Abstract:
A drywall-joint fixture has a drywall-joint cover ( 1, 33, 37, 42 ) that can be attached to a drywall arch, wall flat or other drywall structure after a first sheet ( 3 ) and a second sheet ( 4 ) of drywall of the drywall joint are positioned on wall framework ( 5, 35, 39 ) of a building. A paper face ( 49 ) that is resistant to sanding is positioned on the drywall-joint cover. The drywall-joint cover includes a first side ( 6 ), a second side ( 7 ) and an attachment flange ( 8 ). The attachment flange is extended orthogonally from an inside surface of either the first side or the second side and is longer than a side opposite from which it is extended for receiving fastener shanks ( 12 ) that are stuck through sheets and into a wall framework. A selection of shapes are provided for differing wall structures. A method includes using the attachment flange to maintain the drywall-joint cover in place.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to structure of drywall joints for corner beads, arches, edges, flats and other drywall applications after the drywall has been positioned.  
         [0002]     Drywall cornering, beads and joints are a common feature of construction of private and many commercial dwellings and business structures. Numerous devices and methods for joining drywall at corners, arches windows and flats are known, but continue to be devised because none have proved sufficiently adequate to satisfy needs of this feature of construction. Included have been freehand plastering and many differing rigid corner beads, paste-on beads, tack-on beads and combinations thereof.  
         [0003]     None, however, have post-positioning corner beads and joints for all drywall applications in a manner taught by this invention.  
         [0004]     Listed below for consideration is known related but different prior art:  
                                       US Patent/Publication No.:   Inventor   Issue/Publication Date                   6,447,872   Larson   Sept. 10, 2002       6,438,914   Robertson   Aug. 27, 2002       2002/0073638   Kunz et al.   Jun. 20, 2002       2002/0073639   Kunz et al.   Jun. 20, 2002       D458,388   Harel   Jun. 4, 2002       D457,658   Harel   May 21, 2002       6,338,229   Botzen   Jan. 15, 2002       6,131,348   Dunham   Oct. 17, 2000       6,073,406   Kearney   Jun. 13, 2000       5,836,122   Rennich et al.   Nov. 17, 1998       5,444,953   Koenig et al.   Aug. 29, 1995       6,223,486   Dunham   May 1, 2001       6,148,573   Smythe, Jr.   Nov. 21, 2000       6,295,776   Kunz et al.   Oct. 2, 2001                  
 
       SUMMARY OF THE INVENTION  
       [0005]     Objects of patentable novelty and utility taught by this invention are to provide a drywall-joint fixture and method which can decrease costs for installation of all forms of drywall construction substantially.  
         [0006]     This invention accomplishes these and other objectives with a drywall-joint fixture and method having a drywall-joint cover that can be attached to a drywall joint, arch, wall flat or other drywall structure after drywall is positioned on wall framework of a building and before the drywall and the drywall-joint cover are surfaced with paint or other wall cover. The drywall-joint cover has a surface covering for each of at least two drywall surfaces to be covered by a single drywall-joint cover. Intermediate a front surface covering and a side surface covering of the drywall-joint cover is an attachment flange for being extended from an inside surface of the drywall-joint cover and inserted between an end edge of a first drywall and a joint edge of a second drywall. Fastener shanks are affixed through a side drywall and into the wall framework. The attachment flange is inserted between the end edge of the first drywall and the joint edge of the second drywall. Then a side-surface covering is positioned on and fastened to the side-positioned drywall and a front-surface covering is positioned on and fastened to the second drywall.  
         [0007]     The above and other objects, features and advantages of the present invention should become readily apparent to those skilled in the art from reading the following detailed description in conjunction with the drawings wherein illustrative embodiments of the invention are shown and described.  
