Drywall Cornering Tool

Abstract

The present invention provides an improved drywall cornering tool adapted for receipt of a cone liner said improved drywall cornering tool including a pole attachment, a pyramid shaped head centrally aligned about the pole attachment and extending from an apex to a bottom where the pyramid shaped head is configured for receiving of a disposable cone liner.

Description

FIELD OF THE INVENTION

The present invention is broadly directed to the field of drywall construction and more particularly to a drywall cornering tool that provides for an improved method and device for finishing a drywall corner on three sides.

BACKGROUND OF THE INVENTION

Mudding or applying joint compound to sheetrock in a finished space has long been considered an art form because of the difficulty in applying the joint compound in a uniform visually appealing manner.

Typically joining sheet of sheetrock together involves applying joint compound and tape, in consecutive passes over several hours. Several coats of joint compound must be applied manually and then thinned uniformly allowing for time to dry between coats. After the joint compound is dried, it is then sanded create a uniform surface. This is especially true for the areas like inside corners where three drywall sheets meet together for example along a vertical, horizontal and third. It is difficult to apply joint compound along all three axes at the same time. The problem with traditional corners is that only one side at a time can be tooled. If an attempt is made to tool both sides of a corner at the same time, either the guide on the mud dispensing box will disturb (and ruin) the mud on the other side of the corner, or the mud coming out of the box will flow onto the other side. In either case, the corner would be left in an unacceptable condition.

This often requires that tooling or boxing must be done on one side of each corner at a time. One side is tooled, then the joint compound must be allowed to dry, a process that requires coming back at least a day later. Only after the joint compound on the first side is totally dry, can the second side be tooled. As a result, drywall workers must typically pass through a construction site tooling the first sides of each inside corner. Then they must come back on a subsequent day to tool the second side of the inside corners. This puts at least an extra day into the construction cycle. Thus, there is a need for an improved manner of mudding a corner which applies joint compound along all three axes uniformly and efficiently while saving time.

Prior attempt at addressing this problem include using a joint knife or tool which applies joint compound along a planar surface. However, these are time consuming and difficult to use. The knife, having a sharp straight edge, can damage or move the tape while spreading the joint compound leading to a weak or visually displeasing corner. In addition, a mudding knife manually spreads joint compound along a sheetrock pair as spreads the applied compound thinly. However, it can only be used along one plane at a time. In addition to being inefficient, using the mudding knife to spread joint compound along one plane may actually scrape or damage the surface of the adjacent sheetrock plane. Therefore, there exists a need to apply joint compound to along three dimensions efficiently and without damaging the adjacent surface.

Another attempt to address the above-mentioned problem includes using a cornering tool. The cornering tool is manually used to spread joint compound along a pair of sheetrock surfaces joined together at an angle. The cornering tool also referred to as a butterfly has historically been viewed as inefficient, unstable and difficult to work with, often resulting in application of a non-uniform bead or surface between adjacent sheets. In addition, the cornering tool may also damage or move the tape joining the adjacent sheets while spreading joint compound along the two sheets. The cornering tool is also limited to working along two planes and is not configured for spreading joint compound or work along all three axis simultaneously. Therefore, there exists a need for an improved drywall cornering tool which can be used to join sheetrock together along an inside corner in an efficient, effective visually appealing manner.

Accordingly, there is a need for an improved method and device for finishing a three-sided drywall corner, like an inside corner which is quicker, easier and more efficient and at least in part, addresses the aforementioned shortcomings.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, an improved drywall cornering tool is adapted for receipt of a disposable cone liner said improved drywall cornering tool comprising a pole attachment, a pyramid shaped head aligned about said pole attachment and extending from an apex to a bottom and said pyramid shaped head configured for receipt of a disposable cone liner extending from said apex to said bottom.

The present invention relates to drywall corner tools that apply a cone liner to a mudded surface while the mud is still wet. The cone liner extends downward from an apex along three substantially planar sides, which once applied by the drywall cornering tool provides a flat finished surface to the three sides which is prepared to receive paint or texture. This apex is fabricated from a partially plastic material, while the downward extensions are substantially fibrous, including paper. Each finished side can be mudded without any mud on the apex. This then allows for mudding of the remaining sides without any interference to the first side.

