Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DRYWALL TAPE, METHOD OF MAKING AND METHOD OF USING THE SAME
PRIORITY CLAIM AND CROSS-REFERENCE
[0001] This application claims the benefit of U.S. Provisional
Application No.
62/285,939, filed November 13, 2015, which application is expressly
incorporated by reference
herein in its entirety.
FIELD OF THE INVENTION
[0002] The disclosure relates to a tape for construction generally.
More particularly, the
disclosed subject matter relates to a drywall sealing tape and a method for
using the drywall
sealing tape for finishing drywall joints or seams or taping gaps, seams and
joints between
wallboard or drywall members in the fields of commercial, residential and do-
it-yourself
construction and finishing or re-furbishing.
BACKGROUND
[0003] In the field of modern building construction or refinishing,
both commercial and
residential building techniques incorporate the use of interior wall boards
formed by flat sheets
or panels. These wall boards are available in standard dimensions, such as
1.23 meter (m) x 2.44
m (4 feet x 8 feet), 1.23 m x 3.05 m (4 feet x 10 feet), or 1.23 m x 3.66 m (4
feet x 12 feet), for
example, and are intended to be mounted to standard wood or metal studs having
separations of
typically 0.41 m (16 inches) or 0.61 m (24 inches) for walls and ceilings.
These wallboards are
generally referred to as drywall, and also may be called gypsum board,
wallboard, gyp-board,
and Sheetrock (a registered trademark of United States Gypsum Company).
[0004] A plurality of drywall sheets are secured to the underlying
wood or metal
members in adjacent or abutting side-to-side, end-to-end, and/or side-to-end
relation in order to
form a wall surface of larger dimensions. The long edges of the drywall are
tapered so that when
panels are set adjacent to each other, these "factory edges" create a shallow
recess. Even though
the adjacent drywall sheets are placed as closely as possible next to each
other, a shallow recess
or gap is present between adjacent or abutting side and/or adjacent factory
edges of the sheets.
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Furthermore drywall joints also are formed along the adjacent or abutting
factory edge and/or the
end or cut edges of adjacent or abutting drywall sheets. The end of a drywall
panel (normally the
1.23-meter length edge) is cut, not tapered, and it is much more difficult to
conceal the "butt
edge" or cut edge. An individual wall surface typically has numerous joints,
which interrupt the
continuity of the wall surface and present an unattractive appearance. If left
unfinished, the
joints would be visible through the final wall finish, such as paint,
wallpaper or other decorative
coating applied to the wall surface.
[0005] Conventional building or refinishing techniques involve
finishing the joints
formed by adjacent or abutting drywall sheets so as to render the joints or
seams as invisible as
possible after application of the final wall finish. The joints are finished
conventionally using a
drywall tape that is secured over the joints with joint compound, or mud, an
aqueous, cement-
like adhesive. Conventional drywall tapes are 5.08 centimeters (two inches) in
width and of a
uniform minimal thickness. The tape is supplied in rolls of various lengths.
[0006] According to typical drywall finishing methods, an initial or
bedding layer or coat
of j oint compound is applied over the joints, and the drywall tape is
thereafter applied to the
joints over the initial or bedding layer of j oint compound. When applying the
tape, the width of
the tape is centered or substantially centered over the corresponding joint so
that the tape bridges
the gap or groove and is secured to the outer surfaces of the adjacent or
abutting drywall sheets,
respectively, forming the joint. The bedding coat of joint compound serves the
purposes of
filling the gaps of the drywall joints, filling the depressions formed at the
joints and by the
sloping outer surface portions, i.e., the factory edges, of the adjacent or
abutting drywall sheets
and securing the drywall tape to the outer surfaces of the drywall sheets. The
end of the drywall
sheets, or cut edge (normally the four-foot length) is not tapered, and it is
much more difficult to
conceal the butt edge or cut edge with drywall tape and joint compound.
[0007] After the bedding layer of j oint compound dries, another layer or
coat of j oint
compound is applied over the tape, a step known as "blocking," to smoothly
blend or merge the
tape with the non-sloping outer surface portions of the drywall sheets.
Typical "blocking"
involves applying the layer or coat of j oint compound as a band or strip
extending along the
corresponding joint. The joint compound serves to blend or merge the side
edges of the tape into
the non-sloping outer surface portions of the drywall sheets. Conventionally,
the band or strip is
applied so as to have a width of approximately 20.32 centimeters to 25.4
centimeters (8 to 10
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inches) for drywall tape that is 5.08 centimeters (2 inches) wide, the width
of the band or strip
being centered over the width of the drywall tape. The joint compound is
allowed to dry, which
takes approximately 24-48 hours, and, thereafter, one or more layers of j oint
compound are
applied over the joints in a step known as "skimming." Skimming renders the
joints as
indistinguishable as possible from the non-sloping outer surface portions of
the dry wall sheets.
The joint compound typically has to dry for 24-48 hours between each
additional coat or layer of
joint compound, and, when dry, the individual coats of j oint compound must be
sanded to obtain
a smooth surface blending imperceptively, with the non-sloping outer surfaces
of the drywall
sheets. In addition, the joints have to be cleaned between each application of
individual coats or
layers of j oint compound in order to achieve the best result aesthetically.
For example, it is
preferable that the joints be cleaned to remove dust or other surface debris,
such as that rendered
by sanding.
