Note: Descriptions are shown in the official language in which they were submitted.
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The invention relates to the forming of joints between drywall
sheets and, more particular1y, to methods and apparatus for embedding drywall
5 tape in joint compound.
BACKGROUND OP T~ INVE~llON
Drywa11 joints can be formed largeb with bladed spreading
tools. Joint compound is applied to a gap between drywall panels and may be
partially spread and smoothed. Drywa11 tape can then be run along and adhered
10 to the joint compound. A putty knife may then be used to embed the tape in the
compound and to spread any excess compound beneath the tape. The exposed
face of the tape may then be cleaned and excess compound removed. Purther
steips, iwluding feathering the joint, are normally involved, but the invention is
prirnarlly concerned with the preliminary steps noted.
lS The manual process is very time-consuming. Current practice ;
involves mechanized dispensing of compound and tape. An elongate hollow
tool about six feet in length is used. Joint compound is pumped into the interior
of the tool and maintained under pressure. A nozzle for dispensing the
compound is located at a forwa d end of the tool. A roll of tape is mounted on
20 the exterior of the taping tool and runs to a roller at the forward end of the tool.
Appropriate controls are provided to trigger dispensing of thc compound from
the nozzle. The roller and the nozzle are posidoned so that the compound is
applied to the joint and the tape simultaneously àpp1ied to the compound. The
r~ller generally has equal-diameter rings which engage the tape at its centre and
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;~ 2S adjacent either side edge, the object being to contact the tape against the drywall ~
compound. A tape cutdng mechanism can be triggered once the tape has been ;;
applied. With a singlo pass of thc tool, joint compound is applied along a
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drywall joint and tape is contacted along the length of the compound.
Such tools and practices having shortcomings. The tape is only
lightly adhered to the surface of the joint compound. Steps must then be taken
to embed the tape and spread the compound, which is nonnally done by hand
S with a bladed tool. The exposed face of the tape must then be cleaned. The
embedding and cleaning process is time-consuming.
SUM~IARY OF T~E INVENTION
In one aspect, the invention provides a method of applying and
embedding drywall tape in joint compound along a drywall joint. It involves
10 guiding one face of the tape onto a roller rotatably mounted on a movable
support structure. The roller is used to press the guided tape onto the joint
compound of the drywall joint with sufficient force to spread the joint
compound and is simultaneously r~lled over the one face of the tape along the
drywall 30int. This condnually embeds the tape in the drywall compound along
the drywall joint and spreads the joint compound contacted by the other face of ,
the tape. The process is fast and no extensive cleaning of the exposed face of
tho tape is required.
The method preferably involves continual application of a
movement- resisting force to the tape to prevent slippage of the tape relative to
20 the roller. The movement-resisdng force is overcome and tape is drawn onto
the roller with the pressing of the tape onto the joint compound and the
simultaneous rolling of the roller over the tape. The tape is preferably cut after
the embedding with a cutting blade fixed to the support structure. The cutting
blade may be positioned such that it extends forwardly over the roller and trails
25 the roller as the roller embeds the tape in the drywall compound along the
drywall joint. The cutting may comprise piercing the tape where it h adhered to
the joint compound with a forward pointed portion of the blade to form a slit
and manipulating the support structure largely by pivoting to extend the slit and
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sever the tape.
In another aspect, the invention provides apparatus for applying
drywall tape to joint compound along a drywall joint and simultaneously
therewith embedding the tape in the joint compound and spreading the joint
S compound contacted by the tape. The apparatus includes a support structure
having forward and rear end portions. A handle is fixed to the support
structure, permitting the support structurei to be manipulated. A roller is
mountcd for rotation on thc forward end portion of the support structure.
Guide means mounted on the support structure direct one face of the tape onto
10 the roller in response to pressing of the tape by the roller against the joint
compound and simultaneous rolling of the roller over the one face of the
drywall tape along the drywall joint. Cutting means are attached to the support
structure for cutting of the tape after application to the drywall compound. Thecutting means preferably comprise a Uade with a generally V-shaped cutting
lS edgo that extends forwardly over the roller. The blade trails the roller during
embedding of tho tape in the joint compound along the joint, but can bc engaged ;~
with tho tape by pivoting the support structure. The roller may be formed with
a 90-degreo V-shapod rolUng surface to permit taping of corners.
