U.S. patent application number 14/293740 was filed with the patent office on 2015-03-12 for arch drywall trim product.
The applicant listed for this patent is Timothy Smythe, JR.. Invention is credited to Timothy Smythe, JR..
Application Number | 20150068142 14/293740 |
Document ID | / |
Family ID | 39705455 |
Filed Date | 2015-03-12 |
United States Patent
Application |
20150068142 |
Kind Code |
A1 |
Smythe, JR.; Timothy |
March 12, 2015 |
Arch Drywall Trim Product
Abstract
A notched drywall trim piece that can take the form of a bead,
hinged trim piece or bullnose piece that generally is constructed
from a semi-rigid core that forms two flanges. At least one of the
flanges is notched allowing the piece to follow the shape of an
arch or arbitrarily curved corner. The piece can be installed using
only wet mud or other mastic. The outer or room-facing surface can
optionally be treated or prepared to bond with the mud or can be
prepared to directly receive paint or texture. The preparation of
the flange surface can take the form of a paper or other fibrous
layer, scoring, frocking (bonding a powered fibrous material),
roughing, protrusions, or a water-activated adhesive or pressure
sensitive (or any other) adhesive may be used.
Inventors: |
Smythe, JR.; Timothy; (Bend,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Smythe, JR.; Timothy |
Bend |
OR |
US |
|
|
Family ID: |
39705455 |
Appl. No.: |
14/293740 |
Filed: |
June 2, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13302092 |
Nov 22, 2011 |
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14293740 |
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12758233 |
Apr 12, 2010 |
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13302092 |
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11707647 |
Feb 17, 2007 |
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12758233 |
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Current U.S.
Class: |
52/287.1 |
Current CPC
Class: |
E04F 2203/08 20130101;
E04F 2013/061 20130101; E04F 2019/0427 20130101; E04F 13/06
20130101 |
Class at
Publication: |
52/287.1 |
International
Class: |
E04F 13/06 20060101
E04F013/06 |
Claims
1. An arch drywall corner trim product comprising: a continuously
extruded elongated plastic semi-rigid core with a centerline and
two plastic flanges separated by a flexible hinge, each flange with
a room-facing surface and a wall-facing surface, said flexible
hinge allowing the product to be bent repeatedly to any angle about
said hinge; wherein, a first of said flanges has a plurality of
notches running along said flange allowing the product to be bent
along the centerline to match an arch, and a second of said flanges
has no notches; and wherein the wall-facing surface of at least one
flange is prepared to bond with drywall mastic such that no
mechanical attachments are necessary; and wherein in the
wall-facing surface of at least one of said flanges is bonded to a
layer of fibrous material. wherein said layer of fibrous material
is supplied coated with a layer of water-activated or
pressure-sensitive adhesive.
2. The arch drywall corner trim product of claim 1 wherein said
layer of fibrous material is coated with a layer of water-activated
adhesive.
3. the arch drywall corner trim product of claim 2 wherein said
adhesive is pressure sensitive.
4. The arch drywall corner trim product of claim 1 wherein said
product is bullnose.
5. The arch drywall corner trim product of claim 1 wherein the
wall-facing surface of at least one of said flanges is prepared by
roughening.
6. The arch drywall corner trim product of claim 1 wherein the
wall-facing surface of at least one of said flanges is prepared by
scoring or protrusions.
7. The arch drywall corner trim product of claim 1 wherein the
wall-facing surface of at least one of said flanges is prepared by
coating with a mastic compound.
8. The arch drywall corner trim product of claim 7 wherein said
mastic compound is an adhesive.
9. The arch drywall corner trim product of claim 1 wherein the
wall-facing surface of at least one of said flanges is prepared by
frocking.
10. The arch drywall corner trim product of claim 1 further
comprising a bead along said centerline.
Description
[0001] This application is a continuation of application Ser. No.
13/302,092 filed Nov. 22, 2011 which was a continuation of
application Ser. No. 12/758,233 filed Apr. 12, 2010 which was a
continuation of application Ser. No. 11/707,647 filed Feb. 17,
2007. Application Ser. No. 13/302,092, 12/758,233 and 11/707,647
are hereby incorporated by reference in their entireties.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of
drywall corner trim and more particularly to an arch drywall trim
product that needs no mechanical attachments.