[0008] Nails, screws, and similar fasteners that secure the drywall
sections into the
framework are driven into the drywall sections until the fastener heads are
recessed below the
surface of the drywall sections. The fastener heads are covered by joint
compound. While
filling the opening, a thin layer of j oint compound is spread a few
centimeters wide onto the
drywall surfaces adjacent to the filled opening. A length of drywall tape is
applied by hand or
machine to bridge across the filled opening and adheres onto the thin layer of
j oint compound.
The thin layer is at least as wide as the drywall tape to adhere the entire
width of the drywall tape
to the drywall sections. After drying the thin layer, at least one more layer
of joint compound is
applied to cover the drywall tape. The second layer is applied and spread and
smoothed out by
hand using a trowel, referred to as a drywall knife or blade, to blend
smoothly coplanar with the
surfaces of the drywall sections, such that the drywall joint compound hides
the openings, and
the drywall sections appear to be smooth and seamless covering the holes made
by the screws,
nail or other fasteners.
[0009] Wall finishing in accordance with this typical procedure is
costly, time-
consuming, and labor-intensive due to the materials and labor required. In
particular, the need
for several coats or layers of j oint compound and the need for relatively
wide bands of j oint
compound to "block" the joints add to construction and finishing costs. Since
the coats of j oint
compound must be allowed to dry for at least 24-48 hours prior to sanding and
the application of
additional layers of joint compound, it conventionally takes several days to
finish a wall for
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painting, papers or other final wall finish. In addition to the substantial
time and cost required,
conventional wall finishing techniques also require considerable skill and
expertise. It is crucial,
for instance, that the tape lays uniformly or evenly as flush or flat as
possible with the non-
sloping outer surface portions of the drywall. It also is required that the
tape not be wrinkled and
that there are no air bubbles under the tape. The finished drywall joints
should not present abrupt
variations in level but, rather, should be imperceptible after wall finishing.
It is essential,
accordingly, that the right amount of joint compound be applied to the joints
in the correct
manner for each layer or coat. The drywall tape itself requires skill to apply
over the bedding
layer of joint compound. Further, for each additional layer of joint compound,
the proper
amount of time to dry, prior to the application of additional coats or layers
of joint compound
and prior to sanding, is required to ensure the aesthetic and structural
integrity of the joints.
[0010] Over time, methods for sealing drywall panels and joints have
evolved from a
simple paper tape to more sophisticated tapes with pressure-sensitive or
elastic adhesive strips.
For instance, the original paper tape used to seal drywall joints consisted of
thick paper tape that
was coated on top and bottom with joint compound and placed over a seam. This
was allowed to
dry and one or more additional coats of joint compound were applied the now-
dry tape to smooth
the seam to match the drywall panels. A variety of devices also have been used
to increase the
speed of applying the paper tape over the joint compound. One device, known as
a "bazooka,"
dispenses both the paper tape and joint compound simultaneously to cover the
seams in one step.
If a seam is taped by hand, the seam receives the bed of mud, over which the
tape is applied, and
then one or more layers of joint compound are applied.
[0011] While paper drywall tape is generally effective, it can be
difficult to handle due to
the slippery nature of the joint compound used to hold it in place, and it is
prone to shrinkage
when drying. This can be particularly problematic in seam applications where a
large amount of
joint compound is needed for larger seams, i.e., 0.375 inch, factory edge to
butt edge seams, and
patchwork over nails, screws or indentations in the drywall. To try to avoid
shrinkage of a
sealed joint and reduce drying time, a common practice has been to apply a
minimal thickness of
the bedding layer of joint compound between the paper and the drywall panels.
However, if too
little joint compound were applied, following application of the tape, the
tape would either fall
off or bubble in areas of very thin joint compound once it had dried.
Excessive shrinkage,
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difficult application, and extended drying times, and proclivity to mold, have
made paper tape
difficult to use.
[0012] Another drawback to conventional finishing of j oints and
seams is that joints also
crack in response to natural contraction and expansions in response to the
associated wall or
walls. In such cases, the joints as well as the final wall finish need to be
repaired. Cracking,
however, tends to recur. A further problem with conventional methods of
applying drywall tape
to finish a joint is that joints may be impaired due to environmental
conditions during the
finishing procedure. Wall finishing often takes place in partially completed
and unheated
structures. Depending on the temperature and/or humidity present during
conventional wall
finishing, the quality of the joints finished may be less desirable, even if
they were finished with
a high level of skill and expertise.
[0013] Numerous drywall tapes have been proposed in order to
facilitate wall finishing as
illustrated in U.S. Pat. No. T887,014 to Overbay, et al., U.S. Pat. No.
1,751,327 to Haire, et al.,
U.S. Pat. No. 2,064,785 to Crandell, U.S. Pat. No. 4,042,739 to Emal et al.,
U.S. Pat No.
4,313,991 to Lamb, U.S. Pat. No. 4,792,473 to Vitale, U.S. Pat. No. 5,246,775
to Loscuito, U.S.
Pat. No. 5,486, 394 to Stough, U.S. Pat No. 5,604,001 to Schold, U.S. Pat. No.
5,687,523 to
Stough, and U.S. Pat. No. 5,711,124 to Stough, et al.
