U.S. patent application number 10/144515 was filed with the patent office on 2003-11-13 for drywall joint and system and process for making.
Invention is credited to House, James Robert, House, Michael Paul, House, William Kenneth.
Application Number | 20030208977 10/144515 |
Document ID | / |
Family ID | 29400349 |
Filed Date | 2003-11-13 |
United States Patent
Application |
20030208977 |
Kind Code |
A1 |
House, William Kenneth ; et
al. |
November 13, 2003 |
Drywall joint and system and process for making
Abstract
A method of making a drywall joint includes steps of positioning
a butt block that has a recessed surface on an interior side of a
joint that is to be formed between a first drywall sheet and a
second drywall sheet, securing at least one of the first and second
drywall sheets to the butt block so that the secured sheet is made
to conform in shape to the recessed surface, thereby forming a
secondary recess on an exterior of the drywall sheet in the area at
which the joint is to be made, and applying joint compound within
the secondary recess.
Inventors: |
House, William Kenneth;
(Forest Lake, MN) ; House, James Robert; (Forest
Lake, MN) ; House, Michael Paul; (Forest Lake,
MN) |
Correspondence
Address: |
KNOBLE & YOSHIDA
EIGHT PENN CENTER
SUITE 1350, 1628 JOHN F KENNEDY BLVD
PHILADELPHIA
PA
19103
US
|
Family ID: |
29400349 |
Appl. No.: |
10/144515 |
Filed: |
May 13, 2002 |
Current U.S.
Class: |
52/459 ; 52/256;
52/257; 52/742.13 |
Current CPC
Class: |
E04F 13/06 20130101;
E04F 19/022 20130101; E04F 13/042 20130101; E04F 13/04
20130101 |
Class at
Publication: |
52/459 ; 52/256;
52/257; 52/742.13 |
International
Class: |
E04B 001/00; E04D
001/36 |
Claims
What is claimed is:
1. A method of making a drywall joint, comprising steps of: (a)
positioning a butt block that has a recessed surface on an interior
side of a joint that is to be formed between a first drywall sheet
and a second drywall sheet; (b) securing at least one of the first
and second drywall sheets to the butt block so that the secured
sheet is made to conform in shape to the recessed surface, thereby
forming a secondary recess on an exterior of the drywall sheet in
the area at which the joint is to be made; and (c) applying joint
compound within the secondary recess.
2. A method of making a drywall joint according to claim 1, wherein
step (b) is further performed by securing both the first and second
sheets to the recessed surface, whereby the secondary recess is
formed on an exterior of both of the drywall sheets in the area at
which the joint is to be made.
3. A method of making a drywall joint according to claim 2, wherein
step (b) is further performed by securing first portions of the
respective sheets to the butt block, and then securing second
portions of the sheets, which are closer to the area at which the
joint is to be made than the first portions, to the butt block,
thereby gradually pulling the sheets against the recessed surface
to form the secondary recess.
4. A method of making a drywall joint according to claim 1, wherein
step (b) is further performed by securing a first portion of the
sheet to be secured the butt block, and then securing a second
portion of the sheet to the butt block that is closer to the area
at which the joint is to be made than the first portion, thereby
gradually pulling the sheet against the recessed surface to form
the secondary recess.
5. A method of making a drywall joint according to claim 1, wherein
step (c) is performed so as to complete a joint that is
substantially planar on an exterior surface thereof.
6. A butt block for forming a drywall joint, comprising a first
surface for engaging a first sheet of drywall, a second surface for
engaging a second sheet of drywall; and recess defining means for
defining a recessed area between said first and second surfaces,
said recess defining means being constructed and arranged to be
drawn into contact with butt edge areas of the first and second
sheets of drywall when fully secured to said sheets of drywall,
whereby the butt edge areas will be caused to form a concave
secondary recess on an exterior surface of the drywall joint
7. A butt block according to claim 6, wherein said butt block is
fabricated from a material that may be penetrated by a drywall
screw and that will provide sufficient anchoring for the drywall
screw for the drywall screw to be able to pull the butt edge area
of a sheet of drywall against the recessed area.
8. A butt block according to claim 7, wherein said butt block is
fabricated from a material comprising fiberglass.
