MAGNETIC CORNER GUARD
20240368901 ยท 2024-11-07
Inventors
Cpc classification
E04F19/061
FIXED CONSTRUCTIONS
International classification
Abstract
A wall trimming (also called a corner guard) is provided for protecting a corner of a wall. The corner guard is an elongated body in an L-shape having recessed portions within inner surface facing the wall. The recessed portions hold magnets configured to hold the corner guard using magnetic attraction to a magnetic material fixed inside the wall, which may be a metal corner bead or magnetic inserts, for example. The recessed portions may be dimensioned according to the dimensions of the insert magnets, such that magnets are flush with the inner surface of the corner guard. The corner guard may have three layers with the recessed portions cut out of the inner layer, a decorative pattern cut into the outer layer, and the middle layer providing a backstop to prevent the recessed portions and magnets from being visible through the decorative pattern cut into the outer layer.
Claims
1. A wall trimming element for positioning at an angled section of a wall, the wall trimming element comprising: a corner guard member having an elongated body including planar portions joined at a corner, the planar portions respectively being configured to have an inner surface and an outer surface, the inner surface being configured to abut a wall surface of a wall, and a magnet affixed to the corner guard member, the magnet being configured to induce a magnetic attraction to a magnetic material in the wall, wherein a combined pull force of the wall trimming element is 10 pounds or greater.
2. The wall trimming element of claim 1, wherein the magnet is arranged at a location of the corner guard member that overlaps a corner bead of the wall when the corner guard member is positioned at the angled section of the wall.
3. The wall trimming element of claim 1, wherein the magnet is a rare earth magnet.
4. The wall trimming element of claim 1, wherein the magnet comprises neodymium.
5. The wall trimming element of claim 1, wherein the magnet is a plurality of magnet pieces affixed at respective locations within each of the planar portions, and the plurality of magnet pieces is configured to affix the corner guard member at an angled section of a wall by the combined pull force greater than or equal to 70 pounds.
6. The wall trimming element of claim 1, wherein the corner guard member comprises structural material selected from a group consisting of a thermoplastic, a metal, a polymer, a plastic, a rubber, a plant fiber, a wood, a ceramic, an organic material, a resin, a composite material, a fiber reinforce polymer, an elastomer, a synthetic fiber, and gypsum board.
7. The wall trimming element of claim 1, wherein the corner guard member comprises an outer surface having a decorative design.
8. The wall trimming element of claim 1, wherein the corner guard member includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion.
9. The wall trimming element of claim 8, wherein a depth of the recessed portion in the inner surface is sized according to dimensions of the magnet such that when the magnet is affixed within the recessed portion the magnet does not extend beyond a plane of the inner surface that is configured to abut a wall surface.
10. The wall trimming element of claim 1, wherein the elongated body includes a plurality of layers, each layer having respective planar portions that are joined at a wall corner, the plurality of layers includes an outer layer and an inner layer, the outer layer facing away from the wall corner, and the inner layer facing toward the wall corner.
11. The wall trimming element of claim 10, wherein the inner layer includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion.
12. The wall trimming element of claim 1, wherein the elongated body has a length of between 15 inches and 48 inches.
13. The wall trimming element of claim 10, wherein the plurality of layers includes a middle layer configured to prevent a recesses cut into the inner layer from being visible through a cut in the outer layer.
14. The wall trimming element of claim 10, wherein the outer layer is fixed to a next layer of the plurality of layers using an adhesive.
15. The wall trimming element of claim 1, wherein, when positioned at the angled section of the wall, the wall trimming element is configured to provide an impression of being permanently fixed to the angled section of the wall.
16. A wall trimming system for positioning a corner guard at an angled section of a wall, the wall trimming system comprising: a magnetic material fixed within a wall and arranged proximate with an angled section of the wall, wherein the magnetic material is a metal corner bead, a metal lath, or a magnetic insert; a corner guard member having an elongated body including planar portions joined at a wall corner, the planar portions respectively being configured to have an inner surface and an outer surface, the inner surface being configured to abut a wall surface of a wall, and a magnet affixed to the corner guard member, the magnet being arranged such that, when the corner guard member is positioned at the angled section of the wall, the magnet will be proximate to the magnetic material fixed within the wall and inducing a magnetic attraction of 10 pounds or greater.