[0004] 2. Description of the Prior Art
[0005] Drywall corner trim finishing materials available for use on
arches are known in the art. The most common are made of vinyl
without any surface preparation for bonding to joint compound or
other common mastics.
[0006] Each of the prior art products are designed for a particular
installation process which includes nailing, screwing, crimping or
otherwise fastening the material to an archway corner. This is
sometimes done in conjunction with the use of adhesives. Once the
installation is finished, the installer must overlay the assembly
with large quantities of drywall mud to cover and hide the
fasteners and to blend the assembly into a seamless surface with
the flat wall. This is very time consuming and requires that the
installer have a drill, screws, or other hardware and equipment in
order to perform the installation. It is also very difficult to
mechanically attach the trim to the arch, either with screws or
otherwise, in a manner such that the arch forms a smooth radius and
is free of kinks or steps since the trim material cannot be
adjusted after being fastened to the corner.
[0007] It would be advantageous to have a corner trim arch product
with an inside surface designed so that it can be bonded onto the
corner with common drywall joint compound or other mastic without
any mechanical fasteners.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a notched drywall trim
piece that can take the form of a bead, hinged trim piece or
bullnose piece that generally is constructed from a semi-rigid core
that forms two flanges. At least one of the flanges is notched
allowing the piece to follow the shape of an arch or arbitrarily
curved corner. The notches allow the otherwise rigid, straight trim
piece to be smoothly bent around the corner.
[0009] The products of the present invention can generally be
installed without any mechanical fasteners since the inner or
wall-facing surface of the product is prepared or treated to bond
directly with drywall mud or other mastic. In this manner, the
piece can be installed using only wet mud. The piece can be moved
and adjusted in the wet mud and finally finished with a layer of
mud on its outer surface. The outer or room-facing surface can
optionally be treated or prepared to bond with the mud or can be
prepared to directly receive paint or texture.
[0010] The preparation of the flange surface can take the form of a
paper or other fibrous layer, scoring, frocking, roughing,
protrusions, or a water-activated adhesive or pressure sensitive
(or any other) adhesive may be used.
DESCRIPTION OF THE FIGURES Refer to the following images to better
understand the present invention:
[0011] FIG. 1 shows a bead embodiment of the present invention.
[0012] FIG. 2 shows a trim embodiment of the present invention.
[0013] FIG. 3 shows a bull-nose embodiment of the present
invention.
[0014] Several illustrations and drawings have been presented to
aid in understanding the present invention. The scope of the
present invention is not limited to what is shown in the
figures.
DESCRIPTION OF THE INVENTION
[0015] The present invention relates to an arch corner trim product
with an inside surface designed such that it can be bonded onto a
corner with common drywall mud or other mastic without using any
mechanical fasteners. What I mean by arch is a trim product that
contains a notched flange so that the product can be applied to
match the curvature of an arch or other curved drywall corner. The
notches allow the otherwise rigid, straight piece of corner trim to
be smoothly bent around a curved corner like an arch perfectly
matching the curve of the corner.
[0016] Normally the product includes a semi-rigid core or plastic
or other semi-rigid material with a layer of fibrous material like
paper on the inside surface so that the product can be better
bonded to the corner using only mud. The present invention can be
easily adjusted while the mud is wet. It can also be rolled with a
roller onto the curved or arched corner to insure a perfect fit and
insure that the flanges are tight against the drywall thus using
minimum mud and requiring minimum mud to finish out the job. The
product of the present invention is very easy to install since the
installer does not need to hide screw heads, staples or other
fasteners with large amounts of mud. In addition, various
embodiments of the present invention include a fibrous or paper
layer on the outer surface that has been prepared to directly
receive paint or texture. This surface preparation may take the
form of impregnation with polymers or paint.
[0017] The product of the present invention can generally take the
shape of any corner trim available as long as the inner surface has
been treated, coated, covered or otherwise prepared to bond well
with drywall mud or other mastic joint compound. The preparation of
the flange surface can take the form of a paper or other fibrous
layer, scoring, frocking (bonding a powdered fibrous material),
roughing, protrusions, or a water-activated adhesive or pressure
sensitive (or any other) adhesive may be used. The preferred method
is to use a layer of paper between the semi-rigid core and drywall.