9. A butt block according to claim 6, wherein said butt block
further comprises first and second outboard flange members, and
wherein said first and second surfaces are defined, respectively,
on said first and second outboard flange members.
10. A drywall joint, comprising: a first sheet of drywall having a
first butt edge; a second sheet of drywall having a second butt
edge, said first and second sheets of drywall being positioned so
that said first butt edge is adjacent to said second butt edge at a
butt interface; recess forming means engaging said first and second
sheets for pulling said first and second butt edges inwardly so as
to define a secondary recess in exterior surfaces of the first and
second sheets in the area of the butt interface; and a sealant
applied in said secondary recess.
11. A drywall joint according to claim 10, wherein said sealant
comprises a solidified joint compound.
12. A drywall joint according to claim 10, wherein said sealant is
applied so that an outer surface of said sealant is positioned
substantially within a common plane with exterior surfaces of said
first and second sheets of drywall that are not affected by said
recess forming means.
13. A drywall joint according to claim 10, wherein said recess
forming means comprises a butt block comprising a first surface for
engaging the first sheet of drywall; a second surface for engaging
the second sheet of drywall; and a recess defining means defining a
recessed area between said first and second surfaces, said recess
defining means being constructed and arranged to be drawn into
contact with butt edge areas of the first and second sheets of
drywall when fully secured to said sheets of drywall, whereby the
butt edge areas will be caused to form a concave secondary recess
on an exterior surface of the drywall joint.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to the field of
architecture and construction. More specifically, this invention
relates to the field of drywall construction, which is the most
common method that is used today to finish interior walls and
ceilings in buildings such as new homes and offices.
[0003] 2. Description of the Related Technology
[0004] Conventional drywall is fabricated in sheets having a gypsum
core that is contained within a fibrous, cardboard-like outer skin.
Drywall sheets typically are approximately four feet in width by
eight feet in height, although this may vary depending upon the
manufacturer and the part of the world in which the product is
being used.
[0005] Conventional frame-type construction involves assembling the
structural portion of a wall or ceiling from a framework that is
constructed of a plurality of joists, which are typically 2.times.4
pieces of lumber. The drywall must be fastened over the framework
of joists to form the outer surface of the wall or ceiling. Since a
number of drywall sheets will usually have to be applied to a
particular wall or ceiling surface to completely cover the
structural framework of the wall or the ceiling, the individual
sheets of drywall will have to be joined together in a way that is
not easily detectable to a viewer after the wall has been
finished.
[0006] FIG. 1 depicts a conventional drywall joint 10 that is the
most typical example of the current state of construction in this
area. As shown in FIG. 1, a first drywall sheet 12 is positioned
end-to-end with a second drywall sheet 14, with adjacent edges of
the two sheets 12, 14 positioned together in a butt-type interface
16. Because of the irregularities that are unavoidable in
joist-type construction, it is considered preferable to have the
butt interfaces 16 between the different sheets of drywall
positioned over an open area within the structural framework, and
not directly over one of the joists. Instead, a support member 18
is positioned behind the two drywall sheets 12, 14 in order to
provide rigidity to the joint and give alignment to the drywall
sheets 12, 14 during the joining process. As FIG. 1 shows, the
drywall sheets are first joined to the support member 18 by a pair
of drywall screws 20, 22. After the drywall screws 20, 22 have been
so secured, a second pair of screws 24, 26, which are closer to the
butt interface 16, are then inserted and secured between the
support member 18 and the respective drywall sheets 12, 14.
[0007] At this point, the first and second drywall sheets 12, 14
are joined together structurally, but are still aesthetically quite
distinguishable. To hide the visible crack of the butt interface
16, a length of adhesive mesh drywall joint tape 28 is applied to
the crack at the butt interface 16, and a substance that is known
as joint compound 30, or more commonly by the term "mud," is
trowled on top of the tape 28 and is spread as smoothly as possible
outwardly over the exterior surface of the two drywall sheets 12,
14 so as to disguise the joint 10 from view as effectively as
possible.
