Drywall And Cement Board Seam Improvement

Abstract

A system and method for installing drywall and other sheet materials faster, and with seam improvement providing a better fit, durability, and finish. It employs a device having a wide rear stud connecting member and a narrower front retaining member in parallel orientation with one another. A middle rib separates the two members, creating two open-ended tracks extending away from the rib that may be angled relative to one another 180-degrees or less for differing applications, including butt joints, inside corners, and outside corners, with 180-degree angulation employed in butt joints. Stud connecting members preferably have lateral pre-formed fastener holes, and after being mounted to a stud/joist or other structural support, when edge portions of different sheets are inserted into each track, the sheets cover/conceal from view all fasteners used to mount the device. Thus, fewer coats of mud are required in seams, reducing sheet installation labor and material expense.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This patent application relates in subject matter to U.S. provisional patent application 62/531,688, having the title of Drywall Seam Improvement, which was filed on Jul. 12, 2017, by the same applicant/inventor herein. As a result of the overlapping subject matter involved, the applicant/inventor herein respectfully requests that domestic priority be granted for his currently filed and now pending U.S. utility patent application herein based upon his earlier-filed, and still co-pending, U.S. provisional patent application 62/531,688.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to construction materials, specifically to improvements in the installation of drywall, cement board, and other sheet materials, wherein use of the present invention system and method in association with the corners/seams created between two adjacent pieces of sheet material saves material and labor expense, and provides a better fit and finish, particularly in interior corner applications where present invention use makes a true corner instead of the flimsy corners often created with tape that can be more easily damaged after completion by user contact and influences such as truss uplift. In addition, the present invention device improves the look and fit of a seam made between two adjacently positioned pieces of drywall or other sheet material in both corner and non-corner applications. For brevity in the ensuing invention description, the word “drywall” will most commonly be used when installation of sheet materials is mentioned, and such use should generally be considered as having no intent of limitation unless otherwise specifically noted. Thus, when use of the term “drywall” is encountered hereinafter in this invention disclosure, it is intended that all products generally/commonly referred to as “drywall” in the construction industry be included within its definition, and also any construction sheet products that may be referred to by other names, such as but not limited to plasterboard, wallboard, plaster wallboard, Sheetrock®, gypsum panel, gypsum board, magnesia board, Hardie® board, and other cement board products. Furthermore, and unless specifically noted otherwise, when the word “stud” is used in the ensuing invention description, it is intended for it to also be interpreted broadly herein, to include ceiling joists and other sheet material framing and support.

The drywall supporting/retaining device used as a part of the most preferred embodiment of the present invention is rigid and preferably made from thin extruded plastic material in 8-foot and 10-foot lengths (respectively for use with 4-foot by 8-foot and 4-foot by 10-foot sheet materials), but should not be considered as limited thereto. Accordingly, if 12-foot or 14-foot ceilings were specified for an interior space, or other dimensions were necessary for custom work, the present invention devices (used with sheet materials for creating inside corners, outside corners, and butt joints) could be manufactured with increased/decreased length dimensions corresponding to that of the sheet materials selected for such use. The most preferred embodiments of the present invention sheet material seam/corner improvement device also comprise a rear stud connecting member and a front retaining member, both in substantially parallel orientation with one another and having the same length dimension. However, the width dimension of the rear stud connecting member and a front retaining member are typically different, with the front retaining member having a width dimension less than that of the rear stud connecting member to provide added convenience to installers while fastening the rear stud connecting members to the supportive pre-installed construction framing situated behind them. The two present invention front and rear members together create two opposing tracks extending outwardly in different directions from a single middle rib, which for most contemplated applications is centered so that both tracks have the same length dimension, but such centered positioning is not considered critical, or a limiting feature of present invention structure. The tracks are open-ended at their distal ends (the one of their opposed ends remote from the middle rib), allowing each to receive the edge portion of a different sheet of drywall, cement board, or other construction material produced in sheet form, thus creating a strong seam/joint between the edges of the two adjacent inserted sheets that subsequently requires less finishing work to produce a finished/paintable surface than would be otherwise needed when prior installation materials and methods are used.

For 90-degree corner installations, and creating other angulations between adjacent walls that are greater or less than 90-degrees, the rear stud connecting member and front retaining member of the present invention each have a similar bend at the middle rib that allows both of its tracks to maintain a uniform width dimension substantially throughout their entire length. The bend is set during manufacture and it is not intended for the bend to be altered by an installer. It is contemplated for the present invention rear stud connecting member to always have a width dimension greater than that of the front retaining member for easy and unobstructed insertion of fasteners through the lateral portions of the rear stud connecting member and into a supporting stud, joist, or other framing support positioned behind it, which would otherwise be more difficult to secure in a desired position of use if the front retaining member and the rear stud connecting member had similar width dimensions. It is also preferred for present invention rear stud connecting members to comprise pre-formed fastener holes therein, which may have an elongated configuration for easy installation adjustment during connection of the present invention device to a stud/joist positioned behind it, however, no holes are contemplated for the front retaining member which has no intended fastener connection to the inserted sheet material, a stud/joist, or other framing/support structure. In addition, when the edge portions of two different pieces of sheet material are each inserted into a different one of the two opposed tracks in each present invention device, the sheet material after such insertion hides/conceals all view of fasteners and fastener holes associated with the joint/seam that have been used to secure the present invention rear stud connection device to a pre-installed stud/joist (or other framing/support) behind it, saving the labor and material expense that would otherwise be needed in prior art sheet material installations to cover exposed fasteners and/or fastener holes with tape and multiple finishing coats of compound/mud. A better looking fit and finish is provided by present invention use, the corners it creates are strong and true, seams created by the present invention system and method are more durable than seams made via prior art systems and methods, and since no tape and less finishing coats of compound/mud are required during use of the present invention for sheet material installation, drying time and labor/material costs are also reduced.

