WO2025109414A1

WO2025109414A1 - Apparatus and method for baseboard system used in drywall construction

Info

Publication number: WO2025109414A1
Application number: PCT/IB2024/060935
Authority: WO
Inventors: Jerry Moscovitch
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-11-23
Filing date: 2024-11-05
Publication date: 2025-05-30
Anticipated expiration: 2026-05-23

Abstract

A drywall board system is set forth that includes a horizontal reveal component having a square-edge drywall edge component and a portion that extends downwardly from behind the drywall edge component, creating the back of the reveal. The downwardly extending component has a 90 degree bend at one end to receive a groove in the baseboard and to align the baseboard without having to measure. A truncated stud is positioned inside the stud wall and in between studs for locating the horizontal reveal component, such that the entire drywall board system is independent of how the wall has been framed. The truncated stud includes an attachment mechanism for mounting the horizontal reveal component. The attachment mechanism is configured to move vertically for properly positioning the horizontal reveal component to accommodate different baseboard heights.

Description

APPARATUS AND METHOD FOR BASEBOARD SYSTEM USED IN DRYWALL CONSTRUCTION

FIELD OF THE INVENTION

[0001] The present invention is directed to a drywall apparatus and method, and more particularly to a system for creating a reveal between a baseboard and a drywall board, and method for doing same.

BACKGROUND OF THE INVENTION

[0002] One aesthetically pleasing way to construct a wall using gypsum or drywall board involves leaving a gap, referred to as a “reveal”, between a baseboard and a drywall board above it. The gap can be in the form of a groove, usually 1/2” or 5/8” wide and a depth equal to that of the drywall, either 1/2” or 5/8” deep. The groove sits between the baseboard, which is positioned with one end on the floor and an upper end facing the groove. The drywall and the baseboard sit on the same plane to create the effect that the wall is one plane from ceiling to floor, but with a consistent groove running all around the horizontal wall and where a door is located, running vertically up the door jam and over the top of the door, back down and continuing horizontally around the room.

[0003] A typical method for creating a drywall reveal is to use a “Z-shaped” moulding that is glued and/or stapled on the front side of the drywall at the bottom thereof. In position, the moulding gives a clean line along the bottom front edge of the board. The moulding is also designed to cover the back of the recessed space or gap between the drywall board and the baseboard to hide studs or insulation behind the board.

[0004] Drywall compound is added to the moulding and drywall board, and then feathered out. After drying, the compound is sanded. This process of applying compound, feathering and sanding may be repeated several times with the aim of achieving a transition from the raised surface of the moulding to the surface of the drywall that is seamless so as to be invisible when the wall is painted.

[0005] There are several problems with such prior art reveal systems. They require highly skilled installers and tapers to do the work, and the work is relatively time consuming and costly.

SUMMARY OF THE INVENTION

[0006] It is an aspect of the present invention to provide a drywall board system for use in conjunction with a baseboard. The drywall board system includes a horizontal reveal component that, in embodiments, comprises a square-edge drywall component and a portion that extends downwardly from behind the drywall component, creating the back of the reveal. In some embodiments, the downwardly extending component functions as a baseboard locator having a 90 degree bend at one end to receive a groove in the baseboard and to align the baseboard without having to measure.

[0007] A truncated stud can be positioned inside the stud wall and between studs for locating the drywall component relative to the baseboard, such that the entire drywall board system is independent of how the wall has been framed. An attachment mechanism is included for mounting the drywall component and is configured to move vertically for properly positioning the drywall component to accommodate different baseboard heights.

[0008] Since all of the components are knockdown and modular and shipped as finished components in packages, the system and method set forth herein permit the installation of a drywall reveal using only a single installer.

[0009] These together with other aspects and advantages which will be subsequently apparent, reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 shows a front perspective view of a baseboard system according to principles of the present invention.

[0011] FIG. 2 shows a rear perspective view of the baseboard system of FIG. 1 .

[0012] FIG. 3 shows a truncated stud, according to an embodiment.

[0013] FIG. 4 shows the truncated stud of FIG. 2 mounted to the bottom plate of a stud wall.

[0014] FIG. 5 shows a ball and screw height adjustment mechanism of the truncated stud of FIG. 2.