The cornering tool applies the cone liner in a way to resemble a standard drywall corner. At the apex is the finished surface that never needs mud. The surface of the apex can be finished in any way that will allow it to take paint or texture. It can be roughed slightly, or it can be coated by a material to which paint or texture will adhere. The bead can be made from any plastic, high impact plastic, metal, or any other rigid material.

In the process, the worker applies the cone liner (which may be sized accordingly based on the desired corner dimensions) to the drywall cornering tool. Upon receipt of the cone liner, the user raises the tool and presses the head against the desired corner applying the liner into the corner. The cone liner may be applied to the corner by any method (nailing, gluing, or mudding), mudding the first side. Immediately after mud is applied to the first side, the worker can move to the second side and mud it in an identical manner and then move to the third side and mud it in the same way. The corner is thus totally mudded in minutes without any drying wait period. The cone liner can be configured to provide for a regular or bullnose style cornering beads, and interior trim or flex-trim for interior corners and can be custom or standard dimensions.

Various objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein, by way of illustration and example, certain embodiments of this invention are set forth. The drawings submitted herewith constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom perspective view of an exemplary embodiment of the present invention attached.

FIG. 2 is a side perspective view of the exemplary embodiment illustrated in FIG. 1.

FIG. 3 is a top perspective of the exemplary embodiment illustrated in FIG. 1 with a head adapted for receipt of an exemplary cone liner.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus the following specific structural and functional details disclosed herein (including the drawings) are not to be interpreted as limiting, but merely representative of the selected embodiments of the invention and as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

The features, structures or characteristics of the invention described throughout this specification may be combined in any suitable manner in one or more embodiments. For example, the usage of the phrases “example embodiments,” “some embodiments,” or other similar language, throughout this specification refers to the fact that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present invention. Thus, appearances of the phrases, “example embodiments,” “in some embodiments,” “in other embodiments,” or other similar language, throughout this specification do not necessarily all refer to the same group of embodiments and the described features, structure or characteristics may be combined in any suitable manner in one or more embodiments.

Referring to the drawings in more detail, and specifically FIG. 1, the reference numeral 10 generally refers to a new and improved drywall cornering tool with a mountable attachment 6, for example, as a pole attachment or adapted for use with a hand tool or extension tool (not shown). Generally, the pole attachment 6 presents a central axis about which a pyramid shaped head 20 is aligned. The illustrated embodiment of the mountable attachment 6, in FIG. 1, includes a threaded member adapted for threadable receipt by another device like a pole, but could be alternatively configured for receipt by another tool or extension device (not shown) which includes a quick release fitting (not shown) or other releasable fastening mechanism generally known.

In addition, the mountable attachment 6 includes a circular spacer with a frictional outer surface which separates the threaded receiver (not shown) from a biasing member 14 and allows for a better rotational gripping surface while attaching the pyramid shaped head 20 to the extension device (not shown).

The pyramid shaped head 20 extends from an apex 25 to a bottom 19 and is adapted for receipt of a cone liner 18 for finishing or boxing drywall corners like inside corners (not shown). In general, the drywall cornering tool 10 with pyramid shaped head 20 and cone liner 18 is used to simplify and expedite the drywall process. Use of the pyramid shaped head 20 for the finishing or drywall process allows for concurrent pressure against multiple sheetrock sheets during drywalling.

The depicted embodiment of the pyramid shaped head 20 of FIGS. 1-2 includes a first triangular face 24, second triangular face 26 and third triangular face 28 joined together along a plurality of edges. Each of the first, second and third faces 24, 26, 28 include a first, second and third notch 17a, 17b, 17c at each vertex of each first, second and third triangular face 24, 26, 28.

As generally depicted in FIG. 2, a first edge 23a extends between the first face 24 and the second face 26, a second edge 23b extends between the second face 26 and the third face 28 and a third edge 23c extends between the third face 28 and the first face 24. Each of the first, second and third edges 23a, 23b, 23c extend from the apex 25, where the first, second and third triangular faces 24, 26, 28 present a central vertex 27, downward for presentation of the bottom 19.