[0014] U.S. T887,014, U.S. 4,042,739, U.S. 4,313,991, U.S. 4,792,473,
U.S. 5,246,775,
U.S. 5,486,394, U.S. 5,687,523, U.S. 5,687,523, and U.S. 5,711,124 relate to
adhesive drywall
tapes for direct application to drywall joints without the need of a bedding
coat of joint
compound. U.S. 4,042,739 discloses an adhesive drywall tape with a synthetic
resin-based
adhesive. Drywall tapes with acrylic adhesives are disclosed in U.S.
4,792,473, U.S. 5,246,775,
U.S. 5,486, 394, U.S. 5,687,523, and U.S. 5,711,124. Adhesive drywall tapes
having a hot melt
adhesive are disclosed in U.S.T887,014 and U.S. 5,604,001.
[0015] U.S. T887,014 discloses that the hot melt adhesive is applied to the
drywall tape
non-uniformly so as to provide a maximum amount of adhesive along a centerline
of the tape.
U.S. 4,313,991 teaches an adhesive drywall tape having a central projection on
an outer or non-
adhesive surface of the tape to cause a trowel for applying plaster over the
tape to form a
perfectly feathered edge. U.S. 4,042,739 teaches an adhesive drywall tape
wherein the tape has a
thickened center portion on an outer or non-adhesive surface thereof so that
the non-adhesive
surface becomes flat when the tape is applied to a joint.
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[0016] U.S. 5,604,001 teaches an adhesive drywall tape wherein side
edges of the tape
are buffed so that the side edges are thinner than the center of the tape
whereby a finish coat of
spackle can be applied over the side edges of the tape to obtain a smooth
finish. U.S. 5,604,001
also discloses a plastic bead on an inner or adhesive surface of the tape, the
bead having raised
portions for enhancing the hinging action of the tape with the tape is applied
to corner joints.
[0017] U.S. Pat. No. 1,039,363 relates to an adhesive tape for
joining abutting or adjacent
edges of corners of paper boxes. The tape is formed of a narrow inner strip of
tape and a wider
outer strip of tape placed over the inner strip. The inner and outer strips of
tape are made of
materials having different strengths, with the inner strip being made of cloth
and the outer strip
of paper.
[0018] U.S. Pat. No. 4,042,739 relates to a paper drywall tape with
self- adhesive on one
side of the tape, which can be wetted and adhered against the drywall and
dried. Once the
adhesive is dried, the adhesive becomes impervious to water. A top layer of j
oint compound is
applied to cover the paper tape. The tape separates the top layer from the
remainder of the
drywall joint, which prevents the top layer of joint compound from penetrating
the paper tape
and bonding to the remainder of the drywall joint. The entire surface of the
tape may be
perforated with holes to expel trapped air bubbles. However, the holes
covering the entire
surface of the tape compromise the tape's strength. As the inventor has
experienced, a user finds
many problems with this type of tape such as one commercial product called E-Z
Taping
Systems. The top layer of j oint compound is susceptible to forming a crack
over time and the
tape is also susceptible to mold or mildew growth over time in a humid
environment, such as
kitchens or bathrooms.
[0019] While some paper tapes are generally effective, but it can be
difficult to handle
due to the slippery nature of the joint compound used to hold it in place.
Another alternative
taping method includes the use of a mesh tape, formed with mesh pattern of
fibrous material.
Mesh tapes often are covered on one slide with a slight adhesive material to
facilitate placement
of the mesh tape on the drywall. Once in position, the mesh tape is covered
with a bedding layer
of j oint compound and allowed to dry. Due to the rough and perforated surface
texture of the
mesh tape, joints sealed with this tape also are prone to cracking or showing
the mesh pattern in
the joint compound. Thus, this tape requires multiple coats of j oint compound
to achieve a
smooth wall surface for finishing.
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[0020] Another drawback of the mesh tape is the tendency of joint
compound to pass
completely through the mesh if too much pressure is applied by the taping
knife during
application. In these instances, the top surface of the mesh tape has no joint
compound covering
it and can be totally exposed. Eventually, the mesh tape peels from the wall
leaving a
checkerboard pattern of joint compound on the wall. Hairline cracks also will
develop in at wall,
at a joint seam, or at corners and can be visible through the mesh tape. Such
small cracks
particularly occur around doors or windows.
[0021] Other variations in the design of drywall tape have been used
but not successfully.
U.S. Pat. No 5,246,775 relates to a self-sticking tape with holes extending in
rows across the
width of the tape with one row being spaced or staggered from the other along
the length of the
tape. The pattern of perforations comprises a multiplicity of perforations
extending across the
width and spaced along the entire length of the tape. An acrylic adhesive with
a release backing
is applied to one surface of the tape, after peeling away the release backing,
so that the perforated
tape can be attached to the drywall seam. Joint compound placed on the top or
outer surface of
the tape supposedly penetrates the perforations and holding the tape to the
seams. This tape has
the same drawbacks and disadvantages as the tape disclosed in U.S. Pat. No.
4,042,739 as
discussed above. The drawbacks also include that the tape weakens and falls
apart when wet.
