WALLBOARD TAPE

• US 20100266835A1
• Filed: 04/30/2010
• Published: 10/21/2010
• Est. Priority Date: 04/20/2009
• Status: Abandoned Application

• Current Assignee: John S. Conboy
• Original Assignee: John S. Conboy
• Inventors: Conboy, John S.
• Application Number:
  US12/772,151
• Publication Number:
  US 20100266835A1
• Time in Patent Office: Days
• US Class Current: 428/306.600
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0238 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2405/00 Adhesive articles, e.g. adhesive tapes labels B32B2519/00
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/04 : characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: D04H 1/4218 : Glass fibres
• CPC Class Codes: D04H 1/4242 : Carbon fibres
• CPC Class Codes: D04H 5/06 : strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
• CPC Class Codes: D04H 5/08 : characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
• CPC Class Codes: D04H 5/12 : Glass fibres
• CPC Class Codes: Y10T 428/249955 : Void-containing component partially impregnated with adjacent component

Abstract

Wallboard tapes having flexibility and elasticity are provided comprising a nonwoven mat or from at least 50% to 90% rigid fibers and no more than 50% to 10% of flexible fibers. The preferred tapes are comprised of glass fiber as the rigid fiber and polyester fiber as the flexible fiber.

Claims

1. A wallboard tape comprising a nonwoven mat of a mixture of at least 50% to about 90% of one or more rigid fibers and no more than 50% to about 10% of one or more flexible fibers, provided that the flexible fiber is not a natural fiber, said non-woven mat having sufficient structural integrity and strength to be suitable for use as a wallboard seaming tape and having a porosity which allows for the interpenetration of a conventional mud.

2. The wallboard tape of claim 1 wherein the amount of rigid fiber is from more than 70% to about 85% by weight and the amount of flexible fiber is from less than 30% to about 15% by weight.

3. The wallboard tape of claim 1 wherein the rigid fiber is chopped glass fiber of from about ¼

″

to 1½

″

in length.

4. The wallboard tape of claim 1 wherein the flexible fiber is a synthetic polymer fiber whose polymer is selected from the group consisting of polyethylene, polypropylene, polyester and nylon,

5. The wallboard tape of claim 1 wherein the rigid fiber is chopped glass fiber and the flexible fiber is polyester.

6. A wallboard tape comprising a nonwoven mat of a mixture of more than 70% to about 90% of one or more rigid fibers and less than 30% to about 10% of one or more flexible fibers, said non-woven mat having sufficient structural integrity and strength to be suitable for use as a wallboard seaming tape and having a porosity which allows for the interpenetration of a conventional mud.

7. The wallboard tape of claim 6 wherein the rigid fiber is chopped glass fiber of from about ¼

″

to 1½

″

in length.

8. The wallboard tape of claim 6 wherein the flexible fiber is a synthetic polymer fiber whose polymer is selected from the group consisting of polyethylene, polypropylene, polyester, and nylon.

9. The wallboard tape of claim 6 wherein the rigid fiber is chopped glass fiber and the flexible fiber is polyester.

10. A wallboard tape comprising a nonwoven mat of a mixture of at least 50% to about 90% of one or more rigid fibers and no more than 50% to about 10% of one or more flexible fibers, and a top layer of a floc material bonded to the surface of said mat, said mat and said top layer having a porosity which allows for the interpenetration of a conventional mud.

11. The wallboard tape of claim 10 wherein the amount of rigid fiber is from more than 70% to about 85% by weight and the amount of flexible fiber is from less than 30% to about 15% by weight.

12. The wallboard tape of claim 10 wherein the rigid fiber is chopped glass fiber of from about ¼

″

to 1½

″

in length.

13. The wallboard tape of claim 10 wherein the flexible fiber is a synthetic polymer fiber whose polymer is selected from the group consisting of polyethylene, polypropylene, polyester, and nylon.

14. The wallboard tape of claim 10 wherein the rigid fiber is chopped glass fiber and the flexible fiber is polyester.

15. The wallboard tape of claim 10 wherein the floc is a fibrous material selected from the group consisting of nylon, rayon, dacron, polyester, cotton, and other cellulosic-type fibers.

16. The wallboard tape of claim 10 wherein the floc is a natural fiber material.

17. The wallboard tape of claim 10 wherein the top coat comprises two layers of floc material.

18. The wallboard tape of claim 17 wherein the second layer of floc material only covers the central area of the tape.

19. The wallboard tape of claim 10 having a weakness along its central axis such that the wallboard tape is easy to bend at its central axis.

20. The wallboard tape of claim 10 wherein a thin film of a hot melt adhesive is present along the central axis of the tape.