Abstract:
The present invention relates to a fluid-activated drywall tape applicator. The applicator includes a roll of fluid-activated drywall tape, a container, a lid and at least two slits. In operation the roll of tape is affixed to the applicator and a lead end of the tape is fed through a first slit. Once in the first slit the tape enters the container where the container is filled with a fluid. The fluid saturates the tape and the tape leaves the container through the second slit. After leaving the container via the slit, the tape&#39;s adhesive properties are activated and a user may apply the tape to a working surface.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a drywall tape applicator. Specifically, the present invention relates to a fluid-activated drywall tape applicator that allows fluid-activated drywall tape to be submerged in a fluid for activation. 
         [0003]    2. Prior Art 
         [0004]    There is significant commercial interest in the fabrication of drywall tape applicators. But further improved compositions and methods are needed to enhance the application of the drywall tape to surfaces. 
         [0005]    The objective of wallboard tape is to join and conceal gypsum drywall segments in a smooth seamless transition from section to section. The standard established procedure for taping wallboards is set in motion after wallboards are secured to a building frame. First, a layer of joint compound, called a bedding layer, is applied (mud or plaster) to cover the spaces between drywall sections. Joint tape is then embedded within the compound running the length of the wallboard joint. After this tape application is completed, an important drying period is required. 
         [0006]    Conventional drywall tape is formulated from pulp becoming kraft paper as the finished product. The conventional kraft paper allows the penetration of the moist compound. Depending upon the ambient atmosphere, the aeration time for drying after application of the compound is approximately 18 to 24 hours. The drying is a critical factor so that the joint environment is free of moisture. Moisture breeds mold and mildew that can spread throughout the wallboard perpetuating building decay and promoting a health hazard. This is equally true where the wallboard is of other than gypsum construction. 
         [0007]    After the conventional drywall tape is dried, sanding is necessary prior to a second coat of compound covering the tape, again needing to dry fully. Smooth sanding completes preparation for the final finishing, painting, etc. This basic procedure, established in the construction industry, requires two to three time-consuming drying periods, regardless of the basic components found in the compounds used. 
         [0008]    To quicken the above conventional process, U.S. Co-pending application Ser. No. 11/129,642 discloses a fluid-activated drywall tape that does not require the amount of time to dry the tape. These tapes are resin-impregnated and have a dry adhesive on the tape. For application, the tape is submerged in a fluid (e.g., water) and applied to the wall joint. Then a sponge, plaster knife or hand used to smooth the compound and make a seamless transition between the wallboards. 
         [0009]    For convenience, the drywall tape applicator of the present invention has an improved unique method of applying a fluid-activated drywall tape in roll form to a wall joint. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention enhances the characteristics of wallboard tape application by providing a fluid-activated drywall tape applicator. This applicator is used in conjunction with a roll of fluid-activated drywall tape as described in U.S. Pending application Ser. No. 11/129,642 entitled “Wallboard Tape and Method of Using the same,” filed May 16, 2005, hereby incorporated by reference. 
         [0011]    The fluid-activated drywall tape applicator includes a container, a lid and at least two slits. The container is capable of holding a fluid for activating the adhesive properties of the fluid-activated drywall tape while the lid retains the fluid within the container. The two slits are used to receive a lead end of the drywall tape. That is, the lead end is threaded into a first slit and the tape is submerged in fluid within the container and then the lead end is threaded through the second slit with the tape in its activated position. Once activated the tape is ready for application. 
         [0012]    In order to hold the fluid-activated drywall tape on the applicator a top roller section is provided. This roller section is mounted on the lid and holds the roll of tape so that the tape may be unrolled from the applicator. The top roller section includes a mounting frame, a spin chock, and an elongate protrusion that receives the spin chock. The roll of tape is removably slid onto the spin chock and held in place by a washer and an end cap or in some instances may be held by a cotter pin. 
         [0013]    To wind the tape through the container a bottom roller section is affixed to the bottom side of the lid. This bottom roller section includes a mounting frame and at least one cylindrical roller that has a pair of end caps. The at least one roller is affixed to the mounting frame via the end caps which are attached to the mounting frame via protrusions. 
