DRYWALL CORNER TOOL

Abstract

Disclosed is an adjustable drywall corner tool. The adjustable drywall corner tool includes a compound receiver and an adjustable compound supply. The compound receiver is disposed on a back side of a first plate and a second plate. The first plate and second plate is adjustably coupled to one another and adjustable to accommodate an angle of an outside corner of a wall. The compound receiver is shaped to receive a drywall compound. The adjustable compound supply is coupled in fluid communication with the compound receiver to receive the drywall compound from the compound receiver and flexibly deliver the drywall compound to a front side of the first plate and the second plate.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/599,524 entitled “DRYWALL CORNER TOOL” and filed on 15 Dec. 2017 for Tom Nuttall, which is incorporated herein by reference.

FIELD

This invention relates to drywall installation and more specifically to a drywall corner construction.

BACKGROUND

Drywall installation is a common stage of residential and commercial construction. Traditionally, drywall installation includes cutting drywall board to fit to a frame or surface, securing the drywall board in place, and applying a joint compound (also known as mud or mastic) to joints between sections of drywall board and in places where screws or other securing hardware may need to be hidden. The joint compound is then sanded or otherwise smoothed to prepare for paint or some other surface treatment.

SUMMARY

Disclosed is a drywall corner tool. The drywall corner tool includes a first portion, a second portion, and at least one compound port. The first portion includes an induction structure, a blade, and a distribution channel. The induction structure is on a first edge of a first surface of the first portion. The blade is positioned along a second edge of the first surface. The second edge is located opposite the first edge. The distribution channel is substantially between the induction structure and the blade. The distribution channel includes a recess in the first surface of the first portion. The second portion includes a second surface coupled to the first portion to form an angle less than 180° with the first surface of the first portion. The second surface includes a second blade and a second distribution channel mirroring the blade and distribution channel of the first portion. The at least one compound port is disposed in or between at least one of the first portion or the second portion to allow compound to pass through.

Also disclosed herein is an adjustable drywall corner tool. The adjustable drywall corner tool includes a compound receiver and an adjustable compound supply. The compound receiver is disposed on a back side of a first plate and a second plate. The first plate and second plate is adjustably coupled to one another and adjustable to accommodate an angle of an outside corner of a wall. The compound receiver is shaped to receive a drywall compound. The adjustable compound supply is coupled in fluid communication with the compound receiver to receive the drywall compound from the compound receiver and flexibly deliver the drywall compound to a front side of the first plate and the second plate.

Also disclosed herein is a method. The method includes applying a first layer of compound to a corner. The method also includes applying a corner bead to the first layer of compound on the corner with a second layer of compound simultaneously applied and smoothed onto the corner bead.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention, and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1A is a perspective view illustrating one embodiment of a drywall corner tool;

FIG. 1B is a perspective view illustrating the drywall corner tool of FIG. 1A;

FIG. 2 is a perspective view illustrating another embodiment of a drywall corner tool;

FIG. 3 is a perspective view illustrating one embodiment of a dry wall corner system;

FIG. 4 is a perspective view illustrating one embodiment of a back side of an adjustable dry wall corner tool;

FIG. 5 is a perspective view illustrating one embodiment of a crowning bar of an adjustable dry wall corner tool;

FIG. 6 is a perspective view illustrating one embodiment of a front side of an adjustable dry wall corner tool;

FIG. 7 is a perspective view illustrating another embodiment of an adjustable dry wall corner tool; and

FIG. 8 is a flowchart illustrating one embodiment of a method of using a drywall corner tool.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.

In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “upward,” “downward,” “horizontal,” “vertical,” “left,” “right,” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise.

Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

As used herein, the phrase “at least one of” or “one or more”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

The flowcharts included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding blocks shown.

These features and advantages of the embodiments will become more fully apparent from the following description and appended claims, or may be learned by the practice of embodiments as set forth hereinafter. As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, apparatus, and/or method.

