U.S. patent application number 15/376176 was filed with the patent office on 2017-11-02 for formable corner finishing and trim strip.
The applicant listed for this patent is UNITED STATES GYPSUM COMPANY. Invention is credited to Salvatore Immordino, Guy Rosenthal.
Application Number | 20170314275 15/376176 |
Document ID | / |
Family ID | 60157394 |
Filed Date | 2017-11-02 |
United States Patent
Application |
20170314275 |
Kind Code |
A1 |
Rosenthal; Guy ; et
al. |
November 2, 2017 |
FORMABLE CORNER FINISHING AND TRIM STRIP
Abstract
A formable trim strip for use in connection with drywall
applications includes two or more layers, including a trim strip
body and a backing paper. The trim strip body extends along a body
axis and has a top surface and a bottom surface. The trim strip
body comprises a polymer material. The backing paper includes a
portion secured to the bottom surface of the trim strip body
without an intervening layer of adhesive material. The trim strip
body is coated onto the portion of the backing paper when a
temperature of the trim strip body is within the melting point
range such that the bottom surface of the trim strip body contacts
the portion of the backing paper. As the trim strip body cools to a
temperature below the melting point range, the portion of the
backing paper bonds to the bottom surface of the trim strip
body.
Inventors: |
Rosenthal; Guy; (Wheaton,
IL) ; Immordino; Salvatore; (Trevor, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED STATES GYPSUM COMPANY |
Chicago |
IL |
US |
|
|
Family ID: |
60157394 |
Appl. No.: |
15/376176 |
Filed: |
December 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62345480 |
Jun 3, 2016 |
|
|
|
62328383 |
Apr 27, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 2290/044 20130101;
B29C 48/21 20190201; E04F 13/06 20130101; E04F 21/0053 20130101;
C09J 5/06 20130101; E04F 2013/063 20130101; E04F 21/1655 20130101;
E04F 13/0733 20130101; B29C 48/154 20190201; E04F 13/24 20130101;
B29C 48/0022 20190201; E04F 21/1652 20130101; E04F 13/077 20130101;
E04F 19/022 20130101; E04F 19/028 20130101; E04F 21/026
20130101 |
International
Class: |
E04F 21/00 20060101
E04F021/00 |
Claims
1. A formable trim strip for use in connection with drywall
applications, the formable trim strip comprising: a trim strip body
extending along a body axis and having a top surface and a bottom
surface, the trim strip body comprising a polymer material; and a
backing paper, wherein a portion of the backing paper is secured to
the bottom surface of the trim strip body without an intervening
layer of adhesive material, and wherein the trim strip body is
coated onto the portion of the backing paper when a temperature of
the trim strip body is within the melting point range such that the
bottom surface of the trim strip body contacts the portion of the
backing paper, and as the trim strip body cools to a temperature
below the melting point range, the portion of the backing paper
bonds to the bottom surface of the trim strip body.
2. The formable trim strip of claim 1, wherein the polymer has a
melting point range between about 250.degree. F. and about
400.degree. F.
3. The formable trim strip of claim 1, wherein at least one forming
feature extends along the trim strip body, the at least one forming
feature extending along a forming feature axis, the at least one
forming feature being configured to allow the trim strip body to be
deformed about the forming feature axis.
4. The formable trim strip of claim 1, wherein the forming feature
axis is parallel to the body axis.
5. The formable trim strip of claim 1, wherein the forming feature
comprises a void in the trim strip body.
6. The formable trim strip of claim 1, wherein the at least one
forming feature comprises a channel.
7. The formable trim strip of claim 6, wherein the channel has a
generally rectangular cross-section, a generally 90-degree
cross-section or a generally U-shaped cross-section.
8. The formable trim strip of claim 1, wherein a cross-sectional
shape of the flexible trim strip is uniform from a first end of the
flexible trim strip to a second end of the flexible trim strip.
9. The formable trim strip of claim 1, wherein the at least one
forming feature comprises a plurality of forming features.
10. The formable trim strip of claim 9, wherein each one of the
plurality of forming features extends parallel to the body
axis.
11. The formable trim strip of claim 1, wherein a cross-section of
the formable trim strip is symmetrical about the body axis.
12. A method of forming a formable trim strip for use in connection
with drywall applications, the method comprising: heating a polymer
material to a temperature within its melting point range; advancing
a backing paper positioned proximal to the polymer material;
depositing the polymer material directly onto at least a portion of
the backing paper to form a trim strip body having a top surface
and a bottom surface, the bottom surface being in direct contact
with the backing paper; allowing the trim strip body to cool to a
temperature below the melting point range such that the portion of
the backing paper bonds to the bottom surface of the trim strip
body.
13. The method of claim 12, further comprising forming at least one
forming feature along the top surface of the trim strip body, the
at least one forming feature extending along a forming feature axis
and being configured to allow the trim strip body to be deformed
about the forming feature axis.
14. The method of claim 13, wherein forming the at least one
forming feature occurs before the trim strip body is allowed to
cool completely.
15. The method of claim 12, further comprising depositing an
adhesive to the top surface of the trim strip body opposite the
backing paper.
16. An assembly for forming a formable trim strip for use in
connection with drywall applications, the assembly comprising: a
formable trim strip comprising a trim strip body having a top
surface and a bottom surface, the trim strip body extending along a
body axis and having a first cross-sectional shape normal to the
body axis; a die comprising a first aperture having a second
cross-sectional shape that is different than the first
cross-sectional shape of the trim strip, the first aperture adapted
to receive the formable trim strip such that the trim strip body is
changed from having the first cross-sectional shape to a
cross-sectional shape that corresponds to the second
cross-sectional shape as the formable trim strip is displaced
through the first aperture.
17. The assembly of claim 16, wherein the second cross-sectional
shape comprises one of: (a) a generally 90-degree cross-section;
and (b) a generally bull-nosed cross-section.
18. The assembly of claim 16, wherein a backing paper is affixed to
the bottom surface of the trim strip body by depositing the trim
strip directly thereon, without an intervening layer of
adhesive.
19. The assembly of claim 18, wherein the trim strip body comprises
a polymer material having a melting point range between about
250.degree. F. and about 400.degree. F., and wherein the bottom
surface of the trim strip body contacts a portion of the backing
paper when a temperature of the trim strip body is within the
melting point range, and as the trim strip body cools to a
temperature below the melting point range, the portion of the
backing paper bonds to the bottom surface of the trim strip
body.
20. The assembly of claim 18, further comprising a heating element
thermally coupled to the die.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The priority benefit of U.S. Provisional Application No.
62/328,383, filed on Apr. 27, 2016, and U.S. Provisional
Application No. 62/345,480, filed Jun. 30, 2016, is claimed and the
entire contents of each are expressly incorporated herein by
reference.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to a trim strip for
protecting a corner formed by at least two sheets of drywall.
BACKGROUND
[0003] During the construction process, a trim strip (also referred
to as a "corner bead") is often used when finishing drywall (i.e.,
gypsum wallboard). This trim strip is typically a length of rigid
or semi-rigid material that covers exposed drywall at a corner
junction to protect the corner and to provide a finished and clean
appearance to the corner. Generally, any corner where two sheets of
drywall meet to form an angle less than 180 degrees may be
protected with trim strip, and in most applications, the corner
angle is usually approximately 90 degrees.
[0004] The trim strips, once formed, can be attached over a desired
corner via mechanical fasteners, using adhesives, and/or using
drywall joint compound. Mechanical fasteners such as screws can be
inserted through apertures formed along both side walls of the trim
strip and then anchored to the drywall to secure the trim strip
over the corner. The joint compound, in paste form, is then applied
over the trim strip and the mechanical fasteners. When dry, the
resulting joint compound has a smooth finish that can be
subsequently sanded and painted.
[0005] Trim strips attached with mechanical fasteners make
finishing processes such as sanding more difficult, and also make
the trim strips prone to edge cracking of the joint compound.
Additionally, the use of joint compound requires a substantial
drying time. For example, if a backing paper is used, the joint
compound generally requires a drying time of at least twelve hours,
during which time no corner finishing or painting may occur.
