Drywall exterior corner simultaneous setting and wiping tool

Abstract

The present invention is a tool for use with drywall exterior paper-faced metal corner bead application which sets and wipes the corner bead in one motion. It is a roller tool having equal number wheels on each side of a rigid frame bent vertically on an axis to the angle desired. The tool has a wiping device attached to the top of the rigid frame that is also bent vertically along the same axis which has a wiping edge that extends past the edge of the wheels that makes contact with the wall board during use and feathers the excess joint compound after the corner bead has been set by the wheels. This invention has a hollow socket on the back for a ball-shaped connector which is what gives the operator the control needed to operate the tool in the proper direction.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Non-Provisional Utility patent application is being filed in reference to a Provisional Application for a patent which I, Michael Jason Carpenter, earlier filed for the same invention from which I would like the benefit of the earlier filing date. The application Number and Filing date are:

61/343,504 Apr. 30, 2010 Michael Jason Carpenter

Other related patent applications are as follows:

4,767,297	Aug. 30, 1988	Mower et al.
5,010,618	Apr. 30, 1991	Croft
5,203,954	Apr. 20, 1993	Moore
5,368,461	Nov. 29, 1994	Murphy
5,544,384	Aug. 13, 1996	Forselius et al.
6,450,232	Sep. 17, 2002	Smythe Jr.
6,869,492	Mar. 22, 2005	Kooistra
2007/0261334	Nov. 15, 2007	Conboy
D583839S	Dec. 30, 2008	Rosso et al.
D599831	Sep. 8, 2009	Rosso et al.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

FIELD OF THE INVENTION

The present invention is in the field of drywall. More particularly, the present invention is in the technical field of drywall finishing and is a tool used for the installation of paper-faced metal outside corners, known as corner bead.

BACKGROUND OF THE INVENTION

It is a common practice to use gypsum drywall board to cover interior walls and ceilings in modern construction. This process consists of screwing, or nailing, the gypsum boards to studs of the building. It takes numerous sheets of gypsum board, with the edges butted firmly together, to cover the desired area. These seams must be taped and finished with joint compound to achieve the desired smooth look. For the flat seams and the interior corners of the walls and ceilings, joint tape with a thin layer of joint compound is applied usually using a drywall tool referred to as a banjo. The tape is then wiped with a drywall knife, forcing out the excess joint compound, leaving it relatively smooth and flat. Two more coats of joint compound are then typically feathered over the tape making the wall appear smooth.

When the gypsum boards meet forming an exterior corner, special metal corners are installed covering the entire length of the seam. These special metal corners are thin lengths of metal that are bent to the same angle as the drywall corner, and extend an inch on each side of the corner. The edges of the metal corner have paper glued to them. This paper covers, and extends an inch past, the metal part of the corner. The paper edge is what holds the metal corner in place, when it is set using joint compound. Joint compound can be applied one of two ways. The first way is to apply it with a taping knife directly to the edges of the corner where the corner bead is to be installed. The second way is to apply the joint compound with a hopper, which, when corner bead is forced through it, leaves a uniform amount of joint compound on the corner bead itself. The corner bead can then be pressed on the corner by hand. Next, a common roller tool, which has freely rotating wheels and is angled so that it fits the outside corner, is pushed along the length of the corner bead. This sets the corner bead while forcing out the excess joint compound. The excess joint compound then forms a ridge that must be wiped clean with a taping knife. After the corner bead dries, it is ready for the two finishing coats of joint compound.

The process of installing the corner bead has many steps making it a time-consuming process. This new roller tool technology will reduce the number of steps involved in installing the corner bead and, as a result, will greatly reduce the amount of time required for it.

SUMMARY OF THE INVENTION

The present invention is an outside corner roller device consisting of two main parts: a roller device that sets the corner bead into the joint compound, and a wiping device that feathers the excess joint compound. This is done in the same motion. This invention is generally used with a separate tool that applies a controlled amount of joint compound directly on the piece of corner bead, or on the outside corner of the drywall itself. On each side of the invention, a screw is located slightly below the wiping edge of the blade. These screws can be tightened, or loosened, to achieve the desired feathering of the excess joint compound. This leaves the corner bead ready for the two finishing coats of joint compound.

Another feature of this invention is the hollow ball connector located on the backside. This connector is very important to the invention because it allows the invention to be attached to a pole that has a ball-end, making it possible to control what direction the invention is facing. For example, if you are installing a vertical piece of corner bead, you can put the invention on the desired length ball-ended pole and, with the wiping edge of the invention at the top of the corner bead, move the invention down the corner, setting the corner bead and wiping the joint compound as it goes. When the invention gets half way down the corner, you can turn it upside down by rotating the pole that it is connected to. The wiping edge will then be at the bottom of the corner and you can move the invention up the corner, setting the corner bead and wiping the rest of the joint compound. It is vital that this invention be used in the proper direction and the ball connector is the key to that control. Other drywall tools also utilize the same type of ball connector. This means that you will only need one pole to use many different tools. This also gives you the ability to choose what length of pole you wish to use with this invention.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a view of the invention from the back, where it will attach to the pole.

FIG. 2 is a view of the invention from the front, where it will press against the drywall corner.

FIG. 3 is a view of the invention from the side.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the invention in more detail, in FIG. 1 there is shown the frame 1. The frame 1 is bent vertically along an axis, so when the wheels 2 are attached they will align properly on both sides of the intended angle of use, in this case 90 degrees. Four wheels 2 are used in these drawings but any number of wheels could be used to make this invention as long as there is at least one wheel 2 on each side of the corner to set the corner bead. The invention can be manufactured to be used with any angle desired. The wheels 2 extend far enough along the drywall on each side of the corner to properly set the paper edge of the corner bead.

The wiping device 7 is bent at a slightly more acute angle than the angle desired to be wiped. The reason for this is, when you push the invention against the corner, the wiping device 7 is forced apart, tightly fitting the angle. This force is necessary to maintain tight contact between the wiping edges 14 of the invention and the drywall. The wiping device 7 is made of stainless steel 1/32 inch thick, or equivalent material. The tips 13 of the wiping edge 14, shown in FIG. 2, are bent slightly while maintaining the same plane as the rest of the wiping edge 14. This keeps the joint compound from being forced past the wiping edge 14 and leaving a ridge. The angle of the wiping device 7 is such that the tips 13 of the wiping edge 14 remain tight against the drywall while the rest of the wiping edge 14 has less pressure against the drywall. The wiping edge 14 slightly looses contact with the drywall when the two wiping edges 14 meet at the corner. This is what feathers the joint compound to the drywall. The support 8 is a slightly thicker, stronger piece of metal, 1/16 inch thick. This support 8 applies more pressure to the tips 13 of the wiping edge 14 ensuring they keep contact with the drywall during operation. The support 8 also has two holes with threads tapped in them. These holes are located on each side of the invention. They are slightly below (¼ inch) and near the middle of the wiping edge 14. These holes are what the tensioner screws 11 are screwed into. When the tensioner screws 11 are tightened, they go through the support 8 and press against the thinner metal of the wiping device 7. You can control the pressure the wiping edge 14 has on the drywall by tightening, or loosening, these screws 11. The tensioner screws 11 can be tightened independently applying more pressure to one or both sides of the wiping edge 14. The support 8 is attached to the wiping device 7 by a bolt 4 with wing nuts for easy removal if necessary.

An angled bracket 9 with a flat base is attached to the wiping device 7 also using bolts 4 with wing nuts. The frame 1 has a flat bracket 10. The angle bracket 9 and the flat bracket 10 are secured together using bolts 4 and wing nuts. This is what holds the wiping device 7 securely to the frame 1 of the rolling device. A variation of holding the wiping device 7 to the frame 1 of the rolling device is to weld them together or form them as one solid piece.

The ball socket connector 6 is made of thick metal with a ball-shaped hole in the middle. A spring 12 holds the ball end of the pole in the ball socket connector 6. This allows for necessary control of the invention and easy removal from the pole. The ball socket connector 6 is fastened securely to the frame 1 using two screws 5. These screws are screwed into the holes that have been drilled and tapped in the sides of the ball socket connector 6. The screws 5 could be eliminated by welding the ball socket connector 6 to the frame 1 or by forming them as one solid piece. The ball socket connector 6 should also be slightly above the center of the frame 1 so, when pressure is applied using the pole, it is distributed to the device in a way that keeps enough pressure on the wiping edge 14 of the invention.

FIG. 3 shows the side view of this invention. This view makes it clear that the wiping device is angled forward towards the corner. This angle is vital to the proper function of the invention because it makes only the wiping edge 14 of the wiping device 7 have contact with the drywall. This creates a space between the rest of the wiping device 7 and the drywall. The angle makes the space become slightly larger as the wiping device 7 gets closer to the point where it connects to the roller device. This allows the excess joint compound to build up in the space, being evenly feathered on the drywall, not just dripping to the floor. Also, this extra joint compound will automatically fill in any dry or thin spots along the corner bead, as the invention is moved along it, creating a very even and consistent application. When this invention is used properly, the only points of contact it will have with the drywall on the exterior corner are, the wheels 2, and the wiping edge 14.

FIG. 3 also shows that the sides forming the wiping device 7 extend ½ inch further than the wheels 2. This is also vital to the proper function of this invention because, when the wheels force the joint compound out from under the corner bead, it creates a ridge of joint compound ¼ inch further than the edge of the wheels 2. The wiping edge 14 has to be long enough to easily wipe over that ridge of joint compound and feather it out. This invention could be created using any length of wiping device 7, as long as it extends far enough to properly feather the excess joint compound. FIG. 3 also shows a small space between the top wheels 2 on the roller device and the bottom of the wiping device 7. This space is necessary for all the wheels 2 to rotate freely.

The advantages of the present invention include, without limitation, setting and wiping of the corner bead in one continuous motion. The invention can be removed from the pole on which it is being used, making this invention interchangeable with the other drywall tools. Also, the pressure on the wiping edge can be adjusted for different applications.

In broad embodiment, the present invention is a tool to set and wipe outside angles of drywall, known as corner bead.

While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods with the scope and spirit of the invention as claimed.

Claims

1. A device for setting and wiping the excess joint compound of exterior paper-faced metal corners, commonly known as corner bead in drywall applications, comprising of: a rigid metal frame: two or more wheels: a hollow ball-shaped connecting device: a wiping device: a screw on each side of the wiping edge of the wiping device.

2. The device of claim 1 wherein the metal frame is of thick enough metal or other solid material so as not to bend under the normal pressure exerted during use.

3. The device of claim 1 wherein the rigid frame is bent vertically on an axis to the intended angle of use.

4. The device of claim 1 wherein the wheels of equal number on each side of the frame roll when the device is used setting the corner bead in the previously applied joint compound.

5. The device of claim 1 wherein the metal frame has a hollow ball shaped connector for easy removal and giving the operator the necessary control needed for operation of the device.

6. The device of claim 1 wherein a wiping device comprised of a metal flange on either side of the axis at the top of the frame and extending past the edge of the wheels feathers out the remaining joint compound after the wheels set the corner bead.

7. The device of claim 1 wherein two screws are located in the center and slightly below the wiping edge of the wiping flange of the device that when tightened or loosened allow the operator to control the feathering of the excess joint compound.

8. The device of claim 1 sets the corner bead and feathers the excess joint compound removing one step of the process.