Wallboard fastening device for fastening wallboard in an inside corner configuration

Abstract

A wall plate fastening device for fastening first and second wall plates in an inside corner configuration includes a first framing panel having a first longitudinal edge and a second framing panel having opposite second and third longitudinal edges, the second longitudinal edge being directly connected to the first longitudinal edge. A first leaf spring flange having a fourth longitudinal edge is directly connected to the third longitudinal edge, the first leaf spring flange, the first framing panel and the second framing panel forming a channel sized to receive the first wall plate. A second leaf spring flange having a fifth longitudinal edge is connected to the third longitudinal edge. The first leaf spring flange flexes against the first wall plate when the first wall plate is inserted into the channel and the second leaf spring flange flexes against the second wall plate when a back surface of the second framing panel is pressed against the second wall plate.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 63 / 266,701, filed January 12, 2022, which is incorporated by reference in its entirety. [Technical field]

[0002] The purpose of wallboard construction is to provide safe, structurally sound, durable and aesthetically pleasing wall and ceiling surfaces for commercial and residential buildings. Summary of the Invention

[0003] The present embodiments include wallboard fastening devices and methods for fastening and finishing wallboard panels in an inside corner configuration. These wallboard fastening devices advantageously provide two important functions in wallboard installation: (1) physically fastening or securing the wallboard to a framing member; and (2) finishing and sealing any gaps, joints, or seams between two adjacent wallboard panels. The present embodiments accomplish these functions while minimizing common installation errors and oversights that occur during installation and without the need for adjustment joints in continuous wall lengths of 30 feet or more. The present embodiments may be used in vertical wallboard installations where the wallboard functions as a wall, or in horizontal wallboard installations where the wall meets a ceiling. The present embodiments may be used in either parallel installations where the edges of the wallboard are parallel to the underlying framing members, or in vertical installations where the edges of the wallboard are perpendicular to the framing members. The present embodiments may be used with either tapered or non-tapered wallboard panels.

[0004] Prior art wallboard installation methods (see, for example, "Application and Finishing of Gypsum Panel Products, GA-216-2018," published by the Gypsum Association in 2018) teach that a wallboard panel is first secured to a framing member using fasteners that pass through the wallboard panel and into the framing member. At the seam or joint where two adjacent wallboard panels meet, a "joint tape" is applied over the joint and a "joint compound" or "mortar" is spread evenly or "buttered" over the joint tape to create a smooth finish that is unnoticeable relative to the rest of the wallboard surface. The joint tape and joint compound cover the heads of the fasteners that would be visible after the wallboard panel is secured to the framing member, preventing the heads of the fasteners from being visible after installation. Wallboard accessories such as trim, beads (corner beads, casing beads, etc.), and adjustment joints (expansion joints, etc.) may be used at corners or under certain other conditions. After the joint compound dries or cures, sand (or another type of smoothing) the dry areas to remove high spots and / or excess joint compound. The surface finish can be improved by applying repeated applications of joint compound and smoothing repeated applications of joint compound after they dry.

[0005] In this embodiment, the wallboard panel is secured to the framing members by continuously compressing the edge of the wallboard panel along its entire length. This advantageously increases structural strength and resistance to shear forces as compared to prior art construction methods that teach fasteners to be secured to the wallboard panel at 16 inch intervals (e.g., as required by some building codes). In fact, this embodiment does not require fasteners to penetrate visible portions of the wallboard panel, thereby eliminating the need to cover the heads of fasteners required by prior art construction methods. Furthermore, by eliminating some of the fasteners that would otherwise penetrate the wallboard in prior art construction methods, this embodiment advantageously avoids several types of construction errors (e.g., improperly installed fasteners) commonly made in prior art construction methods that can compromise the strength of the wallboard panel and its attachment to the underlying framing members. Examples of improperly installed fasteners include the wrong type of fasteners, fasteners driven deep enough that they penetrate the face paper of the wallboard panel, fasteners not installed at the required intervals (e.g., 16 inch intervals) along the edge of the wallboard panel, fasteners installed too close to the edge of the wallboard panel, and fasteners that are not long enough to fully penetrate the underlying framing members.

[0006] The present embodiment also visually covers the gap, joint, or seam between two adjacent wallboard panels, advantageously creating a "treated joint" without the application of joint tape, and avoids the time-consuming process of repeatedly applying joint compound and sanding each joint compound application. The present embodiment further improves structural strength and fire resistance by avoiding incomplete and / or improper application of joint tape and / or joint compound, which often hides underlying structural defects and voids in the joints.

[0007] The above examples of construction errors are often the result of human error, shortcuts, and / or improper training of wallboard installers (e.g., contractors, laborers). Thus, the present embodiments advantageously speed up construction by simplifying and standardizing construction, thereby reducing the number of errors and the amount of skill and training required of wallboard installers. The present embodiments also advantageously reduce waste and costs by minimizing the materials (e.g., wallboard, joint tape, joint compound) that must be replaced when construction errors occur. The present embodiments can reduce environmental hazards at the job site by eliminating or minimizing harmful airborne dust caused by repeated aggressive sanding of joint compound seams in conventional construction.

[0008] Any of the wallboard fastening device embodiments described herein can be fastened to the underlying framing members with fasteners that do not pass through areas of the wallboard panel that are visible after installation, unlike prior art installation methods. Once the wallboard panel is physically fastened by inserting its panel edge into the attached wallboard fastening device, the wallboard panel is continuously and securely fastened and sealed to the underlying framing members along the entire length of the wallboard panel without the use of any joint tape and / or joint compound (parallel application). In some implementations, additional fasteners penetrate the wallboard panel to further secure the wallboard panel to the underlying framing members. Furthermore, unlike many prior art installation methods, embodiments of the present device can be used with industry standard framing assemblies and configurations without any modifications to the standard framing assemblies.

