Abstract:
What is disclosed is a sheetrock corner bead that features an elongated core and paper flange extension for the elongated core. The flanges provide a layered tapered appearance that allow for less mud to be used and fewer mud applications required for installing the corner. The sheetrock corner bead provides for an improved method of installation that generally requires less mud and less time spent in installation.

Description:
PRIORITY/CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/723,904 filed Nov. 8, 2012, the disclosure of which is incorporated by reference. 
    
    
     BACKGROUND 
     Customarily when finishing drywall construction workers use various types of corner beads to finish the corners around doors, windows, and the edges of walls. These walls are typically framed in either 2″×6″ or 2″×4″ framings with half inch or ⅝″ drywall. Generally the drywall corner bead comprises a paper combined with metal corner, known as tape on corner bead and the metal and paper has a centerline with two metal flanges. Drywall corner bead can also be a metal corner that is fastened to the wall and mudded over. These flanges are fairly short and have an extended paper flange for attaching to a wall typically via joint compound (also known as mud). In this situation, typically the corner bead contains a recessed portion created along the two opposing flanges of the metal nose or point and a paper layer over the metal portion to allow for adhering to sheet rock. The recessed portion is prominent in the corner when the paper exterior sheet is present on the metal section, as is the case when the corner is applied in sheetrock finishing. This recessed portion allows for a worker to fill the recessed portion with mud, which is commonly known to those having experience in sheetrock/drywall application. 
     Customarily in dry wall applications, mud is applied with a trowel, a knife, or with the worker&#39;s hands or tools with similar function. The worker uses similar tools to smooth the mud and/or to remove excess mud. When the worker applies the corners disclosed in the previous art, the worker has to 1) apply mud to sheet rock surface with knife or with mud hopper, 2) press the corner firmly in place, 3) wipe paper edges of the corner bead to remove excess mud, 4) roll the corner into place with corner bead roller then remove excess mud, 5) allow mud layer to dry, 6) sand dried layer and apply an additional layer of mud and allow to dry, 7) sand dried layer and apply additional layer of mud and allow to dry. The worker must return sand and apply mud to areas needed per required finish. This mudding and sanding must be done before the worker can prime the wall for painting or texturing in order to generate a smooth corner. What is needed is a simple to apply corner that a worker does not have to repeatedly apply mud to, thus saving the worker time and material. 
     In tape on corner bead applications mud is applied to the sheetrock by hand using a drywall knife, trowel or mud application too. Mud can also be applied directly to corner bead by use of a sluice box or hopper to apply mud to the corner. The corner bead flanges are then affixed by using a corner bead roller, with excess mud being removed by hand using a drywall knife, making the edges of the corner bead smooth and attached. 
     SUMMARY OF THE DISCLOSURE 
     A disclosed embodiment has an elongated core having an outer surface and an inner surface. The elongated core has two flanges extending outward from the center of the elongated core. The flanges have a recessed portion beginning at a point outward from the center of the elongated core. This outward section of the flange has a paper section which abuts the end of the flange. On top of this core layer is an outer layer or exterior paper section that is attached to the inner of the core and to the paper section that is attached beginning at the recessed portion of the elongated core and extends outward to the end of the section abutting the elongated core. There is also an interior section that is on the inside of the corner. This section is configured for attachment to sheetrock. The outer section is such that it can be made out of fire resistant or mold resistant paper. The outer section is designed to be finished using a texture or can just be painted. The overall appearance of the corner provides a staggered tapered appearance such that the outer layer is wider than the interior layer. This allows for the sheetrock mud to placed along the tapered portion such that the a worker does not have to apply multiple sequential layers of mud followed by sanding between each application of mud. Once the corner is applied to the sheetrock wall, the mud on the edges of the corner can be sanded and the entire corner can be textured along with the sheetrock wall and subsequently painted. 
     In a preferred embodiment, the elongated core is a galvanized metal elongated core. It is in a preferred embodiment that this elongated core be 0.015 inches thick. In a preferred embodiment the overall flange length of the entire corner is between 1½ inches and 5¼ inches. This will allow for a variety of corners. In the event that the flange is too long for the worker, the worker can use a knife, such as a utility knife to cut the flange down to the correct size. Two opposing flanges can be of various sizes depending on the corner type that the corner is going to be installed on. The staggered tapered appearance of the corner allows for mud to be placed toward the edge of the corner and less mud to be used as the paper corners are tapered. 
