Patent Application
20090090471
The present invention relates generally to wallboard finishing tools, and more specifically to corner bead roller tools for use in generally finishing corners of wallboard.
Corner bead products offer a thin layer of protection over the easily damaged edges of wallboard panels. The corner bead category is divided into four main segments: bare metal (nail-on), vinyl (conventional and flex roll), paper-faced bead metal and paper-faced bead plastic. A corner bead roller tool is used to accurately align the tape-on bead and squeeze out excess settable wallboard compound with greater ease and efficiency.
In use, a first piece of wallboard is mounted and a second piece of wallboard is mounted such that an end of the first piece abuts adjacently to an end of the second piece of wallboard to form a corner. The user will then apply wallboard compound to the corner of the wallboard in preparation of the finishing. The next step is to cover the wallboard compound with tape to form a corner of wallboard. To properly finish the corner and edge of the wallboard, the corner and tape must be pressed firmly along the corner seam of the wallboard to remove any excess wallboard compound and at the same time press the tape firmly against the wallboard to ensure a desirable finish.
The present corner bead tool includes a bumper that extends beyond the tool bracket in order to prevent accidental damage to a wall during use. The bumper also holds a bracket nut in place such that the bracket nut is non-rotatable. A shaft rotatably attaches a roller/wheel to the bracket engaging the bracket nut without requiring an external force to hold the bracket nut during tightening. In addition, the corner bead tool provides that the shaft head is at least partially exposed from the wheel of the roller assembly to facilitate access for roller/wheel replacement. Also, the roller assembly includes wheels that have a dual taper that also allows the wheels to provide better traction against the wallboard and to facilitate removing excess wallboard compound from the corner. The wheels are connected to a bushing using a tongue-in-groove connection, which prevents longitudinal movement of the wheel with respect to the bushing and holds the wheel in place to prevent “slipping.”
In one embodiment, and to facilitate the finishing of wallboard, the present corner bead tool provides an elongated bracket having two ends. Each end of the elongated bracket includes a first roller assembly and a second roller assembly such that the first roller assembly includes a center axis that is perpendicular to a center axis of the second roller assembly. Each of the roller assemblies includes a wheel that is mounted to a bushing. The bushing in turn is rotatably mounted to a shaft that is connectable to the elongated bracket. The shaft is connected to the bracket utilizing a bracket nut. A bumper associated with the bracket is also included and is configured to non-rotatably capture the bracket nut.
In another embodiment, and to facilitate the finishing of wallboard, the present corner bead tool provides an elongated bracket having two ends. Each end of the elongated bracket includes a first roller assembly and a second roller assembly such that the first roller assembly includes a center axis that is perpendicular to a center axis of the second roller assembly. Each of the roller assemblies includes a wheel that is mounted to a bushing. The bushing is in turn rotatably mounted to a shaft that is connectable to the elongated bracket. A bumper is also included and includes a contact end surface and a portion of the bumper that extends beyond the length of the elongated bracket such that the bumper protects a wall from damage that is potentially caused by the bracket.
In yet another embodiment, and to facilitate the finishing of wallboard, the present corner bead tool provides an elongated bracket having two ends. Each end of the elongated bracket includes a first roller assembly and a second roller assembly such that the first roller assembly includes a center axis that is perpendicular to a center axis of the second roller assembly. Each of the roller assemblies includes a wheel that is mounted to a bushing. The bushing is rotatably mounted to a shaft that is connectable to the elongated bracket. Each wheel of each roller assembly includes a dual taper, a traction portion and a tapered end portion. The traction portion of the end of the roller assembly furthest from the bracket has less of a taper than does the tapered end of the roller assembly closest to the bracket.
In a further embodiment, and to facilitate the finishing of wallboard, the present corner bead tool provides an elongated bracket having two ends. Each end of the elongated bracket includes a first roller assembly and a second roller assembly such that the first roller assembly includes a center axis that is perpendicular to a center axis of the second roller assembly. Each of the roller assemblies includes a wheel that is mounted to a bushing. The bushing is rotatably mounted to a shaft that is connectable to the elongated bracket. Each wheel is mounted to each bushing utilizing a tongue and groove connection.