[0009] In parallel applications of wallboard panels, the present embodiment can advantageously improve fire safety by inhibiting and limiting the spread of fire within a building as compared to prior art wallboard construction methods. More specifically, one wallboard fastening device can completely seal the joint formed by two adjacent wallboard panels, thereby completely blocking air flow through the joint such that air cannot flow from the room in front of the wallboard to the area behind the wallboard or vice versa. In conjunction with fire retardant materials commonly used in wallboard panels, the present embodiment can inhibit the spread of oxygen-fueled fires and prevent the spread of fire from one room of a building to another (or at least slow the growth and spread of the fire, thereby buying people valuable time to escape the building and / or protecting firefighters by reducing the resulting size and severity of the fire). The present embodiment can be used at all wallboard joints within a room (i.e., wall joints and ceiling joints), thereby blocking air flow through all such wallboard joints. These fire protection benefits cannot be guaranteed with vertical applications because prior art methods may not completely seal the joints to the framing members or may not properly mortar or tape the joints (those not backed by framing members) to block air flow through the joints and prevent the spread of fire.

[0010] To achieve what is referred to in the art as a Level 5 finish (i.e., the most labor-intensive and skill-demanding level of finish, often used in high-end residential construction), a wallboard installer using this embodiment may apply a "skim coat" to the installed wallboard panel and the exposed portions of the wallboard fastening devices that secure the wallboard panel to one or more underlying framing members. The skim coat may be applied using joint compound, gypsum, or other approved skim coat finish. The skim coat may be applied directly over the seam formed between the edge of the installed wallboard fastening device and the visible side of the corresponding installed wallboard panel. The skim coat conceals the seam without the need for any joint tape and / or pre-applied joint compound, so that tasks that would take several days with traditional wallboard installation methods (e.g., repeated applications of joint compound and sanding) can be accomplished in one day.

[0011] In some embodiments, a wall plate fastening device for fastening first and second wall plates in an inside corner configuration includes a first framing panel having a first longitudinal edge and a second framing panel having opposing second and third longitudinal edges, the second longitudinal edge directly connected to the first longitudinal edge. The wall plate fastening device also includes a first flat spring flange having a fourth longitudinal edge directly connected to the third longitudinal edge, the first flat spring flange, the first framing panel, and the second framing panel forming a channel of suitable size to receive the first wall plate. The wall plate fastening device also includes a second flat spring flange having a fifth longitudinal edge directly connected to the third longitudinal edge. The first flat spring flange flexes and presses against the first wall plate when the first wall plate is inserted into the channel. The second flat spring flange flexes and presses against the second wall plate when the back surface of the second framing panel presses against the second wall plate.

[0012] In another embodiment, a wallboard fastening device for fastening first and second wallboards in an internal corner configuration includes a first framing panel having a first longitudinal edge and a second framing panel having opposing second and third longitudinal edges. The second framing panel is directly connected to the first longitudinal edge away from the second and third longitudinal edges, the second framing panel having first and second longitudinal portions separated by the first framing panel. The first longitudinal portion includes a second longitudinal edge and the second longitudinal portion includes a third longitudinal edge. The wallboard fastening device also includes a first leaf spring flange having a fourth longitudinal edge directly connected to the third longitudinal edge, the first leaf spring flange, the first framing panel, and the second longitudinal portion of the second framing panel forming a channel sized to receive the first wallboard. The wallboard fastening device also includes a second leaf spring flange having a fifth longitudinal edge directly connected to the third longitudinal edge. The first leaf spring flange flexes and presses against the first wall panel when the first wall panel is inserted into the channel, and the second leaf spring flange flexes and presses against the second wall panel when the back surface of the second framing panel presses against the second wall panel. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a cross-sectional view of a first wall panel and a second wall panel installed in an inside corner configuration using a conventional installation method.

[0014] [Diagram 2] FIG. 2 is a cross-sectional view of a wallboard fastening device used in installing the wallboard panels of FIG. 1 in an inside corner configuration, in one embodiment.

[0015] [Diagram 3] FIG. 3 illustrates the placement of the wallboard fastening device of FIG. 2 relative to a second wallboard panel and a first stud in one embodiment.

[0016] [Figure 4] FIG. 4 illustrates one embodiment of the wallboard fastening members of FIG. 2 fastened to a first stud to install a first wallboard panel.

[0017] [Diagram 5] FIG. 5 illustrates the longitudinal extension in the z-direction of the wall paneling device of FIG. 2 in one embodiment.

[0018] [Figure 6] FIG. 6 is another view of the wall panel fastening device of FIG. 2, illustrating its longitudinal extension in the z-direction in one embodiment.

[0019] [Figure 7] FIG. 7 is a cross-sectional view of a wallboard device similar to the wallboard device of FIG. 2 except including a third framing panel, in one embodiment.

[0020] [Figure 8] FIG. 8 illustrates how the wallboard fastening device 700 of FIG. 7 may be used in a slap stud construction process, in one embodiment.

[0021] [Figure 9] FIG. 9 illustrates the longitudinal extension in the z-direction of the wall panel fastening device of FIG. 7 in one embodiment.

[0022] [Figure 10] FIG. 10 is another view showing the longitudinal extension in the z-direction of the wall panel fastening device of FIG. 7 in one embodiment.

[0023] [Figure 11] FIG. 11 illustrates how, in one embodiment, two wallboard fastening devices of FIG. 2 may be used in a slap-stud construction method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] definition

[0025] Wallboard: Flat panels used to construct interior walls and ceilings, often, but not necessarily, containing gypsum as a substrate. In this context, "wallboard" includes drywall, plasterboard, sheetrock, gypsum board, gypsum board, backing board, coreboard, greenboard, blueboard, cement board, soundboard, ceiling board, etc.

[0026] FRONT AND BACK: The paper bound sides of the wallboard panel.

[0027] End Face: The faces perpendicular to the front and back of a wallboard panel.

[0028] Framing Member: The part of framing, beam, truss, block, etc. to which a panel product is attached. Wall studs and sealing joints are examples of framing members. Framing members can be constructed of steel, wood, or other rigid materials.

[0029] Fasteners: Nails, screws, or staples used to mechanically fasten wallboard panels together.

[0030] Treated Joint: Joints between wallboard panels that have been reinforced and concealed with tape or joint compound, or that are covered by strip molding.

[0031] Finishing: The act of concealing joints, usually accomplished with joint compound and tape, and including concealing the heads of fasteners (if present) and the ends or flanges of attachments.

[0032] Control Joint: An engineered separation between adjacent wallboard panels to allow for movement due to expansion and / or contraction of the wallboard panels, framing members, and / or other components used to fasten or finish the wallboard panels.

