Patent Publication Number: US-2009220688-A1

Title: Drywall tape and joint compound dispenser

Description:
RELATED APPLICATION DATA 
     This application is a continuation-in-part of U.S. application Ser. No. 11/190,298 filed on Jul. 27, 2005, which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to a drywall or wallboard tape and joint compound dispenser and method. More specifically, the invention relates to a tool used in applying joint compound to drywall tape and a method for applying joint compound to drywall tape. 
     BACKGROUND OF THE INVENTION 
     The joints formed between adjoining drywall or wallboard panels are generally covered with a lamination of joint compound and fibrous drywall tape to hide the cracks or seams defined by and between the abutting panels. Joint compound and tape are typically applied manually by trowel or by a pressurized hand-operated tape and compound applicator to lay down a thin layer of compound and tape over each joint. The compound is typically applied only to that side of the tape which faces the wallboard panel. 
     Once the initial layer or coat of joint compound and tape is applied, it is smoothed over with a tool, such as a taping knife or trowel, and allowed to dry overnight. A relatively narrow and thin coating of joint compound is subsequently applied over the initial lamination of joint compound and tape using a trowel or a pressurized joint compound applicator. This second operation covers the exposed or outer side of the drywall tape and sandwiches the tape between the first layer of joint compound and the newly applied layer. 
     This second layer of joint compound is then allowed to dry. After it dries, a third wider layer of joint compound is then applied over the second layer. Sanding is then required to smooth over the joint. 
     Numerous dispensers have been developed for applying a substance to a strip of material prior to application of the strip to another surface, including drywall joint compound dispensers which apply compound to the tape prior to application of the tape on the seams of wallboards. Examples of these prior art dispensers are shown in U.S. Pat. Nos. 3,496,909; 3,513,809; 3,381,661; 3,292,575; 4,067,294; 1,935,060; 2,717,575; 2,679,232; 2,779,307; and 4,159,695. 
     Although these known prior art dispensers serve their intended purposes, including providing solutions to many problems experienced in drywall installation, most of these dispensers are complicated devices which are expensive to manufacture and are time-consuming and expensive to maintain in proper working condition since they include moving parts subject to wear which ultimately require repair or replacement. Further, such dispensers typically are bulky and, thus, occupy significant space as they are stored and/or transported. 
     SUMMARY OF THE INVENTION 
     The present invention provides a drywall tape dispenser and method that deposits drywall joint compound on tape as the tape is dispensed from the dispenser. More particularly, different regions of the tape are coated with joint compound having different thicknesses. This facilitates seam filling as the tape is applied to a seam (e.g., the extra joint compound is deposited on a region of the tape that covers the seam). Additionally, the present invention provides a drywall tape dispenser that can be stacked, wherein when stacked, the dispensers nest with one another so as to enable one to store multiple dispensers in a compact space. Further, the dispenser can be easily cleaned, and simple to manufacture. 
     According to one aspect of the invention, a dispenser for dispensing drywall tape and joint compound includes a first port configured to deposit the joint compound on a first region of the tape at a first thickness, and to deposit the joint compound on a second region of the tape at a second thickness, wherein the first thickness is greater than the second thickness. Preferably, the first region of the tape includes a longitudinal centerline of the tape, and the second region of the tape includes at least one edge of the tape that is parallel to the longitudinal centerline of the tape. 
     The port can be formed to have a hemispherical, triangular or step configuration. Additionally, the dispenser can include a first receptacle for holding the drywall joint compound, wherein the first port is formed in the first receptacle. The dispenser can also include a tape holder for holding the tape, and a second port formed in the first receptacle, the second port configured to receive tape from the tape holder. 
     According to another aspect of the invention, there is provided a stackable drywall tape and joint compound dispenser that includes a tape holder and a reservoir for storing drywall joint compound. The dispenser can be configured such that when the dispenser is placed on another dispenser of substantially the same configuration, at least one of the respective tape holders and/or reservoirs of each dispenser nest with one another. 