[0006] When using joint compound, backing paper (also referred to
as "wings") may be coupled to the trim strip to improve the bond
with the joint compound to aid in attachment and in durability of
the finished corner. The backing paper is typically secured to a
surface of the trim strip using an adhesive, and the trim strip may
be positioned on the corner so the backing paper is disposed on the
outside (i.e., the trim strip is disposed between the drywall and
the backing paper).
[0007] For corners that may be subject to impact, plastic trim
strips are commonly used. These trim strips are typically made of a
polymer that is shaped to a desired angle and cross-sectional
geometry. The bulk trim strips then are cut into desired lengths or
"sticks" that correspond to the interior height of the wall. Some
existing products are constructed from flexible plastics, in strip
form, that can be adjusted to various angles. These products are
generally manufactured for use in smaller batches. However, in
these products, the plastic remains flexible, (i.e., not rigid),
and it cannot be permanently formed into many desired
cross-sectional shapes (such as bullnose curves) when cooled.
SUMMARY
[0008] A formable trim strip for use on a corner of at least two
sheets of drywall includes a trim strip body extending along a body
axis and having a top or inside surface and a bottom surface. The
trim strip body is formed from a polymer material having a melting
point range between about 250.degree. F. and about 400.degree. F.
The multi-layer formable trim strip also includes a backing paper,
and a portion of this backing paper is secured to the bottom
surface of the trim strip body. The backing paper is not secured to
the bottom surface of the trim strip body by an adhesive. Rather,
the trim strip body is deposited onto the portion of the backing
paper when a temperature of the trim strip body is within the
melting point range such that the bottom surface of the trim strip
body contacts the portion of the backing paper. As the trim strip
body cools to a temperature below the melting point range, the
portion of the backing paper bonds to the bottom surface of the
trim strip body.
[0009] A method of forming a multi-layer formable trim strip for
use on a corner of at least two sheets of drywall that includes
heating a polymer material having a melting point range between
about 250.degree. F. and about 400.degree. F. to a temperature
between the melting point range. The method also includes advancing
a backing paper positioned proximal to the polymer material, and
depositing the polymer material onto a portion of the backing paper
to form a trim strip body having a top surface and a bottom
surface, whereby the bottom surface is in contact with the backing
paper. The method further includes allowing the trim strip body to
cool (or cooling the trim strip body) to a temperature below the
melting point range such that the portion of the backing paper
bonds to the bottom surface of the trim strip body.
[0010] An assembly for forming a formable trim strip for use on a
corner of two sheets of drywall includes a formable trim strip
having a trim strip body that has a top surface and a bottom
surface, the trim strip body extending along a body axis and having
a first cross-sectional shape normal to the body axis. The assembly
also includes a die having a first aperture that has a second
cross-sectional shape that is different than the first
cross-sectional shape of the trim strip. The first aperture is
adapted to movably receive the formable trim strip such that the
trim strip body of is changed from having the first cross-sectional
shape to a cross-sectional shape that corresponds to the second
cross-sectional shape as the formable trim strip is displaced
through the first aperture.
[0011] A trim strip assembly is provided for use on a corner formed
by at least two sheets of drywall. The trim strip assembly includes
a trim strip body extending along a body axis that may extend
longitudinally, and the trim strip body may have at least one
inside surface 18. The trim strip assembly also includes an
adhesive layer formed over at least a portion of the at least one
inside surface of the trim strip body, the adhesive layer having a
softening point range such that when the adhesive layer is heated
to a temperature within the softening point range, the adhesive
layer bonds to at least one of the at least two sheets of drywall
to secure the trim strip body to the at least one of the at least
two sheets of drywall.
[0012] A trim strip assembly is provided for use on a corner of at
least two sheets of drywall, the trim strip assembly including a
trim strip body extending along a body axis and having at least one
inside surface and at least one outside surface. The trim strip
body comprises an adhesive material having a softening point range,
wherein when the trim strip body is heated to a temperature within
the softening point range, at least a portion of the inside surface
of the trim strip body bonds to at least one of the at least two
sheets of drywall to secure the trim strip body to the at least one
of the at least two sheets of drywall.
[0013] An application tool is provided for securing a trim strip
assembly on a corner of at least two sheets of drywall, the trim
strip assembly including a trim strip body having a first side wall
and a second side wall and a heat activated adhesive layer formed
over at least a portion of an inside surface of the first side wall
and an inside surface of the second side wall. The application tool
includes a base member having a first base wall and a second base
wall, the first base wall having an inside surface and an outside
surface and the second base wall having an inside surface and an
outside surface, the base member extending parallel to a base axis
from a first end to a second end. The application tool also
includes a first heating member coupled to the inside surface of
the first base wall of the base member and a second heating member
coupled to the inside surface of the second base wall of the base
member. When the application tool is positioned along the trim
strip assembly such that an outer surface of the first heating
member is disposed in contact with or adjacent to a portion of the
outside surface of the first side wall of the trim strip body and
an outer surface of the second heating member is disposed in
contact with or adjacent to a portion of the outside surface of the
second side wall of the trim strip body, (a) heat generated by the
first heating member is adapted to be transferred through the first
side wall of the trim strip body to activate the heat activated
adhesive layer disposed on the inside surface of the first side
wall to bond the first side wall of the trim strip body to the
first of the two sheets of drywall and (b) heat generated by the
second heating member is adapted to be transferred through the
second side wall of the trim strip body to activate the heat
activated adhesive layer disposed on the inside surface of the
second side wall to bond the second side wall of the trim strip
body to the second of the two sheets of drywall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above needs are at least partially met through provision
of the formable corner finishing and trim strip described in the
following detailed description, particularly when studied in
conjunction with the drawings, wherein:
[0015] FIG. 1A is top view of a portion of an embodiment of a
formable trim strip;
[0016] FIG. 1B is a cross-sectional view of the embodiment of the
formable trim strip taken along line I-I of FIG. 1;
[0017] FIG. 1C is a cross-sectional view of an alternative
embodiment of the formable trim strip taken along line I-I of FIG.
1;
[0018] FIG. 1D is a cross-sectional view of another alternative
embodiment of the formable trim strip taken along line I-I of FIG.
1;
[0019] FIG. 2 is a perspective view of an embodiment of a formable
trim strip secured to a corner formed by two sheets of drywall;
[0020] FIGS. 3A-3C are cross-sectional views of alternative
embodiments of a formable trim strip taken along line I-I of FIG.
1;
[0021] FIG. 4 is a cross-sectional view of an embodiment of a
formable trim strip secured to a corner formed by two sheets of
drywall;
[0022] FIG. 5 is a side view of one embodiment of a manufacturing
system for manufacturing a trim strip according to the
disclosure;
[0023] FIGS. 6A and 6B are schematic top and side views,
respectively, of an embodiment of an assembly or kit for forming a
formable trim strip for use on a corner of two sheets of
drywall;
[0024] FIGS. 7A and 7B are cross sectional views of alternative
embodiments of a die taken along line II-II of FIG. 6;
[0025] FIG. 8A is a top view of a portion of another alternative
embodiment of a trim strip assembly;
[0026] FIG. 8B is a cross-sectional view of the embodiment of the
trim strip assembly of FIG. 8A taken along line III-III;
[0027] FIG. 9 is cross-sectional view of an alternative embodiment
of the trim strip assembly of FIG. 8A taken along line III-III;
[0028] FIG. 10A is a top view of a portion of an alternative
embodiment of a trim strip assembly;
[0029] FIG. 10B is a cross-sectional view of the embodiment of the
trim strip assembly of FIG. 10A taken along line IV-IV
[0030] FIG. 11A is a perspective view of an embodiment of an
application tool adapted to secure a trim strip assembly along a
corner formed by two sheets of drywall; and
[0031] FIG. 11B is a front view of the embodiment of the
application tool illustrated in FIG. 11A.
[0032] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions and/or
relative positioning of some of the elements in the figures may be
exaggerated relative to other elements to help to improve
understanding of various embodiments of the present invention.