17. The wall trimming system of claim 16, wherein the magnet is a plurality of magnet pieces affixed at respective locations within each of the planar portions, and the plurality of magnet pieces is configured to affix the corner guard member at the angled section of a wall by a pull force greater than or equal to 70 pounds.
18. The wall trimming system of claim 16, wherein the elongated body includes a plurality of layers, each layer having respective planar portions that are joined at a corner, the plurality of layers includes an outer layer and an inner layer, the outer layer facing away from the wall corner, and the inner layer facing toward the wall corner.
19. The wall trimming system of claim 16, wherein the corner guard member includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion.
20. The wall trimming system of claim 19, wherein a depth of the recessed portion in the inner surface is sized according to dimensions of the magnet such that when the magnet is affixed within the recessed portion the magnet does not extend beyond a plane of the inner surface that is configured to abut a wall surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In order to describe the manner in which the above-recited and other advantages and features can be obtained, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting in scope, embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
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DETAILED DESCRIPTION
[0041] As discussed above, known permanent corner guards have several drawbacks, and therefore improved corner guards are desired. For example, installation and/or removal of known corner guards damages the underlying wall. Further, known corner guards can be complicated and require an assortment of tools and additional hardware. Additionally, replacement of known corner guards can also be complicated and require an assortment of tools and additional hardware.
[0042] The embodiments disclosed herein overcome the above-noted drawbacks of corner guards by integrating strong magnets into novel corner guards, such that the corner guards can be installed simply by placing the corner guards at the corner of a wall that includes a magnetic material, such a metal corner bead. Then magnetic attraction to a corner bead in the wall (or to other magnetic material that has been preinstalled at the corner of the wall) causes the corner guards to remain fixed in place, and because a strong magnet is used, users will observe no difference between the magnetic corner guard and a conventional corner guard that has been installed using adhesives or fasteners. In certain embodiments, the magnetic attraction is sufficiently strong that the corner guards can only be dislodged and removed from the wall if considerable force (e.g., 70 pounds) is applied to pull the corner guards away from the wall. For example, the force required to remove the corner guard would be greater than encountered during normal usage. Thus, the corner guards will not be accidentally dislodged, but, with sufficient force applied in a particular direction (i.e., away from the corner), the corner guards can be intentionally removed and replaced. Nevertheless, when attached, the corner guard provides a look and feel that provides a visible impression of being permanently fixed to the angled section of the wall.
[0043] Referring now to
[0044] In certain embodiments, a decorative design may be cut in the first layer 110. The second layer 112 (or middle layer) can function as backstop to prevent the recessed cut outs in the third layer 114 (i.e., the recesses for the magnets 120) from being visible through the decorative pattern cut into the first layer 110. When the layers are metal, the layers can be spot welded together. Alternatively, the layers can be brazed or soldered together. In certain embodiments the layers can be combined using an adhesive (i.e., VHB Very High Bond Double Stick Tape). Depending on the materials of the layers, any known process for combining the layers may be used.
[0045] When the first layer 110 and second layer 112 are metal, these two layers may be combined by welding the layers together at respective points, for example. The recesses in the third layer 114 may cut or stamped out of the third layer 114, or the third layer 114 may be a molded material and the recesses may be created by the mold, for example. The layers may be combined using an adhesive. The exterior layers may be harder than the interior layers. For example, the outer/exterior layer (e.g., the first layer 110) may be metal to avoid dents when impacted, and the inner/interior layer (e.g., the third layer 114) may be elastomeric to absorb and dissipate the force of an impact across a broader area of the wall.
[0046] In certain embodiments, the magnetic corner guard 100 may be painted. Alternatively, a powder coating may be applied. The powder coating may be applied using a finishing process in which dry, free-flowing, thermoplastic or thermoset powder material is applied to a surface, melted, and hardened into an even coating. This finishing process can be performed using electrostatic spray deposition (ESD). For example, powder coating may include a preparation stage, an application stage, and curing stage, which are variously performed using a spray gun, spray booth, and curing oven. During the process, the powder is applied to a substrate's pretreated surface, melted, and then dried and hardened into a protective/decorative coating.
[0047] In the surface-preparation stage, the surface of the substrate can be cleaned and treated to ensure that the part is free of dust, dirt, and debris. For example, this surface prepare may include cleaning, rinsing, etching, blasting, and drying, which steps may be variously performed using a wash station, a blast room, and a dry-off oven.
