CA2041860A1 - Wallboard taping process, apparatus and composition therefor - Google Patents
Wallboard taping process, apparatus and composition thereforInfo
- Publication number
- CA2041860A1 CA2041860A1 CA 2041860 CA2041860A CA2041860A1 CA 2041860 A1 CA2041860 A1 CA 2041860A1 CA 2041860 CA2041860 CA 2041860 CA 2041860 A CA2041860 A CA 2041860A CA 2041860 A1 CA2041860 A1 CA 2041860A1
- Authority
- CA
- Canada
- Prior art keywords
- joint compound
- layer
- wallboard
- weight
- tape
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 38
- 238000000034 method Methods 0.000 title claims abstract description 22
- 230000008569 process Effects 0.000 title abstract description 11
- 239000011499 joint compound Substances 0.000 claims abstract description 174
- 239000012530 fluid Substances 0.000 claims abstract description 32
- 239000011505 plaster Substances 0.000 claims abstract description 22
- 239000010440 gypsum Substances 0.000 claims abstract description 19
- 229910052602 gypsum Inorganic materials 0.000 claims abstract description 19
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229920002689 polyvinyl acetate Polymers 0.000 claims abstract description 11
- 239000011118 polyvinyl acetate Substances 0.000 claims abstract description 11
- 239000004372 Polyvinyl alcohol Substances 0.000 claims abstract description 7
- 229920002451 polyvinyl alcohol Polymers 0.000 claims abstract description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 10
- 150000001875 compounds Chemical class 0.000 claims description 10
- 239000010445 mica Substances 0.000 claims description 10
- 229910052618 mica group Inorganic materials 0.000 claims description 10
- 239000000454 talc Substances 0.000 claims description 10
- 229910052623 talc Inorganic materials 0.000 claims description 10
- 239000000080 wetting agent Substances 0.000 claims description 10
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 8
- 238000009499 grossing Methods 0.000 claims description 6
- 239000004576 sand Substances 0.000 claims description 6
- 238000003892 spreading Methods 0.000 claims description 6
- 230000007480 spreading Effects 0.000 claims description 6
- 229920002472 Starch Polymers 0.000 claims description 5
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 239000008107 starch Substances 0.000 claims description 5
- 235000019698 starch Nutrition 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 4
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 claims description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 2
- -1 propyl alcohols Chemical class 0.000 claims description 2
- 239000011592 zinc chloride Substances 0.000 claims description 2
- 235000005074 zinc chloride Nutrition 0.000 claims description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims 10
- 239000007864 aqueous solution Substances 0.000 claims 1
- 239000013521 mastic Substances 0.000 description 15
- 239000000463 material Substances 0.000 description 9
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive effect Effects 0.000 description 8
- 235000019441 ethanol Nutrition 0.000 description 5
- 239000003973 paint Substances 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 235000002020 sage Nutrition 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 210000003746 feather Anatomy 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 238000002372 labelling Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 231100000252 nontoxic Toxicity 0.000 description 1
- 230000003000 nontoxic effect Effects 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
Landscapes
- Coating Apparatus (AREA)
Abstract
Abstract of The Disclosure An apparatus, process and composition for taping joints between pieces of wallboard. The apparatus includes a taping head, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in the first layer of the joint compound, and overcoating the embedded wallboard tape with at least one additional layer of the joint compound; a handle, connected to the taping head, for supporting the taping head, the handle being manually graspable by an operator, the handle having a fluid couduit formed therein for passing joint compound to the taping head; a tape supply mounted on the handle for supplying wallboard tape to the taping head; a backpack, wearable by the operator, for supporting a supply of the joint compound and for producing a pressurized stream of the joint compound; and a flexible connecting means for fluidically interconnecting the backpack and the fluid conduit to pass the pressurized stream of the joint compound from the backpack to the fluid conduit.
The method includes the substantially simultaneous steps of applying a first layer of a joint compound to a joint between pieces of wallboard; embedding a wallboard tape in said first layer of the joint compound; and overcoating the embedded wallboard tape with at least one additional layer of the joint compound. The composition includes 35-60% by weight of a gypsum base plaster; from about 30-70% by weight of an alcohol-water mixture; 10-25% by weight of polyvinyl acetate;
and optionally from about 0-5% by weight of polyvinyl alcohol.
The alcohol-water mixture comprises from about 0-30% by weight of water.
4280b/10
The method includes the substantially simultaneous steps of applying a first layer of a joint compound to a joint between pieces of wallboard; embedding a wallboard tape in said first layer of the joint compound; and overcoating the embedded wallboard tape with at least one additional layer of the joint compound. The composition includes 35-60% by weight of a gypsum base plaster; from about 30-70% by weight of an alcohol-water mixture; 10-25% by weight of polyvinyl acetate;
and optionally from about 0-5% by weight of polyvinyl alcohol.
The alcohol-water mixture comprises from about 0-30% by weight of water.
4280b/10
Description
2~ 3~,~
Tile present invention ls directed to a process o taping jolnts between adjacent pieces of wallboard and an apparatus eor effecting such taping of the joints. More partlcularly, the present invention is directed to a process and apparatus whereby a finished joint between adjacent pieces of wallboard may be completed in one step.
Wallboard ~also known as drywall) has become the domlnant material in the production of interior bullding partitions. In particular, interior building partitions generally comprise a studwall of ~paced parallel vertical members ~studs) which are used as a support for preformed panels (wallboard) whlch are attached to the studwall by screws, nails, adhesive or any other conventional attachment system. Obviously, joints exlst between adjacent preformed paneLs. In order to provide a continuous flat surface to the wall, it is necessary to "finish" the joint between adjacent panels. Generally, such "finishing" requires the building up of multiple layers of a mastic materlal (joint compound) and the blending of thls joint compound into the panel surface so a~ to form the deslred flat and contiguous wall surface. In order to facllitate this finishing of the joints, most manufacturers bevel the longitudinal edges of the wallboard panels so as to allow a buildup of mastic material which will then match the level of the major surface area of the preformed panel. Typically, the buildup of the mastic material in the joint area comprises the application of a first layer of mastic material, the embedding of a wallboard tape (for example a paper tape or a fiberglas~ tape) in the flrst layer of mastic material and then the overcoating of the tape with one or more, generally two layers of additional mastic material. This finishing of the joints is a time consuming process, 61nce it is generally necessary to wait 24 hours between each application of a coat of mastic material in order to allow the coat to dry before the application of an overcoat of an additional layer of mastic material. Moreover, it is then necessary generally to sand the joint area so as to produce a fin1sh which will match the major portion of the 10 surface area of the wallboard panels. The "finishing" process thus is both time-consuming and labor-intensive.
In this regard, numerous attempts have been made to speed up and/or reduce the labor involved in the finishing products . In this regard, attention is directed tG U.S. Patents 2,666,323 and 2,824,442, to Ames, which disclose a tool designed to apply a layer of mastic to a wallboard joint.
U.S. Patent 3,007,837, to Goode, Jr., discloses a tape and joint compound dispensing wallboard taping machine which uses air pressure to supply joint compound to the head of the tool 20 where it is applied to one side of the tape which side of the tape is then applied to the wall.
U.S. Patent 3,131,108, to Kennard, discloses a wallboard taping machine which may have interchangeable heads for different conditions, e.g. flat joints versus corner joints.
U.S. Patent 3,343,202, to Ames, discloses a tool for applying mastic to wallboard which includes a swlngable arcuate trawling blade.
U.S. Patent 3,404,060, to Taylor, Jr., dlscloses a wallboard taping machine including a supply of both joint compound and tape. The device includes a tape cutting knlfe which 18 automatically retractable and the tape has the ~oint compound applied on one slt3e thereof.
U.S. Patent 3,707,427, to Erickson, discloses a tape and joint compound dispenser wherein the tape is drawn through a joint compound reservoir so that the joint compound is applied on one side thereof. The quantlty of jolnt compound ln the dispensing chamber is automatically regulated.
U.S. Patent 3,880,701, to Moree, discloses a tape and 10 joint applying tool including applicator rolls and a blade for cuttlng the tape.
U.S. Patent 3,925,145 discloses a tool for embedding tape into mastic at the corner of a room after the mastic and tape have been previously applied to the corner joint of the room.
U.S. Patent 3,960,643, to Dargitz et al., disclo~es a device to apply a tape and covering finish plaster to a drywall 6eam in a single pass lengthwise thereover, wherein a relatively llghtweight, hand supported frame has a unit thereon operative to 20 first apply glue to a length of tape and then glue-affix the tape to the drywall over the seam and another unit on the frame operative, I)ut trailing the tape gluing and applying unit, the apply a thin, smooth, layer of joint compound over the then-in-place tape.
U.S. Patent 4,080,240 to Dysart, discloses a device Eor applying tape to wallboard and including valve-controlled mud supply. The device also includes a ~evering knlfe and a retractable V-shaped roller.
U.S. Patent 4,086,121, to Ames, disclose6 a ~elf-30 contained drywall taper having a hollow elongated body for 2 ~
holding mastic and supports a roll of tape with tape feeding means to deliver the tape to tape applying wheels then in turn apply it to cover a joint between two wallboard sections. A
piston is slidably mounted in the hollow body and is automatically moved by a mechanism actuated by the rotating wheels, as they are moved over the wallboard surface, to force a layer of mastic onto the tape just prior to it being applied to the surface.
U.S. Patent 4,090,914, to ~lauk et al., discloses an 10 apparatus for applying tape and adhesive to wallboard joints which is then convertlble to deposit adhesive over the previously applied tape.
U.S. Patent 4,196,02B, to Mills, discloses a joint compound and tape applying tool having the provision of a following corner roller.
U.S. Patent 4,208,239, to Lass, di~closes a drywall taping machlne including a flex~ble resilient wiper blade which presses the cement-laden tape into engagement with the wall and, in addition, feathers the cement onto the drywall along both side 20 edges oE the tape in a single pass. A backpack support for the joint compound supply is disclosed.
U.S. Patent 4,309,238, to llauk, discloses a drywall taping devlce which has a control for adjucting the tensioning force applied to tootl-ed traction wheels thereof.
U.S. Patent 4,358,337, to Johnson et al., discloses a tape applicator which utilizes a replaceable joint compound cartridge system.
U.S. Patent 4,452,663, disoloses ~ wallboard joint taping apparatus including an elongated frame having a tape press 30 wheel mounted on the Eorward end with a compound reservoir 2 ~ fi ,r~
mounted on the frame, intermediate the ends, with allgned slots through the lower edge of the wall with a source of tape mounted on the other end of the frame with the tape passing through the slots in the compound container for picking up taping compound on the surface thereof and passing over the roller for application and pressing by the press wheel into a joint between adjacent wallboard panels.
U.S. Patent 4,516,868, to Molnar, discloses a device designed to apply a layer of joint compound over an already installed length of tape.
U.S. Patent 4,592,797, to Carlson, discloses a tube including a cylindrical roller for applying pressure to embed a tape in adhesive, the roller being designed to allow the mud which is on the underside of the tape to flow over the top of the tape and coat that surface as well.
U.S. Patent 4,608,116, to Braselton, discloses a baseboaed edge taping tool which includes a severing knife and which is specifically designed to enable cutting operations at a corner.
Otller reEerences relating to tape dispenslng and mastlc dispensing include U.S. Patent 2,972,428, to Dubbs, which discloses a tape applicator including microswitch controls for advancing, severing and applying a pressure sensitive tape.
Movements of the tape are controlled incrementally on a cyclicable basis.
U.S. Patent 3,785,535, to ~mes, discloses a mastic supply pump outlet for filling different types of mastic-applying tools.
U.S. Patent 4,406,247, to Baughman et al., discloses control of the flow of adhesive in an adhesive dispensing system ,~ J~
wherein a logic control unit receives signals ind1cative of ~various process cond~tions and in response thereto controls-adhes~ve dispensing.
U.S. Patent 4,477,304, to Westermann~ discloses a tool designed to apply a predetermined quantity of adhesive on a workpiece.
U.S. Patent 4,584,047, to Vanderpool et al., dlscloses a hand-held labeling device whlch senses the pos~tion o~ the web of labels and controls other operation in response to this sensed condition.
Despite the great efforts which have been applied to reduce the labor and time involved in wallboard finishing, there is still a marked need for an efficient and useful tool which is easy to operate and which will allow a one-step finishing of wallboard.
Accordingly, it is an object of the present invention to provide an apparatus, process, and composition for wallboard finishing which requires only a single step.
As will become readily apparent hereinafter, the above object of the invention is achieved by the provision of an apparatus, process, and compositions for the taping of joints between pieces of wallboard. The composition of the present invention comprises from about 35 to 60% by weight of a gypsum base plaster, 30 - 70% by weight of an alcohol-water mixture, 0 to 5% by weight of polyvinyl alcohol, and 10- 25~ by weight of polyvinyl acetate.
In a preferred embodiment, the gypsum base plaster comprises from about 40-70, more preferably 45-60, most preferably 6.5% by weight of calcium carbonate, up to 5%, more preferably about 2% by weight of silica sand, up to 6, most ~ ~3 ~ 3 preferably about 4% by weight of starch, small amounts of conventional drying accelerators for the gypsum base plaster, 0-10% by weight of talc and 0-10% by weight of mica. The total amount of talc plus mica constituting from about 4-20% by weight.
The wetting agent used in the composition of the present invention preferably comprises a non-toxic alcohol-water mixture. In a preferred embodiment the wetting agent comprises 30-70, more preferably 37-56, most preferably 42% by weight of an alcohol-water mixture. The alcohol-water mixture may contain from about 0 to 30~ by weight of water.
Preferably, the composition of the present invention contains from about 0 to 5% of polyvinyl alcohol, preferably about 1%.
The composition of the present invention contains an adhesive material which preferably comprises a polyvinyl acetate in an amount of from about 10 to 25, most preferably 14% by weight.
Applicant discovered that upon application to a surface of a conventional plaster containing polyvinyl chloride and water as the wetting agent, the polyvinyl chloride quickly forms an outer skin through which the water must migrate in order for the plaster to completely dry and harden. As a consequence, it becomes necessary in construction projects to maintain an ambient temperature of at least 55F in the room where the plaster is to be applied. The cost of heaters, fuel, and labor to maintain this temperature adds significantly to the cost of construction. Applicant unexpectedly discovered that when a plaster comprises a gypsum base, an alcohol-water wetting agent, and polyvinyl acetate, the wetting agent migrates much 2 ~
faster through the skin formed on the polyvinyl acetate, than the water which migrates through the skin on polyvinyl chloride in conventional gypsum plasters. This accelerated drying rate of the composition of the present invention was unexpectedly found to be unaffected by temperature over a relatively wide range. For example, the composition of the present invention can be applied satisfactorily at temperatures of from about 10-120F.
It was also unexpectedly discovered that the dried composition of the present invention absorbs conventional paints, including both water and oil base paints, at a rate approximating the absorption rate of the paper used on the outer surface of conventional drywall. As a result, satisfactory painting of the surface of a wall finished with the composition of the present invention can be accomplished with only one coat of paint, thus eliminating the need for a primer and a second top coat.
In addition, applicant has found that the apparatus described herein can be satisfactorily cleaned with a cleaning solvent comprising an aqueous mixture of zinc chloride, optionally containing a minor amount of alcohol. The compositions of the present inventions can be used in a process comprising the substantially simultaneous steps of: (a) applying a first layer of the joint compound to a joint between pieces of wallboard, the first layer of the joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint; (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially ~ 3~
e~ual to the first predetermined width, the wallboard tape being substantially centered, widthwise, on the joint; (c) overcoating the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of the joint compound having a width qreater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the joint.
In a preferred embodiment of the method using the compositions of the present invention, the step (c) comprises the substantially simultaneous sub-steps of: (c-l) overcoating the embedded wallboard tape with a second layer of the joint compound, the second layer of the joint compound ~aving a second predetermined width, the second predetermined width being greater than the first predetermined width, the second layer of the joint compound being substantially centered, widthwise, on the joint; and (c-2) overcoating the second layer of the joint compound with a third layer of the joint compound, the third layer of the joint compound having a third predetermined width, the third predetermined width being greater than the second predetermined width, the third layer of the joint compound being substantially centered, widthwise, on the joint.
In a particularly preferred embodiment of the present method, the method comprises the further step (d) of imprinting a surface pattern on the third layer of the joint compound, preferably, the surface pattern matches a surface pattern on the wallboard.
t ~ ~
The peesent inventlon also provides an apparatus for taping joints between pieces of wallboard, comprising a taping head, slidingly contactable with a wall, for sub6tantlally simultaneously applying a first layer o a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in the first layer of the joint compound and overcoating the embedded wallboard tape with at least one additional layer of the joint compound a handle, connected to the taping head, for supporting the taping head, the handle being manually graspable by an operator, the handle havlng a fluld condult formed thereln for passing jOillt compound to the taping head~ a tape supply mounted on the handle for supplying wallboard tape to the taping head a backpack, wearable by the operator, for supporting a supply of the joint compound and for produclng a pressurized stream of the joint compound; a flexible connection for fluidically interconnecting the backpack and the fluid conduit to pass the pressurized stream of the joint comFound from the backpack to the fluid conduit.
In a preferred embodiment oE the apparatus according to the present invention, the taping head comprises a Elrst support plate, attached to the handle a guide meanS, attached to the first support plate, for guiding a wallboard tape of predetermined width being applied to a joint first orlfice means, attached to the first support plate, for feeding a first layer of joint compound to a surface of the wallboard tape intermediate the joint and the wallboard tape, the flrst orifice means fluldically connected to the fluid conduit means a second support plate, releasably attachable to the handle~ biasing means, attached to the second support plate, for yieldably urging the wallboard tape and, hence, the first layer of joint compound, into contact with the wall, when the taping head i~ in contact with the wall, to embed the wallboard tape ln the first layer oE
jolnt compound second orifice means, formed in the second support plate proximate the flrst support plate, for overcoatlng the wallboard tape with a second layer of the joint compound, the second orifice means having a width greater than the wallboard tape, the second orifice means belng centered, widthwise, with respect to the guide means; first pa~sage means, formed ln the second support plate, for fluldlcally connecting the second oriflce means and the fluid conduit means; flrst gate means, pivotally connected to the second support plate for pivotal movement between a first position and a second position, the first gate means preventing flow of joint compound through the second oriflce means when ln the first position and allowing flow of joint compound through the second orifice means when in the second position second biasing means for yieldably urglng the first gate means to the first position; thlrd orlfice means, formed in the second support plate remote from the first support plate, for overcoating the second layer of the joint compound with a third layer of the jolnt compound, the third orifice means having a width greater than the second orlfice means, the third orifice means being centered, widthwise, with respect to the guide means; second passage means, formed in the second support plate, for fluidically connectlng the thlrd orlfLce means and the fluid conduit means second gate means, pivotally connected to 6~
the second support plate for pivotal movement between a first position and a second positlon, the second gate means preventing flow of joint compound theough the third orifice means when in the first position and allowlng flow o joint compound through the third oriice means when in the second position: third biasing means for yieldably urging the second gate means to the first position; first resilient wiper means, mounted on the second support plate intermediate the second orifice means and the third orifice means, for spreading and smoothing the second layer of the joint compound; second recilient wiper blade means, mounted on the second support plate on the opposite side of the third orifice means from the first resilient wiper blade means, for spreading and smoothing the third layer of the joint compound.
In a particularly preferred embodiment, the taping head further comprises roller means, mounted on the second support plate, for imprinting a surface pattern on the third layer of the joint compound, wherein the imprinted surace pattern preferably matches a surface pattern on the wallboard.
Fig. lA is a partially cutaway view oE the right hand side of the backpack unit according to the present invention.
Fig. lB is a left hand view of the backpack unit according to the present invention.
Fig. 2 is a partially exploded view of the backpack unit showing the pumping mechanism.
Fig. 3 illustrates a section of the handle according to the present invent1on.
Fig. 4 illustrates another section of the handle according to the present invention.
;?, fi l'~
Fig. 5 is a perspective view of a pottion of the handle section ill U8 trated in Fig. 3.
Fig. 6 is a perspective view of a portion of the handle sectlon illustrated in Pig. 4.
Fig. 7 is a partially exploded view of certaln elements of the handle ~ection illustrated in Fig. 4.
Fig. 8 is a bottom view of the taping head unit.
Fig. 9 i8 a partially cutaway view of the taping head unit.
Fig. lO is a perspective view of the underside of an alternative taping head unit.
Figure 11 is an illustration of the completely assembled apparatus.
Turning now to the deawing Eigures, Figs. lA and lB (a rlght hand view and a left hand view, respectively) illustrate the backpack portion of the present invention. In particular, the backpack comprises a support frame l which is adapted to be fitted with suitable webblng (not shown) so as to allow the backpack to be worn on the back of an operator. A container support 3 is attached to the support frame by brackets 5 which may be screwed to or welded to support frame 1 and contalner support 3. Container support 3 comprises an upper section 7 in the form of a box open at its top which is receivable of a unit container 11 of joint compound. The container support also comprises a lower section 9 which contains pumps 13 and 15 and related equipment, as will be described hereinaEter.
The unit container ll is Eitted with a pair of grommets 17 and l9 which deflne puncturable portions of the bottom wall of the container ll. When the container ll is placed within the upper section 7, a pair of up~qtanding pipe portions 21 and 23, which are cut at an angle so as to form a "aharpened" edge, are aligned wlth the grommets 17 and 19, respectively, and insertion of the container 11 Eully into the upper section 7 causes these upstandlng pipe sections 21 and 23 to pierce the wall of the container and provide fluid communication between the container and the pumps as will be described hereinafter.
~ s may best be seen in Fig. 2, pipe section 21 is connected through elbow 25 and pipe 27 to the inlet 29 of pump 15. Likewise, pipe 23 is connected through elbow 31 and pipe 33 to the inlet 35 of pump 13. In turn, the outlet 37 of pump 15 is connected via elbow 39 and pipe 41 to outlet fitting 43.
Likewise, the outlet 45 of pump 13 is connected via pipe 47, elbow 49 and pipe 51 to the outlet fitting 43. The outlet fitting 43 and/or the plpes 41 and 51 may be supported by a bracket 53 mounted on the support frame 1. The outlet fitting 43 ls detachably connectable to an inlet fltting 55 of flexible hose 57.
Pumps 13 and 15, which are preferably positive displacement pumps, and most preferably rotary flexible impeller (vane) pumps, are driven by motoes 59 and 61, respectively.
Motors 59 and 61 are preferably electric motors driven by 120 V electrical supply. The electrical motors 59 and 61 may be supplied with power by a flexible electrical cable connected to a suitable source of power, Joint compound which is pumped from unit contalner 11, via pumps 13 and 15, to flexible hose 57 is passed to the handle assembly. The handle assembly comprises a control sectlon 65 (as shown in Fig. 3) and a delivery section 67 (as shown in Fig. 4).
The control section 65 compcises a handgrip 69 and a tape supply element 71. A fluid passageway 73 (as shown in dotted lines in Fig. 3) passes through the control section 65 s~
from a socket 75, where 1exible hose 57 i8 fluidically connected to the fluid passage 73, to a socket 77 wherein a plug 79 o the delivery sectlon 67 may be recelved so as to fluldlcally connect with tlle dellvery sectlon 67. The handgrlp 69 is fltted wlth ~witche6 (in the form of buttons 81-86) for operatlon of the various functions of the apparatus, as will be disclosed herelnafter. The handgrip 69 i8 also fltted wlth a socket 87 for electrlcal connection of the switches to the various electrical elements in the backpack unit. Addltlonally, the handgrip 69 is also fltted with an additional socket tnot shown) for connectlon (vla a cable connection) to the various electrical devices ln the delivery section 67.
The tape supply element 71 is shaped substantially as a hollow rectangle (as best seen ln Fig. 5) and comprise8 first and second cros~ members, 89 and 91, and eirst and second connecting members 93 and 95. A first disc 97 is rotatably mounted on connecting member 93. A second disc 99 is rotatably mounted on connecting member 95. The mounting of discs 97 and 99 is such that the discs are rotatably mounted substantially coaxially.
Disc 97 is provided with a radially extending flange 101 and disc 99 is provided with a radially extending flange 103. At least one of the discs 97 and 99 is moveable axially with respect to the other disc by being supported for rotation on a- pin 105 or 107, respectively, received within a corresponding bore 109 or 111 formed in cross member 93 or 95. A spring (not shown) may be fitted in bore 109 and/or 111 so as to yieldably urge at least one of discs 97 and 99 axially toward the other disc. The discs are of such a diameter as to be received within the core of a roll of wallboard tape, whereby a roll of wallboard tape may be supported on the discs for rotation so as to supply tape through the delivery sectlon 67 of the handle.
The delivery section 67 substantially comprises a fluid condult assembly 113 and a support plate 115. The fluid conduit assembly, as best seen ln Fig. 7, comprises the plug 79 wllicl~ is fluidically connected to a chamber 117 whlch in turn is connected to three fluid supply pipes 119, 121 and 123. Pipe 121 is fluidically connected to supply nozzle 125 and pipe 123 is fluidically connected to supply nozzle 127. Pipe 119 is fluidically connected via elbow 129, pipe 131 and valve 133 to tape supply nozzle 135, which when as6embled is disposed in region 137 of the support plate 115.
A first stepping motor 139 is mounted on chamber 117 and connected via Elexible drive cable 141 to a ~lrst bevel gear 143. First bevel gear 143 mates with a second bevel gear 145 which is mounted for rotation with a first shaft 147, shaft 147 having a screw thread formed on the outer periphery thereof. A
slider 149 is slidably mounted on rails 151 and 153 with a knife edge (not sh~wn) depending in the gap between rails 151 and 153.
Connection member 155 is connected to slider 149 and is fitted with a screw threaded bore corresponding to tlle screw thread Eormed on the outer periphery of the flrst shaft 147, whereby rotation of the first shaEt will cause movement of the slider 149 along rails 151 and 153, thereby drawing the knife edge across plate 115. ~eversal of the rotation of the first shaft 147 by reversal of the rotation of the first stepping motor 139 will draw the slider, and hence the knife edge, back across plate 115. By alternating the direction oE rotation of first stepping motor 139, the knife edge may be drawn back and Eorth across plate 115 as needed.
A second stepping motor 157 ~8 also mounted on chamber 117 and 18 connected via flexible drive cable 159 to gear box 161. Gear box 161, in turn, contains gears to drive second shaft 163 upon which Eriction rollers 165, 167 are mounted for rotation therewith. Plate 115 is fitted with guide rails 169 and 171 so as to guide wallboard tape beneath rollers 165 and 167, beneath rails 151 and 153 as well as shaft 147 and over tape supply nozzle 135.
In operation, a tape passing between guide rails 169 and 171 on plate 115 may be advanced a predetermined amount by actuation of stepping motor 157 80 as to cause a predetermined rotation of shaft 163 and the friction rollers 165 and 167 mounted thereon. Likewise, the tape may be cut by actuation of the stepping motor 139 and the concomitant rotation of shaft 147 causing slider 149 (which is Eitted with a knife edge) to slide across the width of the tape on plate 115. In this regacd, for example, switch 81 on handgrip 69 can actuate stepping motor 157 so as to cause the tape to advance in a predetermined amount.
Likewise, switch 84 can be connected to stepping motor 139 80 as 20 to cause movement of slider 149 across the tape. It should be noted, however, that switch 84 alternatively changes the polarity of electrical current fed to stepping motor 139 so as to alteenately draw the slider across and then back across the plate 115. As the tape passes over tape supply nozzle 135 joint compound is applied to the lower face 173 of the tape 175.
Turning now to Figs. 8 and 9, a second plate 177 is releasably attachable to the delivery section 67 of the handle.
In this regard, as may best be seen in Fig. 9, supply nozzles 125 and 127 may be respectively received in passages 179 and 181 in a 30 snap-fit or force-fit manner. Pa~sage 179 communicates with an 3~
orifice 183 formed in plate 177. The orifice 183 ls fltted with a gate 185 which is plvotally mounted on plate 177 so as to be moveable from a first posltion in which fluid passage through the orifice ls prevented to a second position (as shown in Fig. 9) wherein ~luid passage through orifice 183 is permitted. The gate may be biased, by a torsion spring 187, so as to be yieldably urged to the first position.
In a similar manner, passage 181 communicates with an orifice 189 formed in plate 177. Orifice 189 is also fitted with a gate 191 pivotally connected to plate 177 so as to be moveable from a first position in which fluid flow through the oriEice is prevented and a second position in which fluid flow through the orifice is permitted. Gate 191 may also be biased, as by torsion spring 193, so as to yieldably urge the gate to the first position. ~ollers 195, 197 and 199 may be supported on a shaft 201 which in turn is journaled ln a support membee 203 carried in bore 205 ~ormed in the plate 177. ~ biasing spring 207 yieldably urges the rollers downwardly so as to force the lower side 173 of tape 175 into contact with wallboard 209. A ~irst resilient wiper blade 211 adjustably mounted in the plate 177 as by a screw support 213 smoothes and spreads joint compound delivered through the orifice 183. A second flexlble wiper blade 215 adjustably mounted in plate 177 as by screw support 217 moves and spreads the joint compound delivered to the wallboard through orifice 189. ~ printing roller 219 may be provided with a surface pattern matching the surface pattern of the wallboard 209 so as to aid in disguising the position of the seams formed by the present apparatus. The roller 219 may be supported by support 221 which in turn is pivotally attached to plate 177 and ~ Q ~
may be biased into contact with the seam urface as by a tor~ion spring 223.
~ s shown in Fig. 10, the second support plate may also be formed in other configurations 80 as to allow specialized taping operations, e.g. the taping of inside corners. In this regard, the plate is formed in two sections 177A and 177B which are at right angles to one another. ~ pair of printing rollers 219A and 219B is also provided, each of the rollers being disposed so as to imprint one side of the seam. Likewise, a palr of rollers 195A and 195s are also provided B0 as to bias the tape into contact with the respective ~sides of the seam. A pair of orifices 183A and 183B are provided so as to place a first coat of joint compound on the upper surface of the tape and these orifices are controlled in a manner similar to the flat taping head 6hown in Figs. 8 and 9 by the provision of gates 185~ and 185B. Likewise, a pair of second orifices 189~ and 189B are also provided so as to place a second coat of joint compound on the tape. Although not shown in Fig. 10, a pair of gates analogous to gate 191 in the flat taping head may also be provided to control the flow of joint compound through orifice 189A and orifice 189B. A first wiper 211' and a second wiper 215' are also provided so as to spread and smooth the respective coats of joint compound.
ln operation, the operator will turn on the apparatus as by the depression of switch 82 which cause.s power to be supplied to motor 59 which drives pump 13. Ibwever, the pressure developed by pump 13 is insufElcient by ltself to overcome the biasing action of springs 187 and 193 in malntalning gates 185 and 191 in the closed posltion. IIowever, joint compound will be supplied through tape supply nozzle 135 to the underside of the 2 Q i~
wallboard tape. Immediately upon turning on the apparatus, the operator will then activate the wallboard tape advance ~o as to cause the coating of the bottom portion of a predetermined length of wallboard tape which wlll then be placed into contact with the wallboard 209 by pressure from rollers 195, 197 and 199. The wallboard tape which is 80 pressed agalnst the wallboard is effectlvely adhesively adhered to the wallboard and the operator may now move the taplng head downwardly (or upwardly) along the wall 80 as to draw tape from the tape supply wheel ~the rollers 165 and 167 permitting such passage of the tape slldingly thereover). With the beginning of motion of the taping head across the wall, the operator may then activate motor 61 driving pump 15 so as to overcome the bias Oe springs 187 and 198 holding gates 185 and 191 shut. By controlling the opetatlon o~ p~mp 15, the operator may control the amount of joint co~pound being fed to the head 80 as to suit the particular application conditions being dealt with. When the operator comes to the end of the stroke, the knife edge carried on slider 149 may be activated so as to cut the tape Oef and allow the operator to finish the end of the tape. This cycle may then be repeated in taping the next seam in the operation.
In the case where the operator is merely patching nail or screw holes in the wallboard, e.g. or in those situatlons where no tape feed is desired, the valve 133 may be closed so as to prevent the feed of joint compound through tape supply nozzle 135 and jolnt compound may be fed exclusively through orifice 183 and orlfice 189.
In order to effectuate the process and apparatus of the present invention, it i8 neces~ary to utilize a fast-drying joint compound so as to allow multiple coats to be d1sposed one upon 2 0 - ~ ~ 8 ~ ~3 the other in a substantially simultaneous manner.
In the compositions of the present inYention ~he alcohol can comprise methyl, ethyl and propyl alcohols. Preferably, the alcohol comprises commercially denature~ ethyl alcohol.
As previously noted, the present apparatus allows for the taping of joints between pieces of wallboard by the substantially simultaneous steps of (a) applying a first layer of a joint compound to the joint between pieces oE wallboard, the first layer of joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially equal to the first predetermlned width, the wallboard tape being substantially centered, widthwise, on the jolntJ and (c) overcoating of the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of joint compound having a width greater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the jolnt.
Tile present invention ls directed to a process o taping jolnts between adjacent pieces of wallboard and an apparatus eor effecting such taping of the joints. More partlcularly, the present invention is directed to a process and apparatus whereby a finished joint between adjacent pieces of wallboard may be completed in one step.
Wallboard ~also known as drywall) has become the domlnant material in the production of interior bullding partitions. In particular, interior building partitions generally comprise a studwall of ~paced parallel vertical members ~studs) which are used as a support for preformed panels (wallboard) whlch are attached to the studwall by screws, nails, adhesive or any other conventional attachment system. Obviously, joints exlst between adjacent preformed paneLs. In order to provide a continuous flat surface to the wall, it is necessary to "finish" the joint between adjacent panels. Generally, such "finishing" requires the building up of multiple layers of a mastic materlal (joint compound) and the blending of thls joint compound into the panel surface so a~ to form the deslred flat and contiguous wall surface. In order to facllitate this finishing of the joints, most manufacturers bevel the longitudinal edges of the wallboard panels so as to allow a buildup of mastic material which will then match the level of the major surface area of the preformed panel. Typically, the buildup of the mastic material in the joint area comprises the application of a first layer of mastic material, the embedding of a wallboard tape (for example a paper tape or a fiberglas~ tape) in the flrst layer of mastic material and then the overcoating of the tape with one or more, generally two layers of additional mastic material. This finishing of the joints is a time consuming process, 61nce it is generally necessary to wait 24 hours between each application of a coat of mastic material in order to allow the coat to dry before the application of an overcoat of an additional layer of mastic material. Moreover, it is then necessary generally to sand the joint area so as to produce a fin1sh which will match the major portion of the 10 surface area of the wallboard panels. The "finishing" process thus is both time-consuming and labor-intensive.
In this regard, numerous attempts have been made to speed up and/or reduce the labor involved in the finishing products . In this regard, attention is directed tG U.S. Patents 2,666,323 and 2,824,442, to Ames, which disclose a tool designed to apply a layer of mastic to a wallboard joint.
U.S. Patent 3,007,837, to Goode, Jr., discloses a tape and joint compound dispensing wallboard taping machine which uses air pressure to supply joint compound to the head of the tool 20 where it is applied to one side of the tape which side of the tape is then applied to the wall.
U.S. Patent 3,131,108, to Kennard, discloses a wallboard taping machine which may have interchangeable heads for different conditions, e.g. flat joints versus corner joints.
U.S. Patent 3,343,202, to Ames, discloses a tool for applying mastic to wallboard which includes a swlngable arcuate trawling blade.
U.S. Patent 3,404,060, to Taylor, Jr., dlscloses a wallboard taping machine including a supply of both joint compound and tape. The device includes a tape cutting knlfe which 18 automatically retractable and the tape has the ~oint compound applied on one slt3e thereof.
U.S. Patent 3,707,427, to Erickson, discloses a tape and joint compound dispenser wherein the tape is drawn through a joint compound reservoir so that the joint compound is applied on one side thereof. The quantlty of jolnt compound ln the dispensing chamber is automatically regulated.
U.S. Patent 3,880,701, to Moree, discloses a tape and 10 joint applying tool including applicator rolls and a blade for cuttlng the tape.
U.S. Patent 3,925,145 discloses a tool for embedding tape into mastic at the corner of a room after the mastic and tape have been previously applied to the corner joint of the room.
U.S. Patent 3,960,643, to Dargitz et al., disclo~es a device to apply a tape and covering finish plaster to a drywall 6eam in a single pass lengthwise thereover, wherein a relatively llghtweight, hand supported frame has a unit thereon operative to 20 first apply glue to a length of tape and then glue-affix the tape to the drywall over the seam and another unit on the frame operative, I)ut trailing the tape gluing and applying unit, the apply a thin, smooth, layer of joint compound over the then-in-place tape.
U.S. Patent 4,080,240 to Dysart, discloses a device Eor applying tape to wallboard and including valve-controlled mud supply. The device also includes a ~evering knlfe and a retractable V-shaped roller.
U.S. Patent 4,086,121, to Ames, disclose6 a ~elf-30 contained drywall taper having a hollow elongated body for 2 ~
holding mastic and supports a roll of tape with tape feeding means to deliver the tape to tape applying wheels then in turn apply it to cover a joint between two wallboard sections. A
piston is slidably mounted in the hollow body and is automatically moved by a mechanism actuated by the rotating wheels, as they are moved over the wallboard surface, to force a layer of mastic onto the tape just prior to it being applied to the surface.
U.S. Patent 4,090,914, to ~lauk et al., discloses an 10 apparatus for applying tape and adhesive to wallboard joints which is then convertlble to deposit adhesive over the previously applied tape.
U.S. Patent 4,196,02B, to Mills, discloses a joint compound and tape applying tool having the provision of a following corner roller.
U.S. Patent 4,208,239, to Lass, di~closes a drywall taping machlne including a flex~ble resilient wiper blade which presses the cement-laden tape into engagement with the wall and, in addition, feathers the cement onto the drywall along both side 20 edges oE the tape in a single pass. A backpack support for the joint compound supply is disclosed.
U.S. Patent 4,309,238, to llauk, discloses a drywall taping devlce which has a control for adjucting the tensioning force applied to tootl-ed traction wheels thereof.
U.S. Patent 4,358,337, to Johnson et al., discloses a tape applicator which utilizes a replaceable joint compound cartridge system.
U.S. Patent 4,452,663, disoloses ~ wallboard joint taping apparatus including an elongated frame having a tape press 30 wheel mounted on the Eorward end with a compound reservoir 2 ~ fi ,r~
mounted on the frame, intermediate the ends, with allgned slots through the lower edge of the wall with a source of tape mounted on the other end of the frame with the tape passing through the slots in the compound container for picking up taping compound on the surface thereof and passing over the roller for application and pressing by the press wheel into a joint between adjacent wallboard panels.
U.S. Patent 4,516,868, to Molnar, discloses a device designed to apply a layer of joint compound over an already installed length of tape.
U.S. Patent 4,592,797, to Carlson, discloses a tube including a cylindrical roller for applying pressure to embed a tape in adhesive, the roller being designed to allow the mud which is on the underside of the tape to flow over the top of the tape and coat that surface as well.
U.S. Patent 4,608,116, to Braselton, discloses a baseboaed edge taping tool which includes a severing knife and which is specifically designed to enable cutting operations at a corner.
Otller reEerences relating to tape dispenslng and mastlc dispensing include U.S. Patent 2,972,428, to Dubbs, which discloses a tape applicator including microswitch controls for advancing, severing and applying a pressure sensitive tape.
Movements of the tape are controlled incrementally on a cyclicable basis.
U.S. Patent 3,785,535, to ~mes, discloses a mastic supply pump outlet for filling different types of mastic-applying tools.
U.S. Patent 4,406,247, to Baughman et al., discloses control of the flow of adhesive in an adhesive dispensing system ,~ J~
wherein a logic control unit receives signals ind1cative of ~various process cond~tions and in response thereto controls-adhes~ve dispensing.
U.S. Patent 4,477,304, to Westermann~ discloses a tool designed to apply a predetermined quantity of adhesive on a workpiece.
U.S. Patent 4,584,047, to Vanderpool et al., dlscloses a hand-held labeling device whlch senses the pos~tion o~ the web of labels and controls other operation in response to this sensed condition.
Despite the great efforts which have been applied to reduce the labor and time involved in wallboard finishing, there is still a marked need for an efficient and useful tool which is easy to operate and which will allow a one-step finishing of wallboard.
Accordingly, it is an object of the present invention to provide an apparatus, process, and composition for wallboard finishing which requires only a single step.
As will become readily apparent hereinafter, the above object of the invention is achieved by the provision of an apparatus, process, and compositions for the taping of joints between pieces of wallboard. The composition of the present invention comprises from about 35 to 60% by weight of a gypsum base plaster, 30 - 70% by weight of an alcohol-water mixture, 0 to 5% by weight of polyvinyl alcohol, and 10- 25~ by weight of polyvinyl acetate.
In a preferred embodiment, the gypsum base plaster comprises from about 40-70, more preferably 45-60, most preferably 6.5% by weight of calcium carbonate, up to 5%, more preferably about 2% by weight of silica sand, up to 6, most ~ ~3 ~ 3 preferably about 4% by weight of starch, small amounts of conventional drying accelerators for the gypsum base plaster, 0-10% by weight of talc and 0-10% by weight of mica. The total amount of talc plus mica constituting from about 4-20% by weight.
The wetting agent used in the composition of the present invention preferably comprises a non-toxic alcohol-water mixture. In a preferred embodiment the wetting agent comprises 30-70, more preferably 37-56, most preferably 42% by weight of an alcohol-water mixture. The alcohol-water mixture may contain from about 0 to 30~ by weight of water.
Preferably, the composition of the present invention contains from about 0 to 5% of polyvinyl alcohol, preferably about 1%.
The composition of the present invention contains an adhesive material which preferably comprises a polyvinyl acetate in an amount of from about 10 to 25, most preferably 14% by weight.
Applicant discovered that upon application to a surface of a conventional plaster containing polyvinyl chloride and water as the wetting agent, the polyvinyl chloride quickly forms an outer skin through which the water must migrate in order for the plaster to completely dry and harden. As a consequence, it becomes necessary in construction projects to maintain an ambient temperature of at least 55F in the room where the plaster is to be applied. The cost of heaters, fuel, and labor to maintain this temperature adds significantly to the cost of construction. Applicant unexpectedly discovered that when a plaster comprises a gypsum base, an alcohol-water wetting agent, and polyvinyl acetate, the wetting agent migrates much 2 ~
faster through the skin formed on the polyvinyl acetate, than the water which migrates through the skin on polyvinyl chloride in conventional gypsum plasters. This accelerated drying rate of the composition of the present invention was unexpectedly found to be unaffected by temperature over a relatively wide range. For example, the composition of the present invention can be applied satisfactorily at temperatures of from about 10-120F.
It was also unexpectedly discovered that the dried composition of the present invention absorbs conventional paints, including both water and oil base paints, at a rate approximating the absorption rate of the paper used on the outer surface of conventional drywall. As a result, satisfactory painting of the surface of a wall finished with the composition of the present invention can be accomplished with only one coat of paint, thus eliminating the need for a primer and a second top coat.
In addition, applicant has found that the apparatus described herein can be satisfactorily cleaned with a cleaning solvent comprising an aqueous mixture of zinc chloride, optionally containing a minor amount of alcohol. The compositions of the present inventions can be used in a process comprising the substantially simultaneous steps of: (a) applying a first layer of the joint compound to a joint between pieces of wallboard, the first layer of the joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint; (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially ~ 3~
e~ual to the first predetermined width, the wallboard tape being substantially centered, widthwise, on the joint; (c) overcoating the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of the joint compound having a width qreater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the joint.
In a preferred embodiment of the method using the compositions of the present invention, the step (c) comprises the substantially simultaneous sub-steps of: (c-l) overcoating the embedded wallboard tape with a second layer of the joint compound, the second layer of the joint compound ~aving a second predetermined width, the second predetermined width being greater than the first predetermined width, the second layer of the joint compound being substantially centered, widthwise, on the joint; and (c-2) overcoating the second layer of the joint compound with a third layer of the joint compound, the third layer of the joint compound having a third predetermined width, the third predetermined width being greater than the second predetermined width, the third layer of the joint compound being substantially centered, widthwise, on the joint.
In a particularly preferred embodiment of the present method, the method comprises the further step (d) of imprinting a surface pattern on the third layer of the joint compound, preferably, the surface pattern matches a surface pattern on the wallboard.
t ~ ~
The peesent inventlon also provides an apparatus for taping joints between pieces of wallboard, comprising a taping head, slidingly contactable with a wall, for sub6tantlally simultaneously applying a first layer o a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in the first layer of the joint compound and overcoating the embedded wallboard tape with at least one additional layer of the joint compound a handle, connected to the taping head, for supporting the taping head, the handle being manually graspable by an operator, the handle havlng a fluld condult formed thereln for passing jOillt compound to the taping head~ a tape supply mounted on the handle for supplying wallboard tape to the taping head a backpack, wearable by the operator, for supporting a supply of the joint compound and for produclng a pressurized stream of the joint compound; a flexible connection for fluidically interconnecting the backpack and the fluid conduit to pass the pressurized stream of the joint comFound from the backpack to the fluid conduit.
In a preferred embodiment oE the apparatus according to the present invention, the taping head comprises a Elrst support plate, attached to the handle a guide meanS, attached to the first support plate, for guiding a wallboard tape of predetermined width being applied to a joint first orlfice means, attached to the first support plate, for feeding a first layer of joint compound to a surface of the wallboard tape intermediate the joint and the wallboard tape, the flrst orifice means fluldically connected to the fluid conduit means a second support plate, releasably attachable to the handle~ biasing means, attached to the second support plate, for yieldably urging the wallboard tape and, hence, the first layer of joint compound, into contact with the wall, when the taping head i~ in contact with the wall, to embed the wallboard tape ln the first layer oE
jolnt compound second orifice means, formed in the second support plate proximate the flrst support plate, for overcoatlng the wallboard tape with a second layer of the joint compound, the second orifice means having a width greater than the wallboard tape, the second orifice means belng centered, widthwise, with respect to the guide means; first pa~sage means, formed ln the second support plate, for fluldlcally connecting the second oriflce means and the fluid conduit means; flrst gate means, pivotally connected to the second support plate for pivotal movement between a first position and a second position, the first gate means preventing flow of joint compound through the second oriflce means when ln the first position and allowing flow of joint compound through the second orifice means when in the second position second biasing means for yieldably urglng the first gate means to the first position; thlrd orlfice means, formed in the second support plate remote from the first support plate, for overcoating the second layer of the joint compound with a third layer of the jolnt compound, the third orifice means having a width greater than the second orlfice means, the third orifice means being centered, widthwise, with respect to the guide means; second passage means, formed in the second support plate, for fluidically connectlng the thlrd orlfLce means and the fluid conduit means second gate means, pivotally connected to 6~
the second support plate for pivotal movement between a first position and a second positlon, the second gate means preventing flow of joint compound theough the third orifice means when in the first position and allowlng flow o joint compound through the third oriice means when in the second position: third biasing means for yieldably urging the second gate means to the first position; first resilient wiper means, mounted on the second support plate intermediate the second orifice means and the third orifice means, for spreading and smoothing the second layer of the joint compound; second recilient wiper blade means, mounted on the second support plate on the opposite side of the third orifice means from the first resilient wiper blade means, for spreading and smoothing the third layer of the joint compound.
In a particularly preferred embodiment, the taping head further comprises roller means, mounted on the second support plate, for imprinting a surface pattern on the third layer of the joint compound, wherein the imprinted surace pattern preferably matches a surface pattern on the wallboard.
Fig. lA is a partially cutaway view oE the right hand side of the backpack unit according to the present invention.
Fig. lB is a left hand view of the backpack unit according to the present invention.
Fig. 2 is a partially exploded view of the backpack unit showing the pumping mechanism.
Fig. 3 illustrates a section of the handle according to the present invent1on.
Fig. 4 illustrates another section of the handle according to the present invention.
;?, fi l'~
Fig. 5 is a perspective view of a pottion of the handle section ill U8 trated in Fig. 3.
Fig. 6 is a perspective view of a portion of the handle sectlon illustrated in Pig. 4.
Fig. 7 is a partially exploded view of certaln elements of the handle ~ection illustrated in Fig. 4.
Fig. 8 is a bottom view of the taping head unit.
Fig. 9 i8 a partially cutaway view of the taping head unit.
Fig. lO is a perspective view of the underside of an alternative taping head unit.
Figure 11 is an illustration of the completely assembled apparatus.
Turning now to the deawing Eigures, Figs. lA and lB (a rlght hand view and a left hand view, respectively) illustrate the backpack portion of the present invention. In particular, the backpack comprises a support frame l which is adapted to be fitted with suitable webblng (not shown) so as to allow the backpack to be worn on the back of an operator. A container support 3 is attached to the support frame by brackets 5 which may be screwed to or welded to support frame 1 and contalner support 3. Container support 3 comprises an upper section 7 in the form of a box open at its top which is receivable of a unit container 11 of joint compound. The container support also comprises a lower section 9 which contains pumps 13 and 15 and related equipment, as will be described hereinaEter.
The unit container ll is Eitted with a pair of grommets 17 and l9 which deflne puncturable portions of the bottom wall of the container ll. When the container ll is placed within the upper section 7, a pair of up~qtanding pipe portions 21 and 23, which are cut at an angle so as to form a "aharpened" edge, are aligned wlth the grommets 17 and 19, respectively, and insertion of the container 11 Eully into the upper section 7 causes these upstandlng pipe sections 21 and 23 to pierce the wall of the container and provide fluid communication between the container and the pumps as will be described hereinafter.
~ s may best be seen in Fig. 2, pipe section 21 is connected through elbow 25 and pipe 27 to the inlet 29 of pump 15. Likewise, pipe 23 is connected through elbow 31 and pipe 33 to the inlet 35 of pump 13. In turn, the outlet 37 of pump 15 is connected via elbow 39 and pipe 41 to outlet fitting 43.
Likewise, the outlet 45 of pump 13 is connected via pipe 47, elbow 49 and pipe 51 to the outlet fitting 43. The outlet fitting 43 and/or the plpes 41 and 51 may be supported by a bracket 53 mounted on the support frame 1. The outlet fitting 43 ls detachably connectable to an inlet fltting 55 of flexible hose 57.
Pumps 13 and 15, which are preferably positive displacement pumps, and most preferably rotary flexible impeller (vane) pumps, are driven by motoes 59 and 61, respectively.
Motors 59 and 61 are preferably electric motors driven by 120 V electrical supply. The electrical motors 59 and 61 may be supplied with power by a flexible electrical cable connected to a suitable source of power, Joint compound which is pumped from unit contalner 11, via pumps 13 and 15, to flexible hose 57 is passed to the handle assembly. The handle assembly comprises a control sectlon 65 (as shown in Fig. 3) and a delivery section 67 (as shown in Fig. 4).
The control section 65 compcises a handgrip 69 and a tape supply element 71. A fluid passageway 73 (as shown in dotted lines in Fig. 3) passes through the control section 65 s~
from a socket 75, where 1exible hose 57 i8 fluidically connected to the fluid passage 73, to a socket 77 wherein a plug 79 o the delivery sectlon 67 may be recelved so as to fluldlcally connect with tlle dellvery sectlon 67. The handgrlp 69 is fltted wlth ~witche6 (in the form of buttons 81-86) for operatlon of the various functions of the apparatus, as will be disclosed herelnafter. The handgrip 69 i8 also fltted wlth a socket 87 for electrlcal connection of the switches to the various electrical elements in the backpack unit. Addltlonally, the handgrip 69 is also fltted with an additional socket tnot shown) for connectlon (vla a cable connection) to the various electrical devices ln the delivery section 67.
The tape supply element 71 is shaped substantially as a hollow rectangle (as best seen ln Fig. 5) and comprise8 first and second cros~ members, 89 and 91, and eirst and second connecting members 93 and 95. A first disc 97 is rotatably mounted on connecting member 93. A second disc 99 is rotatably mounted on connecting member 95. The mounting of discs 97 and 99 is such that the discs are rotatably mounted substantially coaxially.
Disc 97 is provided with a radially extending flange 101 and disc 99 is provided with a radially extending flange 103. At least one of the discs 97 and 99 is moveable axially with respect to the other disc by being supported for rotation on a- pin 105 or 107, respectively, received within a corresponding bore 109 or 111 formed in cross member 93 or 95. A spring (not shown) may be fitted in bore 109 and/or 111 so as to yieldably urge at least one of discs 97 and 99 axially toward the other disc. The discs are of such a diameter as to be received within the core of a roll of wallboard tape, whereby a roll of wallboard tape may be supported on the discs for rotation so as to supply tape through the delivery sectlon 67 of the handle.
The delivery section 67 substantially comprises a fluid condult assembly 113 and a support plate 115. The fluid conduit assembly, as best seen ln Fig. 7, comprises the plug 79 wllicl~ is fluidically connected to a chamber 117 whlch in turn is connected to three fluid supply pipes 119, 121 and 123. Pipe 121 is fluidically connected to supply nozzle 125 and pipe 123 is fluidically connected to supply nozzle 127. Pipe 119 is fluidically connected via elbow 129, pipe 131 and valve 133 to tape supply nozzle 135, which when as6embled is disposed in region 137 of the support plate 115.
A first stepping motor 139 is mounted on chamber 117 and connected via Elexible drive cable 141 to a ~lrst bevel gear 143. First bevel gear 143 mates with a second bevel gear 145 which is mounted for rotation with a first shaft 147, shaft 147 having a screw thread formed on the outer periphery thereof. A
slider 149 is slidably mounted on rails 151 and 153 with a knife edge (not sh~wn) depending in the gap between rails 151 and 153.
Connection member 155 is connected to slider 149 and is fitted with a screw threaded bore corresponding to tlle screw thread Eormed on the outer periphery of the flrst shaft 147, whereby rotation of the first shaEt will cause movement of the slider 149 along rails 151 and 153, thereby drawing the knife edge across plate 115. ~eversal of the rotation of the first shaft 147 by reversal of the rotation of the first stepping motor 139 will draw the slider, and hence the knife edge, back across plate 115. By alternating the direction oE rotation of first stepping motor 139, the knife edge may be drawn back and Eorth across plate 115 as needed.
A second stepping motor 157 ~8 also mounted on chamber 117 and 18 connected via flexible drive cable 159 to gear box 161. Gear box 161, in turn, contains gears to drive second shaft 163 upon which Eriction rollers 165, 167 are mounted for rotation therewith. Plate 115 is fitted with guide rails 169 and 171 so as to guide wallboard tape beneath rollers 165 and 167, beneath rails 151 and 153 as well as shaft 147 and over tape supply nozzle 135.
In operation, a tape passing between guide rails 169 and 171 on plate 115 may be advanced a predetermined amount by actuation of stepping motor 157 80 as to cause a predetermined rotation of shaft 163 and the friction rollers 165 and 167 mounted thereon. Likewise, the tape may be cut by actuation of the stepping motor 139 and the concomitant rotation of shaft 147 causing slider 149 (which is Eitted with a knife edge) to slide across the width of the tape on plate 115. In this regacd, for example, switch 81 on handgrip 69 can actuate stepping motor 157 so as to cause the tape to advance in a predetermined amount.
Likewise, switch 84 can be connected to stepping motor 139 80 as 20 to cause movement of slider 149 across the tape. It should be noted, however, that switch 84 alternatively changes the polarity of electrical current fed to stepping motor 139 so as to alteenately draw the slider across and then back across the plate 115. As the tape passes over tape supply nozzle 135 joint compound is applied to the lower face 173 of the tape 175.
Turning now to Figs. 8 and 9, a second plate 177 is releasably attachable to the delivery section 67 of the handle.
In this regard, as may best be seen in Fig. 9, supply nozzles 125 and 127 may be respectively received in passages 179 and 181 in a 30 snap-fit or force-fit manner. Pa~sage 179 communicates with an 3~
orifice 183 formed in plate 177. The orifice 183 ls fltted with a gate 185 which is plvotally mounted on plate 177 so as to be moveable from a first posltion in which fluid passage through the orifice ls prevented to a second position (as shown in Fig. 9) wherein ~luid passage through orifice 183 is permitted. The gate may be biased, by a torsion spring 187, so as to be yieldably urged to the first position.
In a similar manner, passage 181 communicates with an orifice 189 formed in plate 177. Orifice 189 is also fitted with a gate 191 pivotally connected to plate 177 so as to be moveable from a first position in which fluid flow through the oriEice is prevented and a second position in which fluid flow through the orifice is permitted. Gate 191 may also be biased, as by torsion spring 193, so as to yieldably urge the gate to the first position. ~ollers 195, 197 and 199 may be supported on a shaft 201 which in turn is journaled ln a support membee 203 carried in bore 205 ~ormed in the plate 177. ~ biasing spring 207 yieldably urges the rollers downwardly so as to force the lower side 173 of tape 175 into contact with wallboard 209. A ~irst resilient wiper blade 211 adjustably mounted in the plate 177 as by a screw support 213 smoothes and spreads joint compound delivered through the orifice 183. A second flexlble wiper blade 215 adjustably mounted in plate 177 as by screw support 217 moves and spreads the joint compound delivered to the wallboard through orifice 189. ~ printing roller 219 may be provided with a surface pattern matching the surface pattern of the wallboard 209 so as to aid in disguising the position of the seams formed by the present apparatus. The roller 219 may be supported by support 221 which in turn is pivotally attached to plate 177 and ~ Q ~
may be biased into contact with the seam urface as by a tor~ion spring 223.
~ s shown in Fig. 10, the second support plate may also be formed in other configurations 80 as to allow specialized taping operations, e.g. the taping of inside corners. In this regard, the plate is formed in two sections 177A and 177B which are at right angles to one another. ~ pair of printing rollers 219A and 219B is also provided, each of the rollers being disposed so as to imprint one side of the seam. Likewise, a palr of rollers 195A and 195s are also provided B0 as to bias the tape into contact with the respective ~sides of the seam. A pair of orifices 183A and 183B are provided so as to place a first coat of joint compound on the upper surface of the tape and these orifices are controlled in a manner similar to the flat taping head 6hown in Figs. 8 and 9 by the provision of gates 185~ and 185B. Likewise, a pair of second orifices 189~ and 189B are also provided so as to place a second coat of joint compound on the tape. Although not shown in Fig. 10, a pair of gates analogous to gate 191 in the flat taping head may also be provided to control the flow of joint compound through orifice 189A and orifice 189B. A first wiper 211' and a second wiper 215' are also provided so as to spread and smooth the respective coats of joint compound.
ln operation, the operator will turn on the apparatus as by the depression of switch 82 which cause.s power to be supplied to motor 59 which drives pump 13. Ibwever, the pressure developed by pump 13 is insufElcient by ltself to overcome the biasing action of springs 187 and 193 in malntalning gates 185 and 191 in the closed posltion. IIowever, joint compound will be supplied through tape supply nozzle 135 to the underside of the 2 Q i~
wallboard tape. Immediately upon turning on the apparatus, the operator will then activate the wallboard tape advance ~o as to cause the coating of the bottom portion of a predetermined length of wallboard tape which wlll then be placed into contact with the wallboard 209 by pressure from rollers 195, 197 and 199. The wallboard tape which is 80 pressed agalnst the wallboard is effectlvely adhesively adhered to the wallboard and the operator may now move the taplng head downwardly (or upwardly) along the wall 80 as to draw tape from the tape supply wheel ~the rollers 165 and 167 permitting such passage of the tape slldingly thereover). With the beginning of motion of the taping head across the wall, the operator may then activate motor 61 driving pump 15 so as to overcome the bias Oe springs 187 and 198 holding gates 185 and 191 shut. By controlling the opetatlon o~ p~mp 15, the operator may control the amount of joint co~pound being fed to the head 80 as to suit the particular application conditions being dealt with. When the operator comes to the end of the stroke, the knife edge carried on slider 149 may be activated so as to cut the tape Oef and allow the operator to finish the end of the tape. This cycle may then be repeated in taping the next seam in the operation.
In the case where the operator is merely patching nail or screw holes in the wallboard, e.g. or in those situatlons where no tape feed is desired, the valve 133 may be closed so as to prevent the feed of joint compound through tape supply nozzle 135 and jolnt compound may be fed exclusively through orifice 183 and orlfice 189.
In order to effectuate the process and apparatus of the present invention, it i8 neces~ary to utilize a fast-drying joint compound so as to allow multiple coats to be d1sposed one upon 2 0 - ~ ~ 8 ~ ~3 the other in a substantially simultaneous manner.
In the compositions of the present inYention ~he alcohol can comprise methyl, ethyl and propyl alcohols. Preferably, the alcohol comprises commercially denature~ ethyl alcohol.
As previously noted, the present apparatus allows for the taping of joints between pieces of wallboard by the substantially simultaneous steps of (a) applying a first layer of a joint compound to the joint between pieces oE wallboard, the first layer of joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially equal to the first predetermlned width, the wallboard tape being substantially centered, widthwise, on the jolntJ and (c) overcoating of the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of joint compound having a width greater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the jolnt.
Claims (37)
1. An apparatus for taping joints between pieces of wallboard comprising:
a taping head means, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, overcoating said embedded wallboard tape with a second layer of said joint compound, and overcoating said second layer of said joint compound with a third layer of said joint compound;
a handle means, connectable to said taping head means, for supporting said taping head means, said handle means being manually graspable by an operator, said handle means having fluid conduit means formed therein for passing joint compound to said taping head means;
tape supplying means, mounted on said handle means, for supplying wallboard tape to said taping head means;
backpack means, wearable by said operator, for supporting a supply of said joint compound and for producing a pressurized stream of said joint compound;
flexible connecting means for fluidically interconnecting said backpack means and said fluid conduit means to pass said pressurized stream of said joint compound from said backpack means to said fluid conduit means;
wherein said taping head means comprises:
a first support plate, attached to said handle means;
a guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for feeding a first layer of joint compound to a surface of said wallboard tape intermediate said joint and said wallboard tape, said first orifice means fluidically connected to said fluid conduit means;
a tape cutting means, mounted on said first support plate, intermediate said guide means and said first orifice means, for cutting said wallboard tape widthwise after having passed through said guide means;
a second support plate, releasably attachable to said handle means;
second orifice means, formed in said second support plate proximate said first support plate, for overcoating said wallboard tape with a second layer of said joint compound, said second orifice means having a width greater than said wallboard tape, said second orifice means being centered, widthwise, with respect to said guide means;
third orifice means, formed in said second support plate remote from said first support plate, for overcoating said second layer of said compound with a third layer of said joint compound, said third orifice means having a width greater than said second orifice means, said third orifice means being centered, widthwise, with respect to said guide means.
a taping head means, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, overcoating said embedded wallboard tape with a second layer of said joint compound, and overcoating said second layer of said joint compound with a third layer of said joint compound;
a handle means, connectable to said taping head means, for supporting said taping head means, said handle means being manually graspable by an operator, said handle means having fluid conduit means formed therein for passing joint compound to said taping head means;
tape supplying means, mounted on said handle means, for supplying wallboard tape to said taping head means;
backpack means, wearable by said operator, for supporting a supply of said joint compound and for producing a pressurized stream of said joint compound;
flexible connecting means for fluidically interconnecting said backpack means and said fluid conduit means to pass said pressurized stream of said joint compound from said backpack means to said fluid conduit means;
wherein said taping head means comprises:
a first support plate, attached to said handle means;
a guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for feeding a first layer of joint compound to a surface of said wallboard tape intermediate said joint and said wallboard tape, said first orifice means fluidically connected to said fluid conduit means;
a tape cutting means, mounted on said first support plate, intermediate said guide means and said first orifice means, for cutting said wallboard tape widthwise after having passed through said guide means;
a second support plate, releasably attachable to said handle means;
second orifice means, formed in said second support plate proximate said first support plate, for overcoating said wallboard tape with a second layer of said joint compound, said second orifice means having a width greater than said wallboard tape, said second orifice means being centered, widthwise, with respect to said guide means;
third orifice means, formed in said second support plate remote from said first support plate, for overcoating said second layer of said compound with a third layer of said joint compound, said third orifice means having a width greater than said second orifice means, said third orifice means being centered, widthwise, with respect to said guide means.
2. The apparatus according to Claim 1, wherein said taping head means further comprises roller means, mounted on said second support plate, for imprinting a surface pattern on said third layer of said joint compound.
3. The apparatus according to Claim 3, wherein said surface pattern imprinted on said third layer of said joint compound matches a surface pattern on said wallboard.
4. The apparatus according to Claim 1, wherein said taping head means further comprises tape advance means, mounted on said first support plate, for advancing a predetermined length of said wallboard tape through said guide means.
5. The apparatus according to Claim 1, wherein said tape supply means comprises:
a first disc rotatably mounted on said handle, said first disc having a radially extending flange;
a second disc rotatably mounted on said handle, said second disc having a radially extending flange;
said first and second discs being rotatable about a common axis and movable on said axis relative to one another;
said first and second discs being receivable within a core supporting a roll of wallboard tape;
biasing means for causing at least one of said first and second discs to yieldably move toward the other.
a first disc rotatably mounted on said handle, said first disc having a radially extending flange;
a second disc rotatably mounted on said handle, said second disc having a radially extending flange;
said first and second discs being rotatable about a common axis and movable on said axis relative to one another;
said first and second discs being receivable within a core supporting a roll of wallboard tape;
biasing means for causing at least one of said first and second discs to yieldably move toward the other.
6. The apparatus according to Claim 1, wherein said backpack means comprises:
a support frame;
a container support mounted on said support frame, said container support being receivable of a unit container of said joint compound in a predetermined orientation;
pump means, mounted on said support frame, for producing a pressurized stream of said joint compound;
power supply means, mounted on said support frame, for driving said pump means;
piping means for supplying joint compound from a unit container mounted in said container support to said pump means;
outlet means for fluidically receiving said pressurized stream of said joint compound from said pump means, said outlet means including connection means for releasably connecting said outlet means to said flexible connecting means.
a support frame;
a container support mounted on said support frame, said container support being receivable of a unit container of said joint compound in a predetermined orientation;
pump means, mounted on said support frame, for producing a pressurized stream of said joint compound;
power supply means, mounted on said support frame, for driving said pump means;
piping means for supplying joint compound from a unit container mounted in said container support to said pump means;
outlet means for fluidically receiving said pressurized stream of said joint compound from said pump means, said outlet means including connection means for releasably connecting said outlet means to said flexible connecting means.
7. The apparatus according to Claim 6, wherein said pump means comprises a pair of pumps.
8. The apparatus according to Claim 7, wherein said power supply means comprises a pair of electric motors, each of said electric motors driving a respective pump.
9. The apparatus according to Claim 8, wherein said power supply means further comprises rechargeable battery means for supplying electric power to said electric motors.
10. The apparatus according to Claim 7, wherein said piping means further includes means for piercing a wall of said unit container, when it is received within said container support, to form a hermetic fluidic connection between said container and said pumps.
11. The apparatus according to Claim 1, wherein said taping head means further comprises biasing means, attached to said second support plate, for yieldably urging said wallboard tape and, hence, said first layer of joint compound, into contact with said wall, when said taping head means is in contact with said wall, to embed said wallboard tape in said first layer of joint compound.
12. The apparatus according to Claim 1, further comprising:
first passage means, formed in said second support plate, for fluidically connecting said second orifice means and said fluid conduit means;
first gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said first gate means preventing flow of joint compound through said second orifice means when in said first position and allowing flow of joint compound through said second orifice means when in said second position;
second biasing means for yieldably urging said first gate means to said first position;
second passage means, formed in said second support plate, for fluidically connecting said third orifice means and said fluid conduit means;
second gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said second gate means preventing flow of joint compound through said third orifice means when in said first position and allowing flow of joint compound through said third orifice means when in said second position; and third biasing means for yieldably urging said second gate means to said first position.
first passage means, formed in said second support plate, for fluidically connecting said second orifice means and said fluid conduit means;
first gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said first gate means preventing flow of joint compound through said second orifice means when in said first position and allowing flow of joint compound through said second orifice means when in said second position;
second biasing means for yieldably urging said first gate means to said first position;
second passage means, formed in said second support plate, for fluidically connecting said third orifice means and said fluid conduit means;
second gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said second gate means preventing flow of joint compound through said third orifice means when in said first position and allowing flow of joint compound through said third orifice means when in said second position; and third biasing means for yieldably urging said second gate means to said first position.
13. The apparatus according to Claim 12, wherein said taping head means further comprises:
first resilient wiper blade means, mounted on said second support plate intermediate said second orifice means and said third orifice means, for spreading and smoothing said second layer of said joint compound; and second resilient wiper blade means, mounted on said second support plate on the opposite side of said third orifice means from said first resilient wiper blade means, for spreading and smoothing said third layer of said joint compound.
first resilient wiper blade means, mounted on said second support plate intermediate said second orifice means and said third orifice means, for spreading and smoothing said second layer of said joint compound; and second resilient wiper blade means, mounted on said second support plate on the opposite side of said third orifice means from said first resilient wiper blade means, for spreading and smoothing said third layer of said joint compound.
14. An apparatus for taping joints between pieces of wallboard comprising:
a taping head means slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means, for supporting said taping head means, said handle being manually graspable by an operator, said handle having fluid conduit means formed therein for passing joint compound to said taping head means;
tape supplying means, mounted on said handle, for supplying wallboard tape to said taping head means;
backpack means, wearable by said operator, for supporting a supply of said joint compound and for producing a pressurized stream of said joint compound;
flexible connecting means for fluidically interconnecting said backpack means and said fluid conduit means to pass said pressurized stream of said joint compound from said backpack means to said fluid conduit means;
a first support plate, attached to said handle;
a guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for feeding a first layer of joint compound to a surface of said wallboard tape intermediate said joint and said wallboard tape, said first orifice means fluidically connected to said fluid conduit means;
a second support plate, releasably attachable to said handle;
biasing means, attached to said second support plate, for yieldably urging said wallboard tape and, hence, said first layer of joint compound, into contact with said wall, when said taping head means is in contact with said wall, to embed said wallboard tape in said first layer of joint compound;
second orifice means, formed in said second support plate proximate said first support plate, for overcoating said wallboard tape with a second layer of said joint compound, said second orifice means having a width greater than said wallboard tape, said second orifice means being centered, widthwise, with respect to said guide means;
first passage means, formed in said second support plate, for fluidically connecting said second orifice means and said fluid conduit means;
first gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said first gate means preventing flow of joint compound through said second orifice means when in said first position and allowing flow of joint compound through said second orifice means with in said second position;
second biasing means for yieldably urging said first gate to said first position;
third orifice means, formed in said second support plate remote from said first support plate, for overcoating said second layer of said joint compound with a third layer of said joint compound, said third orifice means having a width greater than said second orifice means, said third orifice means being centered, widthwise, with respect to said guide means;
second passage means, formed in said second support plate, for fluidically connecting said third orifice means and said fluid conduit means;
second gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said second gate means preventing flow of joint compound through said third orifice means when in said first position and allowing flow of joint compound through said third orifice means with in said second position;
third biasing means for yieldably urging said second gate means to said first position;
first resilient wiper blade means, mounted on said second support plate intermediate said second orifice means and said third orifice means, for spreading and smoothing said second layer of said joint compound; and second resilient wiper blade means, mounted on said second support plate on the opposite side of said third orifice means from said first resilient wiper blade means, for spreading and smoothing said third layer of said joint compound.
a taping head means slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means, for supporting said taping head means, said handle being manually graspable by an operator, said handle having fluid conduit means formed therein for passing joint compound to said taping head means;
tape supplying means, mounted on said handle, for supplying wallboard tape to said taping head means;
backpack means, wearable by said operator, for supporting a supply of said joint compound and for producing a pressurized stream of said joint compound;
flexible connecting means for fluidically interconnecting said backpack means and said fluid conduit means to pass said pressurized stream of said joint compound from said backpack means to said fluid conduit means;
a first support plate, attached to said handle;
a guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for feeding a first layer of joint compound to a surface of said wallboard tape intermediate said joint and said wallboard tape, said first orifice means fluidically connected to said fluid conduit means;
a second support plate, releasably attachable to said handle;
biasing means, attached to said second support plate, for yieldably urging said wallboard tape and, hence, said first layer of joint compound, into contact with said wall, when said taping head means is in contact with said wall, to embed said wallboard tape in said first layer of joint compound;
second orifice means, formed in said second support plate proximate said first support plate, for overcoating said wallboard tape with a second layer of said joint compound, said second orifice means having a width greater than said wallboard tape, said second orifice means being centered, widthwise, with respect to said guide means;
first passage means, formed in said second support plate, for fluidically connecting said second orifice means and said fluid conduit means;
first gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said first gate means preventing flow of joint compound through said second orifice means when in said first position and allowing flow of joint compound through said second orifice means with in said second position;
second biasing means for yieldably urging said first gate to said first position;
third orifice means, formed in said second support plate remote from said first support plate, for overcoating said second layer of said joint compound with a third layer of said joint compound, said third orifice means having a width greater than said second orifice means, said third orifice means being centered, widthwise, with respect to said guide means;
second passage means, formed in said second support plate, for fluidically connecting said third orifice means and said fluid conduit means;
second gate means, pivotally connected to said second support plate for pivotal movement between a first position and a second position, said second gate means preventing flow of joint compound through said third orifice means when in said first position and allowing flow of joint compound through said third orifice means with in said second position;
third biasing means for yieldably urging said second gate means to said first position;
first resilient wiper blade means, mounted on said second support plate intermediate said second orifice means and said third orifice means, for spreading and smoothing said second layer of said joint compound; and second resilient wiper blade means, mounted on said second support plate on the opposite side of said third orifice means from said first resilient wiper blade means, for spreading and smoothing said third layer of said joint compound.
15. An apparatus for taping joints between pieces of wallboard comprising:
taping head means, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means for supporting said taping head means;
tape supply means, mounted on said handle, for supplying wallboard tape to said taping head means;
supply means for supplying a pressurized stream of joint compound to said taping head means;
said taping head means comprising:
a first support plate attached to said handle;
guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for directing a first portion of said pressurized stream of joint compound to a first surface of said wallboard tape intermediate said joint and said wallboard tape such that a first layer of joint compound adheres to said tape;
a second support plate releasably attachable to said handle;
applying means for applying said wallboard tape against said wallboard joint, when said taping head means is in contact with said wall, to embed said wallboard tape into said first layer of joint compound;
second orifice means, formed in said second support plate proximate said first support plate, for directing a second portion of said pressurized stream of joint compound to a second surface of said wallboard tape with a second layer of joint compound; and third orifice means, formed in said second support plate remote from said first support plate, for directing a third portion of said pressurized stream of joint compound to said second layer of joint compound so as to overcoat said second layer of joint compound so as to overcoat said second layer of joint compound with a third layer of joint compound.
taping head means, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means for supporting said taping head means;
tape supply means, mounted on said handle, for supplying wallboard tape to said taping head means;
supply means for supplying a pressurized stream of joint compound to said taping head means;
said taping head means comprising:
a first support plate attached to said handle;
guide means, attached to said first support plate, for guiding a wallboard tape of predetermined width being applied to a joint;
first orifice means, attached to said first support plate, for directing a first portion of said pressurized stream of joint compound to a first surface of said wallboard tape intermediate said joint and said wallboard tape such that a first layer of joint compound adheres to said tape;
a second support plate releasably attachable to said handle;
applying means for applying said wallboard tape against said wallboard joint, when said taping head means is in contact with said wall, to embed said wallboard tape into said first layer of joint compound;
second orifice means, formed in said second support plate proximate said first support plate, for directing a second portion of said pressurized stream of joint compound to a second surface of said wallboard tape with a second layer of joint compound; and third orifice means, formed in said second support plate remote from said first support plate, for directing a third portion of said pressurized stream of joint compound to said second layer of joint compound so as to overcoat said second layer of joint compound so as to overcoat said second layer of joint compound with a third layer of joint compound.