By applying concurrent pressure against all three triangular faces 24, 26, 28 a smoother, cleaner corner finish may be obtained. In addition, by applying concurrent pressure against the first, second and third triangular face 24, 26, 28, the corner finish may be obtained more quickly and without damage to the adjacent sheetrock surfaces which may be caused by consecutive finish of adjacent sheetrock surfaces. Use of the drywall cornering tool 10 allows for a quicker, more consistent cornering process than traditional corning methods and tools provide while boxing the drywall corner along adjacent sheets of drywall.

Generally, the head 20 provides a unique edge surface for applying the cone liner 18. The head 20 may be fabricated from plastic, metal, rubber or such materials as are well known or a combination of any of those materials. The cone liner 18 may be reinforced or fabricated for use with or without joint compound at the tip of the liner 18. Depending on the reinforcement provided, application of joint compound may be unnecessary and the user may be able to mud one side of the liner without interfering with the other sides.

The embodiment illustrated in FIG. 3 includes the cone liner 18 or paper cone which is adapted for receipt by the pyramid shaped head 20. Generally, the cone liner 18 has a complementary opening for receipt of the pyramid shaped head 20. In one embodiment, the cone liner 18 includes a plurality of liner faces including a first liner face 18a, a second liner face 18b, and a third liner face 18c which extends downward from a center 18d. In one embodiment, the center 18d is at least partially rigid to provide a straighter edge for forming the shape of the inside corner formed at the junction of three or more sheetrock surfaces (not shown). Generally, the cone liner 18 may be fabricated from plastic, paper or a combination of plastic and paper.

Radiating outwardly from the center 18d, the fibrous material associated with the cone liner 18 absorbs or is coated by the joint compound (not shown). In addition, the fiber portions provide for less touch up or check out in the angle. The system including the improved drywall corner tool 10 with cone liner 18, will speed up the installation process, provide for easier installation and clean-up of drywall material, providing for better more visually appealing corners.

In one embodiment of the present invention, at least one plurality of spacers 21 extend from the head 20 depicted in FIG. 1. Each spacer 21 extends along each face 24, 26, 28 for separation of the cone liner 18 from the head 20. Generally, the spacers 21 are mechanically fastened with spacer fasteners 29 to each of the triangular faces 24, 26, 28. By providing a raised surface extended from the substantially planar surface of the triangular face 24, 26, 28, the spacers 21 help provide uniform pressure against the cone liner during application and assist in spacing the received cone liner 18 from the head 20 and in selectively applying the cone liner 18 into the adjacent sheetrock surfaces forming the inside corner.

A crown 12, is illustrated in FIG. 1, extended from the pole attachment 6 configured for telescopic movement with a biasing member 14 in communication with the pole attachment 6. As the biasing member 14 is compressed, the crown 12 extends vertically along the central axis. The crown 12 is operably connected to the first, second and third triangular faces 24, 26, 28 with a brace 22. The depicted embodiment of the crown 12 is circular with arcuate brace connectors which are configured for receipt of a frustoconical spacer 12a which as depicted in FIG. 2 extends between the biasing member 4 and the crown 12 for telescopic movement of the crown 12. As the crown 12 moves telescopically the brace 22 provides outward support for each of the triangular faces 24, 26, 28.

As illustrated in FIG. 1, one embodiment of the head 20 is attached to the pole attachment 6 using a reactionary supporting structure. In another embodiment, the head 20 moves during telescopic operation of the crown 12.

The embodiment of the reactionary support structure illustrated in FIG. 1 includes at least one brace 22 extending from the crown 12 to at least one rib 16. As pressure is exerted upon the first, second and third triangular faces 24, 26, 28, the force is distributed from the rib 16 to the corresponding brace 22 along the other reactionary support members. During static operation, the reactionary support structure assists in supporting and connecting the head 20 along the central axis extending along the pole attachment 6. The rib 16 is illustrated in FIG. 1 as being secured along the interior side of the first, second and third triangular faces 24, 26, 28 with the rib 16 mechanically secured to each of the triangular faces 24, 26, 28 with a mechanical fastener 16d. The embodiment of the mechanical fastener 16d includes a cylindrical end secured through the triangular face, but may also include a number of other fasteners including mechanical, or chemical such as a rivet, bolt, screw, nail, glue, or welded. Alternatively, the ribs 16 may be formed as part of the manufacturing process such as plastic molding.

