AU2007231901B2 - Caulking or grouting method - Google Patents

Description

Australian Patents Act 1990 Regulation 3.2 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Caulking or grouting method The following statement is a full description of this invention, including the best method of performing it known to me:- P/00/011 5951 P XWPDOCS AG ofistri.os2U30998 FRANK LIAN d.- 00 00 -1- SCAULKING OR GROUTING METHOD SField of the invention This invention relates to a method for applying caulk or grout in ceramic tile corners.

Background ,IC Ceramic tiles are a common wall and floor covering. It is obviously desirable that the tiles have the most attractive appearance possible. Ceramic tile is typically installed by I gluing the tiles to the surface, with great care being used to achieve a regular and uniform pattern. After the glue has dried, the spaces between the tiles are filled with a cement-like substance known as grout. The grout is spread out over the tile surface filling the spaces, and the residue wiped away. When done properly, this technique provides a uniform and attractive result.

The corners between perpendicular walls present a problem however. The abovedescribed grouting technique cannot be employed in the corners. Here a caulking gun, or other similar device, is used to inject the grout. In bathrooms or other areas exposed to water, such corners are often filled with silicone rubber caulking, which as a practical matter can only be applied with a caulking gun.

The installer uses a caulking gun by squeezing a trigger, which causes the caulking substance to flow from a pointed nozzle, while at the same time moving the nozzle along the corner. Unfortunately, it is very difficult to achieve a uniform and attractive result using a caulking gun. The caulking substance flows from the nozzle more quickly when the trigger is first squeezed. If the installer does not precisely regulate the O speed at which the caulking gun is moved along the wall, an irregular and unattractive result will be achieved.

0 One solution to this problem has been to adhere masking tape along each side of the corner. This is a very time-consuming and difficult procedure however. The two separate strips of tape must be applied at an equal distance from the corner and be kept parallel to each other along the entire length of the wall.

(Ni US 10/489737, the contents of which are expressly incorporated herein by reference, S 10 discloses an adhesive tape that can be easily adhered in the corner created by (,i perpendicular walls, and which creates an evenly-spaced, parallel channel in which grout or caulk can be applied. The present application provides, inter alia, an improved method of corner grouting.

Brief description of the drawings The present invention will be described with reference to the following figures, wherein Figs. 1, 2 and 3 are perspective views of a tape roll according to one aspect of the invention.

Fig. 4 is a perspective illustration of a tape-affixing step of the method.

Fig. 5 is a perspective illustration of a tape-unfolding step of the method.

Fig. 6 is perspective illustration of a caulking or grouting step of the method.

Fig. 7 perspective illustration of a caulk or grout smoothing and removal step of the method.

Detailed description of the invention According to one aspect of the invention a method of caulking or grouting is provided, utilizing a tape roll as depicted in Figs 1, 2 and 3.

As depicted in Fig. 1, the tape according to the invention is packaged as a role 10. As >will become evident below, this packaging is not only convenient, but is also important 0 Z for the function of the invention.

The tape according to the invention comprises two double-sided adhesive strips, an outer adhesive strip 12 and an inner adhesive strip 12'. Adhesive strips 12 and 12' have a front side and a back side. As shown in Figs. 2 and 3, said backsides of said adhesive strips 12 and 12' are attached to a backing strip 14 such that adhesive strips 12 and 12' (,i are parallel to one another when the backing strip is in an unfolded state. Backing strip 14 is preferably made of a flexible plastic film or other suitable nonadhesive material.

Adhesive strips 12 and 12' are affixed along but not extending past the outer edges of backing strip 14 such that, when backing strip 14 is folded in half and packaged as roll adhesive strips 12 and 12' are in vertical alignment with one another, with the nowfolded backing strip 14 sandwiched between them as depicted in Fig. 1. As can be further appreciated from Fig. 1, the width of backing strip 14 must be greater than two times the width of adhesive strip 12. This is in order to provide an exposed portion of backing strip 14 extending past the edges of adhesive strips 12 and 12' as shown in Fig.

1.