[0048] In the coating-application stage, when the substrate is metal, the coating material may be applied via electrostatic spray deposition, which is performed using a powder spray booth, a powder feeder, and an electrostatic spray gun. Electrically-charged particles adhere to the electrically grounded surface of the substrate to be coated and will remain adhered as long as they maintain some of their charge.
[0049] In the heat-curing stage, the part that has previously been coated via ESD is then cured in a powder curing oven. The curing schedule for a part is dependent on its size, shape, and thickness. For example, smaller powder coated parts require less curing time and lower volumes of heated air to cure fully, and larger parts require more. However, generally, a curing oven that is being operated between 325 to 450 degrees Fahrenheit will cure the powder coating in a period ranging between ten minutes to over an hour. As the ESD coated part reaches the optimum curing temperature within the oven, the powder particles melt and flow together to form a continuous film over the part's surface.
[0050] Powder coating me be performed using a thermoset powder coating (i.e., short polymer molecules). During the curing process, the p thermoset powder coating undergoes an irreversible chemical cross-linking reaction, which bonds together long chains of polymer molecules. This reaction changes the physical properties and chemistry of the material and allows it to harden into a thin, even, hard finish.
[0051] Advantageously, using thermosets has the benefit that the finished surface can withstand high temperatures and has a high scratch and mar resistance. Thermoset powder coating are primarily applied to a metal surface, such as steel, stainless steel, and aluminum. However, they can also be applied to non-metal substrates, such as glass, wood, or medium density fiberboard. The range of suitable materials for the powder coating process is limited to materials that can withstand the temperatures required to melt and cure the coating powder without melting, deforming, or burning itself. They can be applied in a wide range of colors, finishes, textures, and thicknesses that are not readily achievable through conventional liquid coating methods.
[0052] Powder coating offers several advantages over conventional liquid coating methods, including increased durability, capabilities for more specialized finishes, less environmental impact, faster turnaround time, and lower material costs. They demonstrate higher resistance to impact, moisture, chemicals, and wear, and offer greater protection from scratches, abrasion, corrosion, fading, and general wear. These characteristics make them well-suited for high use and high traffic applications.
[0053] Alternatively, when the magnetic corner guard 100 is a metal, the outer face of the magnetic corner guard 100 may have a burnished metal appearance, an anodized aluminum appearance, a matte appearance, a polished appearance, a distressed antique appearance, a distressed statuary appearance, a textured appearance, a sand blasted appearance, or any other known finish or appearance. In certain embodiments, the magnetic corner guard 100 may have a rubber coating or an outer paint coating.
[0054] In certain embodiments, the magnetic corner guard 100 may have more or fewer than three layers. For example, the magnetic corner guard 100 may be a single layer, such as a molded thermoplastic having recesses molded into the thermoplastic to accommodate the magnets 120, which are held in place via an adhesive or fasteners such as screws. Alternatively or additionally, the recesses may be shaped with a lip that holds the magnets 120 in place, after the magnets 120 are clipped into place. In certain embodiments, the magnetic corner guard 100 will include a magnetic material, and the magnets 120 may be held in place by a magnetic force.
[0055] In certain embodiments, the magnets 120 are bar magnets that are dimensioned 6 inches by 0.5 inches by 0.125 inches. Alternatively, the magnets 120 are bar magnets that are dimensioned 6 inches by 0.5 inches by 0.0625 inches. The magnets 120 are arranged between 1.25 inches and 0.5 inches from the corner of the of the corner guard 100. In certain embodiments, the corner guard 100 is an elongated body that is 16 inches or 48 inches long. In certain embodiments, the corner guard 100 is an extruded L-shape, and the L-shape is symmetric with each leg of the L-shape being between 2 inches and 5 inches. In certain embodiments, the thickness of each leg (i.e., the combined thickness of the layers in
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[0059] In certain embodiments, the magnets 120 are neodymium bar magnets with dimensions 6 inches by 0.5 inches by 0.125 inches and 17.8 pounds of pull force each. The corner guard 100 may be held to the wall corner 200 with of force of more than 70 pounds of force.
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[0062] Referring again to
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[0064] In certain embodiments the recesses in the corner guard 100 to accommodate the magnets 120 may be dimensioned to have the same dimensions as the magnets 120. Generally, the closer the proximity of the magnets 120 to the metal corner bead 220, the greater the magnetic force adhering the corner guard 100 to the wall corner 200. Thus, making the surface of the magnets 120 flush with the surface of the corner guard 100 ensures that the magnetic force is not diminished due to a large distance between the magnets 120 and the magnetic material in the wall corner 200.