         [0014]    In alternate embodiments a belt clip, a handle and/or a cutting knife may be included. The belt clip is provided for convenience to a user during use of the product, the handle provides an ergonomic feel so that a user hands do not tire during use and the cutting knife easily detaches activated sections of the drywall tape from the applicator. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description and accompanying drawings where: 
           [0016]      FIG. 1  is a prospective view of a disassembled applicator according to a first embodiment of the present invention; 
           [0017]      FIG. 2  is a prospective view of the assembled applicator without a container, a tape roll and spin chock; 
           [0018]      FIG. 3  is a front prospective view of the completely assembled applicator; 
           [0019]      FIG. 4  is a rear prospective view of the completely assembled applicator; 
           [0020]      FIG. 5  is a side view of an assembled applicator according to a second embodiment of the invention; and 
           [0021]      FIG. 6  is a side view of an assembled applicator according to a third embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    The present invention enhances the characteristics of wallboard tape application by providing a fluid-activated drywall tape applicator. This applicator is used in conjunction with a roll of fluid-activated drywall tape as described in U.S. Pending application Ser. No. 11/129,642 entitled “Wallboard Tape and Method of Using the same,” filed May 16, 2005, hereby incorporated by reference. 
         [0023]    The wallboard tape includes of a first layer of fibrous material and a water-soluble, water-activated adhesive layer applied to one surface thereof. The tape may be conveniently packaged in roll form as known in the art. The tape may be in a variety of widths, mostly ranging between one-eighth inch and six inches, and lengths from 20 feet to 600 feet, most commonly approximately 2 feet by 300 feet, which will be normally adequate to cover the gaps formed by abutting wallboards. 
         [0024]    Extending between the outer surface and the inner surface of the fibrous layer there may be air-conducting perforations covering substantially the entire area at intervals of one-eighth inch, which may be either punched or spark-perforated. As is known in the art, a preferred centerfold may be employed to enable the tape to be used with angle joints, as well as joints formed by inside corners of a wall. This centerfold, known in the art as a center margin, serves as a rule guide for the user. The adhesive layer is preferably roll-coated using known techniques to conventional thickness. Since resin impregnated paper is mechanically stronger than kraft paper, the fibrous material may be of a lesser thickness than the conventional product. 
         [0025]    The tape may be employed either by moistening the adhesive layer using a wetted sponge, immersing the tape roll in a vessel of water, or a dispensing device that may or may not incorporate a wetted sponge. Preferably, a sponge, plaster knife or hand brushing of the applied tape length across the joint takes place after application to ensure proper contact, bonding wetness and a smooth drying result. 
         [0026]    The wetting is facilitated by the fact that the paper layer which is resin impregnated does not absorb and retain substantial amounts of moisture, which also facilitates subsequent drying of the adhesive. As a result, the tape is sufficiently dried and ready for the application of a finish coat of plaster compound in most cases less than an hour. 
         [0027]      FIG. 1  shows an unassembled fluid-activated drywall tape applicator  10 . The applicator  10  includes a container  11 , a lid  12  and at least two slits  13 ,  14 . 
         [0028]    The container  11  is capable of holding a fluid  14  for activating adhesive qualities of the fluid-activated drywall tape  15 . The container  11  has an outer edge  29  that encompasses the entire upper lip of the container  11 . The outer edge  29  is used to encounter the lid  12  as will be described below. The container  11  is approximately 100 to 110 mm in height, 90 mm in width and 120 mm in length. The outer edge  29  of the container  11  overhangs from the container  11  body by about 5 mm. The container  11  holds any fluid  14  that may be used to activate the tape  15 . The most common fluid  14  being water. 
         [0029]    The lid  12  retains the fluid  14  within the container  11 . The lid  12  frictionally snaps onto the outer edge  29  of the container  11  for a tight, waterproof fit. In this embodiment, the lid  12  has two slits  13 ,  14  located parallel to each other. These slits  13 ,  14  are used to receive a lead end  16  of the drywall tape  15 . That is, the lead end  16  is threaded into a first slit  13  and the tape  15  is submerged in fluid  14  within the container  11  and then the lead end  16  is threaded through the second slit  14  with the tape  15  in its activated position. 
         [0030]    In order to hold the fluid-activated drywall tape  15  on the applicator  10  a top roller section  17  is provided. This roller section  17  is mounted via a mounting frame  20  on the lid  12  and holds the roll of tape  15  so that the tape  15  may be unrolled from the applicator  10 . 
         [0031]    The mounting frame  20  includes a base  26  and a back  27 . The base  26  frictionally snaps onto the lid  12  or may be incorporated into the lid  12  at the time of manufacture. In either case the base  26  includes two slits  34 ,  35  that align with the slits  13 ,  14  found the lid  12 . 