[0033] Figure 1 is a cross-sectional view of a first wallboard panel 110(1) and a second wallboard panel 110(2) installed in an inside corner configuration 100 using prior art installation techniques. In Figure 1, a first fastener 112(1) passes through the first wallboard panel 110(1) and into a first stud 102(1), thereby securing the first wallboard panel 110(1) to the first stud 102(1). Similarly, a second fastener 112(1) passes through the second wallboard panel 110(2) and into a second stud 102(2), thereby securing the second wallboard panel 110(2) to the second stud 102(2). Although not shown in FIG. 1 , additional fasteners 112, similar to fasteners 112(1) and 112(2), may pass through wallboard panels 110(1) and 110(2) to further secure wallboard panels 110(1) and 110(2) to studs 102(1) and 102(2).

[0034] Wallboard panels 110(1) and 110(2) form two adjacent walls that bound a room 114. The first wallboard panel 110(1) has a first front face 122(1) that is visible from the room 114. The first wallboard panel 110(1) also has a first back face 124(1) that is opposite the first front face 122(1) such that the first back face 124(1) is not visible from the room 114. Similarly, the second wallboard panel 110(2) has a second front face 122(2) that is visible from the room 114 and a second back face 124(2) that is not visible from the room 114. The wallboard panels 110(1) and 110(2) are perpendicular to each other; that is, the front faces 122(1) and 122(2) form a 90 degree angle in the xy plane (see right-handed coordinate system 108) when viewed from the room 114.

[0035] To hide the seam or transition where the wallboard panels 110(1) and 110(2) meet, mortar is typically applied to the portions of the front faces 122(1) and 122(2) closest to the seam. The mortar may also cover the heads of the fasteners 112(1) and 112(2) (and other fasteners 112) that would otherwise be visible from the room 114. Once the mortar has dried, it may be sanded to create a visually smooth surface. Paint, joint compound, spray, roll-on texture, or another type of surface treatment may be applied instead of or in addition to the mortar.

[0036] FIG. 1 shows studs 102(1) and 102(2) meeting at a corner. In this case, fastener 112(1) penetrates stud 102(1) away from centerline 104. If fastener 112(1) penetrates too close to the right edge of stud 102(1) (i.e., toward the +x direction), it may not be able to adequately fasten wallboard panel 110(1). A similar problem may occur if fastener 112(1) penetrates wallboard panel 110(1) too close to the left edge of stud 102(1). To solve this problem, stud 102(1) may be moved in the +x direction (see, for example, vertical displacement 256 in FIG. 4). For example, if stud 102(1) is displaced the width of second wallboard panel 110(2), fastener 112(1) may penetrate stud 102(1) along centerline 104, as may fastener 112(2). However, installing stud 102(1) in this displaced position (i.e., not corner-contacting) may require work planning between the framer and drywaller, which is not always possible in the field. Thus, unless instructed to the contrary, the framer will install stud 102(1) so that the corners touch, as shown in FIG. 1. Although this can be time consuming and wasteful of materials, drywallers may continue to install wallboard panel 110(1) as shown in FIG. 1 rather than fixing the position of stud 102(1), which may result in wallboard panel 110(1) not being fully secured.

[0037] In FIG. 1, the first stud 102(1) has a first stud width in the x-direction and a second stud width in the y-direction. Thus, the second stud 102(1) has a first stud width in the y-direction and a second stud width in the x-direction. In FIG. 1, each of the studs 102(1) and 102(2) is shown as a standard 2×4 with a first stud width of approximately 3.5 inches and a second stud width of approximately 1.5 inches. However, this embodiment may use studs having different dimensions (e.g., 2×6) or with other types of frame members without departing from the scope of the present specification. Each of the studs 102(1) and 102(2) may be constructed of wood, metal, or another material used in framing.

[0038] FIG. 2 is a cross-sectional view of a wallboard fastening device 200 that may be used to install wallboard panels 110(1) and 110(2) in recessed corner configuration 100. Wallboard fastening device 200 includes a first framing panel 202 having a first longitudinal edge 204. Wallboard fastening device 200 also includes a second framing panel 206 having a second longitudinal edge 208 and a third longitudinal edge 210 opposite second longitudinal edge 208. Framing panels 202 and 206 are joined longitudinally along first longitudinal edge 204 and second longitudinal edge 208 to form approximately a 90 degree corner 230. Here, the term "longitudinal" means along the z-direction (referring to right-hand coordinate system 108). Also, as used herein, two components described as "joined" mean that they are directly connected to one another without an intervening component (e.g., another planar panel). Although the various panels / flanges are shown and described as having "longitudinal edges," this is for purposes of illustration. The wallboard fastening device 200 may be formed from a single piece of material, or any combination of the separate parts described herein may be combined into a single integral piece.

[0039] The wallboard fastening device 200 also includes a first leaf spring flange 212 having a fourth longitudinal edge 214 joined to the third longitudinal edge 210, such that the first leaf spring flange 212, the first framing panel 202, and the second framing panel 206 form a channel 216 sized to receive the first wallboard panel 110(1). The wallboard fastening device 200 also includes a second leaf spring flange 218 having a fifth longitudinal edge 220 joined to the third longitudinal edge 210 (and thus to the fourth longitudinal edge 214). In an embodiment, the first leaf spring flange 212 has a sixth longitudinal edge 232 opposite the fourth longitudinal edge 214, and the second leaf spring flange 218 has a seventh longitudinal edge 234 opposite the fifth longitudinal edge 220. Although FIG. 2 shows that longitudinal edges 232 and 234 are tapered, alternatively, one or both of longitudinal edges 232 and 234 may not be tapered.

[0040] The second framing panel 206 has a width in the y-direction that matches the thickness of the first wallboard panel 110(1) so that the channel 216 fits into the end face of the first wallboard panel 110(1). The width in the x-direction of the first framing panel 202 may be greater than the width in the x-direction of the first leaf spring flange 212, as shown in FIG. 2. However, one or both of the first framing panel 202 and the first leaf spring flange 212 may have a different width than that shown. In an embodiment, the width of the leaf spring flanges 212 and 218 is less than the width of the first framing panel 202. In an embodiment, the framing panels 202 and 206 have a similar first thickness and the leaf spring flanges 212 and 218 have a similar second thickness, the second thickness being less than the first thickness. In further embodiments, first framing panel 202, second framing panel 206, first leaf spring flange 212, and second leaf spring flange 218 each have a constant thickness. The constant thickness may be the same for all four components. Alternatively, the four components may have different constant thicknesses. In yet other embodiments, one or both of leaf spring flanges 212 and 218 have a tapered thickness. For example, leaf spring flange 212 may have a thickest thickness near longitudinal edge 214 and a thinnest thickness near longitudinal edge 232.