The schematic flowchart diagrams and/or schematic block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of apparatuses, systems, and methods according to various embodiments of the present invention. In this regard, each block in the schematic flowchart diagrams and/or schematic block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions of the program code for implementing the specified logical function(s).

It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more blocks, or portions thereof, of the illustrated Figures.

Although various arrow types and line types may be employed in the flowchart and/or block diagrams, they are understood not to limit the scope of the corresponding embodiments. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the depicted embodiment. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted embodiment. It will also be noted that each block of the block diagrams and/or flowchart diagrams, and combinations of blocks in the block diagrams and/or flowchart diagrams, can be implemented by special purpose hardware that perform the specified functions or acts.

Some of the embodiments described herein pertain to drywall corner tool for applying a drywall compound (such as mud, mastic, or other material or mix of materials) to an outside corner or adjustably to an inside corner or wall section. As used herein, the term “outside corner” applies to a convex corner of an interior or exterior portion of a building or structure and “inside corner applied to a concave corner of an interior or exterior portion of a building or structure. In some embodiments, the drywall corner tool provides a tool to apply a corner bead to a corner having a first layer of compound applied. The drywall corner tool may also be used to apply the first layer of compound to the corner.

The drywall corner tool places the corner bead on the first layer of compound and, in the same pass, applies a second layer of compound and smooths the second layer of compound onto the corner bead. After a single pass of the drywall tool, the corner bead is positioned on the first layer of compound and the second layer of compound is applied and smoothed over the corner bead.

FIG. 1A is a perspective view illustrating one embodiment of a drywall corner tool 100. The illustrated embodiment includes a first portion 102 and a second portion 104.

In some embodiments, some or all of the drywall corner tool 100 is fixed relative to the rest of the drywall corner tool 100. In some embodiments, some or all of the first portion 102 is flexibly connected to some or all of the second portion 104. For example, a component of the first portion 102 carrying the blades 110 may be flexible relative the rest of the first portion 102 and the second portion 104.

In some embodiments, a flexible connection between the first portion 102 and the second portion 104 includes a hinge or other connection. In other embodiments, the flexible connection includes a force mechanism such as a spring, piston, magnet, or other mechanism capable of exerting a force. In some embodiments, the force mechanism applies a force to at least one of the first portion 102 and the second portion 104 towards a relative position or orientation between the first portion 102 and the second portion 104. Embodiments of the force mechanism are illustrated and described in greater detail below with reference to FIG. 1B.

In some embodiments, the first portion 102 and the second portion 104 having corresponding first and second surfaces that are oriented relative to one another to form a vertex having a non-zero angle. In some embodiments, the non-zero angle is less than 90°. In other embodiments, the non/zero angle is equal to or greater than 90° and less than 180°. In some embodiments, the first portion 102 and the second portion 104 close against each other in the resting position or can be closed in a storage positon. In some embodiments, the first portion 102 and the second portion 104 close in a clam-shell manner.

In the illustrated embodiment of the drywall corner tool 100, the first portion 102 and the second portion 104 are coupled to form a joint that is linear. In other embodiments, the first portion 102 and the second portion 104 form a joint that is non-linear. In some embodiments, a curved joining of the first portion 102 and the second portion 104 facilitates use of the drywall corner tool 100 on a rounded drywall corner or in conjunction with a rounded corner bead. Additional structure may be added to accommodate non-linear corners, as described below with respect to FIG. 2.

In some embodiments, the first portion 102 and the second portion 104 include a compound port 106, distribution channels 108, blades 110, and structures 112. In the illustrated embodiment, the compound port 106 is centrally located at the vertex between the first portion 102 and the second portion 104. In some embodiments, the compound port 106 facilitates introduction of drywall joint compound into the drywall corner tool 100. In the illustrated embodiment, the compound port 106 is round in geometry. In other embodiments, the compound port 106 has another geometry.

In some embodiments, the compound port 106 is a straight through hole in the drywall corner tool 100 that is devoid of any obstructions. In other embodiments, the compound port 106 includes a curved portion, a diverting portion, or other structure to affect the flow of compound passing through the compound port 106.

