DRYWALL TAPE, METHOD OF MAKING AND METHOD OF USING THE SAME

Abstract

A tape includes a paper substrate, and a coating of resin-remoistening adhesive on one surface of the paper substrate. The paper substrate defines a plurality of holes or interstices patterned longitudinally in a single line along or near a center line of the paper substrate. The tape is used for taping gaps, seams or joints between wallboard or drywall members, for example, for sealing a dry wall joint. Methods of making the tape and using the tape are also provided.

Claims

1. A tape for sealing a dry wall joint, comprising: a paper substrate; and a coating of resin-remoistening adhesive on one surface of the paper substrate; wherein the paper substrate defines a plurality of holes or interstices patterned longitudinally in a single line along or near a center line of the paper substrate.

2. The tape of claim 1, wherein the plurality of holes or interstices are spaced evenly apart along the centerline of the paper substrate.

3. The tape of claim 1, wherein each of the plurality of holes or interstices is in a shape being round, oval, oblong or any combination thereof.

4. The tape of claim 1, wherein each of the plurality of holes or interstices has a diameter or length in the range of from 3.175 mm to 22.225 mm.

5. The tape of claim 1, wherein the plurality of holes or interstices are spaced by about 6.35 mm or about 3.175 mm.

6. The tape of claim 1, wherein the plurality of holes or interstices are spaced by 3.175 mm while a space of 6.35 mm in length is interposed between two holes or interstices in every 20.32 cm of the tape in length.

7. The tape of claim 1, wherein the paper substrate has a base weight in the range from 2.44 Kg/m.sup.2 to 3.25 Kg/m.sup.2.

8. The tape of claim 1, wherein the paper substrate has a dry tensile strength of at least 9.5 Kg of force per centimeter in a longitudinal direction, and at least 4.5 Kg of force per centimeter in a cross direction.

9. The tape of claim 1, wherein the paper substrate has a width of about 2.54 cm.

10. The tape of claim 1, wherein the coating of resin-remoistening adhesive is activatable with water or a wetting gel.

11. The tape of claim 1, further comprising a longitudinal line of crease along the centerline of the tape.

12. A tape product, comprising: a core; and a tape for sealing a dry wall joint wound in a roll around the core, the tape comprising: a paper substrate; and a coating of resin-remoistening adhesive on one surface of the paper substrate; wherein the paper substrate defines a plurality of holes or interstices patterned longitudinally in a single line along or near a center line of the paper substrate.

13. The tape product of claim 12, wherein the tape has a length in the range of from 7.62 m to 152.4 m, and the core has a diameter in the range from 6.35 cm to 7.62 cm.

14. The tape product of claim 12, wherein each of the plurality of holes or interstices in the tape has a diameter or length in the range of from 3.175 mm to 22.225 mm.

15. The tape product of claim 12, wherein the paper substrate has a width of about 2.54 cm, and the plurality of holes or interstices in the tape are spaced by about 6.35 mm or about 3.175 mm.

16. The tape product of claim 12, wherein the coating of resin-remoistening adhesive is activatable with water or a wetting gel.

17. A method of using the tape of claim 1, comprising: moistening the coating of resin-remoistening adhesive on one side of the tape; applying the tape to a joint between two drywall panels, wherein 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; and applying a joint compound for a first time, wherein the joint compound enters into the joint through the plurality of holes or interstices.

18. The method of claim 17, further comprising: drying the joint compound after applying a joint compound for a first time.

19. The method of claim 17, further comprising: applying the joint compound for a second time.

20. The method of claim 17, wherein the coating is moistened and the tape is applied using a machine.

Description

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.

[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.sup.1 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.

[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 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 inch to about 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. inch).

[0061] Referring to FIG. 2, a 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 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). 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 16 is uniformly spaced by a distance (L) of 3.175 mm (i.e. 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. 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/m.sup.2 to 3.25 Kg/m.sup.2 (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).

[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, Wis. 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 20 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 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 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 inch to about 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 mm (i.e. 1/4 inch) or about 3.175 mm (i.e. 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/m.sup.2 (i.e. 20 lbs. per 3,000 sq. feet). The tape 20 or 30 is wound on a core that is 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.

[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.

[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.