It is dosirable to make the tool operable with one hand and
20 remove tho weight of a roll of drywall tape. One reason is that the work
would othen~ise be obUged throughout a warkday to hold the tape with an
oxtended arm. Another roason is to permit the worker to hold a trowd carrying
joint compound in one hand and the taping apparatus in another and readily ~ -
switch between the two so that compound and tape app1ication can proccod ~ ;
~S quickly~ In that regard, the irlvendon also provides a tape dispenser which ~ ;;
fasten8 to tho usor's clothing near his waist, preferably by fastening to a belt.
Tke tapo dispenser comprises a framo, means for fastening the frame to an item
of the user's clothing (preferably a hook that fits to the uscr s belt), moans
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attached to the frame for recdving and retaining the roll permitting the roll torotate to dispense the tape. To ensure that the tape follows a worker's hand
movement, the frame is formed with an upper frame portion to which the
fastening means are secured, a lower frame portion to which the roll receiving
S and retaining means are secured, and means joining the upper and 10wer frameportions and permitting reladve pivodng at least about an axis substantially
parallel to the rotadonal axis of the roll. Accordingly, when a worker kneels tocomplete the lower end of a verdcal drywall joint, the lower frame pivots and
permits the tape delivery angle to change.
O~er aspects of the invendon will be apparent from a
descripdon below of a preferted embodiment and the various aspects of the
invendon will be more speciflcaUy defined in the appended c1aims.
nE~SCRln'lON OF T~E DRAWI~GS
The hvendon will be better understood with reference to
lS drawhgs illustrating preferred embodiments h which: ;
fig. 1 is a perspectdve view showhg a worker using a drywa11
taping tool and cooperathg tape dispens~,
figs. 2 and 3 shows pordons of a drywall joint respecdve1y
before and after using the taphg tool to apply and embed drywall tape;
fig. 4 is a perspecdve view of the taping tool;
fg. S is a view along lines S-S of fig. 4 further detailing thc
taphg tool and showhg tape being applied and embedded in a drywall pint;
fig. 6 is a perspecdve view of a taping tool adapted to embed -
drywall tape in joint compound along 90 degree corners;
2S fig. 7 is an exploded perspective view of the tape dispensa of
fig. l;
fig. 8 is a fragmented verdcal cross-secdon showing the tape
applicator of fig.1 pivoted to engage a cutting element with the drywall tape.
Reference is made to figs. 4 and 5 which illustrate a taping tool
10 constructed according to the invendon. The taping tool 10 comprises a
S support structure 12 having forwart and rear end pordons 14, 16. The support
structure 12 consists of a pair of substantiaUy parallel, spaced-apart metal plates
18, 20 and forward and rear cross-members 22, 24 spot-welded to and rigidly
joining the pair of plates 18, 20. The forward cross-member 22 is integrally
formet with an upwartly and rearwardly extending bracket 26. The taping tool
10 can be operatet with one hant using a generaUy cylintrical wooden handle
28 fixet to the rear cross-member 24 and the bracket 26 with screws. A metal
loop 30 in pivotaUy eonneetod to the exteriorof one plate 18. The permits
temporary loeation of the taping tool 10 on a worker's thumb to free his
prefotred hand, right or loft, for applieation of joint eompound from a trowel
1S otherwise held in the other hand.
