Drywall corner finishing device

Abstract

A finishing device used to form a corner between two panels of drywall has a flexible joint extending along a predetermined axis. Two wings are connected to and extend outwardly in a diverging relation from the flexible joint to form a corner having an adjustable angle. Each wing has a front surface, a rear surface, and an edge distal from the flexible joint. The device is adjustable to fit various thicknesses of drywall panel. A layer of primer or adhesive laminate is applied to the front surface of the wings so that paint can bond to the front surface. The finishing device is capable of forming both inside and outside corners. To form inside and outside corners, the finishing device bends along the flexible joint.

Description

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates to finishing interior walls. In particular, this invention relates to finishing the edges at intersections where two walls meet.

[0004] 2. Statement of the Problem

[0005] Drywall panels are widely used in the construction industry for forming the interior walls and ceilings of rooms. Drywall panels are made of a gypsum or reinforced gypsum core covered with paper. Drywall panels have the advantages of being easy to cut to desired sizes and to attach to assorted types of framing. However, it is very difficult to cut drywall panels so that the edges are perfectly straight and smooth and can meet to form a perfectly straight corner, which is aesthetically to be desired. In addition, when the drywall panels are cut to the desired sizes, the edges of the panels are left exposed. This exposed gypsum core is soft and tends to crumble unless the severed edges are somehow protected. This is especially important at outside wall corners.

[0006] When walls and ceilings are built of framing materials such as wood, the inside and outside corners thereby formed are seldom perfectly straight. Small variations in the sizes of the wood framing members, warping of the wood, and inconsistent building practices lead to imperfectly straight corners where walls and ceilings meet, and where walls end at doorways and passageways. When drywall panels are then attached to the crooked framing materials, their intersections will also be crooked.

[0007] An assortment of devices has been used to provide a smooth and durable finish for the intersections where two pieces of drywall abut to form an inside or outside corner. Among the conventional devices used are drywall tape and metal corner beads. Conventional drywall tape is provided in narrow, elongated ribbons or strips of porous paper wound into rolls. The paper is sometimes perforated to increase moisture penetration and to prevent air bubbles from being entrapped behind the tape. The drywall tape is first applied to joints and edges of abutting drywall panels and is then covered with wet plaster, sometimes called “mud.” The plaster is feathered and smoothed along the edges of the tape to conceal the demarcations between the tape edges and the drywall panels to which the tape is applied. When the wet plaster has dried, the tape and drywall can be painted or otherwise covered with a suitable wall covering.

[0008] A great deal of skill is needed to apply the plaster to both sides of an inside corner such that a perfectly straight intersection is achieved. Also, to correct the crookedness resulting from the warped framing members and inconsistent building practices described above often several coats of plaster must be applied, with an entire day of drying time needed between each coat. Even then, a perfectly straight corner seldom results. It is also likely that, unless in the most highly skilled hands, the plaster trowel will mar the first side of the plaster while the second side is being applied. Once the plaster has been applied and dried, it must be sanded to an appropriate finish to provide a surface suitable for the application of paint or wallpaper.

[0009] Coffered and vaulted ceilings have recently become very popular among homebuilders and buyers. Often the peak of such ceilings will form an acute angle. It is difficult to fit a conventional plaster trowel into such angles.

[0010] Because drywall tape is formed of paper, it is quite flexible and will conform to various surface configurations of the edges of intersecting panels of drywall. When conventional drywall tape is used at the outside corners of walls, the flexibility of the tape often results in a corner demarcation that is irregular, since the tape conforms to irregularities in the exposed, severed edges of the drywall panels. The tape is also fragile and does not stand up well to the constant physical abuse suffered by outside corners. As a consequence, conventional drywall tape cannot be used at exposed outside corners.

[0011] To finish outside corners in building construction, therefore, metal corner beads are often used. Conventional metal beads are configured in an L-shaped or angle-shaped cross section and are typically fabricated from elongated perforated strips of metal, such as galvanized steel, permanently deformed with a lengthwise 90-degree bend to form elongated angles. The metal beading is typically positioned at the intersections of adjacent drywall panels that meet at right angles to form an outside corner within a room. The sections of metal beading are nailed in place through the drywall panels to wooden supporting structural members located behind the drywall panels. Wet plaster is then smoothed into place to cover the metal flanges or leg members of the metal beading, and the edges of the plaster are smoothed and feathered to attempt to conceal the metal edges.

