CASING BEAD WITH A REMOVABLE LEG AND METHOD OF CONSTRUCTING A WALL STRUCTURE

Abstract

A casing bead for constructing a wall structure includes a bead wall, a flange, and a removable leg. The flange extends away from the bead wall and is configured to receive a viscous construction material thereon to facilitate embedment of the casing bead within the viscous construction material to form part of the wall structure. The casing bead may be positioned adjacent to a frame member thereby forming a gap between the bead wall and the frame member. The leg is removably connected to the bead wall and configured to extend into the gap thereby inhibiting the viscous construction material from being introduced into the gap. Furthermore, the leg is configured to be selectively removed from the bead wall to reveal at least a portion of the gap to allow a user to introduce a sealant into the gap.

Description

BACKGROUND

At the intersection of plaster and/or stucco wall structures and windows or doors, often a casing bead is installed adjacent to the frame of the window or jamb of the door. After the casing bead is attached to the wall structure, a viscous construction material, such as plaster or stucco, is then applied to the wall and is substantially contained by the casing bead. In some conventional wall structures, the casing bead is installed such that there is a gap between the bead wall of the casing bead and the frame or jamb of the window or door and a backer rod or backing strip occupies that gap between the casing bead and the window frame or door jamb. In some wall structures, the backer rod may comprise a completely independent component that is installed separately from the casing bead. Alternatively, other wall structures may include a casing bead, such as the embodiments shown and described herein, that includes a backing strip that is a separate component that is attached to the bead wall of the casing bead, such that the casing bead and backing strip are installed against the window frame or door jamb at the same time. Once the casing bead and backing strip or backer rod have been installed, then caulk is applied over the backing strip or backer rod to seal the joint.

While a variety of casing beads have been made and used, it is believed that no one prior to the inventors have made or used an invention as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

It is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

FIG. 1 depicts a top perspective view of an exemplary casing bead with a removable leg;

FIG. 2 depicts a bottom perspective view of the casing bead of FIG. 1;

FIG. 3 depicts a top elevational view of the casing bead of FIG. 1;

FIG. 4 depicts a bottom elevational view of the casing bead of FIG. 1;

FIG. 5 depicts a left elevational view of the casing bead of FIG. 1;

FIG. 6 depicts a right elevational view of the casing bead of FIG. 1;

FIG. 7 depicts a front elevational view of the casing bead of FIG. 1;

FIG. 8 depicts a rear elevational view of the casing bead of FIG. 1;

FIG. 9 depicts the top perspective view of the casing bead similar to FIG. 1, but showing the leg partially removed;

FIG. 10 depicts a sectional top perspective view of a wall structure including the casing bead of FIG. 1; and

FIG. 11 depicts a sectional top perspective view of the wall structure similar to FIG. 10, but showing the removable leg removed from the casing bead.

The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

FIGS. 1-4 illustrate an exemplary casing bead (10) with a body (12) and a leg (14) removably connected to the body (12). Each of body (12) and leg (14) extends in the longitudinal direction of casing bead (10) and may be cut to any desirable longitudinal length for use as described below in additional detail. Body (12) of casing bead (10) comprises a bead wall (16), a perforated flange (18) extending from a bottom portion of bead wall (16), and an upper lip (20) extending from a top portion of bead wall (16). Leg (14) is removably connected to bead wall (16) of body (12). In the illustrated embodiment, perforated flange (18) extends along the bottom edge of bead wall (16) and upper lip (20) extends along the top edge of bead wall (16). As shown, perforated flange extends substantially perpendicularly relative to bead wall (16) and upper lip (20) extends substantially perpendicularly relative to bead wall (16) and substantially parallel to perforated flange (18). Upper lip (20) includes a return (21) that extends downwardly toward perforated flange (18). In some embodiments, return (21) may extend substantially perpendicularly relative Casing bead (10) further comprises a backing strip (22) positioned against a rear surface of bead wall (16) and extending in the longitudinal direction of casing bead (10). In some embodiments, each of upper lip (20) and perforated flange (18) extend in a first direction away from bead wall (16), whereas leg (14) and backing strip (22) extend in a second direction away from bead wall (16) that is opposite the first direction. For example, in the illustrated embodiment, each of upper lip (20) and perforated flange (18) extend leftward away from bead wall (16), whereas leg (14) and backing strip (22) extend rightward away from bead wall (16). In addition, in some embodiments, the first direction may be oriented at least about 90 degrees, and preferably about 180 degrees, relative to the second direction. In the illustrated embodiment, leg (14) extends substantially perpendicularly relative to the upper portion of bead wall (16) over at least a portion of backing strip (22).