For example, the compound port 106 may include a diverter within the compound port 106 to divert compound into one or more distribution channels 108 near or in fluid communication with the compound port 106. In another example, the compound port 106 may include a screen to prevent unmixed clumps of compound from passing into the drywall corner tool 100. In another example, the compound port 106 may include a mixing element to further mix the compound as it is injected into the drywall corner tool 100.

In the illustrated embodiment, the distribution channels 108 are in fluid communication with the compound port 106 to facilitate flow of the compound from the compound port 106 across the first portion 102 and the second portion 104 of the drywall corner tool 100. In the illustrated embodiment, the distribution channels 108 have a geometry that is angled away from the compound port 106. In some embodiments, the angle in the distribution channels 108 facilitates movement of the compound away from the compound port 106 during movement of the drywall corner tool 100 on a drywall corner.

For example, if the drywall corner tool 100 is drawn along a corner, the compound passing through the compound port 106 will experience shearing forces in the angle direction. With the angle in the distribution channels 108, the shearing forces may tend to move the compound away from the compound port 106 along the angle across the first portion 102 and the second portion 104. In some embodiments, the spreading of the compound in this manner provides more efficient and uniform coverage of compound during a pass of the drywall corner tool 100.

In the illustrated embodiment, the drywall corner tool 100 also includes blades 110. In some embodiments, the blades 110 provide structure for smoothing the compound applied by the drywall corner tool 100. In other embodiments, the blades 110 are arranged to remove excess compound from the working surface. In the illustrated embodiment, the blades 110 are arranged on the separate ends of the first portion 102 and the second portion 104 as well as the shared edge opposite one or more induction structures 112 in the illustrated embodiment of the drywall corner tool 100.

In some embodiments, the blades 110 are made of the same material as the corresponding first portion 102 or second portion 104. In other embodiments, the blades 110 include separate materials such as, for example, metal, ceramic, stone, or other natural or synthetic materials.

In some embodiments, the shape or profile of the blades 110 is a rectangular profile. In other embodiments, the blades 110 have a rounded, triangular, or other profile. In some embodiments, the blades 110 are straight. In other embodiments, the blades 110 are convex or concave. In some embodiments, the blades 110 have a variable profile or geometry. In some embodiments, at least one of the blades 110 is different from another of the blades 110.

In the illustrated embodiment, the drywall corner tool 100 is primarily rectangular in geometry. In other embodiments, the drywall corner tool 100 includes a curved or angled geometry at one or more of the edges of the drywall corner tool 100. In some embodiments, the blades 110 follow a curved path. In some embodiments, one or both of the first portion 102 and second portion 104 includes a curved geometry at an edge of the drywall corner tool 100 distal from where the first portion 102 and the second portion 104 are joined.

In the illustrated embodiment, the drywall corner tool 100 also includes induction structures 112. In some embodiments, the induction structures 112 form a slanted region of the first portion 102 and the second portion 104 of the drywall corner tool 100.

In some embodiment, the induction structure 112 facilitate the intake and smoothing of compound previously applied to the drywall corner during a pass of the drywall corner tool 100.

For example, as the drywall corner tool 100 is passed downward along a corner, previously applied compound (from joint taping, corner treatment, or other operations) may be encountered. In some embodiments, the induction structures 112 facilitate drawing in of the compound as the drywall corner tool 100 passed over it. The newly introduced compound may be applied to the corner bead and otherwise incorporated into the compound applied during the pass of the drywall corner tool 100. In this example, the induction structures 112 prevent waste or unnecessary cleanup of extra compound.

In some embodiments, the induction structures 112 are structurally separate from the distribution channels 108. In other embodiments, the induction structures 112 and the distribution channels 108 are unified structures of the drywall corner tool 100.