Also, common but well-understood elements that are useful or
necessary in a commercially feasible embodiment are often not
depicted in order to facilitate a less obstructed view of these
various embodiments. It will further be appreciated that certain
actions and/or steps may be described or depicted in a particular
order of occurrence while those skilled in the art will understand
that such specificity with respect to sequence is not actually
required. It will also be understood that the terms and expressions
used herein have the ordinary technical meaning as is accorded to
such terms and expressions by persons skilled in the technical
field as set forth above except where different specific meanings
have otherwise been set forth herein.
DETAILED DESCRIPTION
[0033] As illustrated in FIGS. 1A-2, a formable trim strip 10 is
provided for use on a corner 12 formed by at least two sheets of
drywall 14. With reference to FIGS. 1A and 1B, the formable trim
strip 10 may have any number of layers and may include a trim strip
body 16 having a top surface 18 and a bottom surface 20. The trim
strip body 16 may extend along a body axis 22. The body axis 22 may
extend longitudinally (that is, parallel to the X-axis of the
reference coordinate system of FIGS. 1A and 1B). The trim strip
body 16 may comprise or be made of a polymer material (e.g., a
thermo-formable polymer) having a melting point range between about
250.degree. F. and about 400.degree. F. In some examples, the
polymer used is DHM 5000 FA40, which is commercially available from
DHM Adhesives Inc. of Calhoun, Ga., USA. Other examples of suitable
polymers are possible. It is understood that the polymer may be a
pure polymer or may include any number of fillers to provide
desired characteristics such as increased flexibility, increased
rigidity, decreased shrinkage, flame retardation, and the like.
Some fillers may include calcium carbonate, silica, titanium oxide,
colorants, carbon, glass, Kevlar, silanes, titanates, chlorine,
bromine, and any other known fillers.
[0034] The formable trim 10 may also include a backing paper 24, a
portion 25 of which, as will be described in further detail, may be
affixed or secured to the bottom surface 20 of the trim strip body
16. When the portion 25 of the backing paper 24 is placed in
contact with the bottom surface 20 of the trim strip body 16 when a
temperature of the trim strip body 16 is within the melting point
range, the polymer material itself acts as an adhesive. That is,
when the polymer material cures and/or cools to a temperature
outside of or below its melting point range, the portion 25 of the
backing paper 24 is secured to, bonds to, and/or adheres to the
bottom surface 20 of the trim strip body 16. Accordingly, an
adhesive that is typically used to secure the trim strip body 16 to
the backing paper 24 is eliminated, thereby eliminating the
material cost of the adhesive and the manufacturing costs of
adhesive application during production.
[0035] Turning to the formable trim strip 10 in more detail, the
formable trim strip 10 (as well as the trim strip body 16) may be
elongated and may extend along the body axis 22 from a first end 28
to a longitudinally-opposite second end 30, as illustrated in FIG.
1A. The distance between the first end 28 and the second end 30 may
be any suitable distance, and may be longer than a typical length
of trim strip such that a suitable portion or portions of the
formable trim strip 10 may be cut to size for particular corner
applications. In some versions, the trim strip 10 may be provided
to customers/contractors coiled in a large roll thereby allowing
custom lengths to be cut on the job site. A first side edge 32 of
the trim strip 10 may be spaced a lateral distance (that is, a
distance along the Y-axis of the reference coordinate system of
FIGS. 1A and 1B) from a second side edge 34. The first side edge 32
and the second side edge 34 may extend along the body axis 22 such
that the first side edge 32 and the second side edge 34 may
laterally define the trim strip body 16, and the first side edge 32
may be separated a lateral distance of 1.00'' to 3.00'' (or about
1.00'' to about 3.00)'' from the second side edge 34. In some
embodiments, the first side edge 32 and the second side edge 34 may
be mutually parallel and parallel to the body axis 22.
[0036] As illustrated in FIG. 1B, the top surface 18 of the trim
strip body 16 and the bottom surface 20 of the trim strip body 16
may extend between but not necessarily entirely between the first
side edge 32 and the second side edge 34. This is because in some
versions the backing paper 24 is wider than the trim body 16. The
bottom surface 20 is planar or substantially planar to correspond
with the planar configuration of the portion 25 of the backing
paper 24. The bottom surface 20 may be defined in cross-section by
a bottom edge 36 that may extend laterally or generally laterally
when viewed in a cross-section normal to the body axis 22 (i.e.,
the cross-section view of FIG. 1B), and the bottom edge 36 may be a
linear segment that extends between a bottom end of the first side
edge 32 and a bottom end of the second side edge 34.
[0037] The top surface 18 is adapted to be placed in contact with
an outer surface of a portion of the at least two sheets 14 of
drywall when disposed along the corner 12 (as illustrated in FIGS.
2 and 4), and the top surface 18 may have any suitable shape to be
used on or secured over the corner 12. The top surface 18 may be
defined in cross-section by a top edge 38 that may extend laterally
or generally laterally when viewed in a cross-section normal to the
body axis 22 (i.e., the cross section view of FIG. 1B), and the top
edge 38 may have any suitable shape or combination of shapes. For
example, as illustrated in FIGS. 1B-1D, the top edge 38 may be
linear and parallel to the bottom edge 36. The top edge 38 may be
defined by two or more segments that extend between a top end of
the first side edge 32 and a top end of the second side edge 34.
For example, the top edge 38 may be at least partially defined by a
first segment 38a that extends from the top end of the first side
edge 32 to a first point 40a at, aligned with, or adjacent to the
body axis 22. The top edge 38 may also be at least partially
defined by a second segment 38b that extends from the top end of
the second side edge 34 to a second point 40b at, aligned with, or
adjacent to the body axis 22. The first point 40a may be coincident
with the second point 40b or may be laterally offset from the
second point 40b. The first and second segments 38a, 38b may be
symmetrical about the body axis 22. The thickness of the first and
second segments 38a, 38b, as well as the trim strip body 16 in
general, may be between, in a non-limiting example, approximately
0.005'' and approximately 0.100'', such as a range of about 0.008''
to about 0.030''.
[0038] As illustrated in FIGS. 1A-1D, the formable trim strip 10
may also include at least one forming feature 42 that extends along
at least a portion of the trim strip body 16. It is understood that
in some examples, the formable trim strip 10 may not include a
forming feature 42. The at least one forming feature 42 extends
along a forming feature axis 44. The at least one forming feature
42 is configured to allow the trim strip body 16 to be deformed--or
easily deformed--about the forming feature axis 44 and/or about the
body axis 22. In some embodiments, when the formable trim strip 10
is deformed (e.g., folded) and positioned on a corner 12, an edge
19 defining the corner 12 may be disposed within a void 21 formed
by the at least one forming feature 42, as illustrated in FIG. 4.
In some embodiments, the at least one forming feature 42 may extend
along the forming feature axis 44 from the first end 28 to the
second end 30 of the trim strip body 16. In some embodiments, the
forming feature axis 44 may be parallel to or collinearly aligned
with the body axis 22.
[0039] The at least one forming feature 42 may be defined by a
forming feature edge 46 when viewed in cross-section, as
illustrated in FIGS. 1B-1D. The forming feature edge 46 may extend
from the first point 40a to the second point 40b, and the forming
feature edge 46 may be at least partially comprised of two or more
linear segments and/or one or more non-linear segments. The at
least one forming feature 42 may have any suitable shape or
combination of shapes to allow the trim strip body 16 to be
deformed about a forming feature axis 44 after the formable trim
strip 10 has cooled such that the temperate is lower than the
lowest range of the melting point range. At such a temperature, the
polymer is rigid or substantially rigid and is capable of
protecting the corner 12 when installed. For example, as
illustrated in FIG. 1B, the forming feature 42 may be a void
defining a generally rectangular channel or slot adapted to
facilitate bending of the trim strip 10 and optionally receive the
edge 19 defining the corner 12. In other examples, and as
illustrated in FIGS. 1C and 1D, the void of the forming feature 42
may have a U-shaped cross-section (FIG. 1C) or a 90-degree (e.g.,
V-shaped) cross-section (FIG. 1D), or any other desirable shape. A
vertical distance between the bottom surface 20 and the lowermost
portion of the forming feature edge 46 may be any suitable distance
that facilitates bending but ensures that the trim strip body 16
will not be damaged when bent or formed about the forming feature
axis 44, and the distance may be between approximately 0.01% to
approximately 25% of the lateral width of the trim strip body 16.