[0012] While the rigidity of the metal beading does allow an outside corner of an inside building wall to be finished with a sharp, straight edge, which is aesthetically pleasing, the use of metal beading involves some significant problems. Over time, the metal corner bead will rust, thereby producing rust stains that are clearly visible on the surfaces of the walls at the corner. It is not always possible to completely cover the edges of the metal flanges or the nail heads used to attach the metal corner bead to the drywall panel, detracting from the desired smooth appearance of the wall. Cracks often develop in the overlying plaster at the outer edges of the flanges. To prevent this from happening, often two or three coats of plaster are applied, with prior coats allowed to dry and harden, which may take as long as 24 hours, before a subsequent coat is applied. When the corners are crooked or jagged due to problems with the underlying framing, metal beads do not cover enough surface area or have enough flexibility to correct the inequalities that exist. Another problem is inherent in the fact that the malleable metal from which the metal beads are made has a very poor memory and is subject to being dented or wrinkled, after which it is difficult to straighten it to produce a smooth finish. Because of the rough handling to which most of the material at a work site is subjected, it is not uncommon for the strips to be wrinkled, dented, and perhaps twisted, thus rendering them either unusable, or usable only to produce an inferior end result. In addition, the metal strips are used in large quantities in construction and can add up to considerable cost.

[0013] A number of corner finishing devices have been developed to address the above-described problems. Among these devices are the following:

	Inventor	U.S. Pat. No.	Date Issued
	Swanson	3,444,657	May 20, 1969
	Baker	3,989,397	Nov. 2, 1976
	Ellingson	4,012,878	Mar. 22, 1977
	Lamb	4,313,991	Feb. 2, 1982
	Schaafsma	4,315,390	Feb. 16, 1982
	Weinar	4,553,363	Nov. 19, 1985
	Schneller	4,624,087	Nov. 25, 1986
	Bernard	4,719,732	Jan. 19, 1988
	Tucker	4,863,774	Sept. 5, 1989
	Conboy	5,037,686	Aug. 6, 1991
	Tucker	5,045,374	Sept. 3, 1989
	Weldy	5,086,598	Feb. 11, 1992
	Ritchie et al.	5,131,198	July 21, 1992
	Rutkowski et al.	3,964,220	June 22, 1976
	Cannon	1,215,345	Dec. 9, 1970
	Stibolt et al.	5,459,969	Oct. 24, 1995
	Stibolt et al.	5,531,050	July 2, 1996
	Stibolt	5,916,101	June 29, 1999

[0014] Swanson (U.S. Pat. No. 3,444,657) and Lamb (U.S. Pat. No. 4,313,991) describe plastic joint strips that can be reversibly bent to be adhesively secured to both inside and outside corners.

[0015] Baker (U.S. Pat. No. 3,989,397) shows an outside corner connector for waterbed pedestals in which the panels forming the pedestal are inserted into the connector.

[0016] Ellingson (U.S. Pat. No. 4,012,878) provides a double layer wall member guard structure for outside corners made of a resilient material.

[0017] Schaafsma (U.S. Pat. No. 4,315,390) describes two types of wallboard corners, one for inside corners that is held in place by putty and another for outside corners that is held in place by the drywall panels themselves. The former is disadvantaged by the fact that it is held on only by putty; if the putty does not adhere well to the drywall, the corner will become loose. The outside corner must be placed under the drywall panels, involving considerable blending or, if placed on the corner before the panels, a certain amount of extra effort to hold the corner in place while the panels are being nailed over it. Both corners use tape to provide a smooth top finish that can be blended in with the drywall finish by applying plaster and sanding.

[0018] Weinar (U.S. Pat. No. 4,553,363) provides a plastic or metal T-shaped corner construction in which the post of the T sits between two abutting pieces of drywall and the cross bar lies atop the drywall panels. Part of the paper covering from one panel is wrapped around the cross bar to provide a finished appearance, leaving a ridge down one side of the corner. This corner construction can only be used on outside corners.

[0019] Schneller (U.S. Pat. No. 4,624,087) describes yet another type of metal outside corner bead in which an additional flange extends over the edge of the drywall board forming the outside corner. Ridges are left on both sides of the corner, and this corner bead can only be used on outside corners.