         [0032]    The back  27  of the mounting frame  20  extends mostly at a 90 degree angle from the base  26  but, the bottom of the back  27  moves slightly horizontal so as to align the slits  34 ,  35  with a mounted tape roll  15 . The back  27  has a thickness of approximately 10 mm and a height of approximately 100 mm. 
         [0033]    Attached to a distal end of the back  27  is an elongate protrusion  22 . The elongate protrusion  22  extends from the back  27  at a 90 degree angle. This protrusion  22  is used in conjunction with a spin chock  21 . The spin chock  21  is capable of sliding over the protrusion  22  and also fits inside a cylindrical opening  28  of the tape roll  15 . Together, the spin chock  21  and protrusion  22  suspend the tape  15  over the lid  12  and aligned the tape  15  with the slits  13 ,  14  to allow the tape  15  to be feed into the slits  13 ,  14 . 
         [0034]    The spin chock  21  is held in place by a washer  23 , an end cap  24  and an end-cap lock  25  or in some instances a cotter pin (not shown). To secure the tape roll  15  to the mounting frame  20 , the spin chock  21  is fitted into the opening  28  on the tape roll  15  and then slid onto the protrusion  22 . The end-cap lock  25  is then fitted into the spin chock  21  and locked onto the protrusion  22 . The washer  23  is then slid over the end-cap lock  25  and the end cap  24  is secured to the end-cap lock  25  thereby locking the spin chock  21  to the mounting frame  20 . Now the tape roll  15  may spin on the axis of the protrusion  22  without falling off the mounting frame  20 . Please note, this is one method for locking the tape roll  15  in place but other methods known in the art may be used. 
         [0035]    In order to wind the tape  15  through the container  11  and to ensure the tape  15  is completely immersed in the fluid  14 , the applicator  10  includes a bottom roller section  18 . This bottom roller section  18  is affixed to the bottom side of the lid  12  or may be incorporated into the lid  12  at the time of manufacture. 
         [0036]    The bottom roller section  18  includes a mounting frame  30  and a cylindrical roller  31  that has a pair of end caps  32 . The mounting frame  30  extends vertically from the lid  12  and extends to almost the bottom of the container  11 . The mounting frame  30  has two sides  35 ,  36  that taper to a vertex  37 . At the vertex  37  of the sides  35 ,  36 , the sides  35 ,  36  contain two opening  38 . These openings  38  are used to fixedly secure the roller  31  to the mounting frame  30 . That is, the rollers  31  each include a pair of end caps  32  with each end cap  32  having a protrusion  33 . These protrusions  33  snap into the openings  38  on the mounting frame  30 . Once snapped in place the roller  31  is capable of spinning on an axis that is on the same plane as the axis of the protrusion  22  of the upper mounting frame  17 . This alignment of the tape roll  15  and bottom roller  31  allow the tape  15  to be dispensed in a uniform manner. 
         [0037]      FIG. 2  shows an assembled applicator  10  without the tape roll  15 , the spin chock  22  and the container  11 . The lid  12  is connected to both the upper roller section  17  and the bottom roller section  18 . The washer  23  and end cap  24  are placed over the end cap lock  25 . In order to mount the tape roll  15 , the spin chock  22  will be inserted into the opening on the tape roll  28  and the spin chock  22 -will be slid onto the protrusion  21  after the washer  23 , end-cap lock  25  and end cap  24  are removed. Once the spin chock  22  is in place the washer  23 , end-cap lock  25  and end cap  24  will be reapplied allowing the tape roll  15  to spin freely on the protrusion  22 . 
         [0038]    The bottom roller  31  is affixed on the bottom roller section  18 . And the roller  31  is secured to the mounting frame  30  by protrusions  33 . This allows the roller  31  to spin freely on the mounting frame  30 . 
         [0039]      FIG. 3  shows the fully assembled applicator  10 . The tape  15  is affixed to the spin chock  22  and mounted on the protrusion  21  and the lid  12  is snapped over the lip  29  of the container  11 , as described above. In order to thread the tape  15  through the slits  13 ,  14 , it is easiest to remove the lid  12  from the container  11  and thread the lead end  16  of the tape  15  through the first slit  13  around the roller  31  and out of the second slit  14 . The lid  12  may then be placed over the fluid-filled container  11  thereby submerging the tape  15  in the fluid  14 . 