During extended operation, such as when applying the cone liner 18 within an inside corner (not shown), each triangular face 24, 26, 28 extends radially by the telescopic operation of the crown 12 to apply uniform pressure against the cone liner 18 and assist in impregnating the cone liner 18 into the inner corner surface (not shown). The reactionary support structure includes the braces 22 extending from the crown 12 to each face 24, 26, 28. The optional biasing member or top spring 14 assists in the upward extension of the crown 12 for outward extension of the brace 22, for example, during telescopic movement.

The reactionary support structure allows for redistribution of pressure from one of the triangular faces 24, 26, 28 along all faces on the head 20 reducing the pressure exerted along any single sheetrock surface (not shown) individually and distributing it along all sheetrock surfaces collectively. Reactionary support structures, other than the depicted rib 16 and brace 22 combination may be utilized for distribution of the force from at least one of the triangular faces 24, 26, 28 to the other triangular faces during static or extended operation of the head 20.

The illustrated embodiment of the rib 16 in FIG. 1 is an elongated rectangular structure with a pair of side members 16a spanning a brace receiver 16b adapted for pivotal receipt of the brace 22 about a centrally extending support pin 16c. Each rib 16 extends vertically along the interior surface of each first, second and third triangular face 24, 26, 28 and interconnects the brace 22 to each triangular face 24, 26, 28. Each rib 16 is attached to one end of a brace 22, the other end of the brace 22 being attached to the adjustable crown 12. During operation, each brace 22 extends outwardly as the crown 12 is telescoped.

FIG. 2 illustrates an embodiment of the head 20 with each face 24, 26, 28 extending from the apex 25 downwardly. In the depicted embodiment of the triangular shaped faces 24, 26, 28 are substantially planar and are triangular shaped. The spacing of each edge 23a, 23b, 23c from each pair of adjoining triangular faces, 24, 26, 28 presents a bullnose edge along each edge surface 23a, 23b, 23c.

FIG. 3 includes the head 20 and the cone liner 18, the cone liner 18 being shaped for overlying the head 20 during operation.

The cone liner 18 may be fabricated to be finished directly or be prepared to receive paint or texture. This preparation can be a slightly roughed surface, or a coating of any suitable material that paint or texture will adhere to. If the structure is a laminate containing an outer paper layer, the paper can be of a type that can directly receive paint or texture, or it can be prepared to receive paint or texture with a suitable coating. The entire surface of the cone liner 18 could optionally be bonded with paper that can directly receive paint or texture.

It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of the parts described and shown.

Claims

1. An improved drywall cornering tool adapted for receipt of a cone liner said improved drywall cornering tool comprising: a pole attachment;a pyramid shaped head aligned about said pole attachment and extending from an apex to a bottom; andsaid pyramid shaped head configured for receipt of a disposable cone liner extending from said apex to said bottom.

2. The improved drywall cornering tool of claim 1 wherein said pyramid shaped head further comprising: a first triangular face,a second triangular face,a third triangular face spaced between said second triangular face and said first triangular face;said first triangular face and second triangular face spanned by a first edge;said second triangular face and said third triangular face spanned by a second edge; andsaid third triangular face and said first triangular face spanned by a third edge wherein said first edge, said second edge and said third edge extend substantially from said apex to said bottom.

3. The improved drywall cornering tool of claim 2 wherein said first triangular face, said second triangular face and said third triangular face are substantially planar.

4. The improved drywall cornering tool of claim 2 wherein said first triangular face, said second triangular face and said third triangular face present a central vertex.

5. The improved drywall cornering tool of claim 2 wherein at least one of said first triangular face, said second triangular face and said third triangular face includes a notch.

6. The improved drywall cornering tool of claim 1 wherein said pyramid shaped head further comprising at least one spacer extending outwardly from said head.

7. The improved drywall cornering tool of claim 1 wherein said pyramid shaped head further comprises a reactionary support structure extending between said pole attachment and said pyramid shaped head.

8. The improved drywall cornering tool of claim 7 wherein said reactionary support structure further comprises: a crowna rib; anda brace extending between said crown and said rib.

9. The improved drywall cornering tool of claim 8 wherein said crown is centrally aligned with a center axis, said brace is mounted to said pyramid shaped head, said brace extending therebetween.