Accordingly, when casing bead (10) is installed as part of a wall structure, such as wall structure (26) (see FIG. 10), each of leg (14) and backing strip (22) are thus configured to be positioned within a gap (24) between bead wall (16) and a portion of wall structure (26), such as frame member (44). As such, leg (14) inhibits a viscous construction material, such as stucco (28) or plaster, from being inadvertently introduced into gap (24) and potentially contacting backing strip (22), the rear surface of bead wall (16), and/or frame member (44) during preparation of wall structure (26). Following preparation of wall structure (26), leg (14) is further configured to be selectively removed from body (12) to open gap (24) (see FIG. 11) in order to allow a user to fill gap (24) with a filler material, such as a sealant or caulk (32). As described herein, the terms “top,” “bottom,” “upper,” “lower,” “right,” “left,” “front,” and “rear” are defined here relative to the view of casing bead (10) shown in FIG. 1. The terms “top,” “bottom,” “upper,” “lower,” “right,” “left,” “front,” and “rear” are thus relative terms as viewed in FIG. 1 and are not intended to unnecessarily limit the invention described herein.

In the illustrated embodiment, leg (14) includes an inner edge along a first end of the leg (14) and a free edge (39) along a second end of leg (14). In this embodiment, leg (14) is removably attached to the bead wall along the inner edge of leg (14) and the free edge (39) is located opposite the inner edge of leg (14). In this embodiment, free edge (39) of leg (14) is laterally spaced away from bead wall (16) a first distance (A). As shown, backing strip (22) includes an inner surface that is positioned against bead wall (16) and an outer surface (46) that is opposite the inner surface of backing strip (22). In this embodiment, outer surface (46) of backing strip (22) is substantially parallel to the rear surface of bead wall (16) and is laterally spaced away from bead wall (16) a second distance (B). The first distance (A) may be less than or substantially equal to the second distance (B).

In one embodiment, perforated flange (18), bead wall (16), upper lip (20), and leg (14) may be formed from a single integral piece of unitary construction that is extruded or co-extruded together as shown and described herein. In alternative embodiments, one or more of perforated flange (18), bead wall (16), upper lip (20) and leg (14) may comprise non-integral, separate components that are attached to each other. It will thus be appreciated that casing bead (10) may be unitarily formed or be comprised of various components attached together to collectively form casing bead (10). In some embodiments, casing bead (10), including one or more of perforated flange (18), bead wall (16), upper lip (20), and leg (14) may comprise polyvinyl chloride (PVC) or any other suitable material, including but not limited to other suitable plastics. In some embodiments, perforated flange (18), bead wall (16), upper lip (20), and leg (14) may all comprise the same material, while in other embodiments perforated flange (18), bead wall (16), upper lip (20), and leg (14) may comprise two or more different materials.

Perforated flange (18) shown in FIGS. 1-4 includes openings (34) extending therethrough. Openings (34) are configured to provide a flow path for the viscous construction material that allows the viscous construction material to engage both perforated flange (18) and support structure (50) and harden around perforated flange (18). To this end, perforated flange (18) and openings (34) form a lattice within wall structure (26) (see FIG. 10) for embedment of the casing bead (10) within wall structure (26) (see FIG. 10). By way of example, openings (34) are arranged in a pattern consisting of a series of adjacent columns on perforated flange (18). It will be appreciated that any suitable number of openings (34) may be included in perforated flange (18) and may be arranged in any desired pattern and/or size suitable to allow the viscous construction material to sufficiently engage both perforated flange (18) and support structure (50) of wall structure (26).

In the illustrated embodiment, leg (14) extends longitudinally along body (12).

As shown in FIGS. 1-4, removable leg (14) extends from the top portion of bead wall (16) adjacent to but spaced downward from the top edge of bead wall and the junction between bead wall (16) and upper lip (20). In other words, in this embodiment, leg (14) is attached to bead wall (16) at a position that is between upper lip (20) and perforated flange (18). In other embodiments, removable leg (14) may be positioned in another location along bead wall (16) suitable to inhibit or even prevent the viscous construction material from contacting backing strip (22) within gap (24) (see FIG. 10).

