U.S. patent application number 12/099484 was filed with the patent office on 2008-10-23 for wallboard tape and method of using same.
This patent application is currently assigned to Dura-Tape International. Invention is credited to Lee Goldman.
Application Number | 20080256886 12/099484 |
Document ID | / |
Family ID | 37417717 |
Filed Date | 2008-10-23 |
United States Patent
Application |
20080256886 |
Kind Code |
A1 |
Goldman; Lee |
October 23, 2008 |
Wallboard Tape And Method Of Using Same
Abstract
The present invention is a wallboard tape that simplifies the
covering of elongated wallboard joints formed by the abutting of
adjacent wallboards. The wallboard tape includes a fibrous paper
tape having a resin-impregnated body and a water-soluble,
water-activated adhesive layer applied to a surface of the body.
The resin impregnated body remains relatively non-moisture
absorbent during wetting of the adhesive layer thereby allowing the
adhesive layer to dry several minutes after installation of the
tape over a wall joint.
Inventors: |
Goldman; Lee; (Millburn,
NJ) |
Correspondence
Address: |
SILLS CUMMIS & GROSS P.C.
ONE ROCKEFELLER PLAZA, IP DEPARTMENT - 25TH FLOOR
NEW YORK
NY
10020
US
|
Assignee: |
Dura-Tape International
Bloomfield
NJ
|
Family ID: |
37417717 |
Appl. No.: |
12/099484 |
Filed: |
April 8, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11129642 |
May 16, 2005 |
|
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12099484 |
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Current U.S.
Class: |
52/366 |
Current CPC
Class: |
E04F 21/00 20130101;
E04F 13/04 20130101; E04F 13/042 20130101 |
Class at
Publication: |
52/366 |
International
Class: |
E04F 13/07 20060101
E04F013/07 |
Claims
1-6. (canceled)
7. A wallboard tape for covering elongated joints in gypsum and
other type wallboards comprising: a fibrous paper tape having a
resin-impregnated body defining first and second planar surfaces;
and a water-soluble, water-activated adhesive layer applied to one
of said first and second surfaces, whereby the resin impregnated
body remains relatively non-moisture absorbent during wetting of
the adhesive layer thereby allowing the adhesive layer to dry
several minutes after installation of the tape over a wall
joint.
8. The wallboard tape of claim 7 wherein the wallboard tape is
elongated.
9. The wallboard tape of claim 8 wherein the elongated wallboard
tape is packaged in roll form.
10. The wallboard tape of claim 9 wherein the elongated wallboard
tape has a width of approximately 1/8-6 inches and a length of
approximately 20-600 feet.
11. The wallboard tape of claim 7 wherein the tape is in the form
of rectangles, squares, circles, and/or frames of rectangles,
squares or circles.
12. The wallboard tape of claim 7 wherein the wallboard tape is
used in conjunction with a wetted sponge.
13. The wallboard tape of claim 7 wherein the wallboard tape is
used in conjunction with a vessel of water.
14. The wallboard tape of claim 7 wherein the wallboard tape is
used in conjunction with a dispensing device.
15. The wallboard tape of claim 7 further comprising: a mold and
mildew inhibitor.
16. The wallboard tape of claim 15 wherein the mold and mildew
inhibitor is a liquid polysiloxane.
17. The wallboard tape of claim 16 wherein the mold and mildew
inhibitor is incorporated into the water-soluble, water-activated
adhesive layer by mixing in a proportion of less than five percent
by volume.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 11/129,642 filed May 16, 2005, hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the construction and
building trade, and more particularly to an improved unique version
of paper-fiber wallboard tape. The wallboard tape of the present
invention is used to join gypsum drywall segments and to conceal
the fusion of the segments in a smooth seamless transition from
section to section.
BACKGROUND OF THE INVENTION
[0003] The standard established procedure for joining wallboards is
set in motion after securing wallboards to the building frame. Once
secured, a layer of joint compound is applied (mud or plaster) to
cover the space between drywall sections. Joint tape is then
embedded within the compound running the length of the wallboard
joint.
[0004] The generally accepted conventional tape calls for 80-100
pound kraft paper with 0-2% wet strength properties. These
conventional drywall tapes are usually formulated from pulp
becoming kraft paper as the finished product. Specifications of
paper used require set standards of high tensile fiber composition
with wet, dry and cross tear strengths as the standard determined
properties (ASTM-475). It is important to note that the above kraft
paper allows the penetration of the moist compound into the paper
itself.
[0005] These paper tapes are produced with either a
spark-perforated surface or a plain surface gypsum ribbon. Both
paper types are typically slightly sanded creating a fine nap for
greater adhesion qualities. These tapes include a defined center
margin for an accurate taping guide, particularly for corners. The
benefits of spark-perforation are a faster and even drying
outcome.
[0006] After this tape application is completed, an important
drying period is required. Depending upon the ambient atmosphere,
the aeration time is approximately 8 to 12 hours. The drying is a
critical factor so that the joint environment is free of moisture.
Moisture breeds mold and mildew that can spread throughout the
wallboard perpetuating building decay and promoting a health
hazard. This is equally true where the wallboard is of other than
gypsum construction.
[0007] After the above step is completed, a second coat of compound
covers the tape, again needing to dry fully. Smooth sanding
completes preparation for the final finishing, painting, etc.
[0008] This procedure, very well established, is easily executed
and requires two time-consuming drying periods, regardless of the
basic components (animal, starch, or polyvinyl acetate) found in
the majority of compounds used.
[0009] In addition to the paper fiber tape, the art also employs
fiberglass mesh tape as a joint seam. It is available in either a
self-adhesive roll (one side adhesively coated) or a plain,
non-adhesive staple roll, depending upon the user's preference. The
benefit of this tape is a grid fabrication that interlocks with the
initial layer of compound. The general practice allows for the mesh
as a first stage of application, and then follows the same
procedures including the two coats of compound that require
extensive drying time as described above. The drywall mesh tape is
more expensive than conventional paper tape, thus being used more
often for repairs than for wallboard joint connection.
SUMMARY OF THE INVENTION
[0010] In brief, the present invention contemplates the provision
of a fibrous or paper wallboard tape, which may be employed without
the necessity of first applying an initial coat of compound or
plaster. The merits of this are both economical and practical from
the vantage point of the end user.
[0011] To this end, the inner surface of the tape with the general
basic conventional product qualities is coated with a formulated
water soluble, water-activated adhesive that may contain mold and
mildew inhibitors. The tape is inert until wetted. Once activated
by water, the tape adhesion to the adjacent joint follows. The
adhesive begins to bond as it aerates.
[0012] Drying is quick as the tape ventilation properties allow
moisture to evaporate rapidly via the perforations. Substantial
wetting of the paper tape is of little consequence to the bonding
properties. The absence of the bedding coat allows moisture to
evaporate quickly from the underlying joint. In less than one hour
after beginning the process, the final coat of either plaster or
compound may be applied.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side view of the wallboard tape according to a
first embodiment of the present invention;
[0014] FIG. 2 is a bottom view of the wallboard tape according to a
second embodiment of the present invention; and
[0015] FIG. 3 is a bottom view of the wallboard tape according to a
third embodiment of the present invention.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENT
[0016] In accordance with the invention, the disclosed embodiment
may include many forms, although the majority of use is in the form
of an elongated resin impregnated tape. Other such forms may be
rectangles, squares, circles, and frames of those shapes, as well
as appliques combined with other materials for use as adjuncts or
as accessories in activities associated with the construction
industry and general crafts where applicable.
[0017] As shown in FIG. 1, the first embodiment 10 of the present
invention comprises of a first layer of fibrous material 11 and a
water-soluble, water-activated adhesive layer 12 applied to one
surface thereof. The tape 10 may be conveniently packaged in roll
form as known in the art. The tape 10 may be in a variety of
widths, mostly ranging between one-eighth inch and six inches, and
lengths from 20 feet to 600 feet, most commonly approximately 2
inches by 300 feet, which will be normally adequate to cover the
gaps formed by abutting wallboards, and more specifically, about 2
1/16 inches by 250 feet.
[0018] As shown in FIG. 2, extending between the outer surface and
the inner surface of the fibrous layer 21 may be air-conducting
perforations 22 covering substantially the entire area of the tape
20 at intervals of one-eighth inch, which may be either punched or
spark-perforated.
[0019] As is known in the art and shown in FIG. 3, a preferred
centerfold 33 may be employed to enable the tape 30 to be used with
angle joints, as well as joints formed by inside corners of a wall.
This centerfold 33, known in the art as a center margin, serves as
a rule guide for the user.
[0020] The adhesive layer 12 is preferably roll-coated using known
techniques to conventional thickness. Since resin impregnated paper
is mechanically stronger than kraft paper, the fibrous material 11
may be of a lesser thickness than the conventional product. The
adhesive 12 may contain mold and mildew inhibitors as described in
more detail below.
[0021] The tape 10 may be employed either by moistening the
adhesive layer 12 using a wetted sponge (not shown), immersing the
tape roll in a vessel of water, or a dispensing device that may or
may not incorporate a wetted sponge. It is possible to wet the
exposed surface of the wallboard adjacent to the joint so that
moisture transfer from the wallboard wets the adhesive surface 12
of the tape 10 when applied. Preferably, a sponge brushing of the
applied tape length across the joint takes place after application
to ensure proper bonding wetness and a smooth drying result. During
this period, the tape 10 may be accurately positioned if not
originally properly aligned without difficulty. The wetting is
facilitated by the fact that the paper layer 11 which is resin
impregnated does not absorb and retain substantial amounts of
moisture, which also facilitates subsequent drying of the adhesive.
As a result, the tape 10 is sufficiently dried and ready for the
application of a finish coat of plaster compound after several
minutes, specifically, after 30 minutes to an hour or in less than
one hour.
[0022] An important feature to be noted is that within the adhesive
formula there may be provided mold and mildew inhibitors for
preventing bacterial growth. While a variety of such agents are
commercially available, a preferred composition is sold under the
trademark "Sil-75", a liquid polysiloxane available from the Dow
Chemical Corporation of Midland, Mich. This composition is
preferably incorporated into the adhesive by mixing in a proportion
of less than five percent by volume. The preferred and most
effective embodiment, however, is in a range of one to two percent
by volume.
[0023] It will be observed that since the adhesive layer is not
activated prior to actual application to the joint, should any
longitudinal twisting occur as the strip is handled, it can be
readily straightened as the strip is applied without danger of the
adhering layer adhering to itself, as is the case where pressure
sensitive adhesives are employed. Of equal importance is the fact
that the cost of manufacture of the disclosed tape is only
marginally greater than that of conventional paper tape, and well
within the price range of the highest quality fiberglass tape.
[0024] With the elimination of the initial layer of compound, fewer
person-hours are necessary to accomplish the drywall joint task and
a great savings emerges. The improved tape may be used in
connection with wallboards of other than gypsum type with equal
facilities.
[0025] The present invention is not limited to the precise details
of structure described in the specification, for obvious
modifications will occur to those skilled in the art to which the
invention pertains. And although the present invention has been
described in detail and with particularity, it will be appreciated
by those skilled in this art that changes and modifications can be
made therein without departing from the scope and spirit of the
invention.
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