FIG. 1B is a perspective view of one embodiment of the drywall corner tool 100 of FIG. 1. In the illustrated embodiment, the drywall corner tool 100 is oriented in a top-down perspective. In the illustrated embodiment, the drywall corner tool 100 includes the first portion 102 and the second portion 104. In some embodiments, the first portion 102 and the second portion 104 are fixed relative to one another. In other embodiments, the first portion 102 and the second portion 104 are moveable relative to one another.

In some embodiments, a relative position of the first portion 102 and the second portion 104 is adjustable. In some embodiments, the first portion 102 and the second portion 104 are adjustable to accommodate use of the drywall corner tool 100 on a range of corner angles.

In the illustrated embodiment, the drywall corner tool 100 includes the induction structures 112. In the illustrated embodiment, the drywall corner tool 100 includes two separate induction structure 112. In other embodiments, the drywall corner tool 100 includes a single induction structure 112 or more than two induction structures 112.

The illustrated embodiment also includes the blades 110 arranged along at least a portion of the periphery of the drywall corner tool 100 as described above. In some embodiments, the blades 100 apply pressure to a working surface in response to force applied by spring members 114. In some embodiments, the blades 110 move independent of the corresponding first portion 102 and second portion 104 of the drywall corner tool 100. In other embodiments, the blades 110 are fixed to the corresponding first portion 102 and second portion 104 of the drywall corner tool 100 and at least one of the first portion 102 and the second portion 104 is moveable relative to the other.

In the illustrated embodiment, the spring members 114 provide a return force on the blades 110 and/or the first portion 102 and the second portion 104 of the drywall corner tool 100. In some embodiments, the spring members 114 are separate spring elements uncoupled from one another. In other embodiments, the spring members 114 are a unified structure.

In the illustrated embodiment, the spring members 114 are blade springs having a structure to apply force to blades 110 and/or the first and second portions 102 and 104 of the drywall corner tool 100. In some embodiments, the spring members 114 include contours in the spring members 114 to apply a spring force to the blades 110.

In other embodiments, the spring members 114 include compression springs, tension springs, torsion springs, constant force springs, clock springs, coil springs, wave springs, or other spring elements. In some embodiments, the spring members 114 are made of metal, plastic, rubber, elastic or other materials.

In some embodiments, the spring members 114 include other force applicators that are not mechanical springs. For example, the spring members 114 may include a piston, a rubber, foam, or elastic pad, magnets, levers, etc.

In some embodiments, the force applied by the spring members 114 is sufficient to keep the blades 110 in contact with a wall corner or other work surface during use. For example, the spring members 114 may apply sufficient force to the blades 110 during a pass of the drywall corner tool 100 to maintain the blades 110 approximately in contact with the work surface to remove and/or spread joining compound on the work surface.

FIG. 2 is a perspective view illustrating another embodiment of a drywall corner tool 200. In the illustrated embodiment, the drywall corner tool 200 includes rollers 202. In some embodiments, the rollers 202 provide a support to align the drywall corner tool 200 on an outside wall corner. In some embodiments, the rollers 202 provide alignment for placing a corner bead on the outside wall corner.

In the illustrated embodiment, the rollers 202 are pinned wheels. In other embodiments, the roller 202 are raised friction surfaces. In other embodiments, the rollers 202 are bearings or spherical rollers. In the illustrated embodiments, the rollers 202 are supported on two sides. In other embodiments, the rollers 202 include a single support or more than two supports.

The illustrated embodiment of the drywall corner tool 200 includes removable blades 204. In some embodiments, the removable blades 204 include a steel or other metal. In some embodiments, the removable blades 204 include a plastic or other non-metal. In some embodiments, the removable blades 204 are secured in the drywall corner tool 200 with screws. In other embodiments, the removable blades 204 are secured by a securing mechanism. For example, the securing mechanism may include roll pins, solid pins, friction locks, magnets, snap retainers, spring locks, tongue and groove retainers, or other securing structures.

The illustrated embodiment of the drywall corner tool 200 includes a corner treatment attachment 206. In the illustrated embodiment, the corner treatment attachment 206 is a bullnose or rounded corner attachment for applying a rounded effect to an outside corner. In the illustrated embodiment, the corner treatment attachment 206 is secured to the drywall corner tool 200 near the removable blades 204. In other embodiments, the corner treatment attachment 206 is positioned opposite a central corner formed by the removable blades 206.

