Abstract:
A drywall-frame-affixable corner bead has a corner-bead wall ( 1 ) with a corner-bead base that is affixed directly to corners of drywall framework ( 4 ) for extending the corner-bead wall outwardly to where outside surfaces of drywall ( 3 ) will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework. The corner bead can be shaped arcuately or otherwise as desired. Positional framework is extended intermediate the corner-bead wall and the corner-bead base for positioning the corner-bead walls at outside edges of drywall that is attached over the corner-bead base. A domed bead joint ( 17 ) is provided for three-sided bead corners. A use method includes affixing the corner-bead base to the drywall framework prior to attaching the drywall in order to position the corner-bead base intermediate the drywall and the drywall framework. A method for using the domed bead joint for three-sided drywall corners includes shaping corner slants ( 31 ) of the drywall to match edge walls of positional framework of the domed bead joints prior to attaching the three sides of drywall corners.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to corner beads for drywall construction and in particular to corner beads that are affixed directly to drywall framework and projected outwardly to match drywall thicknesses before the drywall is attached to the drywall framework.  
           [0002]    Conventional drywall beads at corners and edges of drywall are formed after drywall has been attached to drywall framework. This has required a further finishing function that is expensive in addition to its being delayed until after official approval of insulation behind the drywall framework, which increases total construction time and costs.  
           [0003]    There are numerous known devices and methods for forming drywall-corner beads. None, however, provide a bead wall having a corner-bead base that is affixed directly to drywall framework for extending the bead wall outwardly to where outside surfaces of the drywall will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework in a manner taught by this invention.  
           [0004]    Examples of most-closely related known but different devices without a corner bead having a corner-bead base affixed directly to drywall framework and other features of this invention are described in the following patent documents:  
                                                       U.S. Patent No.   Inventor   Issue Date                           5,544,463   Bergin   Aug. 13, 1996           6,148,573   Smythe, Jr.   Nov. 21, 2000           6,212,836   Larson   Apr. 10, 2001           6,189,273   Larson   Feb. 20, 2001           5,752,353   Koenig, et al.   May 19, 1998           6,223,486   Dunham   May 01, 2001           5,131,198   Ritchie, et al.   Jul. 21, 1992           5,613,335   Rennich, et al.   Mar. 25, 1997           6,295,776   Kunz, et al.   Oct. 02, 2001           1,634,862   Yoder   Jul. 05, 1927           6,352,382   Hatlan, et al.   Mar. 05, 2002                      
 
         SUMMARY OF THE INVENTION  
         [0005]    Objects of patentable novelty and utility taught by this invention are to provide a drywall-frame-affixable corner bead and method which:  
           [0006]    provides a strong corner bead for drywall construction;  
           [0007]    is adaptable to a plurality of known classes of drywall corners including without limitation, bullnose-shaped corners;  
           [0008]    can be affixed directly to drywall framework before the drywall is applied to decrease construction time waiting for inspection approval of drywall framework and wall insulation prior to attachment of drywall to the drywall framework;  
           [0009]    avoids need for finishing or optionally can be finished easily with painting or other covering;  
           [0010]    can be protected with an adhered covering prior to use; and  
           [0011]    prevents unevenness and joint lines at drywall corners.  
           [0012]    This invention accomplishes these and other objectives with a drywall-frame-affixable corner bead having a corner-bead wall with a corner-bead base that is affixed directly to drywall framework. Positional framework extends the corner-bead wall outwardly to where outside surfaces of the drywall will be when the drywall is added later after the corner-bead base has been affixed securely to drywall framework. The corner-bead wall can be shaped arcuately or otherwise as desired.  
           [0013]    The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.  