[0020] Bernard (U.S. Pat. No. 4,719,732) presents a plastic L-shaped outside corner cover that uses heat-shrinkable plastic tape along the arms both as a method of attachment and as a method of providing a smooth junction between the cover and the drywall. This cover can be used for outside corners having a variety of angles.

[0021] Tucker (U.S. Pat. No. 4,863,774) provides a paper drywall ribbon having a centrally located plastic bead extending longitudinally along the ribbon. Plaster is used to attach the ribbon to the drywall. This plastic bead is designed to be used with outside corners only.

[0022] Conboy (U.S. Pat. No. 5,037,636) describes a plastic drywall tape that can be used on both inside and outside corners. Again, this plastic tape is held on the corner with plaster, and plaster is used to provide a finished appearance.

[0023] Tucker (U.S. Pat. No. 5,045,374) describes a stiff plastic strip with a curved center section and two flanges that is attached to outside or inside corners with adhesive. The flanges are then covered with paper tape strips and plaster.

[0024] Weldy (U.S. Pat. No. 5,086,598) provides a wall edging system for both inside and outside corners that comprises a plastic strip having an arcuate center portion to which are attached two flanges at right angles. The strip is attached to the drywall with nails. Plaster is then smoothed over the strip to finish the edges. The side of the strip facing out toward the room can be finished with primer.

[0025] Ritchie et al. (U.S. Pat. No. 5,131,198) describe a corner bead for outside corners that has a metal core and that is completely covered by paper. This bead has a rounded nose and side flanges. The paper covering is further coated with a reinforcing emulsion. The corner bead is nailed to the drywall, and plaster is used to hide the edges.

[0026] Rutkowski et al. (U.S. Pat. No. 3,964,220) describe an elongate strip to be placed between the junctions of adjacent drywall boards forming a planar wall in order to absorb movement within the wall. The strip has two flanges attached on either side of a central flexible portion.

[0027] Cannon (U.S. Pat. No. 1,215,345) describes a building in which the walls are inserted into corner posts. The posts have two channels into which are placed the edges of walls. The walls are held within the channels by a bolt and corner plate that connects with cladding on the walls.

[0028] Stibolt et al. (U.S. Pat. No. 5,459,969) describe a corner finishing device that can be used on both outside and inside corners having various angles. The device can also be used to cover juxtaposed outside corners, such as are found at the edges of interior doorways or other openings of various dimensions. The device provides a perfectly straight corner without the use of multiple coats of plaster. The device also simplified installation of drywall in acutely angled inside corners.

[0029] Stibolt et al. (U.S. Pat. No. 5,531,050), which is a continuation-in-part of Stibolt et al. (U.S. Pat. No. 5,459,969), disclosed further embodiments of the invention disclosed in the parent patent.

[0030] Stibolt (U.S. Pat. No. 5,916,101), which is a continuation in part of Stibolt et al. (U.S. Pat. No. 5,531,050), disclosed a further embodiment able to accommodate various thickness of drywall panel. This embodiment was found to have the disadvantage of being very costly to manufacture by a plastic extrusion process, due to its complex cross-sectional shape.

[0031] A need exists for a drywall finishing device that, simplifies installation of drywall, provides a perfectly straight corner without the use of multiple coats of plaster, can be used on both inside and outside corners having various angles, can be used to cover juxtaposed outside corners, can be used with various thicknesses of drywall, and is able to be economically manufactured.

[0032] None of the above-described drywall corners fulfills these needs.

[0033] 3. Solution to the Problem

[0034] The drywall corner finishing device described herein can be used for both inside and outside corners having various angles. Builders will not have to order two or more versions to cover different types of corners. The drywall corner finishing device described herein can also be used to cover two adjacent outside corners without requiring the use of a narrow strip of drywall panel between the corners and two finishing devices, one for each outside corner. A layer of primer or laminate covers the side of the drywall corner finishing device of the present invention that faces into the room. Because of this primer or laminate layer, plaster need only be used on the outside edges of the corner finishing device where it abuts the drywall. The drywall corner finishing device of the present invention is capable of hiding crooked, uneven corners. The present drywall corner finishing device is affixed directly to the framing members of the wall, thereby providing stability. The drywall corner finishing device is adjustable to fit various thicknesses of drywall panels. Finally, the drywall corner finishing device may be economically manufactured due to its simplified cross-sectional shape.