[0041] The first framing panel 202 may further define one or more fastener holes 222. If there are multiple fastener holes 222, they may be spaced apart heightwise (i.e., in the z-direction) along the first framing panel 202. A fastener (e.g., fastener 112(1) in FIG. 1) may pass through each hole 222 to secure the wallboard fastening device 200 to an underlying stud (e.g., stud 102(1) in FIG. 1). In embodiments, the second framing panel 206 also defines one or more fastener holes (not shown) spaced apart heightwise along the second framing panel 206. In other embodiments, the first framing panel 202 does not define holes 222. In these embodiments, the fasteners 112 may be forced through the first framing panel 202 to pierce an underlying stud.

[0042] The first leaf spring flange 212 and the second framing panel 206 are joined along longitudinal edges 210 and 214 to form a first nominal angle 224 that is less than 90 degrees. For example, the first nominal angle 224 may be 85 degrees, 87 degrees, or 89 degrees. Thus, when the first wall board panel 110(1) is not present (i.e., not inserted into the channel 216), the first leaf spring flange 212 is not parallel to the first framing panel 202. Furthermore, the width of the channel 216 (in the y-direction) is greatest near the second framing panel 206 and decreases with increasing distance from the second framing panel 206 (in the +x-direction).

[0043] The second leaf spring flange 218 is joined to the second framing panel 206 such that the second leaf spring flange 218 would not be flush with the second framing panel 206 if the second wallboard panel 110(2) were not present (i.e., not in direct physical contact with the wallboard fastening device 200, as described in Figures 3 and 4 below). The second leaf spring flange 218 forms a second nominal angle 226 with the mathematical plane in which the second framing panel 206 lies. For example, the second nominal angle 226 can be between 1 degree and 5 degrees.

[0044] Figures 3 and 4 illustrate the installation of wallboard panels 110(1) and 110(2) with the wallboard fastening device 200 of Figure 2. Figures 3 and 4 are best viewed in conjunction with the following discussion.

[0045] FIG. 3 illustrates the position of the wallboard fastening device 200 relative to the second wallboard panel 110(2) and the first stud 102(1). In FIG. 3, the second wallboard panel 110(2) is fastened to the second stud 102(2) using the second fastener 112(2) and is therefore installed similarly to the installation technique shown in FIG. 1. As indicated by arrow 302, the wallboard fastening device 200 is then positioned by both (i) pressing the back surface 242 of the first framing panel 202 against the first stud 102(1) and (ii) pressing the back surface 240 of the second framing panel 206 against the second front surface 122(2) of the second wallboard panel 110(2). In this position, the second framing panel 206 and the second leaf spring flange 218 cover the head of the second fastener 112(2).

[0046] 4 illustrates the fastening of the wallboard fastening device 200 to the first stud 102(1) and the installation of the first wallboard panel 110(1). The first stud 102(1) is positioned such that its left face is vertically displaced from the right face of the second stud 102(2) by a non-zero vertical displacement 256. The vertical displacement 256 is measured along the x-direction from the mathematical plane 410 in which the right face of the second stud 102(2) lies. The vertical displacement 256 allows the first fastener 112(1) to pass through the fastener hole 222 and penetrate the first stud 102(1) near the centerline 104. The wallboard panel 110(1) is installed after the first framing panel 202 is fastened to the stud 102(1), so that the wallboard panel 110(1) covers the head of the first fastener 112(1).

[0047] One advantage of the wallboard fastening device 200 is that the first fastener 112(1) can be configured to completely avoid the first stud 102(1) when it meets the second stud 102(2) at a corner (see FIG. 1). In this case, the drywaller would immediately know that the wallboard panel 110(1) is unsafe because the stud 102(1) is installed in the wrong position. However, the wallboard fastening device 200 helps prevent the drywaller from devising a quick-fix "solution" or workaround that would result in improperly fastening the wallboard panel 110(1). Instead, the drywaller would be more likely to report the situation (e.g., to a supervisor) so that the stud 102(1) can be properly repositioned. As a result, the wallboard fastening device 200 helps ensure that all wallboard panels are properly installed.

[0048] Once wallboard fastening device 200 is positioned and secured, second leaf spring flange 218 flexes to be coplanar with second framing panel 206 (i.e., second nominal angle 226 approaches 0 degrees), causing second leaf spring flange 218 to exert a second restoring force against second wallboard panel 110(2), which ensures that second leaf spring flange 218 is in direct contact with second front surface 122(2).

[0049] The first leaf spring flange 212 is then bent to increase the first nominal angle 224, which opens the channel 216 to facilitate insertion of the first wallboard panel 110(1) therein. After the first wallboard panel 110(1) is inserted into the channel 216, the first leaf spring flange 212 is released so that it rests perpendicular to the second framing panel 206. In this position, the first leaf spring flange 218 is parallel to the first framing panel 202 and exerts a first restoring force on the first wallboard panel 110(1). This first restoring force presses the first wallboard panel 110(1) against the first framing panel 202, thereby physically securing the first wallboard panel 110(1) to the first stud 102(1).

[0050] The first leaf spring flange 212 acts as a spring with a spring constant determined by the geometry (e.g., thickness and width) of the leaf spring flange 212, the first nominal angle 224, and the material properties (e.g., Young's modulus) of the material forming the wall plate fastening device 200. In the small angle approximation, assuming the leaf spring flange 212 is not bent beyond its elastic limit, the magnitude of the first restoring force is linearly proportional to the angular deviation from the first nominal angle 224. The material may be a plastic such as PVC, vinyl, or other extrudable material. Thus, for a given material, the first restoring force can be controlled by specifying the thickness and first nominal angle 224 of the leaf spring flange 212. Similar arguments apply to the second leaf spring flange 218, the second nominal angle 226, and the second restoring force.