In some examples, and as illustrated in FIG. 3A, the void of the
forming feature 42 may extend entirely through the body 16 such
that it divides the trim strip body 16 into two separate
segments.
[0040] The forming feature 42 may be formed using any number of
tools which can form a void as the trim strip body 16 advances
during manufacturer. For example, as will be described further
below, during manufacture while the trim strip body 16 remains in a
molten state at a temperature within its range of melting
temperatures, a tool such as a pin, a wheel, a blade, of other such
device may be introduced against the top surface 18 of the cooling
trim strip body 16 in a manner that forms a depression or cut in
the trim strip body 16 that remains after the trim strip body 16
cools and hardens. In other versions, it is foreseeable to use a
tool to create the forming feature 42 during or after the trim
strip body 16 cools. Such a tool could include a rotary or circular
saw having any number of cross-sectional shapes, an etching device,
a machining tool, etc.
[0041] In some embodiments, such as that illustrated in FIGS. 3B
and 3C, a plurality of forming features 42 may extend across or
along the top surface 18, and each of the plurality of forming
features 42 may have any cross-sectional shape, dimension and
geometry. For example, each of the plurality of forming features 42
may have an identical cross-sectional shape. In some embodiments,
the plurality of forming features 42 may be U-shaped voids (e.g.,
grooves or recesses, as shown in FIG. 3C) that extend between
elongated portions of the trim strip body 16. Each of the plurality
of forming features 42 may extend along a corresponding forming
feature axis 44 that may each be parallel to the body axis 22. Any
or all of the plurality of forming features 42 may extend from the
first end 38 to the second end 40 of the trim strip body 16. The
trim strip body 16 may be bent or rotated about any, some, or all
of the forming feature axes 44, and any of the plurality of forming
features 42 may be adapted to receive the edge 19 defining the
corner 12.
[0042] As previously mentioned, the formable trim strip 10 may
include the backing paper 24, and the portion 25 of the backing
paper 24 may be secured to the bottom surface 20 of the trim strip
body 16. The backing paper 24 may be made of any suitable, durable
material (such as, for example, a paper material, a woven fiber
material, or other similar material or combination of materials),
and the backing paper 24 may facilitate the attachment of the
formable trim strip 10 to the drywall 14 by bonding with drywall
joint compound during installation. In some versions, the backing
paper 24 can be wallboard tape paper or other known industry
materials. The backing paper 24 may extend along any suitable
longitudinal length of the trim strip body 16, and the backing
paper 24 may extend from the first end 28 to the second end 30 of
the trim strip body 16. The backing paper 24 may have a lateral
width that is greater than the lateral width of the trim strip body
16. In some embodiments, the backing paper 24 may have a lateral
width that is equal to or substantially equal to the lateral width
of the trim strip body 16. In other embodiments, such as the
embodiment illustrated in FIG. 1B, a first portion 50a of the
backing paper 24 may extend beyond the first side edge 32 of the
trim strip body 16 (and beyond the portion 25 secured to the trim
strip body 16), and a second portion 50b of the backing paper 24
may extend beyond the second side edge 34 of the trim strip body 16
(and beyond the portion 25 secured to the trim strip body 16). The
first portion 50a and the second portion 50b may each have
identical or nearly identical widths, and as a non-limiting
example, the first portion 50a and the second portion 50b may each
be approximately 0.250'' to approximately 0.750'', for example.
[0043] During manufacturing, the backing paper 24 is not attached
to the trim strip body 16 by an adhesive. Instead, it is the
adhesive properties of the material of the trim strip body 16
itself (as it cools from a temperature within a melting point range
to a temperature outside or below the melting point range, or below
the lowest temperature of the melting point range) that secures the
portion 25 of the backing paper 24 to the bottom surface 20 of the
trim strip body 16. That is, the trim strip body 16 is made of,
fabricated from, and/or comprises a polymer material (such as a
thermoformable polymer, e.g., ethylene vinyl acetate or poly alpha
olefin) having a melting point range between about 250.degree. F.
and about 400.degree. F. The melting point range may be defined as
a range of temperatures of the material (or a portion of the
material) in which the material has reached a melted (liquid or
semi-liquid) state and is not in a fully solid state. The melting
point range is also defined as a range of temperatures of the
material (or a portion of the material) in which the material has
reached a liquid or semi liquid state, forms a bond to surfaces
(such as the backing paper 24), and will not sustain damage due to
overheating.
[0044] With reference now to FIG. 5, one system 100 and method for
manufacturing the disclosed trim strip 10 will be described. While
not necessarily depicted here, one system for applying the trim
strip body 16 to the backing paper 24 could be an Acumeter coating
machine commercially available from Acumeter Laboratories
Incorporated. The system 100 in FIG. 5 generally includes a hopper
102 storing polymer material to be melted and formed into the trim
strip body 16. The hopper 102 is disposed above a conveyor system
106 that moves paper backing 24 off of a roll and beneath an outlet
port 104 of the hopper 102. Accordingly, when the trim strip body
16 is manufactured, the stock polymer material is heated in the
hopper 102 to a temperature that is within the melting point range
to move the polymer into a molten state. Simultaneously, the
backing paper 24 is moved off of a roll and carried by the conveyor
system 106 beneath the hopper 102. The molten polymer is then
expelled from the outlet port 104 of the hopper 102 and deposited
or coated directly onto the backing paper 24. In some versions, the
outlet port 104 includes a specific geometry and/or configuration
such that the molten polymer may be evenly deposited onto the
backing paper 24 at the desired portion 25 create the desired
shape. As the combined backing paper 24 and molten polymer travel
away from the hopper 102 (to the right relative to the orientation
of FIG. 5), the polymer begins to cool and harden into the trim
strip body 16. As illustrated in FIG. 1B, the resulting trim strip
body 16 may be generally rectangular in shape, and in other
examples (as illustrated in FIG. 1D), the first and second side
edges 32, 34 may be generally curved due to gravitational forces
acting on the molten material as it cools. Other examples of
cross-sectional shapes are possible.
[0045] As the trim strip body 16 cools to a temperature that is
below the melting point range, the portion 25 of the backing paper
24 that supports the molten polymer bonds and/or becomes secured to
the bottom surface 20 of the trim strip body 16. The cooling
process that secures the portion 25 of the backing paper 24 to the
bottom surface 20 of the trim strip body 16 may take any suitable
amount of time, and the trim strip body 16 may cool to a cooling
range (between approximately 40.degree. F. and approximately
80.degree. F.) before any further processing. No adhesive--and no
manufacturing process applying adhesive--is required. Accordingly,
the cost associated with both the material and the process is
eliminated. When the trim strip body 16 cools to a temperature that
is below the melting point range (and may be within the cooling
range) and when the backing paper 24 is suitably secured to the
bottom surface 20 of the trim strip body 16, the formable trim
strip 10 may be then fully cured but yet flexible such that the
formable trim strip 10 may be coiled or rolled (not shown) for
transport to a retailer or a job site, for example. However, when
the trim strip body 16 cools to a temperature that is below the
melting point range, the formable trim strip 10 is sufficiently
flexible that it may be deformed and unrolled, and ultimately bent
about one or more of the forming feature axes 44 yet sufficiently
rigid to protect the corner 12 when installed as described
below.