Description of the Related Art

There is nothing known at this time in the construction industry that is similar in form or function to the present invention sheet material seam/joint improvement device and method. The present invention provides two predetermined opposed tracks extending away from one another at a middle rib, and into which the edge portions of two different sheets of drywall (or other sheet material) are inserted to create a strong joint/seam between them. Use of the present invention also results in a more readily paintable surface and a better/stronger seam/joint between the edges of two adjacent pieces of drywall, or other sheet material (whether used in a corner or non-corner application) than could be achieved by prior art methods and devices.

Opposing present invention tracks can be provided at any angle relative one another that is needed to create a desired inside or outside corner, or the present invention tracks can have end-to-end alignment with a 180-degree angle at the middle rib so that the sheet edge portions inserted therein become aligned in the same plane to create a butt joint. Prior to present invention use, drywall tape has been widely used to secure seams between adjacent sheets of drywall. However, present invention use requires no tape, and once it is secured to a stud/joist and in its preferred position of use, and the edge portions of two different drywall sheets are installed into its opposing tracks, the fasteners used to secure the rear stud connecting member to a stud or joist become hidden/concealed behind the inserted sheet material, avoiding the application of tape and the multiple finishing coats of drywall compound/mud over all visible fasteners and fastener holes to obtain a smooth/finished surface that is ready for painting. Instead, only a small amount of compound/mud is needed as a thin skim coat over the small ridge-like interface created between the front retaining member and the portion of the sheet material's front surface immediately adjacent to it. The small thickness dimension needed in the present invention front retaining member is responsible in large part for the reduced material and labor expense associated with present invention use. Also, once the material sheets are inserted into the opposed present invention tracks, compound/mud can be immediately applied, avoiding construction delay. Thus, while prior art drywall installation methods might require up to three days of combined tape and compound/mud application and drying time (and potentially more) to create properly prepared paintable sheet material seams/joints, when the present invention system and method are used for creating the seams/joists needed between adjacent construction material sheets, the created wall and/or ceiling might be paintable the next day. In addition, present invention use provides a better looking fit and finish, with approximately half the material and labor expense.

While the present invention provides benefits and advantages in butt joint creation, it is also advantageously used in the creation of inside and outside corners to replace the slow-drying corners which are commonly created by prior art drywall installation methods. Experienced installers with special tools, such as a corner knife, are often preferred to achieve faster/better corner construction, and more particularly the use of an installer with enough skill to place compound/mud on one side of a corner and not nick or otherwise disturb the previously-applied compound/mud on other side of the same corner. Prior art seam finishing, in both corner and non-corner applications, when two pieces of drywall are each secured via fasteners directly to a stud/joist or other support structure, can involve multiple steps, including the application of a base coat of compound/mud to cover fasteners, fastener holes, and the seam created between adjacent edges of the drywall or other material sheets. Drywall tape is then typically pressed into the base coat with fingers, followed by a step of wiping off excess compound/mud, and application of a first finishing coat of compound/mud over the tape with a 5-inch knife. Following suitable drying time, a second finishing coat of compound/mud is applied over the first coat with an 8-inch knife, and perhaps a third finishing coat of compound/mud is then applied with a 10-inch knife. After overnight drying, sanding can take place, if needed prior to painting.

Inside corners prepared using prior art devices and methods typically require more work and skill than butt joints, since they dry slower, compound/mud applications are needed on both sides of the corner from ceiling to floor, and precautions must be taken during application of compound/mud in both sides of a corner to avoid nicking the opposing side. A base coat can be applied in a corner via prior art devices and methods using a 5-inch knife, with drywall tape then embedded into the base coat, and a layer of compound/mud applied over the tape with an 8-inch knife. Any exposed fasteners or depressions are also filled, and excess compound/mud thereafter is scraped off. A layer of paper tape having a center crease can also be set into the corner, followed by a top/finishing coat of compound/mud applied with an 8-inch knife. After sufficient drying time, a second finishing coat of compound/mud is applied to both sides of the corner, typically with a 10-inch knife, and even a third finishing coat of compound/mud may also be applied, with sanding after drying (where needed to improve the appearance of the surface prior to the application of paint).

Again, the prior art systems and methods include more steps than are needed during present invention drywall installation, which requires no tape, less compound/mud, and provides a better fit and finish, with less work and material expense. Also, truss uplift may pull drywall tape out of a corner, something which is avoided by present invention use. U.S. Pat. No. 9,388,582 B1 to Smythe (Jul. 12, 2016) discloses a re-moistenable adhesive-coated drywall corner trim piece having an elongated semi-rigid core piece with right and left flanges. The core piece can be bent and re-bent to any angle any number of times, and the Smythe flanges also curve inward slightly for perfect bonding. In addition, its flanges are thinner than the center portion so that it can be wet mudded simultaneously on both sides without an intermediate drying step. However, although the Smythe invention appears to be an improvement for corner construction, the present invention has structure and function patentably distinct from the Smythe corner trim, and there is nothing in the construction industry known at this time to have the same structure, or provide all of the benefits and advantages of the present invention.

SUMMARY OF THE INVENTION

The primary objective of the present invention seam/joint improvement devices is to save time and money during the installation of drywall and other sheet material, with stronger and improved seams/joints created between adjacent pieces of sheet material, and also providing a better looking fit and finish (in both corner and non-corner applications). A further object of this invention is to provide drywall seams/joints that are more durable, and created with less work than anything on the market today. It is also an objective of this invention to provide a drywall seam installation device that can be made from extruded ABS plastic and provide an appropriate amount of rigidity for effective and expedient drywall seam/joint installation. A further object of this invention is to provide a drywall seam installation device made with pre-formed/elongated fastener holes that allow quick/easy on-site adjustment and expedited installations. It is also an objective of this invention to provide a drywall seam installation device adapted for inside corner, outside corner, and non-corner installations through a simple difference in track angulation (created during manufacture) at its middle rib.