     It is thought that the tapering of the papered corner will allow for a layer of mud to be placed on the corner, the corner to be smoothed down, excess mud removed, the corner sanded, if necessary, without additional applications of mud. This will provide for faster application of the corner because a worker, in the traditional methodology in which the recessed portion of the flange is not filled by paper, but instead is filled by mud that is sequentially layered and sanded several times in order to provide the overall finished appearance in which the corner tapers into the sheetrock. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of the new corner bead. 
         FIG. 1P  is an isometric view of the prior art corner bead. 
         FIG. 2  is a top view of the new corner bead. It shows a small piece of angled metal and four layers of paper. The outside mud fill areas are eliminated. 
         FIG. 2P  is a top view of the prior art corner bead. It shows a large piece of angled metal and one layer of paper. Prior art corner bead has outside mud fill areas on the part. 
         FIG. 3  is a top exploded view of the new corner bead. 
         FIG. 4  is an isometric view of the new corner bead normally used in windows using 2″×6″ window framing. 
         FIG. 5  is an isometric view of new corner bead normally used in windows using 2″×4″ window framing. 
         FIG. 6  is a top view of the new corner bead normally used in windows using 2″×6″ window framing. The metal and paper layers are similar to  FIG. 2 . 
         FIG. 7  is a top view of new corner bead normally used in windows using 2″×4″ window framing. The metal and paper layers are similar to  FIG. 2 . 
         FIG. 8  is an isometric view showing the wall preparation for a window corner using 2″×4″ walls. This wall preparation applies to the use of both (corner bead  FIG. 7 ) and (bullnose  FIG. 12 ). 
         FIG. 8P  is an isometric view showing the prior art wall preparation for a window corner using 2″×4″ walls. This wall preparation applies to the use of both (corner bead  FIG. 2P ) and (bullnose  FIG. 12P ). 
         FIG. 9  is an isometric view showing next installation step after  FIG. 8  for the new corner bead. 
         FIG. 9P  is an isometric view showing next installation step after  FIG. 8P  for the prior art corner bead. 
         FIG. 10  is an isometric view showing next installations step after  FIG. 9  for the new corner bead. 
         FIG. 10P  is an isometric view showing the results for the next three installation steps after  FIG. 9P  for the prior art corner bead. 
         FIG. 10A  is an isometric detail view of the finished corner for  FIG. 10 . 
       FIG.  10 PP is an isometric detail view of the finished and filled  FIG. 10P . 
         FIG. 11  is an isometric view of the new bullnose. 
         FIG. 11P  is an isometric view of the prior art bullnose. 
         FIG. 12  is a top view of the new bullnose. It shows a reduced curved metal support and three layers of paper. The outside mud fill areas are eliminated. 
         FIG. 12P  is a top view of the prior art corner bead. It shows a large piece of angled metal and one layer of paper. It has outside mud fill areas on the part. 
         FIG. 13  is a top exploded view of new bullnose. 
         FIG. 14  is an isometric view of the new bullnose, used with 2″×6″ window framing. 
         FIG. 15  is an isometric view of the new bullnose, for use with 2″×4″ window framing. 
         FIG. 16  is a top view of new bullnose, for use in windows using 2″×6″ window framing. 
         FIG. 17  is a top view of new bullnose, for use in windows using 2″×4″ window framing. 
         FIG. 18  is an isometric view showing the new bullnose installation for a window in a 2″×4″ wall. This step follows the wall preparation shown in  FIG. 8 . 
         FIG. 18P  is an isometric view showing prior art bullnose installation for a window in a 2″×4″ wall. This step follows the wall preparations shown in  FIG. 8P . 
         FIG. 19  is an isometric view showing next installations step after  FIG. 18  for the new bullnose. 
         FIG. 19P  is an isometric view showing the results for the next three installation steps after  FIG. 18P  for the prior art bullnose. 
         FIG. 19A  is an isometric detail view of the finished corner for  FIG. 19 . 
       FIG.  19 PP is an isometric detail view of the finished and filled  FIG. 19P . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates an isometric view of the new corner bead. The new corner bead is constructed such that minimal mud is needed to finish the corner bead. The newly disclosed corner bead  2  of the application features a metal or plastic support corner  3  that is attached to layers (or sections) of paper, such that the paper forms a gradual tapering from the thicker center part of the corner  3  down to the edge of the corner bead  11 . This allows for the gradual tapering of the corner bead and allows for the mud just to be applied in fewer applications, such that multiple layers and drying time for the mud and subsequent multiple sandings are not needed. This is done by providing the corner  3 , which in a preferred embodiment which is approximately 0.015 inches thick (in other wording, approximately ⅛″ thick). This corner, in a preferred embodiment is thirty gage galvanized metal, can also be made using plastic or a combination of metal and plastic. The preferred width of each of the flanges of the metal is approximately ⅜ inch with paper extending the width up to 5¼ inches. It is thought that this is the preferred width that can be used, although smaller or wider could be potentially used. 
