Patent Publication Number: US-6209609-B1

Title: Apparatus for dispensing sheet material

Description:
FIELD OF THE INVENTION 
     This invention relates generally to dispensing apparatus and, more particularly, to improved methods and apparatus for dispensing sheet material. 
     BACKGROUND OF THE INVENTION 
     Drywall installation is very labor intensive. In fact, more than half the cost of installing drywall is borne by labor. One of the most labor-intensive steps in drywall installation is the patching of the seams separating adjacent drywall panels. This process normally involves applying a layer of tape over the seams and then sealing the tape with a suitable drywall compound. The application of the tape over the seams proves especially difficult because the seams can prove challenging to reach, and workers find it difficult to cut the tape to desired lengths. Although various devices have been constructed to enhance the ease and efficiency of applying tape to the seams separating adjacent drywall panels, they are difficult to construct and workers find them messy, difficult to clean and cumbersome. These and other disadvantages with known devices therefore necessitate certain new and useful improvements. 
     Accordingly, it would be highly desirable to provide improved apparatus and methods for dispensing and applying sheet material to a surface and, more particularly, improved apparatus and methods for dispensing and applying tape to a surface. 
     It is a purpose of the present invention to provide new and improved apparatus for dispensing sheet material that is easy to construct. 
     It is another purpose of the present invention to provide new and improved apparatus for dispensing sheet material that is easy to use. 
     It is still another purpose of the present invention to provide new and improved apparatus for dispensing sheet material that is inexpensive. 
     It is a further purpose of the present invention to provide new and improved apparatus for dispensing sheet material constructed to allow a worker to install precisely measured courses of sheet material. 
     It is still a further provision of the present invention to enhance the ease and efficiency of patching the seams formed by adjacent drywall panels. 
     It is yet still a further provision of the present invention to reduce the labor costs associated with drywall installation, 
     It is another purpose of the present invention to provide new and improved apparatus for dispensing sheet material that is easy to clean and maintain. 
     It is still another purpose of the present invention to provide new and improved apparatus for dispensing sheet material that allows for quick and efficient installation. 
     It is yet still another provision of the present invention to substantially reduce the labor investment normally associated with patching the seams separating adjacent drywall panels. 
     SUMMARY OF THE INVENTION 
     The above problems and others are at least partially solved and the above purposes and others are realized in new and improved apparatus for dispensing and applying sheet material, especially tape, to a surface. In a particular embodiment, apparatus of the present invention is generally comprised of an elongate body with a head assembly supported at one end and a roll of tape supported by the elongate body adjacent the head assembly for rotation. The head assembly includes a chassis with an upstream end directed toward the elongate body and a downstream end directed away from the elongate body. The chassis supports a drive assembly engagable against a surface for receiving, dispensing and applying tape to the surface, a cutting assembly and a measuring assembly for allowing installation of precisely measured courses of tape. 
     Drive assembly includes an outfeed roller carried by the chassis for rotation and an infeed roller carried by the chassis for rotation spaced from the outfeed roller and drivenly coupled with the outfeed roller, the outfeed and infeed rollers for positively driving sheet material from the infeed roller to the outfeed roller in response to movement of the outfeed roller against a surface. A continuous belt couples the outfeed roller with the infeed roller in driving engagement. The continuous belt is normally supported by a drive pinion carried by the outfeed roller and a driven pinion carried by the infeed roller. A guide roller is also carried by the chassis for rotation against, and in response to rotation of, the infeed roller. 
     The drive assembly may further include an applicator head engagable for movement against a surface for positively driving sheet material through the drive assembly from the infeed roller to the outfeed roller and for applying the sheet material to a surface in a first position, and stowable in a second position different from the first position. The applicator head is carried for rotation by a framework mounted for movement between the first and second positions of the applicator head. A proximal pinion is supported by the chassis as part of the drive assembly, a distal pinion is carried by the applicator head and an intermediate pinion mounted with the framework in meshing engagement with the distal pinion. The intermediate pinion is engagable in meshing engagement with the proximal pinion in the first position of the applicator head for coupling the applicator head in driving engagement with the outfeed roller. 
     To sever tape after application to a surface, the present invention provides a cutting assembly including a cutting element carried by the chassis for movement along a cutting path for severing the sheet material and an assembly for moving the cutting element along the cutting path. The assembly comprises a support element or cam wheel carried by the chassis for movement between normal first and second positions for moving the cutting element along the cutting path. The cutting element is normally carried by the cam wheel. Lever apparatus is coupled with the cam wheel for moving it between the normal first and second positions. The lever apparatus comprises a handle mounted for movement in reciprocal directions and a cordage assembly interconnecting the handle with the cam wheel and movable in response to movement of the handle in reciprocal directions for moving the cam wheel between the normal first and second positions. A biasing element mounted with the chassis and the cam wheel normally bias the cam wheel in its normal first position. 