[0008] Unfortunately, the added thickness of the joint tape 28 and
the joint compound 30 creates a bulge 32 at the conventional
drywall joint 10. A skillful contractor will be able to disguise
the bulge 32 as well as it can be disguised, mainly by spreading
the joint compound outwardly for some distance, but there are some
instances in which the bulge 32 will remain noticeable, such as
when there is overhead spot lighting that will strike the bulge 32
obliquely, which will tend to make the bold 32 very evident to even
the least discerning viewers.
[0009] In addition to the disadvantages of the conventional drywall
joint 10 that are discussed above, it takes a great amount of time
and material to smooth the conventional drywall joint 10 when one
considers the number of such joints that will have to be made in
the construction of a large building such as a house.
[0010] A need exists for an improved drywall joint-and a system and
process for making such a joint that will reduce the amount of
labor and materials necessary to form the joint, and that will
enhance the aesthetic value of the finished joint.
SUMMARY OF THE INVENTION
[0011] Accordingly, it is an object of the invention to provide an
improved drywall joint and a system and process for making such a
joint that will reduce the amount of labor and materials necessary
to form the joint, and that will enhance the aesthetic value of the
finished joint.
[0012] In order to achieve the above and other objects of the
invention, a method of making a drywall joint according to a first
aspect of the invention includes steps of positioning a butt block
that has a recessed surface on an interior side of a joint that is
to be formed between a first drywall sheet and a second drywall
sheet; securing at least one of the first and second drywall sheets
to the butt block so that the secured sheet is made to conform in
shape to the recessed surface, thereby forming a secondary recess
on an exterior of the drywall sheet in the area at which the joint
is to be made; and applying joint compound within the secondary
recess.
[0013] According to a second aspect of the invention, a butt block
for forming a drywall joint includes a first surface for engaging a
first sheet of drywall; a second surface for engaging a second
sheet of drywall; and recess defining structure for defining a
recessed area between the first and second surfaces, the recess
defining structure being constructed and arranged to be drawn into
contact with butt edge areas of the first and second sheets of
drywall when fully secured to the sheets of drywall, whereby the
butt edge areas will be caused to form a concave secondary recess
on an exterior surface of the drywall joint.
[0014] According to a third aspect of the invention, a drywall
joint includes a first sheet of drywall having a first butt edge; a
second sheet of drywall having a second butt edge, the first and
second sheets of drywall being positioned so that the first butt
edge is adjacent to the second butt edge at a butt interface;
recess forming structure engaging the first and second sheets for
pulling the first and second butt edges inwardly so as to define a
secondary recess in exterior surfaces of the first and second
sheets in the area of the butt interface; and a sealant applied in
the secondary recess.
[0015] These and various other advantages and features of novelty
that characterize the invention are pointed out with particularity
in the claims annexed hereto and forming a part hereof. However,
for a better understanding of the invention, its advantages, and
the objects obtained by its use, reference should be made to the
drawings which form a further part hereof, and to the accompanying
descriptive matter, in which there is illustrated and described a
preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a fragmentary cross-sectional view depicting a
conventional drywall joint;
[0017] FIG. 2 is a perspective view of a butt block that is
constructed according to a preferred embodiment of the
invention;
[0018] FIG. 3 is a fragmentary cross-sectional view depicting a
first method step in a process that is performed according to a
preferred embodiment of the invention;
[0019] FIG. 4 is a fragmentary cross-sectional view depicting a
second method step in the process that is first shown in FIG. 3;
and
[0020] FIG. 5 is a fragmentary cross-sectional view depicting a
completed joint that is constructed according to a preferred
embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0021] Referring now to the drawings, wherein like reference
numerals designate corresponding structure throughout the views,
and referring in particular to FIG. 2, a butt block 40 constructed
according to a preferred embodiment of the invention includes a
first outboard flange 42 and a second outboard flange 44. As may be
seen in FIG. 2, the first outboard flange 42 includes a first
surface 46 defined by a forward portion of the flange 42. The
second flange 44 likewise is provided with a second surface 48 on a
front portion thereof. The purpose of first and second surfaces 46,
48 is to engage the interior surfaces of first and second sheets of
drywall 12, 14, as will be described in greater detail below. The
first and second surfaces 46, 48 are substantially planar, and
preferably lie within substantially the same plane.