The roll 10 further comprises a cylindrical core 16 about which the tape is rolled. Core 16 has a width equal to or preferably less than the width of the rolled tape, such that the edges of the core do not extend past the edges of the tape. The tape further comprises a non-adhesive divider strip 18, illustrated with dashed lines in Figs. I and 2, and shown in Fig 3. Divider strip 18 is arranged on top of outer adhesive strip 12, such that when the tape is rolled together said strip does not become stuck to inner strip 12' of a successive turn of the roll. In other words, the tape is rolled together such that divider strip 18 appears on the outside of the final turn of the tape roll.

The method according to one aspect of the invention comprises forming a uniform and attractive bead of caulk or grout in a corner between a first wall 20 and a second wall -4-

O

22. It should be appreciated, however, that the method can be applied to a corner >between many different surfaces, such as for example a countertop and a wall.

O

z The tape according to the invention is used by first unrolling a short length of tape from role 10. The divider strip is thereafter peeled back, exposing a portion of upper strip of adhesive tape 12. Roll 10 is thereafter placed flush against first wall 20, such that the 01 folded edge of backing strip 14 is inserted into the corner. Pressure is applied to roll in the direction of second wall 22, such that outer adhesive strip 12 adheres to second wall 22.

t As shown in Fig. 4, Roll 10 is thereafter moved longitudinally along the corner, while maintaining flush contact with first wall 20, and applying pressure against second wall 22. Adhesive strip 12 is thus automatically affixed to second wall 22 along the length of the corner as the tape unrolls. Divider strip 18 is continuously removed as the tape unrolls by pulling on the divider strip with one hand, while the roll is moved along the corner with the other hand. Because the edges of core 16 do not extend beyond the folded edge of backing strip 14, the roll itself can be used as guide, allowing the tape to be adhered in a rapid manner along the entire length of second wall 22 in a smooth, continuous motion.

After outer strip 12 has been affixed along the entire length of second wall 22, the tape is cut from the roll. Thereafter, the tape is unfolded, and inner adhesive strip 12' is pressed against first wall 20, as shown in Fig. 5. Because the tape has first been adhered along the entire length of second wall 22, the unfolding operation is much more precise and easy to accomplish than had one unrolled a greater length of tape and attempted to affix the tape to both walls simultaneously along the corner. After inner strip 12'is affixed to first wall 20, the backing strip 14 is removed, exposing a perfectly parallel channel between strips 12 and 12'.

P X\PDOCSWAGspccincrnFo-mO3U9898 FRANK LIANdoc- 00 ;As shown in Fig. 6, a caulking gun 24 is then utilized to apply the caulk or grout in the space between adhesive strips 12 and 12'. After the caulk or grout has been applied, according to one aspect of the invention, a specially designed caulk or grout removal tool 26 is used to smooth out and remove excess caulk or grout, as depicted in Fig. 7.

The tool comprises a curved tip, the diameter of the curve of which is predetermined to Cc correspond to the space between the strips of adhesive tape, and according to one aspect of the invention is packaged together with the tape as a kit. The tip of the tool is inserted into the comer, and drawn along the corner, smoothing and remove excess grout. Thereafter the strips are removed from the wall, leaving an attractive and uniform bead of caulk or grout in the corner.

