Wallboard trim and building components and methods for making same

Abstract

A metal corner bead having a pair of flanges oriented in an L-shape and having a first lateral edge and a second lateral edge that each have been frictionally deburred. Other embodiments of the present invention comprise apparatuses and methods for forming such a metal corner bead.

1 . A metal corner bead, comprising: 
 a first flange having a first substantially burr-free, frictionally formed lateral edge; and    a second flange integrally formed with said first flange and protruding therefrom, said second flange having a second substantially burr-free, frictionally formed lateral edge.    
   
   
       2 . The metal corner bead of  claim 1  wherein at least one of said first and second flanges has at least one fastener hole therethrough.  
   
   
       3 . The metal corner bead of  claim 1  wherein at least one of said first and second flanges has a plurality of ridges formed therein.  
   
   
       4 . Metal trim, comprising: 
 a first portion having a first substantially burr-free, frictionally formed lateral edge; and    a second portion integrally formed with said first portion and protruding therefrom, said second portion having a second substantially burr-free, frictionally formed lateral edge.    
   
   
       5 . The metal trim of  claim 4  wherein at least one of said first and second portions has at least one fastener hole therethrough.  
   
   
       6 . The metal trim of  claim 4  wherein said metal trim is selected from the group of metal trim consisting of: square corner bead, bull nose corner bead, kerf bull nose corner bead, J-round bull nose corner bead, J-trim, U-trim and L-trim.  
   
   
       7 . Apparatus for manufacturing a metal corner bead from metal material having an upper surface and a lower surface, comprising: 
 a slitter for slitting the metal material into a strip having a desired width and a first lateral edge and a second lateral edge;    a deburring tool for frictionally removing at least one burr from at least one of said first and second lateral edges;    a rollforming apparatus for bending said material into a desired shape; and    a cutter for cutting the bent material into desired lengths.    
   
   
       8 . The apparatus of  claim 7  wherein said deburring tool comprises: 
 a base member;    a first support member attached to said base member;    a second support member spaced from said first support member and slidably supported on said base member for selective slidable travel towards and away from said first support member;    a first deburring assembly attached to said first support member and oriented such that when said first lateral edge is brought into moving contact therewith, said first deburring assembly frictionally removes at least one burr therefrom; and    a second deburring assembly attached to said second support member and oriented such that when said first lateral edge is in contact with said first deburring assembly, said second lateral edge is in contact with said second deburring assembly to frictionally remove at least one burr therefrom.    
   
   
       9 . The apparatus of  claim 8  wherein said first deburring assembly comprises: 
 a first lower deburring insert attached to said first support member such that a portion of the lower surface of the metal material adjacent the first lateral edge is in frictional contact with said first lower deburring insert as the metal material passes through said deburring tool; and    a first central deburring insert attached to said first support member such that the first lateral edge of the metal material is in frictional contact therewith as the metal material passes through the deburring tool.    
   
   
       10 . The apparatus of  claim 9  wherein said second deburring assembly comprises: 
 a second lower deburring insert attached to said second support member such that a portion of the lower surface of the metal material adjacent the second lateral edge is in frictional contact with said second lower deburring insert as the metal material passes through said deburring tool; and    a second central deburring insert attached to said second support member such that the second lateral edge of the metal material is in frictional contact therewith as the metal material passes through the deburring tool.    
   
   
       11 . The apparatus of  claim 10  wherein at least one of said first lower deburring insert, said first central deburring insert, said second lower deburring insert, and said second central deburring insert has multiple deburring ends that can be selectively oriented in a deburring orientation.  
   
   
       12 . The apparatus of  claim 11  wherein said first lower deburring insert, said first central deburring insert, said second lower deburring insert and said second central deburring insert each has four deburring ends.  
   
