)
Conduit, trim, or shield member at corner
C052S255000, C052S417000, C052S717050, C052S745110
Reexamination Certificate
active
06332296
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to apparatuses for forming corners of drywall or wallboard constructed wall segments, and more particularly to a method and apparatus for forming inner and outer corners between two drywall or wallboard sections during a construction process.
2. Discussion
In the construction of buildings it is now common to use drywall or wallboard (hereinafter simply referred to as “drywall”) on the interior of the structure to finish interior walls of the structure. The edges of adjacent sections which meet along a flat portion of a wall or ceiling (i.e., not at a corner) are relatively easy to finish, even by individuals without expertise in drywall finishing. The edges are tapered such that when two drywall sections are positioned adjacent one another a “cove” or depression is formed. The cove is first filled with mud and then tape is pressed into the mud along the full length of the cove. More mud is then placed over the tape before the first sanding of the resulting joint is performed.
When finishing corner areas where two sections of drywall meet and form a corner, however, the finishing process is time consuming and highly dependent upon the skill of the drywall finisher. The corner area, whether an interior or exterior corner, has to be taped, mudded and then sanded. The mudding and sanding process is usually performed several times, even by an experienced and highly skilled drywall finisher, before the corner joint takes on the appearance of a cleanly, integrally formed corner area with no visually perceptible joint areas. The corner areas are especially difficult to form at the areas where the walls meet the ceiling of a structure. As will be appreciated, this adds to the overall cost of constructing any structure where drywall is used and increases the time needed for drywall finishing.
The above finishing process can be particularly troublesome for home remodeling applications undertaken by “do-it-yourself” persons. By this term, it is meant those individuals who do not have extensive experience in working with drywall finishing and have not acquired the necessary skill to finish inner and outer corner areas of a structure in a manner that produces clean, well-finished corner areas free from visual imperfections. Whereas the portions of adjacent drywall panels that meet at a flat point along a wall or ceiling can usually be finished adequately by even a “do-it-yourself” person, the inner and outer corner areas are usually very difficult and time consuming for such persons to finish.
When forming outer corners between two drywall sections, it has previously been necessary to nail or screw a metal corner section over the corner before taping and mudding the corner. Obviously, the metal corner member has to be attached carefully such that it forms a straight vertical edge. If this component is not attached properly, a “wavy”, non-linear edge will be formed, requiring even further finishing efforts.
It is therefore a principal object of the present invention to provide an apparatus and method for enabling inner and outer drywall corners to be quickly and easily constructed without having to tape and mud these corner areas when working with drywall panels.
It is still a further object of the present invention to provide an apparatus and method which is inexpensive to produce, easy to ship and install, and which further does not add appreciably to the overall construction costs when working with drywall panels, and which further enables the drywall finishing process to be performed much more quickly and efficiently.
It is still another object of the present invention to provide an apparatus and method which can be readily adapted for forming either an inner corner or an outer corner area between two drywall panels, with the only requirement being the use or non-use of an additional metal member which is attached to the apparatus before the apparatus is installed in the corner area to thereby form a clean, straight vertical corner line over which taping and mudding may be performed.
It is still a further object of the present invention to provide a corner apparatus which enables rounded inner or outer corners to be formed without any mudding and taping at the corners.
SUMMARY OF THE INVENTION
The above and other objects are provided by a corner apparatus and method in accordance with preferred embodiments of the present invention. The corner apparatus, in one preferred embodiment, comprises a pair of extruded plastic panel portions which are attached by a thin, living hinge. The two panel portions and the living hinge are extruded from high strength plastic to form a relatively low cost, lightweight assembly that can be laid flat for shipping purposes. Each of the panel portions has a thickness of preferably either ⅜″ or ½″, depending upon the thickness of the drywall panels with which the apparatus is intended to be used to form a corner area. Each of the panel portions further has an outer surface and an inner surface, with each of these surfaces having a slightly tapered distal end portion to allow the edges of each panel portion to be blended in with adjacently positioned drywall panels to form a clean corner area with no visually perceptible joint lines. Thus, the only finishing required is along the outer distal ends of each of the panel portions which meet adjacently positioned drywall sections, which are relatively easily and quickly finished.
In the preferred embodiment the inner ends of each panel portion are formed with a groove extending the entire length thereof. The groove accepts the arm portions of a metal corner member. The arm portions of the metal corner member are slid into the grooves which lock the two panel portions in a corner configuration. The metal corner member itself presents a very straight longitudinal outer corner edge which does not need to be nailed or screwed to the panel portions. Taping and mudding may then be performed more accurately and easily, even by unskilled persons, to form a clean, straight outer corner edge.
The apparatus of the present invention does not require the above-mentioned metal corner member if an interior corner is being formed. In that instance, the panel portions are simply secured to studs in the corner area. Each of the front and rear surfaces of the panel members further include drywall paper laminated thereon so no finishing is needed whatsoever at the inner corner formed by the two panel portions. The living hinge enables the panel portions to be secured at a range of angles relative to each other in the event that the inner corner formed is not a perfect 90° corner.
In yet another alternative preferred embodiment, two panel portions are provided which are connected by a thin flexible section of plastic along the entire length of each panel. The thin section of plastic permits a rounded inner or outer corner to be formed. The two panel portions comprise sections of plastic which are also extruded with the thin flexible section as a single piece component which is lightweight and which can be laid flat for shipping purposes.
Various corner assemblies are also disclosed for more quickly and easily forming a corner at the intersection of three perpendicular wall sections. Assemblies for forming ninety degree corners and radiused corners are both disclosed.
The various preferred embodiments enable inner and outer corners of wall structures to be more easily and quickly finished by either a professional drywall installer or by an individual without extensive drywall finishing experience. The various preferred embodiments further enable angled or rounded corners to be easily created.
REFERENCES:
patent: 2227581 (1941-01-01), Henderson
patent: 2882564 (1959-04-01), Couse et al.
patent: 3086328 (1963-04-01), Peterson et al.
patent: 3090087 (1963-05-01), Miller
patent: 3200547 (1965-08-01), Johnson
patent: 3235118 (1966-02-01), Kewley
patent: 3444657 (1969-05-01), Swanson
patent: 3964220 (1976-06-01), Rutkowski et al.
patent: 3989397
Harness & Dickey & Pierce P.L.C.
Yip Winnie S.
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