Paper beading apparatus for wallboard corner beads

A paper beading apparatus, includes a hopper having a body defining a chamber for holding a quantity of joint compound, and having an open upper end, an upper rim, and a lower end; a lid pivotally secured to the body for movement between an open position and a closed position, wherein in the closed position, the lid engages the open upper rim, the lid having a releasably sealable air port; and a base configured for and accommodating the hopper lower end, for receiving joint compound, and for applying the joint compound to a corner paper bead.

BACKGROUND OF THE INVENTION

The present invention relates generally to construction using gypsum wallboard, and more particularly, to an apparatus used to apply joint compound to corner paper beads prior to their attachment to joints or corners between adjacent wallboard panels.

Corner beads are elongated, narrow strips of metal or plastic, often having a paper face on one side, and are typically folded or angled along their longitudinal center line to produce a generally v-shaped cross-section. They are made with various angles and corner shapes, including 90-degree angle corners and rounded or so-called “bullnose” corners of various angles. Corner beads are also designed for covering both inside (concave) and outside (convex) corners. For application to an inside corner, joint compound is applied to the outside (convex) faces of an inside corner bead. For application to an outside corner, joint compound is applied to the inside (concave) faces of an outside corner bead. Joint compound is applied to the appropriate faces of the bead, and the bead is then pressed against the corner, with the joint compound forming an adhesive joint between the corner bead and the wallboard corner.

Although wallboard joint compound may be applied to corner beads by hand, this is a time consuming and messy process. Hopper devices have been used to reduce the time needed to apply joint compound to the paper bead and provide for a cleaner process. Such devices typically include a hopper retaining a supply of wallboard joint compound, and a passageway in a bottom of the container where the corner bead is passed through the passageway to receive a coating of joint compound and to provide a guide for locating the corner bead.

Two design criteria of such a device are to increase efficiency and increase cleanliness when applying joint compound to a corner bead. Further, since joint compound generally has a highly viscous property and some compounds set rapidly, it is often difficult to remove unwanted joint compound from the hopper upon completion of a job. Thus, another design criteria of such a device is the ability to readily remove unwanted joint compound.

BRIEF SUMMARY OF THE INVENTION

The above-listed needs are met or exceeded by the present paper beading apparatus, which features a hopper having a lid that provides a seal over the hopper, thus preventing joint compound from inadvertently escaping out of the hopper. A releasably sealable air port is provided on the lid, which allows a batch of unused joint compound to be stored overnight without setting. The hopper also has an obstruction-free floor which allows for easy cleaning and further is supported by a base, which features a set of rings having spaced, stepped fins for accommodating support buckets of varying dimensions, thereby reducing the likelihood of the beading apparatus being inadvertently knocked over, causing joint compound to leak out.

The apparatus also features a single, reversible tray that allows for the application of joint compound to either an inside corner bead or an outside corner bear, depending on the tray's orientation. A mouth at each end of the tray is elongated to reduce dripping of joint compound and to provide a guide for locating the bead in the tray.

The apparatus also features an internal gate having an application portion and a reinforcement portion, each made of distinctive materials. A positioning lug is provided on the gate for engaging a positioning opening on a base, thereby assisting a user in correctly position the gate in the base. Upon assembly, the hopper is positioned over the base and secured thereto.

More specifically, a paper beading apparatus is provided, which includes a hopper having a body defining a chamber for holding a quantity of joint compound, and having an open upper end, an upper rim, and a lower end. Further included is a lid pivotally secured to the body for movement between an open position and a closed position, wherein in the closed position, the lid engages the open upper rim. The lid also includes a releasably sealable air port. Further included is a base configured for and accommodating the hopper lower end, for receiving joint compound, and for applying the joint compound to a corner paper bead.

A second embodiment of the present invention is a paper beading apparatus which includes a hopper having a body defining a chamber for holding a quantity of joint compound and a floor having a depending skirt defining a discharge opening. The apparatus further includes a base configured for receiving the hopper and defining a cavity, a front bead opening, and a rear bead opening at opposite ends of the base and in communication with the cavity, and an inlet chute defining an inlet opening in communication with the discharge opening.

A third embodiment of the present invention is a tray for use in a paper beading apparatus for applying joint compound to a corner bead, the apparatus having a base defining a cavity and having at least one tray track. The tray includes at least two flanges, each flange being generally parallel and equidistant from both a tray upper plane and a tray lower plane, the tray being reversible along a longitudinal axis of the tray and having two positions, an outside bead position wherein the tray has a generally “M”-shape when viewed on end and an inside bead position wherein the tray has a generally “W”-shape when viewed on end, and wherein the at least one tray track each accommodates a corresponding one of the tray flanges when the tray is in either the outside bead position or the inside bead position, the tray being disposed in the cavity.