[0051] The thickness of the first leaf spring flange 212 provides a trade-off between the magnitude of the first restoring force and the distance the first leaf spring flange 212 protrudes from the first front surface 122(1). The thicker the leaf spring flange 212, the more the leaf spring flange 212 protrudes from the first wall board panel 110(1) in the -y direction, and therefore the size of the "step" at the vertical edge 232. A larger step typically requires more mortar and preparation time to visually conceal it.

[0052] After the wallboard fastening device 200 and wallboard panels 110(1) and 110(2) are installed, mortar may be applied to the sixth longitudinal edge 232 to visually hide the transition where the first leaf spring flange 212 meets the first front surface 122(1) of the first wallboard panel 110(1). Similarly, mortar may be applied to the seventh longitudinal edge 234 to visually hide the transition where the second leaf spring flange 218 meets the second front surface 122(2) of the second wallboard panel 110(2).

[0053] FIG. 4 illustrates each of the leaf spring flanges 212 and 218 having an outer surface 260 that is visible from the room 114. Although the outer surfaces 260 are shown in FIGS. 2-4 as being smooth, one or both of the outer surfaces 260 may be textured or striated to enhance adhesion of mortar, joint compound, paint, or another type of surface treatment. For example, the outer surfaces 260 may form ridges. However, each outer surface 260 may be textured in other manners without departing from the scope of the present specification. In one embodiment, only a portion of each outer surface 260 is textured while the remaining portion is smooth.

[0054] In FIG. 4, first framing panel 202 has a width such that it does not extend past the right side of first stud 102(1) in the +x direction. In this case, a small gap is formed between a portion of stud 102(1) and back surface 124(1) of wallboard panel 110(1). This gap does not affect the performance of this embodiment. However, first framing panel 202 may alternatively have a sufficient width to extend completely past first stud 102(1) in the +x direction. In these embodiments, there is no gap between stud 102(1) and wallboard panel 110(1).

[0055] 5 and 6 are diagrams illustrating the vertical Z-direction extension of wallboard fastening device 200. In these figures, first framing panel 202 is formed with a plurality of fastener holes 222 spaced along the length of first framing panel 202. Each fastener hole 222 may be formed in a stadium shape (as shown), a circle, or another shape. Although not shown, second framing panel 206 may further include fastener holes similar to fastener holes 222. In one embodiment, neither framing panel 202 nor 206 has fastener holes 222 formed therein. In this embodiment, fastener 112 is threaded through first framing panel 202 if it is formed of a material (e.g., PVC) that is soft enough to be pierced.

[0056] In the z-direction, the length of the wallboard fastening device 200 may be selected to match the corresponding length (e.g., 4 feet or 8 feet) of the wallboard panels 110(1) and 110(2). As shown in Figures 5 and 6, each of the leaf spring flanges 212 and 218 may be a solid, uniform, planar panel without holes. The wallboard fastening device 200 may be made of PVC, vinyl, or another extrudable material. Although not shown, the second framing panel 206 may include one or more springs that press against the end face of the first wallboard panel 110(1) to function as a rectifying joint. For an example of such a spring, see v-shaped springs 902(1) and 902(2) in Figures 21 and 22 of WO 2020 / 168301.

[0057] FIG. 7 is a cross-sectional view of a wallboard fastening device 700 similar to wallboard fastening device 200 of FIG. 2, except that it includes a third framing panel 718 that is flush with second framing panel 206. The third framing panel 718 has a vertical edge 710 that is joined to vertical edges 204 and 208 to form a "tee" configuration in which the first framing panel 202 forms right angles with each of the framing panels 206 and 718. One of these right angles is shown in FIG. 7 as framing corner 720. The third framing panel 718 also has a vertical edge 712 opposite vertical edge 710. In the example of FIG. 7, fastener holes 222 are formed in the third framing panel 718 instead of the first framing panel 202. However, wallboard fastening device 700 may alternatively be manufactured with fastener holes 222 formed in both framing panels 202 and 718 or with no fastener holes 222 formed in either framing panels 202 and 718.

[0058] In some implementations, the framing panels 206 and 718 form a single composite framing panel having vertical edges 210 and 712. In this case, the first vertical edge 204 of the first framing panel 202 is joined to the composite framing panel at a location away from the vertical edges 210 and 712 to form a "tee" configuration. The composite framing panel has a first vertical portion between the vertical edges 712 and 204 that is similar to the third framing panel 718. The composite framing panel also has a remaining second vertical portion between the vertical edges 210 and 204 that is similar to the second framing panel 206. Thus, in FIG. 7, the first framing panel 202 forms a right angle with each of the first and second vertical portions.

[0059] In some embodiments, the first vertical portion is formed with vertically spaced fastener holes 222 (see FIGS. 9 and 10). The first framing panel 202 may further include fastener holes 222 formed therein, as shown in FIG. 2. In other embodiments, the composite framing panel does not include any fastener holes 222 formed therein. In some embodiments, the composite framing panel has a uniform thickness. However, some or all of the composite framing panel may alternatively be formed with a non-uniform thickness (e.g., tapered). In some embodiments, the first framing panel 202 and the composite framing panel have similar thicknesses. However, the first framing panel 202 and the composite framing panel may alternatively have different thicknesses.

[0060] FIG. 8 illustrates the wallboard fastening device 700 of FIG. 7 being used in a slap-stud construction method. A room enclosed by a second wallboard panel 110(2) is divided into a first room 814(1) and a second room 814(2) by a partition wall 804. In slap-stud framing, the left edge (i.e., in the -x direction) of the partition wall 804 butts or "slaps" against a portion of the front surface 122(2) of the wallboard panel 110(2), thereby forming an inside corner in each of the rooms 814(1) and 814(2). Thus, the wallboard panel 110(2) is first attached using conventional construction techniques. In the example of FIG. 8, the wallboard panel 110(2) is attached to a first stud 802(1) and a second stud 802(2). Wallboard panel 110(2) may be attached to additional studs (eg, typically at 18 inch or 24 inch intervals) depending on its length in the y-direction.