     The internal layers of paper  4 , 6 , 8  are preferably made from a 9 pt suture stock (5111-120). This paper is made by Monadnock in a preferred embodiment, although any paper will work consistent with the spirit of the current invention. The outer paper layer  10  is preferably made from drywall trim paper (1720-097) also constructed by Monadnock which can be treated with a mold or fire resistance paper. 
       FIG. 1P  illustrates what is thought to be the current prior art in a generalized drawing. Illustrated in  FIG. 1P , the prior art features a central metal or plastic corner  14 , as well as an extended paper  18 . These paper flanges are not tapered from a uniform flat exterior to the end and instead flange provides an indented section such that corner  14  provides recess  17 , that is filled with mud in sequential applications. This gap is filled with mud adhesive typically at least three times, with each of the layers being allowed to dry and typically are sanded before another layer of mud is applied in sequence. This leads to substantial increase of time in preparing drywall corners. The layered paper corner bead of the current invention uses a minimal metal or plastic center, although other material consistent with the spirit of the invention may be used. 
     Mud or adhesive is applied to the outside paper near the edge such that the adhesive or mud is layered over the edge of the paper onto the sheetrock. This outer paper is to be pre-finished for text or paint such that is not required to mud or outer adhesive before applying any further paint or texture. It is thought that in an ideal situation in which the framing of the building has been relatively straight, minimal mud will be needed on the paper bead in order to generate a proper corner. However, in the event that the framing is crooked or off center, multiple layers of mud can be used in order to square the corner. The paper can also be made with nodules for using mud to apply the corner of the wall to enhance mud application. This generates increased mud adhering to the paper of the corner bead. Alternatively, the paper can be left smooth to adhere by using glue. The pre-finished outside paper can be primed or textured without having coating with anything. Again, any type of metal or plastic can be used to make the corner consistent with the spirit of the invention. Alternatively, the corner bead can be made in a variety of corners, including square kerf jambs, bullnosed, baby bull, L-metal, an open angle or one thirty five degrees corner. The paper flange (and overall width of the flange of the corner bead) is generally from 1¼ inches to 5¼ inches wide depending on the overall width of the corner to be finished. A worker can finish the edge using either his or her hand or with tools. The corner bead can also be taped on and finished over. 
     A typical building is framed using 2″×4″ or 2″×6″ framing with ½ inch or ⅝ inch drywall. Thus a 1¼ to 5¼ inch corner bead flange can be used, eliminating coating at all on window returns while adjusting for different window thickness, between ½ inch to 1¼ inch. The worker can trim paper edge with razor knife as needed to match the window width. Thus 5¼ inch corner bead width reaches the window. There is no need to coat the window return with mud. This is, for example, illustrated in  FIG. 10 . 
       FIG. 2  illustrates a top view of the new corner bead. As illustrated the length of elongate core  32  is slightly angled and is attached to four layers (also called sheets or sections) of paper to provide the new corner bead. In contrast  FIG. 2P  shows what is thought to be the prior art. Prior art features a wider metal core  38  and includes a single layer of paper  36 . As illustrated in  FIG. 2 , the four layers of paper of the current invention creates a layered corner that provides for the general tapering of the corner from the point of the corner to the edge of paper  22 . This alleviates the need to fill the recess that is created by the angle of the core  32 . The small piece of metal  32  abuts with paper  26  such that the length of the piece of metal (or other core material) needed is reduced, thus likely decreasing cost of manufacturing the corner. The increased paper layers add longer rigidity to the corner without requiring a longer metal flange as shown in  FIG. 2P ,  38 . 
       FIG. 3  illustrates a top exploded view of the new corner bead.  FIG. 3  illustrates the outer paper layer  52  that is attached to elongated metal core  42 . The elongated metal core  42  is attached to a layer of paper  50  that fills recessed portion  41 . Recessed portion  41  is approximately a ⅛ inch fill gap that is filled by paper  50 . The thickness of the interior layer  48  being generally 0.015 inches, second layer  44  is generally 0.015 inches, the third layer is generally 0.01 inches and the outer layer is generally 0.09 inches. This is thought to be the preferred embodiment, is exemplary of the invention, and is not meant to be limiting to the paper width. The edges as depicted in  FIG. 3  are generally tapered in a preferred embodiment in order to provide a layered structure. The distance between the tapered edges of the four layers of paper is thought in a preferred embodiment to be  1 / 4  to ¾ of an inch although it can be smaller or greater depending on a worker&#39;s need. In a preferred embodiment, 9/16″ to ⅝″ is the preferred distance between the edges of the paper. As illustrated elongate core  42  abuts with edge portion  45  at seam  46 . This allows for the continued layering of the paper layers from the center metal portion. 