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0008]     This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are explained briefly as follows:  
         [0009]      FIG. 1  is a top view of a drywall-joint cover of a right-angle drywall joint positioned on drywall sheets that are attached to wall framework and held with a fastener shank which engages an attachment flange between a first sheet of drywall and the wall framework;  
         [0010]      FIG. 2  is top view of the  FIG. 1  drywall-joint cover separately;  
         [0011]      FIG. 3  is a top view of the drywall-joint cover having cover steps on which wall-finishing material is positioned;  
         [0012]      FIG. 4  is a perspective view of a drywall-joint cover having a side-surface covering with mud apertures for application of finishing mud;  
         [0013]      FIG. 5  is a perspective view of a drywall-joint cover having a side-surface covering with net material;  
         [0014]      FIG. 6  is a perspective view of a drywall-joint cover having a side-surface covering with fiberglass sheeting;  
         [0015]      FIG. 7  is a, fragmentary top view of a wall-end drywall-joint cover having bull-nose corners;  
         [0016]      FIG. 8  is a fragmentary top view of a drywall-joint cover of a right-angle drywall joint having an L-leg second side for extension to nearby window and other wall structure;  
         [0017]      FIG. 9  is a fragmentary top view of an open-cornered wall-end drywall-joint cover of a right-angle drywall joint having the attachment flange extended from second sides with fastener shanks affixed through first sheets of the drywall and bull-nose covering of the open corners;  
         [0018]      FIG. 10  is the  FIG. 9  illustration with closed corners;  
         [0019]      FIG. 11  is a fragmentary top view of an open-cornered wall-end drywall-joint cover of a single right-angle drywall joint having the attachment flange extended from the second side with a fastener shank affixed through the first side and with bull-nose covering of the open corner;  
         [0020]      FIG. 12  is a fragmentary top view of an open-cornered wall-end drywall-joint cover of a single right-angle drywall joint having the attachment flange extended from the first side with a fastener shank affixed through the second side and with bull-nose covering of the open corner;  
         [0021]      FIG. 13  is a fragmentary top view of an inside drywall-joint cover having a concave corner with the attachment flange glued between the first-sheet edge and the second-sheet edge;  
         [0022]      FIG. 14  is the  FIG. 13  illustration with addition of an inside-wall edge extended intermediate the second side and the attachment flange;  
         [0023]      FIG. 15  is a top view of the  FIG. 14  illustration with an open corner;  
         [0024]      FIG. 16  is a top view of the  FIG. 15  illustration with an open corner;  
         [0025]      FIG. 17  is a fragmentary top view of an inside drywall-joint cover having a concave corner with the attachment flange extended from the second side and glued to the first-sheet edge of an open corner and having the inside-wall edge extended intermediate the first side and the attachment flange;  
         [0026]      FIG. 18  is the  FIG. 17  illustration without the inside-wall edge;  
         [0027]      FIG. 19  is a fragmentary top view of the inside drywall-joint cover having the concave corner with the attachment flange extended from the first side intermediate the second side and inside-wall framework and having the fastener shank affixed through the second side, the attachment flange and the inside-wall framework;  
         [0028]      FIG. 20  is the  FIG. 19  illustration with the inside-wall edge;  
         [0029]      FIG. 21  is the  FIG. 19  illustration with an open corner;  
         [0030]      FIG. 22  is the  FIG. 20  illustration with the open corner;  
         [0031]      FIG. 23  is a fragmentary top view of the inside drywall-joint cover having the concave corner with the attachment flange extended from the second side intermediate the first side and inside-wall framework and having the fastener shank affixed through the first side, the attachment flange and the inside-wall framework;  
         [0032]      FIG. 24  is the  FIG. 23  illustration with the inside-wall edge;  
         [0033]      FIG. 25  is a fragmentary top view of an juxtapositional drywall-joint cover having the attachment flange extended intermediate the first side and the second side and positioned intermediate the first-sheet edge and the second-sheet edge with fastener shanks affixed through the first sheet, the second sheet, the second side and into juxtapositional wall framework;  
         [0034]      FIG. 26  is the  FIG. 24  illustration with the first side and the second side at an acute angle and the fastener shanks affixed also to a cap backer on the juxtapositional wall framework;  
         [0035]      FIG. 27  is the  FIG. 25  illustration with the first side and the second side at an acute angle and the fastener shanks affixed directly to the juxtapositional wall framework;  
         [0036]      FIG. 28  is the  FIG. 25  illustration with the first side and the second side at an obtuse angle and the fastener shanks affixed directly to the juxtapositional wall framework;  
         [0037]      FIG. 29  is a fragmentary top view of the juxtapositional drywall-joint cover having the attachment flange extended intermediate the first side and the second side and positioned intermediate the first-sheet edge and the second-sheet edge with fastener shanks affixed through the first sheet, the second sheet and the second side which is integrated with a cap backer which is attached to the juxtapositional wall framework;  
         [0038]      FIG. 30  is a fragmentary top view of a dual drywall-joint cover having an attachment base from which first and second cover walls and first and second attachment flanges are extended; and  
         [0039]      FIG. 31  is an end view of the  FIG. 30  illustration showing optional slots or cuts on ends of the first and second cover walls and first and second attachment flanges.  