[0065] In certain embodiments the surface of the magnets 120 will be recessed from the surface of the corner guard 100. For example, the magnets 120 may be marking, such that when touching the wall marks will be left on the wall after the corner guard 100 is removed. In contrast the primary material of the corner guard 100 may be non-marking. Accordingly, when the surface of the magnets 120 is recessed from the surface of the corner guard 100, marks on the wall may be advantageously avoided. In certain embodiments, the magnets 120 may be entirely enclosed within the layers of the corner guard 100. Notably, the embodiment illustrated in
[0066] As illustrated in the figures herein, in certain embodiments, the corner guard 100 may be a wall trimming element that is to be arranged/positioned at an angled section of a wall (or wall corner), a desk, furniture, or other corner that one wants to protect from wear and tear. The angle can be 90 degrees, 120 degrees, or some other angle. Generally, the angle will be between 0 degrees and 180 degrees. The corner guard 100 may include a corner guard member having an elongated body (e.g., an extruded L-shape) that includes planar portions joined at a corner. The planar portions may respectively have an inner surface and an outer surface. The inner surface may be configured to abut a wall surface of a wall. The corner guard 100 may include a magnet affixed to the corner guard member. The magnet may be arranged to induce a magnetic attraction to a corner bead of the wall or another magnetic object within the wall.
[0067] In certain embodiments of the corner guard 100, the magnet is arranged at a location of the corner guard member that overlaps the corner bead of the wall, when the corner of the corner guard member is positioned at the angled section of the wall.
[0068] In certain embodiments of the corner guard 100, the magnet is a rare earth magnet, such as a neodymium magnet (e.g., Nd.sub.2Fe.sub.14B) or a samarium-cobalt magnet. Rare-earth magnets are strong permanent magnets made from alloys of rare-earth element.
[0069] In certain embodiments of the corner guard 100, the magnets 120 are magnet pieces affixed at respective locations within each of the planar portions, and the magnet pieces is configured to affix the corner guard member at an angled section of a wall by a magnetic force that is greater than or equal to 70 pounds of force.
[0070] In certain embodiments of the corner guard 100, the corner guard member is made using one or more structural materials including, e.g., a thermoplastic, a metal, a polymer, a plastic, a rubber, a plant fiber, a wood, a ceramic, an organic material, a resin, a composite material, a fiber reinforce polymer, an elastomer, a synthetic fiber, and/or gypsum board.
[0071] In certain embodiments of the corner guard 100, the corner guard member comprises an outer surface having a decorative design. As illustrated in
[0072] In certain embodiments of the corner guard 100, the corner guard member includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion.
[0073] In certain embodiments of the corner guard 100, a depth of the recessed portion in the inner surface is sized according to dimensions of the magnet such that when the magnet is affixed within the recessed portion the magnet does not extend beyond a plane of the inner surface that is configured to abut a wall surface.
[0074] In certain embodiments of the corner guard 100, the inner surface of the corner guard member comprises a non-marking material that mitigates marks on an outer surface of the wall when the corner guard member is applied to and then later removed from the angled section of the wall.
[0075] In certain embodiments, the corner guard 100 is part of a wall-trimming system, and the wall trimming system is used for positioning the corner guard 100 at an angled section of a wall (or wall corner). The wall-trimming element includes a corner bead comprising a magnetic (ferrous) material arranged proximate with the angled section of the wall. The wall-trimming element includes a corner guard member having an elongated body including planar portions joined at a corner. The planar portions respectively being configured to have an inner surface and an outer surface, the inner surface being configured to abut a wall surface of a wall. The wall-trimming element includes a magnet affixed to the corner guard member. The magnet being arranged proximate to the corner bead and inducing a magnetic attraction to a corner bead.
[0076] In the examples above it should be noted that although not shown various alternatives can be implemented. For example, in any of the embodiments illustrated, a backside fill (i.e. foam, rubber or plastic) may be used or may be omitted. Alternatively, or additionally, while the active areas have been shown as being substantially square in nature, it should be appreciated that the active areas may be rectangular or other appropriate shapes.
[0077] The discussion above refers to a number of methods and method acts that may be performed. Although the method acts may be discussed in a certain order or illustrated in a flow chart as occurring in a particular order, no particular ordering is required unless specifically stated, or required because an act is dependent on another act being completed prior to the act being performed.