The present invention seam/joint improvement devices each have two predetermined tracks into which the edge portions of two pieces of drywall, or other construction sheet material that are in need of adjacent positioning, become inserted and remain after the constructed wall or ceiling is completed. The extruded plastic material from which the most preferred embodiment of the present invention is made also typically provides a readily paintable surface requiring minimal preparation time prior to painting. Previously, drywall tape has been widely used to secure adjacent drywall seams. However, present invention use requires no tape, and once its rear stud connecting member is secured to construction framing (a stud/joist, or other structural support) and is situated in its preferred position of use, the edge portions of two different drywall sheets can be easily installed (one each into its opposing tracks), after which the seam/joint between sheets becomes covered/hidden/concealed by the present invention's front retaining member, ready to finish, and avoids the need for an installer to cover any fastener holes with compound/mud. Also, only a thin skim coat of compound/mud is needed to cover the small ridge present between the front retaining member and the adjacent surface of the inserted sheet material, which can be dry and ready for painting in a shorter period of time than when seams/joints are prepared using drywall tape. After sheet material insertion into the opposing present invention tracks, drywall compound can be immediately applied (with a reduced amount of drywall compound needed than is required by prior art drywall installation methods), which in addition to reduced material expense provides a labor-saving advantage. Furthermore, present invention use provides a better looking fit and finish, and the seams/joints it helps to create are stronger and more durable than those created with drywall tape. Three different present invention embodiments are typically contemplated for use as a part of the same ceiling and/or wall construction, with their tracks at differing angles (180-degrees or less) to accommodate inside corners, outside corners, and non-corner joints/seams, with the 180-degree angulation used for non-corner (butt joint) installations. Although the majority of inside and outside corner installations are contemplated to have 90-degree angulation, it is considered within the scope of the present invention system and method to provide other angulations less than 180-degrees to create special/custom construction features. The combination of advantages and benefits provided by the present invention disclosed herein are not currently known in the prior art.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an end view of a first embodiment of the most preferred present invention drywall seam installation device adapted for creating a seam/joint between adjacent pieces of sheet material used in an outside corner, with broken lines, associated arrowheads, and measurement markings identifying preferred dimensions thereof, which may be produced from extruded plastic materials in 8-foot and 10-foot lengths, although not limited thereto.

FIG. 2 is an end view of a second embodiment of the most preferred present invention drywall seam installation device adapted for creating a seam/joint between adjacent pieces of sheet material used in an inside corner, with broken lines, associated arrowheads, and measurement markings identifying preferred dimensions thereof, which may be produced from extruded plastic materials in 8-foot and 10-foot lengths, although not limited thereto.

FIG. 3 is an end view of a third embodiment of the most preferred present invention drywall seam installation device adapted for adjacent pieces of sheet material aligned in an edge-to-edge orientation to create a butt joint, with broken lines, associated arrowheads, and measurement markings identifying preferred dimensions thereof, which may be produced from extruded plastic materials in 8-foot and 10-foot lengths, although not limited thereto.

FIG. 4 is a perspective view of the second embodiment shown in FIG. 2 and adapted for creating a seam/joint between adjacent pieces of sheet material used in an inside corner, with the rear stud connecting member having a plurality of elongated fastener holes positioned near each of its opposed lateral edge portions, and the rear edge of the rear stud connecting member having a thin break line marking to indicate extruded manufacture with optional variation in length dimension of the manufactured device for differing applications.

FIG. 5 is a perspective view of the first embodiment shown in FIG. 1 and adapted for creating a seam/joint between adjacent pieces of sheet material used in an outside corner, with the rear stud connecting member having a plurality of elongated fastener holes positioned near each of its opposed lateral edge portions, and the rear edges of the rear stud connecting member and the front retaining member each having a thin break line marking to indicate extruded manufacture with optional variation in length dimension of the manufactured device for differing applications.

FIG. 6 is a perspective view of the third embodiment shown in FIG. 3 and adapted for adjacent pieces of sheet material aligned in an edge-to-edge orientation to form a butt joint, with the rear stud connecting member having a plurality of elongated fastener holes positioned near each of its opposed lateral edge portions, and the rear edge of the rear stud connecting member having a thin break line marking to indicate extruded manufacture with optional variation in length dimension of the manufactured device for differing applications.

FIG. 7 is a schematic view from the top of the first, second, and third preferred embodiments of the present invention drywall seam installation device (shown in FIGS. 1-6) in use with five drywall sheets to form one outside corner, two inside corners, and one butt joint where the edge portions of adjacent sheets are aligned in a planar, edge-to-edge orientation.

DETAILED DESCRIPTION OF THE INVENTION

The present invention devices (first preferred embodiment 1, second preferred embodiment 1′, third preferred embodiment 1″, and other embodiments not specifically illustrated herein) each have two predetermined tracks 5A and 5B into which the edge portions of adjacent sheets of drywall or other sheet material (marked with the number 7 in FIG. 7) become inserted to form a seam or joint. Tracks 5A and 5B are formed between a rear stud connecting member 2 and a front retaining member 4, which is substantially parallel to the rear stud connecting member 2 in the same track (5A or 5B). Tracks 5A and 5B are also separated by a middle rib 3. The differences between present invention embodiments (1′, 1, 1″ and other) is the angulation at middle rib 3 used between tracks 5A and 5B, which determines whether they are used to create an inside corner, outside corner, or a butt joint (end-to-end, planar alignment of adjacent material sheets 7). It is contemplated for tracks 5A and 5B to be slightly larger in width dimension than the thickness of the sheet material 7 intended for insertion therein (often 0.5-inches, ⅜-inches, ⅝-inches, or ¾-inches, but not limited thereto). However, the width dimension of tracks 5A and 5B must allow easy insertion of the edge portion of a construction material sheet 7 therein, while at the same time providing a snug fit around the edge portion once it becomes inserted into track 5A or 5B. While “drywall” is a sheet material/product that is mentioned repeatedly in this invention disclosure, other construction materials and methods for their installation are also considered to be within the scope of the present invention, such as but not limited to use with Hardie® board, Sheetrock® plasterboard, wallboard, plaster wallboard, gypsum panels, gypsum board, magnesia board, and other cement board products, and unless otherwise specifically noted, use of the term “drywall” should be interpreted as including all of these products and their equivalents. Furthermore, and unless specifically noted otherwise, when the word “stud” is used in the invention description herein, it should also be interpreted broadly, to include ceiling joists and other structural supports.