[0046] It is understood that the forming feature or features 42 may
be formed at different points in the manufacturing process. For
example, the forming feature 42 may be formed while the body
material is within the melting point range or after the material
has cooled and formed the trim strip body 16. In those embodiments
where the forming feature 42 comprises one or more recesses,
channels or grooves in the trim strip body 16 (see, e.g., FIGS. 1B,
1C, 1D, and 3C) such features 42 may be formed by a tooling device
108 such as that depicted in FIG. 5. The device 108 may include a
tool 210 such as a pin, a knife, a wheel, etc., for directly
engaging and forming the forming feature 42 into the molten polymer
material before it hardens into the trim strip body 16. In some
versions, the tool 210 could be selected from a plurality of
available tools for creating a forming feature 42 of a desired
shape. In some versions, the tool 110 may resemble a fork or other
arrangement with multiple points of contact with the molten
material such that the arrangement of multiple forming features 42
depicted in FIG. 3C could easily be achieved. For other versions of
the trim strip 10 where the trim strip body 16 includes two or more
segments separated by a gap (see, e.g., FIGS. 3A and 3B), this may
be achieved by the hopper 102 in the system of FIG. 5 having two or
more separate side-by-side outlet ports 104 such that two or more
parallel portions of the trip strip body 16 can be coated onto the
backing paper 24 simultaneously. In still other versions that are
not depicted in in the drawings of the present application, it is
foreseeable to have a trim strip 10 that includes a trim strip body
16 with both gaps (as shown in FIGS. 3A and 3B) and recesses,
channels, or grooves (as shown in FIGS. 1B, 1C, 1D and 3C). Thus,
it would be appreciated that the system 100 in FIG. 5 could include
a combination of multiple outlet ports 104 (whether form a common
or separate hoppers) and one or more tools 110 each having one or
more points of contact with the molten polymer.
[0047] Further, any number of additional manufacturing processes
may be implemented before or after the formation of the trim strip
body 16. For example, the formable trim strip 10 may include any
number of additional layers such as an adhesive layer applied to
the top surface 18 of the trim strip body 16 to assist in securing
the formable trim strip 10 to the wall. This adhesive layer may be
applied after or at the same time the trim strip body 16 is flowed,
deposited, or coated onto the backing paper 24. With such an
arrangement, the applied adhesive opposite the backing paper 24
would be utilized to actually secure the trim strip 10 to the
drywall at the construction site. It is understood that a number of
suitable approaches to applying the adhesive may be used, such as,
for example, spraying via a nozzle, rolling, film, painting, and
the like. In the system of FIG. 5, an adhesive applicator 112 is
depicted downstream of the tooling device 208 and this applicator
112 could be a spray applicator, a roller applicator, a film
applicator, etc. In some of these examples, an additional release
layer may be applied over the adhesive surface which can be removed
prior to affixing the formable trim strip 10 to the corner 12. In
FIG. 5, one version of the manufacturing system 100 can include a
roll of release layer 114 disposed downstream of the adhesive
applicator which can be applied over the adhesive after the
adhesive is applied to the trim strip body 16. Other examples are
possible.
[0048] Once at the job site, when it is desired to secure the
formable trim strip 10 on or over a corner 12 formed by at least
two sheets 14 of drywall, a suitable length of the formable trim
strip 10 may be uncoiled and cut to desired dimensions based on the
length of the corner 12. This (or any) length of formable trim
strip 10 may extend from the first end 28 to the second end 30, and
if more than one portion of the formable trim strip 10 is cut from
a single coil, each portion of the formable trim strip 10 may
extend from the first end 28 to the second end 30. The formable
trim strip 10 can then be bent by any suitable angle along the
forming feature axis 44 (which may be parallel to the body axis 22)
to fit around a desired corner 12. For example, as illustrated in
FIG. 4, the formable trim strip 10 can then be bent along the
forming feature axis 44 over a corner having any angle less or
greater than 180.degree. and secured to the drywall 14 using any
known manner.
[0049] In some examples, materials such as drywall joint compound
and/or adhesives may be used to secure the trim strip 10 to
drywall. For example, as depicted in FIG. 4, one application
technique includes applying portions 53a, 53b of joint compound to
the top surface 18 of the trim strip body 16 and the immediately
adjacent portions 50a, 50b of the backing paper 24. The trim strip
10 is then applied to the wall, and additional portions 52a, 52b of
joint compound is applied to fill side recess 52a, 52b formed along
an outer surface 23 of the backing paper 24 adjacent to the trim
strip body 16. This material can be used to create a smooth corner
surface free of blemishes and to increase the adhesion of the
formable trim strip 10 to the corner.
[0050] Referring now to FIGS. 6-7B, an assembly 200 (or system or
kit) may be used to form the previously discussed formable trim
strip 10 for use on a corner 12 of two sheets of drywall. The
assembly can include a die 204 having an aperture 206 (FIGS. 7A and
7B) having a second cross-sectional shape 208 that is different
than a first cross-sectional shape 202 (as illustrated in various
example forms in FIGS. 1B-1D) of the formable trim strip 10. For
example, as illustrated in FIG. 7A, which illustrates an example
die 204 cross-section, the second cross-sectional shape 208 may
have a 90-degree shape (or a general V-shape), and in other
examples, as illustrated in FIG. 7B, an example die 204 has a
bull-nosed second cross-sectional shape 208. In some versions, the
die 204 can include a clamshell or sandwich type construction such
that when opened (not shown), the formable trim strip 10 is
positioned between opposing first and second portions 204a, 204b of
the die 204. Then, once the die 204 is closed (depicted in FIGS.
7A, 7B), the trim strip 10 can be pushed or pulled out of the die
204 through the aperture 206. Such clamshell or sandwich type dies
204 may include a hinge 209 for moving the first portion 204a of
the die 204 relative to the second portion 204b of the die 204
between open and closed (depicted in FIGS. 7A, 7B) positions. In
other versions, the die 204 may be of single piece construction and
the first aperture 206 may be adapted to slidably receive (or
movably or displaceably receive) the formable trim strip 10 such
that as the formable trim strip body is displaced (e.g., pushed or
pulled) through the aperture 206. The formable trim strip body 16
of the formable trim strip 10 is changed, modified, altered, or
adjusted from having the first cross-sectional shape 202 to a
cross-sectional shape that corresponds to the second
cross-sectional shape 208.
[0051] Referring to FIG. 6A, the first aperture 206 may extend
along a longitudinal axis 210 of the die 204, and the first
aperture 206 may be uniform or constant over the length of the
longitudinal axis 210. This is particularly true when the die 204
includes a clamshell or sandwich type construction as discussed
above.
[0052] In other examples, including those for example where the die
204 is of single piece construction, a geometry or profile of the
first aperture 206 may change along the longitudinal axis 210 from
a first end 212 of the die 204 to a second end 214 of the die 204.
That is, at the first end 212, the first aperture 206 may have a
cross-sectional shape that closely corresponds to the first
cross-sectional shape 202 and at the second end 214, the first
aperture 206 may have a cross-sectional shape that corresponds to
the second cross-sectional shape 208. Accordingly, the formable
trim strip 10 may be easily inserted into the die 204 without
needing manipulation.
[0053] The transition between the first cross-sectional shape 202
at the first end 212 and the second cross-sectional shape 208 at
the second end 214 may be gradual, and the die 204 may have any
suitable longitudinal length between the first end 212 and the
second end 214 to allow the cross-sectional shape of the formable
trim strip 10 to be changed from the first cross-sectional shape
202 to the second cross-sectional shape 208.
[0054] As shown in FIG. 6A, a heating element 216 may be thermally
coupled to the die 204 to heat the trim strip body 16 of the
formable trim strip 10 to a temperature within a softening point
range of the polymer material used to construct the trim strip body
16. In some embodiments, the heating element 216 may heat the die
204 to a temperature within the softening point range of the
polymer material. The softening point range may be defined as a
range of temperatures of the material (or a portion of the
material) forming the trim strip body 16 in which the material can
be formed or shaped using moderate pressure, but in which the
material does not flow as a liquid or semi-liquid. The highest
temperature within the softening point range may be below the
lowest temperature of the melting point range so that during the
forming process, the material does not melt. The polymer material
of the trim strip body 16 may have softening point range between
approximately 110.degree. F. and approximately 210.degree. F., and
more particularly, between approximately 125.degree. F. and
approximately 175.degree. F.
[0055] When a suitable portion of the formable trim strip 10
emerges or exits from the second end 214 of the of the die 204, a
cutting element 217 may be used to cut the formable trim strip 10
to a desired longitudinal length, thereby creating a new first end
28 and second end 30. The cutting element 217 may be any suitable
blade or blade assembly capable of cutting the formable trim strip
10 in a lateral direction, such as a blade that moves normal to the
longitudinal axis 210.
[0056] In some examples, the assembly 200 may include a kit that
include any number of alternative dies having different apertures.
These additional dies can be used to alter the cross-sectional
shape of the trim strip body 16 based on customer demands, for
example, and can operate in a similar manner to the die 204.
