Patent Application
20130189500
1. Field of the Invention
The field of the present invention relates to mesh-type drywall tapes having indexing patterns for indicating a tape edge.
2. Background
In the construction industry, drywall panels for walls and ceilings are affixed to wall studs or ceiling joists with drywall screws or other fasteners. The drywall panels are installed adjacent to one another. The spaces or seams between adjacent drywall panels and the heads of the drywall screws or fasteners are covered with mesh-type drywall tape, and then in turn with a series of coats of joint compound (sometimes called “mud”). After the joint compound has dried, it may be sanded to a smooth finish, and sometimes is covered again with a skim coating of joint compound or plaster.
Mesh-type drywall tapes are manufactured with a plurality of strands arranged in an open pattern, having crosswise and lengthwise strands. After formation of the mesh or scrim layer, adhesives are applied to couple the strands and provide an adhesive backing on the underside of the tape. Afterwards, the adhesive backed mesh is wound onto a roller element, typically made of cardboard.
Unfortunately, because of the method of manufacture and materials used for mesh-type drywall tapes, it is difficult to determine starting, torn, or cut edges of tape visually. Visual determination is particularly difficult because most mesh-type drywall tapes are manufactured such that all of the strands are uniform in color. How the strands are positioned when rolled onto a roller also makes visual determination of a tape edge difficult.
In addition, the texture and arrangement of strands can increase difficulty in detecting a tape edge by feel. Many types of mesh-type drywall tapes are manufactured with fiberglass strands, arranged in a grid or Leno weave pattern. These types of arrangements result in an outer surface, which is not smooth compared to non-mesh-type tapes, which have substantially uniform cross-sections.
The drywall installers who tape the seams, sometimes called “tapers”, frequently have difficulty removing mesh-type drywall tape from a roll. The cut end or edge of the mesh-type drywall tape is difficult to distinguish if the cut end has not been folded back upon itself at the cut end or edge.
While some methods have been proposed to visually detect starting edges for tape materials, these methods are not specific to mesh-type tapes. Rather, these methods seek to detect starting, torn, or cut edges of tape materials having uniform cross-sections and smooth outer surfaces. Although suitable for their intended purpose, these methods are not necessarily applicable to mesh-type drywall tapes.
Given the limitations of the prior art, as well as the considerations noted, there is a clear need for improved mesh-type drywall tapes.
A mesh-type drywall tape has a scrim layer with a plurality of lengthwise strands coupled to a plurality of crosswise strands. To form the indexing pattern, the strands are marked with markings. Preferably, the upper surfaces of the strands are so marked.
In one embodiment, the indexing pattern has a v-shape configuration, having diagonal portions that may vary in shape and color. The v-shape pattern repeats itself along the entire length of the tape. In another embodiment, the indexing pattern has a series of substantially parallel markings of different colors along the lengthwise strands that are offset from one another.
The mesh-type drywall tape may further comprise adhesives used to couple or join the strands to one another, and a backing adhesive used to couple or join the tape to drywall surfaces, or other similar surfaces. When produced in a roll-form, the mesh-type drywall tape also may include a cylindrical core upon which the tape is wound.
The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure. In the drawings:
Turning in detail to the drawings,
As used herein, “drywall” refers to panels or sections of building materials, including, but not limited to, gypsum boards, cement boards and wallboards. In typical drywall applications that use mesh-type drywall tapes, sections of drywall are secured against a framework of vertical studs, which are erected as part of a wall, or joists, which are erected as part of a ceiling. After the drywall sections are initially secured, seams remain visible between opposed edges of adjacent drywall sections. Mesh-type drywall tape is installed over such seams, as well as over the screw heads or fasteners joining the drywall sections to the studs or joists. Then, the mesh-type drywall tape is covered with joint compound to cover the seams and create seamless joints.
Mesh-type drywall tapes generally comprise a series of strands that form the mesh. Strands 18, 20 may be formed by coupling together a plurality of yarns or fibers using any known method, such as, but not limited to, twisting. A scrim layer 16 is then formed with multiple strands 18, 20. The scrim layer 16 may be any arrangement suitable for forming mesh-type drywall tapes. In the embodiment shown in
The mesh-type drywall tape 10 also may include additional backing adhesives 28 (
As shown in the
Alternatively, markings 34 include an overlay material that is suitable for attaching or adhering to the scrim layer. The overlay material is any suitable material suitable for use during scrim manufacture. For example, the overlay material may comprise at least one strand or thread of a contrasting color that is attached to or adhered to the scrim layer. In one embodiment, the thread or strand has a contrasting color that is superimposed over the scrim layer. In another embodiment, the markings form an indexing pattern having a series of parallel markings of differing colors along the lengthwise strands, which are offset from one another, as further described below.
The markings may comprise ink, paint, stain, or any other material that changes strand or yarn color, adheres to strands or yarns, or that embeds into strands or yarns. The term “marking” as used herein, is not only surface coatings applied to one or more strands or yarns, but also defined as physical changes to the composition or structure of the strands or yarns. For example, sections of the strands or yarns may be colored throughout the strand or yarn material. The markings also may provide altered areas (not shown) on the strands, such that the tape edge may be detected by feel. For example, inked strands may result in a texturized upper surface. The markings also may modify the textural feel of the strands by etching, for example.
Markings 34 form the indexing pattern 12, as shown particularly in
The indexing pattern 12 is applied to upper surfaces of strands 18, 20 to aid in detection of a tape edge 14. The tape edge 14 may be formed by cutting, tearing, or any other methods that can severe a plurality of strands. As shown in
Often, mesh type drywall tapes are sold in rolled form, as shown in
While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims.