   
       13 . The apparatus of  claim 8  wherein said first deburring assembly comprises: 
 a first lower deburring insert attached to said first support member such that a portion of the lower surface of the metal material adjacent the first lateral edge is in frictional contact with said first lower deburring insert as the metal material passes through said deburring tool;    a first upper deburring insert attached to said first support member and spaced from said first lower deburring insert such that a portion of the upper surface of the metal material adjacent the first lateral edge thereof is in frictional contact with said first upper deburring insert as the metal material passes through said deburring tool; and    a first central deburring insert attached to said first support member such that the first lateral edge of the metal material is in frictional contact therewith as the metal material passes through the deburring tool and wherein said second deburring assembly comprises:    a second lower deburring insert attached to said second support member such that a portion of the lower surface of the metal material adjacent the second lateral edge is in frictional contact with said second lower deburring insert as the metal material passes through said deburring tool;    a second upper deburring insert attached to said second support member and spaced from said second lower deburring insert such that a portion of the upper surface of the metal material adjacent the second lateral edge thereof is in frictional contact with said second upper deburring insert as the metal material passes through said deburring tool; and    a second central deburring insert attached to said second support member such that the second lateral edge of the metal material is in frictional contact therewith as the metal material passes through the deburring tool.    
   
   
       14 . The apparatus of  claim 13  wherein at least one of said first lower deburring insert, said first upper deburring insert, said first central deburring insert, said second lower deburring insert, said second upper deburring insert and said second central deburring insert has multiple deburring ends that can be selectively oriented in a deburring orientation.  
   
   
       15 . The apparatus of  claim 14  wherein said first lower deburring insert, said first upper deburring insert, said first central deburring insert, said second lower deburring insert, said second upper deburring insert and said second central deburring insert each has four deburring ends.  
   
   
       16 . The apparatus of  claim 8  wherein said second deburring assembly is biased against the second lateral edge of the metal strip as it passes through the deburring tool.  
   
   
       17 . The apparatus of  claim 16  further comprising: 
 an elongated fastener extending through a hole in said second support member such that said second support member is slidably jounaled thereon, said elongated fastener having a first end attached to said first support member and a head portion on a second end protruding from said second support member; and    a biasing member between said second support member and said head portion of said elongated fastener.    
   
   
       18 . The apparatus of  claim 17  wherein said biasing member comprises a coil spring journaled on said portion of said elongated fastener protruding from said second support member.  
   
   
       19 . The apparatus of  claim 8  further comprising a handle attached to said second support member.  
   
   
       20 . A method of manufacturing trim from metal material having a first side and a second side, comprising: 
 slitting the metal material into a strip having a desired width such that the metal material has at least one lateral edge;    frictionally removing at least one burr from the at least one lateral edge of the strip of metal material; and    bending the strip of metal material into a desired shape.    
   
   
       21 . The method of  claim 20  wherein the metal material has at least one first lateral edge and at least one second lateral edge and wherein said frictionally removing further comprises frictionally removing at least one burr from at least one of said first lateral edges and frictionally removing at least one other burr from at least one of said second lateral edges.  
   
   
       22 . The method of  claim 20  further comprising cutting the bent strip of material into desired lengths.  
   
   
       23 . The method of  claim 20  further comprising forming ridges into the strip of metal material prior to said bending.  
   
   
       24 . The method of  claim 20  further comprising forming holes in the strip of metal material prior to said bending.  
   
   
       25 . The method of  claim 20  wherein the metal material is in a coil prior to said slitting and wherein said method further comprises: 
 uncoiling the metal material from the coil;    slitting the uncoiled metal material into discrete strips of metal material having desired widths;    recoiling the discrete strips of metal material into discrete coils;    uncoiling the discrete coils of strips of metal material one at a time for said frictionally removing burrs.    
   
   
       26 . The method of  claim 20  wherein the metal material is in a coil prior to said slitting and wherein said method further comprises uncoiling the metal material from the coil prior to said slitting.  
   
   
       27 . The method of  claim 20  wherein said frictionally removing burrs from at least one lateral edge comprises movably contacting the at least one lateral edge with a deburring assembly.  
   
   
       28 . The method of  claim 21  wherein said frictionally removing at least one burr from the first lateral edge and at least one other burr from the second lateral edge comprises: 
 movably contacting the first lateral edge with a first deburring assembly; and    movably contacting the second lateral edge with a second deburring assembly.