As discussed briefly above and with respect to FIGS. 3-7, in one embodiment removable leg (14) is integrally attached to bead wall (16) via extrusion of body (12) during the manufacturing process. Body (12) of casing bead (10) has a frangible connection (36) extending between bead wall (16) and leg (14). More particularly, frangible connection (36) has a thin and/or weakened section of material configured to selectively fracture upon being manipulated by a user. The user may thus separate leg (14) from bead wall (16) by grasping leg (14) and applying sufficient force to leg (14) in a direction generally away from bead wall (16) (e.g., an upward force, a downward force, a rightward force, or an angled force there between which is generally away from bead wall (16)). As used herein, the term “fracture” generally refers to the failure of the material itself such that the material may crack, rip, and/or tear for separation of leg (14) from body (12). The term “fracture” is not intended to unnecessarily limit the invention described herein.

In some embodiments, leg (14) includes one or more apertures and/or perforations along frangible connection (36) between leg (14) and bead wall (16) to weaken frangible connection (36) and facilitate removal of leg (14). It will be appreciated that such apertures and/or perforations are not required, but may be desirable to facilitate removal depending on the material(s) from which casing bead (10) may be manufactured. Furthermore, leg (14) is configured to be gripped directly by the user for being manipulated and removed from bead wall (16). However, the user may alternatively grip leg (14) indirectly with a tool, such as a pair of pliers or other similar gripping device, to manipulate leg (14) relative to bead wall (16) and apply the necessary force to fracture frangible connection (36). Other methods and/or tools for separating leg (14) from bead wall (16), such as cutting leg (14) along frangible connection (36) with a knife, may also be so used. While leg (14) is removably connected to bead wall (16) via frangible connection (36) as shown and described herein, alternative embodiments of casing bead (10) may include alternative connections, such as adhesive connections or mechanical connections, for removably connecting leg (14) to bead wall (16).

As best seen in FIGS. 7-8, one embodiment of leg (14) comprises a t-shaped cross-section. Specifically, in this embodiment, leg (14) includes a base member (38) that is attached to bead wall (16) and extends away from the rear surface of bead wall (16) and a gripping member, such as gripping tab (40), that extends upward from base member (38). As shown, base member (38) extends substantially perpendicularly relative to bead wall (16) and gripping tab (40) extends substantially perpendicularly relative to base member (38) and substantially parallel to bead wall (16). Gripping tab (40) is configured to facilitate the gripping and manipulation of leg (14) by the user in order to facilitate separation of leg (14) from bead wall (16). In other embodiments, leg (14) may comprise other cross-sections, including but not limited to round, rectangular, or square cross-sections, configured to facilitate covering of backing strip (22) (see FIG. 10) and gripping of leg (14) by the user. Alternatively, in other embodiments, gripping tab (40) may be omitted entirely and base member (38) may be gripped directly by the user.

Leg (14) is generally configured to inhibit the viscous construction material from being inadvertently introduced into gap (24) and potentially onto the upper surface of backing strip (22), the rear surface of bead wall (16), and/or frame member (44), as discussed briefly above. To this end, base member (38) extends away from bead wall (16) in the same direction as backing strip (22) such that base member (38) at least partially covers and overlaps the upper surface of backing strip (22). As shown, base member (38) is spaced above the upper surface of backing strip (22) and extends substantially perpendicular to the rear surface of bead wall (16) and substantially parallel to perforated flange (18) and upper lip (20). The distance from the rear surface of bead wall (16) to the free edge (39) of base member (38) is less than or substantially equal to the distance from the rear surface of bead wall (16) to the outer surface (46) of backing strip (22) (i.e., the thickness of backing strip (22)). In some embodiments the distance from the rear surface of bead wall (16) to the free edge (39) of base member (38) is less than the distance from the rear surface of bead wall (16) to the outer surface (46) of backing strip (22) in order to accommodate at least some compression of backing strip (22) and to provide room for a user to grasp the free end of base member (38) when casing bead (10) is installed adjacent to a framing member. In other words, in some embodiments, backing strip (22) extends laterally away from the rear surface of bead wall (16) at least as far as free edge (39) of base member (38).

Backing strip (22) may comprise a resilient and/or compressible material, such as closed cell foam. In some embodiments, backing strip (22) may comprise a material substantially similar to the material used for conventional backer rod. In some embodiments, backing strip (22) may comprise a material that does not bond very well, if at all, with conventional caulk and other sealants. As a result, in these embodiments, the caulk or other sealants may bond with the rear surface of bead wall (16) of casing bead (10) and an adjacent surface of wall structure (26), such as a surface of frame member (44). In other embodiments where the backing strip comprises a material that readily bonds with conventional caulk and other sealants, a layer of bond breaking tape may be applied to the upper surface of backing strip (22), although this is not required. In embodiments where the backing strip (22) comprises a material that does not readily bond with conventional caulk and other sealants, the bond breaking tape may be omitted entirely.

