Finishing tool for smoothing wallboard tape joints

Claim 2

A tool for smoothing joints between adjacent wallboards, the joints having been prepared with a tape joint compound, the tool comprising: a fluid retaining resilient foam pad having first and second major surfaces; an adhesive layer bonded to and covering substantially all of the first major surface; a wettable abrasive surface formed by a plurality of coarse, short, stiff synthetic polymer fibers oriented generally perpendicularly to the first major surface and bonded to the first major surface by the adhesive layer at first ends and having second free ends wherein the fibers are of a thickness of about 100 Denier and a length of not more than about 0.100 inch so that when the free ends are placed in moving abrasive contact with the wetted tape joint compound, the wetted compound is smoothed flush with the adjacent wallboards as a result of moving abrasive action of the free ends.

Claim 3

The tool of claim 1 wherein the fibers are nylon.

Claim 4

The tool of claim 1 wherein the pad is a polyester foam.

Claim 5

The tool of claim 3 wherein the pad is a non-reticulated polyester foam.

Claim 6

The tool of claim 1 and further comprising a handle attached to the resilient foam pad adjacent the second major surface and wherein the pad is a generally rectangular solid having generally rectangular first and second end surfaces, generally rectangular first and second side surfaces, wherein the first and second major surfaces are generally rectangular.

Claim 7

The tool of claim 5 wherein the pad has a length of about 10 inches, a width of about 21/2 inches, and a thickness of about 11/2 inches.

Claim 8

The tool of claim 5 wherein the handle has a generally planar surface adjacent the second major surface of the pad and first and second side flanges which engage and hold the first and second side surfaces, respectively, of the pad.

Claim 9

The tool of claim 7 wherein the handle is a generally rigid plastic.

Claim 10

The tool of claim 7 wherein the first and second side flanges extend about one-half of a distance from the second to the first major surface of the pad when the pad is in an uncompressed state.

Claim 11

The tool of claim 7 wherein the first and second side flanges have concave longitudinal grooved portions.

Claim 12

The tool of claim 10 wherein the concave longitudinal grooved portions engage and hold the pad.

Claim 13

A tool comprising: a generally rectangular non-reticulated resilient foam pad having first and second generally rectangular major surfaces, first and second generally rectangular side surfaces spaced sufficiently apart so that the pad is graspable manually, and first and second generally rectangular end surfaces; an adhesive layer bonded to and covering substantially all of the first rectanguar major surface; and a wettable abrasive surface formed by a plurality of coarse, short, stiff nylon fibers having a length of not more than about 0.100 inch and a thickness of about 100 Denier and having first free ends and second ends, the fibers providing abrasive force when the free ends are placed in moving abrasive contact with a surface, the fibers being oriented generally perpendicularly to the first major surface and bonded with the second ends to the first major surface by the adhesive layer.

Claim 14

A tool comprising: a generally rectangular non-reticulated resilient foam pad having first and second generally rectangular major surfaces, first and second generally rectangular side surfaces spaced sufficiently apart so that the pad is graspable manually, and first and second generally rectangular end surfaces; an adhesive layer bonded to and covering substantially all of the first rectanguar major surface; and a wettable abrasive surface formed by a plurality of coarse, short, stiff nylon fibers having a length of not more than about 0.100 inch and a thickness of about 100 Denier and having first free ends and second ends, the fibers providing abrasive force when the free ends are placed in moving abrasive contact with a surface, the fibers being oriented generally perpendicularly to the first major surface and bonded with the second ends to the first major surface by the adhesive layer.

Claim 15

The tool of claim 12 and further comprising a handle having first and second side flanges with longitudinal concave portions therein for engaging and holding the first and second side surfaces, respectively.

Claim 16

The tool of claims 12 or 13 wherein the pad is a non-reticulated polyester foam having a length of about 10 inches, a width of about 21/2 inches, and a thickness of about 11/2 inches.