[0057] In use, the trim strip body 16 of formable trim strip 10 is
advanced through the first aperture 206 of the die 204 (along arrow
230 of FIG. 6) as described. Thus, as the formable trim strip 10
exits the second end 214 of the first aperture 206, the formable
trim strip 10 (and the trim strip body 16 of the trim strip 10)
will be formed or molded to have a cross-sectional shape that
corresponds to the second cross-sectional shape 208. The formable
trim strip 10 may then be cut to size using the cutting element
217. The cutting may occur before or after the trim strip body 16
has a temperature within the cooling range. If a different
cross-sectional shape of trim strip is required, a suitable die is
used (i.e., an alternative second die), and the trim strip body 16
of the formable trim strip 10 is advanced through a second aperture
of this second die.
[0058] Accordingly, when the material of the formable trim strip 10
is cooled to a temperature below the softening point range (e.g.,
to a temperature within the cooling range) after forming by the die
204, the formable trim strip 10 maintains its second
cross-sectional shape 208 yet remain rigid. As such, this system
advantageously enables on site forming of custom shaped trim
strips. Because the final product, after forming, is rigid and
holds the angle or curve that has been formed, the finishing will
be of higher quality and greater versatility than when using a
conventional flexible plastic strip.
[0059] As illustrated in FIGS. 8A and 8B, a formable trim strip
assembly 310 is provided for use on a corner formed by at least two
sheets of drywall 314. The trim strip assembly 310 may include a
trim strip body 316 extending along a body axis 322 that may extend
longitudinally (that is, parallel to the X-axis of the reference
coordinate system of FIG. 8A), and the trim strip body 316 may have
at least one inside surface 318, which may correspond to the upper
surface 18 previously discussed. The inside surface 318 may be an
inside surface of a first side wall 328 of the trim strip body 314.
In some embodiments, the trim strip body 316 may also include an
inside surface 320 of a second side wall 330 of the trim strip body
316. The first side wall 328 and the second side wall 330 may have
a 90-degree (e.g., V-shaped) cross-section when viewed along the
body axis 322. The trim strip assembly 310 also includes an
adhesive layer 323 formed over at least a portion of the at least
one inside surface 318 of the trim strip body 316 (e.g., the inside
surface 318 of the first side wall 328). In some examples, the
adhesive layer 323 has a softening point range such that when the
adhesive layer 323 is heated to a temperature within the softening
point range, the adhesive layer 323 bonds to at least one of the at
least two sheets of drywall 314 to secure the trim strip body 316
to at least one of the at least two sheets of drywall 314.
[0060] So configured, by heating the adhesive layer 323 to a
temperature within the softening point range and applying the trim
strip assembly 310 over the corner 12, the adhesive layer 323 bonds
to at least one of the least two sheets of drywall 314.
Importantly, because the bond is formed nearly instantaneously,
thereby eliminating the need for both mechanical fasteners and the
use of the slow-drying joint compound. In addition, by eliminating
the need for mechanical fasteners and joint compound, the trim
strip assembly 310 presents an esthetically-pleasing low-profile
when secured over the corner 12.
[0061] The trim strip body 316 may be elongated and may extend
along the body axis 322 from a first end 324 to a
longitudinally-opposite second end 326, as illustrated in FIG. 8A.
The distance between the first end 324 and the second end 326 may
be any suitable distance for a particular corner application. The
trim strip body 316 may include the first side wall 328 and a
second side wall 330, and the first side wall 328 and the second
side wall 330 may extend from the first end 324 and the second end
326. The first side wall 328 and the second side wall 330 may each
be planar, and a top portion of the first side wall 328 may be
integrally formed with or coupled to a top portion of the second
side wall 330 such that the first side wall 328 and the second side
wall 330 have (or cooperate to form) a cross-sectional shape of a
"V" when viewed along the body axis 322. In some embodiments, the
first side wall 328 and the second side wall 330 may each be curved
or have curved portions, and a top portion of the first side wall
328 may be integrally formed with or coupled to a top portion of
the second side wall 330 such that the first side wall 328 and the
second side wall 330 have (or cooperate to form) a cross-sectional
shape of a "U" when viewed along the body axis 322.
[0062] As illustrated in FIG. 8B, the first side wall 328, when
viewed in cross-section, may extend from a bottom edge 332 to an
upper edge 334 at the top portion of the first side wall 328. In
addition, the second side wall 330 may extend from a bottom edge
336 to the upper edge 334 at the top portion of the second side
wall 30. When viewed in cross-section, the first side wall 328 may
form any suitable angle with the second side wall 330. This angle
may typically be between approximately 60.degree. and approximately
120.degree., for example, approximately 90.degree.. The first side
wall 328 may include the inside surface 318 and an outside surface
340 opposite to the inside surface 318. Similarly, the second side
wall 330 may include the inside surface 320 and an outside surface
344 opposite to the inside surface 320. The first side wall 328 and
the second side wall 330 may each have any suitable thickness or
combination of thicknesses. In some embodiment, the bottom edge 332
of the first side wall 328 and the bottom edge 336 of the second
side wall 330 may be mutually parallel and parallel to the body
axis 322. The upper edge 334 may be parallel and co-linearly
aligned with the body axis 322.
[0063] As previously described, the trim strip body 316 may be made
of, fabricated from, and/or comprise a polymer material (such as,
for example, a polystyrene, polyolefin, polyester, polyvinyl
chloride, or acrylonitrile butadiene styrene) having a melting
point range between about 250.degree. F. and about 450.degree. F.
In other embodiments, the trim strip body 316 may be made of,
fabricated from, and/or comprise a heavy paper material (such as
cardboard) alone or in combination with a polymer such as an
infused polymer or absorbed polymer. Other examples are
possible.
[0064] As illustrated in FIG. 8B, a backing paper 346 may be
secured to the outside surface 340 of the first side wall 328 of
the trim strip body 316 and the outside surface 344 of the second
side wall 330 of the trim strip body 316. The backing paper 46 may
be made of any suitable, durable material (which may be a paper
material, a woven fiber material, or other similar material or
combination of materials), and the backing paper 46 may facilitate
the attachment of the trim strip assembly 10 to the drywall 314 by
bonding with drywall joint compound during installation.
[0065] As illustrated in FIG. 8B, the trim strip assembly 10 also
includes the adhesive layer 323 formed over or disposed on at least
a portion of the inside surface 318 of the trim strip body 316. As
previously explained, the inside surface 318 may be the inside
surface 318 of the first side wall 328 of the trim strip body 316,
and a first portion 323a of the adhesive layer 323 may be formed
over or disposed on the entire inside surface 318 of the first side
wall 328 or a portion thereof. In addition, a second portion 323b
of the adhesive layer 323 may be formed over or disposed on the
entire inside surface 320 of the second side wall 330 or a portion
thereof. In some embodiments, the first portion 323a of the
adhesive layer 323 and the second portion 323b of the adhesive
layer 323 may be integrally formed at or adjacent to the upper edge
334 at the top portion of the first side wall 28 and the second
side wall 330. In other embodiments, the first portion 323a of the
adhesive layer 323 may be separated from the upper edge 34 at the
top portion of the first side wall 328 by a gap that extends
parallel to the upper edge 334, and the second portion 323b of the
adhesive layer 323 may be separated from the upper edge 334 at the
top portion of the second side wall 330 by a gap that extends
parallel to the upper edge 334.
[0066] The adhesive layer 323 may be made from or comprise any
material having a softening point range such that when the adhesive
layer 323 is heated to a temperature within the softening point
range, the adhesive layer 323 bonds to at least one of the at least
two sheets of drywall 314 to secure the trim strip body 316 to the
at least one of the at least two sheets of drywall 314. The
softening point range may be a range of temperatures in which the
material (or a portion of the material) forming the adhesive layer
323 has adhesive properties or qualities, and when temperatures of
the material (or a portion of the material) forming the adhesive
layer 323 are below the softening point range, the material (or a
portion of the material) forming the adhesive layer 323 does not
have adhesive properties or qualities. The highest temperature
within the softening point range may be below the lowest
temperature of the melting point range so that during the
activation (or heating) process of the adhesive layer 323, the
material comprising or forming the trim strip body 316 does not
melt. In some embodiments, the softening point range is between
approximately 125.degree. F. and approximately 225.degree. F. The
adhesive layer 323 may be any suitable material having a suitable
softening point range, such as a heat-activated hot melt adhesive.