This paper can be continuously extruded with the semi-rigid core. A
possible form of the product of the present invention can be
similar to that disclosed in U.S. Pat. No. 6,148,573 with notches
as described above.
[0018] Turning to FIG. 1, a "bead" type embodiment of the present
invention can be seen. By bead, I mean a trim product that is
manufactured to an approximately fixed flange angle and has a
structure along its nose 1 or apex that runs along its length. At
least one of the flanges 2 may be notched 5 to allow the piece to
bend along the curve of the corner. The nose 1 may optionally also
be notched. The wall-facing surface of the flanges 8 is normally
treated to bond tightly with mastic preferably by being bonded to a
wall-facing paper layer. The outside, or room-facing surfaces 4 of
the flanges 2 are also normally treated to directly receive paint
or texture.
[0019] FIG. 2 shows a "trim" type embodiment of the present
invention where rather than a bead type nose like the embodiment of
FIG. 1, the piece has a grooved hinge 6 that allows the piece to
flex to any angle. Normally, this embodiment has optionally tapered
flanges 2 that are thickest near the nose and taper off toward the
edges. Again, at least one of the flanges is normally notched 5 to
allow the piece to follow the curvature of an arch corner.
[0020] FIG. 3 shows a "bullnose" embodiment of the present
invention. Here the nose 7 is replaced by a large radius crown
which connects the flanges 2 and is commonly known as bullnose in
the art. Again, this embodiment is normally notched 5 to allow the
piece to follow the curvature of an arch corner.
[0021] The wall-facing and room-facing surfaces (4 and 8
respectively) of the embodiments shown in FIGS. 2 and 3 are similar
to those described for the embodiment shown in FIG. 1.
[0022] As has been previously discussed, the product of the present
invention can take the shape of any type of corner trim as long as
the inside surface has been treated as described so that it will
bond well with drywall mastic. In general, the present invention is
manufactured with a rigid core whose inside or wall-facing surface
bonds well with drywall mud. The present invention can also take
the shape of flat or tapered products currently used in the trade
for off-angles (angles different from 90 degrees). These products
usually incorporate some sort of hinge along the centerline (such
as the embodiment shown in FIG. 2).
[0023] The surface preparation to make the products of the present
invention bond well with drywall mud can take the form of a
treatment to the semi-rigid core such as roughening the surface,
scoring, protrusions, a fiber coating like paper, or frocking. Any
treatment or preparation of the wall-facing surface is within the
scope of the present invention. The treatment may optionally also
be applied to the outer or room-facing surface, or the room facing
surface may include a paper or other layer treated or prepared to
directly receive paint or texture.
[0024] A particular embodiment of the present invention can have
the inside and outside of the product treated in the same manner.
This can aid in the ability of the product to be bonded to an
arched corner only with drywall mud. This is because, in the final
installation, the flanges will be captured between an inside and
outside layer of mud creating a 2-sided bond. Another embodiment of
the present invention can have the wall-facing side of the flanges
(or a single flange) pre-treated with a mastic material. This
mastic can optionally be an adhesive of any type. A preferred
adhesive is one that is water-activated or pressure sensitive.
[0025] A possible method for manufacturing the arch corner trim
products of the present invention is to extrude a semi-rigid core
piece such as high impact plastic and then notch one or more of the
flanges. The wall-facing surface of the flanges can then be
prepared to bond with drywall mud or other mastic. If an adhesive
is used, they can be coated with adhesive. It is also possible to
continuously extrude the core piece with a layer of fibrous
material such as paper that itself can bond with drywall mastic. It
is also possible to extrude the core with paper or other surface
preparation on the room-facing side that can directly received
paint or texture.
[0026] Several descriptions and illustrations have been provided to
better aid in the understanding of the invention. One of skill in
the art will realize that numerous variations and changes are
possible without departing from the spirit of the invention. Each
of these changes and variations is within the scope of the present
invention.
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