     To measure precise courses of tape, the invention further includes a measuring assembly. The measuring assembly includes an extension of the chassis movable between forward and normal rearward positions and having a distal end, wherein the tape may be severed to form a free end to terminate adjacent a point corresponding with the distal end of the extension in the forward position. The extension is normally mounted for movement in pivotal directions between its forward and normal rearward positions. A lever assembly may be actuated for moving the extension between the forward and normal rearward positions. The lever assembly includes a lever mounted for movement in pivotal directions and cordage interconnecting the lever with the extension and movable in response to movement of the lever for moving the extension between the forward and normal rearward positions. A biasing element mounted with the chassis and the extension normally bias the extension in its normal rearward position. 
     Consistent with the foregoing, associated methods may also be provided. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description thereof taken in conjunction with the drawings in which: 
     FIG. 1 is an isometric view of apparatus for dispensing sheet material comprising an elongate body and a head assembly carried by the elongate body for receiving and dispensing sheet material carried by a roll; 
     FIG. 2 is an enlarged view of the head assembly of FIG. 1; 
     FIG. 3 is a vertical sectional view of the head assembly of FIG. 2 with sheet material shown as it would appear feeding through a drive assembly; 
     FIG. 4 is a view very similar to the view of FIG. 3; 
     FIG. 5 is an exploded isometric view of the drive assembly of FIG. 3; 
     FIG. 6 is a schematic isometric view of the drive assembly of FIG. 3; 
     FIG. 7 is another exploded isometric view of the drive assembly of FIG. 3; 
     FIG. 8 is an isometric view of the head assembly of FIG. 1 with an extension shown as it would appear in a forward position; 
     FIG. 9 is an isometric view very similar to the view of FIG. 8 showing another embodiment of an extension shown as it would appear in a rearward position; 
     FIG. 10 is an isometric view very similar to the view of FIG. 9 showing the other extension as it would appear in a forward position; 
     FIG. 11 is a fragmented perspective view of the head assembly of FIG. 10 shown as it would appear applying sheet material to a surface with the other extension shown in the forward position; 
     FIG. 12 is a fragmented side elevational view of the head assembly of FIG. 11; 
     FIG. 13 is a plan view of an applicator head of the drive assembly of FIG. 2; 
     FIG. 14 is an enlarged isometric view of the head assembly of FIG. 1 showing a cutting assembly for severing sheet material; 
     FIG. 15 is a view very similar to the view of FIG. 11; and 
     FIG. 16 is a vertical sectional view of the head assembly of FIG. 1 showing the drive assembly of FIG. 3 as it would appear in an open position. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     The present invention provides, among other things, new and improved apparatus and methods for dispensing and applying sheet material, especially tape, to a surface. Ensuing embodiments of the invention are easy to construct and use, and prove particularly useful for the quick and efficient installation of tape over seams separating adjacent drywall panels. 
     Turning now to the drawings, in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to FIG. 1 illustrating an isometric view of apparatus  50  for dispensing and applying sheet material, such as tape, to a surface. Apparatus  50  is a hand held device and is generally comprised of an elongate body  51  with a head assembly  52  supported at one end and a roll  53  of tape  54  supported adjacent head assembly  52  for rotation. Referring also to FIG. 2, head assembly  52  includes a chassis  60  with an upstream end  61  directed toward elongate body  51  and a downstream end  62  directed away from elongate body  51 . Chassis  60  supports a drive assembly  63  engagable against a surface for receiving, dispensing and applying tape  54  to the surface, a cutting assembly  64  and a measuring assembly  65  for allowing installation of precisely measured courses of tape  54 . To support roll  53  of tape  54  for rotation normally upstream of head assembly  52 , apparatus  50  includes a wheel  55  supported for rotation by an arm  56  depending from elongate body  51 . Wheel  55  is sized for engaging the core  57  of roll  53 . In this regard, a user may insert wheel  55  into the core  57  for detachably capturing roll  53  for rotation. 
     For ease of discussion, drive assembly  63  will be discussed in §I, cutting assembly  64  will be discussed in §II and measuring assembly  65  will be discussed in §III. 