SUMMARY OF THE INVENTION

[0035] A finishing device used to form a corner between two panels of drywall has a flexible joint extending along a predetermined axis. Two wings are connected to and extend outwardly in a diverging relation from the flexible joint to form a corner having an adjustable angle. Each wing has a front surface, a rear surface, and an edge distal from the flexible joint. The device is adjustable to fit various thicknesses of drywall panel. A layer of primer or adhesive laminate is applied to the front surface of the wings so that paint can bond to the front surface. The finishing device is capable of forming both inside and outside corners. To form inside corners, the finishing device bends along the flexible joint.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present invention can be more readily understood in conjunction with the accompanying drawings, in which:

[0037] FIG. 1 is a partial perspective view of the drywall corner finishing device in accordance with the present invention;

[0038] FIG. 2 shows a cross-sectional view of the drywall corner finishing device in accordance with the present invention;

[0039] FIG. 3 is a detailed cross-sectional view taken from the outlined section of FIG. 2 showing the front surface of the drywall corner finishing device in accordance with the present invention covered with a layer of primer;

[0040] FIG. 4 shows a detailed cross-sectional view taken from the outlined section of FIG. 2. showing the front surface of a second embodiment of the drywall corner finishing device in accordance with the present invention covered with a layer of adhesive laminate;

[0041] FIG. 5 shows a cross-sectional view of the drywall corner finishing device in accordance with the present invention bent to fit inside corners;

[0042] FIG. 6 is a detailed cross-sectional view of the center joint of the drywall corner finishing device as shown in FIG. 2, showing an embodiment of the invention with a tapered joint;

[0043] FIG. 6 a shows a detailed cross-sectional view of the center joint of the drywall corner finishing device as shown in FIG. 5, showing an embodiment of the invention with a tapered joint;

[0044] FIG. 7 is a detailed cross-sectional view of the center joint of the drywall corner finishing device as shown in FIG. 2, showing an embodiment of the invention with a parallel joint;

[0045] FIG. 7 a shows a detailed cross-sectional view of the center joint of the drywall corner finishing device as shown in FIG. 5, showing an embodiment of the invention with a parallel joint;

[0046] FIG. 8 shows a cross-sectional view of the drywall corner finishing device in accordance with the present invention applied to an inside corner between a wall and a ceiling;

[0047] FIG. 9 is a cross-sectional view of the drywall corner finishing device in accordance with the present invention applied to an inside corner formed at the top of a ceiling;

[0048] FIG. 10 is a cross-sectional view of the drywall corner finishing device in accordance with the present invention showing the application of plaster to the joint.

[0049] FIGS. 11(a), 11(b) and 11(c) are partial cross sections of the drywall corner finishing device of FIG. 2 illustrating the use of the device with a ½″ thick drywall panel.

[0050] FIGS. 12(a) and 12(b) are partial cross sections of the drywall corner finishing device of FIG. 2 illustrating the use of the device with a ⅝″ thick drywall panel.

[0051] FIG. 13 is a further partial cross-section of the drywall corner finishing device illustrating the use of the device with a ⅝″ thick drywall panel and a block as affixed to a framing structure.

DETAILED DESCRIPTION

[0052] Drywall panels are conventionally supplied in predetermined widths, for example, and not meant to be inclusive, ⅜ inch, ½ inch, and ⅝ inch widths, etc. Rather than use a separate drywall corner finishing device for every predetermined thickness of drywall panel, one can use the embodiment of the drywall corner finishing device illustrated in FIGS. 1 through 13 to conform to any width of drywall panel.

[0053] Turning to FIG. 1, the left 102 and right 104 wings of the drywall corner finishing strip are attached to a flexible center joint 100 and extend outwardly therefrom to a distal edge 110. The wings 102, 104 have a front surface 106 and a rear surface 108. The front surface 106 and rear surface 108 extend outwardly beyond the outer strut 110 of the wings 102, 104 to cover the outer strut 110. When the drywall corner finishing device covers either an inside corner or an outside corner, the rear surface 108 of the device is juxtaposed to the framing of an interior wall while the front surface 106 faces out into the room, contiguous with the surface of the drywall panels forming the wall. The front surface 106 may be covered with a layer of primer 300 as shown in FIG. 3 so that any paint or wall covering that is eventually used to decorate the wall will adhere easily. Alternatively, the front surface 106 may have an adhesive laminate 400 attached to it as shown in FIG. 4.

