MULTI-DIRECTIONAL REINFORCING DRYWALL TAPE

• US 20130045351A1
• Filed: 06/01/2012
• Published: 02/21/2013
• Est. Priority Date: 06/01/2011
• Status: Active Grant

• Current Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Inventors: Spanton, David L., Griffin, James, Moreland, Kristyn, Dibley, Francis P.
• Granted Patent: US 8,795,808 B2
• Time in Patent Office: Days
• US Class Current: 428/61
• CPC Class Codes: C09J 2400/263 in the substrate
• CPC Class Codes: C09J 7/21 Paper; Textile fabrics
• CPC Class Codes: C09J 7/38 Pressure-sensitive adhesives [PSA]
• CPC Class Codes: E04F 13/042 Joint tapes
• CPC Class Codes: E04F 21/165 for finishing joints, e.g. implements for raking or filling joints, jointers bricklayers' tools E04G21/16; repairing, e.g. filling cracks, E04G23/02 ; wallpaper scrapers or the like B44C7/02; implements for cleaning joints A47L13/10
• CPC Class Codes: E04F 21/1657 for applying tape to joints, e.g. drywall taper tools
• CPC Class Codes: Y10T 428/197 with noncoplanar reinforcement
• CPC Class Codes: Y10T 428/24091 with additional layer[s]
• CPC Class Codes: Y10T 428/24107 including mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24116 Oblique to direction of web
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 442/191 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/198 Coated or impregnated

Abstract

A reinforcing drywall tape and a method of making the same, the tape having a greige combined with a laid scrim constructed in situ on the greige and bonded to the greige by a resin coating, and a pressure sensitive adhesive fully covering an inward facing surface of the greige wherein the greige is adapted for adherence to drywall sections.

Claims

1. A reinforcing drywall tape to reinforce a joint compound, comprising:

a greige combined with a laid scrim having nonwoven elongated yarns laid in situ on the greige and bonded to the greige and to one another by a resin coating, and a pressure sensitive adhesive fully covering an inward facing surface of the greige wherein the greige is adapted for adherence to drywall sections.

2. The reinforcing drywall tape of claim 1, wherein the greige yarns comprise relatively thinner warp yarns lengthwise and relatively thicker weft yarns between lateral edges of the reinforcing drywall tape, wherein the relatively thicker weft yarns are stiffened in straight orientations by having the resin coating thereon and by having the adhesive coating thereon, and wherein the weft yarns stiffen the reinforcing drywall tape in a straight orientation between the lateral edges of the reinforcing drywall tape.

3. The reinforcing drywall tape of claim 1, comprising:

the greige providing a carrier for the scrim.

4. The reinforcing drywall tape of claim 1, wherein the greige warp yarns are longer and thinner than the greige weft yarns, and are stiffened by having the resin coating thereon and by having the adhesive thereon, while being relatively thinner than the weft yarns to droop in a substantially or essentially wide arc lengthwise of the tape in order to press flatly against drywall sections, and bridge across a gap between the drywall sections.

5. The reinforcing drywall tape of claim 1, wherein the greige weft yarns are stiffened by having the resin coating thereon and by having the adhesive thereon, while being relatively thicker than the warp yarns, wherein the weft yarns stiffen the reinforcing drywall tape in a substantially or essentially straight orientation between the lateral edges of the reinforcing drywall tape.

6. The reinforcing drywall tape of claim 1, wherein

beginning at the first lateral edge of the tape, the tape has a series pattern of a group of three greige warp yarns on even pitch spacing, followed by a group of two warp yarns and a scrim warp yarn therebetween on lesser pitch spacing, followed by another group of three greige warp yarns on even pitch spacing, followed by a group of one greige warp yarn substantially superposed with one scrim warp yarn;

the series pattern is fully repeated once; and

the series pattern is partially repeated once to provide yet another group of three greige warp yarns on even pitch spacing adjacent a second lateral edge of the tape.

7. The reinforcing drywall tape of claim 1, wherein individual scrim yarns are oblique-angled relative to the greige yarns, and the individual scrim yarns cross one another and form a grid against the outer surface of the greige;

the resin coating fully covering the outer surface of the greige and fully covering the scrim yarns against the outer surface of the greige and bonding the scrim yarns and the outer surface of the greige;

the pressure sensitive adhesive fully covering an inward facing surface of the greige wherein the greige is adapted for adherence to drywall; and

openings through the grid and the greige, respectively, providing passages for drywall compound in slurry form.

8. A method of making a reinforcing drywall tape, comprising:

constructing a laid scrim in situ on a first surface of a greige by laying first scrim yarns in a series thereof, extending longitudinally straight at a desired oblique angle relative to an X axis of greige warp yarns, and laying second scrim yarns in a series thereof, extending longitudinally straight at a desired oblique angle relative to a Y axis of greige weft yarns, wherein the scrim yarns extend at oblique angles relative to the greige yarns;

applying a resinous coating to bond the scrim and the greige; and

coating an adhesive on a second surface of the greige, wherein the second surface is opposite the first surface of the greige.

9. The method of claim 8, further comprising:

constructing the greige with warp yarns of lesser tex, and with weft yarns of greater tex wherein the weft yarns extend between lateral sides of the reinforcing drywall tape and the warp yarns are longer than the weft yarns and extend lengthwise of the reinforcing drywall tape.

10. A drywall joint, comprising:

a reinforcing drywall tape adhered to drywall sections;

a joint compound imbedding therein the reinforcing drywall tape; and

the reinforcing drywall tape comprising;

a greige combined with a laid scrim constructed in situ on the greige and bonded to the greige by a resin coating, and a pressure sensitive adhesive fully covering an inward facing surface of the greige wherein the greige is adapted for adherence to drywall sections.

11. The drywall joint of claim 10, wherein the greige yarns comprise relatively thinner warp yarns lengthwise and relatively thicker weft yarns between lateral edges of the reinforcing drywall tape, wherein the relatively thicker weft yarns are stiffened in straight orientations by having the resin coating thereon and by having the adhesive coating thereon, and wherein the weft yarns stiffen the reinforcing drywall tape in a straight orientation between the lateral edges of the reinforcing drywall tape.