[0061] The partition wall 804 includes an upper track (not shown) attached to the ceiling, a lower track (not shown) attached to the floor below the upper track, one or more partition studs (or similar framing members) extending vertically to connect directly between the upper and lower tracks, and additional wallboard panels 110(1) and 110(3) that cover the tracks and partition studs to provide a finished appearance when viewed from both rooms 814(1) and 814(2). The upper and lower tracks (not shown in FIG. 8) extend perpendicularly (i.e., in the x-direction) to the wallboard panels 110(2). FIG. 8 shows the leftmost of the partition studs, stud 802(3). Thus, the partition wall 804 may include additional studs located to the right of stud 802(3) (i.e., in the +x-direction).

[0062] In FIG. 8 , each of studs 802(1), 802(2), and 802(3) includes a web 810, a first flange 812(1) longitudinally joined to a first edge 818(1) of web 810, and a second flange 812(2) longitudinally joined to a second edge 818(2) opposite the first edge 818(1) of web 810. The first flange 812(1) is perpendicular to the web 810 except for a first lip 816(1) formed on the edge opposite the first edge 818(1). Similarly, the second flange 812(2) is perpendicular to the web 810 except for a second lip 816(2) formed on the edge opposite the second edge 818(2). 8, web 810, flanges 812(1) and 812(2), and lips 816(1) and 816(2) are depicted only on stud 802(1). Other types of studs may alternatively be used without departing from the scope of this specification.

[0063] Framing corner 720 of first wallboard fastening device 700(1) presses against the lower left corner of stud 802(3). Stud 802(3) is "open" to the right, i.e., web 810 is to the left of lips 816(1) and 816(2). Framing corner 720 therefore contacts both web 810 and first flange 812(1) of stud 802(3). Thus, third framing panel 718 fixes the position of device 700(1) in the x-direction relative to stud 802(3), and first framing panel 202 fixes the position of device 700(1) in the y-direction relative to stud 802(3). Similarly, framing corner 720 of second wallboard fastening device 700(2) presses against the upper left corner of stud 802(3), thereby contacting web 810 and second flange 812(2) of stud 802(3). Stud 802(3) and devices 700(1) and 700(2) are then moved together in the -x direction such that web 810 of stud 802(3) directly contacts third framing panels 718 of both devices 700(1) and 700(2), which in turn press directly against front surface 122(2) of wallboard panel 110(2). In this position, stud 802(3) may then be secured (e.g., using fasteners) to the upper and lower tracks to secure its position.

[0064] Fasteners 112 (e.g., self-tapping screws) are then drilled into webs 810 of studs 802(3) and through second wallboard panel 110(2) from the +x direction. Each fastener 112 penetrates third framing panel 718 of one of devices 700(1) and 700(2). Thus, the fasteners 112 secure both devices 700(1) and 700(2) together to wallboard panel 110(2). The width (in the y direction) of third framing panel 718 is desirably less than or equal to half the width of web 810 so that devices 700(1) and 700(2) do not interfere with each other. Additionally, although leaf spring flanges 212 are shown in FIG. 8 as having a width similar to the width of flanges 812(1) and 812(2), each leaf spring flange 212 may alternatively have a width that is less than or greater than the width of flanges 812(1) and 812(2).

[0065] Wallboard panels 110(1) and 110(3) can then be inserted into channels 216 of devices 700(1) and 700(3), respectively, and assembled with wallboard panel 110(2) to create an inside corner. Wallboard panels 110(1) and 110(3) can be secured to additional partition studs (not shown in FIG. 8) if desired. The resulting inside corner can then be finished with mortar, joint compound, or another type of surface treatment.

[0066] 9 and 10 are perspective views of wallboard fastening device 700 showing its vertical extension in the z-direction. In these figures, third framing panel 718 (or alternatively a first vertical portion of a composite framing panel) is formed with a plurality of vertically spaced fastener holes 222. Each of fastener holes 222 may be formed in a stadium shape (as shown), a circle, or another shape. Although not shown, first framing panel 202 may be formed with additional fastener holes similar to fastener holes 222, thereby allowing wallboard fastening device 700 to be used in the same manner as wallboard fastening device 200. In one embodiment, neither of framing panels 202 and 718 are formed with fastener holes 222. In these embodiments, fasteners 112 are threaded through third framing panel 718 if third framing panel 718 is formed from a material soft enough to be penetrated by fasteners 112 (e.g., PVC).

[0067] FIG. 11 shows how two wallboard fastening devices 200 of FIG. 2 are used in a slap-stud construction. FIG. 11 is similar to FIG. 8 except that wallboard fastening devices 700(1) and 700(2) are replaced with wallboard fastening devices 200(1) and 200(2), respectively. Device 200(1) is attached to stud 802(3) by fastener 112 passing through a first flange 812(1) of stud 802(3). Similarly, device 200(2) is attached to stud 802(3) by fastener 112 passing through a second flange 812(2) of stud 802(3). Stud 802(3) may be displaced in the +x direction so that fastener 112 passes through the centerline of stud 802(3) and web 810 does not contact wallboard panel 110(2). As shown in FIG. 11, this displacement creates a gap 1102 between the web 810 and the front surface 122(2) of the wallboard panel 110(2).

[0068] Although the third framing panel 718 is shown in FIGS. 7, 9, and 10 as being coplanar with the second framing panel 206, the third framing panel 718 may alternatively not be coplanar with the second framing panel 206. For example, the third framing panel 718 may form a non-zero angle with the mathematical plane of the second framing panel 206, similar to the second nominal angle 226. In this case, the third framing panel 718 may behave similarly to the second leaf spring flange 218 in that it flexes to be coplanar with the second framing panel 206 when pressed against the wallboard 110(2). The third framing panel 718 may have an outer surface that is textured to accept mortar, similar to the outer surface 260 of FIG. 4. 7, 9, and 10, the longitudinal edge portion 712 is not tapered, however, the longitudinal edge portion 712 may be tapered, similar to the seventh longitudinal edge portion 234.

[0069] 7, 9, and 10, the first framing panel 202 forms a right angle with the second framing panel 206 and the third framing panel 718, the first framing panel 202 may alternatively form an acute angle with the second framing panel 206, similar to the first leaf spring flange 212. In this case, the first framing panel 202 may act similar to the first leaf spring flange 212 in that it flexes as the wall plate 110(1) is inserted into the channel 216. The first framing panel 202 may have an outer surface that is textured to accept mortar, similar to the outer surface 260 of FIG. 4. In FIGS. 7, 9, and 10, the distal longitudinal edge 732 of the first framing panel 202 is not tapered, however, the distal longitudinal edge 732 may be tapered, similar to the sixth longitudinal edge 232.