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0014]    This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are explained briefly as follows:  
         [0015]    [0015]FIG. 1 is a partially cutaway top view of the drywall-frame-affixable corner bead having a single corner-bead wall affixed to drywall framework behind ninety-degree corner walls and having bendable surfacing material adhered to a face of the corner-bead wall and to orthogonal edges of corner sheets of drywall;  
         [0016]    [0016]FIG. 2 is an enlarged top view of the drywall-frame-affixable corner bead separately and having the bendable surfacing material, which can include paper, cloth-like or plastic sheeting, bent outwardly from adhered attachment to either a curved surface of the corner-bead wall or to positional framework to which the corner-bead wall is connected;  
         [0017]    [0017]FIG. 3 is an enlarged top view of the FIG. 1 embodiment showing detail of affixment of the drywall-frame-affixable corner bead to the drywall framework behind drywall that is attached to the drywall framework and having the bendable surfacing material adhered to the curved face of the corner-bead wall and to the drywall adjacent to the corner-bead wall;  
         [0018]    [0018]FIG. 4 is the FIG. 2 illustration showing detail of adherence of the bendable surfacing material to the positional framework of the corner-bead wall and showing fasteners for fastening a corner-bead base to the drywall framework;  
         [0019]    [0019]FIG. 5 is the FIG. 4 illustration with the bendable surfacing material adhered to the corner-bead wall that is shown with dashed lines;  
         [0020]    [0020]FIG. 6 is a side view of the drywall-frame-affixable corner bead as seen from a top side of the FIG. 4 illustration to show a convenient plurality of fastener orifices and a fastener in one of them for affixing the corner-bead wall to drywall framework;  
         [0021]    [0021]FIG. 7 is a bottom view of the drywall-frame-affixable corner bead as seen from a bottom side of the FIG. 4 illustration to show the plurality of fastener orifices and showing the bendable surfacing material on the positional framework;  
         [0022]    [0022]FIG. 8 is the bottom view of the drywall-frame-affixable corner bead as seen from the bottom side of the FIG. 4 illustration;  
         [0023]    [0023]FIG. 9 is a partially cutaway front view of the drywall-frame-affixable corner bead and a domed-bead joint having three corner-bead walls attached to a top corner of three drywall surfaces;  
         [0024]    [0024]FIG. 10 is a partially cutaway top view of the domed-bead joint having three corner-bead walls for attachment to a top corner of the three drywall surfaces;  
         [0025]    [0025]FIG. 11 is a fragmentary end view of an arcuate corner-bead wall in relationship to the positional framework and base walls;  
         [0026]    [0026]FIG. 12 is a fragmentary end view of a straight corner-bead wall in relationship to the positional framework and base walls;  
         [0027]    [0027]FIG. 13 is a fragmentary end view of an angled corner-bead wall in relationship to the positional framework and base walls;  
         [0028]    [0028]FIG. 14 is a partially cutaway side view of the drywall-frame-affixable corner bead affixed over drywall and having the surfacing material adhered to the drywall;  
         [0029]    [0029]FIG. 15 is a partially cutaway side view of the drywall-frame-affixable corner bead and the domed bead joint in position for being assembled to be affixed over three surfaces of the drywall;  
         [0030]    [0030]FIG. 16 is a top end view of the corner-bead wall positioned at an orthogonal corner of drywall sheets by the positional framework which is attached to drywall framework with an attachment base having a locator base wall;  
         [0031]    [0031]FIG. 17 is a top end view of the corner-bead wall positioned on a wall edge or protrusion such as sides of an archway;  
         [0032]    [0032]FIG. 18 is the FIG. 17 illustration with addition of an under-surface material; and  
         [0033]    [0033]FIG. 19 a top end view of a corner of drywall sheets covered by the corner-bead wall at a side of a window. 
     
    
     DESCRIPTION OF PREFERRED EMBODIMENT  
       [0034]    Listed numerically below with reference to the drawings are terms used to describe features of this invention. These terms and numbers assigned to them designate the same features throughout this description.  
                                                        1.   Corner-bead wall            2.   Outside surfaces            3.   Drywall            4.   Drywall framework            5.   First base wall            6.   Second base wall            7.   First bead edge            8.   Second bead edge            9.   First framework extension           10.   Second framework extension           11.   Filler support           12.   Connector lip           13.   Covering           14.   Covering extension           15.   Fastener aperture           16.   Fastener           17.   Domed bead joint           18.   Joint ends           19.   First bead wall           20.   Second bead wall           21.   Third bead wall           22.   First edge plate           23.   Second edge plate           24.   Third edge plate           25.   First corner-base wall           26.   Second corner-base wall           27.   Third corner-base wall           28.   First edge wall           29.   Second edge wall           30.   Third edge wall           31.   Corner slants           32.   Convex arc           33.   Plain surface           34.   Angled corner           35.   Attachment base wall           36.   Locator base wall           37.   Bead flat           38.   Rigid support           39.   Bead flat           40.   Wall edge           41.   Wall-edge extension           42.   Window structure           43.   Undersurface material                      
 
         [0035]    Referring to FIGS.  1 - 3 , a drywall-affixable corner bead has at least one corner-bead wall  1  with shape and size for being extended intermediate edges of outside surfaces  2  of drywall  3  and related structure that is attachable to drywall framework  4 . The drywall framework  4  can be metallic, wooden, plastic, other material or combinations thereof that may be devised and provided from-time-to-time for construction of inside walls for buildings.  
         [0036]    At least one corner-bead base is affixable directly to the drywall framework  4 . The corner-bead base has one or more base walls that can include a first base wall  5  and a second base wall  6 . The corner-bead wall  1  can include a first bead edge  7  and a second bead edge  8 .  
         [0037]    Positional framework is extended predeterminedly intermediate the corner-bead base and the corner-bead wall  1 . The positional framework for a large portion of applications can include a first framework extension  9  and a second framework extension  10 . The first framework extension  9  is extended intermediate the first base wall  5  and the first bead edge  7 . The second framework extension  10  is extended intermediate the second base wall  6  and the second bead edge  8 .  