[0022] U.S. Pat. No. 5,687,523 discloses a drywall tape for taping
seams between
adjacent drywall units. Such a tape includes a first layer of flexible paper
material with an
inwardly facing pressure-sensitive adhesive coating, a second layer of
reinforcing woven fiber
materials overlying the first layer, and a third layer of flexible material
overlying the woven fiber
material to encapsulate the fiber material between the first and second
layers. The third layer has
an outwardly facing release coating. The process of applying multiple layers
of joint compound
over the tape is costly, time-consuming and messy to handle. Such a tape has
serious drawbacks
in installation. Specifically, the tape is only held in place on the wall seam
with the adhesive
instead of the joint compound. Thus, when the adhesive eventually weakens, the
tape will
delaminate from the drywall panels, likely creating a crack through the
overcoat of joint
compound. Further, because the adhesive provides different expansion
characteristics from the
drywall panels, the walls exposed to severe temperatures and humidity
variations are prone to
cracking.
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[0023] U.S. Pat. No. 5,711,124 discloses a self-adhesive wallboard
joint tape, which
includes a paper base layer with a mud- or compound-receptive surface and the
other surface
with a pressure sensitive adhesive, and a transfer release liner. The transfer
release liner is
applied with a release coating against the adhesive surface of the paper base
layer, and is coated
on the backside with a low-tack releasable adhesive. The drawbacks of such a
tape include the
complex structure of the tape, high cost, and several layers of joint
compound, with the
necessitated drying time and costly labor and other materials of the
conventional drywall tape
and seaming methods.
[0024] U.S. Pat. No. 6,413,606 teaches a drywall paper tape having a
narrow paper tape
of uniform width but non-uniform thickness, including a central portion of
greater thickness and
side portions of less thickness. The tape has a width to be disposed in a
depression formed at a
drywall joint by sloping outer surface portions of drywall sheets,
respectively, forming the joint
or seam, such that a planar outer surface of the tape is substantially flush
with non-sloping outer
surface portions of the drywall sheets, respectively. The tape has a layer of
yucca adhesive pre-
applied on one surface. The drawback of these tapes is that the raised central
portion of the tape
tends to bubble rather than sink into the depressions.
[0025] U.S. Pat. No. 7,141,284 This invention relates to a composite
construction for use
as a label or a tape to be adhered to a second substrate comprising a rubber-
based material (e.g.,
vehicular tire). U.S. Pat. No. 8, 795,808 discloses a reinforcing drywall tape
having a greige
combined with a laid scrim constructed in situ on the greige and bonded to the
greige by a resin
coating, and a pressure sensitive adhesive fully covering an inward facing
surface of the greige
wherein the greige is adapted for adherence to drywall sections.
[0026] U.S. Pat. Pub. No. 20080139064 (issued as U.S. 9,376,824)
discloses a joint tape
for finishing joints between wallboards comprising a nonwoven substrate (e.g.,
polymer or glass
fibers) that does not swell substantially in the presence of water. A method
of finishing a joint
includes steps of applying the joint tape to the joint between boards by
embedding the joint tape
in a first coat of joint compound; applying a second coat of joint compound
over the tape before
the first layer of joint tape and compound have substantially dried and,
optionally, applying a
third fill or finish coat of joint compound over the tape wherein this third
application is carried
out before the joint tape and second coat have substantially dried.
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[0027] U.S. Pat. No. 8,291,663 discloses a drywall sealing tape,
which includes a
substrate layer and a mesh layer made of mesh filament. The mesh layer is an
array of filaments
formed together which, when adjacent the substrate, create an inter-filament
cavity for receiving
and retaining joint compound between the substrate and the drywall panel. The
inter-filament
cavities retain a volume of joint compound corresponding to the approximate
thickness of the
mesh filament. The joint compound retained within the cavities serves to
adhere to the drywall
sealing tape to the drywall panels. Such a tape may also include an adhesive
coating on the mesh
layer. The substrate is either paper or a polymer. The filaments can be made
of nylon, glass
fibers, rigid vinyl, or metal.
[0028] U.S. Pat. No. 8,828,892 discloses a drywall tape having a nonwoven
fabric and a
reinforcing scrim, wherein the nonwoven fabric has chopped glass fibers laid
flat in the
nonwoven fabric. The fibers are substantially straight, randomly laid and
bonded to one another
to resist forces exerted in random directions. The reinforcement scrim has
elongated reinforcing
strands of low profile thickness joined against a side of the nonwoven fabric,
such that the scrim
and the nonwoven fabric reinforce each other, and reinforce a joint compound
in which the
drywall tape is imbedded.
[0029] Some of the tapes comprising glass fibers are described "fire-
retardant," and
"mold or mildew- resistant." But they are very expensive and may not be
actually "fire-
retardant," and "mold or mildew- resistant."
[0030] The drawbacks of the tapes disclosed in U.S. 8,291,663 and U.S.
8,828,892 are
that these tapes require at least three layers of joint compound to be applied
to form a seamless
joint and does not reduce the time, labor or materials needed to create seams
between the
wallboards.
SUMMARY OF THE INVENTION
[0031] The present disclosure provides a tape, a method of using the
tape and a method
of making the tape. The tape is used for taping gaps, seams or joints between
wallboard or
drywall members, for example, for sealing a dry wall joint. Such a tape may be
also called as a
drywall tape or a drywall sealing tape, and is used in the fields of
commercial, residential and do-
it-yourself construction and finishing or re-furbishing.
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[0032] In one aspect, a tape for sealing a dry wall joint is
provided. Such a tape
comprises a paper substrate, and a coating of resin-remoistening adhesive on
one surface of the
paper substrate. The paper substrate and the tape define a plurality of holes
or interstices
patterned longitudinally in a single line along or near a center line of the
paper substrate.
