US20250092687A1

US20250092687A1 - Method and system for finishing wallboard

Info

Publication number: US20250092687A1
Application number: US18/468,253
Authority: US
Inventors: Mavis Shaw; Tamara Dolinsky
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-09-15
Filing date: 2023-09-15
Publication date: 2025-03-20

Abstract

An apparatus and method for gypsum board finishing wherein the present invention is configured to provide finishing of the surface of adjacent gypsum boards without utilization of drywall mud. The present invention includes gap plugs wherein the gap plugs are provided in alternate embodiments so as to mateably fill the voids present between two adjacent gypsum boards. The gap plugs are provided to fill joints such as but not limited to tapered joints and butt joints. A contiguous or separate tape member is provided to be superposed the gap plug and joint wherein the tape member includes an adhesive on one side thereof. The present invention further includes a cover member wherein the cover member includes lower members that extend outward from the second side of the cover member. The cover member is operable to provide concealment of screw holes and the like.

Description

FIELD OF THE INVENTION

The present invention relates generally to construction techniques, more specifically but not by way of limitation, a system and method for finishing gypsum board subsequent installation thereof wherein the present invention does not employ conventional drywall mud or tape.

BACKGROUND

Most interior walls of commercial and residential building are constructed with gypsum board, commonly referred to as drywall. Gypsum board has an inherent fire resistance and has been the most common material utilized to construct walls and ceilings within the interior of buildings. Gypsum board is easy to work with and can be cut and secured to the wall supports very easily and quickly.
There is one intrinsic problem with the utilization of gypsum board that exists in the construction industry. Current techniques employ the utilization of drywall mud and tape to finish the gypsum board subsequent to installation to cover the joints and holes. This typically involves several layers of mud and the time and number of employees to finish the gypsum board is extensive. Additionally, after the drywall mud is applied and dried, it must be sanded so as to provide a smooth appearance. The sanding of drywall mud takes a significant amount of time and results in a fine drywall dust being spread all over the interior of the building. The dust must be removed from the surface of the gypsum board prior to any coatings being applied thereto. As construction companies are currently short on laborers, the conventional finishing methodology for gypsum board creates delays in construction and further require higher costs for the construction company.
Accordingly, there is a need for a system and a method of finishing gypsum board that executes the task without the need for conventional drywall mud and tape and wherein present invention can be executed in significantly less time as compared to conventional techniques.

SUMMARY OF THE INVENTION

It is the object of the present invention to provide a method for finishing gypsum board ensuing installation so as to provide coverage of joints and holes wherein the present invention includes utilization of gap plugs and or tape or film. The gap plugs may or may not be attached contiguously to the film or tape.
Another object of the present invention is to provide a method configured to provide finishing of installed gypsum board so as to be prepared for any desired coating wherein the gap plugs and or tape or film of the present invention are provided in alternate embodiments.
A further object of the present invention is to provide a method for finishing gypsum board ensuing installation so as to provide coverage of joints and holes wherein the present invention further includes a film wherein the film includes an adhesive on one side thereof.
Yet a further object of the present invention is to provide a method configured to provide finishing of installed gypsum board so as to be prepared for any desired coating wherein the present invention further includes a tape having protrusions extending outward from one side thereof.
Still another object of the present invention is to provide a method for finishing gypsum board ensuing installation so as to provide coverage of joints and holes wherein the gap plugs are operable to provide coverage of joints such as but not limited to butt joints and tapered joints.
An additional object of the present invention is to provide a method configured to provide finishing of installed gypsum board so as to be prepared for any desired coating wherein the gap plugs may or may not be manufactured from malleable material.
Yet a further object of the present invention is to provide a method for finishing gypsum board ensuing installation so as to provide coverage of joints and holes wherein the film of the present invention can employ the utilization of a pressure sensitive adhesive or heat activated adhesive or other method of adhesion.
To the accomplishment of the above and related objects the present invention may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact that the drawings are illustrative only. Variations are contemplated as being a part of the present invention, limited only by the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be had by reference to the following Detailed Description and appended claims when taken in conjunction with the accompanying Drawings wherein:

FIG. 1 is a diagrammatic view of the present invention demonstrating a filling of a tapered joint; and

FIG. 1 a is a detailed view of an alternate shaped joint with mateable shaped gap plug; and

FIG. 1 b is a detailed view of an alternate shaped joint with mateable gap plug; and

FIG. 2 is a diagrammatic view of the present invention demonstrating a filling of a butt joint; and

FIG. 2 a is a detailed view of a butt joint with the tape member; and

FIG. 3 is a diagrammatic view of corner taper configuration of the present invention; and

FIG. 4 is a side diagrammatic view of the tape member of the present invention; and