[0054] In the preferred embodiment of the invention, a laminate 400 is used on the front surface 106. For best results the laminate should have extensible or flexible properties to it so that the laminate does not crack when the device is bent at the flexible joint, but otherwise have surface characteristics as similar to those of drywall panels. Through extensive testing, best results were had using a paper laminate manufactured by Fibermark of Fitchburg, Mass., and sold under product number X41693. It is understood that disclosure of this particular laminate does not limit the invention to use of only this laminate nor exclude the use of other laminates which are also suitable for use with the device.

[0055] In the preferred embodiment, the paper laminate is affixed to the device by a pressure sensitive adhesive, which remains pliable after application and during normal operating conditions of the device. Through extensive testing, best results were had using an adhesive manufactured by Worthern Industries of Nashua, New Hampshire, and sold under product number Nylco E-68. This adhesive provides a fusion level bond between the device and the laminate, which greatly reduces the tendency of the laminate to separate from the device. Other suitable adhesives include those which do not harden nor negate the extensible properties of the applied paper laminate.

[0056] The device itself may be extruded using various materials. In the preferred embodiment of the invention, a PVC plastic is used, manufactured by Veka, Inc. of Fombell, Pa., and sold under product number X-15. It is understood that disclosure of this particular material does not limit the invention to use of only this material nor exclude the use of other materials which are also suitable for use with the device.

[0057] The structure of the drywall corner finishing device is more clearly seen in FIG. 2. The flexible center joint 100 preferably extends from the front surface of each wing to the other and is either tapered or has parallel walls, but it is to be expressly understood that any joint shape, such as arcuate, V-shaped, U-shaped, C-shaped, etc. can be used that allows the device to bend through a variety of angles at the center joint 100. The center joint 100 extends along an axis that extends linearly to form a corner or edge.

[0058] The tapered joint 101 embodiment of the flexible joint has a front surface which extends parallel to the front surface 106 of the device. The rear surface of the tapered joint 101 tapers inwardly from the two wings, toward the front surface. This allows for a sharp, clean corner to form along the front surface of the tapered joint 101 here it is the thinnest, when the device is bent along the joint, as can be more clearly seen in FIGS. 6 and 6a.

[0059] The parallel joint 103 embodiment of the flexible joint has both front and rear surfaces extending parallel to each other, the front surface extending from and parallel to the front surface 106 of the device. This allows for a rounded corner to form along the front surface of the parallel joint when the device is bent along the joint, as can be more clearly seen in FIGS. 7 and 7a. The length of the parallel joint, as manufactured, may be varied in order to correspondingly vary the radius of the rounded corner.

[0060] Both the tapered joint 101 and parallel joint 103 embodiments of the flexible joint may be used to form both inside and outside corners.

[0061] A number of struts 206 separate the rear surface 108 of each wing 102, 104 from the front surface 106 of each wing 102, 104. In the preferred embodiment shown in FIGS. 1 and 2, the pattern of struts 206 provides stability to the structure of the corner device and also allows the device to be folded around outside corners, as discussed in more detail below. It will be obvious to one skilled in the art that the pattern of struts 206 shown in FIGS. 1 and 2 is not the only pattern that will provide these features of stability and folding and that other patterns would be suitable and are to be included in the present invention.

[0062] The edge 202 of the rear surface 108 extends beyond the edge 200 of the front surface 106. The outer portion 204 of the front surface 106 tapers slightly toward the rear surface 108 so that, as discussed in more detail below, the edge of a drywall panel can be placed in the space 114 between the front surface 106 and the rear surface 108 such that the edge 202 of the rear surface 108 and the edge 200 of the front surface 200 are in close apposition to the drywall panel.

[0063] A flexible flange joint 113 is located at the intersection of the rear surface 108 and the outer edge 110. The rear surface 108 may then be bent at the flexible flange joint 113 thereby allowing the rear surface flange 112 to pivot about the flexible flange joint 113 to adjust the space 114 between the front surface 106 and rear surface 108 to fit various thickness drywall panels.