According to a further aspect, the present invention provides a method for caulking or grouting a corner between two surfaces, the method including: a. Providing a roll of tape comprising two elongated strips of double-sided adhesive tape, an outer strip and an inner strip, said strips having a front side, a back side, an inside edge and an outside edge, said strips of double-sided adhesive tape being spaced apart in parallel arrangement to one an other such that a channel is formed therebetween, with the back sides of said strips of double-sided adhesive tape being affixed in direct contact with a first side of a removable, non-adhesive flexible film having a width greater than the combined widths of said strips of double-sided adhesive tape, wherein the strips of double sided adhesive tape are affixed to the removable film such that the outside edges of the strips do not extend past the outside edges of the removable film, and further wherein said flexible film is folded along the centerline of the channel between said strips of double-sided adhesive tape such that the second side of the flexible film is folded back upon itself thus leaving the folded edge of the non-adhesive film protruding past the inside edges of the strips of double sided adhesive tape, said tape being further rolled upon a cylindrical core, said core having a width equal to or less than the width of folded backing strip, and further including a non-adhesive divider strip arranged on top of the outer strip of adhesive tape such that the divider strip appears on the outside of the final turn of the tape roll, b. Peeling back a segment of the dividing strip from the end of the outer adhesive strip, P:\WPDOCSAGci(ciilios O29)SgY8 FRANK LIAN doe- 00 -6c. Placing the roll of tape flush against a first of the surfaces forming the corner, and pressing the roll against a second of the surfaces forming the corner such that the now-exposed adhesive surface of the outer adhesive strip adheres to the second surface, and wherein the folded edge of backing strip is inserted into the corner, d. Moving the roll longitudinally along the corner while maintaining the roll in (Ni flush contact with the first surface and applying pressure against the second surface, Sprogressively unrolling tape from the roll and unpeeling the dividing strip, such that the outer adhesive strip is affixed to the second surface along the entire length of the corner, e. Cutting the tape from the roll, f. Unfolding the backing strip and pressing the inner adhesive strip against the first surface along the entire length of the corner, g. Removing the backing strip, revealing a parallel channel in the corner between the inner and outer adhesive strips, h. Applying caulk or grout in the channel between the adhesive strips along the length of the corner, and i. Removing the adhesive strips from the wall.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims (6)

1. A method for caulking or grouting a corner between two surfaces, the method including: a. Providing a roll of tape comprising two elongated strips of double-sided adhesive tape, an outer strip and an inner strip, said strips having a front side, a back side, an inside edge and an outside edge, said strips of double-sided adhesive tape being spaced apart in parallel arrangement to one an other such that a channel is formed therebetween, with the back sides of said strips of double-sided adhesive tape being affixed in direct contact with a first side of a removable, non-adhesive flexible film having a width greater than the combined widths of said strips of double-sided adhesive tape wherein the strips of double sided adhesive tape are affixed to the removable film such that the outside edges of the strips do not extend past the outside edges of the removable film, and further wherein said flexible film is folded along the centerline of the channel between said strips of double-sided adhesive tape such that the second side of the flexible film is folded back upon itself thus leaving the folded edge of the non-adhesive film protruding past the inside edges of the strips of double sided adhesive tape, said tape being further rolled upon a cylindrical core, said core having a width equal to or less than the width of folded backing strip, and further including a non-adhesive divider strip arranged on top of the outer strip of adhesive tape such that the divider strip appears on the outside of the final turn of the tape roll, b. Peeling back a segment of the dividing strip from the end of the outer adhesive strip, c. Placing the roll of tape flush against a first of the surfaces forming the corner, and pressing the roll against a second of the surfaces forming the corner such that the now-exposed adhesive surface of the outer adhesive strip adheres to the second surface, and wherein the folded edge of backing strip is inserted into the corner, P:\WPDOMAG~rp-ri=IiiMNUO 00 FRANK LIAN doc.-6/180008 00 -8- ;Z Sd. Moving the roll longitudinally along the corner while maintaining the roll N, in flush contact with the first surface and applying pressure against the second surface, progressively unrolling tape from the roll and unpeeling the dividing strip, such that the outer adhesive strip is affixed to the second surface along the entire length of the corner, e. Cutting the tape from the roll, f. Unfolding the backing strip and pressing the inner adhesive strip against ~the first surface along the entire length of the corner, g. Removing the backing strip, revealing a parallel channel in the corner between the inner and outer adhesive strips, h. Applying caulk or grout in the channel between the adhesive strips along the length of the corner, and i. Removing the adhesive strips from the wall.

2. The method according to claim 1, wherein the core has a width less than the width of the folded backing.

3. The method according to claim 1 or 2, further including the step of smoothing and removing excess caulking or grout from the corner prior to removal of the adhesive strips from the wall.

4. The method according to claim 3, wherein the caulking or grout is smoothed and excess caulking or grout removed by a tool having a curved tip, the diameter of the curve of which corresponds to the width of the channel between the adhesive strips.

The method of claim 4 wherein the roll of tape and the tool are provided prepackaged in a kit.

6. A method for caulking or grouting a comer between two surfaces substantially as herein described with reference to the accompanying figures.