In some embodiments, the corner treatment attachment 206 is a flat edge to provide a chamfer effect on a wall corner. In other embodiments, the corner treatment attachment 206 applies a decorative corner. In some embodiments, the corner treatment attachment 206 is removable or swappable. In some embodiments, the corner treatment attachment 206 is attached to the drywall corner tool 200 with screws. In other embodiments, other attachment structures are used to attached the corner treatment attachment 206 to the drywall corner tool 200.

FIG. 3 is a perspective view illustrating one embodiment of a dry wall corner system 300. In the illustrated embodiment, the drywall corner tool 100 is coupled to a compound dispensing tube 302. In some embodiments, the drywall corner tool 100 attaches to an adapter 304 of the compound dispensing tube 302. In some embodiments, the adapter 304 provides a connection to secure the drywall corner tool 100 to the compound dispensing tube 302 and communicate compound from the compound dispensing tube 302 to the drywall corner tool 100.

In the illustrated embodiment, the adapter 304 is coupled to the compound dispensing tube 302 with a first coupler 306. In the illustrated embodiment, the first coupler 306 secures the adapter 304 to the compound dispensing tube 302 and facilitates removal of the adapter 304 to refill the compound dispensing tube 302. In some embodiments, the adapter 304 is separate from the drywall corner tool 100. In other embodiments, the adapter 304 is incorporated into the drywall corner tool 100.

The illustrated embodiment of the drywall corner system 300 also includes a handle 308 at an opposite end of the compound dispensing tube 302 from the drywall corner tool 100. In some embodiments, the handle 308 allows a user to apply a dispensing force to the compound dispensing tube 302 via a rod 310 which moves within the compound dispensing tube 302 to dispense compound into the drywall corner tool 100 in response to force applied at the handle 308. In the illustrated embodiment, the handle 308 and rod 310 are coupled to the compound dispensing tube 302 with a second coupler 312.

In some embodiments, the second coupler 312 is substantially similar to the first coupler 306. In other embodiments, the second coupler 312 is different from the first coupler 312. In some embodiments, the second coupler 312 can be released to facilitate refilling the compound dispensing tube 302 with compound.

While the illustrated embodiment includes a compound dispensing tube 302 coupled to the drywall corner tool 100, in other embodiments, the drywall corner tool 100 is coupled to other structures such as a handle or extendable pole.

FIG. 4 is a perspective view illustrating one embodiment of a back side of an adjustable dry wall corner tool 400. In the illustrated embodiment, the adjustable dry wall corner tool 400 includes a first plate 402 and a second plate 404. In the illustrated embodiment, the first plate 402 and the second plate 404 are connected by a hinge 406. The first and second plates 402 and 404 may be made of sheet metal, composite, or some other material having rigid structural characteristics. Additional details regarding the first and second plates 402 and 404 is provided below.

In the illustrated embodiment, the hinge 406 connecting the first and second plates 402 and 404 is a pinned hinge. In other embodiments, the hinge 406 is a flexible hinge, an interlocking hinge, a magnetic hinge, a one-way pivot hinge, a two-way pivot hinge, a rack and pinion pivot, a spring-loaded or other forced hinge, a stop hinge, or the like.

In the illustrated embodiment, the adjustable dry wall corner tool 400 includes a compound receiver 408. In some embodiments, the compound receiver 408 has a round geometry to accept a ball-style connector from a dispensing tube such as the compound dispensing tube 302 of FIG. 3. The compound receiver 408 may have another geometry. In some embodiments, the compound receiver 408 includes a securing structure 410 to secure a dispensing tube at the compound receiver 408.