[0064] It is to be understood that types of flexible flange joints 113 other than that illustrated in FIGS. 1-13 can be used in the present invention and that the present invention includes all types and designs of joints that provide the above-described bending and pivoting.

[0065] In the preferred embodiment of the device, the front surface 106 and the rear surface 108 taper slightly towards each other, as they extend towards the distal ends of each wing 102, 104. This tapering of the wings 102, 104 helps to facilitate a smooth transition from the surfaces of the device and the surfaces of the inserted drywall panels.

[0066] FIG. 8 illustrates the inside corner formed when a vertical wall meets a coffered, cathedral or open ceiling. FIG. 9 shows the inside corner formed at the vault of such a ceiling. Depending on the design of the building, these corners may have angles ranging from less than 90 degrees to 180 degrees. When the drywall corner finishing device is used to finish an inside corner, the rear surface 108 is first placed directly against the framing. The center joint 100 flexes from 180 degrees, shown in FIG. 6 to the appropriate angle needed to fit the angle made by the corner, as shown by arrow 500 in FIG. 5 and arrows 700 in FIG. 7.

[0067] As an example, in FIG. 8, the finishing device is attached to the wall framing 800 and ceiling rafter 802 by use of nails 806. The finishing device is made of plastic soft enough to permit the nails 806 to be driven through the flange 112 of the rear surface 108 without the need for pre-formed holes. It is to be expressly understood that other methods such as the use of screws, bolts, adhesive, etc. will be equally efficacious in attaching the finishing device to the supporting members of the wall or ceiling. The attachment location of the device and the positions of the nails 806 can be varied to enable the device to correct inequalities that may exist within the framing and from one framing member 800 to the next. If necessary, shims may be placed behind the device before it is attached by nails 806. After the device has been securely attached to the framing 800 and rafter 802, the edges of the drywall panels 804 are inserted into the spaces 114 between the front surface 106 and rear surface 108, such that the edges of the drywall panels 804 abut the outer strut 110 of the wings 102, 104. It can be seen in FIG. 8 that the spaces 114 between the front surface 106 and rear surface 108 are just large enough to accommodate the drywall panels 804 and that the front surface 106 and rear surface 108 are closely juxtaposed to the drywall panels 804. The drywall panels 804 thus hide the nails 806. The drywall panels 804 are attached to the framing 800 and rafter 802 in the usual fashion.

[0068] As FIG. 10 shows, plaster 1300 is then applied to the tapered distal portion 204 of the front surface 106 and the tapered edge of the drywall panel 804 to hide the edge 200 and provide a smooth, level surface. Because plaster 1300 is applied only to the tapered portion 204 of the finishing device, difficulties inherent in plastering within corners are avoided. Such difficulties include, among others, the difficulty in maneuvering a plaster trowel within a corner, the skill need to produce a perfectly straight edge where the two sides of the corner meet, and the need for several layers of plaster 1300 to completely hide the joint between the finishing device and the drywall or to correct the inequalities resulting from mis-sized, mis-placed, or warped framing members, with each layer requiring considerable time to dry. Once plaster 1300 has been applied, the surface of the wall can be finished by painting, wallpapering, or any other method desired. The primer 300 bonded to the front surface 106 enables paint or other wall coverings to adhere to the front surface 106 of the finishing device. In another embodiment, a laminate 400 can be adhesively affixed to the front surface 106 to provide a surface for subsequent painting.

[0069] Plaster alternatives may also be used to hide the edge 200. Plaster alternatives include, but are not limited to stucco, stucco plasters, synthetic stucco and cement siding products.

[0070] A second example of the use of the finishing device for inside corners is shown in FIG. 9. Here, the finishing device provides an inside corner essentially as described above, except here the corner is that formed by the vault of a coffered ceiling. The device is attached to the rafters 900 by driving nails 904 through the flanges 112. The attachment location of the device and the positions of the nails 904 can be varied to enable the device to correct inequalities that may exist within the rafters 900 and from one rafter 900 to the next. If necessary, shims may be placed behind the device before it is attached by nails 904. The edges of the drywall panels 902 are then inserted into the spaces 114 between the front surface 106 and rear surface 108. As above, these spaces 114 are just large enough to accommodate the edges of the drywall panels 902, so that the front surface 106 and rear surface 108 are in close apposition to the drywall panels 902. The drywall panels 902 thus hide the nails 904. The drywall panels 902 are attached to the rafters 900 in the usual fashion. Plaster 1300 is then applied to the tapered distal portion 204 of the front surface 106 and the edge of drywall panels 902 to provide an even surface. Because of the primer 300 or laminate 400 covering the front surface 106, is not necessary to use plaster on the remainder of the front surface 106, and the difficulties of plastering within the tight angles formed by inner corners are avoided. The surface of the wall is then painted or otherwise finished as desired.

[0071] FIG. 11(a) illustrates the drywall corner finishing device in a resting position. When ½″ drywall panel 1500 is inserted into space 114 between the edges 200, 202 as shown in FIG. 11(b), the drywall panel 1500 is held against the rear surface flange by edge 200 as shown in FIG. 11(c).

[0072] FIG. 12(a) illustrates ⅝″ drywall panel 1600 inserted into space 114 between the edges 200, 202. With the greater thickness drywall panel 1600, rear surface flange 112 pivots at flexible flange joint 113, away from the front surface 106. Front surface 106 remains relatively straight due to outer strut 110, which extends from the front surface 106 of the device away from the end of each wing, to the rear surface. Another consideration which helps to allow the front surface 106 to remain relatively straight while the rear surface flange 112 pivots, is that the wall thickness of the rear surface 108 is slightly thinner than that of the front surface 106. This effect could also be facilitated in other ways such as reducing the wall thickness of the rear surface 108 where it intersects the outer strut 110 at the flexible flange joint 113, thereby weakening the immediate area, allowing the flange joint 113 to pivot more easily.

[0073] FIG. 12(b) illustrates rear surface flange 112 held in place adjacent drywall panel 1600 once the device and drywall panel 1600 are installed, as further shown in FIG. 17. Best results when using the device were found when an adhesive was used to affix the inside surface of space 114 of the device with the drywall. Preferably a fusion bond adhesive is used. Two adhesives which were found to be suitable for this application are product number PL Premium manufactured by OSI Sealants of Mentor, Ohio and product number F2100 in combination with product number F2100A, manufactured by ITW Foam Seal of Oxford, Mich. It is understood that disclosure of these particular adhesives does not limit the invention to use of only these adhesives nor exclude the use of other adhesives which are also suitable for use with the device.

[0074] FIG. 13 illustrates how the device is installed with a ⅝″ panel 1600. A block 1700 may be used to keep the device and the drywall panel 1600 parallel with the framing surface which the drywall panel 1600 is attached. The block 1700 is affixed to the rear surface 108 of the device. The device and drywall panel 1600 are affixed to the framing surface by nails 1702 or some other fastening device. When the nails 1702 are fastened into the framing surface, the rear surface flange 112 is sandwiched between and adjacent to the framing surface and the drywall panel 1600. Thus, this drywall corner finishing device can be used for drywall panels that are thicker than the thickness of the device.

Claims

1. A finishing device for use in forming a joint or a corner between two panels of drywall having edges of a predetermined thickness, said finishing device comprising two wings each having a front and rear surface, said front and rear surface having inner and outer edges, reinforcing structure extending between the front and rear surfaces of each of the two wings, the inner edges of the two wings being joined at a flexible joint extending along a longitudinal axis, the inner edges of the rear surface being spaced apart from each other outwardly of the flexible joint, the portions of said front and rear surfaces adjacent the outer edges of said front and rear surfaces being free of reinforcing structure, the outer portion of the rear surface forming a longitudinal hinge with the adjacent reinforcing structure whereby the outer portion of the rear surface of each wing may pivot rearwardly to receive drywall panels of different thicknesses.

2. The drywall corner finishing device of claim 1 wherein said flexible joint has a front surface and a rear surface and the rear surface of the flexible joint includes opposite inwardly tapered portions.

3. The drywall corner finishing device of claim 1 wherein said flexible joint has a front surface and a rear surface and the front and rear surfaces of the flexible joint are essentially parallel to each other.