A roller 32 i8 rotatably mounted on the f~rward strueture ponion
14 of tho suppon struetute 12 with a pin 34 fixed between tho plates 18, 20. Its ~;
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rotatlonal axio i8 perpondieular to tho plate8 18,20. A guido structure is defined
by flvo steol posts 3644 (ovon numbet8 only) whieh oxtend porpendicularly
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botwoon tho pair of spaeod-apan p1atos 18, 20. Tho guido strueture teeeivos the
tape 46 from a roll 48 and guide8 ono faco S0 of tho tape 46 onto tho roller 32.Tho roller 32 has a eireu1ar cylindrieal rolling sutfaee S2 (indieated in fig. 4)
appropriate for use on a planar joint, such as the joint S4 formed bet~,veen the - ~ `
pair of drywall panels S6, S8 illustrated in fig. 1-3. A eutting blade 60 is fixed
2S to the suppon strueture 12, el~tends forwatdly over the roUer 32, and has a
fotwatdly-diteeted cutting etgo 62.
Tho relativo configuratlon of tho various elements of tho taping
tool 10 should be noted. Tho configuration has beon seleeted to onsute proper ;~
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and safe application of the tape 46 along the fu11 length of the joint 54 and toensure proper cutting of the tape 46 against the joint S4. It will be noted that the
support structure 12 has upper and lower surfaces (genera11y indicated with
reference numbers 66,68 in fig.5) extending transversely between the forward
S and rear end portions. In this embodiment of the invention, the surfaces are
defined essentially by side edges of the pair of plates 18,20. The handle 28
and the cutting blade 60 are posidoned over the upper surface 66, and the
handle 28 extends in a rearward direction relative to the support structure 12
from a position rearwardly of the cutting blade 60. The guide posts 36-44
define a path below the upper surface 66, along which the tape 46 is guided to
the roller 32. D~wall tape has par~icularly shatp edges that can readily cut a
worker's skin. The arrangement avoids such contact, particularly during taping
of the upper and lower ends of the drywall joint S4. It simultsneous1y ensures
that the taping too1 10 can be properly manipulated with the handle 28,
lS particuhrly at upper and lower ends of the joint S4, to apply sufficient force to
the tape 46 to embed the tape 46 in the joint compound 64. ~Iso, when the tape
46 has boen fully Nn to the bottom of tho joint S4, the handlc 28 and the cutdngblado 60 aro proporly posidonod to pierco and sever tho tapo 46.
A force is continually applied to tho tape 46 to resist movement
of the tapo 46 leladvo to tho guido pO8tS 36-44 and roller 32. This force is
applied by a ~silient metal plate 70 fixed to the forward cross-member 22 and
bent to press against the one face S0 of the tape 46 and fo~ce the opposite face71 against one post 40. The amount of force applied is not particularly critical.
It should be sufficient to prevent slipping of the tape 46 rehtive to tho roller 32
2S ant koep the cut tape oporatively locatet on the roller 32 so that atjustment is
not sequiret to apply tho tapo 46 to a series of joints. It should, however,
pormit fonvar~ movement of the tapo 46 through the assembly of guide posts
36-44 onto the roller 32 in response to pressing of the tape 46 by the roller 32
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against the joint S4 to be taped and simultaneous rolling over the tape 46. The
arrangement of resilient meta1 plate 70 and post 40 represents a very simple andcost-effective configuration of means for app!ying the movement-resisting
force.