FIG. 5 is an outline of the exemplary method of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings submitted herewith, wherein various elements depicted therein are not necessarily drawn to scale and wherein through the views and figures like elements are referenced with identical reference numerals, there is illustrated a system and method for gypsum board finishing 100 constructed according to the principles of the present invention.
An embodiment of the present invention is discussed herein with reference to the figures submitted herewith. Those skilled in the art will understand that the detailed description herein with respect to these figures is for explanatory purposes and that it is contemplated within the scope of the present invention that alternative embodiments are plausible. By way of example but not by way of limitation, those having skill in the art in light of the present teachings of the present invention will recognize a plurality of alternate and suitable approaches dependent upon the needs of the particular application to implement the functionality of any given detail described herein, beyond that of the particular implementation choices in the embodiment described herein. Various modifications and embodiments are within the scope of the present invention.
It is to be further understood that the present invention is not limited to the particular methodology, materials, uses and applications described herein, as these may vary. Furthermore, it is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the claims, the singular forms “a”, “an” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.
References to “one embodiment”, “an embodiment”, “exemplary embodiments”, and the like may indicate that the embodiment(s) of the invention so described may include a particular feature, structure or characteristic, but not every embodiment necessarily includes the particular feature, structure or characteristic.
Referring in particular to the Figures submitted herewith, the system and method for gypsum board finishing 100 is illustrated therein. It should be understood within the scope of the present invention that the method illustrated and discussed herein is exemplary and that steps thereof could be executed in alternate orders or be eliminated. The system and method for gypsum board finishing 100 includes the utilization of gap plugs 10. The tape member 30 is configured to be placed over union 8 of two gypsum boards 98,99 when no void 2 is present. Illustrated herein in FIG. 1 is a gap plug 10 that is formed to fill a void 7 that is tapered in shape. The gap plug 10 includes a body having a first side 11 and a second side 12. The first side 11 of the gap plug 10 is planar in manner so as to be flush with the outer surface 97 of the gypsum boards 98,99 ensuing placement of the gap plug 10 into void 7. The second side 12 of the gap plug 10 is formed in a shape so as to mateably engage the shape of the joint 5. It should be understood within the scope of the present invention that the shape of the second side 12 of the gap plug 10 could be provided in alternate shapes so as to mateable fit into a joint 5. Furthermore, it should be understood within the scope of the present invention that the gap plug 10 is provided in various lengths and widths so as to accommodate joints 5 that extend the length of the gypsum boards 98,99. In one embodiment of the gap plug 10 the second side 12 may or may not be manufactured from a malleable material. Utilization of a malleable material may facilitate mateable connection with the joint 5. Extending outward from the second side 12 is protrusion 14. Protrusion 14 is formed to fill void 2 during placement of the gap plug 10. It is contemplated within the scope of the present invention that the protrusion 14 could be provided in alternate sizes and shapes so as to mateably fill void 2.
The tape member 30 illustrated herein in FIG. 2 is provided for a butt joint of gypsum boards 97,98. Tape member 30 includes a first side 31 and a second side 32. Tape member 30 includes protuberance 14 extending outward from the second side 32. Protuberance 14 is formed to mateably fill void 22 during placement of the tape member 30. It should be understood within the scope of the present invention that the tape member 30 is provided in a size that can extend the length of the gypsum board 97,98 so as to cover a butt joint extending the full length thereof. While various embodiments of the gap plug 10 have been illustrated herein, it is contemplated within the scope of the present invention that alternate embodiments could be provided. By way of example but not limitation, a gap plug 10 sized to solely fit into void 22 could be provided and the tape member 30, contiguous or non contiguous, to the gap plug 10 superposed across the void 22 having a gap plug 10 solely installed in the void 22.
The system and method for gypsum board finishing 100 further includes a tape member 30. The tape member 30 includes a first side 31 and second side 32 and is utilized to cover both gap plugs 10 subsequent installation thereof. The tape member 30 has a thickness capable of being concealed by a coat of paint. This tape may or may not be used to join two pieces of gypsum board where there is no gap present as well as inside or outside corners. The tape member 30 has an adhesive on the second side 32 thereof wherein the adhesive is operable to secure the tape member 30 to the gypsum boards 97,98. It is contemplated within the scope of the present invention that the adhesive on the second side 32 of the tape member 30 could be but is not limited to a pressure sensitive adhesive or a heat activated adhesive. The tape member 30 is thin in form and it should be understood within the scope of the present invention that the tape member 30 could be provided in alternate lengths and widths. It is desired within the scope of the present invention that the tape member 30 be capable of being concealed by a coat of paint. The aforementioned thickness is capable of being covered with a coat of paint and no longer be visible underneath the coat of paint applied to the gypsum boards 97,98. FIG. 3 illustrates the utilization of the tape member 30 on a corner wherein the tape member 30 is applied to the corner being generally split longitudinally down a center line thereof.
Illustrated herein in FIG. 4 is a cover member 50. The cover member 50 includes a portion 51 having a first side 52 and second side 53. The cover member 50 includes lower members 55 wherein the lower members 55 extend outward from the second side 53 being contiguously formed therewith. The cover member 50 is configured to provide coverage of items such as but not limited to screw holes. The lower member 55 provides filling of the screw hole with portion 51 having a thickness capable of being concealed by a coat of paint. The cover member 50 is provided in alternate lengths and widths and it should be understood within the scope of the present invention that the cover member 50 can be segmented into a size required to include as few as one lower member 55 or a plurality of lower members 55.
Referring in particular to FIG. 5 submitted herewith, the method of the system and method for gypsum board finishing 100 is outlined therein. In step 501, the gypsum boards are installed in desired locations on walls and/or ceilings of a structure. Step 503, the joints between the gypsum boards are identified wherein the joints can be different types as previously discussed herein. In step 504, a user will select the type of gap plugs needed to mateably fill the identified joints. Step 505, the user will place the gap plugs, which may or may not be contiguous with the tape or film into the identified joints. In step 507, the user will select the required quantity of tape member and superposed the tape member over the joints having the gap plugs, if required, placed therein. As discussed herein, the tape member includes an adhesive layer to secure the tape member in position. Step 509, a user will identify any screw holes or similar elements on the surface of the gypsum board. In step 511, the user will select the size of cover member required to provide coverage and filling of the identified screw holes. Step 513, the user will superpose the cover member over the identified screw hole so as to provide concealment thereof.
In the preceding detailed description, reference has been made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments, and certain variants thereof, have been described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other suitable embodiments may be utilized and that logical changes may be made without departing from the spirit or scope of the invention. The description may omit certain information known to those skilled in the art. The preceding detailed description is, therefore, not intended to be limited to the specific forms set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the appended claims.