[0015] FIG. 6 shows a rear view of the truncated stud of FIG. 2.

[0016] FIG. 7 shows a square-edge drywall edge component being mounted to the truncated stud of FIG. 2.

[0017] FIG. 8 shows a pair of square-edge drywall edge components vertically positioned using a pair of truncated studs of FIG. 2.

[0018] FIG. 9 shows a locating tool for use with the truncated stud of FIG. 2.

[0019] FIG. 10 shows a pair of square-edge drywall edge components vertically positioned using a pair of truncated studs of FIG. 2, relative to a baseboard.

[0020] FIG. 11 shows a top-front perspective view of a baseboard system for creating an inside corner with reveal, according to an embodiment.

[0021] FIG. 12 is a bottom front view of a detail of a horizontal reveal component attached to and extending downwardly from the backing of the drywall edge component to create the reveal, according to the embodiment of FIG. 11.

[0022] FIG. 13 shows a baseboard system having a groove to permit rotation for creating inside and outside comers.

[0023] FIG. 14 shows a baseboard system configured as an inside corner, as shown in FIG. 11.

[0024] FIG. 15 shows a baseboard system configured as an outside corner.

[0025] FIG. 16 shows an embodiment wherein a horizontal reveal component is attached to the back face of a framing drywall liner where the side edges of the horizontal reveal component extend beyond the drywall edge component at the groove so that the edges are flush at an inner corner.

[0026] FIG. 17 shows an embodiment wherein the groove extends beyond side edges of the horizontal reveal component so that the edges are flush at an outer corner.

[0027] FIG. 18 shows a top-front perspective view of a baseboard system for creating an outside corner with reveal, according to an embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] FIG. 1 shows a baseboard system 100 according to an embodiment, comprising a horizontal reveal component having a square-edge drywall edge component 120 and a baseboard locatorl 10 attached to the backing of a drywall board 120 that extends downwardly from behind the drywall edge component for locating a baseboard 130, as set forth in US patent application number 18/242120 filed September 5, 2023, and entitled APPARATUS AND METHOD FOR BASEBOARD SYSTEM USED IN DRYWALL CONSTRUCTION, the contents of which are incorporated herein by reference,

[0029] Baseboard locatorl 10 includes a 90 degree rib 140 that projects horizontally and is dimensioned to fit into a corresponding groove in the baseboard 130. Baseboard locator 110 can be made of metal or other suitable material and can be of various dimensions. Similarly, the groove in baseboard 130 can be located at any suitable location along the height of baseboard. The groove can, for example, be made using a saw blade or a router, or can be molded, and can have small radii comers.

[0030] In embodiments, square-edge drywall edge component 120 can be produced in a factory with baseboard locatorl 10 attached with adhesive to the back thereof. In embodiments, each square-edge drywall edge component 120 is 12” x 8 foot and shipped with an attached baseboard locator 110 as a 4-pack in a box. This finished square edge product can then be delivered to a jobsite for installation and thereafter painted, with no finishing required.

[0031] The system described in US patent application number 18/242120 may be installed by two workers who place two pencil marks on either end of the horizontal square-edge drywall edge component 120. The marks are usually in the centre of the vertical dimension of the piece. The workers hold the piece with the marks against the studs at the correct height from the floor for assembly. A laser is then set to the marks and runs all around the room. The laser line is then used as a guide to set all the other drywall pieces for fastening against the wall.

[0032] In order to accommodate different baseboard heights for different projects (e.g. a 2” or 2.5” or 3” or 3.5” etc.), the square-edge drywall edge component 120 must be vertically adjustable vertically to accommodate variations in baseboard height.

[0033] Therefore, according to an embodiment of the invention, a truncated stud 300 is provided, as shown in FIG. 3, for locating the square-edge drywall edge component 120 relative to the height of baseboard 130 and independently of the wall framing. As shown in FIG. 4, truncated stud 300 can be positioned inside the stud wall and in between studs and affixed to the bottom plate of the stud wall via screws though flanges 310 on opposite sides. As a result, installation of a reveal between the baseboard and drywall board may be accomplished by a single installer rather than two installers and the requirement for highly skilled tradespersons, as in the prior art.