S The cutting blade 60 is formed on a generally U-shaped metal
plate fixed to each of the metal plates 18,20 of the support structure 12 by
spot-welting. The forwardly-directed cutting edge 62 i8 V-shapsd with a
pointed cutting edge portion 72 and a pair of cutting edge portions 73,74
(indicated in fig.4) extending laterally and rearwardly relative to the pointed
cutting edge portion 72. As apparent in figs. S and 8, the pointed portion 72
extents forwardly beyont the most forward surface of the roller 32. This ~ ;
permits the forwart pointet portion 72 to be phroted readily about the roller 32through the one face S0 of the tape 46 against the drywall joint S4, as apparentin fig. 8, to form a slit in the tape 46. The rear support structure portion 16 can ; `
lS then bo further pivotct upwardly re1ative to the forward structure portion 14 to ` ;~ ~ ~
causo tho cutting edge portions 73,74 to extent the slit and sever the tape 46. ` ~ Y
This i8 tho tapo cutting mothot prefer~cd by tho inventor. The minor gouging of
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tho d ywallpint S4 is inconsequential. Altffnativoly, the tapo 46 may bo
pani~llly drawn from thopht S4 and ten8ioned over the roller 32 (with the
movoment-resisting forco). Tho support structure may bo thon pivoted about
tho roller 32 to ffngage tho pointct portion 72 with the tape 46 to form an initial ;
slit, and then pivoted further to causo the tape 46 to be seve~ The 1atter ;method is dependable if more complex means are provided to resist tape
mo~omont in a more positiv~, manner during cutting, and is consequently not
2S prefffTod. -
The taping tool 10 is used in comblnadon with a tape dispenser
7S adapted to recoive the roll 48. The tapo dispensor 75 is illustratcd in fig. 1 in
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use with the taping tool 10 and is detailed in the exploded perspective view of
fig. 7. The tape dispenser 75 comprises a &ame formed of metal strap. It has
upper and lower frame portions 76, 78 which are freely pivoting relative to one
another. The upper frame portion 76 is bent to define a hook 80 for fitting
S about a user's belt 82. The lower frame portion 78 comprises a vertical member 84 and a horizontal cross-member 86. Flanges are used to delineate a
compartment for receiving and providing some protection for the roll 48. These
include a horizontal1y-oriented flange 88 extending transversely from a lower
end of the vertical member 84, and a pair of vertically-oriented flanges 90, 92
10 extending transversely from opposite ends of the horizontal cross-member 86,
in the same direction as the horizontally-oriented flange 88.
~ cylindrical member 94 is fixed to the horizontal member and is
dimcnsioned to fit into a central aporturo 100 of the roll 48 along the roll's
rotational axis. A length of wire 102 is used to join the pair of vertically
oriented flanges 90,92 to retain the roll 48 on the cylindrical
member 94. One end of tho wiro 102 is formed with a spring-like hook 104,
whilo the othcr end 106 is straight. The straight end 106 is inserted through one
of a pair 108 of holes in one vertical flange 90 and extended through a single
holo l lO in the opposito vortical flange 92. The hook 104 is shaped
appropriately and is
sufficiently resilient to lodge in the twin holes 108 thereby
releasably retaining the length of wire 102 between the vertical flanges 90, 92.It can be readily removed to replace the roll 48.
The uppcr and lower frame portions 76,78 pivot freely about a ;:
bolt 112. The pivot axis is p~rallel and substandally concentric with the
2~ rotational axis of the roll 48. A pair of apertures are provided, one aperture 114
in the upper framo pordon 76, the other aperture 116 in the lower frame pordon
78 substandally concentric with the roll 48 suppordng member. The bolt 112 is
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extended through the aligned apertures 114,116 and secured by a pair of nuts(on1y one nut 118 illustrated), the head 120 of the bolt 112 being located in the
interior of the cylindrical member 94 and abutted against the horizonta1 cross-
member 86. Tension on the free end of a tape 46 causes the roll 48 to rotate andS dispense tape. When the worker kneels, for example, at the foot of a vertical
drywall joint 54, the lower frame portion 78 is free to pivot relative to the upper
frame portion 76 so the tape end can follow movement of the tape taping tool
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Use of the taping tool 10 and dispenser 75 will be described
10 with reference to figs. 1-3,5 and 8. Preliminary step,s involve installing the roll ~ ;.
48 in the dispensor and securing the dispenser 7S to the worker's belt 82. The
frce end of the tape 46 is fed by hand through the guide posts 36-44 until the
one face S0 engages tho roller 32. This involves manually deflecting the
resilient met~al plate 70 to permit threading of the tape 46 between the posts 36
lS 44. The metal p1ate 70 is then re-engaged with the tape 46 whose face are
lightly clampcd betwcen the plate 70 and the post 40 to prevent rearward
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slippage of the tape 46.
The wker first applies the joint compound 64 along the joint
; S4. Assuming that the worlter is right~hnded, he can suspend the taping too1
20 10 from the thumb of his left hant using tho loop 30. He transfers the trowd
containing the compound to his right hand and applies compound along the ;
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length of thc joint S4 so that the joint S4 has the appcarance indicated in fig.2.
