Drywall joint systems and method for making the same

Claim 2

In simulated monolithic wall construction the method of concealing the joints formed between adjacent wallboard panels comprising the steps of: a. heating a solid thermoplastic adhesive comprising a thermoplastic polymer to an elevated temperature whereat it has fluid properties, b. applying said fluid adhesive to a wall surface formed by at least two wallboard panels erected in substantially edge abutting relationship, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface, with said fluid adhesive adjoining at least the portion of each of the abutting edge surfaces of said wallboard panels immediately adjacent the respective outer surfaces thereof, c. cooling said thermoplastic adhesive to ambient temperature thereby returning it to a solid form d. disposing thereover at least one layer of an aqueous cementitious adhesive comprising a minor amount of binder material, a major amount of inorganic filler material and a quantity of water sufficient to form a pastelike mixture of workable consistency, each layer of said cementitious adhesive being wider than the layer of thermoplastic adhesive or cementitious adhesive immediately beneath it and having a smooth substantially flat outer surface tapering out to thin edges, and e. drying each layer of said cementitious adhesive before a succeeding layer is laid down thereover whereby a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects is formed.

Claim 3

The method as defined in claim 3 wherein the fluid adhesive applied to the wall surface is in the form of a layer contacting at least the portion of said outer face surfaces of said wallboard panels immediately adjacent to the abutting edge surfaces thereof, said layer having a smooth, substantially flat outer surface and tapering out to thin edges.

Claim 4

In simulated monolithic wall construction the method of concealing the joints formed between adjacent wallboard panels comprising the steps of: a. heating a narrow strip of joint-reinforcing tape having adhered thereto a solid thermoplastic adhesive comprising a thermoplastic polymer to an elevated temperature whereat said adhesive becomes substantially tacky, b. applying said strip of tape to a wall surface formed by at least two wallboard panels erected in substantially edge abutting relationship, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface with said tape adjoining at least the portion of said face surfaces of said panels immediately adJacent said abutting edges thereof and said thermoplastic adhesive contacting said portion of the outer surfaces of said panels, and c. cooling said strip of tape and said thermoplastic adhesive to ambient temperature thereby returning the adhesive to a solid form whereby a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects is formed.

Claim 5

In simulated monolithic wall surface construction the method of concealing the joints formed between adjacent wallboard panels comprising the steps of: a. heating a narrow strip of joint-reinforcing tape having adhered thereto a solid thermoplastic adhesive comprising a thermoplastic polymer to an elevated temperature whereat said adhesive becomes substantially tacky, b. applying said strip of tape to a wall surface formed by at least two wallboard panels erected in substantially edge abutting relationship, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface with said tape adjoining at least the portion of said face surfaces of said panels immediately adjacent said abutting edges thereof and said thermoplastic adhesive contacting said portion of the outer surfaces of said panels, c. cooling said strip of joint-reinforcing tape and said thermoplastic adhesive to ambient temperature thereby returning the adhesive to a solid form, d. disposing thereover at least one layer of an aqueous cementitious adhesive comprising a minor amount of binder material, a major amount of inorganic filler material and a quantity of water sufficient to form a pastelike mixture of workable consistency, each layer of said cementitious adhesive being wider than the strip of tape or layer of cementitious adhesive immediately beneath it and having a smooth substantially flat outer surface tapering out to thin edges, and e. drying each layer of said cementitious adhesive before a succeeding layer is laid down thereover whereby a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects is formed.

Claim 6

The method as defined in claim 6 in which said joint-reinforcing tape is a paper tape.

Claim 7

A simulated monolithic wall comprising at least two wallboard panels erected in substantially edge abutting relationship forming a joint therebetween, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface and at least the portion of said abutting edge surfaces of said panels immediately adjacent said face surfaces thereof being adjoined throughout the extent of the joint by a set thermoplastic adhesive adhered to said portion of said edge surfaces, said set thermoplastic adhesive forming with said panels a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects.

Claim 8

A simulated monolithic wall as defined in claim 8 wherein substantially the complete abutting edge surfaces of the adjacent panels are adjoined throughout the extent of the joint by said set thermoplastic adhesive.

Claim 9

A simulated monolithic wall as defined in claim 8 wherein said set thermoplastic adhesive is adhered to the portion of the respective substantially coplanar outer face surfaces of said panels at least immediately adjacent the abutting edge surfaces of said wallboard panels.

Claim 10

A simulated monolithic wall as defined in claim 9 wherein said set thermoplastic adhesive is adhered to the portion of the respective substantially coplanar outer face surfaces of said panels at least immediately adjacent the abutting edge surfaces of said wallboard panels.

Claim 11

A simulated monolithic wall comprising at least two wallboard panels erected in substantially edge abutting relationship forming a joint therebetween, said panels each havinG an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface, at least the portion of said abutting edge surfaces of said panels immediately adjacent said face surfaces thereof being adjoined throughout the extent of the joint by a set thermoplastic adhesive adhered to said portion of said edge surfaces, and at least one layer of a hardened cementitious adhesive comprising a minor amount of binder material and a major amount of inorganic filler material disposed over said thermoplastic adhesive, each layer of said cementitious adhesive being wider than the thermoplastic adhesive or cementitious adhesive immediately beneath it, said set thermoplastic adhesive and said hardened cementitious adhesive forming with said panels a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects.

Claim 12

A simulated monolithic wall as defined in claim 12 wherein substantially the complete abutting edge surfaces of the adjacent panels are adjoined throughout the extent of the joint by said set thermoplastic adhesive.

Claim 13

A simulated monolithic wall surface as defined in claim 12 wherein said set thermoplastic adhesive is adhered to the portion of the respective substantially coplanar outer face surfaces of said panels at least immediately adjacent the abutting edge surfaces of said wallboard panels.

Claim 14

A simulated monolithic wall as defined in claim 13 wherein said set thermoplastic adhesive is adhered to the portion of the respective substantially coplanar outer face surfaces of said panels at least immediately adjacent the abutting edge surfaces of said wallboard panels.

Claim 15

A simulated monolithic wall comprising at least two wallboard panels erected in substantially edge abutting relationship forming a joint therebetween, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface, and a strip of joint-reinforcing tape having a set thermoplastic adhesive adhered thereto adjoining the portion of the outer face surface of the respective panels at least immediately adjacent said abutting edge surfaces thereof with said set thermoplastic adhesive contacting said portions of the outer face surfaces of said panels, said set thermoplastic adhesive and said joint-reinforcing tape forming with said panels a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects.

Claim 16

A simulated monolithic wall comprising at least two wallboard panels erected in substantially edge abutting relationship forming a joint therebetween, said panels each having an outer face surface arranged in substantially coplanar relationship with each other and an abutting edge surface which is substantially perpendicular to said outer face surface, a strip of joint-reinforcing tape having a set thermoplastic adhesive adhered thereto adjoining the portion of the outer face surface of the respective panels at least immediately adjacent the abutting edge surfaces thereof with said set thermoplastic adhesive contacting said portions of the outer face surfaces of said panels and at least one layer of a hardened cementitious adhesive comprising a minor amount of binder material and a major amount of inorganic filler material, each of said layers of said cementitious adhesive being wider than said strip of joint-reinforcing tape or layer of cementitious adhesive immediately beneath it, said set thermoplastic adhesive, said joint-reinforcing tape and said hardened cementitious adhesive forming with said wallboard panels a rigid unitary structure resistant to displacement or distortion otherwise caused by external effects.