FORMABLE CORNER FINISHING AND TRIM STRIP

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.

FIELD OF THE DISCLOSURE

This disclosure relates generally to a trim strip for protecting a corner formed by at least two sheets of drywall.

BACKGROUND

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.

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.

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.

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).

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

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° F. and about 400° 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.

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° F. and about 400° 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.

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.

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 surface18. 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.

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.

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.

DETAILED DESCRIPTION

As illustrated inFIGS. 1A-2, a formable trim strip10is provided for use on a corner12formed by at least two sheets of drywall14. With reference toFIGS. 1A and 1B, the formable trim strip10may have any number of layers and may include a trim strip body16having a top surface18and a bottom surface20. The trim strip body16may extend along a body axis22. The body axis22may extend longitudinally (that is, parallel to the X-axis of the reference coordinate system ofFIGS. 1A and 1B). The trim strip body16may comprise or be made of a polymer material (e.g., a thermo-formable polymer) having a melting point range between about 250° F. and about 400° 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.

The formable trim10may also include a backing paper24, a portion25of which, as will be described in further detail, may be affixed or secured to the bottom surface20of the trim strip body16. When the portion25of the backing paper24is placed in contact with the bottom surface20of the trim strip body16when a temperature of the trim strip body16is 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 portion25of the backing paper24is secured to, bonds to, and/or adheres to the bottom surface20of the trim strip body16. Accordingly, an adhesive that is typically used to secure the trim strip body16to the backing paper24is eliminated, thereby eliminating the material cost of the adhesive and the manufacturing costs of adhesive application during production.

Turning to the formable trim strip10in more detail, the formable trim strip10(as well as the trim strip body16) may be elongated and may extend along the body axis22from a first end28to a longitudinally-opposite second end30, as illustrated inFIG. 1A. The distance between the first end28and the second end30may 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 strip10may be cut to size for particular corner applications. In some versions, the trim strip10may be provided to customers/contractors coiled in a large roll thereby allowing custom lengths to be cut on the job site. A first side edge32of the trim strip10may be spaced a lateral distance (that is, a distance along the Y-axis of the reference coordinate system ofFIGS. 1A and 1B) from a second side edge34. The first side edge32and the second side edge34may extend along the body axis22such that the first side edge32and the second side edge34may laterally define the trim strip body16, and the first side edge32may be separated a lateral distance of 1.00″ to 3.00″ (or about 1.00″ to about 3.00)″ from the second side edge34. In some embodiments, the first side edge32and the second side edge34may be mutually parallel and parallel to the body axis22.

As illustrated inFIG. 1B, the top surface18of the trim strip body16and the bottom surface20of the trim strip body16may extend between but not necessarily entirely between the first side edge32and the second side edge34. This is because in some versions the backing paper24is wider than the trim body16. The bottom surface20is planar or substantially planar to correspond with the planar configuration of the portion25of the backing paper24. The bottom surface20may be defined in cross-section by a bottom edge36that may extend laterally or generally laterally when viewed in a cross-section normal to the body axis22(i.e., the cross-section view ofFIG. 1B), and the bottom edge36may be a linear segment that extends between a bottom end of the first side edge32and a bottom end of the second side edge34.

The top surface18is adapted to be placed in contact with an outer surface of a portion of the at least two sheets14of drywall when disposed along the corner12(as illustrated inFIGS. 2 and 4), and the top surface18may have any suitable shape to be used on or secured over the corner12. The top surface18may be defined in cross-section by a top edge38that may extend laterally or generally laterally when viewed in a cross-section normal to the body axis22(i.e., the cross section view ofFIG. 1B), and the top edge38may have any suitable shape or combination of shapes. For example, as illustrated inFIGS. 1B-1D, the top edge38may be linear and parallel to the bottom edge36. The top edge38may be defined by two or more segments that extend between a top end of the first side edge32and a top end of the second side edge34. For example, the top edge38may be at least partially defined by a first segment38athat extends from the top end of the first side edge32to a first point40aat, aligned with, or adjacent to the body axis22. The top edge38may also be at least partially defined by a second segment38bthat extends from the top end of the second side edge34to a second point40bat, aligned with, or adjacent to the body axis22. The first point40amay be coincident with the second point40bor may be laterally offset from the second point40b. The first and second segments38a,38bmay be symmetrical about the body axis22. The thickness of the first and second segments38a,38b, as well as the trim strip body16in 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″.