When a wall or ceiling is to be created using the present invention (or a joint/connection between a wall and ceiling), and structural support for that wall or ceiling is framed (using studs, joists, or other structural supports), following installer measurement to determine the number and positioning of outside corners, insider corners, and butt joints needed, an appropriate number/length of present invention embodiments (1, 1′, 1″, or other) are selected, and then secured to the structural supports provided via fasteners 8 inserted at spaced intervals through the opposed lateral portions of each rear stud connecting member 2 and along its full 8-foot, 10-foot, or other length dimension (the lateral portions thereof defined as the part extending beyond the distal ends of tracks 5A and 5B). For maximum savings of material and labor expense during use of the present invention embodiments (1, 1′, 1″, or other) to construct an interior wall, the sheet material 7 used is selected with a length dimension equivalent to that of the intended height of the interior ceiling to be created above it (such as, 4-foot by 8-foot sheets where an 8-foot ceiling is contemplated, and 4-foot by 10-foot sheets and 4-foot by 12-foot sheets, respectively, where 10-foot or 12-foot ceilings are contemplated, with each sheet 7 hung vertically (and typically ceiling-to-floor with its lower end secured by a baseboard). Thus, most typical interior wall construction with use of present invention embodiments (1, 1′, 1″, or other) contemplates only vertically-extending corner joints/seams and vertically-extending butt joints. A plurality of pre-formed fastener holes (elongated or not) may be included as a part of each of the opposed lateral edge portions of the rear stud connecting members 2 of present invention embodiments (1, 1′, 1″, or other), and such pre-formed fastener holes may be in the form of the elongated holes 6 (shown in FIGS. 4-6), which provide easy adjustment during fastener 8 installation through rear stud connecting members 2 and into a supporting stud or joist (not shown) located behind them. While it is preferred, but not critical, for pre-formed fastener holes to be a part of the present invention, it is not contemplated for the size, number, configuration, orientation, and/or spaced-apart positioning of fastener holes in present invention rear stud connecting members 2 to be limited to that shown for the elongated holes 6 illustrated in FIGS. 4-6, but instead be appropriate to the intended application (common or custom).

Once all of the rear stud connecting members 2 are secured to the construction framing (not shown) and in their intended positions of use, they are used in pair to install sheet material, such as drywall sheet 7), wherein one side edge portion of a drywall sheet 7 is inserted into a track (5A or 5B) of a first present invention device (1, 1′, 1″, or other), and following a small/brief installer flexing of the drywall sheet 7, its opposing side edge portion is eased into the opposed track (5A or 5B) of a second present invention device (1, 1′, 1″, or other) that is aligned substantially parallel to the first present invention device (1, 1′, 1″, or other) and attached to a different stud/joist or other structural support in the pre-installed structural framing. Once the slight flexing of drywall sheet 7 is released and the drywall sheet 7 snaps into its two supporting tracks (5A, 5B) now engaging its side edge portions, one of the opposed ends of sheet 7 can then be inserted into the track (5A or 5B) of a third present invention device (1, 1′, 1″, or other) attached substantially perpendicular to the tracks (5A or 5B) of the first and second present invention devices (1, 1′, 1″, or other) that currently support its two side edges. For example, if sheet 7 is used for wall construction, once snapped into side support it can be slid in an upward direction and its top edge inserted into the downwardly-facing track (5A or 5B) of the third (and horizontally-extending) present invention device (such as embodiment 1′) to create a ceiling-to-wall joint.

When the final/desired/installed positioning of drywall sheet 7 is achieved, fasteners 8 are then used to secure the drywall sheet 7 in multiple places to every stud (or other structural support) positioned behind it. Thus, a vertically-oriented 4-foot by 8-foot drywall sheet 7 used in wall construction may have present invention devices (1, 1′, 1″, or other) supporting three of its edges (top edge and two adjacent side edges), with the bottom edge thereof secured to studs (or other structural support) as a part of baseboard installation. Additional drywall sheets 7 are then inserted into the opposed tracks 5A and 5B of other paired present invention devices (1, 1′, 1″, or other) previously secured to the framing supports (studs/joists/other) at the outset of the installation process, completing the wall or ceiling surface, which next is prepared for painting or other finishing work. Each drywall sheet 7 inserted into tracks 5A and 5B hides/conceals the fasteners 8 and fastener holes 6 (or other) associated with rear stud connecting members 2 (now positioned behind it), and only a thin skim coat of compound/mud is then required to cover the small interface/ridge existing between the distal edge of front retaining member 4 and the inserted drywall sheet 7 to initially prepare the completed wall or ceiling surface for painting (without an drywall tape). Middle rib 3 strengthens the connection between rear stud connecting member 2 and front retaining member 4 in each newly formed seam/joint created by the present invention where the edge portions of adjacent drywall sheets 7 are hidden/concealed between rear stud connecting member 2 and front retaining member 4, and not subject to forces that might otherwise loosen fasteners 8 directly securing drywall sheets 7 to studs/joists, such as but not limited to truss uplift. One final coat of compound/mud applied over the thin skim coat (used to cover the previously noted slightly raised interface between the present invention's front retaining member 4 and the adjacent surface of an inserted material sheet 7) will then finish the preparation of drywall sheets 7 for painting in approximately half of the time, and with half of the compound/mud, than would otherwise be required for prior art drywall sheet 7 installations (particularly those using drywall tape to cover seams/joints between adjacent drywall sheets 7 and the fasteners 8 directly connecting adjacent drywall sheets 7 to studs, joists, or other structural supports).