A fourth embodiment of the present invention is a gate for use with a paper beading apparatus for applying joint compound to a corner bead, the apparatus having a base defining a cavity and at least one gate positioning opening, and a tray being disposed in the cavity. The gate includes at least one gate application edge, a plurality of gate teeth disposed on the at least one application edge, and at least one positioning lug. The gate is disposed in the cavity with the at least one positioning lug engaging the corresponding gate positioning opening, and is arranged such that a bead gap is formed between the at least one gate application edge and the tray. In use, the corner bead is fed through the bead gap such that it makes contact with the gate teeth, the at least one gate application edge defining the amount of joint compound dispensed on the corner bead.

DETAILED DESCRIPTION OF THE INVENTION

Referring now toFIGS. 1,2A, and2B, a paper beading apparatus, generally designated10has a hopper12with a lid14, the hopper being attached to a base16. The hopper12has a body18defining a chamber20for holding a quantity of joint compound. On the hopper12is an open upper end22, an upper rim24, and a lower end26. At least two hand holds28are disposed on the body18near the open upper end22, for facilitating lifting and/or movement of the paper beading apparatus10. Preferably, the hand holds28are on diametrically opposite sides of the apparatus10and are disposed on an annular rib or lip30, extending radially from a longitudinal axis of the hopper12. The annular rib30is preferably disposed near the open upper rim24. An alternative way to lift and/or move the paper beading apparatus10is provided by way of a handle32having two ends, a handle first end34preferably being attached to one of the hand holds28, and a handle second end36being attached to the other hand hold. Preferably, each handle end34,36is pivotally fastened to the corresponding hand hold28at a pivot point38.

To reduce the likelihood of joint compound spilling out of the open upper end22of the hopper body18, to prevent unwanted materials from entering the body through the open upper end, and to preserve unused joint compound overnight for use the next day, the lid14(FIG. 3) is pivotally secured to the body18for movement between an open position and a closed position. In the closed position, the lid14engages the hopper upper rim24, generally forming a seal over the open upper end22.

An adjustable hinge42is constructed and arranged such that the lid14pivots on the hinge between the open position and the closed position. The hinge42is made up of a hinge body portion44, preferably extending from the annular rib30, which generally complements and engages a hinge lid portion46, preferably extending from an outer rim48of the lid14. An adjustable hinge clamp49for varying a clamping force executed on the lid14has a clamp knob50with a threaded bore and a threaded bolt51that passes through at least one hinge fastener opening52in each of the hinge body portion44and the hinge lid portion46. Upon tightening the hinge clamp49, the lid14incurs greater resistance in moving between the open position and the closed position, thereby allowing a user to control the ease with which the lid moves about the hinge42. As such, the user can tighten the hinge clamp49sufficiently such that the lid14does not freely rotate about the hinge42, but instead remains in a fixed position. Upon removing the hinge clamp49, the lid14can be completely removed from the hopper12.

A latch54, preferably of the over center cam or toggle type and being attached to the body18near the open upper end22, has a latched position and an unlatched position and rotates on a latch attaching extension56on the body18, preferably near the open upper end22. When the lid14is in the closed position and the latch54is in the latched position, the latch clamps the lid to the body18such that the lid sealingly engages the open upper end22. Preferably, the latch54clamps the lid14to the body18by grippingly engaging a latch receiving lip58on the lid. Variations in the configuration of the latch54are contemplated.

At least one, but preferably five lid ribs60extend from a top side62of the lid14. When the lid14is placed upside down on a generally flat surface, the lid ribs60, instead of the top side62, make contact with the surface. As a result, the top side62has a reduced likelihood of sustaining wear. Also on the lid14is a releasably sealable, preferably circular air port64. In a preferred embodiment, a stopper66is tethered to the lid14and has a generally peg-shaped air plug68constructed and arranged to releasably seal the air port64. It is noted that the stopper66could alternatively be tethered to the body18. The lid14also has at least one, but preferably two grips70extending radially from an edge72of the lip14, which provides the user with an increased surface area for gripping the lid14when moving the lid between the open position and the closed position.

Referring now toFIG. 4, a feature of the hopper12is a preferably obstruction-free floor72having a depending skirt74that defines a discharge opening76. By lacking any obstructions such as fastener heads, the chamber20is much easier to clean with a standard taping knife compared to a conventional beading apparatus.

Referring now toFIGS. 2B and 5, supporting the hopper12is the base16which is configured for and accommodates the hopper lower end26. The base16defines a cavity78, a front bead opening80and a rear bead opening82(FIG. 8) at opposite ends of the base and in communication with the cavity, and an inlet chute84defining an inlet opening86being in communication with the discharge opening76. Preferably, the inlet opening86and the discharge opening76are generally rectangular-shaped having generally equivalent dimensions. To facilitate flow of joint compound into the cavity78, the skirt74preferably telescopes into the opening86.