[0034] Truncated stud 300 include at least one face plate 320 that slides within grooves 330 on each side of truncated stud 300, for vertically positioning square-edge drywall edge component 120 relative to the height of baseboard 130. The vertical movement of plate 320 is controlled by a ball and screw height adjustment mechanism 340, shown in FIG. 5, to allow plate 320 to move within grooves 330 under control of an adjustment knob 350 at the top of the truncated stud 300, as shown in FIG. 6. Ball and screw height adjustment mechanism 340 includes a block 345 for receiving the at least one face and preferably two plates 320 at either of its end faces. Face plates 320 are attached to block 345 which move within grooves 330 when ball screw 348 is rotated.

[0035] In embodiments, truncated stud 300 and face plate 320 can be produced as moulded plastic. The dimensions of truncated stud 300 can be about 12” height x 3.5” x 3.5”. Ball and screw height adjustment mechanism 340 can be fabricated from plastic so as to be cost effective.

[0036] As shown in FIG. 3, an attachment mechanism 360 is provided, which can in embodiments comprise a pair of pins or screws mounted in block 345 to which squareedge drywall edge component 120 can be mounted, as shown in FIG. 7, and secured by a locating tool 370, as shown in FIG. 8. [0037] In embodiments, the two pins can be spaced 1” apart and each 1/2" off the centre line of the plate 320 so as to project into the space of the room. For 1/2” drywall, the pin projects 3/8” into the drywall and for 5/8” drywall it projects 1/2” into the drywall. System 100 can work as a setup for one wall or if two rooms are back to back, then back to back plates 320 can be mounted to the truncated stud 300 so that two rooms can be done at one time, substantially reducing labour cost.

[0038] A hole of 1/2’ diameter can be machined into each drywall square edge component 120 at either end of the 8 foot part. Each hole 380 can be inset 1/2” from each end and on the centreline of the height of the square edge component 120. The pins that extend from truncated stud 300 can be 3/16” diameter so the square edge component can be easily docked in position at either end. Locating tool 370 preferably has a handle and two elastomeric bosses, as shown in FIG. 9 for insertion into the holes 380 of the drywall and docks and onto the pins extending from the truncated stud 300, for final positioning of each square edge drywall component, as shown in FIG. 10.

[0039] Once positioned and aligned, the drywall square edge components 120 can be screwed into the studs and the handles removed for the next installation. The truncated studs 300 remain in the wall.

[0040] Although not shown, the face of each truncated stud 300 can include markings for 2”, 2.5”, 3” etc., for initial height adjustment based on a known baseboard size. Then, a laser can be set to the exact height for the baseboard and reveal system 100. Once the laser crosses the truncated stud 300, the installer makes a final fine height adjustment using knob 350. The installer can then adjust the height of each truncated stud 300 mounted in the wall to the laser line so as to correctly position all square-edge drywall edge components 120 around the room at one time.

[0041] Because the baseboard 130 and square edge drywall 120 are placed at floor level, an error can occur because of the optical angle of the installer’s eye versus the alignment device. Therefore, in other embodiments, additional features may be provided to simplify alignment. For example, a sound emitting diode or circuit board can be docked to the vertically adjustable plates 320 such that when the installer aligns the plates correctly with the laser, a sound is emitted, signaling that alignment has been completed.

[0042] During installation of the baseboard 130, because the floor is generally uneven, installers modify the bottom edge of the baseboard that touches the floor to reflect the ups and downs in the floor. Otherwise, the reveal cannot be a consistent dimension all around the room. To do this, the installers raise the top edge of the baseboard 130 until it touches the bottom of square edge drywall 120, so that they know they are 5/8" or 1/2" (depending on reveal groove dimension) above the floor. The installers then set a compass to 5/8" and run one point along the floor and the pencil point to scribe the bottom of the baseboard 130. Currently, the installers hold up the baseboard 130 to do this.

[0043] It is contemplated that the groove in baseboard 130 can be double cut, with the second cut being 5/8" lower than the first cut. In this way the installers can first put the baseboard 130 into position on the 90 degree edge of the baseboard locator 110 and scribe the line and modify the baseboard bottom to place it in the final position on the first cut and then nail baseboard 130 into place.