         [0038]    Optionally, the positional framework can include a filler support  11  that can be flexible in combination with or in lieu of the first framework extension  9  and the second framework extension  10  as shown in FIG. 5.  
         [0039]    The corner-bead wall  1  can include a convex arc  32  as shown in FIG. 11, a plane surface  33  as shown in FIG. 12 or an angled corner  34  as shown in FIG. 13. Either can include a connector lip  12  as a bead-alignment member as shown in FIGS.  10 - 13  and  15 .  
         [0040]    The corner-bead wall  1  can be predeterminedly finished with coloring, covering or texture or a combination thereof that does not require further treatment or coloring. Optionally, the corner-bead wall  1  can be textured to receive coloring that includes painting.  
         [0041]    As shown in FIGS.  1 - 5  and  7 , the corner-bead wall  1  can be predeterminedly covered with covering  13  intermediate the first bead edge  7  and the second bead edge  8 . The covering  13  can include covering extensions  14  having covering adhesive on drywall sides of the covering extension  14 . The covering extensions  14  can be adherent or can be made adherent to outside surfaces  2  of the drywall  3 . Prior to being adhered to the outside surfaces  2  of the drywall  3 , the covering extension  14  can be positioned against either the first framework extension  9  and the second framework extension  10 , against the outside surface of the corner-bead wall  1  or not against either. FIG. 2 shows the covering extensions  14  without being fixed against either the corner-bead wall  1  and the first bead edge  7  and the second bead edge  8 , or after being removed therefrom to be adhered to the outside surfaces  2  of the drywall  3 .  
         [0042]    As shown in FIGS.  6 - 8 , the first base wall  5  and the second base wall  6  can include a plurality of fastener apertures  15  into which fasteners  16  can be inserted conveniently for affixing the corner-bead wall  1  directly to the drywall framework  4 .  
         [0043]    Referring to FIGS.  9 - 10 , the at least one corner-bead wall  1  can include a domed bead joint  17  having a plurality of three corner-bead walls  1 . The three corner-bead walls  1  each include the first bead edge  7  and the second bead edge  8 . The three corner-bead walls  1  have joint ends  18  which are affixed to the domed bead joint  17  from which a first bead wall  19 , a second bead wall  20  and a third bead wall  21  comprising the three corner-bead walls  1  are extended. The first bead edge  7  of the first bead wall  19  is orthogonal to the second bead edge  8  of the second bead wall  20 . The first bead edge  7  of the second bead wall  20  is orthogonal to the second bead edge  8  of the third bead wall  21 . The first bead edge  7  of the third bead wall  21  is orthogonal to the second bead edge  8  of the first bead wall  19 .  
         [0044]    As shown most clearly in FIG. 10, a first edge plate  22  is extended intermediate the first bead edge  7  of the first bead wall  19  and the second bead edge  8  of the second bead wall  20 . A second edge plate  23  is extended intermediate the first bead edge  7  of the second bead wall  20  and the second bead edge  8  of the third bead wall  21 . A third edge plate  24  is extended intermediate the first bead edge  7  of the third bead wall  21  and the second bead edge  8  of the first bead wall  19 .  
         [0045]    Also shown most clearly in FIG. 10, the corner-bead base includes a first corner-base wall  25 , a second corner-base wall  26  and a third corner-base wall  27  that are affixable directly to the drywall framework  4 . The positional framework for the domed bead joint  17  includes a first edge wall  28  extended from the first edge plate  22  to the first corner-base wall  25 , a second edge wall  29  extended from the second edge plate  23  to the second corner-base wall  26  and a third edge wall  30  extended from the third edge plate  24  to the third corner-base wall  27 .  
         [0046]    The drywall-frame-affixable corner bead having a single corner-bead wall  1  is affixed to two-wall corners of drywall  3  as shown separately in FIG. 14 or below the drywall-frame-affixable corner bead having the three corner bead walls  19 - 21  extending from the domed bead joint  17  as shown in FIG. 15. For affixing the three corner bead walls  19 - 21  extending from the domed bead joint  17 , corner slants  31  on the drywall  3  are shaped to match wall slants of the first edge wall  28 , the second edge wall  29  and the third edge wall  30 .  
         [0047]    Referring to FIG. 16, the plurality of base walls of the corner-bead base  1  can include an attachment base wall  35  and a locator base wall  36 . The locator base wall  36  is extended at a predetermined angle from a base end of the attachment base wall  35 . The first framework extension  9  and the second framework extension  10  can be attached directly to the attachment base wall  35  proximate the locator base wall  36 .  
