Drywall Tape

Abstract

The present invention relates to an improved drywall tape for use in drywall installation applications. More specifically, the improved drywall tape is comprised of a woven mesh body portion positioned between, and fixedly attached to, two solid end portions. The shape and size of the mesh body portion is meant to substantially fill the valley created by two factory tapered edge portions of adjacently hung drywall sheets, thereby requiring less joint compound/drywall mud than would otherwise be required to finish the drywall joint and reducing labor/material costs. The shape and configuration of the improved drywall tape also enables the same to be used to finish an inside corner, and may further comprise an adhesive backing for easier installation.

Claims

1. A drywall tape for placement in a valley created by two adjacent sheets of drywall, wherein the drywall tape comprises: a pair of end portions; and a body portion positioned between and attached to said pair of end portions.

2. The drywall tape of claim 1, wherein the pair of end portions are comprised of paper.

3. The drywall tape of claim 1, wherein the pair of end portions further comprise an adhesive backing.

4. The drywall tape of claim 1, wherein the valley has a depth and the body portion further comprises a thickness that is substantially equal to the depth.

5. The drywall tape of claim 1, wherein the valley has a shape and the body portion substantially conforms to the shape.

6. The drywall tape of claim 1, wherein the body portion comprises a top surface, a bottom surface and a plurality of openings that extend from said top surface to said bottom surface.

7. The drywall tape of claim 7, wherein the bottom surface further comprises an adhesive.

8. The drywall tape of claim 7, wherein the bottom surface further comprises a nipple.

9. The drywall tape of claim 1, wherein the body portion bottom is comprised of a woven mesh.

10. A drywall tape comprising: a first solid end portion; a second solid end portion; and a mesh body portion comprised of a top surface, a bottom surface and a plurality of openings that extend from said top surface to said bottom surface.

11. The drywall tape of claim 10, wherein the mesh body portion is positioned between and attached to said first solid end portion and second solid end portion.

12. The drywall tape of claim 10, wherein the mesh body portion has a thickness of between and inches, as measured between the top and bottom surfaces.

13. The drywall tape of claim 10, wherein each of the first solid end portion and the second solid end portion further comprise an adhesive.

14. The drywall tape of claim 10, wherein the bottom surface of the mesh body portion further comprises an adhesive.

15. The drywall tape of claim 10, wherein the bottom surface of the mesh body portion further comprises a nipple.

16. The drywall tape of claim 10, wherein the mesh body portion has a width of between 3 and inches and 4 and inches, as measured between the first and second solid end portions.

17. The drywall tape of claim 10, wherein the mesh body portion further comprises a pair of tapered side portions.

18. A drywall tape comprising: a first solid end portion comprised of a first adhesive backing; a second solid end portion comprised of a second adhesive backing; and a body portion positioned between said first and second solid end portions, wherein the body portion is further comprised of a top surface, a bottom surface, a pair of tapered side portions, and a plurality of openings that extend from said top surface to said bottom surface.

19. The drywall tape of claim 18, wherein the mesh body portion has a width of between 3 and inches and 4 and inches as measured between said first and second solid end portions and further comprises a nipple.

20. The drywall tape of claim 18, wherein the mesh body portion has a thickness of between and inches, as measured between the top and bottom surfaces and further comprises an adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 illustrates a partial cross-sectional view of two adjacent sheets of drywall attached to a wall stud, wherein the respective tapered factory edge of each sheet of drywall is the portion attached to the wall stud with fasteners and further wherein the two adjacent tapered factory edges create a valley or a trough.

[0019] FIG. 2 illustrates a cross-sectional view of one embodiment of the improved drywall tape of the present invention, wherein said improved drywall tape is comprised of two side or end portions separated by and fixedly attached to a mesh body portion of a desired width and thickness in accordance with the disclosed architecture.

[0020] FIG. 3 illustrates a partial cross-sectional view of two adjacent sheets of drywall attached to a wall stud, wherein the respective tapered factory edge of each sheet of drywall is the portion attached to the wall stud with fasteners and further wherein the two adjacent tapered factory edges create a valley or a trough that is substantially consumed by the improved drywall tape of the present invention in accordance with the disclosed architecture.

[0021] FIG. 4 illustrates a top view of a length of one embodiment of the improved drywall tape of the present invention, wherein said improved drywall tape is comprised of two side or end portions separated by and fixedly attached to a mesh body portion of a desired width and thickness in accordance with the disclosed architecture.

[0022] FIG. 5 illustrates a perspective view of a roll of one embodiment of the improved drywall tape of the present invention in accordance with the disclosed architecture.

[0023] FIG. 6 illustrates a front view of two adjacent sheets of drywall attached to a wall stud (not shown) and one embodiment of the improved drywall tape of the present invention substantially filling in the valley or trough created by the factory edges of the drywall sheets in accordance with the disclosed architecture.

[0024] FIG. 7 illustrates a cross-sectional view of two adjacent sheets of drywall attached to a wall stud and forming an inside corner, and one embodiment of the improved drywall tape of the present invention substantially filling in the valley or trough created by the factory edges of the drywall sheets in accordance with the disclosed architecture.

DETAILED DESCRIPTION

[0025] The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof.

[0026] As noted above, there exists a long felt need in the art for an improved drywall tape that overcomes the limitations of prior art drywall tapes. More specifically, there is a long felt need in the art for an improved drywall tape of mesh-based composition that is capable of substantially filling in the valley created by two adjacent drywall tapered factory edges, and that allows the user to utilize less joint compound/drywall mud when applying said tape than is currently needed to apply when using existing paper/mesh-based drywall tape. Further, there is a long felt need in the art for an improved drywall tape that requires less time to properly finish the hung drywall sheets, thereby reducing labor costs and improving overall efficiency of a drywall finishing operation.

[0027] Referring initially to the drawings, FIG. 1 illustrates a partial cross-sectional view of two adjacent sheets of drywall 10 attached to a wall stud 20 via fasteners 30, such as nails, screws and the like. Each sheet of drywall 10 is comprised of a beveled or tapered portion 12, a back face 13, a pair of opposing ends 14, and an outward face 16. More specifically, the factory side edges of a typical sheet of drywall 10 are comprised of tapered portions 12 that begin on the outward face 16 of the drywall sheet, approximately two inches from the opposing side ends 14. Each of the tapered portions 12 gradually slopes toward the side end 14 of the drywall sheet 10, thereby forming a prolonged beveled edge on both ends of the outwardly face 16 of drywall sheet 10 that extends the entire length thereof.

[0028] Additionally, as best shown in FIG. 1, when two factory edges or tapered portions 12 are butted up against one another and attached to a wall stud 20 via fasteners 30, a trough or valley 18 is formed. Because the width of each of said tapered portions is approximately two inches, the combined width of the valley 18 is approximately four inches. Further, the typical thickness of the tapered portion 12 at end 14 on a inch thick drywall sheet 10 is of an inch. Therefore, the depth of valley 18 above the ends 14 of adjacent factory edges of drywall sheets 10 is also approximately of an inch.

[0029] As previously stated, in prior art drywall constructions, the intersection of the two factory edges or tapered portions 12 is typically covered with a thin, flat strip of prior art drywall paper or woven mesh tape and then several coats of joint compound/drywall mud are applied to the entire valley 18 in successive layers, with intermittent sanding of the same, which is both labor intensive and time consuming. Further, the thicker the void or valley 18 that must be filled in with drywall mud/joint compound, the longer the required drying time before the same can be sanded, primered and painted. Additionally, thicker drywall mud/joint compound areas are prone to cracking, which can be unsightly and require additional finishing. Unfortunately, similar issues exist when two drywall sheets 10 having tapered portions 12 are placed adjacent to one other to form an approximate right angle or inside or outside corner.

[0030] To overcome the limitations of prior art drywall tapes, the improved drywall tape 100 of the present invention is comprised of a paper and mesh drywall tape combination that is configured to substantially fill the valley 18, thereby requiring less joint compound/drywall mud and shortened cure periods. More specifically, FIG. 2 illustrates a cross-sectional view of one embodiment of the improved drywall tape 100 of the present invention, wherein said improved drywall tape 100 is comprised of two side or end portions 110 separated by and fixedly attached to a body portion 120 having a desired width and thickness in accordance with the disclosed architecture.

[0031] Each of end portions 110 is a generally thin and flat elongated structure, and is preferably comprised of a solid paper (i.e., with no openings therein) or paper like material. Further, each of end portions 110 are positioned on and fixedly attached to one end or side of the body portion 120 as best shown in FIGS. 4 and 6, and extend the entire length of the improved drywall tape 100. A glue or adhesive 130 may also be applied to the underside of each of end portions 110 to enable end portions 110 to better adhere to the outward face 16 of drywall sheets 10. The width of each of end portions 110 is preferably less than of an inch and, in application, overlaps the flat outward face 16 of drywall sheet 10 immediately adjacent to the tapered portion 12, as explained more fully below, and as best shown in FIGS. 3, 6 and 7.

[0032] As best shown in FIGS. 2 and 3, body portion 120 is preferably comprised of a self-adhesive mesh having a top surface 122, a bottom surface 124, opposing side portions 125, and a plurality of openings 128 extending between the top surface 122 and the bottom surface 124 to permit air to flow therein (which increased curing speed) and for receipt of joint compound/drywall mud, as explained more fully below. The overall size and shape of body portion 120 is designed to substantially fill the valley 18 formed by the butting together of two factory edges or tapered portions 12 of drywall sheets 10. For example, inasmuch as the tapered portion 12 of most drywall sheets 10 is typically two inches, the width of the valley 18 formed by two adjacently placed tapered portions 12 will be four inches. Accordingly, for that particular application, the width of body portion 120, as measured between end portions 110, is preferably between 3 and inches and 4 and inches to account for any gap that may exists between drywall sheets 10, and more preferably approximately four inches. Therefore, when accounting for the width of the two end portions 110 and the width of body portion 120, the entire width of improved drywall tape 100 is approximately five inches, as compared to existing drywall tapes that have an entire width of two inches or less and therefore don't span the entire valley 18. This significant increase in width with improved drywall tape 100 adds additional strength to the drywall joint, and makes the same less prone to cracking and the need for repair.

[0033] Similarly, the thickness of body potion 120, as measured between top surface 122 and bottom surface 124, preferably substantially matches the depth of the valley 18 across the two adjacently placed tapered portions 12. For example, the depth of the valley 18 directly above the ends 14 of two abutting sheets of inch thick drywall sheets 10, as measured from the outward surface of the tapered portion 12 to the outward surface 16 of the drywall sheet 10, is approximately of an inch. Accordingly, in this particular application, the thickness of body portion 120 at its center or mid width point would preferably be between and of an inch, and more preferably approximately of an inch, and then narrow across its width in the direction of end portions 110. More specifically, side portions 125 of body portion 120 are tapered from bottom surface 124 in the direction of end portions 110 to match the general contour of the tapered portion 12 of drywall sheet 10, as best shown in FIGS. 2 and 3.

[0034] FIG. 3 illustrates a partial cross-sectional view of two adjacent sheets of drywall 10 attached to a wall stud 20 via fasteners 30 (e.g., nails or drywall screws), wherein the tapered factory edges 12 of each adjacently placed sheet of drywall 10 create a trough or valley 18 that is substantially consumed by the improved drywall tape 100 of the present invention in accordance with the disclosed architecture. Further, as best shown in FIGS. 2 and 3, the bottom surface 124 of mesh body portion 120 may further comprise a nipple or protrusion 126 that is meant to fill the void created by the rounded or chamfered ends 14 of drywall sheets 10.

[0035] FIG. 4 illustrates a top view of a length of one embodiment of the improved drywall tape 100 of the present invention, wherein said improved drywall tape 100 is comprised of two side or end portions 110 separated by, and fixedly attached to, a mesh body portion 120 of a desired width and thickness in accordance with the disclosed architecture. As stated above, an adhesive 130 may be placed on the underside of end portions 110 and/or the bottom surface 124 of mesh body portion 120 to enable improved drywall tape 100 to better adhere to the outward surface of drywall sheet 10. Additionally, improved drywall tape 100 may come in an easy to use roll 200, as best shown in FIG. 5.

[0036] FIG. 6 illustrates a front view of two adjacent sheets of drywall 10 attached to a wall stud (not shown in this particular FIG., but shown in FIGS. 1 and 3) with fasteners (also not shown in this particular FIG., but shown in FIGS. 1 and 3) and one embodiment of the improved drywall tape 100 of the present invention wherein the mesh body portion 120 substantially fills in the valley 18 created by the factory edge tapered portions 12 of the drywall sheets 10 in accordance with the disclosed architecture. Further, each of the end portions 110 are positioned along the outward faces 16 of drywall sheets 10 immediately adjacent to tapered portions 12 and adhered thereto by adhesive 130.

[0037] Similarly, FIG. 7 illustrates a cross-sectional view of two adjacent sheets of drywall 10 attached to wall studs 20 via fasteners 30 to form an inside corner, and one embodiment of the improved drywall tape 100 of the present invention wherein the mesh body portion substantially fills in the valley 18 created by the factory edge tapered portions 12 of the drywall sheets 10 in accordance with the disclosed architecture. Further, each of the end portions 110 are positioned along the outward faces 16 of drywall sheets 10 immediately adjacent to tapered portions 12 and adhered thereto by adhesive 130.

[0038] Notwithstanding any of the forgoing, it is contemplated that the components of improved drywall tape device 100 can by any suitable size, shape, and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the shape and size of the device 100 and its various components, as show in the FIGS. are for illustrative purposes only, and that many other shapes and sizes of the device 100 are well within the scope of the present disclosure. Although dimensions of the device 100 and its components (i.e., length, width, and height) are important design parameters for good performance, the device 100 and its various components may be any shape or size that ensures optimal performance during use and/or that suits user need and/or preference. By way of example and not limitation, it is contemplated that improved drywall tape 100 may come in different shapes and sizes to accommodate a particular application. For example, one particular size of improved drywall tape 100 may be designed specifically for use with inch thick drywall, while a different size of improved drywall tape 100 may be designed specifically for use with inch thick drywall.

[0039] Having described the general construction of improved drywall tape 100 in just a few examples of its various potential embodiments, its use and usefulness will now be described. More specifically, a user (not shown) desiring to finish a joint or inside corner formed by two adjacently hung sheets of drywall 10 would simply unroll the improved drywall tape 100 from roll 200 and attach the same to the drywall joint such that (a) the mesh body portion 120 substantially fills in the valley 18 created by the factory edge tapered portions 12 of the drywall sheets 10 and (b) each of the end portions 110 are positioned along the outward faces 16 of drywall sheets 10 immediately adjacent to tapered portions 12 and adhered thereto by adhesive 130.

[0040] Once improved drywall tape 100 has been applied to the joint created by the adjacently hung drywall sheets 10, a relatively thin coating of joint compound/drywall mud (not shown) can be applied over top of the entire width of improved drywall tape 100 to conceal its attachment to the drywall. Further, as the joint compound/drywall mud is being applied it can be inserted or forced into the openings 128 in the mesh body portion 120 of the improved drywall tape 100 with a device or tool, such as a drywall knife (not shown), and permitted to dry, thereby adding additional strength to the mesh body portion 120 and the joint itself. Also, inasmuch as the mesh body portion 120 substantially fills the valley 18 created by the tapered edge portions 12 of the two adjacent sheets of drywall 10, less joint compound/drywall mud is required. Because less joint compound/drywall mud is required, less curing time before said joint compound/drywall mud is ready to be sanded, primered and painted is also required, thereby decreasing the amount of time associated with the drywall installation process and reducing overall costs.

[0041] What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term includes is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term comprising as comprising is interpreted when employed as a transitional word in a claim.