[0033] In some embodiments, the plurality of holes or interstices is spaced
evenly apart
along the centerline of the paper substrate. Each of the plurality of holes or
interstices is in a
shape being round, oval, oblong or any combination thereof Each of the
plurality of holes or
interstices has a suitable size to permit a joint compound to penetrate
through the holes or
interstices to a drywall joint so as to bond the drywall panels. The plurality
of holes or
interstices are patterned in a line and spaced apart in a suitable distance.
The coating of resin-
remoistening adhesive is activatable with water, a wetting gel or any other
suitable fluid.
[0034] In some embodiments, the tape further comprises a longitudinal
line of crease
along the centerline of the tape. The centerline of the tape is creased or
folded down. The
plurality of the holes or interstices are also disposed along the centerline
of the paper substrate
and the tape.
[0035] In another aspect, a tape product comprising a core and the
tape described herein
is provided. The tape for sealing a dry wall joint is wound in a roll around
the core. The tape
comprises a paper substrate; and a coating of resin-remoistening adhesive on
one surface of the
paper substrate. The paper substrate (and the tape) define a plurality of
holes or interstices
patterned longitudinally in a single line along or near a center line of the
paper substrate. Such a
tape product is configured to be pulled and applied manually or by a machine
at the longitudinal
direction.
[0036] In another aspect, the present disclosure provides a method of
using the tape or
the tape product described above. Such a method comprises the following steps:
moistening the
coating of resin-remoistening adhesive on one side of the tape; applying the
tape to a joint
between two drywall panels. The one side of tape with the coating of resin-
remoistening
adhesive faces the two drywall panels, and the plurality of holes or
interstices are aligned
longitudinally along about the center line of the joint. The coating is
moistened and the tape may
be applied manually or using a machine. The machine direction is the
longitudinal direction.
The method further comprises applying a joint compound for a first time,
wherein the joint
compound enters into the joint through the plurality of holes or interstices.
The method may also
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comprise a step of drying the joint compound after applying a joint compound
for a first time.
The method can further comprise applying the joint compound for a second time.
[0037] The present disclosure also provides a method of making the
tape described
above. Such a method comprises at least one step of forming the plurality of
holes or interstices
aligned longitudinally along or near the center line of the tape. The holes or
interstices can be
formed on the paper substrate or the tape by any suitable means such as die
cutting. The tape can
be wound around the core to form a tape product as described.
[0038] In some embodiments, the present disclosure provides a novel
paper drywall tape
that has holes or interstices in a round, oval, slit or other shape that are
die cut in a singular
longitudinal pattern down the center of the tape in machine direction. Because
the tape has only
a single line of holes or interstices down the center of the tape, the tensile
strength of the tape is
not compromised. On one side of the tape a resin-remoistening adhesive is
applied. When the
tape is moistened on the adhesive side with water, a wetting gel or similar
fluid mixture, either
manually or by the use of an applicator with an enclosed reservoir of water,
the tape is easily
applied directly to the surface areas of two adjacent drywall boards. The
center holes or
interstices make it easy to align and apply the tape down the center of the
joint between the
boards whether on walls, floorboards, corners or in ceiling applications. A
first layer of j oint
compound is applied over the tape to secure the tape fully to the outer
surface portions of the
wallboards. The longitudinal holes down the center of the tape allow the joint
compound to
enter between the tape and the drywall seam and adhere to the tape to the
seam. The holes
aligned longitudinally also permit air bubbles to release as needed.
[0039] As the joint compound and tape dry after approximately 24
hours or a shorter
period if using a dry-type joint compound, the center holes or interstices
recess into the seam or
joint between the wall panels to form depressions or recesses in the shape of
the holes. When a
second application of j oint compound is applied over the seams, the recesses
or depressions in
the seams completely disappear, leaving smoothly surfaced joints ready for
further finishing of
the walls with plaster, paper or other material. The advantages of the present
invention include
that it obviates the need for a third layer of j oint compound, saves
considerable time, materials
and money over the conventional method of drywall tape application. Further,
the tape retains
its tensile strength, does not require a multilayer structure with fibers in
the structure, and is less
expensive to manufacture than multilayer nonwoven structures containing fiber
materials.
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[0040] The advantages also include the ease of application of the
tape and formation of
joints or seams between wallboard panels that does not require the lengthy 48-
to 72-hour drying
time before finishing because two additional joint compound layers are not
applied over the
conventional tapes and bedding compound, as is the conventional joint sealing
method. Rather,
it may take only 15-20 minutes for the tape to set after application to the
drywall panel before a
layer of bedding joint compound can be applied and the recesses or depressions
in the tape form.
Moreover, upon application of a second layer of joint compound, the recesses
or depressions
disappear and a smooth joint for wall finishing is created. Thus, a third
application of joint
compound is unnecessary. The tape obviates the need for an additional joint
compound
application, saving considerable cost, materials and labor.