     §I. THE DRIVE ASSEMBLY 
     Drive assembly  63  is operative for receiving, dispensing and applying tape  54  to a surface in a direction from upstream end  61  to downstream end  62 . Referring to FIG. 3 illustrating a vertical sectional view of head assembly  52 , drive assembly  63  is generally comprised of an infeed roller  70  carried by chassis  60  adjacent upstream end  61  for rotation and an outfeed roller  71  carried by chassis  60  adjacent downstream end  62  for rotation. Also included is a guide roller  72  carried by chassis  60  adjacent upstream end  61  for rotation against, and in response to rotation of, infeed roller  70 . Infeed, outfeed and guide rollers,  70 ,  71  and  72 , are captured by chassis  60  for rotation at their free ends and rotate about axes each substantially perpendicular to the direction tape  54  travels through drive assembly  63  from infeed roller  70  to outfeed roller  71 . 
     Infeed roller  70  is drivenly coupled to outfeed roller  70  with, as shown in FIG. 5, a continuous belt  73 . In this specific embodiment, continuous belt  73  is supported by a drive pinion  74  carried by a free end  75  of outfeed roller  71  and a driven pinion  76  carried by a free end  77  of infeed roller  70 . Continuous belt  73  carries teeth  78  at spaced intervals for meshing engagement with the drive and driven pinions  74  and  76 . 
     Turning back to FIG. 3, drive assembly  63  further includes an applicator head  80 . Applicator head  80  is carried by a framework  81  for rotation about an axis substantially parallel to each one of the axes of rotation of infeed, outfeed and guide rollers,  70 ,  71  and  72 . Framework  81  is mounted with chassis  60  for movement in pivotal directions at an end thereof between a first position of applicator head  80  adjacent and somewhat downstream of outfeed roller  71  and a second position of applicator head  80  adjacent upstream end  61  of chassis  60  spaced from outfeed roller  71  as shown in FIG. 16 for stowage when not in use. In its first position, applicator head  80  is coupled in driving engagement with outfeed roller  71 . 
     Regarding FIG. 7, framework  81  comprises first and second substantially coextensive supporting arms  81 A and  81 B captured by chassis  60  at ends thereof for pivotal movement about an axle  81 C. As shown in FIGS. 6 and 7, outfeed roller  71  substantially rigidly carries a proximal pinion  82  (not shown in FIG. 7) at a somewhat intermediate location, applicator head  80  substantially rigidly carries a distal pinion  83  and framework  81  carries an intermediate pinion  84  for rotation. Proximal, intermediate and distal pinions,  82 ,  84  and  83 , are positioned such that in the first position of applicator head  80  will meshingly engage in series. 
     In a first mode of operation, a user may feed a free end of tape  54  between the infeed and guide rollers,  70  and  72 , to capture tape  54  by the infeed and guide rollers,  70  and  72 . For normal operation, it is desirable for the adhesive side of tape  54  to face guide roller  72 . At this point, a user may grasp elongate body  51  and, with framework  81  in the second position of applicator head  80 , engage and move outfeed roller  71  for rotation against a surface in a direction leading with outfeed roller  71 . Because outfeed roller  71  is coupled with infeed roller  70  in driving engagement, as the user moves outfeed roller  71  against a surface for rotation, outfeed and infeed rollers,  70  and  71 , cooperate to positively drive tape  54  through drive assembly  63  from infeed roller  70  to outfeed roller  71 . To apply tape  54  to a surface, the user may wrap the non-adhesive side of tape  54  around outfeed roller  71  and by bearing and moving outfeed roller  71  against the surface leading with outfeed roller  71 , positively drive tape  54  through drive assembly  63  and force the adhesive side of tape  54  against surface  85  for application as shown substantially in FIG.  12 . 
     In a second mode of operation, a user may feed a free end of tape  54  between the infeed and guide rollers,  70  and  72 , to capture tape  54  by the infeed and guide rollers,  70  and  72  as previously mentioned. At this point, a user may grasp elongate body  51  and, with framework  81  in the first position of applicator head  80 , engage and move applicator head  80  against a surface in a direction leading with applicator head  80 . Because the proximal, intermediate and distal pinions,  82 ,  84  and  83 , meshingly engage in series with framework  81  in the first position of applicator head  80 , applicator head  80  is coupled with outfeed roller  71  in driving engagement. Therefore, as the user moves applicator head  80  against a surface for rotation, applicator head  80 , outfeed roller  71  and infeed roller  70  cooperate to positively drive tape  54  through drive assembly  63  from infeed roller  70  to outfeed roller  71 . It will be readily understood that because the proximal and distal pinions,  82  and  83 , are separated by a single pinion, the proximal and distal pinions,  82  and  83 , will rotate in the same direction a the user bears and moves applicator head  80  against a surface for rotation. It will also be understood that the proximal and distal pinions,  82  and  83 , need only be separated in meshing engagement via an odd number of pinions for them to rotate in the same direction. 