Furthermore, gripping tab (40) extends upward from base member (38) above the top end of bead wall (16) and upper lip (20). Gripping tab (40), base member (38), and bead wall (16) thus collectively define an elongated collection channel (42) extending longitudinally along body (12). In addition to being gripped, gripping tab (40) is further configured to deflect the viscous construction material away from gap (24) (see FIG. 10) toward collection channel (42). Collection channel (42) collects the flowing viscous construction material and may disperse the viscous construction material along collection channel (42) to further inhibit an overflow of the viscous construction material from traveling past leg (14) and being introduced into gap (24) and potentially onto the upper surface of backing strip (22), the rear surface of bead wall (16) and/or an adjacent surface of frame member (44).

In use, casing bead (10) is configured to be installed against a frame member (44), such as a window frame or a door jamb, in order to form wall structure (26) shown in FIGS. 10-11. In one embodiment, casing bead (10) is more particularly installed such that an outer surface (46) of backing strip (22) abuts against and engages an edge of frame member (44). Exemplary wall structure (26) further includes an elongated stud (48) with a support structure (50), such as plywood, positioned thereagainst It will be readily appreciated that the relative positions and general construction of frame member (44), elongated stud (48), and support structure (50) may collectively form wall structure (26) using traditional materials and methods. It will be further appreciated that other materials, such as felt, galvanized wire or metal lath may also be attached to support structure (50) and may be positioned between casing bead (10) and support structure (50) in some applications. One or more coats (e.g., a scratch coat and a finishing coat) of the viscous construction material, such as stucco (28), plaster or other similar material, may then be applied to wall structure (26).

In the illustrated embodiment, casing bead (10) includes backing strip (22), which is a separate component attached to bead wall (16). Backing strip (22) may be attached to bead wall (16) using an adhesive or any other conventional fasteners or attachment methods. In some alternate embodiments, backing strip (22) may be integral with bead wall (16) instead of being a separate component that is attached to bead wall (16). As such, backing strip (22) may be integrally formed with or attached to bead wall (16) during the manufacturing process prior to use by the user. Alternatively, casing bead (10) may be provided without backing strip (22) and the user may attach backing strip (22) to bead wall (16) during construction of wall structure (26). Backing strip (22) is configured to abut frame member (44) once casing bead (10) is installed in wall structure (26) to facilitate the positioning of casing bead (10) a suitable distance away from frame member (44) to create gap (24). To this end, body (12) of casing bead (10) and backing strip (22) are simultaneously positioned relative to frame member (44) and support structure (50) in the exemplary installation. In turn, frame member (44), backing strip (22), and bead wall (16) of casing bead (10) collectively define gap (24). Alternatively, body (12) and backing strip (22) may be independently and separately installed in wall structure (26) to define gap (24).

In one exemplary method of use, user applies a desirable amount of stucco (28), or other viscous construction material, along casing bead (10) and support structure (50) such that stucco (28) fills openings (34). Perforated flange (18) thus forms a lattice within wall structure (26). In addition, leg (14) within gap (24) inhibits the user from inadvertently introducing stucco (28) within gap (24) and contacting backing strip (22), the rear surface of bead wall (16) and/or frame member (44). More particularly, base member (38) and gripping tab (40) deflect stucco (28) into collection channel (42) rather than allowing stucco (28) into gap (24). It will be appreciated that some small amount of stucco (28) may still enter and occupy gap (24) and even contact backing strip (22), the rear surface of bead wall (16) and/or frame member (44), so long as gap (24), backing strip (22), the rear surface of bead wall (16), and frame member (44) remain free of enough stucco (28) to receive sealant (32) and allow for sealant (32) to function as intended. To this end, references to inhibiting viscous construction material from being introduced into gap (24) may still include the introduction of a small amount of viscous construction material, such as stucco (28), so long as the plugging material generally functions as intended.

In this exemplary method of use, after the desired coat or coats of stucco (28) have been applied, the user manipulates leg (14) and fractures frangible connection (36) to remove leg (14) from body (12) of casing bead (10). Specifically, the user grasps gripping tab (40) and applies sufficient force in a direction generally away from bead wall (16) to fracture frangible connection (36). Removing leg (14) from bead wall (16) leaves a substantially smooth, clean surface along bead wall (16) and a substantially clean backing strip (22) that is generally free of stucco (28) to receive sealant (32), such as caulk, functionally thereagainst. The user applies one or more layers of sealant (32) in gap (24) between bead wall (16) and frame member (44) to seal gap (24).