       FIG. 4  illustrates an isometric view of the new corner bead designed for windows using 2″×6″ window framing. The corner bead is generally in four layers or sections to create the staggered tapered appearance, although additional layers or sections could be added. 
       FIG. 5  illustrates an isometric view of a new corner bead used in windows that are framed using 2″×4″ window framing.  FIGS. 6 and 7  illustrate the top views of the new corner bead for 2″×6″ window framing and 2″×4″ window framing, respectively. As illustrated for the 2″×6″ window corner  62  there is an elongated flange due to the wider stud of the window framing. In contrast, the 2″×4″ window framing uses a smaller flange, as illustrated. The edge of the flange abuts with the window, allowing for the entire framing to be finished with minimal mud application and sanding. 
       FIG. 8  illustrates an application of a corner to a windowed wall section.  FIGS. 8 and 8P  illustrate what must be done to prep the wall corner before both the current invention or the prior art can be applied as a corner.  FIG. 8  illustrates the current invention, while  FIG. 8P  illustrates the standard prior art.  FIG. 8  illustrates the sheetrock wall corner  66  having first sheetrock wall  70  and second sheetrock wall  72  against stud  71 . Mud is placed on the whole sheetrock surface of sheetrock  70 . The entire surface  70  of sheetrock wall  70  or alternately on the whole inside surface of the corner bead, or bullnose. Mud is also placed on the sheetrock wall from the closest edge of the sheetrock to the point  68  beyond where the corner bead or will cover. Subsequently, the comma as illustrated in  FIGS. 9 and 9P , the corner bead is placed over the mud then pressed in place with a roller or taping knife. Excess mud is then wiped off. 
     FIGS.  10 A and  10 PP illustrate where mud is required on each of the perspective current invention and the prior art. In the current invention, minimal or no mud is required on the exterior of the corner  107   a ,  107   b , but is required on the exterior of the corner at  107   c . This is because mud is not required to fill in the gap provided as shown in the prior art. In the prior art, mud must be used to cover the entire sheetrock surface  110 . Mud may need to be applied up to three times or even more depending on the shrinkage and drying of the mud on the sheetrock wall. 
       FIG. 10  illustrates a sheetrock window corner according to the present invention, while  FIG. 10P  illustrates a sheetrock corner according the prior art. As illustrated in  FIG. 10 , mud is spread over flange  96  of corner  95 . Flange  98  does not require mud as it is adhered to the sheetrock behind it by the previously applied mud or adhesive. In  FIG. 10P  mud is required to be applied to both  102  and  104 . Again this mud is required to be applied in sequential layers and subsequently sanded after each layer. This allows for filling the gap as illustrated in FIG.  10 PP.  FIGS. 11 through 13  represent the standard size of bullnose used for the invention. Bullnose, or round corner bead is used to create rounded corners. The corner and method can also be used on the interior of corner wall. 
       FIG. 13  illustrates an exploded view of the round bullnose corner, having paper sections  117  and metal section  115 . The corner differs from the prior art as the prior art has a recessed section that is to be filled with mud and sanded to finish the corner. 
       FIG. 14  illustrates a further view of the rounded end bullnose with an elongated flange  119 . 
       FIG. 15  illustrates a rounded bullnose section  120  having an elongated flange  121 . 
       FIG. 16  illustrates the top view of the bullnose corner of the current invention to be used in windows having 2″×6″ framing. 
       FIG. 17  illustrates the top view of the new bullnose used in windows having 2″×4″ framing. 
       FIG. 18  illustrates an isometric view showing the new bullnose installed in 2″×4″ window framing. This follows the same wall preparation steps shown in  FIG. 8  and associated figures, illustrating steps for applying the corner. 
       FIG. 18P  illustrates an isometric view showing the prior art bullnose installed in a window having 2″×4″ framing. This step follows the wall preparation shown in  FIG. 8P  and associated figures. 
       FIG. 19  illustrates an isometric view showing the steps following  FIG. 18  for application. This illustrates that mud only has to be placed on one side  135  of the drywall pairing. 
       FIG. 19P  illustrates that for prior art corner  146 , mud must be applied at both drywall sides of  137 . 
       FIG. 19A  is an isometric detailed view of the finished corner for  FIG. 19 . This illustrates that no mud is required to finish the side of sheetrock  139 . 
     FIG.  19 PP illustrates the close up view of corner  140  of the prior art. Side  140  is required to be finished with mud  141  that is layered and sanded sequentially.