     To apply tape  54  to a surface in the second mode of operation of apparatus  50 , the user may wrap the nonadhesive side of tape  54  around applicator head  80  and by bearing and moving applicator head  80  against a surface leading with applicator head  80 , positively drive tape  54  through drive assembly  63  and force the adhesive side of tape  54  against surface  86  for application as shown substantially in FIG.  13 . Surface  86  is provided as a corner and applicator head  80  shaped for generally conforming with the corner as it rotates to allow for the easy installation of tape  54  into the corner. Those of ordinary skill will appreciate that applicator head  80  may take on variety of shapes and dimensions as needed for tape-to-surface application. 
     For proper operation, it is important to prevent tape  54  from sticking against the applicator head  80  and the infeed, guide and outfeed rollers,  70 ,  71  and  72 . To prevent sticking, and with momentary attention directed back to FIGS. 5 and 6, the outer surface of applicator head  80  comprises a non-stick elastomeric surface  87 , the outer surfaces of infeed and outfeed rollers,  70  and  71 , comprises non-stick elastomeric surfaces,  88  and  89 , respectively, and the outer surface of guide roller  72  is defined by a plurality of non-stick elastomeric bands  90 . Other suitable non-stick surfaces may be used if desired. 
     §II. THE CUTTING ASSEMBLY 
     When a desired length or course of tape  54  has been dispensed and applied to a surface, the user may sever tape  54  with cutting assembly  64 . With attention directed to FIG. 14, cutting assembly  64  comprises a cutting element or blade  100  supported for movement along a cutting path for severing tape  54  and an assembly  101  for moving cutting element  100  along the cutting path. In this specific embodiment, assembly  100  comprises a supporting element comprising, in this specific example, a cam wheel  102  carried by chassis  60  for rotation intermediate the infeed and outfeed rollers,  70  and  71 , for movement between normal first and second positions. Cutting element  100  is captured against cam wheel  102  with a nut  103  that extends through a groove  104  of cutting element  100  and into cam wheel  102  for threaded engagement. In the normal first position of cam wheel  102 , cutting element  100  extends outwardly and resides along one side of tape  54 . Assembly  101  further includes lever apparatus  110  coupled with cam wheel  102  that may be actuated for moving cam wheel  102  between its normal first position in FIG.  14  and its second position in FIG. 15 for moving cutting element  100  along the cutting path for severing tape  54 . The cutting path of cutting element  100  extends transverse to the travel path of tape  54  through drive assembly  63 . 
     Regarding FIG. 1, lever apparatus  110  includes a handle  111  carried by elongate body  51  spaced from head assembly  52  for movement in reciprocal directions relative head assembly  52  as generally indicated by the double arrowed line A. Handle  111  is coupled with cam wheel  102  via a cordage assembly generally indicated by the reference character  108 . Cordage assembly  108  includes a connector  112  and cordages  114  and  115 . Connector  112  is supported by elongate body  51  adjacent upstream end  61  of head assembly for movement in reciprocal directions relative upstream end  61 . Handle  111  is coupled with connector via cordage  114  which is partially contained by elongate body  51 . Turning back to FIG. 14, connector  112  is in turn coupled with cam wheel  102  via cordage  115 . Cordage  115  extends from cam wheel  102  to wheels  116  supported by chassis  60  for rotation that cooperate to constrain and direct cordage  115  toward cam wheel  102 . Cordage  115  extends from wheels  116  into a groove  117  of cam wheel  102  and terminates with an enlarged  11  free end  118  captured by a slot  119  carried by cam wheel  102 . A biasing element  120  is also provided having an end captured against cam wheel  102  via nut  103  and an end fixed to chassis  60  for normally biasing cam wheel  102  in the normal first position. In this specific example, biasing element  120  includes a compression spring, although other suitable biasing mechanisms may be used. 
     To sever tape  54 , a user may grasp handle  111  and, from a starting position, move it away from head assembly  52  to cause the cordage assembly  108  interconnecting handle  110  with cam wheel  102  to move. As cordage assembly  108  moves in response to movement of handle  111  in this regard, cam wheel  102  will move in response thereto from its normal first position in FIG. 14 to its second position in FIG. 15 to move cutting element  100  along the cutting path to sever tape  54 . Once severed, the user may then move handle  111  toward head assembly  52  into its starting position with biasing element  120  operative for biasing cam wheel  102  back to its normal first position. 