As illustrated inFIGS. 1A-1D, the formable trim strip10may also include at least one forming feature42that extends along at least a portion of the trim strip body16. It is understood that in some examples, the formable trim strip10may not include a forming feature42. The at least one forming feature42extends along a forming feature axis44. The at least one forming feature42is configured to allow the trim strip body16to be deformed—or easily deformed—about the forming feature axis44and/or about the body axis22. In some embodiments, when the formable trim strip10is deformed (e.g., folded) and positioned on a corner12, an edge19defining the corner12may be disposed within a void21formed by the at least one forming feature42, as illustrated inFIG. 4. In some embodiments, the at least one forming feature42may extend along the forming feature axis44from the first end28to the second end30of the trim strip body16. In some embodiments, the forming feature axis44may be parallel to or collinearly aligned with the body axis22.

The at least one forming feature42may be defined by a forming feature edge46when viewed in cross-section, as illustrated inFIGS. 1B-1D. The forming feature edge46may extend from the first point40ato the second point40b, and the forming feature edge46may be at least partially comprised of two or more linear segments and/or one or more non-linear segments. The at least one forming feature42may have any suitable shape or combination of shapes to allow the trim strip body16to be deformed about a forming feature axis44after the formable trim strip10has 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 corner12when installed. For example, as illustrated inFIG. 1B, the forming feature42may be a void defining a generally rectangular channel or slot adapted to facilitate bending of the trim strip10and optionally receive the edge19defining the corner12. In other examples, and as illustrated inFIGS. 1C and 1D, the void of the forming feature42may 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 surface20and the lowermost portion of the forming feature edge46may be any suitable distance that facilitates bending but ensures that the trim strip body16will not be damaged when bent or formed about the forming feature axis44, and the distance may be between approximately 0.01% to approximately 25% of the lateral width of the trim strip body16. In some examples, and as illustrated inFIG. 3A, the void of the forming feature42may extend entirely through the body16such that it divides the trim strip body16into two separate segments.

The forming feature42may be formed using any number of tools which can form a void as the trim strip body16advances during manufacturer. For example, as will be described further below, during manufacture while the trim strip body16remains 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 surface18of the cooling trim strip body16in a manner that forms a depression or cut in the trim strip body16that remains after the trim strip body16cools and hardens. In other versions, it is foreseeable to use a tool to create the forming feature42during or after the trim strip body16cools. Such a tool could include a rotary or circular saw having any number of cross-sectional shapes, an etching device, a machining tool, etc.

In some embodiments, such as that illustrated inFIGS. 3B and 3C, a plurality of forming features42may extend across or along the top surface18, and each of the plurality of forming features42may have any cross-sectional shape, dimension and geometry. For example, each of the plurality of forming features42may have an identical cross-sectional shape. In some embodiments, the plurality of forming features42may be U-shaped voids (e.g., grooves or recesses, as shown inFIG. 3C) that extend between elongated portions of the trim strip body16. Each of the plurality of forming features42may extend along a corresponding forming feature axis44that may each be parallel to the body axis22. Any or all of the plurality of forming features42may extend from the first end38to the second end40of the trim strip body16. The trim strip body16may be bent or rotated about any, some, or all of the forming feature axes44, and any of the plurality of forming features42may be adapted to receive the edge19defining the corner12.

As previously mentioned, the formable trim strip10may include the backing paper24, and the portion25of the backing paper24may be secured to the bottom surface20of the trim strip body16. The backing paper24may 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 paper24may facilitate the attachment of the formable trim strip10to the drywall14by bonding with drywall joint compound during installation. In some versions, the backing paper24can be wallboard tape paper or other known industry materials. The backing paper24may extend along any suitable longitudinal length of the trim strip body16, and the backing paper24may extend from the first end28to the second end30of the trim strip body16. The backing paper24may have a lateral width that is greater than the lateral width of the trim strip body16. In some embodiments, the backing paper24may have a lateral width that is equal to or substantially equal to the lateral width of the trim strip body16. In other embodiments, such as the embodiment illustrated inFIG. 1B, a first portion50aof the backing paper24may extend beyond the first side edge32of the trim strip body16(and beyond the portion25secured to the trim strip body16), and a second portion50bof the backing paper24may extend beyond the second side edge34of the trim strip body16(and beyond the portion25secured to the trim strip body16). The first portion50aand the second portion50bmay each have identical or nearly identical widths, and as a non-limiting example, the first portion50aand the second portion50bmay each be approximately 0.250″ to approximately 0.750″, for example.

During manufacturing, the backing paper24is not attached to the trim strip body16by an adhesive. Instead, it is the adhesive properties of the material of the trim strip body16itself (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 portion25of the backing paper24to the bottom surface20of the trim strip body16. That is, the trim strip body16is 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° F. and about 400° 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 paper24), and will not sustain damage due to overheating.