[0070] Combination of features

[0071] The features described above, and those claimed below, can be combined in various ways without departing from the scope of the present specification. The following examples are illustrative, but not limiting, of possible combinations of the features and embodiments described above. It will be apparent that other variations and modifications can be made to the present embodiments without departing from the spirit and scope of the present invention.

[0072] (A1) A wall plate fastening device for fastening first and second wall plates in an inside corner configuration includes a first framing panel having a first longitudinal edge portion and a second framing panel having opposing second and third longitudinal edges. The second longitudinal edge portion is directly connected to the first longitudinal edge portion. The wall plate fastening device also includes a first leaf spring flange having a fourth longitudinal edge portion directly connected to the third longitudinal edge portion, such that the first leaf spring flange, the first framing panel, and the second framing panel form a channel sized to receive the first wall plate. The wall plate fastening device also includes a second leaf spring flange having a fifth longitudinal edge portion directly connected to the third longitudinal edge portion. The first leaf spring flange flexes against the first wall plate when the first wall plate is inserted into the channel. The second leaf spring flange flexes against the second wall plate when a back surface of the second framing panel is pressed against the second wall plate.

[0073] (A2) In the wallboard fastening device shown in (A1), the first framing panel and the second framing panel form a right angle.

[0074] (A3) In the wallboard fastening device shown in either (A1) or (A2), the first leaf spring flange forms an angle of less than 90 degrees with the second framing panel when the first wallboard is not present in the channel.

[0075] (A4) In a wall panel fastening device shown in any of (A1) to (A3), the second leaf spring flange is not flush with the second framing panel when the second wall panel is not present behind it.

[0076] (A5) In the wall panel fastening device shown in any of (A1) to (A4), the first leaf spring flange forms a right angle with the second framing panel when the first wall panel is inserted into the channel. The first and second wall panels become perpendicular to each other when the back surface of the second framing panel is again pressed against the second wall panel.

[0077] (A6) In the wall panel fastening device shown in any of (A1) to (A5), the width of each of the first and second leaf spring flanges is less than the width of the first framing panel.

[0078] (A7) In the wallboard fastening device shown in any of (A1) to (A6), one or both of the first and second framing panels are formed with a plurality of fastener holes spaced longitudinally along one or both of the first and second framing panels.

[0079] (A8) In the wallboard fastening device shown in any of (A1) to (A7), the first and second framing panels have a similar first thickness, the first and second leaf spring flanges have a similar second thickness, and the first thickness is greater than the second thickness.

[0080] (A9) In the wall panel fastening device shown in any of (A1) to (A8), the first framing panel, the second framing panel, the first leaf spring flange, and the second leaf spring flange each have a uniform thickness.

[0081] (A10) In the wallboard fastening device shown in any of (A1) to (A9), each of the first and second leaf spring flanges has an outer surface that is textured to receive mortar.

[0082] (A11) In a wall panel fastening device as shown in any of (A1) to (A10), the first leaf spring flange has a sixth longitudinal edge portion opposite the fourth longitudinal edge portion, and the second leaf spring flange has a seventh longitudinal edge portion opposite the fifth longitudinal edge portion, and the sixth and seventh longitudinal edge portions are tapered.

[0083] (A12) The wallboard fastening device as shown in any of (A1) to (A11), further including a third framing panel having a sixth longitudinal edge portion directly connected to the first longitudinal edge portion and the second longitudinal edge portion, the third framing panel being coplanar with the second framing panel.

[0084] (A13) In the wallboard fastening device shown in (A12), the third framing panel is coplanar with the second framing panel and the first framing panel forms a right angle with each of the second and third framing panels.

[0085] (A14) In the wallboard fastening devices shown in either (A12) or (A13), the first and third framing panels have similar widths.

[0086] (A15) In a wallboard fastening device shown in any of (A12) to (A14), the first, second, and third framing panels have similar thicknesses.

[0087] (A16) In the wallboard fastening device shown in any of (A12) to (A15), one or more of the first, second, and third framing panels are formed with a plurality of fastener holes spaced longitudinally along the one or more of the first, second, and third framing panels.

[0088] (A17) In the wallboard fastening device shown in any of (A12) to (A16), the first framing panel forms an angle of less than 90 degrees with the second framing panel when the first wallboard is not present in the channel.

[0089] (A18) In the wallboard fastening device shown in any of (A12) to (A16), the first framing panel forms a right angle with the second framing panel when the first wallboard is not present in the channel.

[0090] (A19) In a wall panel fastening device shown in any of (A12) to (A18), the third framing panel is not flush with the second framing panel when the second wall panel is not present behind it.

[0091] (A20) In a wallboard fastening device shown in any of (A12) to (A18), the third framing panel is flush with the second framing panel when the second wallboard is not present at its rear.

[0092] (B1) A wallboard fastening device for fastening first and second wallboards in an internal corner configuration includes a first framing panel having a first longitudinal edge portion and a second framing panel having opposing second and third longitudinal edges. The second framing panel is directly connected to the first longitudinal edge portion remote from the second and third longitudinal edges, the second framing panel having first and second longitudinal portions separated by the first framing panel. The first longitudinal portion includes a second longitudinal edge portion. The second longitudinal portion includes a third longitudinal edge portion. The wallboard fastening device also includes a first leaf spring flange having a fourth longitudinal edge portion directly connected to the third longitudinal edge portion, such that the first leaf spring flange, the first framing panel, and the second longitudinal portion of the second framing panel form a channel sized to receive the first wallboard. The wallboard fastening device also includes a second leaf spring flange having a fifth longitudinal edge portion directly connected to the third longitudinal edge portion. The first leaf spring flange flexes and presses against the first wall panel when the first wall panel is inserted into the channel, and the second leaf spring flange flexes and presses against the second wall panel when the back surface of the second framing panel presses against the second wall panel.

[0093] In the wallboard fastening device shown in (B1), a first framing panel is perpendicular to each of the first and second longitudinal portions of the second framing panel.