He then returns the trowel to his left hand, removes the taping tool 10 from hisleft thumb, and grips the taping tool 10 in his right hand with the handle 28. He
2S then p~esses the tape 46 with ~he roller 32 onto the joint 54 compound of the
trywall joint using sufficient force to spread the joint compound 64, as in fig.S. He simultaneously rolls the roller 32 over the face S0 of the tape 46 in a
downwart direction along the drywall joint S4. This causes the movement ~
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resisting force applied to the tape 46 by the resilient metal plate 70 and post 50
to be overcome and the tape 46 is continually drawn through the guide posts
36-44 onto the roller 32 and applied to the joint compound 64 along the dtywall
joint 54. As apparent in fig. S, the tape 46 is continua11y applied and embeddedS in the joint compound 64 and the joint compound 64 is continually spread.
The cutting blade 60 trails the roller 32 as the tape 46 is being
applied and embedded in thc joint compound 64, as apparent in fig. S. When
the worker reaches the bottom of the joint S4, the tape 46 is cut substantially as
indicated in fig. 8. The pointed portion 72 of the cutting edge 62 is pushed
through the t~pe 46 into the joint compound 64, and the support structure 12 is
then manipulated,1argely by pi~oting about the rolla 32, to sever the tape 46.
Tho worker can then proceed to another joint. He suspends the
taping tool 10 with the loop 30 from the thumb of his left hand. He moves the
trowel containing the compound from his left hand to his right hand and applies
lS the oompound along the length of thepint. He then transfer the trowel to his
1efe hand and g ips ~he taping tool 10. The taping and spreading steps are
Kpeated. This is done und1 a11 pints are taped or the roll 48 of tape must be
replacod The pints can thercafter be finished in a oonventional manner. The :
taping process is oxceedingly fast, permitting optimal use of a work's time
; 20 and allows wk to be performed in an effective manner by a single worker.
Refera~ is made to fig. 6 which illustrate a taping tool 122
adapted for taping corners. Components common to the taping tools 10, 122
have been labelled with the same reference numerals. The taping too1 122 has a
roller 124 with a 90 degree V-shaped rolling surface 126. For purposes of this
2S specification, the term "90 degree V-shaped rolling surface" should be
understood as corresponding substantially to a surface of revolution produced
by tovolving two lino segmonts through 360 degrees about the rotational axis of
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the roller, the two line segments being co-planar with the rotational axis,
extending from a common point towards the rotational axis, being subtended by
an angle of 90 degrees, and each oriented at 45 degrees relative to the rotational
axis. This configuration is appropriate for embedding tape in a corner where
S drywall panels meet at 90 degrees. The taping tool 122 also has a cutting blade
128 with a V-shaped cutting edge 130 extending forwardly over the roller 124
and bcyond the most forward surface of the roller 124. The pointed portion
132 of the V-shaped cutting edge 130 is substantially centered laterally relative
to the most forward surface of the roller 124. The provision of a V-shaped ;
cutdng cdge in the second taping tool 122 accommodates right-angled panels, ;
fitdng into corner~ and avoiding any gouging of adjacent panels. It should be
noted that the certain claims of this specificadon roquire a "generally V-shaped"
cutdng odge. This should not be interpretcd as requiring the precise V-shape `-
characterisdc of the two taping tools 10, 122. The object of this aspect of the
lS invcndon is to perrnit a forward pordon of the cutting edge to form an initial slit
ccntrally in tho tapc against the drywall joint (without excessive gouging of the
~;~ pane1s ad3accnt thc joint) and penTut broader pordons of the cutdng odge to
sever the tape largely at or above the surface of tho panels with a pivodng-type ~ -
motdon.
It will be apprcciatcd that a pardcul~lr embodimcnt of the
invcntion has been dcscdbed and that modifications may be made therein - - :
without depardng from the spirit of thc inventdon or necessarily depardng from
the scope of the appended claims.
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