     Preferably, at least one of the tape holder and reservoir are tapered such that an upper region of the tape holder or reservoir is wider than a lower region the tape holder or reservoir. The tape holder and/or reservoir can be formed in a V-shape, such that an angle formed between a floor of the tape holder (and/or reservoir) and a wall of the respective tape holder (and/or reservoir) is obtuse. 
     More particularly, a configuration of the tape holder can be different from a configuration of the reservoir. Additionally, the tape holder and reservoir can be formed having rectilinear or curvilinear shapes. 
     Yet more particularly, the reservoir can include an input port for receiving drywall tape, and an output port for dispensing drywall tape coated with joint compound. At least one of the input port and the output port can be formed so as to inhibit leakage of joint compound from the reservoir. Leakage from the input port and/or output port can be inhibited by forming the respective ports to follow a contour of the reservoir. 
     More particularly, the dispenser can be a multi-piece dispenser or single piece dispenser. Further, the dispenser can be configured with no moving parts, and/or can include a channel that guides the drywall tape through a pre-determined path within the dispenser. 
     Yet more particularly, the dispenser can include a cutting edge, such as a sharp or serrated edge, for cutting the drywall tape. Further, the dispenser can include a selectively retractable platform coupled to the dispenser. The platform can be coupled to the dispenser via a hinge, such as a rotatable or elastic hinge, and the platform can be detachable from the dispenser. 
     To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a drywall tape and joint compound dispenser in accordance with a first embodiment of the invention. 
         FIGS. 2A-2D  are top, side, front and back views, respectively, of the dispenser of  FIG. 1 . 
         FIG. 3  is a sectional view of the dispenser of  FIG. 1 . 
         FIG. 4  is an exemplary shipping container that includes multiple dispensers, wherein the dispensers are stacked on one another in a nesting configuration. 
         FIGS. 5A and 5B  illustrate an alternative tape holder in accordance with an embodiment of the invention. 
         FIGS. 6A-6C  are top, side and back views of the base of the dispenser of  FIG. 1 . 
         FIG. 7  is a perspective view of a drywall tape and joint compound dispenser in accordance with a second embodiment of the invention. 
         FIGS. 8A-8D  are top, side, front and back views, respectively, of the dispenser of  FIG. 7 . 
         FIG. 9  is a sectional view of the dispenser of  FIG. 7 . 
         FIG. 10  illustrates dispensers according to  FIG. 7  stacked on one another in a nesting configuration. 
         FIG. 11  illustrates an alternative tape path into the reservoir in accordance with an embodiment of the invention. 
         FIGS. 12A-12B  illustrate side and front views of a dispenser in accordance with another embodiment of the invention. 
         FIGS. 13A and 13B  are sectional views of the dispenser of  FIGS. 12A and 12B  showing the platform in the retracted and extended position. 
         FIG. 14  illustrates dispensers according to  FIG. 12A  stacked on one another in a nesting configuration. 
         FIGS. 15A  illustrates a front view of a dispenser having exemplary port for dispensing drywall tape and joint compound in accordance with an embodiment of the invention. 
         FIG. 15B  illustrates a front and top view of drywall tape extracted from the port of  FIG. 15A , wherein the tape is coated with joint compound. 
         FIG. 15C  illustrates a front view of a dispenser having another exemplary port for dispensing drywall tape and joint compound in accordance with an embodiment of the invention. 
         FIG. 15D  illustrates a front view of a dispenser having another exemplary port for dispensing drywall tape and joint compound in accordance with an embodiment of the invention. 
         FIG. 16  illustrates an exemplary relationship between an outer region and an inner region of drywall tape. 
     
    
    
     DETAILED DESCRIPTION 
     In the detailed description that follows, corresponding components have been given the same reference numerals, regardless of whether they are shown in different embodiments of the present invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale. 