Thus, present invention use for seams/joints between adjacent pieces of sheet material 7 requires no tape, and creates stronger and truer corners, with a better fit and finish, than can be obtained by using known prior art that incorporates drywall tape. The skim coat of drywall compound/mud (not shown), and the final coat used with the present invention devices (1′, 1, 1″, and other) can be immediately applied over part or all of its front retaining member 4, without having to wait for drywall tape embedded into compound/mud to dry, and the needed later applications of at least two subsequent finishing coats of compound/mud over the seam, advantageously reducing material and labor expense. Although drywall screws (see number 8 in FIG. 7) are typically used to secure present invention drywall seam installation devices (1′, 1, 1″, and other) to a stud (not shown), other fastening options (not shown) are also considered within the scope of the present invention, including nailing and stapling (but not limited thereto). The advantages and benefits provided by the present invention devices (1′, 1, 1″, or other) disclosed herein are not currently known in the prior art. Furthermore, while relative dimensions for the present invention devices 1′, 1, and 1″ are shown in FIGS. 1-3, they should not be considered as limiting, although thinner front retaining members 4 increase the reduction of material and labor expense over prior art systems and methods, and are preferred.

FIGS. 1 and 5 show the first embodiment 1 of the most preferred present invention drywall seam installation device adapted for outside corners. Outside corners are particularly vulnerable to impact and contact with furniture and other objects during use, and first embodiment 1 makes them more durable and resistant to such impact/contact. FIGS. 1 and 5 show first embodiment 1 having a wide rear stud connecting member 2 forming an approximate 90-degree angle at its connection with one of the opposing ends of a middle rib 3. FIGS. 1 and 5 also show a narrower front retaining member 4 connected to the second opposing end of middle rib 3, and forming an approximate 90-degree angle at its connection with middle rib 3, wherein rear stud connecting member 2 and front retaining member 4 are situated so that they are substantially parallel to one another throughout their opposed positioning to form drywall receiving track 5A on one side of middle rib 3, and drywall receiving track 5B on the opposing side of middle rib 3.

When first embodiment 1 is used where two sheets 7 of drywall meet to form an outside corner, rear stud connecting member 2 is fastened in the corner to the studs in pre-installed framing using its elongated holes 6. Use of drywall screws 8 are preferred between the opposed lateral portions of rear stud connecting member 2 and studs on opposing sides of the corner. While drywall screw 8 connection is preferred, nailed or other connection of rear stud connecting member 2 and corner studs is also considered to be within the scope of the present invention. What makes first embodiment 1 unique is that once the edge portions of two different drywall sheets 7 are installed into the tracks 5A and 5B to form a an outside corner joint/seam, the fasteners 8 used to connect rear stud connecting member 2 to the corner studs (not shown) become hidden/concealed behind the inserted drywall sheets 7, and are not exposed as in a typical corner prepared according to prior art methods and materials (and in need of extra finishing steps, including the use of drywall tape). First embodiment 1 makes drywall corners more rigid, which gives them a better looking fit and finish. The first embodiment 1 shown in FIGS. 1 and 5 also requires about half of the drywall compound/mud (not shown), cutting the drying process in half and saving labor expense.

Although not limited thereto, first embodiment 1 may be made from extruded ABS plastic. The length dimension of middle rib 3 approximates the thickness dimension of drywall sheet 7 intended for use with first embodiment 1, and should allow a close fit of the intended drywall sheets 7 in tracks 5A and 5B, but also allow the intended drywall sheets 7 to move easily into tracks 5A and 5B during installation. Although FIGS. 1 and 5 show rear stud connecting member 2 having a width dimension about twice that of front retaining member 4, it is not intended for such dimension or proportion to be a limitation. However, rear stud connecting member 2 does need to have a width dimension greater than that of front retaining member 4 for most convenient fastening of the rear stud connecting member 2 to corner studs, the difference in relative dimension between members 2 and 4 being determined by considerations such as, but not limited to, functionality for the intended application, installer convenience, and material expense incurred. In addition, the approximate 90-degree angle shown for first embodiment 1 in FIGS. 1 and 5 should not be considered as limiting, and other angulation for rear stud connecting member 2 and front retaining member 4 are also considered to be within the scope of the present invention. The broken lines, associated arrowheads, and measurement markings in FIG. 1 identify preferred component dimensions and proportions in the most preferred embodiment of the present invention.

In the end view of FIG. 1, the width dimensions of tracks 5A and 5B are shown to be 0.5-inches (but would be different for use with sheet material 7 having a thickness dimension other than 0.5-inches, such as ⅜-inches, ⅝-inches, ¾-inches, or other thickness contemplated in a needed application), the length dimension of each track (5A and 5B) is identified as 1.5-inches, the length dimension of middle rib 3 is identified as about ⅝-inches, and the overall width dimension of rear stud connecting member 2 (combined dimension on both sides of middle rib 3) is shown to be about 6-inches. In addition, the end view of FIG. 1 shows middle rib 3 centered relative to front retaining member 4 and the rear stud connecting member 2 (preferred, although not critical), the front retaining member 4 having a width dimension of about 4-inches (combined dimension on both sides of middle rib 3), and the preferred thickness of the ABS plastic forming rear stud connecting member 2, front retaining member 4, and middle rib 3 to each be about 0.0625-inches.

For maximum labor and material expense reduction over prior art seam/joint installation methods, it is important for front retaining member 4 to have sufficient strength to fulfill its intended function, yet not be overly thick to require more than the application of a skim coat to hide the ridge-like interface between the edge of the front retaining member 4 with the inserted sheet material 7. Although not marked in FIG. 1 or 5, and not limited thereto, elongated holes 6 may each have length and width dimensions respectively of approximately 1.25-inches and 0.25-inches, and may be spaced apart from one another a distance of approximately 2-inches. Furthermore, the thin break line markings on the rear edges of the rear stud connecting member 2 and the front retaining member 4 indicate that the extruded manufacture the first embodiment 1 of the most preferred present may allow its production in a variety of length dimensions, such as but not limited to, 8-feet, 10-feet, 12-feet, and 14-feet.