In the illustrated embodiment, the compound receiver 408 is in fluid communication with an adjustable compound supply 412. In some embodiments, the adjustable compound supply 412 receives compound from the compound receiver 408. In some embodiments, the adjustable compound supply 412 includes two nesting portions which slide relative to one another in response to movement of the first plate 402 relative to the second plate 404. This facilitates adjustment of the first and second plates 402 and 404 while allowing compound to be delivered through the first and second plates 402 and 404.

In some embodiments, the adjustable compound supply 412 is self-adjusting in response to movement of the first and second plates 402 and 404 based on an angle of an inside or outside corner or other wall section to which compound is to be applied. In other embodiments, the adjustable compound supply 412 is manually adjustable to facilitate fixing of the position of the adjustable compound supply 412 based on an application.

In the illustrated embodiment, the adjustable compound supply 412 is coupled, at a first end, to the first plate 402 and, at a second end, to the second plate 404. In some embodiments, this allows the compound to travel from the compound receiver 408, through the adjustable compound supply 412, and out to each of the first and second plates 402 and 404.

In some embodiments, the adjustable compound supply 412 is made of plastic, composite, metal, or another material or combination or materials. The adjustable compound supply 412 may be removable from the adjustable dry wall corner tool 400 to facilitate maintenance, such as cleaning, or replacement.

In some embodiments, the adjustable compound supply 412 is coupled to one or more of the compound receiver 408 and the first and second plate 402 and 404 with connecting hardware. In some embodiments, the connecting hardware includes at least one of a screw, clip, pin, magnet, adhesive, or other structure. In some embodiments, the adjustable compound supply 412 itself can be disassembled. For example, the nested portions of the adjustable compound supply 412 may be separable. In another example, each portion of the adjustable compound supply 412 may be separable into halves or other divisions for cleaning or other maintenance, adjustment, or replacement.

While the adjustable compound supply 412 is shown as a nested structure, other embodiments include a flexible structure such as an elastic, jointed, or other accommodating arrangement of the adjustable compound supply 412. Additionally, while a single nesting of components is shown for the adjustable compound supply 412, multiple stages of nesting or flexure may also be incorporated.

In the illustrated embodiment, the adjustable dry wall corner tool 400 includes biasing elements 414. The illustrated embodiment of the biasing elements 414 include a spring structure. Other embodiments include a piston, magnet, or other force applicator. In some embodiments, the biasing element 414 apply a force to the first and second plates 402 and 404 to secure the first and second plates 402 and 404 in a selected arrangement relative to one another. In some embodiments, the biasing elements 414 apply a biasing force normal to the corresponding surface of the first and second plates 402 and 404.

FIG. 5 is a perspective view illustrating one embodiment of a crowning bar 416 of an adjustable dry wall corner tool 400. In the illustrated embodiment, the adjustable dry wall corner tool 400 includes the crowning bars 416. In some embodiments, one of the crowning bars 416 is coupled to the first plate 402 and another of the crowning bars 416 is coupled to the second plate 404.

In the illustrated embodiment, the crowning bars 416 are coupled to the first and second plates 402 and 404 with screws. In other embodiments, other attachment structures are used to secure the crowning bars 416 to the first and second plates 402 and 404. For example, one or more of the crowning bars 416 may be adhered to or be a unified portion of the corresponding one or more of the first and second plates 402 and 404. In some embodiments, one or more of the crowning bars 416 is removably or permanently coupled to the corresponding one or more of the first and second plates 402 and 404.

The illustrated embodiment includes a set screw 418 in each of the crowning bars 416. In some embodiments, the set screws 418 can be tightened to push the corresponding plate 402, 404 away from the corresponding crowning bar 416.

In some embodiments, the crowning bars 416 are relatively thicker than the material of the first and second plates 402 and 404. For example, if the first and second plates 402 and 404 are made of sheet metal, the sheet metal of the wing is thin compared to the material of the crowning bars 416. The two set screws 418 may clamp the crowning bar 416 to the plate 402, 404 tightly or the set screws 418 can be tightened to push the plates 402 and 404 away from the crowning bar 416 and forces the plates 402 and 404 to curve to stay tight against the frame where it is separately attached to the plates 402 and 404. This curvature in the plates 402 and 404 applies a crowing feature to the compound as it is applied to a corner in a dry wall compound application.