[0022] Referring again to FIG. 2, it will be seen that butt block
40 further includes recess defining structure 50 that is embodied
as a first recessed panel 52, and a second recessed panel 54. The
recessed panels 52, 54 are unitary with each other and are joined
at a center axis 56 that is located at the innermost point of the
recess that is defined by the recess defining structure 50. The
first recessed panel 52 is unitary with the first flange 42, while
the second recessed panel 54 is similarly unitary with the second
flange 44. The butt block 40 is fabricated from a material that is
capable of being penetrated by a standard drywall screw, and that
is traditionally capable of entering such screws to the extent
necessary to perform the steps that are described with reference to
FIGS. 3, 4 and 5 below. In the preferred embodiment, this material
is fiberglass.
[0023] Referring now to FIG. 3, a method of making an improved
drywall joint according to a preferred embodiment of the invention
will now be described. As FIG. 3 shows, the butt block 40 that has
been described in reference to FIG. 2 is cut to an appropriate
length, and is then positioned behind first and second drywall
sheets 12, 14 that are desired to be joined. This is in most cases
performed so that the butt block 40 will be positioned in a void
that is defined by adjacent joists within a framework for a wall or
a ceiling. The butt block 40 is preferably positioned, as shown in
FIG. 3, so that the center axis 56 is substantially aligned with
the butt interface 16 between the edges of the drywall sheets 12,
14 that are to be joined. This alignment may be accomplished by
temporarily placing a number of drywall screws into the butt block
40 along the center axis 56 and then sliding the butt block 40
behind one of the drywall sheets 12, 14 until these temporarily set
drywall screws abut the edge of the drywall sheets 12, 14.
[0024] As FIG. 3 shows, a first series of drywall screws 60 are
used to secure the first flange 42 of the butt block 40 to a
portion of the first drywall sheet 12 that is located some distance
from the butt interface 16. Immediately thereafter, a second series
of drywall screws 62 are similarly driven into the second drywall
sheet 14 to secure a corresponding portion of the sheet 14 to the
second flange 44 of the butt block 40. These actions cause the
first and second surfaces 46, 48 that are described in reference to
FIG. 2 to be drawn tightly against interior surfaces 68, 70 of the
respective sheets 12, 14.
[0025] At this point in time, the exterior surfaces 64, 66 of the
respective drywall sheets 12, 14 are substantially aligned with
each other in substantially the same plane as the rest of the
drywall sheets 12, 14, much in the manner as is shown in the
conventional joint that is depicted in FIG. 1.
[0026] Referring now to FIG. 4, the preferred embodiment of the
invention further includes steps of driving a third series of
screws 74 into portions of the first drywall sheet to 12 that are
fairly close to the butt interface 16. At about the same time, a
fourth series of screws 76 are driven into portions of the second
drywall sheet 14 that are fairly close to the butt interface 16. As
the screws 74, 76 are tightened, the area of the drywall sheets 12,
14 that are adjacent to the butt interface 16 are drawn into the
recess 72 that is defined by the recess defining structure 50 in
the butt block 40, thereby creating a secondary recess 78 to be
formed on the exterior surface of the joint. In other words, the
exterior surfaces 64, 66 of the drywall sheets 12, 14 become
pitched inwardly toward the butt interface 16, as is clearly shown
in FIG. 4.
[0027] Looking now to FIG. 5, the secondary recess 78 that is shown
in FIG. 4 will now be filled by a process that includes applying an
adhesive mesh joint tape that is of conventional construction over
the butt interface 16, and then applying a joint compound 82 to
fill the rest of the secondary recess 78. This is preferably
performed so that the resulting joint 86 has a planar exterior
surface that lies within the same plane 84 as the main portions of
the first and second sheets 12, 14 of drywall.
[0028] It is to be understood, however, that even though numerous
characteristics and advantages of the present invention have been
set forth in the foregoing description, together with details of
the structure and function of the invention, the disclosure is
illustrative only, and changes may be made in detail, especially in
matters of shape, size and arrangement of parts within the
principles of the invention to the full extent indicated by the
broad general meaning of the terms in which the appended claims are
expressed.
* * * * *