As seen in
It is also preferred that the bracket 12 be of a rigid, corrosion-resistant material, such as stainless steel. It is contemplated, however, that certain plastics or even wood could be used as a material of the bracket 12. The bracket 12 is preferably rigid enough to handle variable pressure exerted by a user onto the corner bead tool 10. For example, while less pressure may be required against the bracket 12 for applications that are within the user's reach, there may be applications where the user requires an extension pole to apply the corner bead tool 10 to taller corners or any corners that may be out of the normal arm's reach of the user. In such cases, more pressure may be required to be exerted onto the bracket 12 and it is preferred that the bracket be able to withstand such exerted pressure.
Attached to the bracket 12 is a protrusion or ear 14, preferably located at the center of each wall 13 of the bracket 12. When the bracket 12 is of a v-shape, as depicted in
The extension device is pivotally attachable to the bracket 12 via a handle attachment 18 which pivotally engages the protrusions or ears 14. Preferably, a rod end bearing 20 is placed between the ears 14 on the bracket 12, such that an opening 22 in the rod end bearing 20 is aligned with openings 24 in each of the ears. Once aligned, a bracket fastener 26 such as a bolt is placed through the opening 24 of one ear 14, then through the rod end bearing 20 and passes through the second ear. The openings 24 are preferably circular and are dimensioned to receive the fastener 26. It is contemplated that other sized and shaped openings may be used as would be appreciated by those of ordinary skill. Once passed through the second ear 14, a lock nut 28 is affixed to the bracket fastener 26 to hold the screw in place. It is preferred that the rod end bearing 20 also include at least one spacer bushing 30 to rotatably stabilize the position of the bearing between the ears 14.
Preferably, the rod end bearing 20 includes a threaded portion 32 configured for receiving an extension socket 34, which is preferably has a threaded bore 36 configured for engaging the threaded portion 32 of the rod end bearing 20. The socket 34 is then locked in place on the handle attachment 18 by using a nut 38. The socket is preferably internally threaded to receive the application device 16. It is also contemplated that other forms of attachment may be used for attaching the application device attachment handle and the handle attachment, such as, for example, a bayonet lock arrangement or other attachment technology as would be understood by those of ordinary skill in the art.
Referring again to
As an option, at least one additional roller assembly 43 is located between the first and second pairs of roller assemblies. Such additional pairs of roller assemblies prevent “bowing” of longer length brackets 12 once pressure is applied to the corner bead roller.
Referring to
Each wheel 44 of each roller assembly 40 preferably includes a dual taper, where the traction portion 52 has less of a taper than does the tapered end portion 54. The traction portion 52 of the wheel 44 is flat as it engages the wallboard for effectively flattening drywall tape onto the surface of the wallboard or other target material. The wheel 44 is preferably tapered such that the traction portion 52 has less of a taper than does the tapered portion 54 closest to the bracket 12. While other angles are contemplated, in a preferred embodiment, each wheel 44 includes a traction portion 52 having a taper of 3°. This taper allows the roller assembly 40 to press firmly against the wallboard and press any excess wallboard compound away from the edge of the corner and facilitate finishing of the wallboard. In addition, the tapered end portion 54 preferably has a taper of greater than 3°.
Each wheel 44 is preferably made of a durable, soft-grip silicone to provide added traction when the tool is rolled upon a wallboard corner, especially when setting tape-on bead is provided. Traditional harder wheels have a tendency to slip when coated with joint compound. Embodiments in accordance with the present invention includes an 84° included angle β, see
As shown in
As shown in
Referring to
Once secured, the head 74 of the shaft 48 remains at least partially exposed or extends beyond a length of the wheel 44 such that the head 74 is accessible for tightening or loosening by a user of the corner bead roller 10 using a standard wrench.
A bumper 78 is configured for non-rotatably capturing the bracket nut 50. The bumper 78 is located on the opposite side of the walls 13 of the bracket 12 with respect to the roller assembly 40. A recess 80 is provided on the bumper 78 to non-rotatably capture the bracket nut 50. As shown in
As shown in
While a particular embodiment of the present corner bead tool has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