[0078] Furthermore, the present invention can be described in terms of several additive or alternative configurations. For example, one configuration includes a wall trimming element for positioning at an angled section of a wall, with the wall trimming element including a corner guard member having an elongated body including planar portions joined at a corner, the planar portions respectively being configured to have an inner surface and an outer surface, the inner surface being configured to abut a wall surface of a wall, and a magnet affixed to the corner guard member, the magnet being configured to induce a magnetic attraction to a magnetic material in the wall, wherein a combined pull force of the wall trimming element is 10 pounds or greater. In an additional or alternative configuration, the magnet is arranged at a location of the corner guard member that overlaps a corner bead of the wall when the corner guard member is positioned at the angled section of the wall. In an additional or alternative configuration, the magnet is a rare earth magnet. In an additional or alternative configuration, the magnet comprises neodymium. In an additional or alternative configuration, the magnet is a plurality of magnet pieces affixed at respective locations within each of the planar portions, and the plurality of magnet pieces is configured to affix the corner guard member at an angled section of a wall by the combined pull force greater than or equal to 70 pounds.
[0079] Still further, in an additional or alternative configuration, the corner guard member comprises structural material selected from a group consisting of a thermoplastic, a metal, a polymer, a plastic, a rubber, a plant fiber, a wood, a ceramic, an organic material, a resin, a composite material, a fiber reinforce polymer, an elastomer, a synthetic fiber, and gypsum board In an additional or alternative configuration, the corner guard member comprises an outer surface having a decorative design. In an additional or alternative configuration, the corner guard member includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion. In an additional or alternative configuration, a depth of the recessed portion in the inner surface is sized according to dimensions of the magnet such that when the magnet is affixed within the recessed portion the magnet does not extend beyond a plane of the inner surface that is configured to abut a wall surface. In an additional or alternative configuration, the elongated body includes a plurality of layers, each layer having respective planar portions that are joined at a wall corner, the plurality of layers includes an outer layer and an inner layer, the outer layer facing away from the wall corner, and the inner layer facing toward the wall corner.
[0080] In still further additional or alternative configurations, the inner layer includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion. In an additional or alternative configuration, the elongated body has a length of between 16 inches and 48 inches. In an additional or alternative configuration, the plurality of layers includes a middle layer configured to prevent recesses cut into the inner layer from being visible through a cut in the outer layer. In an additional or alternative configuration, the outer layer is fixed to a next layer of the plurality of layers using an adhesive. In an additional or alternative configuration, when positioned at the angled section of the wall, the wall trimming element is configured to provide an impression of being permanently fixed to the angled section of the wall.
[0081] Another set of one or more configurations of the present invention may include a wall trimming system for positioning a corner guard at an angled section of a wall, the wall trimming system comprising: a magnetic material fixed within a wall and arranged proximate with an angled section of the wall, wherein the magnetic material is a metal corner bead, a metal lath, or a magnetic insert; a corner guard member having an elongated body including planar portions joined at a wall corner, the planar portions respectively being configured to have an inner surface and an outer surface, the inner surface being configured to abut a wall surface of a wall, and a magnet affixed to the corner guard member, the magnet being arranged such that, when the corner guard member is positioned at the angled section of the wall, the magnet will be proximate to the magnetic material fixed within the wall and inducing a magnetic attraction of 10 pounds or greater.
[0082] In an additional or alternative configuration, the magnet is a plurality of magnet pieces affixed at respective locations within each of the planar portions, and the plurality of magnet pieces is configured to affix the corner guard member at the angled section of a wall by a pull force greater than or equal to 70 pounds. In an additional or alternative configuration, the elongated body includes a plurality of layers, each layer having respective planar portions that are joined at a corner, the plurality of layers includes an outer layer and an inner layer, the outer layer facing away from the wall corner, and the inner layer facing toward the wall corner. In an additional or alternative configuration, the corner guard member includes a recessed portion in the inner surface, and the magnet is affixed within the recessed portion. In an additional or alternative configuration, a depth of the recessed portion in the inner surface is sized according to dimensions of the magnet such that when the magnet is affixed within the recessed portion the magnet does not extend beyond a plane of the inner surface that is configured to abut a wall surface.
[0083] The present invention may be embodied in other specific forms without departing from its spirit or 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.