     The present invention will now be described in conjunction with the drawings. Referring initially to  FIG. 1 , there is provided a perspective view of a drywall tape dispenser  10  in accordance with a first embodiment of the invention.  FIGS. 2A-2D  illustrate top, side, front and back views, respectively, of the dispenser  10 , while  FIG. 3  is a cross section of the dispenser  10  taken along section A-A 
     The dispenser  10  includes a tape holder  20  and a reservoir  22 . Drywall tape  24 , such as a roll of drywall tape, is placed in the tape holder  20  of the dispenser  10  and the tape is threaded through a first elongated guide slot  26 , which, via a channel  27  ( FIG. 6A ), connects the tape holder  20  to the reservoir  22 . The drywall tape  24  also is threaded through a second elongated guide slot  28 , from which the drywall tape  24  exits the dispenser  10 . Drywall joint compound or “mud”  30  having a desired consistency then is placed in the reservoir  22  at a level above the drywall tape  24 , thereby covering the drywall tape  24 . 
     As the drywall tape  24  is extracted from the dispenser  10 , the tape  24 , via the first elongated guide slot  26  and channel  27  ( FIG. 6A ), passes from the tape holder  20  into the mud filled reservoir  22 , thereby becoming coated with a layer of mud  30 . The tape  24  is extracted from the reservoir  22  via the second elongated guide slot  28  and can be cut as needed while leaving a free end of drywall tape  24   a  outside the dispenser  10 . The free end  24   a  facilitates grasping and pulling more drywall tape  24  from the dispenser  10 . A cutting edge  32 , such as a sharp or serrated edge, for example, can be used to cut or tear the drywall tape  24  to a desired length. The mud coated tape  24  then can be applied to wallboard panels and, if necessary, the tape and compound can be flattened against each wallboard panel with a putty knife or trowel. 
     As used herein, a reservoir or receptacle is to be construed broadly, and includes a basin, a trough, a container, or the like, that can hold an object or substance in solid, semi-solid, or liquid form. A reservoir or receptacle, as used herein, is not limited to a long and narrow shape as shown in the figures, but can be any shape, including rectilinear shapes, e.g., a frustrum, a wedge, etc., and curvilinear shapes, e.g., a sphere segment, one half of a right circular cylinder, etc., that facilitates dispensing mud  30  and/or drywall tape  24 . 
     The dispenser  10  can be a multi-piece unit having a body  40  and a detachable base  42 . Selectively operable retainers  44 , such as clips or the like, may hold the base  42  to the body  40 . The selectively operable retainers  44  also allow the base  42  to be positioned in one of a plurality of different orientations with respect to the body  40 . By adjusting the position of the base  42  with respect to the body, a height  28   a  of the second elongated slot  28  can also be adjusted. This is advantageous in that it permits an amount of mud  30  deposited on the extracted tape  24  to be set or controlled. If more mud is desired on the tape, the base  42 , via the selectively operable retainers  44 , can be adjusted to increase an overall height  28   a  of the second guide slot  28 . Alternatively, if less mud  30  is desired on the extracted tape  24 , the base  42  can be adjusted to decrease the overall height  28   a  of the second guide slot  28 . 
     In another embodiment, the base  42  can have a tapered or sloped surface in the region of the elongated slot  28 . The slope of the base  42  can be used to adjust the amount of mud deposited on the tape simply by positioning the base further forward or backward with respect to the body  40 . For example, the slope can increase along the base  42 , with a low portion being near the cutting edge  32  and a higher portion away from the cutting edge  32 . If less mud is desired on the tape  24 , the base  42  can be moved forward with respect to the body  40  such that the height  28   a  of the elongated slot  28  is reduced. Conversely, if additional mud is desired on the tape  24 , the base  42  can be moved backward with respect to the body  40  such that the height  28   a  of the elongated slot  28  is increased. As will be appreciated, the base and/or body can be provided with a number of selectively operable retainers  44  at various locations such that the base  42  can be secured to the body  40  in any one of a number of locations. 
     Further, the detachable base  42  facilitates cleaning of the dispenser  10 . Moreover, and as will be discussed in more detail below, once the base  42  is detached from the body  40 , multiple bodies  40  can be stacked together such that the bodies  40  nest with one another. This is particularly advantageous for shipping and/or stocking the dispenser  10  in retail stores, as significantly less space is occupied when the bodies are nested. Multiple bases  42  also may be stacked on one another. 
     The body  40  includes end walls  50   a  and sidewalls  50   b  (collectively referred to as walls), which, in conjunction with a divider wall  52 , define the walls of the tape holder  20  and the reservoir  22 . The walls  50   a,    50   b  and the divider wall  52  are tapered such that top regions  54   a  of the tape holder  20  and/or reservoir  22  are wider than bottom regions  54   b  of the tape holder and/or reservoir. For example, an angle  56  ( FIG. 2D ) formed between a floor  58  of the tape holder  22 , e.g., the base  42  as the base is attached to the body  40 , (or reservoir) and the walls of the tape holder (or reservoir) is obtuse, such that opposing walls form a V-shape. The taper facilitates nesting of multiple bodies  40 , wherein as the bodies are stacked, walls  50   a,    50   b,    52  that define each tape holder and reservoir of the dispenser  10  nest with walls  50   a,    50   b,    52  that define the tape holder and reservoir of an adjacent dispenser  10 . Referring briefly to  FIG. 4 , there is shown an exemplary shipping container  59  that includes a plurality of bodies  40  stacked on top of one another, wherein each body  40  nests with an adjacent body  40  as they are stacked. Also shown are a plurality of bases  42  stacked on one another. 
     While the dispenser  10  is shown as having a tape holder  20  and reservoir  22  that are substantially equal in shape and size, it will be appreciated that the tape holder and reservoir may have different dimensions and/or different configurations from one another. For example, the reservoir  22  may be larger than the tape holder  20 , thereby accommodating a larger volume of mud. Alternatively, the tape holder  20  may have a curvilinear shape, while the reservoir  22  may have a rectilinear shape. Further, the tape holder  20  may be formed having a structure significantly different from the reservoir  22 . For example, and referring briefly to  FIGS. 5A and 5B , the tape holder  20  can include an arm  20   a  having a spool or roll holder  20   b  for accepting the drywall tape  24 . The arm  20   a  can be attached to the dispenser  10  via a hinge, swivel, or the like (not shown), such that the arm  20   a  can be moved to a location appropriate for storage and/or shipping. Alternatively, the arm  20   a  and spool holder  20   b  can be configured such that when two dispensers are stacked, the arm and spool holder of the respective dispensers nest within one another (e.g., the arm  20   a  can have a tapered configuration with an open top portion, and the spool holder  20   b  can be configured to have a semi-circular shape also with an open top portion). 
     With further reference to  FIGS. 6A-6C , the base  42  can be a rectangular base (or any shape that conforms to a desired shape of the tape holder and/or reservoir) formed from metal, plastic, or other suitable materials. The base  42  can include elongated ridges  60  that form the channel  27 , which tends to maintain the drywall tape  24  in a desired location. For example, the channel  27  can maintain the tape in a center region of the tape holder and reservoir as the tape is drawn through the dispenser  10 . The base  42  can further include assembly guides  62 , which facilitate alignment of the base  42  to the body  40  as the base and body are attached and/or detached from one another. The assembly guides  62  can be elongated segments that extend above a surface of the base  42  and interface with body  40  so as to guide and/or improve the rigidity of the overall dispenser  10 . 
     Accordingly, a drywall tape dispenser according to the first embodiment of the present invention enables one to stack the dispenser bodies  40  such that the bodies nest with one another. Further, the base  42  can be easily removed from the body  40 , thereby facilitating cleaning of the dispenser. 
     Referring now to  FIG. 7 , there is provided a perspective view of a dispenser  100  in accordance with a second embodiment of the invention.  FIGS. 8A-8D  illustrate top, side, front and back views, respectively, of the dispenser  100 , while  FIG. 9  illustrates a cross section of the dispenser taken along section B-B. The dispenser  100  is a one-piece unit having no detachable or moving parts, and includes a tape holder  20  and a reservoir  22 . Drywall tape  24  is placed in the tape holder  20  and the tape is threaded through a first elongated guide slot  102 , which guides the tape out of the tape holder  20 . The drywall tape then is threaded into a second elongated guide slot  104 , which guides the drywall tape  24  into the reservoir  22 , and a third elongated guide slot  106 , from which the drywall tape  24  exits the dispenser  100 . Mud  30  having a desired consistency then can be placed in the reservoir  22  at a level above the drywall tape  24 , thereby covering the drywall tape  24 . 