While the elements 418 are described as set screws, they may also be or include other structures such as levers, clamps, buttons, ratchets, or the like. In some embodiments, the elements 418 may be adjusted with a tool. In other embodiments, the elements 418 can be adjusted by hand. In some embodiments, the elements 418 are fixed.

FIG. 6 is a perspective view illustrating one embodiment of a front side of an adjustable dry wall corner tool 400. The illustrated embodiment includes a front surface 420 of the first and second plates 402 and 404. In some embodiments, the front surface 420 is a polished or rough surface. In some embodiments, the front surface 420 includes a material different from another part of the first and second plates 402 and 404.

In the illustrated embodiment, the front surface 420 includes a pair of compound outlets 422. In some embodiments, the compound outlets 422 correspond to the adjustable compound supply 412 of FIG. 4. In the illustrated embodiment, the compound outlets 422 are rectangular. In other embodiments, the compound outlets 422 are non-rectangular. In some embodiments, the geometry of the compound outlets 422 correspond to a geometry of the adjustable compound supply 412. In other embodiments, the geometry of the compound outlets 422 differs from the geometry of the adjustable compound supply 412.

In some embodiments, the compound outlets 422 have an angle, slope, lip, or other feature to facilitate delivery of compound through the compound outlets 422. In some embodiments, the compound outlets 422 are the same size. In other embodiments, the compound outlets 422 are sized differently from one another.

The illustrated embodiment also includes runners 424. In the illustrated embodiment, the runners 424 are coupled to the front surface 420 of the first and second plates 402 and 404. In some embodiments, the runners 424 cause the adjustable dry wall corner tool 400 to stand off from an application site, such as a dry wall corner, to facilitate delivery of compound to the site.

In the illustrated embodiment, the runners 424 have a wedge-shaped geometry. In other embodiments, the runners 424 have another geometry. In some embodiments, the runners 424 are similar in geometry. In other embodiments, the runners 424 are dissimilar in geometry.

In some embodiments, the runners 424 are removably coupled to the front surface 420 of the first and second plates 402 and 404. In other embodiments, the runners 424 are permanently coupled to the front surface 420.

In some embodiments, the runners 424 can be switched for runners 424 of a different geometry for a specific application. In some embodiments, the runners 424 are removable to facilitate maintenance such as cleaning or replacement of worn runners 424. The runners 424 may be metal, plastic, composite, or other materials. While the illustrated embodiment includes two runners 424 with one runner 424 on each of the first and second plates 402 and 404, fewer or more runners 424 may be included at different locations on the adjustable dry wall corner tool 400.

As illustrated in FIG. 6, the first and second plates 402 and 404 may have tabs, fins, or other structures to affect movement of the adjustable dry wall corner tool 400 or delivery and dispersion of compound.

FIG. 7 is a perspective view illustrating another embodiment of an adjustable dry wall corner tool 700. In the illustrated embodiment, the drywall corner tool 700 includes a latching linkage 702 secured with a coupling 704. The latching linkage 702 in combination with the coupling 704 may provide for one or more ranges of adjustability. For example, in the illustrated embodiment, the coupling 704 may be secured in a first position relative to the latching linkage 702 to provide a first range of motion of the first plate 402 relative to the second plate 404 of between approximately 85 degrees and 95 degrees while the coupling 704 may be secured in a second position relative to the latching linkage 702 to provide a second range of motion being between approximately 85 degrees and 160 degrees. Other ranges and relative positions may be incorporated.

The dry wall corner too 700 of FIG. 7 includes a sheet metal hinge 706. Other embodiments may include one or more piano hinges, butterfly hinges, butt hinges, flush hinges, pivot hinges, barrel hinges, spring hinges, or the like. Other hinges or combinations of hinges may be used.