         [0048]    Referring to FIGS.  17 - 19 , the positional framework can include a rigid support  38  that is extended intermediate the corner-bead base and an inside surface of the corner-bead wall  1 . The rigid support  38  can be attached to the drywall framework  4  with the fasteners  16 .  
         [0049]    Embodiments with the rigid support  38  are intended primarily for irregular corners that are characteristic of windows, archways and doors.  
         [0050]    As shown in FIG. 17, the corner-bead wall  1  can include a bead flat  39  having oppositely disposed sides extended from the rigid support  38 . The rigid support  38  is extended at a predetermined angle from an attachment side of the bead flat  39  predeterminedly intermediate the oppositely disposed sides. The covering extension  14  can be extended from at least one side of the bead flat  39  for covering a wall edge  40  at an archway or similar structure.  
         [0051]    As shown in FIG. 18, the corner-bead wall  1  can include a wall-edge extension  41  that is extended over subsurface material  43  predeterminedly intermediate a first rigid support  38  that is attachable to a first side of a wall edge  40  and a second rigid support  38  that is attachable to a second side of the wall edge  40 .  
         [0052]    Referring to FIG. 19, the bead flat  39  attached to the rigid support  38  can be positioned on the drywall  3  at an edge of window structure  42 .  
         [0053]    A method is provided with steps for using a drywall-frame-fixable corner bead with at least one corner-bead wall having shape and size for being extended intermediate edge positions of outside surfaces of corners of drywall that is attachable to drywall framework; at least one corner-bead base that is affixable directly to the drywall framework; positional framework with extensions extended predeterminedly intermediate the corner-bead base and the corner-bead wall; and the positional framework having shape and size for positioning the corner-bead wall proximate the edge positions of the outside surfaces of the corners of the drywall predeterminedly.  
         [0054]    The steps comprise:  
         [0055]    affixing the corner-bead base  5 ,  6  directly to corners of the drywall framework  4  of a building under construction; and  
         [0056]    attaching wall-corner edges of drywall  3  to the drywall framework  4  with the wall-corner edges of the drywall  3  being over the positional framework  9 ,  10  and the corner-bead base  5 ,  6  being intermediate the drywall  3  and the drywall framework  4 .  
         [0057]    The use method can relate to the drywall-frame-affixable corner bead wherein the bead corner includes a three-sided drywall corner and the drywall-frame-affixable corner bead includes a domed bead joint having a plurality of three corner-bead walls; the three corner-bead walls each include a first bead edge and a second bead edge; the three corner-bead walls have joint ends which are affixed to the domed bead joint from which a first bead wall, a second bead wall and a third bead wall comprising the three corner-bead walls are extended; the first bead edge of the first bead wall is orthogonal to the second bead edge of the second bead wall; the first bead edge of the second bead wall is orthogonal to the second bead edge of the third bead wall; the first bead edge of the third bead wall is orthogonal to the second bead edge of the first bead wall; a first edge plate is extended intermediate the first bead edge of the first bead wall and the second bead edge of the second bead wall; a second edge plate is extended intermediate the first bead edge of the second bead wall and the second bead edge of the third bead wall; a third edge plate is extended intermediate the first bead edge of the third bead wall and the second bead edge of the first bead wall; the corner-bead base includes a first corner-base wall, a second corner-base wall and a third corner-base wall that are affixable directly to the drywall framework; and the positional framework includes a first edge wall extended from the first edge plate to the first corner-base wall, a second edge wall extended from the second edge plate to the second corner-base wall and a third edge wall extended from the third edge plate to the third corner-base wall.  
         [0058]    The steps include:  
         [0059]    affixing the first corner-base wall  25  to the drywall framework  4 ;  
         [0060]    affixing the second corner-base wall  26  to the drywall framework  4 ;  
         [0061]    affixing the third corner-base wall  27  to the drywall framework  4 ;  
         [0062]    shaping a corner slant  31  of a first panel of drywall  3  to match congruently and to fit against the first edge wall  28  of the positional framework;  
         [0063]    attaching the first panel of drywall  3  to the drywall framework  4  with the first corner-base wall  25  being intermediate the first panel of drywall  3  and the drywall framework  4 ;  
         [0064]    shaping the corner slant  31  of a second panel of the drywall  3  to match congruently and to fit against the second edge wall  29  of the positional framework;  
         [0065]    attaching the second panel of the drywall  3  to the drywall framework  4  with the second corner-base wall  26  being intermediate the second panel of the drywall  3  and the drywall framework  4 ;  
         [0066]    shaping the corner slant  31  of a third panel of the drywall  3  to match congruently and to fit against the third edge wall  30  of the positional framework; and  
         [0067]    attaching the third panel of the drywall  3  to the drywall framework  4  with the third corner-base wall  27  being intermediate the third panel of the drywall  3  and the drywall framework.  
         [0068]    A new and useful drywall-frame-affixable corner bead and method having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention.