Dual Roller Applicator for Seam Tape

This application is a continuation-in-part application of U.S. patent application Ser. No. 18/137,929, filed Apr. 21, 2023, which claims benefit of and priority to U.S. Provisional App. No. 63/333,375, filed Apr. 21, 2022; this application also is a continuation of U.S. patent application Ser. No. 18/513,830, filed Nov. 20, 2023, which is a continuation-in-part application of U.S. patent application Ser. No. 18/137,929, filed Apr. 21, 2023; patent application Ser. No. 18/513,830, filed Nov. 20, 2023, also claims benefit of and priority to U.S. Provisional Application No. 63/546,579, filed Oct. 31, 2023. All of the above-referenced applications are incorporated herein in their entireties by specific reference for all purposes.

This invention relates to a tool or apparatus with dual rollers for single-handed application of a seam or seaming tape. More particularly, the invention relates to a single-handed seaming tape roller with two rollers configured to provide stability and prevent hand twisting.

Seaming tape (also referred to as seam tape) is commonly used to cover, seal or bridge a seam (or joint) between two panels or boards or similar construction material, which are typically used in residential and commercial construction. The tape contacts and adheres to the surface of the panels or boards to either side of the seam, which is generally covered by the middle section of the tape. Seaming tape typically comes in rolls of various widths and total lengths, such as, but not limited to, a 3% inch width and a 6 inch width.

If the seaming tape is not properly installed, then air, water, and/or water vapor may pass through the seam. An example of a compression roller device for use during application of seaming tape is disclosed in Oates, et al., US 2019/0105850 A1 (published Apr. 11, 2019), which is incorporated herein by specific reference for all purpose. The device in Oates, however, marks the tape and has a long handle designed for two-handed use. Such handles often interfere with or prevent precise application of proper pressure to the seaming tape.

In various exemplary embodiments, the present invention comprises a one-handed tool for use in application of seam tape or seaming tape. The device comprises a frame with an upper support with an ergonomic grip attached thereto or integrated therewith. A finger guard or shield extends across the front of the grip to protect the user's fingers. A primary roller support and a secondary roller support extend downward from upper support. Each roller support comprises a pair of parallel arms extending downward at angles behind and in front of the upper support when in use.

A primary roller is located on the primary roller support, generally under and behind the grip. The primary roller comprises a cylinder extending laterally across the width of the tool, and is rotationally mounted on the respective ends of the primary roller support. Mounting can be by mounting posts or the respective ends of a tube, core, or axle that extend from the ends of the cylinder, and that snap-fit into or are otherwise held in respective openings at or proximate to the ends of respective arms of the primary roller support. The primary roller may be removably mounted, and thus a primary roller can be replaced with a roller of the same configuration, material and/or size, or a differing configuration, material and/or size.

The diameter of the ends is the same, and in several embodiments, the outer diameter of the cylinder is the same throughout its length. In other embodiments, the outer diameter of the cylinder of the primary roller may vary for some portion along its length, such that the diameter at either end of the cylinder is greater than the diameter in the middle or center of the cylinder. As shown in the figures, the middle diameter is slightly less than the diameter at the ends (the diameter at each end is the same). This configuration allows the edges of the tape being rolled to receive more pressure, while the smaller diameter center helps to reduce tape puncture over the underlying seam.

The cylinder of the primary roller may be made of rubber (hard or soft), pure gum natural rubber, latex rubber, hard synthetic rubber, plastic, foam (soft or firm), or similar material. The core or axle may be metal or plastic, which prevents bending or warping of the primary roller. Preferably, the face of the cylinder is smooth, so as to reduce deformation or puncture of the tape. In a preferred embodiment, no indentations, indicia, or other markings are made on the tape.

The secondary roller comprises a cylinder with two sections with the same outer diameter proximate the ends of the cylinder, with the center portion or section having a smaller outer diameter. This configuration allows the secondary roller to act as a stable support for the user without touching the tape sections over the underlying seam, thereby reducing tape puncture and tears in that area. In the embodiment shown, the end sections have a diameter equal to the diameter of the ends (or the entirety) of the primary tape roller, thereby providing a stable support for the user, which can help prevent injuries from falls or the like, such as when the user is working in an elevated position (e.g., from a ladder), by allowing the user to maintain “three or multiple points of contact” while rolling the tape.

In various exemplary embodiments, as seen in, the present invention comprises a one-handed toolfor use in application of seam tape or seaming tape. The device comprises a framewith an upper supportwith an ergonomic gripattached thereto or integrated therewith. A finger guard or shieldextends across the front of the grip to protect the user's fingers. A primary roller supportand a secondary roller supportextend downward from upper support. As seen in, each roller support comprises a pair of parallel arms extending downward at angles behind and in front of the upper support when in use.

A primary rolleris located on the primary roller support, generally under and behind the grip. The primary rollercomprises a cylinderextending laterally across the width of the tool, and is rotationally mounted on the respective ends of the primary roller support. Mounting can be by mounting posts or the respective endsof a tube, core, or axle that extend from the ends of the cylinder, and that snap-fit into or are otherwise held in respective openingsat or proximate to the ends of respective arms of the primary roller support. The primary rollermay be removably mounted, and thus a primary roller can be replaced with a roller of the same configuration, material and/or size, or a differing configuration, material and/or size.

The diameter of the ends is the same, and in the configuration shown in, the outer diameter of the cylinder is the same throughout its length. In the embodiment shown in, the outer diameter of the cylinder is 1⅛ inch, and the tube or axle endsextend ¼ inch out from the end of the cylinder, and have an outer diameter of ⅜ inch, although the dimensions may vary in other configurations.

As seen in, the outer diameter of the cylinder of the primary roller may vary for some portion along its length, such that the diameter at either endof the cylinder is greater than the diameter in the middle or centerof the cylinder. As shown in the figures, the middle diameter is slightly less than the diameter at the ends (the diameter at each end is the same). This configuration allows the edges of the tape being rolled to receive more pressure, while the smaller diameter center helps to reduce tape puncture over the underlying seam.

The cylinder of the primary roller may be made of rubber (hard or soft), pure gum natural rubber, latex rubber, hard synthetic rubber, plastic, foam (soft or firm), or similar material. The core or axle may be metal or plastic, which prevents bending or warping of the primary roller. Preferably, the face of the cylinder is smooth, so as to reduce deformation or puncture of the tape. In a preferred embodiment, no indentations, indicia, or other markings are made on the tape.

The secondary rollercomprises a cylinderwith two sectionswith the same outer diameter proximate the ends of the cylinder, with the center portion or sectionhaving a smaller outer diameter. This configuration allows the secondary roller to act as a stable support for the user without touching the tape sections over the underlying seam, thereby reducing tape puncture and tears in that area. In the embodiment shown, the end sections have a diameter equal to the diameter of the ends (or the entirety) of the primary tape roller, thereby providing a stable support for the user, which can help prevent injuries from falls or the like, such as when the user is working in an elevated position (e.g., from a ladder), by allowing the user to maintain “three or multiple points of contact” while rolling the tape.

The edges of the tape being rolled also can receive more pressure from the outer faces of the end sections, helping to ensure proper adhesion along the edges of the tape. The outer faces of the end sectionsare preferably smooth for the same reasons discussed above for the primary roller. Similarly, while the center sectionis not intended to contact the tape, the center section also is preferably smooth in case it does.

The ends comprise holes or spacesconfigured to receive the mounting postson the secondary roller support. The secondary roller thus is rotationally mounted on the secondary roller support. The secondary rollermay be removably mounted, and thus a secondary roller can be replaced with a roller of the same configuration, material and/or size, or a differing configuration, material and/or size.

The secondary roller may be made of rubber (hard or soft), pure gum natural rubber, latex rubber, hard synthetic rubber, plastic, foam (soft or firm), or similar material. The core or axle may extend through the center longitudinal axis, may be metal or plastic, which prevents bending or warping of the secondary roller as well as providing support between the two end sections.