     
    
     DESCRIPTION OF PREFERRED EMBODIMENT  
       [0040]     Listed numerically below with reference to the drawings are terms used to describe features of this invention. These terms and numbers assigned to them designate the same features throughout this description. 
         1 . Drywall-joint cover      2 . Drywall joint      3 . First sheet      4 . Second sheet      5 . Wall framework      6 . First side      7 . Second side      8 . Attachment flange      9 . First-sheet edge      10 . Second-sheet edge      11 . Framework wall      12 . Fastener shanks      13 . Fastener-edge area      14 . First-edge area      15 . Second-edge area      16 . Net material      17 . Mud apertures      18 . Fiberglass sheeting      19 . L-leg second side      20 . Wall-end second side      21 . Bull-nose arcuate corner      22 . Vacant space      23 . Arcuate drywall edges      24 . Concave corner      25 . Inside-wall edge      26 . Wall-end second side      27 . First drywall-joint cover      28 . Second drywall-joint cover      29 . Wall-finishing material      30 . Wall-end first side      31 . First cover step      32 . Second cover step      33 . Inside drywall-joint cover      34 . Inside drywall joint      35 . Inside wall framework      37 . Juxtapositional drywall-joint cover      38 . Juxtapositional drywall joint      39 . Juxtapositional wall framework      40 . Juxtapositional-attachment flange      41 . Cap backer      42 . Dual drywall-joint cover      43 . Attachment base      44 . First attachment flange      45 . Second attachment flange      46 . First cover wall      47 . Second cover wall      48 . Slots      49 . Paper face        
 
         [0089]     Referring to  FIGS. 1-6 , a drywall-joint fixture has a drywall-joint cover  1  that is articulated for covering a predetermined drywall joint  2  of a first sheet  3  of drywall and a second sheet  4  of drywall of the drywall joint  2  after the first sheet  3  and the second sheet  4  of drywall of the drywall joint  2  are positioned on wall framework  5  of a building. A first side  6  of the drywall-joint cover  2  covers a predetermined first-edge area  14  on the first sheet  3 . A second side  7  of the drywall-joint cover  2  covers a predetermined second-edge area  15  on the second sheet  4 .  
         [0090]     An attachment flange  8  that is predeterminedly rigid is extended from an inside surface of either the second side  7  or from the first side  6  of the drywall-joint cover  2 . The attachment flange  8  is predeterminedly longer than and parallel to the side opposite from which it is extended. The attachment flange  8  is articulated for being inserted intermediate a first-sheet edge  9  of the first sheet  3  and a second-sheet edge  10  the second sheet  4 . The attachment flange  8  is articulated further for being inserted intermediate the first-sheet edge  9  of the first sheet  3  and a framework wall  11  of the wall framework  5 .  
         [0091]     As shown in  FIG. 3 , the first side  6  can have a first cover step  31  for matching height of wall-finishing material  29  on the first side  6  and a second cover step  32  for matching height of wall-finishing material  29  on the second side  7  and for providing joint strength.  
         [0092]     The attachment flange  8  is articulated further for being penetrable by fastener shanks  12  which are driven through fastener-edge area  13  that is adjacent to the first-edge area  14  of the first sheet  3  of drywall, through the attachment flange  8  and then into the wall framework  5  proximate the framework wall  11  of the wall framework  5  for maintaining the drywall-joint cover  1  in a covering position on the drywall joint  2 .  
         [0093]     The drywall-joint cover  1  is articulated predeterminedly for application of predetermined surfacing material. The surfacing material can include surfacing mud for which at least a portion of the second side  7  includes mud apertures  17  with porosity for receiving portions of the surfacing mud.  
         [0094]     The portion of the second side  7  which includes the porosity can include porous net material  16  or other porous material that includes fiberglass sheeting  18 .  
         [0095]     Referring to  FIGS. 7-10 , the drywall-joint cover  1  can include an L-leg second side  19  having a length for covering a predetermined length of the second sheet  4 .  
         [0096]     Optionally, the drywall-joint cover  1  can include a wall-end second side  20  that is common to two of the drywall-joint covers  1  for covering a length of the second sheet  4  intermediate two of the first sheets  3  that are spaced apart.  
         [0097]     The drywall-joint cover  1  can include a bull-nose arcuate corner  21  intermediate the first side  6  and the second side  7  for covering vacant space  22  and arcuate drywall edges  23  selectively intermediate the first sheet  3  and the second sheet  4 .  