         [0040]      FIG. 4  shows the fully assembled applicator  10  from the rear. The belt clip  40  is attached to the top rear of back of the upper mounting frame  17 . This belt clip  40  easily attaches to a user&#39;s belt. The belt clip  40  allows the applicator  10  to hang from a user&#39;s tool belt so that the user may have use of both of his hands for the application of the tape  15  to the wallboards. 
         [0041]    In use, with the lid  12 , top roller section  17  and bottom roller section  18  being detached from the container  11  as shown in  FIG. 2 , a roll of tape  15  is mounted on the spin chock  22  and secured to the mounting frame  20  of the top roller section  17 . Once in place a user will take a lead end  16  of the tape  15  and feed the lead end  16  into the first slit  13 , the tape  15  is than feed around the roller  31  on the bottom roller section  18  and feed through the bottom of the second slit  14 . The tape  15  is feed so that a user may easily grasp the lead end  16  of the tape  15 . The container  11  is than filled with a fluid  14  such as water and the lid  12  is securely fastened to the container  11 . Since the tape  15  is wrapped around the bottom roller section  18  both the roller and the tape will be completely submerged in water which will activate the tape  15 . All a user must do is tug on the lead end  16  of tape  15  and the user will be able to pull out as much activated tape that is needed for covering a particular section of wallboard joints. To detach the tape from the roll the user may tear the length from the roll or cut the length from the roll using a utility knife or any other sharp-surfaced object. 
         [0042]      FIG. 5  shows a second embodiment of the present invention. In this embodiment, the applicator  100  has a tape roll mounting system  110  and a container  105 . The applicator  100  also includes a lid  111  and two slits  112 ,  113 . Attached to the lid  111  is an upper roller section  120  that affixes the tape roll  101  to the applicator  100 . The tape roll  101  is mounted to the upper roller section in a way similar to that found in the first embodiment. 
         [0043]    The upper roller section  120  also includes handle  104 . The handle  104  allows a user to hold the applicator  100  while applying the tape  101  directly to a wallboard. The handle  104  also provides an ergonomic feel so that a user&#39;s hands will not tire during use. 
         [0044]    The applicator&#39;s two slits  112 ,  113  are located in different positions than that of the first embodiment. The first slit  112  is located on the lid  111  and the second slit  113  is located on the rear end of the container  105 . This configuration allows the tape  101  to be removed from the applicator  100  while applying the tape  105  directly to the wallboards as will be explained more fully below. 
         [0045]    The applicator  100  also includes a bottom roller section  130  that includes two rollers  106 ,  107 . The first roller  106  is mounted on the front, bottom of the roller section  130  so that when the tape  101  is feed into the first slit  112 , the tape  101  may be fully submerged into the fluid. The second roller  107  is located on the top, rear section of the roller section  130 . When the tape  101  is feed into the first slit  112 , the tape  101  is sent to the bottom roller  106  to fully submerge the tape  101  in the fluid. The tape  101  is then wrapped around the first roller  106  and sent to the second roller  107  where the tape  101  is feed through the second slit  113 . Once the activated tape  102  is feed through the second slit  113  it may be applied directly to the wallboards. Please note, that the container  105  has a different configuration than the first embodiment so that when the applicator  100  is in close proximity to a wall the container  105  will not interfere with the application process. 
         [0046]      FIG. 6  shows a third embodiment of the present invention. The third embodiment  200  includes an upper mounting section  210  having a handle  202  as described above. The bottom roller section  220  differs from the second embodiment in that the pair of bottom rollers  205 ,  206  are both positioned near the bottom of the container  207  with one being in front and the other in the rear. The tape  201  is feed into a first slit  212  located on the lid and feed to wrap around both rollers  205 ,  206 . The tape  201  is then feed out of the container  207 . 
         [0047]    In this embodiment, the tape  201  is feed out of the second slit  213  and into a cutting knife. The tape  201  may then be applied directly to the wall and cut in one motion. That is, this applicator  200  allows a user to apply the tape  201  directly to a wallboard and the knife  203  is utilized to cut the tape  201  after a desired amount of tape  201  is adhered to the wallboard. The cutting knife  203  is a convenient way to easily detach activated sections of the drywall tape  201  from the applicator  200 . 
         [0048]    Although the present invention has been described in detail and with particularity, it will be appreciated by those skilled in this art that changes and modifications can be made therein without departing from the scope and spirit of the invention.