For example, the material may be ethylene vinyl acetate or poly
alpha olefin.
[0067] The adhesive layer 323 may be formed or distributed over the
inside surface 318 of the first side wall 328 and/or the inside
surface 320 of a second side wall 330 in any suitable manner to
allow the material forming the adhesive layer 323 to form a bond or
be secured to one or both of the at least two sheets of drywall
314. For example, the first portion 323a of the adhesive layer 323
and/or the second portion 323b of the adhesive layer 323 may be
formed or distributed as an even, uniform layer over the inside
surface 318 of the first side wall 328 and/or the inside surface
320 of the second side wall 330. In other embodiments, the first
portion 323a of the adhesive layer 323 and/or the second portion
323b of the adhesive layer 323 may be formed as strips, patterns,
shapes, or any combination therefor that include gaps between
portions of the first portion 323a and/or the second portion
323b.
[0068] To secure the trim strip assembly 310 to the corner 12
formed by the at least two sheets of drywall 314, a user may first
position the trim strip assembly 310 in a desired corner location.
In such a position, the adhesive layer 323 (e.g., the first portion
323a of the adhesive layer 323 and the second portion 323b of the
adhesive layer 323) may be positioned to be in contact with (or
adjacent to) one or more corresponding portions of the first sheet
of drywall 314 and/or one or more corresponding portions of the
second sheet of drywall 314. In some embodiments, the first portion
323a of the adhesive layer 323 may be positioned to be in contact
with (or adjacent to) one or more corresponding portions of the
first sheet of drywall 314 and the second portion 323b of the
adhesive layer 323) may be positioned to be in contact with (or
adjacent to) one or more corresponding portions of the second sheet
of drywall 314. A heating element or tool (an embodiment of which
will be described in more detail below) may be placed on (or
adjacent to) the trim strip body 316 (and, in some embodiments,
over the backing paper 346 or in contact briefly with the adhesive
layer 323) to heat the adhesive layer 323 to a temperature within
the softening point range (and below the lowest temperature at
which the material of trim strip body 316 begins to melt). The
heating element or tool may be a flat iron or other hand held iron
(not shown) that may be placed in contact with a flat portion of
the trim strip body 316 or a shaped heating tool (not shown) that
may correspond to the shape of the trim strip body 316 and may be
placed in contact with a longitudinal lengthwise portion of the
trim strip body 316.
[0069] After a suitable amount of heating time, the adhesive or
bonding qualities of the adhesive layer 323 are activated and the
adhesive layer 323 bonds to one or more corresponding portions of
the first sheet of drywall 314 and/or one or more corresponding
portions of the second sheet of drywall 314 to secure the trim
strip assembly 310 to at least one of the first or second sheets of
drywall 314. In some embodiments, the first portion 323a of the
adhesive layer 323 may be heated to a temperature within the
softening point range and may secure the first side wall 328 of the
trim strip assembly 310 to the first sheet of drywall 314 and the
second portion 323b of the adhesive layer 323 may be heated to a
temperature within the softening point range and may secure the
second side wall 330 of the trim strip assembly 310 to the second
sheet of drywall 314.
[0070] In some embodiments, the adhesive layer 323 may be heated to
a temperature within the softening point range (and below the
lowest temperature at which the material of trim strip body 316
begins to melt) prior to positioning the trim strip assembly 310 in
a desired corner location. In such an embodiment, trim strip
assembly 310 may be placed in or pushed through a stationary heater
to heat the adhesive layer. Subsequently, the pre-heated first
portion 323a of the adhesive layer 323 may secure the first side
wall 328 of the trim strip assembly 310 to the first sheet of
drywall 314 and the pre-heated second portion 323b of the adhesive
layer 323 may secure the second side wall 330 of the trim strip
assembly 310 to the second sheet of drywall 314. A corner rolling
tool, flat iron, or any other device (not shown) may also be used
to apply pressure to the first side wall 328 and/or the second side
wall 330 of the trim strip body 316.
[0071] When the adhesive layer 323 cools to a temperate lower than
the lowest temperature of the softening point range, the adhesive
layer 323 provides a secure bond to and/or a permanent bond with
the one or more corresponding portions of the first sheet and/or
one or more corresponding portions of the second sheet of drywall
314.
[0072] Referring to FIG. 9, an embodiment of the trim strip
assembly 310a may include a trim strip body 316a that may be nearly
identical to the trim strip body 316 previously described, and
accordingly, like reference numbers will not be changed. However,
the trim strip body 316a of the trim strip assembly 310a may be
made of, fabricated from, and/or comprise an adhesive material, and
therefore the trim strip assembly 310a does not have an adhesive
layer 323 formed or distributed over the inside surface 318 of the
first side wall 328 and/or the inside surface 320 of a second side
wall 330. More specifically, the entire trim strip body 316a may be
made from or comprise any material having a softening point range
such that when the trim strip body 316a is heated to a temperature
within the softening point range, portion of the trim strip body
316a in contact with any of the at least two sheets of drywall 314
are bonded to the at least two sheets of drywall 314 in the same
manner that the adhesive layer 323 bonds with the at least two
sheets of drywall 314. That is, when the trim strip assembly 310a
is applied to a corner 12 as previously described, the inside
surface 318 of the first side wall 328 bonds to the first sheet of
drywall 314 and/or the inside surface 320 of the second side wall
330 bonds to the second sheet of drywall 314. In some embodiments
of the trim strip assembly 310a, the material comprising the trim
strip body 316a may have a softening point range is between
approximately 125.degree. F. and approximately 175.degree. F. The
adhesive layer 323 may be any suitable material having a suitable
softening point range, such as a heat-activated hot melt
adhesive.
[0073] A further embodiment of the trim strip assembly 310b is
illustrated in FIGS. 10A and 10B. In the trim strip assembly 310b,
the trim strip body 316b is a length of flexible tape or paper that
may have a cross-sectional shape of a thin rectangle when laid flat
prior to securing over a corner 12. Because the trim strip body
316b is flexible, the trim strip body 316b may be coiled or rolled
prior to application for convenient storage. When in a flattened or
planar configuration (as illustrated in FIG. 10A), the trim strip
body 316b (i.e., the flexible tape or paper) may extend from the
first end 324 to the second end 326 along the body axis 322. The
trim strip body 316b may have an inside surface 318, which may be a
bottom surface of the trim strip body 316b, and a top surface 350.
The trim strip body 316b may be defined by a first lateral edge 352
and a second lateral edge 354 that each may extend along (or
parallel to) the body axis 322. The first lateral edge 352 and the
second lateral edge 354 may each be equidistant or substantially
equidistant from the body axis 322.
[0074] The trim strip assembly 310b may also include the adhesive
layer 323 formed over at least a portion of the inside surface 318
of the trim strip body 316b (e.g., the inside surface 318 of the
first side wall 328). As illustrated in FIG. 10B, the adhesive
layer 323 may be formed over the entire inside surface 318 of the
trim strip body 316b (i.e., from the first end 324 to the second
end 326 between the first lateral edge 352 and the second lateral
edge 354. The adhesive layer 323 may be identical to those
previously described, and the adhesive layer 323 may be made from
or comprise any material (such as a heat-activated hot melt
adhesive) having a softening point range such that when the
adhesive layer 323 is heated to a temperature within the softening
point range, the adhesive layer 323 bonds to at least one of the at
least two sheets of drywall 314 to secure the trim strip body 316b
thereto.