With reference now toFIG. 5, one system100and method for manufacturing the disclosed trim strip10will be described. While not necessarily depicted here, one system for applying the trim strip body16to the backing paper24could be an Acumeter coating machine commercially available from Acumeter Laboratories Incorporated. The system100inFIG. 5generally includes a hopper102storing polymer material to be melted and formed into the trim strip body16. The hopper102is disposed above a conveyor system106that moves paper backing24off of a roll and beneath an outlet port104of the hopper102. Accordingly, when the trim strip body16is manufactured, the stock polymer material is heated in the hopper102to a temperature that is within the melting point range to move the polymer into a molten state. Simultaneously, the backing paper24is moved off of a roll and carried by the conveyor system106beneath the hopper102. The molten polymer is then expelled from the outlet port104of the hopper102and deposited or coated directly onto the backing paper24. In some versions, the outlet port104includes a specific geometry and/or configuration such that the molten polymer may be evenly deposited onto the backing paper24at the desired portion25create the desired shape. As the combined backing paper24and molten polymer travel away from the hopper102(to the right relative to the orientation ofFIG. 5), the polymer begins to cool and harden into the trim strip body16. As illustrated inFIG. 1B, the resulting trim strip body16may be generally rectangular in shape, and in other examples (as illustrated inFIG. 1D), the first and second side edges32,34may be generally curved due to gravitational forces acting on the molten material as it cools. Other examples of cross-sectional shapes are possible.

As the trim strip body16cools to a temperature that is below the melting point range, the portion25of the backing paper24that supports the molten polymer bonds and/or becomes secured to the bottom surface20of the trim strip body16. The cooling process that secures the portion25of the backing paper24to the bottom surface20of the trim strip body16may take any suitable amount of time, and the trim strip body16may cool to a cooling range (between approximately 40° F. and approximately 80° 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 body16cools to a temperature that is below the melting point range (and may be within the cooling range) and when the backing paper24is suitably secured to the bottom surface20of the trim strip body16, the formable trim strip10may be then fully cured but yet flexible such that the formable trim strip10may be coiled or rolled (not shown) for transport to a retailer or a job site, for example. However, when the trim strip body16cools to a temperature that is below the melting point range, the formable trim strip10is sufficiently flexible that it may be deformed and unrolled, and ultimately bent about one or more of the forming feature axes44yet sufficiently rigid to protect the corner12when installed as described below.

It is understood that the forming feature or features42may be formed at different points in the manufacturing process. For example, the forming feature42may be formed while the body material is within the melting point range or after the material has cooled and formed the trim strip body16. In those embodiments where the forming feature42comprises one or more recesses, channels or grooves in the trim strip body16(see, e.g.,FIGS. 1B, 1C, 1D, and 3C) such features42may be formed by a tooling device108such as that depicted inFIG. 5. The device108may include a tool210such as a pin, a knife, a wheel, etc., for directly engaging and forming the forming feature42into the molten polymer material before it hardens into the trim strip body16. In some versions, the tool210could be selected from a plurality of available tools for creating a forming feature42of a desired shape. In some versions, the tool110may resemble a fork or other arrangement with multiple points of contact with the molten material such that the arrangement of multiple forming features42depicted inFIG. 3Ccould easily be achieved. For other versions of the trim strip10where the trim strip body16includes two or more segments separated by a gap (see, e.g.,FIGS. 3A and 3B), this may be achieved by the hopper102in the system ofFIG. 5having two or more separate side-by-side outlet ports104such that two or more parallel portions of the trip strip body16can be coated onto the backing paper24simultaneously. In still other versions that are not depicted in in the drawings of the present application, it is foreseeable to have a trim strip10that includes a trim strip body16with both gaps (as shown inFIGS. 3A and 3B) and recesses, channels, or grooves (as shown inFIGS. 1B, 1C, 1D and 3C). Thus, it would be appreciated that the system100inFIG. 5could include a combination of multiple outlet ports104(whether form a common or separate hoppers) and one or more tools110each having one or more points of contact with the molten polymer.

Further, any number of additional manufacturing processes may be implemented before or after the formation of the trim strip body16. For example, the formable trim strip10may include any number of additional layers such as an adhesive layer applied to the top surface18of the trim strip body16to assist in securing the formable trim strip10to the wall. This adhesive layer may be applied after or at the same time the trim strip body16is flowed, deposited, or coated onto the backing paper24. With such an arrangement, the applied adhesive opposite the backing paper24would be utilized to actually secure the trim strip10to 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 ofFIG. 5, an adhesive applicator112is depicted downstream of the tooling device208and this applicator112could 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 strip10to the corner12. InFIG. 5, one version of the manufacturing system100can include a roll of release layer114disposed downstream of the adhesive applicator which can be applied over the adhesive after the adhesive is applied to the trim strip body16. Other examples are possible.

Once at the job site, when it is desired to secure the formable trim strip10on or over a corner12formed by at least two sheets14of drywall, a suitable length of the formable trim strip10may be uncoiled and cut to desired dimensions based on the length of the corner12. This (or any) length of formable trim strip10may extend from the first end28to the second end30, and if more than one portion of the formable trim strip10is cut from a single coil, each portion of the formable trim strip10may extend from the first end28to the second end30. The formable trim strip10can then be bent by any suitable angle along the forming feature axis44(which may be parallel to the body axis22) to fit around a desired corner12. For example, as illustrated inFIG. 4, the formable trim strip10can then be bent along the forming feature axis44over a corner having any angle less or greater than 180° and secured to the drywall14using any known manner.

In some examples, materials such as drywall joint compound and/or adhesives may be used to secure the trim strip10to drywall. For example, as depicted inFIG. 4, one application technique includes applying portions53a,53bof joint compound to the top surface18of the trim strip body16and the immediately adjacent portions50a,50bof the backing paper24. The trim strip10is then applied to the wall, and additional portions52a,52bof joint compound is applied to fill side recess52a,52bformed along an outer surface23of the backing paper24adjacent to the trim strip body16. This material can be used to create a smooth corner surface free of blemishes and to increase the adhesion of the formable trim strip10to the corner.

Referring now toFIGS. 6-7B, an assembly200(or system or kit) may be used to form the previously discussed formable trim strip10for use on a corner12of two sheets of drywall. The assembly can include a die204having an aperture206(FIGS. 7A and 7B) having a second cross-sectional shape208that is different than a first cross-sectional shape202(as illustrated in various example forms inFIGS. 1B-1D) of the formable trim strip10. For example, as illustrated inFIG. 7A, which illustrates an example die204cross-section, the second cross-sectional shape208may have a 90-degree shape (or a general V-shape), and in other examples, as illustrated inFIG. 7B, an example die204has a bull-nosed second cross-sectional shape208. In some versions, the die204can include a clamshell or sandwich type construction such that when opened (not shown), the formable trim strip10is positioned between opposing first and second portions204a,204bof the die204. Then, once the die204is closed (depicted inFIGS. 7A, 7B), the trim strip10can be pushed or pulled out of the die204through the aperture206. Such clamshell or sandwich type dies204may include a hinge209for moving the first portion204aof the die204relative to the second portion204bof the die204between open and closed (depicted inFIGS. 7A, 7B) positions. In other versions, the die204may be of single piece construction and the first aperture206may be adapted to slidably receive (or movably or displaceably receive) the formable trim strip10such that as the formable trim strip body is displaced (e.g., pushed or pulled) through the aperture206. The formable trim strip body16of the formable trim strip10is changed, modified, altered, or adjusted from having the first cross-sectional shape202to a cross-sectional shape that corresponds to the second cross-sectional shape208.

Referring toFIG. 6A, the first aperture206may extend along a longitudinal axis210of the die204, and the first aperture206may be uniform or constant over the length of the longitudinal axis210. This is particularly true when the die204includes a clamshell or sandwich type construction as discussed above.

In other examples, including those for example where the die204is of single piece construction, a geometry or profile of the first aperture206may change along the longitudinal axis210from a first end212of the die204to a second end214of the die204. That is, at the first end212, the first aperture206may have a cross-sectional shape that closely corresponds to the first cross-sectional shape202and at the second end214, the first aperture206may have a cross-sectional shape that corresponds to the second cross-sectional shape208. Accordingly, the formable trim strip10may be easily inserted into the die204without needing manipulation.

The transition between the first cross-sectional shape202at the first end212and the second cross-sectional shape208at the second end214may be gradual, and the die204may have any suitable longitudinal length between the first end212and the second end214to allow the cross-sectional shape of the formable trim strip10to be changed from the first cross-sectional shape202to the second cross-sectional shape208.

As shown inFIG. 6A, a heating element216may be thermally coupled to the die204to heat the trim strip body16of the formable trim strip10to a temperature within a softening point range of the polymer material used to construct the trim strip body16. In some embodiments, the heating element216may heat the die204to 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 body16in 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 body16may have softening point range between approximately 110° F. and approximately 210° F., and more particularly, between approximately 125° F. and approximately 175° F.

When a suitable portion of the formable trim strip10emerges or exits from the second end214of the of the die204, a cutting element217may be used to cut the formable trim strip10to a desired longitudinal length, thereby creating a new first end28and second end30. The cutting element217may be any suitable blade or blade assembly capable of cutting the formable trim strip10in a lateral direction, such as a blade that moves normal to the longitudinal axis210.

In some examples, the assembly200may 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 body16based on customer demands, for example, and can operate in a similar manner to the die204.