         [0098]     The attachment flange  8  can further include articulation for being glued to the framework wall  11  of the wall framework  5  for maintaining the drywall-joint cover  1  in a covering position on the drywall joint  2 . The attachment flange  8  can be articulated additionally for being glued to the first sheet  3 , to the second sheet  4  and to the wall framework  5  selectively.  
         [0099]     Referring to  FIGS. 11-12 , a wall-end second side  26  can be common to a first drywall-joint cover  27  and to a second drywall-joint cover  28  for covering a length of the second sheet  4  intermediate the first drywall-joint cover  27  and the second drywall-joint cover  28 .  
         [0100]     The bull-nose arcuate corner  21  can be positioned intermediate the first side  6  and the second side  7  of the first drywall-joint cover  27  for covering vacant space  22  and arcuate drywall edges  23  selectively intermediate the first sheet  3  and the second sheet  4  proximate the first drywall-joint cover  27 . The bull-nose arcuate corner  21  can be positioned also intermediate the first side  6  and the second side  7  of the second drywall-joint cover  28  for covering vacant space  22  and arcuate drywall edges  23  selectively intermediate the first sheet  3  and the second sheet  4  proximate the second drywall-joint cover  28 .  
         [0101]     The wall-end second side  26 , the bull-nose arcuate corner  21  proximate the first drywall-joint cover  27 , the bull-nose arcuate corner  21  proximate the second drywall-joint cover  28 , the first side  6  of the first drywall-joint cover  27  and the first side  6  of the second drywall-joint cover  28  can be articulated for receiving predetermined wall-finishing material.  
         [0102]     Referring to  FIGS. 13-15 , a wall-end first side  30  can be common to the first drywall-joint cover  27  and to the second drywall-joint cover  28  for covering a length of the first sheet  3  intermediate the first drywall-joint cover  27  and the second drywall-joint cover  28 .  
         [0103]     The wall-end first side  30 , the bull-nose arcuate corner  21  proximate the first drywall-joint cover  27 , the bull-nose arcuate corner  21  proximate the second drywall-joint cover  28 , the first side  6  of the first drywall-joint cover  27  and the first side  6  of the second drywall-joint cover  28  can be articulated for receiving the predetermined wall-finishing material.  
         [0104]     Referring to  FIGS. 16-27 , the drywall-joint fixture can include an inside drywall-joint cover  33  that is articulated for covering a predetermined inside drywall joint  34  of the first sheet  3  of drywall and the second sheet  4  of drywall of the inside drywall joint  34  after the first sheet  3  and the second sheet  4  of drywall of the inside drywall joint  34  are positioned on inside wall framework  35  of a building.  
         [0105]     The first side  6  of the inside drywall-joint cover  33  is for covering the predetermined first-edge area  14  on the first sheet  3 . The second side  7  of the drywall-joint cover  33  is for covering a predetermined second-edge area  15  on the second sheet  4 .  
         [0106]     The attachment flange  8  is predeterminedly rigid and extended from an inside surface of a predetermined side of the drywall-joint cover  33 . The attachment flange  8  is predeterminedly longer than and parallel to the first side  6  of the drywall-joint cover  1 . The attachment flange  8  is articulated for being inserted intermediate the first-sheet edge  9  and the second-sheet edge  10  and is articulated further for being penetrable by fastener shanks  12  and for being glued selectively for maintaining the drywall-joint cover  33  in a covering position on the inside drywall joint  34 .  
         [0107]     The inside drywall-joint cover  33  includes a concave corner  24  intermediate the first side  6  and the second side  7  with the attachment flange  8  positioned intermediate edges of the first sheet  3  and the second sheet  4  as shown in  FIGS. 20-21  and  26 - 27 .  
         [0108]     The attachment flange  8  can be positioned on the first-sheet edge  9  which is intermediate edges of the first sheet  3  and the second sheet  4  as shown in  FIGS. 16-19  and  22 - 25 .  
         [0109]     Optionally, the attachment flange  8  can be positioned on the second-sheet edge  10  intermediate edges of the first sheet  3  and the second sheet  4 .  
         [0110]     An inside-wall edge  25  can be extended intermediate the first side  6  and the attachment flange  8  as shown in  FIGS. 20 and 27 . Optionally, the inside-wall edge  25  can be extended intermediate the second side  7  and the attachment flange  8  as shown in  FIGS. 17, 19 ,  23  and  25 .  