FIG. 8 is a flowchart illustrating one embodiment of a method 800 of using a drywall corner tool. The illustrated embodiment of the method 800 includes, at block 802, a first layer of compound is applied to a corner. In some embodiments, the first layer of compound is applied with the drywall corner tool 100 of FIG. 1.

At block 804, the method 800 further includes applying a corner bead to the first layer of compound on the corner with a second layer of compound simultaneously applied and smoothed onto the corner bead. In some embodiments, the drywall corner tool 100 of FIGS. 1A-B or FIG. 2 is capable of simultaneously applying the corner bead, applying the second layer of compound, and smoothing the second layer of compound onto the corner bead. This efficient application structure and process provides an improvement over existing systems. The adjustability of the systems shown and described herein with respect to FIGS. 4-6 also provide an improvement of existing systems.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A drywall corner tool comprising:

a first portion comprising: an induction structure on a first edge of a first surface of the first portion; a blade positioned along a second edge of the first surface, the second edge located opposite the first edge; and a distribution channel substantially between the induction structure and the blade, the distribution channel comprising a recess in the first surface of the first portion;

a second portion comprising a second surface coupled to the first portion to form an angle less than 180° with the first surface of the first portion, the second surface comprising a second blade and a second distribution channel mirroring the blade and distribution channel of the first portion; and

at least one compound port disposed in or between at least one of the first portion or the second portion to allow compound to pass through.

2. The drywall corner tool of claim 1, wherein the first portion and the second portion are coupled via a hinge.

3. The drywall corner tool of claim 1, wherein a relative position of the first portion relative to the second portion is selectively settable.

4. The drywall corner tool of claim 1, wherein the compound port is disposed at approximately a vertex of the angle formed by the first portion and the second portion.

5. The drywall corner tool of claim 1, further comprising an adjustable compound supply.

6. The drywall corner tool of claim 5, wherein the adjustable compound supply provides a channel for compound to be supplied and allow adjustable positioning of the first portion relative to the second portion.

7. The drywall corner tool of claim 1, further comprising at least one biasing element to apply a biasing force to at least one of the first portion or the second portion.

8. The drywall corner tool of claim 1, further comprising at least one crowning bar coupled to a corresponding one of the first portion and the second portion, the crowing bar applying a force to the corresponding one of the first portion and the second portion.

9. The drywall corner tool of claim 8, wherein the force applied by the at least one crowning bar is adjustable.

10. The drywall corner tool of claim 1, further comprising a latching linkage to control a relative position of the first portion with respect to the second portion.

11. An adjustable drywall corner tool comprising:

a compound receiver disposed on a back side of a first plate and a second plate, the first plate and second plate adjustably coupled to one another and adjustable to accommodate an angle of an outside corner of a wall, the compound receiver shaped to receive a drywall compound;

an adjustable compound supply coupled in fluid communication with the compound receiver to receive the drywall compound from the compound receiver and flexibly deliver the drywall compound to a front side of the first plate and the second plate.

12. The adjustable drywall corner tool of claim 11, wherein the adjustable compound supply is configured to allow for adjustment of the first plate relative to the second plate.

13. The adjustable drywall corner tool of claim 11, further comprising one or more runners coupled to the front side of at least one of the first plate or the second plate.

14. The adjustable drywall corner tool of claim 13, wherein the one or more runners are removable.

15. The adjustable drywall corner tool of claim 11, wherein the compound receiver further comprises a securing structure to removably couple a source of compound with the compound receiver.

16. A method comprising:

applying a first layer of compound to a corner; and

applying a corner bead to the first layer of compound on the corner with a second layer of compound simultaneously applied and smoothed onto the corner bead.

17. The method of claim 16, further comprising adjusting a first plate relative to a second plate to approximate an angle of the corner.

18. The method of claim 17, further comprising adjusting a relative position of a latching linkage to displace a first plate relative to a second plate.

19. The method of claim 16, further comprising removably coupling a supply of compound to a compound receiver.

20. The method of claim 16, further comprising passing compound through an adjustable compound supply to deliver the compound to the corner.