In use, the trim strip body16of formable trim strip10is advanced through the first aperture206of the die204(along arrow230ofFIG. 6) as described. Thus, as the formable trim strip10exits the second end214of the first aperture206, the formable trim strip10(and the trim strip body16of the trim strip10) will be formed or molded to have a cross-sectional shape that corresponds to the second cross-sectional shape208. The formable trim strip10may then be cut to size using the cutting element217. The cutting may occur before or after the trim strip body16has 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 body16of the formable trim strip10is advanced through a second aperture of this second die.

Accordingly, when the material of the formable trim strip10is cooled to a temperature below the softening point range (e.g., to a temperature within the cooling range) after forming by the die204, the formable trim strip10maintains its second cross-sectional shape208yet 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.

As illustrated inFIGS. 8A and 8B, a formable trim strip assembly310is provided for use on a corner formed by at least two sheets of drywall314. The trim strip assembly310may include a trim strip body316extending along a body axis322that may extend longitudinally (that is, parallel to the X-axis of the reference coordinate system ofFIG. 8A), and the trim strip body316may have at least one inside surface318, which may correspond to the upper surface18previously discussed. The inside surface318may be an inside surface of a first side wall328of the trim strip body314. In some embodiments, the trim strip body316may also include an inside surface320of a second side wall330of the trim strip body316. The first side wall328and the second side wall330may have a 90-degree (e.g., V-shaped) cross-section when viewed along the body axis322. The trim strip assembly310also includes an adhesive layer323formed over at least a portion of the at least one inside surface318of the trim strip body316(e.g., the inside surface318of the first side wall328). In some examples, the adhesive layer323has a softening point range such that when the adhesive layer323is heated to a temperature within the softening point range, the adhesive layer323bonds to at least one of the at least two sheets of drywall314to secure the trim strip body316to at least one of the at least two sheets of drywall314.

So configured, by heating the adhesive layer323to a temperature within the softening point range and applying the trim strip assembly310over the corner12, the adhesive layer323bonds to at least one of the least two sheets of drywall314. 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 assembly310presents an esthetically-pleasing low-profile when secured over the corner12.

The trim strip body316may be elongated and may extend along the body axis322from a first end324to a longitudinally-opposite second end326, as illustrated inFIG. 8A. The distance between the first end324and the second end326may be any suitable distance for a particular corner application. The trim strip body316may include the first side wall328and a second side wall330, and the first side wall328and the second side wall330may extend from the first end324and the second end326. The first side wall328and the second side wall330may each be planar, and a top portion of the first side wall328may be integrally formed with or coupled to a top portion of the second side wall330such that the first side wall328and the second side wall330have (or cooperate to form) a cross-sectional shape of a “V” when viewed along the body axis322. In some embodiments, the first side wall328and the second side wall330may each be curved or have curved portions, and a top portion of the first side wall328may be integrally formed with or coupled to a top portion of the second side wall330such that the first side wall328and the second side wall330have (or cooperate to form) a cross-sectional shape of a “U” when viewed along the body axis322.

As illustrated inFIG. 8B, the first side wall328, when viewed in cross-section, may extend from a bottom edge332to an upper edge334at the top portion of the first side wall328. In addition, the second side wall330may extend from a bottom edge336to the upper edge334at the top portion of the second side wall30. When viewed in cross-section, the first side wall328may form any suitable angle with the second side wall330. This angle may typically be between approximately 60° and approximately 120°, for example, approximately 90°. The first side wall328may include the inside surface318and an outside surface340opposite to the inside surface318. Similarly, the second side wall330may include the inside surface320and an outside surface344opposite to the inside surface320. The first side wall328and the second side wall330may each have any suitable thickness or combination of thicknesses. In some embodiment, the bottom edge332of the first side wall328and the bottom edge336of the second side wall330may be mutually parallel and parallel to the body axis322. The upper edge334may be parallel and co-linearly aligned with the body axis322.

As previously described, the trim strip body316may 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° F. and about 450° F. In other embodiments, the trim strip body316may 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.

As illustrated inFIG. 8B, a backing paper346may be secured to the outside surface340of the first side wall328of the trim strip body316and the outside surface344of the second side wall330of the trim strip body316. The backing paper46may 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 paper46may facilitate the attachment of the trim strip assembly10to the drywall314by bonding with drywall joint compound during installation.