[0041] For a more complete understanding of the above listed features
and advantages of
the drywall tape disclosed herein, reference should be made to the attached
drawings. Further,
additional features and advantages of the invention may be described and will
become apparent
from a detailed description of the drawing and the details description. Other
features and
advantages of the present invention will become apparent to those skilled in
the art from the
descriptions herein. It is to be understood, however, that the detailed
description of various
embodiments and specific examples, while indicating preferred and other
embodiments of the
present invention, are given by way of illustration and not limitation. Many
changes and
modifications within the scope of the present invention may be made without
departing from the
spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The present disclosure is best understood from the following
detailed description
when read in conjunction with the accompanying drawings. It is emphasized
that, according to
common practice, the various features of the drawings are not necessarily to
scale. On the
contrary, the dimensions of the various features are arbitrarily expanded or
reduced for clarity.
Like reference numerals denote like features throughout specification and
drawings.
[0043] FIG. 1 is a plan view illustrating an exemplary dual-tape
product which can be cut
into two exemplary tapes in accordance with some embodiments.
[0044] FIG. 2 is a plan view illustrating a portion of an exemplary
tape in accordance
with some embodiments.
12
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[0045] FIG. 3 is a plan view illustrating a portion of another
exemplary tape in
accordance with some embodiments.
[0046] FIG. 4 illustrates the tape of FIG. 2.
[0047] FIG. 5 is a sectional view illustrating the tape of FIGS. 2-4
comprising adhesive
on one side (for example, a section along line a-a' of the tape of FIG. 4).
[0048] FIG. 6 illustrates a tape product comprising a core and a tape
in accordance with
some embodiments.
[0049] FIG. 7 is a flow chart diagram illustrating a method of using
an exemplary tape
for sealing a dry wall joint in accordance with some embodiments.
[0050] FIG. 8 is a sectional view illustrating the structure after a tape
is applied to a joint
between two drywall panels.
[0051] FIG. 9 is a sectional view illustrating the structure after a
joint compound is
applied to the tape in some embodiments.
DETAILED DESCRIPTION
[0052] This description of the exemplary embodiments is intended to
be read in
connection with the accompanying drawings, which are to be considered part of
the entire
written description. In the description, relative terms such as "lower,"
"upper," "horizontal,"
"vertical,", "above," "below," "up," "down," "top" and "bottom" as well as
derivative thereof
(e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to
refer to the
orientation as then described or as shown in the drawing under discussion.
These relative terms
are for convenience of description and do not require that the apparatus be
constructed or
operated in a particular orientation. Terms concerning attachments, coupling
and the like, such
as "connected" and "interconnected," refer to a relationship wherein
structures are secured or
attached to one another either directly or indirectly through intervening
structures, as well as
both movable or rigid attachments or relationships, unless expressly described
otherwise.
[0053] For purposes of the description hereinafter, it is to be
understood that the
embodiments described below may assume alternative variations and embodiments.
It is also to
be understood that the specific articles, compositions, and/or processes
described herein are
exemplary and should not be considered as limiting.
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[0054] The present disclosure provides a tape, an assembled tape
product comprising
such a tape, a method of using the tape and a method of making the tape. The
tape is used for
taping gaps, seams or joints between wallboard or drywall members, for
example, for sealing a
dry wall joint.
[0055] For purposes of this present application, the term "drywall" shall
be used to refer
to the material used on interior walls. Drywall comprises a core of plaster-
like gypsum
sandwiched between layers of heavy paper.
[0056] In FIGS. 1-9, like items are indicated by like reference
numerals, and for brevity,
descriptions of the structure, provided above with reference to preceding
drawings, are not
repeated. FIGS. 1-3 only illustrate a portion or segment of exemplary tapes or
tape product,
which are continuous with a certain length on a roll.
[0057] Referring to FIG. 1, a portion or segment of an exemplary dual-
tape product 10 is
illustrated. Dual-tape product 10 can be cut into two exemplary tapes 20, 30
in accordance with
some embodiments. FIGS. 2 and 3 illustrate the corresponding portions of
exemplary tapes 20,
30. FIG. 4 illustrates a portion of exemplary tapes 20, 30 showing an
exemplary tape may be in
any suitable length. FIG. 5 illustrates a cross-section of exemplary tapes 20,
30. Exemplary
tapes 20, 30 have the same structure except the pattern of the holes or
interstices. So unless
expressly indicated otherwise, an exemplary tape can be referred to tape 20 or
30
interchangeably.
[0058] Referring to FIG. 1, the portion or segment of an exemplary dual-
tape product 10
may have a suitable width, for example, 10.16 centimeters (cm) (4 inches), and
each of resulting
exemplary tapes 20, 30 has a width (T) of 5.08 cm (2 inches). The segment of
an exemplary
dual-tape product 10 and corresponding portions of tapes 20, 30 have any
suitable length, for
example, 20.32 cm (8 inches) as shown for the purpose of illustration only.
The tape 10 is to be
cut down along the center line 15 into tapes 20, 30, which are of equal width
(W). The width (T)
of dual-product 10 is twice the width (W) of tapes 20, 30.
[0059] Referring to FIGS. 1-5, a tape 20 (or 30) provided in the
present disclosure
comprises a paper substrate 12, and a coating of resin-remoistening adhesive
14 on one surface
of the paper substrate 12. The paper substrate and also the tape 20 or 30
define a plurality of
holes or interstices 16 patterned longitudinally (lengthwise) in a single line
along or near a center
line 17 of the paper substrate 12. For example, centers of the holes or
interstices 16 off the
14
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center line 17 by 5% or 10% or less of the width (W) of the tape can be
considered as "near" the
center line 17.
[0060] In some embodiments, the plurality of holes or interstices 16
is spaced evenly
apart along the centerline 17 of the paper substrate 12. Each of the plurality
of holes or
interstices 16 is in a shape, for example, being round, oval, oblong or any
combination thereof
Each of the plurality of holes or interstices 16 has a suitable size, for
example, a diameter or
length (d) in the range of from about 3.175 mm to about 22.225 mm (i.e. from
about 1/8 inch to
about 7/8 inch). The plurality of holes or interstices may be spaced by any
suitable distance (L),
for example, by about 6.35 mm (i.e. 1/4 inch) or about 3.175 mm (i.e. 1/8
inch).
[0061] Referring to FIG. 2, a preferred pattern of holes in a segment of
exemplary tape
having 20.32 cm (8 inches) in length is illustrated. Each of the plurality of
holes or interstices
16 is circular and has a diameter (d) of 6.35 mm (i.e. 1/4 inch). The
plurality of holes 16 is
uniformly spaced by a distance (L) of 6.35 mm (i.e. 1/4 inch) between two
adjacent holes. In
every 20.32 cm (8 inches) long segment, sixteen holes are spaced by 6.35 mm
(i.e. 1/4 inch).
15 Referring to FIG. 4, any two adjacent holes are spaced by spaced by 6.35
mm (i.e. 1/4 inch) in the
whole exemplary tape 20.
[0062] Referring to FIG. 3, another preferred pattern of holes in a
segment of exemplary
tape 20 having 20.32 cm (8 inches) in length is illustrated. Each of the
plurality of holes or
interstices 16 is circular and has a diameter (d) of 6.35 mm (i.e. 1/4 inch).
The plurality of holes
20 16 is uniformly spaced by a distance (L) of 3.175 mm (i.e. 1/8 inch)
between two adjacent holes.
In some embodiments, twenty-one circular holes 16 having a diameter (d) of
6.35 mm (i.e. 1/4
inch) are spaced by 3.175 mm (i.e. 1/8 inch) between two adjacent holes, while
a space of 6.35
mm (1/4) in length is interposed between two holes or interstices 16 in every
20.32 cm (i.e. 8
inches) of the tape 30 in length.
[0063] In some embodiments, the paper substrate has a base weight in the
range from
2.44 Kg/m2 to 3.25 Kg/m2 (i.e. from 15 lbs. to 20 lbs. per 3,000 sq. feet).
The paper substrate
may have a dry tensile strength of at least 9.5 Kg of force per centimeter
(i.e. 53 lb. of force per
inch) in a longitudinal direction, and at least 4.5 Kg of force per centimeter
(i.e. 25 lbs. of force
per inch) in a cross direction. The paper substrate may have any suitable
width, for example,
preferably a width of about 2.54 cm (i.e. 2 inches). The paper substrate
comprises a caliper of at
least 0.001 inch (0.0254 mm).
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[0064] Referring to FIG. 5, the coating of resin-remoistening
adhesive 14 is activatable
with water, a wetting gel or any other suitable liquid. A viscous liquid may
be used. The paper
substrate comprises a wet tensile strength in machine direction (i.e.
longitudinal) of at least 2.3
Kg/cm (i.e.13 lbs. of force per inch). The resin-remoistening (or rewetting)
adhesive can be
water-based, and may comprise a suitable ingredient. Examples of a suitable
ingredient 14
include but are not limited to polyvinyl alcohol, polyvinyl acetate. The
adhesive 14 may have
fast re-wetting tack properties, and also have non-blocking and non-curling
properties.
[0065] Specifically, the tape is generally between slightly less than
two inches or greater
than two inches in width, and the holes or interstices are die cut
longitudinally down the center of
the tape, making it easy to align and apply the tape in corners and center the
tape along the joints
between adjacent or abutting wallboards. The tape is typically a wallboard
tape, of between 20
lb. to 30 lb. basis weight, and the adhesive is a resin-remoistening adhesive
or tape adhesive such
as Sierra Remoistenable WB 145 C1S manufactured by Sierra Coating, LLC located
at 1820
Enterprise Dr., De Pere, WI 54115.
[0066] In some embodiments, the tape 20 or 30 further comprises a
longitudinal line of
crease along the centerline of the tape 17 as shown in FIGS. 1-2. The
centerline 17 of the tape
or 30 is creased or folded down. The plurality of the holes or interstices 16
are also disposed
along the centerline 17 of the paper substrate and the tape.
[0067] Referring to FIG. 6, an exemplary tape product 40 comprises a
core 42 and the
20 tape (for example, exemplary tape 20 or 30) described above. The tape 20
or 30 for sealing a dry
wall joint is wound in a roll around the core 42. The tape 20 or 30 comprises
a paper substrate
12, and a coating of resin-remoistening adhesive 14 on one surface of the
paper substrate 12.
The paper substrate 12 (and the tape 20 or 30) defines a plurality of holes or
interstices 16
patterned longitudinally in a single line along or near a center line 17 of
the paper substrate 12.