In some alternate embodiments, backing strip (22) may be omitted entirely from casing bead (10). In such embodiments, casing bead (10) may be installed by the user with backer rod in a conventional manner. For example, casing bead (10) may be installed proximate to frame member (44) to define gap (24) between bead wall (16) and fame member (44). After stucco (28) is applied to wall structure (26), leg (14) may then be removed from bead wall (16) with gap (24) relatively free of stucco (28). The user may then insert backer rod into gap (24) between bead wall (16) and frame member (44). One or more layers of sealant (32), such as caulk or other plugging material, may then be applied to seal gap (24) between frame member (44) and bead wall (16).

Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometries, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of any claims that may be presented and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

Claims

1. A casing bead, comprising: a bead wall;a flange connected to the bead wall and extending away from the bead wall in a first direction, wherein the flange comprises at least one opening extending through the flange; anda leg removably connected to the bead wall and extending away from the bead wall in a second direction opposite the first direction.

2. The casing bead of claim 1, wherein the bead wall comprises a top edge and a bottom edge, wherein the flange extends along the bottom edge of the bead wall.

3. The casing bead of claim 2, further comprising an upper lip connected to the bead wall and extending from the bead wall in the first direction, wherein the upper lip extends along the top edge of the bead wall.

4. The casing bead of claim 3, wherein the leg is positioned on the bead wall at a position between the flange and the upper lip.

5. The casing bead of claim 1, further comprising a backing strip extending from the bead wall in the second direction.

6. The casing bead of claim 5, wherein the leg is spaced above an upper surface of the backing strip.

7. The casing bead of claim 5, wherein the backing strip comprises a closed cell foam material.

8. The casing bead of claim 1, wherein at least a portion of the leg extends above a top edge of the bead wall.

9. The casing bead of claim 1, wherein the leg comprises a gripping member configured to facilitate removal of the leg from the bead wall.

10. The casing bead of claim 9, wherein the leg further comprises a base member extending from the bead wall, and wherein the gripping member extends from the base member.

11. The casing bead of claim 10, wherein the gripping member and the base member collectively have a t-shaped cross-section.

12. The casing bead of claim 1, wherein the bead wall and the leg are of unitary construction.

13. The casing bead of claim 1, wherein the bead wall, the leg, and the flange are of unitary construction.

14. A casing bead, comprising: a bead wall;a flange extending from the bead wall, wherein the flange comprises at least one opening extending through the flange;a leg comprising an inner edge and a free edge, wherein the leg is removably connected to the bead along the inner edge of the leg and extends away from the bead wall such that the free edge of the leg is laterally spaced a first distance away from the bead wall; anda backing strip comprising an outer surface, wherein the backing strip extends away from the bead wall such that the outer surface of the backing strip is laterally spaced a second distance from the bead wall, wherein the first distance is less than or substantially equal to the second distance.

15. The casing bead of claim 14, wherein at least a portion of the leg is substantially parallel to at least a portion of the flange.

16. A wall structure, comprising: a frame member;a support structure positioned proximate to the frame member; anda casing bead attached to the support structure, wherein the casing bead comprises a bead wall positioned proximate to the frame member such that a gap is defined between the bead wall and the frame member, wherein the bead wall comprises a rear surface that faces the framing member,a flange extending from the bead wall in a direction away from the gap, wherein the flange is positioned on the support structure and comprises at least one opening extending through the flange, anda leg extending from the rear surface of the bead wall into the gap, wherein the leg is removably connected to the rear surface of the bead wall.

17. The wall structure of claim 16, further comprising a backing strip attached to the bead wall, wherein the backing strip is positioned on the bead wall below the leg.

18. A method of constructing a wall structure comprising the steps of: providing a frame member,a support structure, anda casing bead comprising a bead wall,a flange extending from the bead wall, wherein the flange comprises at least one opening extending through the flange, anda leg, wherein the leg is removably connected to the bead wall.attaching the casing bead to the support structure such that the casing bead is positioned adjacent to the frame member such that a gap is formed between the bead wall of the casing bead and the frame member, wherein the casing bead is positioned such that the leg extends into the gap;applying at least one layer of viscous construction material to the support structure such that the at least one layer of viscous construction material at least partially covers the flange of the casing bead;removing the leg from the casing bead.

19. The method of claim 18, further comprising the step of: introducing a sealant into the gap after the removing the leg from the casing bead.

20. The method of claim 18, wherein the casing bead further comprises a backing strip extending from the bead wall into the gap and further comprising the step of applying a sealant to an upper surface of the backing strip after removing the leg from the casing bead.