As illustrated inFIG. 8B, the trim strip assembly10also includes the adhesive layer323formed over or disposed on at least a portion of the inside surface318of the trim strip body316. As previously explained, the inside surface318may be the inside surface318of the first side wall328of the trim strip body316, and a first portion323aof the adhesive layer323may be formed over or disposed on the entire inside surface318of the first side wall328or a portion thereof. In addition, a second portion323bof the adhesive layer323may be formed over or disposed on the entire inside surface320of the second side wall330or a portion thereof. In some embodiments, the first portion323aof the adhesive layer323and the second portion323bof the adhesive layer323may be integrally formed at or adjacent to the upper edge334at the top portion of the first side wall28and the second side wall330. In other embodiments, the first portion323aof the adhesive layer323may be separated from the upper edge34at the top portion of the first side wall328by a gap that extends parallel to the upper edge334, and the second portion323bof the adhesive layer323may be separated from the upper edge334at the top portion of the second side wall330by a gap that extends parallel to the upper edge334.

The adhesive layer323may be made from or comprise any material having a softening point range such that when the adhesive layer323is heated to a temperature within the softening point range, the adhesive layer323bonds to at least one of the at least two sheets of drywall314to secure the trim strip body316to the at least one of the at least two sheets of drywall314. The softening point range may be a range of temperatures in which the material (or a portion of the material) forming the adhesive layer323has adhesive properties or qualities, and when temperatures of the material (or a portion of the material) forming the adhesive layer323are below the softening point range, the material (or a portion of the material) forming the adhesive layer323does 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 layer323, the material comprising or forming the trim strip body316does not melt. In some embodiments, the softening point range is between approximately 125° F. and approximately 225° F. The adhesive layer323may 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.

The adhesive layer323may be formed or distributed over the inside surface318of the first side wall328and/or the inside surface320of a second side wall330in any suitable manner to allow the material forming the adhesive layer323to form a bond or be secured to one or both of the at least two sheets of drywall314. For example, the first portion323aof the adhesive layer323and/or the second portion323bof the adhesive layer323may be formed or distributed as an even, uniform layer over the inside surface318of the first side wall328and/or the inside surface320of the second side wall330. In other embodiments, the first portion323aof the adhesive layer323and/or the second portion323bof the adhesive layer323may be formed as strips, patterns, shapes, or any combination therefor that include gaps between portions of the first portion323aand/or the second portion323b.

To secure the trim strip assembly310to the corner12formed by the at least two sheets of drywall314, a user may first position the trim strip assembly310in a desired corner location. In such a position, the adhesive layer323(e.g., the first portion323aof the adhesive layer323and the second portion323bof the adhesive layer323) may be positioned to be in contact with (or adjacent to) one or more corresponding portions of the first sheet of drywall314and/or one or more corresponding portions of the second sheet of drywall314. In some embodiments, the first portion323aof the adhesive layer323may be positioned to be in contact with (or adjacent to) one or more corresponding portions of the first sheet of drywall314and the second portion323bof the adhesive layer323) may be positioned to be in contact with (or adjacent to) one or more corresponding portions of the second sheet of drywall314. 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 body316(and, in some embodiments, over the backing paper346or in contact briefly with the adhesive layer323) to heat the adhesive layer323to a temperature within the softening point range (and below the lowest temperature at which the material of trim strip body316begins 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 body316or a shaped heating tool (not shown) that may correspond to the shape of the trim strip body316and may be placed in contact with a longitudinal lengthwise portion of the trim strip body316.

After a suitable amount of heating time, the adhesive or bonding qualities of the adhesive layer323are activated and the adhesive layer323bonds to one or more corresponding portions of the first sheet of drywall314and/or one or more corresponding portions of the second sheet of drywall314to secure the trim strip assembly310to at least one of the first or second sheets of drywall314. In some embodiments, the first portion323aof the adhesive layer323may be heated to a temperature within the softening point range and may secure the first side wall328of the trim strip assembly310to the first sheet of drywall314and the second portion323bof the adhesive layer323may be heated to a temperature within the softening point range and may secure the second side wall330of the trim strip assembly310to the second sheet of drywall314.

In some embodiments, the adhesive layer323may be heated to a temperature within the softening point range (and below the lowest temperature at which the material of trim strip body316begins to melt) prior to positioning the trim strip assembly310in a desired corner location. In such an embodiment, trim strip assembly310may be placed in or pushed through a stationary heater to heat the adhesive layer. Subsequently, the pre-heated first portion323aof the adhesive layer323may secure the first side wall328of the trim strip assembly310to the first sheet of drywall314and the pre-heated second portion323bof the adhesive layer323may secure the second side wall330of the trim strip assembly310to the second sheet of drywall314. A corner rolling tool, flat iron, or any other device (not shown) may also be used to apply pressure to the first side wall328and/or the second side wall330of the trim strip body316.

When the adhesive layer323cools to a temperate lower than the lowest temperature of the softening point range, the adhesive layer323provides 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 drywall314.

Referring toFIG. 9, an embodiment of the trim strip assembly310amay include a trim strip body316athat may be nearly identical to the trim strip body316previously described, and accordingly, like reference numbers will not be changed. However, the trim strip body316aof the trim strip assembly310amay be made of, fabricated from, and/or comprise an adhesive material, and therefore the trim strip assembly310adoes not have an adhesive layer323formed or distributed over the inside surface318of the first side wall328and/or the inside surface320of a second side wall330. More specifically, the entire trim strip body316amay be made from or comprise any material having a softening point range such that when the trim strip body316ais heated to a temperature within the softening point range, portion of the trim strip body316ain contact with any of the at least two sheets of drywall314are bonded to the at least two sheets of drywall314in the same manner that the adhesive layer323bonds with the at least two sheets of drywall314. That is, when the trim strip assembly310ais applied to a corner12as previously described, the inside surface318of the first side wall328bonds to the first sheet of drywall314and/or the inside surface320of the second side wall330bonds to the second sheet of drywall314. In some embodiments of the trim strip assembly310a, the material comprising the trim strip body316amay have a softening point range is between approximately 125° F. and approximately 175° F. The adhesive layer323may be any suitable material having a suitable softening point range, such as a heat-activated hot melt adhesive.

A further embodiment of the trim strip assembly310bis illustrated inFIGS. 10A and 10B. In the trim strip assembly310b, the trim strip body316bis 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 corner12. Because the trim strip body316bis flexible, the trim strip body316bmay be coiled or rolled prior to application for convenient storage. When in a flattened or planar configuration (as illustrated inFIG. 10A), the trim strip body316b(i.e., the flexible tape or paper) may extend from the first end324to the second end326along the body axis322. The trim strip body316bmay have an inside surface318, which may be a bottom surface of the trim strip body316b, and a top surface350. The trim strip body316bmay be defined by a first lateral edge352and a second lateral edge354that each may extend along (or parallel to) the body axis322. The first lateral edge352and the second lateral edge354may each be equidistant or substantially equidistant from the body axis322.

The trim strip assembly310bmay also include the adhesive layer323formed over at least a portion of the inside surface318of the trim strip body316b(e.g., the inside surface318of the first side wall328). As illustrated inFIG. 10B, the adhesive layer323may be formed over the entire inside surface318of the trim strip body316b(i.e., from the first end324to the second end326between the first lateral edge352and the second lateral edge354. The adhesive layer323may be identical to those previously described, and the adhesive layer323may 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 layer323is heated to a temperature within the softening point range, the adhesive layer323bonds to at least one of the at least two sheets of drywall314to secure the trim strip body316bthereto.

To secure the trim strip assembly310bto the corner12formed by the at least two sheets of drywall314, a user may first heat the trim strip assembly310bsuch that the temperature of the adhesive layer323is within the softening point range, as previously described. The trim strip assembly310bmay then be positioned in a desired corner location such that a first portion (e.g., a portion between the body axis322and the first lateral edge352) is positioned over a portion of the first sheet of drywall314and a second portion (e.g., a portion between the body axis322and the second lateral edge354) is positioned over a portion of the second sheet of drywall314. So assembled, the trim strip assembly310bmay have a 90-degree or V-shaped cross-section when viewed along the body axis322, similar to the shape of the trim strip body316illustrated inFIG. 8B. In other embodiments, the trim strip assembly310bmay first be positioned on the corner12as described (and temporarily secured to the sheets of drywall314) and then a heating element or tool may activate the adhesive layer323, as previously described. Because the trim strip body316band the adhesive layer323are both flexible, the trim strip assembly310bcan be quickly and easily secured to a corner12having any cross-sectional shape.

As previously explained, a heating element or tool may be placed on (or adjacent to) the trim strip body316(and, in some embodiments, over the backing paper346) to heat the adhesive layer323to a temperature within the softening point range. Such a heating tool may be an embodiment of the application tool400ofFIGS. 11A and 11B. The application tool400may include a base member402having a first base wall404and a second base wall406. The first base wall404may have an inside surface408and an outside surface410, and the second base wall406having an inside surface412and an outside surface414. The base member402may be elongated and may extend parallel to a base axis422from a first end418to a second end420. The distance between the first end418and the second end420may be any suitable distance for a particular corner application, and the first base wall404and the second base wall406may extend from the first end418and the second end420.

The first base wall404and the second base wall406may each be planar, and a top portion of the first base wall404may be integrally formed with or coupled to a top portion of the second base wall406such that the first base wall404and the second base wall406have a cross-sectional shape of a “V” (when viewed along the base axis422). The first base wall404and the second base wall406may each be curved or have curved portions, and a top portion of the first base wall404may be integrally formed with or coupled to a top portion of the second base wall406such that the first base wall404and the second base wall406have a cross-sectional shape of a “U” (when viewed along the base axis422).

When viewed in cross-section, the first base wall404may extend from a bottom edge423to an upper edge424at the top portion of the first base wall404. In addition, the second base wall406may extend from a bottom edge426to the upper edge424at the top portion of the second base wall406. When viewed in cross-section, the first base wall404may form any suitable angle with the second base wall406, and the angle may typically be between approximately 60° and approximately 120°, and the angle may preferably be approximately 90°. The first base wall404and the second base wall406may each have any suitable thickness or combination of thicknesses. In some embodiments, the bottom edge423of the first base wall404and the bottom edge426of the second base wall406may be mutually parallel and parallel to the base axis422. The upper edge424may be parallel and co-linearly aligned with the base axis422.

The application tool400may also include a first heating member428directly or indirectly coupled to the inside surface4108of the first base wall404of the base member102. The first heating member428may be planar or substantially planar and may extend from the first end418to the second end420of the base member402. The first heating member428may have a width that is greater than a corresponding width of the first side wall328of the trim strip body216. The first heating member428may have an application surface340that is adapted to contact the outside surface340of the first side wall328of the trim strip body216when the application tool400is positioned along the trim strip assembly210that is positioned over the corner12. Heat generated by the first heating member428is transferred (or adapted to be transferred) through the first side wall328of the trim strip body216to activate the heat activated adhesive layer323(e.g., the first portion323a) disposed on the inside surface218of the first side wall328to bond the first side wall328of the trim strip body216to the first sheet of the two sheets of drywall214. The first heating member428may 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 member428to a temperature that is sufficient to heat the adhesive layer323(i.e., the first portion323aof the adhesive layer323) to a temperature within the softening point range. The first heating member428may generate heat in any suitable manner, such as by heating coils or wires (not shown).

The first heating member428may also be adapted to provide pressure on the trim strip body216and the adhesive layer323formed on the trim strip body216to facilitate bonding between the adhesive layer323and a corresponding one of the two sheets of drywall214. Specifically, a user may provide pressure on the base member402by pressing the base member402towards the corner12when the base member402is properly positioned along the corner edge. In other alternatives, pressure may be applied to the base member402such by using a handle432that may be movably coupled to the base member402. In some embodiments, the handle432may be movably coupled to the base member402by a ball and socket joint434. In some embodiments, the first heating member428may be coupled to the inside surface408of the first base wall404of the base member402using one or more resilient members436, 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 member402may be transferred by the application surface4340to the first side wall328and to the first portion323aof the adhesive layer323to fix or secure the first side wall328and the first portion323aof the adhesive layer323to the first sheet of drywall214forming the corner12.

The application tool400may also include a second heating member438directly or indirectly coupled to the inside surface412of the second base wall406of the base member402. The second heating member438may be identical to (or substantially identical to) the first heating member428. Specifically, the second heating member438may be planar or substantially planar and may extend from the first end418to the second end420of the base member402. The second heating member438may have a width that is greater than a corresponding width of the second side wall430of the trim strip body316. The second heating member438may have an application surface340that is adapted to contact the outside surface344of the second side wall330of the trim strip body216when the application tool400is positioned along the trim strip assembly210that is positioned over the corner12. Heat generated by the second heating member438is transferred (or adapted to be transferred) through the second side wall330of the trim strip body216to activate the heat activated adhesive layer323(e.g., the second portion323b) disposed on the inside surface320of the second side wall330to bond the second side wall330of the trim strip body216to the second sheet of the two sheets of drywall214. The second heating member438may be connected to a power source (e.g., the same power source that is connected to the first heating member428) that provides power to heat all or a portion of the second heating member438to a temperature that is sufficient to heat the adhesive layer323(i.e., the second portion323bof the adhesive layer323) to a temperature within the softening point range. The second heating member438may generate heat in any suitable manner, such as by heating coils or wires (not shown).

In a manner identical to the first heating member430, the second heating member438may also be adapted to provide pressure on the trim strip body216and the adhesive layer323formed on the trim strip body216to facilitate bonding between the adhesive layer323and a corresponding one of the two sheets of drywall214. In some embodiments, the second heating member438may be coupled to the inside surface412of the second base wall406of the base member402using one or more resilient members436, 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 member402may be transferred by the application surface340to the second side wall330and to the second portion323bof the adhesive layer323to fix or secure the second side wall330and the second portion323bof the adhesive layer323to the second sheet of drywall214forming the corner12. The distance between the first end418and the second end420of the base member may be significantly less than the distance between the first end324and the second end326of the trim strip body216such that the application tool400must be placed over portions of the trim strip assembly210to fully secure the trim strip assembly210along the entire corner12.