[0094] In the wallboard fastening devices shown in either (B1) or (B2), the first and second framing panels have similar thicknesses.

[0095] In the wallboard fastening device shown in any of (B1) through (B3), the first leaf spring flange forms an angle of less than 90 degrees with the second vertical portion of the second framing panel when the first wallboard is not present in the channel.

[0096] In the wall panel fastening device shown in any of (B1) through (B3), the second leaf spring flange is not flush with the second framing panel when the second wall panel is not behind the second framing panel.

[0097] In the wall panel fastening device shown in any of (B1) through (B4), the first leaf spring flange forms a right angle with the second framing panel when the first wall panel is inserted into the channel. The first and second wall panels become perpendicular to each other when the back surface of the second framing panel is again pressed against the second wall panel.

[0098] In the wall panel fastening device shown in any of (B1) to (B5), the width of each of the first and second leaf spring flanges is less than the width of the first framing panel.

[0099] In the wallboard fastening devices shown in any of (B1) through (B6), the first and second framing panels have similar thicknesses.

[0100] In the wall plate fastening device shown in any of (B1) through (B7), the first and second framing panels have a similar first thickness, the first and second leaf spring flanges have a similar second thickness, and the first thickness is greater than the second thickness.

[0101] In the wall panel fastening device shown in any of (B1) to (B8), the first framing panel, the second framing panel, the first leaf spring flange, and the second leaf spring flange each have a uniform thickness.

[0102] In the wallboard fastening device shown in any of (B1) to (B9), the first and second leaf spring flanges each have an outer surface that is textured to receive mortar.

[0103] In the wallboard fastening device shown in any of (B1) to (B10), the first framing panel and the first vertical portion of the second framing panel each have an outer surface that is textured to receive mortar.

[0104] In the wallboard fastening device shown in any of (B1) to (B11), the first longitudinal portion of the second framing panel is formed with a plurality of fastener holes longitudinally spaced along the first longitudinal portion.

[0105] Changes may be made to the above method and system without departing from the scope of the present specification. Accordingly, the matters set forth in the above description or shown in the accompanying drawings should be construed as illustrative and not limiting. The following claims are intended to cover all the general and specific features described herein, as well as all statements of the scope of the methods and systems herein, and may be referred to as lying therebetween as a matter of language.

Claims

1. 1. A wallboard fastening device for fastening first and second wallboards in an inside corner configuration, comprising: a first framing panel having a first longitudinal edge; a second framing panel having second and third opposed longitudinal edges, the second longitudinal edge directly connected to the first longitudinal edge; a first leaf spring flange having a fourth longitudinal edge portion directly connected to the third longitudinal edge portion, wherein the first leaf spring flange, the first framing panel, and the second framing panel form a channel sized to receive the first wall plate; a second leaf spring flange having a fifth longitudinal edge portion directly connected to the third longitudinal edge portion; the first leaf spring flange is deflected and pressed against the first wall panel when the first wall panel is inserted into the channel; the second leaf spring flange flexes and presses against the second wallboard when a rear surface of the second framing panel is pressed against the second wallboard.

2. 2. The wallboard fastening device of claim 1, wherein said first framing panel and said second framing panel form a right angle.

3. 2. The wallboard fastening device of claim 1, wherein said first leaf spring flange forms an angle of less than 90 degrees with said second framing panel when said first wallboard is not present in said channel.

4. 2. The wallboard fastening device of claim 1, wherein said second leaf spring flange is not flush with said second framing panel when said second wallboard is not present at said rear surface.

5. the first leaf spring flange forms a right angle with the second framing panel when the first wall panel is inserted into the channel; 2. The wallboard fastening device of claim 1, wherein said first and second wallboards become perpendicular to one another when the rear surface of said second framing panel is pressed back against said second wallboard.

6. 2. The wallboard fastening device of claim 1, wherein a width of each of said first and second leaf spring flanges is less than a width of said first framing panel.

7. 2. The wallboard fastening device of claim 1, wherein one or both of the first and second framing panels are formed with a plurality of fastener holes spaced longitudinally along one or both of the first and second framing panels.

8. the first and second framing panels have a similar first thickness; the first and second leaf spring flanges have a similar second thickness; The wallboard fastening device of claim 1 , wherein said first thickness is greater than said second thickness.

9. 2. The wall panel fastening device of claim 1, wherein the first framing panel, the second framing panel, the first leaf spring flange, and the second leaf spring flange each have a uniform thickness.

10. 2. The wallboard fastening device of claim 1, wherein the first and second leaf spring flanges each have an outer surface that is textured to receive mortar.

11. the first leaf spring flange has a sixth longitudinal edge portion opposite the fourth longitudinal edge portion; the second leaf spring flange has a seventh longitudinal edge portion opposite the fifth longitudinal edge portion; 2. The wallboard fastening device of claim 1, wherein said sixth and seventh longitudinal edges are tapered.

12. 2. The wallboard fastening device of claim 1 further comprising a third framing panel having a sixth longitudinal edge portion directly connected to said first and second longitudinal edges.

13. the third framing panel is coplanar with the second framing panel; 13. The wallboard fastening device of claim 12, wherein said first framing panel forms a right angle with each of said second and third framing panels.

14. 13. The wallboard fastening device of claim 12, wherein said first and third framing panels have similar widths.

15. 13. The wallboard fastening device of claim 12, wherein said first, second, and third framing panels have a similar thickness.

16. 13. The wallboard fastening device of claim 12, wherein one or more of the first, second, and third framing panels are formed with a plurality of fastener holes spaced longitudinally along one or more of the first, second, and third framing panels.

17. 13. The wallboard fastening device of claim 12, wherein the first framing panel forms an angle of less than 90 degrees with the second framing panel when the first wallboard is not present in the channel.

18. 13. The wallboard fastening device of claim 12, wherein said first framing panel forms a right angle with said second framing panel when said first wallboard is not present in said channel.

19. 13. The wallboard fastening device of claim 12, wherein the third framing panel is not flush with the second framing panel when the second wallboard is not present at the rear surface.

20. 13. The wallboard fastening device of claim 12, wherein said third framing panel is flush with said second framing panel when said second wallboard is not present at said rear surface.

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