The base16also defines at least two gate adjustment slots, a front gate adjustment slot87being adjacent to the front bead opening80and a rear gate adjustment slot88being adjacent to the rear bead opening82(FIG. 5). Further defined by the base16are at least two gate positioning openings, a front gate positioning opening90being adjacent to the front gate adjustment slot87and a rear gate positioning opening92being adjacent to the rear gate adjustment slot88.

Referring now toFIGS. 6 and 7, disposed in the cavity78is at least one, but preferably two identical gates94, a first gate near the front bead opening80, and a second gate94near the rear bead opening82. Each gate94has at least one gate fastener opening95, at least one, but preferably two application edges96with a plurality of gate teeth97preferably with beveled edges98or rounded edges (not shown), and at least one positioning lug99. Preferably, each gate94includes an application portion100and a reinforcement portion102, each portion being made of a different material. In a preferred embodiment, the application portion100is made of thermoplastic elastomer material similar to a stiff rubber and the reinforcement portion102is made of a relatively hard plastic material, with the two portions being chemically and/or mechanically bonded together to form an integrated piece. A peripheral fence104projecting generally normally from a main plane on the reinforcement portion102engages a complementary recess106in the application portion.

In a preferred embodiment, the application portion100has at least one, but preferably several lugs108having a variety of shapes, and extending into and mating with the reinforcement portion102. The lugs108provide for mechanical bonding by having a frictional fit and a mating engagement in their corresponding openings in the reinforcement portion102(FIG. 6). Chemical bonding is achieved by heating or applying chemical adhesive to the two portions100,102. Extending from a rear surface109of the gate94is at least one, but preferably two gate fins110preferably made of a soft plastic material. The base16also defines at least one gate storage compartment111(FIG. 2B) for conveniently storing spare gates94. The gate fins110engage the inside of the gate storage compartment111with a friction fit to reduce gate movement.

Each gate94is arranged such that the positioning lug99engages the corresponding gate positioning opening90,92, the track-like openings being constructed and arranged to allow the gate94to be vertically adjustable. Each gate94is securable by an at least one elongate threaded gate fastener112and a threaded knob116, with the elongate portion passing though the gate fastener opening95at a desired vertical position, and the corresponding gate adjustment slot87,88to engage the knob116, allowing the gate94to be secured at a desired vertical position.

Referring now toFIGS. 2B and 8, further disposed in the cavity78is an elongate tray118having at least two laterally extending flanges120, each flange being generally parallel and equidistant from both a tray upper plane extremity and a tray lower extremity (FIG. 2B). A feature of the tray118is that it is reversible along a longitudinal axis of the tray to have two operational positions, an outside bead position where the tray has a generally “M”-shape when viewed on end, and an inside bead position where the tray has a generally “W”-shape when viewed on end. In a preferred embodiment, the tray118has at least one, but preferably two mouths126located at each tray end128, extending along the longitudinal axis beyond the flanges120. Each mouth126is elongated to reduce dripping of joint compound and to provide a guide for locating the bead in the tray.

On the tray118is at least one, but preferably four tray fastener openings130. The base16also has at least one, but preferably four base fastener openings132(FIG. 5), with the body18having at least one, but preferably four bosses133(FIG. 2A). At least one, but preferably four tray fasteners134are constructed and arranged to fasten the tray118, in either the outside bead position or the inside bead position, the base16, and the body18together by passing through the corresponding tray fastener opening130and the corresponding base fastener opening132to engage the corresponding boss133, which retains a threaded nut (not shown). When the tray118is fastened inside the base16, a bead gap136(FIG. 1) is formed between the at least one gate application edge96of each gate94and the tray. When the gates94and tray118are properly fastened, the corner bead is able to be fed through the bead gap136such that it makes contact with the gate teeth97, with the gate application edge96defining the amount of joint compound dispensed on the corner bead. It is noted and is well-known in the art, that different shaped gate application edges are preferred for different types of corner beading jobs. For example, a gate94with a ninety-degree shaped application edge96is generally preferred for use with a ninety-degree shaped corner bead. Similarly, a gate94bhas a bull-nose shaped application edge96b(FIG. 2B), which is generally preferred for use with a bull-nose shaped corner bead. Also an inside corner gate94chas a distinctive, concave right-angled shape96c(FIG. 3).

Referring now toFIG. 8, while the base16can simply be placed on a floor or other generally solid surface when being used, preferably the base has a lower peripheral edge138configured for engaging a substrate, wherein the base has at least one ring140of spaced, stepped fins142disposed inwardly from the peripheral edge for accommodating a support bucket. Preferably, the base has a plurality of rings140being radially spaced apart for facilitating engagement with support buckets of varying diameters. Each step defines a landing or engagement point for a support bucket with a different diameter.