FIGS. 2 and 4 show the second embodiment 1′ of the most preferred present invention drywall seam installation device adapted for inside corners, including an inside corner connecting adjacent material sheets 7 to form a ceiling/wall joint. FIGS. 2 and 4 show second embodiment 1′ having a wider rear stud connecting member 2 forming an approximate 90-degree angle at its connection with one of the opposing ends of a middle rib 3. FIGS. 2 and 4 also show a narrower front retaining member 4 connected to the second opposing end of middle rib 3, and forming an approximate 90-degree angle at its connection with middle rib 3, wherein rear stud connecting member 2 and front retaining member 4 are situated so that they are substantially parallel to one another throughout their opposed positioning to form drywall receiving track 5A on one side of middle rib 3, as are the opposing ends of rear stud connecting member 2 and front retaining member 4 during their formation of drywall receiving track 5B on the opposing side of middle rib 3.

When second embodiment 1′ is used where two sheets 7 of drywall meet to form an inside corner, rear stud connecting member 2 is fastened in the corner to the studs in pre-installed framing using its elongated holes 6. Use of drywall screws 8 are preferred between the opposed lateral portions of rear stud connecting member 2 and the studs on opposing sides of the corner, but not limited thereto. What makes second embodiment 1′ unique is that once the edge portions of two different drywall sheets 7 are installed into the tracks 5A and 5B to form an inside corner joint/seam, the fasteners 8 used to connect rear stud connecting member 2 to the corner studs become hidden/concealed behind the inserted drywall sheets 7, and are not exposed as in a typical corner prepared according to prior art methods and materials (and in need of further finishing steps, including the use of drywall tape). Second embodiment 1′ makes drywall corners more rigid, which give them a better looking fit and finish. The second embodiment 1′ shown in FIGS. 2 and 4 also requires about half of the drywall compound/mud, cutting the drying process in half and saving labor expense.

Although not limited thereto, second embodiment 1′ may be made from extruded ABS plastic. The length dimension of middle rib 3 in FIGS. 2 and 4 also approximates the thickness dimension of drywall sheets 7 intended for use with second embodiment 1′, and should allow a close fit of the intended drywall sheets 7 in tracks 5A and 5B, but also allow the intended drywall sheets 7 to move easily into tracks 5A and 5B during installation. Although FIGS. 2 and 4 show rear stud connecting member 2 having a width dimension about twice as long as that of front retaining member 4, it is not intended for such dimension or proportion to be a limitation. However, rear stud connecting member 2 does need to have a width dimension greater than that of front retaining member 4 for most convenient fastening of rear stud connecting member 2 to corner studs, the difference in relative dimension between members 2 and 4 being determined by considerations such as, but not limited to, functionality for the intended application, installer convenience, and material expense incurred. In addition, the approximate 90-degree angle shown for second embodiment 1′ in FIGS. 2 and 4 should not be considered as limiting, and other angles for rear stud connecting member 2 and front retaining member 4 are also considered to be within the scope of the present invention.

In the end view of FIG. 2, the width dimension of tracks 5A and 5B are shown to be 0.5-inches (but would be different for use with sheet material 7 having a thickness dimension other than 0.5-inches, such as ⅜-inches, ⅝-inches, ¾-inches, or other thickness contemplated in a needed application), the length dimension of each track (5A and 5B) is identified as 1.5-inches, the length dimension of middle rib 3 is identified as about ⅝-inches, and the overall width dimension of rear stud connecting member 2 (combined dimension on both sides of middle rib 3) is shown to be about 7.2-inches. In addition, the end view of FIG. 2 shows middle rib 3 centered relative to front retaining member 4 and the rear stud connecting member 2 (preferred, but not critical), the front retaining member 4 having a width dimension of about 3-inches (combined dimension on both sides of middle rib 3), and the preferred thickness of the ABS plastic forming rear stud connecting member 2, front retaining member 4, and middle rib 3 to each be about 0.0625-inches.

For maximum labor and material expense reduction over prior art seam/joint installation methods, it is important for front retaining member 4 to have sufficient strength to fulfill its intended function, yet not be overly thick to require more than the application of a skim coat to hide the ridge-like interface between the edge of the front retaining member 4 with the inserted sheet material 7. Although not marked in FIG. 2 or 4, and not limited thereto, elongated holes 6 may each have length and width dimensions respectively of approximately 1.25-inches and 0.25-inches, and may be spaced apart from one another a distance of approximately 2-inches. Furthermore, the thin break line marking on the rear edges of the rear stud connecting member 2 indicate that the extruded manufacture the second embodiment 1′ of the most preferred present may allow its production in a variety of length dimensions, such as, but not limited to, 8-feet, 10-feet, 12-feet, and 14-feet.

FIGS. 3 and 6 show a third embodiment 1″ of the most preferred present invention drywall seam installation device adapted for use where two drywall sheets 7 are aligned in a planar, edge-to-edge orientation (also referred to as a butt joint). FIGS. 3 and 6 show third embodiment 1″ having a wide rear stud connecting member 2 forming an approximate 180-degree angle at its connection with one of the opposing ends of a middle rib 3. FIGS. 3 and 6 also show a narrower front retaining member 4 connected to the second opposing end of middle rib 3, and forming an approximate 180-degree angle at its connection with middle rib 3, wherein rear stud connecting member 2 and front retaining member 4 are situated so that they are substantially parallel to one another throughout their opposed positioning to form drywall receiving track 5A on one side of middle rib 3, as are the opposing ends of rear stud connecting member 2 and front retaining member 4 during their formation of drywall receiving track 5B on the opposing side of middle rib 3.