[0044] It has also been noticed that a slight rocking can occur when baseboard 130 is placed onto the baseboard locator. 110 This is because the baseboard locator 110 has a thickness, for example 1/16", which only partially engages the baseboard dimension and the rest sits directly on studs that are 1/16" further back. In another embodiment, 1/16" of the baseboard material thickness can be removed from its top edge to the first cut, so that the baseboard 110 sits completely parallel to the above drywall and not slightly tilted. This embodiment is particularly advantageous, when using stone or other materials, besides wood, for the baseboard 110.

[0045] Variations and alternatives are contemplated, as follows. A thin, e.g. 1/32” web can be included that hangs down perpendicular and abuts to the front or back face of the floor plate to align the truncated stud 300 to the wall framing. The horizontal square edge drywall 120 can be extruded in plastic instead of drywall. The baseboard locator 110 with right angle bend 140 can be extruded as an integral part of the horizontal square edge drywall 120 which has a square edge on one long edge and a tapered edge along the other long edge that is parallel. The baseboard 110 can be made with a single groove to locate in position or it can have two parallel groove cuts with the second cut 5/8" below the first groove cut, as discussed above. The baseboard 110 can also have its thickness reduced above the first groove cut to the top edge of the baseboard.

[0046] FIG. 11 is a top-front perspective view of a baseboard system 400 for creating an inside corner with reveal, according to an alternative embodiment, comprising a squareedge drywall edge component 420 and a horizontal reveal component 430 attached to and extending downwardly from the backing of the drywall edge component 420 to create a reveal. A stud 440 is located at both comers of a room to hold the horizontal reveal component 430 and the square-edge drywall edge component 420 that extends to the next corner so as to create an inside corner of the room.

[0047] FIG. 12 is a bottom front view of a detail of horizontal reveal component 430 attached to and extending downwardly from the backing of the drywall edge component 420 to create the reveal, according to the embodiment of FIG. 11.

[0048] Drywall edge component 420 includes gypsum material 450, a finishing drywall liner 460 on a finishing side, and a framing drywall liner 470 on a framing side. The finishing drywall liner 460 has an internal (or slurry) side, which during manufacture of the gypsum board is in contact with gypsum slurry, and an external side, which can be painted, wallpapered, etc. Likewise, the framing drywall liner 470 has an internal (or slurry) side, which during manufacture of the gypsum board is in contact with gypsum slurry, and an external side, which is in contact with the framing stud 440 when installed.

[0049] The external side of the finishing drywall liner 460 is typically exposed to an observer inside a room. As mentioned above, the external side can be finished with paint or wallpaper, for example. The external side of the framing drywall liner 470 is typically unexposed to an observer inside a room. As mentioned above, the external side of the framing drywall liner 470 faces and is in contact with framing structures, such as wood or metal studs 440 or joists. [0050] As shown in FIG. 13, the gypsum material 450 is divided by a substantially V- shaped groove 480 into two segments on either side of the groove. The finishing drywall liner 460 connects the two segments while the groove 480 functions as an axis about which the two segments can rotate to form an inner corner 490, as shown in FIG. 14 or an outer corner 500, as shown in FIG. 15.

[0051] The finishing drywall liner 460 can have a maximum width at the groove 480 that is at least 40 thousands of an inch when the first gypsum-containing segment 450 is spread apart as much as possible while not tearing the drywall liner 460. In one embodiment, the width is 52 thousands of an inch.

[0052] As indicated above, the groove 480 is substantially V-shaped in cross section. As used herein, the term “substantially V-shaped” describes not only shapes where the two legs of the V meet at a point, but also blunted shapes in which the two legs of the “V” do not meet at a point, but instead are joined by a flat. The term “substantially V-shaped” also includes shapes where the legs of the V are not perfectly straight, but bowed slightly.

[0053] FIG. 16 shows the horizontal reveal component 430 attached to the framing drywall liner 470 on the back face of the drywall adding about .06" in thickness. Alternatively, a .06" recess can be machined into the drywall so that the horizontal reveal component 430 sits flush, although doing so requires removing part of the paper liner 470 which can weaken the horizontal reveal component 430.

[0054] As shown in FIG. 16, the side edges 510 of horizontal reveal component 430 extend beyond the drywall edge component 420 at groove 480 so that the edges 510 are flush at the inner corner 490, as shown in FIG. 12.