[0075] To secure the trim strip assembly 310b to the corner 12
formed by the at least two sheets of drywall 314, a user may first
heat the trim strip assembly 310b such that the temperature of the
adhesive layer 323 is within the softening point range, as
previously described. The trim strip assembly 310b may then be
positioned in a desired corner location such that a first portion
(e.g., a portion between the body axis 322 and the first lateral
edge 352) is positioned over a portion of the first sheet of
drywall 314 and a second portion (e.g., a portion between the body
axis 322 and the second lateral edge 354) is positioned over a
portion of the second sheet of drywall 314. So assembled, the trim
strip assembly 310b may have a 90-degree or V-shaped cross-section
when viewed along the body axis 322, similar to the shape of the
trim strip body 316 illustrated in FIG. 8B. In other embodiments,
the trim strip assembly 310b may first be positioned on the corner
12 as described (and temporarily secured to the sheets of drywall
314) and then a heating element or tool may activate the adhesive
layer 323, as previously described. Because the trim strip body
316b and the adhesive layer 323 are both flexible, the trim strip
assembly 310b can be quickly and easily secured to a corner 12
having any cross-sectional shape.
[0076] As previously explained, a heating element or tool may be
placed on (or adjacent to) the trim strip body 316 (and, in some
embodiments, over the backing paper 346) to heat the adhesive layer
323 to a temperature within the softening point range. Such a
heating tool may be an embodiment of the application tool 400 of
FIGS. 11A and 11B. The application tool 400 may include a base
member 402 having a first base wall 404 and a second base wall 406.
The first base wall 404 may have an inside surface 408 and an
outside surface 410, and the second base wall 406 having an inside
surface 412 and an outside surface 414. The base member 402 may be
elongated and may extend parallel to a base axis 422 from a first
end 418 to a second end 420. The distance between the first end 418
and the second end 420 may be any suitable distance for a
particular corner application, and the first base wall 404 and the
second base wall 406 may extend from the first end 418 and the
second end 420.
[0077] The first base wall 404 and the second base wall 406 may
each be planar, and a top portion of the first base wall 404 may be
integrally formed with or coupled to a top portion of the second
base wall 406 such that the first base wall 404 and the second base
wall 406 have a cross-sectional shape of a "V" (when viewed along
the base axis 422). The first base wall 404 and the second base
wall 406 may each be curved or have curved portions, and a top
portion of the first base wall 404 may be integrally formed with or
coupled to a top portion of the second base wall 406 such that the
first base wall 404 and the second base wall 406 have a
cross-sectional shape of a "U" (when viewed along the base axis
422).
[0078] When viewed in cross-section, the first base wall 404 may
extend from a bottom edge 423 to an upper edge 424 at the top
portion of the first base wall 404. In addition, the second base
wall 406 may extend from a bottom edge 426 to the upper edge 424 at
the top portion of the second base wall 406. When viewed in
cross-section, the first base wall 404 may form any suitable angle
with the second base wall 406, and the angle may typically be
between approximately 60.degree. and approximately 120.degree., and
the angle may preferably be approximately 90.degree.. The first
base wall 404 and the second base wall 406 may each have any
suitable thickness or combination of thicknesses. In some
embodiments, the bottom edge 423 of the first base wall 404 and the
bottom edge 426 of the second base wall 406 may be mutually
parallel and parallel to the base axis 422. The upper edge 424 may
be parallel and co-linearly aligned with the base axis 422.
[0079] The application tool 400 may also include a first heating
member 428 directly or indirectly coupled to the inside surface
4108 of the first base wall 404 of the base member 102. The first
heating member 428 may be planar or substantially planar and may
extend from the first end 418 to the second end 420 of the base
member 402. The first heating member 428 may have a width that is
greater than a corresponding width of the first side wall 328 of
the trim strip body 216. The first heating member 428 may have an
application surface 340 that is adapted to contact the outside
surface 340 of the first side wall 328 of the trim strip body 216
when the application tool 400 is positioned along the trim strip
assembly 210 that is positioned over the corner 12. Heat generated
by the first heating member 428 is transferred (or adapted to be
transferred) through the first side wall 328 of the trim strip body
216 to activate the heat activated adhesive layer 323 (e.g., the
first portion 323a) disposed on the inside surface 218 of the first
side wall 328 to bond the first side wall 328 of the trim strip
body 216 to the first sheet of the two sheets of drywall 214. The
first heating member 428 may be connected to a power source (e.g.,
a battery, not shown) that provides power to heat all or a portion
of the first heating member 428 to a temperature that is sufficient
to heat the adhesive layer 323 (i.e., the first portion 323a of the
adhesive layer 323) to a temperature within the softening point
range. The first heating member 428 may generate heat in any
suitable manner, such as by heating coils or wires (not shown).
[0080] The first heating member 428 may also be adapted to provide
pressure on the trim strip body 216 and the adhesive layer 323
formed on the trim strip body 216 to facilitate bonding between the
adhesive layer 323 and a corresponding one of the two sheets of
drywall 214. Specifically, a user may provide pressure on the base
member 402 by pressing the base member 402 towards the corner 12
when the base member 402 is properly positioned along the corner
edge. In other alternatives, pressure may be applied to the base
member 402 such by using a handle 432 that may be movably coupled
to the base member 402. In some embodiments, the handle 432 may be
movably coupled to the base member 402 by a ball and socket joint
434. In some embodiments, the first heating member 428 may be
coupled to the inside surface 408 of the first base wall 404 of the
base member 402 using one or more resilient members 436, which may
be, for example, one or more springs or one or more resilient pads.
So configured, pressure applied by a user to the base member 402
may be transferred by the application surface 4340 to the first
side wall 328 and to the first portion 323a of the adhesive layer
323 to fix or secure the first side wall 328 and the first portion
323a of the adhesive layer 323 to the first sheet of drywall 214
forming the corner 12.
[0081] The application tool 400 may also include a second heating
member 438 directly or indirectly coupled to the inside surface 412
of the second base wall 406 of the base member 402. The second
heating member 438 may be identical to (or substantially identical
to) the first heating member 428. Specifically, the second heating
member 438 may be planar or substantially planar and may extend
from the first end 418 to the second end 420 of the base member
402. The second heating member 438 may have a width that is greater
than a corresponding width of the second side wall 430 of the trim
strip body 316. The second heating member 438 may have an
application surface 340 that is adapted to contact the outside
surface 344 of the second side wall 330 of the trim strip body 216
when the application tool 400 is positioned along the trim strip
assembly 210 that is positioned over the corner 12. Heat generated
by the second heating member 438 is transferred (or adapted to be
transferred) through the second side wall 330 of the trim strip
body 216 to activate the heat activated adhesive layer 323 (e.g.,
the second portion 323b) disposed on the inside surface 320 of the
second side wall 330 to bond the second side wall 330 of the trim
strip body 216 to the second sheet of the two sheets of drywall
214. The second heating member 438 may be connected to a power
source (e.g., the same power source that is connected to the first
heating member 428) that provides power to heat all or a portion of
the second heating member 438 to a temperature that is sufficient
to heat the adhesive layer 323 (i.e., the second portion 323b of
the adhesive layer 323) to a temperature within the softening point
range. The second heating member 438 may generate heat in any
suitable manner, such as by heating coils or wires (not shown).
[0082] In a manner identical to the first heating member 430, the
second heating member 438 may also be adapted to provide pressure
on the trim strip body 216 and the adhesive layer 323 formed on the
trim strip body 216 to facilitate bonding between the adhesive
layer 323 and a corresponding one of the two sheets of drywall 214.
In some embodiments, the second heating member 438 may be coupled
to the inside surface 412 of the second base wall 406 of the base
member 402 using one or more resilient members 436, which may be,
for example, one or more springs or one or more resilient pads. So
configured, pressure applied by a user to the base member 402 may
be transferred by the application surface 340 to the second side
wall 330 and to the second portion 323b of the adhesive layer 323
to fix or secure the second side wall 330 and the second portion
323b of the adhesive layer 323 to the second sheet of drywall 214
forming the corner 12. The distance between the first end 418 and
the second end 420 of the base member may be significantly less
than the distance between the first end 324 and the second end 326
of the trim strip body 216 such that the application tool 400 must
be placed over portions of the trim strip assembly 210 to fully
secure the trim strip assembly 210 along the entire corner 12.
[0083] Those skilled in the art will recognize that a wide variety
of modifications, alterations, and combinations can be made with
respect to the above described embodiments without departing from
the scope of the invention, and that such modifications,
alterations, and combinations are to be viewed as being within the
ambit of the inventive concept.
* * * * *