[0068] In some embodiments, the tape 20 or 30 has a length in the range of
from about
7.62 m to about 152.4 m (i.e. from about 25 feet to about 500 feet). The core
42 has a diameter
in the range from about 6.35 cm to about 7.62 cm (i.e. from about 2-1/2 inches
to about 3
inches). Each of the plurality of holes or interstices 16 in the tape has a
suitable size, for
example, a diameter or length in the range of from about 3.175 mm to about
22.225 mm (i.e.
from about 1/8 inch to about 7/8 inch). In some embodiments, the paper
substrate 12 has a width
of about 2.54 cm, and the plurality of holes or interstices 16 in the tape are
spaced by about 6.35
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mm (i.e. 1/4 inch) or about 3.175 mm (i.e. 1/8 inch). The coating of resin-
remoistening adhesive
14 is activatable with water or a wetting gel.
[0069] Preferably, the tape product 40 comprises a 2-inch wide tape
20 or 30 having a
basis weight of 3.25 Kg/m2 (i.e. 20 lbs. per 3,000 sq. feet). The tape 20 or
30 is wound on a core
that is 2-1/2 inches in diameter. The caliper of the tape is approximately
0.0254 mm (0.001
inch), with a dry tensile strength of about 9.5 Kg/cm (53 lb. of force per
inch) in machine
direction, and 4.5 Kg/cm (25 lb. of force per inch) in cross direction. When
re-moistened with
water or a wetting gel or other similar viscous material, the machine
direction tensile strength is
at least 2.3 Kg/cm (13 lb. of force) per inch. The adhesive used before
coating can be a resin-
remoistening adhesive that comprises approximately 55% solids with a viscosity
of
approximately 8,500 centipodes (cps.) in some embodiments. The adhesive may
also be used to
form an envelope seal, has excellent nonblocking and noncurling properties,
and has a fast re-
wetting tack. The adhesive on the tape, for example, on the tape of a roll, is
dry and smooth.
[0070] The present disclosure also provides a method of using the
tape or the tape
product for sealing a dry wall joint described above. Referring to FIG. 7, an
exemplary method
50 of using an exemplary tape 20 or 30 comprises the following steps.
[0071] At step 52, the coating of resin-remoistening adhesive 14 is
moistened on one side
of the tape 20 or 30. Tape 20 or 30 may be pulled out and moistened from a
roll in tape product
40 manually or by a machine. The moistening step may be formed using water, a
wetting gel or
any other suitable liquid. The coating 14 is moistened and the tape may be
applied using a
machine in some embodiments. The machine direction is the longitudinal
direction.
[0072] At step 54, the tape 20 or 30 is applied to a joint 52 between
two drywall panels
50. The one side of tape 20 or 30 with the coating of resin-remoistening
adhesive 14 faces the
two drywall panels 50. The plurality of holes or interstices 16 are aligned
longitudinally along or
approximately along the center line of the joint 52. The structure after step
54 is illustrated in
FIG. 8.
[0073] At step 56, a joint compound 56 is applied for a first time,
wherein the joint
compound 56 enters into the joint 52 through the plurality of holes or
interstices 16, and bond the
drywall panel 50. FIG. 9 illustrates the structure after a joint compound 56
is applied to the tape
20 or 30 in some embodiments. FIG. 9 is for illustration only. The surface is
flat after step 56.
Joint compound 56 may fill a portion of the joint or the whole joint 52.
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[0074] At step 58, the joint compound 56 is dried after applied for
the first time. The
drying may be performed in air. The drying time may last for a time of period,
for example less
than 30 minutes (e.g., 15-20 minutes).
[0075] At step 60, the joint compound 56 is optionally applied for a
second time to
flatten the surface and make the joint invisible. The drywall joint becomes
invisible and the
drywall boards are finished with a flat surface after step 60.
[0076] The present disclosure also provides a method of making the
tape 20 or 30, and
tape product 40 described above. Such a method comprises at least one step of
forming the
plurality of holes or interstices 16 aligned longitudinally along about the
center line of the tape.
The holes or interstices 16 can be formed on the paper substrate or the tape
by any suitable
means such as die cutting. The tape 20 or 30 can be wound around the core 42
to form a tape
product 40 as described.
[0077] The advantages of the present invention are the ease of
application of the tape and
formation of joints or seams between wallboard panels that does not require
the lengthy 48- to
72-hour drying time before finishing because two additional joint compound
layers are not
applied over the conventional tapes and bedding compound, as is the
conventional joint sealing
method. Rather, it may take only 15-30 or 15-20 minutes for the tape and the
moistened
adhesive to dry and set after application to the drywall panel before a layer
of bedding joint
compound can be applied and the recesses or depressions in the tape form.
Moreover, upon
application of a second layer of joint compound, the recesses or depressions
disappear and a
smooth joint for wall finishing is created. Thus, a third application of joint
compound is
unnecessary. The tape obviates the need for an additional joint compound
application, shortens
the drying time, and saves considerable cost, materials and labor. In
comparison, three
application steps of joint compounds are needed in those methods using
existing tapes, and each
application step of joint compound requires a drying period of 24-48 hours.
[0078] In addition, unlike other tapes, the tape in the present
disclosure avoids the
bubbling issue experienced with other tapes, has higher tensile strength and
better adhesion to
walls, and does not crack or shrink when it dries. Other tapes bubble and
shrink due to either the
lack of holes or the configuration of holes throughout the entire surface of
the tape.
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[0079] Although the subject matter has been described in terms of
exemplary
embodiments, it is not limited thereto. Rather, the appended claims should be
construed broadly,
to include other variants and embodiments, which may be made by those skilled
in the art.
19