     Like the previous embodiment, as the drywall tape  24  is extracted from the dispenser  100 , the tape  24 , via the first, second and third elongated guide slots  102 ,  104   106 , passes from the tape holder  20  to the mud filled reservoir  22  and out of the dispenser  100 , thereby becoming coated with a layer of mud  30 . The coated drywall tape  24  can be torn or cut as needed while leaving a free end of drywall tape  24   a  outside the dispenser  100 . This free end  24   a  then is available for grasping and pulling more drywall tape  24  from the dispenser  100  at a later time. The coated tape  24  then can be applied to wallboard panels as described previously. 
     The dispenser  100  includes end walls  110   a  and sidewalls  110   b  (collectively referred to as walls), which, in conjunction with a divider wall  112 , define the walls of the tape holder  20  and the reservoir  22 . The walls  110   a ,  110   b , and the divider wall  112  are tapered such that top regions  54   a  of the tape holder  20  and reservoir  22  are wider than bottom regions  54   b  of the tape holder and reservoir. The wall taper facilitates nesting of multiple dispensers  100 , wherein as the dispensers are stacked, the tape holder  22  and reservoir  20  of each dispenser  100  nest with the tape holder and reservoir of adjacent dispensers. Nesting of the dispensers  100  is illustrated in  FIG. 10 . 
     Depending on the consistency of the mud placed in the reservoir  22 , it may be possible for some mud to “leak” from the second and third elongated slots  104 ,  106  of the dispenser  100 . To minimize or prevent leakage from the respective slots  104 ,  106 , the slots may include extensions that follow a contour of the reservoir  22 , wherein an entry point (or exit point) for the elongated slot is placed at a level likely to be higher than a level of mud in the reservoir  22 . 
       FIG. 11  illustrates this concept applied to the second elongated slot  104 ′. More specifically, the second elongated slot  104 ′ includes an extension  104   a  that follows the contour of the reservoir  22 . Any mud that may leak into the second elongated slot  104 ′ will be contained by the extension  104   a.  To accommodate the alternative entry path to the second elongated slot  104 ′, the location of the first elongated slot  102  may be repositioned so as to provide a path to the second elongated slot that minimizes bending of the tape  24 . For example, the first elongated slot  102  can be placed in an upper region of the tape holder  20  at substantially the same height as the second elongated slot  104 ′. Although not shown, it will be appreciated that the extension can be applied to the third elongated slot  106 . 
     Accordingly, a drywall tape dispenser  100  according to the second embodiment of the invention can be formed as a one-piece unit and with no moving parts. Moreover, the dispenser  100  can be stacked one on top of another, wherein adjacent dispensers nest with one another. 
     Referring now to  FIGS. 12A-12B , a side view and a front view of a third embodiment of the dispenser  100 ′ in accordance with the present invention is illustrated. The dispenser  100 ′ is substantially the same as the dispenser  100  of  FIGS. 7-11 . However, the dispenser  100 ′ includes a retractable extension or platform  120  located at or near the third elongated slot  106 . The platform  120  provides a surface for grasping or holding the tape  24  as the tape is cut or torn from the dispenser  100 ′. The platform  120  can be coupled to the dispenser  100 ′ via a rotatable hinge  122  or the like, such that the extension  120  may be placed in a retracted position or in an extended position. Alternatively, an elastic member, such as an elastic hinge or the like, may be utilized to attached the platform  120  to the dispenser  100 ′. Further, the platform  120  may be detachable from the dispenser, such that the platform  120  can be easily removed and attached from the dispenser  100 ′. 
       FIGS. 13A and 13B  are cross sectional views of the dispenser  100 ′, illustrating the platform  120  in the retracted position ( FIG. 13A ) and the extended position ( FIG. 13B ). Typically, the platform  120  is in the retracted position when the dispensers  100 ′ are stacked in a nesting configuration, as shown in  FIGS. 13A and 14 , and in the extended position during normal use, as shown in  FIG. 13B . The platform  120  can have any shape desired, although it is preferable that the shape of the platform does not inhibit the nesting feature of the dispenser  100 ′. 
     Moving now to  FIG. 15A , there is shown a front view of a dispenser  200  having a guide slot  202  (also referred to as a port) in accordance with another aspect of the invention. With the exception of the guide slot  202 , the dispenser  200  can be generally the same as the dispensers described herein and, thus, only guide slot  202  will be discussed. 
     The guide slot  202  provides a means for drywall tape  24  to be extracted from the dispenser  200 , wherein as the tape  24  is extracted it passes through the first receptacle and is coated with a layer of joint compound  30  (e.g., the guide slot  202  functions as a portal from inside the reservoir  22  to outside the dispenser  200 ). The guide slot  202  is configured such that as drywall tape  24  is extracted, joint compound  30  is applied to the tape  24  at varying thicknesses. More particularly, the guide slot  202  is configured such that a thicker layer of joint compound  30  is applied to inner regions of the tape relative to outer regions of the tape. The additional joint compound  30  on the inner regions of the tape  24  is advantageous, for example, when placing the tape  24  over a seam, as the additional joint compound thoroughly fills gaps within the seam. 
     As used herein, an outer region of the tape refers to a region beginning at the longitudinal sides (e.g., outer longitudinal edges) of the tape and ending a predetermined distance from the longitudinal centerline of the tape. The inner region of the tape refers to a region that includes the longitudinal centerline of the tape and remaining portions of the tape not considered to be part of the outer region. 
     For example, and briefly referring to  FIG. 16 , if the tape  24  is 2 inches wide, each outer region  206   a,    206   b  may be considered to begin at each longitudinal edge  208   a,    208   b,  respectively, and extend inward about 0.66 inches from the outer edge. The inner region  210  may be considered to extend 0.33 inches from each side of the longitudinal centerline (C/L) of the tape (e.g., each region is one-third of the tape width). 
     It is noted that above relationship between the outer and inner regions is merely exemplary, and other relationships are possible without departing from the scope of the invention. For example, and again assuming drywall tape  24  that is 2 inches wide, each outer region may span ¼ inch, and the inner region may span 1.5 inches. As will be appreciated other dimensional relationships between the inner and outer regions are possible. 
     The exemplary guide slot  202  shown in  FIG. 15A  has a two-step configuration, wherein an outer region on each side of the guide slot  202  forms a first step  212  having a predetermined height  212   a.  A second step  214  also having a predetermined height  214   a  is formed on the inner region of the guide slot  202  (e.g., in a center region), wherein the height  214   a  of the second step is greater than the height  212   a  of the first step. Preferably, the first step has a height of about 0.1 inches, while the second step has a height of about 0.2 inches. In one embodiment, the height of the first and/or second step is adjustable. For example, one or more sliding members (not shown) may be formed on the outside of the dispenser  200  and arranged relative to the guide slot  202 . The one or more sliding members can be configured to move relative to the guide slot  202  so as to vary the height  212   a  and  214   a  of the first and second steps  212  and  214 . 
     Referring briefly to  FIG. 15B , a front and top view of drywall tape  24  that has been extracted from the dispenser  200  is shown. As can be seen in  FIG. 15B , the extracted tape  24  includes a layer of joint compound  30  that mirrors the step configuration of the guide slot  202 . 
     Although a two-step configuration is shown in  FIG. 15A , other configurations are possible. For example, the guide slot  202  can be configured to have three, four, or more steps. Alternatively, a dispenser  202 ′ can be configured to have a guide slot  202 ′ formed with a hemispherical shape or generally curved shape, as shown in  FIG. 15C . Other shapes are also possible, (e.g., a dispenser  200 ″ having a guide slot  202 ″ with a triangular shape as shown in  FIG. 15D ), so long as tape dispensed from the guide slot has a thicker layer of joint compound on the inner regions of the tape relative to the outer regions of the tape. 
     Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.