Drywall joint tape and method
First Claim
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1. A joint tape for drywall, comprising:
- a substrate layer having an elongate shape to form a substrate strip, the substrate layer extending in a lengthwise direction to define a length and extending in a transverse direction that is perpendicular to the lengthwise direction to define a width, the width being narrower than the length, the substrate layer strip being made from substrate fibers extending parallel to one another along the lengthwise direction and having a substrate layer strip flexibility in the lengthwise direction and the transverse direction; and
a covering layer having an elongate shape and disposed in overlapping and bonding relation on the substrate layer, the covering layer extending in the lengthwise direction and in the transverse direction to form a strip that extends along the substrate layer strip, the covering layer strip being made from covering fibers extending parallel to one another along the transverse direction and having a covering layer strip flexibility in the transverse direction and configured to withstand compressive forces applied generally in the transverse direction and shear stresses applied generally along the transverse direction;
wherein the substrate fibers and the covering fibers contact each other at intersections, and wherein the joint tape further includes bonds formed by adhesive, the bonds being disposed at least at a majority of intersections between the substrate fibers and the covering fibers to bond the substrate fibers and the covering fibers to one another, the adhesive being made from a material sufficiently rigid so as to prevent the covering fibers from flexing at least locally;
wherein the covering layer strip flexibility is less than the substrate layer strip flexibility.
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Abstract
A joint tape for drywall includes a substrate layer having an elongate shape in a lengthwise direction and being flexible in the lengthwise direction and in a transverse direction. The tape further includes a covering layer disposed in bonding relation on the substrate layer. The covering layer is rigid in the transverse direction and configured to withstand compressive forces applied generally in the transverse direction and shear stresses applied generally along the transverse direction.
60 Citations
18 Claims
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1. A joint tape for drywall, comprising:
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a substrate layer having an elongate shape to form a substrate strip, the substrate layer extending in a lengthwise direction to define a length and extending in a transverse direction that is perpendicular to the lengthwise direction to define a width, the width being narrower than the length, the substrate layer strip being made from substrate fibers extending parallel to one another along the lengthwise direction and having a substrate layer strip flexibility in the lengthwise direction and the transverse direction; and a covering layer having an elongate shape and disposed in overlapping and bonding relation on the substrate layer, the covering layer extending in the lengthwise direction and in the transverse direction to form a strip that extends along the substrate layer strip, the covering layer strip being made from covering fibers extending parallel to one another along the transverse direction and having a covering layer strip flexibility in the transverse direction and configured to withstand compressive forces applied generally in the transverse direction and shear stresses applied generally along the transverse direction; wherein the substrate fibers and the covering fibers contact each other at intersections, and wherein the joint tape further includes bonds formed by adhesive, the bonds being disposed at least at a majority of intersections between the substrate fibers and the covering fibers to bond the substrate fibers and the covering fibers to one another, the adhesive being made from a material sufficiently rigid so as to prevent the covering fibers from flexing at least locally; wherein the covering layer strip flexibility is less than the substrate layer strip flexibility. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 13)
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10. A drywall joint between two adjacent drywall panels, comprising:
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a layer of joint compound disposed along generally abutting edges of the two adjacent drywall panels; a joint tape embedded within the layer of joint compound, the joint tape comprising;
a substrate layer having an elongate shape to form a substrate strip, the substrate layer extending in a lengthwise direction to define a length and extending in a transverse direction that is perpendicular to the lengthwise direction to define a width, the width being narrower than the length, the substrate layer strip being made from substrate fibers extending parallel to one another along the lengthwise direction and having a substrate layer strip flexibility in the lengthwise direction and the transverse direction; anda covering layer having an elongate shape and disposed in overlapping and bonding relation on the substrate layer, the covering layer extending in the lengthwise direction and in the transverse direction to form a strip that extends along the substrate layer strip, the covering layer strip being made from covering fibers extending parallel to one another along the transverse direction and having a covering layer strip flexibility in the transverse direction and configured to withstand compressive forces applied generally in the transverse direction and shear stresses applied generally along the transverse direction; wherein the substrate fibers and the covering fibers contact each other at intersections, and wherein the joint tape further includes bonds formed by adhesive, the bonds being disposed at least at a majority of intersections between the substrate fibers and the covering fibers to bond the substrate fibers and the covering fibers to one another, the adhesive being made from a material sufficiently rigid so as to prevent the covering fibers from flexing at least locally; wherein the covering layer strip flexibility is less than the substrate layer strip flexibility. - View Dependent Claims (11, 12)
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14. A method for manufacturing joint tape for use in drywall joints, comprising:
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providing a substrate layer having a lengthwise direction and a transverse direction that is perpendicular to the lengthwise direction to form a substrate layer strip, the substrate layer strip being made from substrate fibers extending parallel to one another along the lengthwise direction and having a substrate layer strip flexibility in the lengthwise direction and the transverse direction; providing a covering layer having a lengthwise direction and a transverse direction to form a covering layer strip, the covering layer strip being made from covering fibers extending parallel to one another along the transverse direction and having a covering layer strip flexibility in the transverse direction and configured to withstand compressive forces applied generally in the transverse direction and shear stresses applied generally along the transverse direction; depositing the substrate and covering layers in overlapping relation to create a joint tape preform, wherein the substrate fibers and the covering fibers contact each other at intersections; and bonding the substrate layer to the covering layer in the joint tape preform to create a joint tape that is flexible in the lengthwise direction but more rigid in the transverse direction than the lengthwise direction, wherein bonding the substrate layer to the covering layer includes forming bonds of adhesive at least at a majority of the intersections between the substrate fibers and the covering fibers to bond the substrate fibers and the covering fibers to one another, the adhesive being made from a material sufficiently rigid so as to prevent the covering fibers from flexing at least locally. - View Dependent Claims (15, 16, 17, 18)
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Specification