In the embodiment shown in-B, the secondary roller is a single, integrated piece, with the end sectionsbeing relatively narrow compared to the total length of the roller. In the embodiment shown in, the outer diameter of the end sections is 1⅛ inch (i.e., the same outer diameter as the cylinder of the primary roller), and the outer diameter of the center section is ⅝ inch, although the dimensions may vary in other configurations.

In certain embodiments, as seen in, the width of the end sections may be larger, with the cylindrical center section, which may be an axle or rod extending therebetween for strength and support. The two end-section rollers are spaced to contact only the outermost edges of the tape being rolled, and not any part of the tape directly over the underlying seam.

In the embodiment shown, the gripextends forward in a semi-circle with slots, holes or indentations for placement of fingers and/or thumbs. Other shapes and forms of a grip may be used. In one embodiment, the grip may be sized for particular hand sizes, so that the tool can be designed for use by appropriate users with corresponding hand sizes. In another embodiment, the grip may be detachable, and thus replacement grips of various sizes may be installed on the same tool.

In the embodiment shown, the gripmay be used by either the user's right hand or left hand. In alternative embodiments, the grip may be configured to be preferentially right-handed or left-handed.

A retractable blade, knife, or blade tip(made from ceramic, plastic, metal, or similar material) may be located at either or both ends of the upper support. The user may extend the blade and use it to cut seaming tape from the roll without removing his or her hand from the tool. In several embodiments the blade or blades are replaceable.

In a further embodiment, as seen in, the blade or knifemay be located so as to be extendable when the user applies pressure (such as with the thumb) to the endof the blade/knife holding mechanism, which causes the blade/knifeto extend beyond the end or edge of the corresponding support component, where it can be used for cutting tape or similar purposes. When placed on an appropriate roller support, such as the secondary roller supportas seen in the figures, this enables the user to use his or her thumb to extend the blade/knife along a slotin the support while keeping a grip on the roller with his or her hand. A springapplies bias to the mechanism when the blade/knife is extended, causing the blade/knife to retract to an unextended, retracted, home or base position on the corresponding support component, where the blade/knife is protected and not exposed, thereby preventing accidental cutting or injury. The blade/knife mechanism may be removed and/or replaced, such as by removing the nuts holding the bolts in the respective slots. This blade/knife arrangement may found on one or both of the supports, so that a blade/knife may be used by the right hand and the left hand.

One or more attachment points or holesmay be provided in the side or sides of the finger guard, or elsewhere in or on the frame. A security line or lines may be attached to the deviceand secured to the user (e.g., to a belt or harness), to a ladder, or other anchor point, to prevent the device from falling from a height if the user's grip slips or the device is otherwise accidentally released. The user can then easily retrieve the device with descending from the ladder or other high point.

In use, the user applies the seaming tape to a section of seam between two or more panels, grasps the grip with one hand, and then passes the dual roller along the tape one or more times while applying pressure, with the center of the tape generally aligned with the center of the seaming tape. It should be noted that device of the present invention does not have a mount for the tape, and tape is not dispensed from a roll of tape on the device itself. The device can be rolled in either direction on the tape. The user thus is able to easily apply pressure with only one hand, with the multiple points of contact of (side to side, and front and back) providing even pressure and a stable base for the user, in sharp contrast to the instability inherent in using a rolling device with the roller or rollers at one end of a handle. In the present invention, the center of forceapplied by the user during proper operation is between the primary roller and the secondary roller, not to the outside of either. As seen in, in one embodiment, the angle between the primary roller support and secondary roller support, which are integrated in the frame, is approximately 63.63 degrees, and the angle between the secondary roller support and the finger guardis 58.2 degrees.

It should be noted that while the finger guard may be integrated with the frame and fixed in place (e.g., extending straight forward, generally parallel to the panel and tape surface), in some embodiments the finger guard may be rotatably attached to the upper support, and rotated and locked into a desired position. Likewise, a person of ordinary skill in the art would understand that the primary roller support and primary roller may swap locations with the secondary roller support and secondary roller.

Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.