4. The drywall corner finishing device of claim 1 wherein said front and rear surfaces of each wing converge toward each other in a direction outwardly of said flexible joint.

5. The drywall corner finishing device of claim 1 wherein the said reinforcing structure further comprises a plurality of struts extending between said front and rear surfaces of each wing.

6. The drywall corner finishing device of claim 1 wherein said outward portion of said rear surface of each wing provides a flange for attaching said finishing device to framing.

7. The drywall corner finishing device of claim 1 wherein said finishing device can be folded to a plurality of angles at said flexible joint so as to form inside or outside corners having a plurality of angles.

8. The drywall corner finishing device of claim 1 wherein said front surface is covered by a primer or laminate.

9. The drywall corner finishing device of claim 1 wherein said front surface is covered with an extensible paper laminate affixed by an adhesive which remains pliable and does not negate the extensible properties of the paper laminate under normal working conditions.

10. The drywall corner finishing device of claim 1 in combination with a block positioned adjacent to the rear surface of a wing when used with a drywall panel which is thicker than the normal opening between the outer portions of the front and rear surfaces of the wing, to allow the drywall panel and the device to remain parallel to the framing surface on which the drywall panel and device are affixed.

11. The drywall corner finishing device of claim 1 wherein the inside surface of the outer portion of said front and rear surfaces is affixed by an adhesive to the drywall panel which is being used with the device.

12. A method of finishing an inside or outside drywall corner, the corner having two side walls, comprising the steps of: providing a finishing device having two wings each having a front and rear surface, said front and rear surface having inner and outer edges, reinforcing structure extending between the front and rear surfaces of each of the two wings, the inner edges of the two wings being joined at a flexible joint extending along a longitudinal axis, the inner edges of the rear surface being spaced apart from each other outwardly of the flexible joint, the portions of said front and rear surfaces adjacent the outer edges of said front and rear surfaces being free of reinforcing structure, the outer portion of the rear surface forming a longitudinal hinge with the adjacent reinforcing structure whereby the outer portion of the rear surface of each wing may pivot rearwardly to receive drywall panels of different thicknesses; inserting a drywall panel into the space between the front and rear surface of each wing. bending the finishing device at the flexible joint to form the desired angle between the inserted drywall panels; affixing the finishing device to the framing surface; applying plaster or plaster alternative in the area where the finishing device and drywall panels meet to create a smooth, level surface between the device and panels; allowing the plaster or plaster alternative to dry; and applying paint or other surface covering to the installed finishing device and drywall panels.

13. A method of finishing an inside or outside drywall corner, the corner having two side walls, comprising the steps of: providing a finishing device having two wings each having a front and rear surface, said front and rear surface having inner and outer edges, reinforcing structure extending between the front and rear surfaces of each of the two wings, the inner edges of the two wings being joined at a flexible joint extending along a longitudinal axis, the inner edges of the rear surface being spaced apart from each other outwardly of the flexible joint, the portions of said front and rear surfaces adjacent the outer edges of said front and rear surfaces being free of reinforcing structure, the outer portion of the rear surface forming a longitudinal hinge with the adjacent reinforcing structure whereby the outer portion of the rear surface of each wing may pivot rearwardly to receive drywall panels of different thicknesses; cutting the finishing device to a length to fit the drywall corner; applying an adhesive to the inside surface of the outer portion of the front and rear surfaces; inserting a drywall panel into the space between the front and rear surface of each wing. bending the finishing device at the flexible joint to form the desired angle between the inserted drywall panels; if necessary, placing shims between the device and a framing surface; affixing the finishing device to the framing surface; applying plaster or plaster alternative in the area where the finishing device and drywall panels meet to create a smooth, level surface between the device and panels; allowing the plaster or plaster alternative to dry; and applying paint or other surface covering to the installed finishing device and drywall panels.

14. The method as in claim 13 wherein said finishing device is affixed to the framing surface with fasteners which are driven through the drywall panel and the outer portion of the rear surface, into the framing surface.

15. The method as in claim 14 wherein if the inserted drywall panel is thicker than the normal space between the outer portions of the front and rear surfaces, a block is placed adjacent to the rear surface of each wing which accommodates the drywall panel which is thicker than the normal space, to allow the drywall panel and the device to remain parallel to the framing surface on which the drywall panel and device are affixed.