Wallboard joint system

Abstract

The present invention relates to a drywall tape or joint tape comprising a non-woven web of fibers having a coating of a filled, film-forming polymer on one side and being non-coated on an opposite side for covering seams or for repairs generally in connection with fiber mat-faced gypsum wallboard, and more particularly pertains to a method for finishing joint seams and making other repairs in connection with a coated fiber mat-faced gypsum wallboard.

1 . A drywall joint comprising a seam region formed by two adjacent coated fiber mat-faced gypsum wallboards; a drywall tape covering said seam region, said drywall tape comprising a non-woven web of fibers having a coating of a filled, film-forming polymer thereon, said non-woven web of fibers forming an integral bond with joint compound in the seam region characterized by said fibers being embedded in dried joint compound. 
   
   
       2 . The drywall joint of  claim 1  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from monomers of alkyl halides of from 2-12 C atoms, alkene halides of from 2-12 C atoms, alkyl acrylamides of from 2-12 C atoms, alkene acrylamides of from 2-12 C atoms, alkyl acrylates of from 2-12 C atoms, and alkene acrylates of from 2-12 C atoms. 
   
   
       3 . The drywall joint of  claim 2  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from at least one monomer selected from styrene, dimethylstyrene, vinyltoluene, chloroprene, butadiene, ethylene, acrylamide, acrylonitrile, acrolein, methylacrylate, ethylacrylate, acrylic acid, methacrylic acid, methyl methacrylate, n-butyl acrylate, vinylidene chloride, vinyl ester, vinyl chloride, vinyl acetate, acrylated urethane, hydroxyethyl acrylate, dimethylaminoethyleneacrylate, and vinyl acrylate. 
   
   
       4 . The drywall joint of  claim 1  wherein said film-forming polymer is selected from the group consisting of styrene-butadiene-rubber, styrene-butadiene-styrene, ethylene-vinyl-chloride, poly-vinylidene-chloride, modified poly-vinyl-chloride, poly-vinyl-alcohol, ethylene-vinyl-actate, poly-vinyl-acetate, polymers and copolymers of acrylic acid, polymers and copolymers of methacrylic acid, polymers and copolymers of acrylic acid esters, polymers and copolymers of methacrylic acid esters, polymers and copolymers of acrylonitrile, acetate acrylic acid polymers, styrene/acrylate polymers and combinations thereof. 
   
   
       5 . The drywall joint of  claim 1 , further comprising a feathering portion of said joint compound at edges of drywall tape. 
   
   
       6 . A finished drywall seam region or repair region, comprising an unfinished seam region or repair region formed a coated, fiber mat-faced gypsum wallboard; a drywall tape comprising a non-woven web of fibers having a coating of a filled, film-forming polymer on one side and being non-coated on an opposite side, wherein fibers on the non-coated opposite side are embedded in dried joint compound forming an integral bond between the drywall tape and joint compound in said seam region or repair region. 
   
   
       7 . The finished drywall seam region or repair region of  claim 6  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from monomers of alkyl halides of from 2-12 C atoms, alkene halides of from 2-12 C atoms, alkyl acrylamides of from 2-12 C atoms, alkene acrylamides of from 2-12 C atoms, alkyl acrylates of from 2-12 C atoms, and alkene acrylates of from 2-12 C atoms. 
   
   
       8 . The finished drywall seam region or repair region of  claim 7  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from at least one monomer selected from styrene, dimethylstyrene, vinyltoluene, chloroprene, butadiene, ethylene, acrylamide, acrylonitrile, acrolein, methylacrylate, ethylacrylate, acrylic acid, methacrylic acid, methyl methacrylate, n-butyl acrylate, vinylidene chloride, vinyl ester, vinyl chloride, vinyl acetate, acrylated urethane, hydroxyethyl acrylate, dimethylaminoethyleneacrylate, and vinyl acrylate. 
   
   
       9 . The finished drywall seam region or repair region of  claim 6  wherein said film-forming polymer is selected from the group consisting of styrene-butadiene-rubber, styrene-butadiene-styrene, ethylene-vinyl-chloride, poly-vinylidene-chloride, modified poly-vinyl-chloride, poly-vinyl-alcohol, ethylene-vinyl-actate, poly-vinyl-acetate, polymers and copolymers of acrylic acid, polymers and copolymers of methacrylic acid, polymers and copolymers of acrylic acid esters, polymers and copolymers of methacrylic acid esters, polymers and copolymers of acrylonitrile, acetate acrylic acid polymers, styrene/acrylate polymers and combinations thereof. 
   
   
       10 . The finished drywall seam region or repair region of  claim 6  further comprising a feathering portion of said joint compound at edges of the drywall tape. 
   
   
       11 . A method of making a drywall joint in a seam region formed by two adjacent coated fiber mat-faced gypsum wallboards comprising applying a water-containing drying type joint compound or a setting-type joint compound to the seam region, applying a drywall tape comprising a non-woven web of fibers having a coating of a filled, film-forming polymer on one side and being non-coated on an opposite side onto the joint compound to embed fibers on the non-coated opposite side in joint compound to form an integral bond between the drywall tape and dried joint compound in said seam region. 
   
   
       12 . The method of  claim 11 , further comprising: applying a feathering portion of said joint compound at edges of the drywall tape. 
   
   
       13 . The method of  claim 11  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from monomers of alkyl halides of from 2-12 C atoms, alkene halides of from 2-12 C atoms, alkyl acrylamides of from 2-12 C atoms, alkene acrylamides of from 2-12 C atoms, alkyl acrylates of from 2-12 C atoms, and alkene acrylates of from 2-12 C atoms. 
   
   
       14 . The method of  claim 13  wherein said film-forming polymer is selected from the group consisting of at least one polymer derived from at least one monomer selected from styrene, dimethylstyrene, vinyltoluene, chloroprene, butadiene, ethylene, acrylamide, acrylonitrile, acrolein, methylacrylate, ethylacrylate, acrylic acid, methacrylic acid, methyl methacrylate, n-butyl acrylate, vinylidene chloride, vinyl ester, vinyl chloride, vinyl acetate, acrylated urethane, hydroxyethyl acrylate, dimethylaminoethyleneacrylate, and vinyl acrylate. 
   
   
       15 . The method of  claim 11  wherein said film-forming polymer is selected from the group consisting of styrene-butadiene-rubber, styrene-butadiene-styrene, ethylene-vinyl-chloride, poly-vinylidene-chloride, modified poly-vinyl-chloride, poly-vinyl-alcohol, ethylene-vinyl-actate, poly-vinyl-acetate, polymers and copolymers of acrylic acid, polymers and copolymers of methacrylic acid, polymers and copolymers of acrylic acid esters, polymers and copolymers of methacrylic acid esters, polymers and copolymers of acrylonitrile, acetate acrylic acid polymers, styrene/acrylate polymers and combinations thereof.