         [0111]     Referring to  FIGS. 28-32 , the drywall-joint fixture can include a juxtapositional drywall-joint cover  37  that is articulated for covering a predeterminedly juxtapositional drywall joint  38  of the first sheet  3  of drywall and the second sheet  4  of drywall of the juxtapositional drywall joint  38  that are predeterminedly juxtaposed after the first sheet  3  and the second sheet  4  of drywall of the juxtapositional drywall joint  38  are juxtaposed on juxtapositional wall framework  39  of the building. The first side  6  of the juxtapositional drywall-joint cover  37  is for covering the predetermined first-edge area  14  on the first sheet  3 . The second side  7  of the juxtapositional drywall-joint cover  37  is for covering the predetermined second-edge area  15  on the second sheet  4 .  
         [0112]     A juxtapositional-attachment flange  40  is extended intermediate interfacing walls of the first side  6  and the second side  7  of the juxtapositional drywall-joint cover  37 . The second side  7  is predeterminedly longer than the first side  6  of the juxtapositional drywall-joint cover  37 .  
         [0113]     The juxtapositional-attachment flange  40  is articulated for being inserted intermediate the first-sheet edge  9  and the second-sheet edge  10 .  
         [0114]     The second side  7  is articulated for penetration by fastener shanks  12  driven through the first side  6  and through the second side  7  and into the juxtapositional wall framework  39  selectively for maintaining the juxtapositional drywall-joint cover  37  in the covering position on the juxtapositional drywall joint  38 .  
         [0115]     The first side  6  can be articulated to be covered by the wall-finishing material  29 .  
         [0116]     The first sheet  3  and the second sheet  4  can be predeterminedly juxtaposed at an optionally acute angle with the fastener shanks  12  positioned orthogonally in a cap backer  41  and in the juxtapositional wall framework  39  as shown in  FIG. 29 .  
         [0117]     The first sheet  3  and the second sheet  4  can be predeterminedly juxtaposed at an optionally acute angle with the fastener shanks  12  positioned orthogonally in the first sheet  3 , the second sheet  4  and the juxtapositional wall framework  39  as shown in  FIG. 30 .  
         [0118]     The first sheet  3  and the second sheet  4  can be predeterminedly juxtaposed at an optionally obtuse angle with the fastener shanks  12  positioned orthogonally in the first sheet  3 , the second sheet  4  and the juxtapositional wall framework  39  as shown in  FIG. 31 .  
         [0119]     As shown in  FIG. 32 , the first sheet  3  and the second sheet  4  can be predeterminedly juxtaposed at a straight angle with the fastener shanks  12  positioned orthogonally in the second side  7  and the cap backer  41  extended from opposite ends of the second side  7 .  
         [0120]     Referring to  FIGS. 33-34 , the drywall-joint fixture can include a dual drywall-joint cover  42  having an attachment base  43  that is orthogonal to a first attachment flange  44  and a second attachment flange  45  that are extended from an attachment side of the attachment base  43 . A first cover wall  46  is extended from proximate a first end of the attachment base  43 . A second cover wall  47  is extended from proximate a second end of the attachment base  43 . The first cover wall  46  and the second cover wall  47  are predeterminedly shorter than the first attachment flange  44  and the second attachment flange  45  in distance of extension from the attachment base  43 .  
         [0121]     Slots  48  can be included in an end of at least the first cover wall  46  and optionally in an end of at least the first attachment flange  44 .  
         [0122]     A method includes the following steps for using the drywall-joint fixture of claim  2 : 
        affixing the first sheet  3  and the second sheet  4  of the drywall to the wall framework  5 ;     allowing a predetermined amount of space to remain between a side of the first sheet  3  and an end edge of the second sheet  4  of the drywall when being affixed to the wall framework  5 ;     inserting the attachment flange  8  into the space allowed to remain between the first sheet  3  and the second sheet  4  of the drywall;     positioning the first side  6  of the drywall-joint cover  1  in juxtaposed contact with an outside surface of the first sheet  3 ;     positioning the second side  7  of the drywall-joint cover  1  in juxtaposed contact with an outside surface of the second sheet  4 ;     driving a selected plurality of the fastener shanks  12  into and through the fastener-edge area  13  of the first sheet  3 ;     driving the selected plurality of the fastener shanks  12  through the attachment flange  8 ; and     driving the selected plurality of the fastener shanks  12  into the wall framework