Claims

What is claimed is:

1. A method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other wherein the method of the present invention comprises the steps of:

providing at least two embodiments of gap plugs, wherein said gap plugs are configured to be mateably fit into a void present between the two gypsum boards, said gap plugs having a first side and a second side;

identifying at least one joint having a void required to be filled and concealed;

placing one of said at least two embodiments of said gap plugs in the at least one joint, wherein the gap plug further includes a protuberance extending outward from the second side thereof;

providing a contiguous or separate tape member, said tape member being planar in manner, said tape member having a first side and a second side, said tape member having an adhesive on the second side thereof;

cutting the tape member or contiguous gap plug and tape member, wherein the tape member is cut to be of a size suitable to cover the at least one joint;

placing the tape member over the at least one joint having the gap plug installed therein;

activating the adhesive, wherein the adhesive on the second side of the tape member is activated;

identifying at least one hole, said at least one hole being in the gypsum boards;

providing a cover member, said cover member having a portion being planar in manner wherein said portion has a first side and a second side, said cover member further having a lower member, said lower member extending outward from said second side of said portion;

placing the cover member over the at least one hole, wherein the cover member is superposed the at least one hole and wherein the lower member extends inward into the at least one hole.

2. The method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 1, wherein said gap plug has a second side may or may not be manufactured from a malleable material.

3. The method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 2, and further including a step of securing the tape member to an inside or outside corner, wherein the tape member is placed at a corner and folded down a center line thereof longitudinally so as to conceal a seam at the corner.

4. The method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 3, wherein the tape member has a thickness capable of being concealed by a coat of paint.

5. The method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 4, wherein one in embodiment of said gap plugs has a second side thereof that is convex in form.

6. The method for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 5, wherein the adhesive on the second side of said tape member is either a pressure sensitive adhesive or a heat activated adhesive or other method of adhesion.

7. A system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other wherein the system comprises:

a first gap plug, said first gap plug having a segment that is planar in manner having a first side and a second side, said first gap plug further having a protuberance from said second side, said protuberance configured to be inserted into a void present between the two gypsum boards,

a tape member that may or may not be contiguous with the gap plug, said tape member having a first side and a second side, said tape member being of sufficient width and length to cover the void between the two gypsum boards, said tape member having an adhesive on said second side thereof;

a cover member, said having a portion being planar in manner wherein said portion has a first side and a second side, said cover member having a plurality of lower members, said plurality of lower members extending outward from said second side of said portion, said plurality of lower members configured to be inserted into holes present in the surface of the gypsum boards.

8. The system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 7, and further including a second gap plug, said second gap plug having a first side and a second side, said second side of said second gap plug being convex in form.

9. The system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 7, wherein said second side of said second gap plug includes a protrusion extending outward therefrom, said protrusion configured to be inserted into a void present between the two adjacent gypsum boards.

10. The system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 9, wherein said second side of said segment of said second gap plug may or may not be manufactured from malleable material.

11. The system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 10, wherein the adhesive on the second side of said tape member is either a pressure sensitive adhesive or a heat activated adhesive or other method of adhesion.

12. The system for finishing a surface of gypsum boards at a location where two gypsum boards are adjacent each other as recited in claim 11, wherein the tape member has a thickness capable of being concealed by a coat of paint.