16. An apparatus for taping joints between pieces of wallboard, comprising:
taping head means, slidingly contactable with a wall for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means, for supporting said taping head means;
tape supply means, mounted on said handle, for supplying wallboard tape to said taping head means;
supply means for supplying a pressurized stream of joint compound to said taping head means;
said taping head means comprising:
first orifice means for directing a first portion of said pressurized stream of joint compound to a first surface of said wallboard tape intermediate said joint and said wallboard tape such that a first layer of joint compound adheres to said tape;
applying means for applying said wallboard tape against said wallboard joint, when said taping head means is in contact with said wall, to embed said wallboard tape into said first layer of joint compound;
second orifice means for directing a second portion of said pressurized stream of joint compound to a second surface of said wallboard tape so as to overcoat said wallboard tape with a second layer of said joint compound;
second orifice gate means for normally preventing flow of joint compound through said second orifice means, but allowing flow of said joint compound when said pressurized stream of joint compound is pressurized sufficiently to overcome a predetermined bias force;
said supply means comprising:
a supply of joint compound;
fluid conduit means for fluidically connecting said supply of joint compound with said first and second orifice means of said taping head means;
first pump means for delivering a first amount of said joint compound through said fluid conduit means at a pressure insufficient to overcome said predetermined bias force but sufficient to force said joint compound through said first orifice means; and second pump means for delivering additional joint compound through said fluid conduit means at a controllably variable pressure which, when coupled with the pressure created by said first pump means, is sufficient to overcome said predetermined bias force to thus force joint compound through said second orifice means.
taping head means, slidingly contactable with a wall for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in said first layer of said joint compound, and overcoating said embedded wallboard tape with at least one additional layer of said joint compound;
a handle, connectable to said taping head means, for supporting said taping head means;
tape supply means, mounted on said handle, for supplying wallboard tape to said taping head means;
supply means for supplying a pressurized stream of joint compound to said taping head means;
said taping head means comprising:
first orifice means for directing a first portion of said pressurized stream of joint compound to a first surface of said wallboard tape intermediate said joint and said wallboard tape such that a first layer of joint compound adheres to said tape;
applying means for applying said wallboard tape against said wallboard joint, when said taping head means is in contact with said wall, to embed said wallboard tape into said first layer of joint compound;
second orifice means for directing a second portion of said pressurized stream of joint compound to a second surface of said wallboard tape so as to overcoat said wallboard tape with a second layer of said joint compound;
second orifice gate means for normally preventing flow of joint compound through said second orifice means, but allowing flow of said joint compound when said pressurized stream of joint compound is pressurized sufficiently to overcome a predetermined bias force;
said supply means comprising:
a supply of joint compound;
fluid conduit means for fluidically connecting said supply of joint compound with said first and second orifice means of said taping head means;
first pump means for delivering a first amount of said joint compound through said fluid conduit means at a pressure insufficient to overcome said predetermined bias force but sufficient to force said joint compound through said first orifice means; and second pump means for delivering additional joint compound through said fluid conduit means at a controllably variable pressure which, when coupled with the pressure created by said first pump means, is sufficient to overcome said predetermined bias force to thus force joint compound through said second orifice means.
17. The apparatus according to Claim 16, further comprising:
a power supply means for driving said first and second pump means;
said power supply means comprising a first electric motor for driving said first pump means and a second electric motor for driving said second pump means; and rechargeable battery means for supplying electric power to said first and second electric motors.
a power supply means for driving said first and second pump means;
said power supply means comprising a first electric motor for driving said first pump means and a second electric motor for driving said second pump means; and rechargeable battery means for supplying electric power to said first and second electric motors.
18. The apparatus according to Claim 17, wherein said first and second electric motors, said rechargeable battery means, said first and second pumps and said supply of joint compound are mounted to a backpack adapted to be worn on an operator's back.
19. A method for taping joints between pieces of wallboard comprising the substantially simultaneous steps of:
(a) applying a first layer of a joint compound to a joint between pieces of a wallboard, said first layer of said joint compound having a first predetermined width, said first layer of said joint compound being substantially centered, widthwise, on said joint;
(b) embedding a wallboard tape in said first layer of said joint compound, said wallboard tape having a width substantially equal to said first predetermined width, said wallboard tape being substantially centered, widthwise, on said joint;
(c) overcoating said embedded wallboard tape with at least one additional layer of said joint compound, said at least one additional layer of said joint compound having a width greater than said first predetermined width, said at least one additional layer of said joint compound being substantially centered, widthwise, on said joint.
(a) applying a first layer of a joint compound to a joint between pieces of a wallboard, said first layer of said joint compound having a first predetermined width, said first layer of said joint compound being substantially centered, widthwise, on said joint;
(b) embedding a wallboard tape in said first layer of said joint compound, said wallboard tape having a width substantially equal to said first predetermined width, said wallboard tape being substantially centered, widthwise, on said joint;
(c) overcoating said embedded wallboard tape with at least one additional layer of said joint compound, said at least one additional layer of said joint compound having a width greater than said first predetermined width, said at least one additional layer of said joint compound being substantially centered, widthwise, on said joint.
20. The method according to claim 19, further comprising the step of (d) imprinting a surface pattern on said at least one additional layer of said joint compound.
21. The method according to claim 20, wherein said surface pattern imprinted on said at least one additional layer of said joint compound matches a surface pattern on said wallboard.
22. The method according to claim 19, wherein said step (c) comprises the substantially simultaneous sub-steps of:
(c-1) overcoating said embedded wallboard tape with a second layer of said joint compound, said second layer of said joint compound having a second predetermined width, said second predetermined width being greater than said first predetermined width, said second layer of said joint compound being substantially centered, widthwise, on said joint; and (c-2) overcoating said second layer of said joint compound with a third layer of said joint compound, said third layer of said joint compound having a third predetermined width, said third predetermined width being greater than said second predetermined width, said third layer of said joint compound being substantially centered, widthwise on said joint.
(c-1) overcoating said embedded wallboard tape with a second layer of said joint compound, said second layer of said joint compound having a second predetermined width, said second predetermined width being greater than said first predetermined width, said second layer of said joint compound being substantially centered, widthwise, on said joint; and (c-2) overcoating said second layer of said joint compound with a third layer of said joint compound, said third layer of said joint compound having a third predetermined width, said third predetermined width being greater than said second predetermined width, said third layer of said joint compound being substantially centered, widthwise on said joint.
23. The method according to claim 22, further comprising the step of (d) imprinting a surface pattern on said third layer of said joint compound.
24. The method according to claim 23, wherein said surface pattern imprinted on said third layer of said joint compound matches a surface pattern on said wallboard.
25. The method according to claim 19, wherein said joint compound comprises:
about 45% by weight of calcium sulfate, about 35% by weight of a room temperature evaporable alcohol, about 10% by weight of polyvinyl alcohol, about 5% by weight of polyvinyl acetate, about 3% by weight talc, about 2% by weight mica.
about 45% by weight of calcium sulfate, about 35% by weight of a room temperature evaporable alcohol, about 10% by weight of polyvinyl alcohol, about 5% by weight of polyvinyl acetate, about 3% by weight talc, about 2% by weight mica.
26. A joint compound comprising a gypsum base plaster, a wetting agent, and polyvinyl acetate.
27. The composition of claim 26, wherein the composition comprises from about 35-60% by weight of the gypsum base plaster, 30-70% by weight of the wetting agent, and 10-25% by weight of polyvinyl acetate.
28. The composition of claim 27 wherein the composition further comprises from about 0-5% by weight of polyvinyl alcohol.
29. The composition of claim 26, wherein the gypsum base plaster comprises from about 40-70% by weight of calcium sulfate, up to about 10% by weight of calcium carbonate, up to 5% by weight of silica sand, up to 6% by weight of starch, 0-10% by weight of talc, and 0-10% by weight of mica, and, optionally drying accelerators.
30. The composition of claim 26, wherein the gypsum base plaster comprises from about 45-60% by weight of calcium sulfate, up to 10% by weight of calcium carbonate, up to 5% by weight of silica sand, up to 6% by weight of starch, 0-10% by weight of talc, and 0-10% by weight of mica.
31. The composition of claim 26, wherein in the gypsum base plaster the talc and mica comprise from 4-20% by weight.
32. The composition of claim 26, wherein the gypsum base plaster comprises about 55% by weight of calcium sulfate, about 6.5% by weight of calcium carbonate, about 2% by weight of silica sand, about 4% by weight of starch, 0-10% by weight of talc, 0-10% by weight of mica, and the total amount of talc and mica constitutes from about 4-20% by weight of the gypsum base plaster.
33. The composition of claim 26, wherein the composition comprises from about 45-55% by weight of the gypsum base plaster, 37-56% by weight of the wetting agent, 0-5% by weight of polyvinyl alcohol, and 10-25% by weight of polyvinylacetate.
34. Ths composition of claim 26, wherein the composition comprises from about 47-48% by weight of the gypsum base plaster, about 42% by weight of the wetting agent, and about 14% by weight of polyvinyl acetate.
35. A joint compound comprising from about 47-48% of a gypsum base plaster, about 42% by weight of a an alcohol-water mixture, 0.1 to 1% by weight of polyvinyl alcohol, and about 14% by weight of polyvinyl acetate, said gypsum base plaster comprising about 55% by weight of calcium sulfate, about 6.5%
by weight of calcium carbonate, about 2% by weight of silica sand, about 4% by weight of starch, 0-10% by weight of talc, and 0-10% by weight of mica, with the total amount of talc and mica constituting from about 4-20% by weight of the gypsum base plaster, and, optionally small amounts of drying accelerators for a gypsum base plaster.
by weight of calcium carbonate, about 2% by weight of silica sand, about 4% by weight of starch, 0-10% by weight of talc, and 0-10% by weight of mica, with the total amount of talc and mica constituting from about 4-20% by weight of the gypsum base plaster, and, optionally small amounts of drying accelerators for a gypsum base plaster.
36. The composition of claim 35, wherein the wetting agent comprises from about 0-30% by weight of water, and the alcohol is selected from the group consisting of methyl, ethyl, and propyl alcohols.
37. A cleaning solvent for the composition of claim 26, wherein the cleaning solvent comprises an aqueous solution of zinc chloride, optionally containing alcohol.
4280b/1-14
4280b/1-14
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2041860 CA2041860A1 (en) | 1991-05-06 | 1991-05-06 | Wallboard taping process, apparatus and composition therefor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2041860 CA2041860A1 (en) | 1991-05-06 | 1991-05-06 | Wallboard taping process, apparatus and composition therefor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2041860A1 true CA2041860A1 (en) | 1992-11-07 |
Family
ID=4147547
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2041860 Abandoned CA2041860A1 (en) | 1991-05-06 | 1991-05-06 | Wallboard taping process, apparatus and composition therefor |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2041860A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2890652A1 (en) * | 2005-09-12 | 2007-03-16 | Lafarge Platres | JOINT AND SURFACE COATING FOR BUILDING ELEMENTS, PREPARATION METHOD THEREFOR, AND METHOD FOR MAKING A WORK. |
-
1991
- 1991-05-06 CA CA 2041860 patent/CA2041860A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2890652A1 (en) * | 2005-09-12 | 2007-03-16 | Lafarge Platres | JOINT AND SURFACE COATING FOR BUILDING ELEMENTS, PREPARATION METHOD THEREFOR, AND METHOD FOR MAKING A WORK. |
| WO2007031636A3 (en) * | 2005-09-12 | 2007-06-14 | Lafarge Platres | Jointing and surface coating material for building elements, method for preparing same and method for constructing a structure |
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