     As tape  54  is driven through drive assembly  63  from infeed roller  70  to outfeed roller  71 , it rides upon a base plate  130  supported by chassis  60  intermediate the infeed roller  70  and the outfeed roller  71 . Regarding FIGS. 3 and 4, a pinch plate  131  is mounted with chassis  60  toward the outfeed roller  71  in opposition to base plate  130  between which tape  54  travels. Upon actuation of handle  111  to sever tape  54 , pinch plate  131  moves in response to capture and secure tape  54  in a pinched condition (FIG. 4) against base plate  130  to prevent tape  54  from buckling or jamming the drive assembly  63  during, or as a result of, the cutting operation. Upon release of handle  111 , pinch plate  131  moves in response to release tape  54  from its pinched condition (FIG.  3 ). Pinch plate  131  is preferably mounted with chassis for movement in pivotal directions and carries a non-stick surface, such as an elastomeric surface, facing tape  54  to prevent tape  54  from sticking to pinch plate  131 . 
     §III. THE MEASURING ASSEMBLY 
     During installation, it may be desirable to install precisely measured courses of tape  54  with the use of measuring assembly  65 . Turning to FIG. 8, measuring assembly  65  includes an extension  150  supported by chassis  60  adjacent downstream end  62  for movement in pivotal directions between a forward position (also shown in FIG. 11) and a normal rearward position as shown in FIG.  2 . Extension  150  is substantially U-shaped and includes free ends  151  and  152  mounted with chassis  60  for pivotal movement. Extension  150  supports, and terminates with, a distal element  153  having an outer or distal end  154 . 
     Regarding FIG. 1, measuring assembly  65  further includes a lever assembly  160  for moving extension  150  between the forward and normal rearward positions. Lever assembly  160  includes a lever  161  mounted with elongate body  51  adjacent a free end thereof spaced from handle  111  for movement in pivotal directions, and cordage  162  interconnecting lever  161  with extension  150 . Cordage  162  extends downstream from lever  161 , is captured against chassis  60  by free end  152  of extension  150  and terminates with an end  163  fixed to extension  150  intermediate free end  152  and distal element  153 . Cordage  162  is movable in response to movement of lever  161  in pivotal directions for moving extension  150  between the forward and normal rearward positions. A biasing element  164  interconnecting extension  150  with chassis  60  upstream of extension  150  operates for biasing extension  150  in its normal rearward position. In this specific example, biasing element  164  is shown as a compression spring, although other biasing mechanisms may be used. 
     During use of apparatus  50  for applying a course of tape  54  to a surface, a user may decide to terminate the course of tape  54  at a specific point. By moving lever  161 , the user may move extension  150  into the forward position and orient distal end  154  adjacent a desired termination point. At this point, the user may sever the tape  54  to form an end of the course and, by normally moving drive assembly  63  against the surface, complete the installation of the course of tape  54  with the end of the course to terminate at the termination point corresponding with the distal end  154 . 
     When using outfeed roller  71  to force and apply tape  54  against a surface, distal element  153  may be constructed of a length such that with extension  150  in the forward position, placement of distal end  154  at a desired termination point will ensure that when tape  54  is severed to form a free end, the free end of the tape will terminate at the desired termination point. When using applicator head  80  to force and apply tape  54  against a surface, extension  150  may be provided with a distal element  153 ′ (FIGS. 9 and 10) constructed of a length as substantially shown such that with extension  150  in the forward position, placement of distal end  154 ′ at a desired termination point will ensure that when tape  54  is severed to form a free end, the free end of the tape will terminate at the desired termination point. Distal elements  153  and  153 ′ are designed to be interchangeable and, as a result, detachably receivable by a socket  164  carried by extension. Furthermore, because applicator head  80  extends downstream of outfeed roller  71  in its first position, distal element  153 ′ is constructed to be somewhat longer than distal element  153 . 
     The present invention has been described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made in the described embodiments without departing from the nature and scope of the present invention. For instance, FIG. 16 illustrates the drive assembly  63  shown supported by a pivotal extension  165  of chassis  60 . Pivotal extension  165  is comprised of a body  166  that captures and supports drive assembly  63  and which is mounted for movement in pivotal directions at an end  167  directed toward upstream end  61  between an open position as shown and a normal closed position as easily seen in FIGS. 1,  2 . In the closed position, apparatus  50  may be used normally for applying tape  54  to a surface. In the open position in FIG. 16, drive assembly  63  may be easily accessed for maintenance and cleaning. Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims.