Patent Publication Number: US-2021180319-A1

Title: Apparatus and Method for Baseboard System Used in Drywall Construction

Description:
FIELD OF THE INVENTION 
     This invention relates to a drywall apparatus and method, and more particularly to a system for creating a reveal between a baseboard and a drywall board, and method for doing same. 
     BACKGROUND OF THE INVENTION 
     One aesthetically pleasing way to construct a wall using gypsum or drywall board involves leaving a gap of approximately 1 cm between a baseboard and a drywall board above it. This gap is referred to as a “reveal.” A typical method for creating a drywall reveal is to use a “Z-shaped” moulding that is glued and/or stapled on the front side of the drywall at the bottom thereof. In position, the moulding gives a clean line along the bottom front edge of the board. The moulding is also designed to cover the back of the recessed space or gap between the drywall board and the baseboard to hide the studs or insulation behind the board. 
     The moulding is fastened to a standard drywall board at the job site. Drywall compound is then added to the moulding and drywall board, and then feathered out. After drying, the compound is sanded. This process of applying compound, feathering and sanding may be repeated several times with the aim of achieving a transition from the raised surface of the moulding to the surface of the drywall that is seamless and cannot be seen when the wall is painted. This process is relatively time consuming and costly. 
     It is an object of the present invention to provide a system and method for forming a drywall reveal that does not involve so many steps. 
     SUMMARY OF THE INVENTION 
     A drywall board system for use in conjunction with a baseboard is described. The drywall board system includes a drywall board for securing to framing members. The drywall board has a back side designed to be adjacent to the framing members when the drywall board is secured thereto, and a front side opposite the back side. Framing drywall liner lines the back side while finishing drywall liner lines the front side. Gypsum material is sandwiched between the framing and finishing drywall liners. The drywall board system further includes a board backing for receiving at least a portion of the baseboard. The board backing is fastened to the back side of the drywall board, such that the board backing extends downward from a bottom of the drywall board. 
     The board backing may be fastened to the back side of the drywall board with at least one of screws screwed into the back side, nails driven into the back side and adhesive applied to either the gypsum material at the back side or the framing drywall liner. 
     Also described herein is a baseboard system for use in conjunction with a drywall board. The baseboard system includes a baseboard for securing to framing members. The baseboard has a back side designed to be adjacent to the framing members when the baseboard is secured thereto, and a front side opposite the back side. The baseboard system also includes a board backing for receiving a portion of a drywall board. The board backing is fastened to the back side of the baseboard and extends upwards from the top of the baseboard. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A and 1B  show a front and cross sectional view, respectively, of a drywall board system, according to the principles of the present invention. 
         FIGS. 2A-C  show one variation of the drywall board system of  FIGS. 1A and 1B  in which magnets are employed, according to the principles of the present invention. 
         FIGS. 3A and 3B  show one variation of the drywall board system of  FIGS. 1A and 1B  in which a horizontal groove is formed and shown, respectively, in an unfolded position and a folded position, according to the principles of the present invention. 
         FIGS. 4A and 4B  show a drywall board system with a different horizontal groove than that of  FIGS. 3A and 3B , according to the principles of the present invention. 
         FIGS. 5A and 5B  show a baseboard system for use in conjunction with a drywall board, according to the principles of the present invention. 
         FIGS. 6A-C  show a variation of the baseboard system of  FIGS. 5A and 5B  in which a flange runs longitudinally and along a board backing, according to the principles of the present invention. 
         FIG. 7  shows a flow chart for constructing a reveal using the baseboard system of  FIGS. 6A-C . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1A and 1B  show a front and cross sectional view, respectively, of a drywall board system  10  having a drywall board  11  for securing to framing members  12 . As explained in more detail below,  FIG. 1A  does not include a baseboard  28 , whereas  FIG. 1B  includes a baseboard  28 . Framing members  12  can include wood or metal studs to which the drywall board  11  may be screwed or nailed. The drywall board  11  has a back side  14  and a front side  16  opposite the back side  14 . The back side  14  is the side of the drywall board  11  that is adjacent to the framing members  12  when the drywall board  11  is screwed or nailed thereto. The front side  16 , on the other hand, is the opposite side of the drywall board  11  that, after installation, is usually painted, plastered, wall papered or otherwise finished. The back side  14  has framing drywall liner  18 , such as drywall paper. The front side  16  has finishing drywall liner  20 , such as drywall paper. The framing drywall liner  18  and the finishing drywall liner  20  may be the same, or may have different characteristics, such as different thicknesses. Gypsum material  22  is sandwiched between the framing drywall liner  18  and the finishing drywall liner  20 . 
     In addition to the drywall board  11 , the drywall board system  10  further includes a board backing  24  that is fastened to the back side  14  of the drywall board  11 . The board backing  24  extends downward from a bottom  26  of the drywall board  11 , in one embodiment without contacting the front side  16  of the drywall board  11 . The term “bottom” refers to a portion of the board  11  that, when the drywall board system  10  is installed, would be nearest the floor. The board backing  24  receives a portion of a baseboard  28  to form a reveal. The term “receive” can include embodiments in which the baseboard  28  abuts or overlaps the board backing  24 . In one embodiment, the board backing  24  extends downward from the bottom  26  of the drywall board  11  by about two inches. 
     The board backing  24  may be attached to the back side  14  of the drywall board  11  with fasteners, such as screws  29  that are screwed through the framing drywall liner  18  and into the gypsum material  22  without piercing the finishing drywall liner  20 . Alternatively, the board backing  24  may be fastened to the back side  14  of the drywall board  11  by bonding with adhesive, for example. 
     In one embodiment, the board backing  24  contains metal that is attracted to magnetic material in the baseboard  28 , or the opposite arrangement where the baseboard  28  contains metal and the board backing  24  contains magnetic material is also possible. The attraction of the metal to the magnetic material helps affix the baseboard  28  to the board backing  24 . The metal can be white, pre-coated steel or aluminum, for example. In one embodiment, the thickness of the board backing  24  is about 0.032 inches. 
       FIGS. 2A-C  show an embodiment consistent with the present invention that employs a magnet. Pockets  30  are stamped into a metallic board backing  24 . Complimentary magnetic projections  32  are disposed on the surface of the baseboard  28  projecting from the rear of the baseboard  28  (see  FIG. 2C ). The magnetic projections  32  fit into the pockets  30  and are affixed thereto, in whole or in part, via the attraction between magnetic material in the magnetic projections  32  and the metallic baseboard backing  24 . The attraction of the metal to the magnetic material helps affix the baseboard  28  to the board backing  24  in an appropriate position. The appropriate position would leave the board backing  24  levelled and at the right height to leave a suitable gap for the reveal. The gap, for example, can be in the range of 1-3 cm. It is also contemplated that instead of having the pockets  30  in the board backing  24  and the projections  32  in the baseboard  28 , the pockets can reside in the baseboard and the projections in the board backing. 
     It is aesthetically desirable for the front bottom edge of the drywall board  11  to have a sharp edge. At least two ways to form this edge are now described. 
     With reference to  FIGS. 3A and 3B , a horizontal groove  50  is formed on the back side  14  of the drywall board  11 . A hingeable lower lip  52  is thus created at the bottom of the drywall board  11 . In  FIG. 3B , the lip  52  is shown in a folded position attained by rotating the lip  52  to close the groove  50 , which action is suggested by the dashed arrow in  FIG. 3A . Adhesive, for example, can be used to keep the lip  52  in the folded position shown in  FIG. 3B . 
       FIGS. 4A and 4B  show a different horizontal groove  60  formed on the back side  14  of the drywall board  11 . A hingeable lower lip  62  is thus created at the bottom of the drywall board  11 . In  FIG. 4B , the lip  62  is shown in a folded position attained by rotating the lip  62  to close the groove, which action is suggested by the dashed arrow in  FIG. 4A . As in the previous embodiment, adhesive can be used to keep the lip  62  in the folded position shown in  FIG. 4B . 
     Instead of disposing a backing on the drywall board, the backing can instead be disposed on the baseboard. Such an alternative is described in  FIGS. 5A  (front view) and  5 B (cross-sectional view), where a baseboard system  100  that accepts a drywall board  128  is shown. As explained in more detail below,  FIG. 5A  does not include a drywall board, whereas  FIG. 5B  includes a drywall board  128 . The drywall board  128  is secured to framing members  112 . Framing members  112  can include wood or metal studs to which the baseboard system  100  may also be screwed or nailed. The baseboard system  100  includes a baseboard  107  having a back side  114  and a front side  116  opposite the back side  114 . The back side  114  is the side of the baseboard  107  that is adjacent to the framing members  112  when the baseboard system  100  is affixed thereto, such as with screws or nails. The front side  116 , on the other hand, is the opposite side of the baseboard  107  that, after installation, may be left as is, painted or otherwise finished. The baseboard  107  is comprised of an appropriate material, such as wood, gypsum material, elastomer, plastic, metal, stone, medium density fiberboard (MDF), or polyurethane. 
     In addition to the baseboard  107 , the baseboard system  100  further includes a board backing  124 . The board backing  124  extends upward from a top  126  of the baseboard  107 , in one embodiment without contacting the front side  116  of the baseboard  10 . The term “top” refers to a portion of the baseboard  107 , which, when the baseboard system  100  is installed, would usually be the portion furthest from the floor. The board backing  124  receives a portion of a drywall board  128  to form a reveal or gap  130  between the baseboard  107  and the drywall board  128 . The term “receives” can include embodiments in which the drywall board  128  abuts or overlaps the board backing  124 . In the former case, when the drywall board  128  is meant to merely abut the board backing  124 , the height of the portion of the board backing  124  that extends above the top  126  of the baseboard  107  would be the height of the reveal. 
     In some embodiments, the board backing  124  can be rigid or semi-rigid to allow some flex, and can be composed of wood, elastomer, plastic, polyurethane or metal. 
     In one embodiment, the baseboard  107  and the board backing  124  are two separate pieces that are fastened together, such as with nails, screws or adhesive. In another embodiment, the baseboard and board backing may be formed as one piece. For example, such a baseboard system may be manufactured by injection moulding or die casting using a single mould. For this purpose, the baseboard system may be made out of metal, elastomer or thermoplastic. 
     The height of the portion of the backing  124  that extends upwards past the top of the baseboard  107  can range from the height of the intended reveal to many centimetres beyond. In one embodiment, the height of this portion of the backing can be one centimetre or less. This would be useful in a process where the drywall board  128  is affixed to the studs  112  before the baseboard system. In such case, the relatively short height of the portion of the backing  124  can be squeezed between the drywall board  128  and the studs  112 . 
       FIGS. 6A-C  show another embodiment of a baseboard system having a flange. The baseboard system  150 , which includes a baseboard  154 , of  FIG. 6  is similar to the baseboard system  100 , but in addition has a board backing  152  that includes a flange  153  that runs longitudinally. The vertical distance  155  from the top of the baseboard  154  to the flange  153  corresponds to the height of the reveal or gap that is created. Advantageously, as shown in  FIG. 6C , a drywall board  156  can rest on the flange  153  while the board is being secured to the studs  158 . The depth  157  of the flange  153 , which in  FIGS. 6B and 6C  is the distance of the flange as measured from left to right is no larger than the thickness of the drywall board, e.g., half the thickness. In a preferred embodiment, the flange  153  has a depth that is large enough to allow the drywall board  156  to rest thereon, but small enough that it is not easily seen after the baseboard system  150  and drywall board  156  are installed. In one embodiment, a range for the depth of the flange of 25% to 75% of the thickness of the drywall board is appropriate. If the thickness of the board is ½ of an inch, this corresponds to a range for the depth of the flange of 0.125-0.375 inches; if the thickness is ⅜ of an inch, this corresponds to a depth of 0.0938-0.281 inches. In another embodiment, the depth of the flange is equal to the thickness of the drywall board. 
     It will be appreciated that while the flange  153  in the embodiment of Figs. 6 A- 6 C is disposed approximately midway up the backing  152 , in another embodiment the flange can be disposed at or near the top of the backing  152 , including the very top. In the latter case, where the flange  153  is disposed at the very top of the backing, no amount of backing extends above the flange. Such a configuration might be employed when the drywall board  156  is affixed to the studs  158  first, before the baseboard system  150  is affixed to the studs. 
     In addition to providing a resting surface for the drywall board  156  that makes installation easier, the flange  153  furnishes the correct height and levelling of the reveal without having to make measurements. 
       FIG. 7  shows a flow chart for constructing a reveal using the baseboard system of  FIGS. 6A-C . In step  200 , at least one flooring spacer is disposed on a subfloor. The flooring spacer can be a block of wood or any other appropriate material that has the same height as the flooring that will be installed on the subfloor. Alternatively, the flooring spacer can be an element of the flooring that will be installed on the subflooring, such as a hardwood, cork, bamboo floorboard, or tile. In step  202 , the baseboard system is placed on the at least one flooring spacer. In step  204 , the baseboard system is fastened to framing members, such as wood studs, with screws or nails. In step  206 , a drywall board is placed on the flange to rest thereon. In step  208 , the drywall board is fastened to the board backing and to the studs. In optional step  210 , the at least one flooring spacer can be removed. The flooring spacer would typically be removed if the flooring spacer is a block of wood used merely for spacing. On the other hand, if the flooring spacer is a floorboard, the flooring spacer can be left in place if the floorboard is one of many other floorboards comprising the flooring, and more floorboards are to be added on the subflooring to complete the flooring. In the latter case, the floorboard can optionally be removed until the drywall is installed, at which point the flooring can be installed. Such might be the case if the drywall boards or baseboard is to be painted; by removing the floorboards, one avoids getting paint splatter on the floorboards. In any of these alternatives, a suitable spacing is achieved between the bottom of the baseboard and the subflooring to ensure proper fitting of the flooring members therebetween. 
     In this vain, some or all of the baseboard can be covered or shrink wrapped with a protective plastic, or other suitable material, to avoid getting paint splatter on the baseboard if the drywall above the baseboard is to be painted. After the paint dries, the cover or shrink wrap on the baseboard is designed to be easily removed.