[0055] FIG. 17 shows an embodiment wherein groove 480 extends beyond side edges 510 of horizontal reveal component 430 so that the edges 510 are flush at the outer corner 500, as shown in FIG. 18.

[0056] The embodiments of FIGS. 16 and 17 can use a metal reveal component 430, where the edges 510 metal are positioned differently for inside and outside comers, in order to close any gap at the comers once the unit is installed,

[0057] In the embodiment of FIGS. 1 - 10, the 90 degree rib 140 stiffens the baseboard locator 110 against any bending or wowing that can result from the studs not being perfectly aligned so as to create a gap between the straight baseboard 130 and the slightly bowed reveal. This can result in a dark shadow that can be filled with compound whereas the 90 degree rib strengthens the reveal considerably and so as to prevent such .The many features and advantages of the invention are apparent from the detailed specification and, thus, it is intended by the appended claims to cover all such features and advantages of the invention that fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

CLAIMS What is claimed is:

1 . A system for installing drywall to create a reveal in a wall that extends from a floor and that is supported by wall studs, comprising: a truncated stud between the wall studs for receiving a drywall component having a baseboard locator for connection to a baseboard component, and an attachment mechanism for mounting and vertically positioning the drywall component relative to the baseboard component, the attachment mechanism being configured to move vertically for positioning the drywall component above the baseboard component to accommodate different baseboard heights.

2. The system of claim 1 , wherein the truncated stud includes flanges on opposite sides for receiving screws to secure the truncated stud to a bottom plate of the wall studs.

3. The system of claim 1 , wherein the truncated stud includes at least one face plate that slides within grooves on opposite sides thereof for vertically positioning the drywall component.

4. The system of claim 3, further including a ball and screw height adjustment mechanism for vertical movement of the at least one face plate within the grooves under control of an adjustment knob at the top of the truncated stud.

5. The system of claim 4, comprising two face plates attached to a block which move within the grooves when the ball screw is rotated.

6. The system of claim 5, wherein the two face plates are mounted back-to-back to the truncated stud for installing drywall simultaneously in two rooms.

7. The system of claim 1 , wherein the truncated stud and at least one face plate are fabricated from moulded plastic.

8. The system of claim 1 , wherein the truncated stud is about 12” height x 3.5” width x 3.5” depth.

9. The system of claim 1 , wherein the ball and screw height adjustment mechanism is fabricated from plastic.

10. The system of claim 1 , wherein the attachment mechanism comprises a pair of pins mounted in a block to which the drywall component is mounted via a corresponding pair of holes and secured by a locating tool.

11 . The system of claim 10, wherein the pair of pins are spaced apart and off a centre line of the at least one plate to project into a room space.

12. The system of claim 10, wherein the locating tool comprises a handle and two bosses for insertion into the pair of holes in the drywall and onto the pair of pins extending from the truncated stud for final positioning of each drywall component.

13. The system of claim 1 , wherein a face of the truncated stud includes markings for initial height adjustment based on known baseboard size.

14. The system of claim 1 , wherein the baseboard locator comprises a 90-degree rib that projects downwardly and horizontally from the drywall component to form the reveal and is dimensioned to fit into a corresponding groove in the baseboard component.

15. The system of claim 1 , wherein the corresponding groove is double cut, with a first cut higher than a second cut such that an installer can first put the baseboard component into position on the 90-degree rib of the baseboard locator and then scribe a line for final placement of a bottom of the baseboard component.

16. A system for installing drywall to create a reveal in a wall that extends from a floor and that is supported by wall studs, comprising: a truncated stud between the wall studs for receiving a drywall component having a groove that functions as an axis about which two segments of the drywall component can rotate to form a corner, and a horizontal reveal component, an attachment mechanism for mounting and vertically positioning the drywall component relative to the horizontal reveal component, the attachment mechanism being configured to move vertically for positioning the drywall component above the baseboard component to accommodate different baseboard heights, and wherein side edges of the horizontal reveal component are positioned relative to the groove so that the edges are flush at the corner.

17. The system of claim 16, wherein the side edges of the horizontal reveal component extend beyond the drywall edge component at the groove so that the side edges are flush at an inner corner.

18. The system of claim 16, wherein the groove extends beyond the side edges of the horizontal reveal component so that the side edges are flush at an outer corner.