When third embodiment 1″ is used where two sheets 7 of drywall meet in a non-corner application, rear stud connecting member 2 is fastened to a supporting stud in pre-installed framing behind it (not shown) using elongated holes 6. Use of drywall screws 8 are preferred between the opposed lateral portions of the rear stud connecting member 2 of third embodiment 1″ and supporting stud situated behind it, but not limited thereto. What makes third embodiment 1″ unique is that once the edge portions of two different drywall sheets 7 are installed into the tracks 5A and 5B to form a butt joint, the fasteners 8 used to connect rear stud connecting member 2 to the supporting studs become hidden/concealed behind the inserted drywall sheet 7, and are not exposed as in typical drywall installation according to prior art methods and materials. Third embodiment 1″ makes drywall seams/joints more rigid, which give them a better looking fit and finish. The third embodiment 1″ shown in FIGS. 3 and 6 also requires about half of the drywall compound/mud to finish the drywall sheets for painting, cutting the drying process in half and saving labor cost.

Although not limited thereto, third embodiment 1″ may be made from extruded ABS plastic. The length dimension of middle rib 3 in FIGS. 3 and 6 also approximate the thickness dimension of drywall sheets 7 intended for use with third embodiment 1″, and should allow a close fit of the intended drywall sheets 7 in tracks 5A and 5B, but also allow the intended drywall sheets 7 to move easily into tracks 5A and 5B during installation. Although FIGS. 3 and 6 show rear stud connecting member 2 having a width dimension about twice that of front retaining member 4, it is not intended for such dimension or proportion to be a limitation. However, rear stud connecting member 2 does need to have a width dimension greater than that of front retaining member 4 for most convenient fastening of rear stud connecting member 2 to a supporting stud/joist, the difference in relative dimension between members 2 and 4 being determined by considerations such as, but not limited to, functionality for the intended application, installer convenience, and material expense incurred.

In the end view of FIG. 3, the width dimension of tracks 5A and 5B are shown to be approximately 0.5-inches (but would be different for use with sheet material 7 having a thickness dimension other than 0.5-inches, such as ⅜-inches, ⅝-inches, ¾-inches, or other thickness contemplated in a needed application), the length dimension of each track (5A and 5B) is identified as 1.5-inches, the length dimension of middle rib 3 is identified as about 0.5-inches, and the overall width dimension of rear stud connecting member 2 (combined dimension on both sides of middle rib 3) is shown to be about 6-inches. In addition, the end view of FIG. 3 shows middle rib 3 centered relative to front retaining member 4 and the rear stud connecting member 2 (preferred, but not critical), the front retaining member 4 having a width dimension of about 3-inches (combined dimension on both sides of middle rib 3), and the preferred thickness of the ABS plastic forming stud connecting member 2, front retaining member 4, and middle rib 3 to each be about 0.0625-inches.

For maximum labor and material expense reduction over prior art seam/joint installation methods, it is important for front retaining member 4 to have sufficient strength to fulfill its intended function, yet not be overly thick to require more than the application of a skim coat to hide the small ridge-like interface between the edge of the front retaining member 4 with the inserted sheet material 7. Although not marked in FIG. 3 or 6, and not limited thereto, elongated holes 6 may each have length and width dimensions respectively of about 1.25-inches and 0.25-inches, and may be spaced apart from one another a distance of approximately 2-inches. Furthermore, the thin break line marking on the rear edge of the rear stud connecting member 2 indicates that the extruded manufacture the third embodiment 1″ of the most preferred present may allow its production in a variety of length dimensions, such as, but not limited to, 8-feet, 10-feet, 12-feet, and 14-feet.

FIG. 7 is a schematic view of one first preferred embodiment 1 device of the present invention, two second preferred embodiments 1′ devices, and one third preferred embodiment 1″ device, all in use with five drywall sheets 7 and multiple fasteners 8 to form one outside corner (using first preferred embodiment 1), two inside corners (using second preferred embodiments 1′), and one connection of adjacent sheets 7 aligned in an edge-to-edge, planar orientation as a butt joint (using third preferred embodiment 1″). FIG. 7 also identifies a front interior space 9 in front of the material sheets 7 and a rear space 10 behind the material sheets 7 where studs/joists would be positioned (but which are not shown in FIG. 7 to focus on illustrating the relation between sheet material 7 and the present invention devices (1′, 1, and 1″). Therefore, in FIG. 7 one sees the pointed ends of fasteners 8 in the rear space 10 hidden behind material sheets 7 that would otherwise each be inserted into a stud/joist (or other pre-installed support structure). To create the seam/joint between each pair of adjacent drywall sheets 7, FIG. 7 shows a different present invention device (1′, 1, and 1″) receiving the edge portion of the first drywall sheet 7 in a pair within one of its two tracks (5A or 5B), and also receiving the edge portion of the second drywall sheet 7 in the same pair within the opposing one of its two tracks (5B or 5A), which are identified by number in FIGS. 1-6 and formed between the front retaining members 4 and an adjacent and corresponding rear stud connecting member 2. FIG. 7 also shows the narrower front retaining member 4 in each present invention embodiment (1′, 1, or 1″) directed at least in part toward the front interior space identified by the number 9, and the wider rear stud connecting member 2 of the same present invention embodiment (1′, 1, or 1″) used with fasteners 8 inserted through it and directed at least in part toward the rear space identified by the number 10 where supportive pre-installed construction framing would be positioned, if shown. Rear space 10 is also where central portions of material sheets 7 (typically from ceiling-to-floor) are securely fixed to each piece of construction framing behind it (no seam/joint is created) that has not been otherwise used with present invention seam improvement devices (1′, 1, 1″, or other).

As can be further seen in the top schematic view of FIG. 7, fasteners 8 used for creating seams/joints with present invention embodiments (1′, 1, 1″, and other) are not inserted through any drywall sheet 7 or through front retaining member 4, leaving no fasteners 8 or fastener holes 6 exposed for viewing from a vantage point in the front interior space designated by the number 9 (which later would require the application of tape and wallboard compound/mud prior to prepare it for painting). However, the top view of FIG. 7 does not include the perspective needed to show the presence of extra fasteners 8 that would be used across the front surface of the central portions of the material sheets 7 to secure them from ceiling-to-floor (at pre-determined spaced-apart distances) to all studs/joists (or other pre-installed support structure) present behind the central portions of the material sheets 7 (as is also a common step in current drywall installations). Thus, if studs/joists are framed every 16-inches and the material sheets 7 used have a 48-inch width dimension, two studs/joists would become positioned centrally behind each material sheet 7 that would require a coat of compound/mud over all fasteners 8 used at those two locations to secure the directly overlaying central portions of the material sheet 7 to the two studs/joists present spaced apart from one another by approximately 16-inches. Again, this extra compound/mud is only used over fasteners connecting central portions of the material sheet 7 to a stud/joist, and not to any seams/joints created between two adjacently-positioned material sheets 7 form through use of a present invention device (1′, 1, 1″, and other). This top/finishing coat of compound/mud over centrally positioned fasteners 8 on each material sheet 7 must be applied by an installer in addition to the thin skim coat of compound/mud (which does not take long to dry) that is required to cover the small interface/ridge existing between the distal edge of front retaining member 4 and the adjacent surface of the drywall sheet 7 positioned in the track (5A or 5B in part defined by front retaining member 4). The lesser amount of drywall tape and compound/mud used in the joints/seams created with present invention devices (1′, 1, 1″, or other), in addition to the labor saved in applying it, are important advantages of the present invention.

While the written description of the invention herein is intended to enable one of ordinary skill to make and use its best mode, it should also be appreciated that the invention disclosure only provides examples of specific embodiments and methods, and many variations, combinations, and equivalents also exist which are not specifically mentioned. The present invention should therefore not be considered as limited to the above-described embodiments, methods, and examples, but instead encompassing all embodiments and methods identified in the accompanying claims, and also within the scope and spirit of the invention.

Claims

1. A device for securing and finishing a seam between first and second sheets of construction material, comprising:

a rear structural support connecting member having first and second lateral edge portions of a rear width connecting to form an angle;

a front sheet retaining member having third and fourth lateral edge portions of a front width connecting to form the angle, the first and third lateral edge portions being parallel, the second and fourth lateral edge portions being parallel, the front width being less than the rear width; and

a middle rib connecting between the rear structural support connecting member and the front sheet retaining member so as to form first and second open-ended tracks extending outward from the middle rib at the angle;

wherein the front sheet retaining member hides the seam between the first and second sheets when the first sheet is inserted in the first open-ended track and the second sheet is inserted in the second open-ended track.

2. The device of claim 1, each of the first and second open-ended tracks having a width sized to facilitate entry of the corresponding sheet therein.

3. The device of claim 1, each of the rear structural support connecting member, the front sheet retaining member, and the middle rib being formed from extruded manufacture.

4. The device of claim 1, each of the rear structural support connecting member, the front sheet retaining member, and the middle rib being formed from plastic materials.

5. The device of claim 4, plastic materials comprising ABS plastic.

6. The device of claim 1,

the angle being 180 degrees;

wherein the first and second sheets, when inserted into the corresponding open-ended tracks, form a butt joint.

7. The device of claim 1,

the angle being less than 180 degrees; and

the middle rib connecting an inside surface of the rear structural support connecting member and an outside surface of the front sheet retaining member such that each open-ended track is formed from the inside surface of the rear structural support connecting member and the outside surface of the front sheet retaining member;

wherein the first and second sheets, when inserted into the corresponding open-ended tracks, form an inside corner seam.

8. The device of claim 1,

the angle being less than 180 degrees; and

the middle rib connecting an outside surface of the rear structural support connecting member and an inside surface of the front sheet retaining member such that each open-ended track is formed from the outside surface of the rear structural support connecting member and the inside surface of the front sheet retaining member;

wherein the first and second sheets, when inserted into the corresponding open-ended tracks, form an outside corner seam.

9. The device of claim 1,

the rear structural support connecting member having a plurality of fastener holes;

wherein each of the first and second sheets, when inserted in the corresponding open-ended track, hides a plurality of fasteners affixing the device, via the fastener holes, to construction framing.

10. The device of claim 9, at least one of the fastener holes having an elongated configuration.

11. A method for securing and finishing a seam between first and second sheets of construction material, comprising:

affixing one of the devices of claim 1 to construction framing;

inserting the first sheet into the first open-ended track of the device; and

inserting the second sheet into the second open-ended track of the device.

12-20. (canceled)

21. The method of claim 11, affixing the device comprising fastening the rear structural support connecting member of the device to the construction framing.

22. The method of claim 21, wherein affixing further includes aligning the device such that the first and second sheets, after the steps of inserting, form a butt joint.

23. The method of claim 21, wherein affixing further includes aligning the device such that the first and second sheets, after the steps of inserting, form an inside corner seam.

24. The method of claim 21, wherein affixing further includes aligning the device such that the first and second sheets, after the steps of inserting, form an outside corner seam.

25. The method of claim 21, further including sizing the device to match a length of the first and second sheets.

26. A method for continuously manufacturing a device to secure and finish a seam between first and second sheets of construction material, comprising extruding a material to form:

(a) a rear structural support connecting member having first and second lateral edge portions of a rear width connecting to form an angle;

(b) a front sheet retaining member having third and fourth lateral edge portions of a front width connecting to form the angle, the first and third lateral edge portions being parallel, the second and fourth lateral edge portions being parallel, the front width being less than the rear width; and

(c) a middle rib connecting between the rear structural support connecting member and the front sheet retaining member so as to form first and second open-ended tracks extending outward from the middle rib at the angle;

wherein the front sheet retaining member hides the seam between the first and second sheets when the first sheet is inserted in the first open-ended track and the second sheet is inserted in the second open-ended track.

27. The method of claim 26, further comprising forming a plurality of fastener holes in the rear structural support connecting member.

28. The method of claim 27, further comprising sizing the extruded material to match a length of the first and second sheets.