System and method for making wallboard
a technology of wallboard and gypsum, applied in the field of gypsum board, can solve the problems of increased installation and labor costs, and unfavorable wallboard panel recessed areas
Inactive Publication Date: 2007-05-31
CONBOY JOHN S
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- Abstract
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- Application Information
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Benefits of technology
"The present invention is a method of making wallboard by forming recesses in an unfinished length of wallboard. The recesses are formed at both lateral edges of the wallboard using a device that includes three presses. The device is designed to form the recesses in a precise manner, resulting in finished lengths of wallboard with recessed lateral edges. The technical effect of this invention is to provide a more efficient and precise method for making wallboard with recesses, which can improve the overall quality and performance of the wallboard."
Problems solved by technology
Specifically, the recessed areas of the joints are filled with the wallboard compound, taped and smoothed across the joint, such that the joint is covered without the compound creating an unsightly bulge extending outwardly between the panels.
In addition, when wallboard is installed in a vertical orientation, installation and labor costs may be increased as the installers and tapers must use ladders for installation and finishing.
It is very difficult to create the recessed areas in the wallboard panel after the gypsum is fully cured and a particular problem has been delamination of the paper from the gypsum core.
Method used
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[0026] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
[0027] Referring to FIG. 1, a preferred embodiment of the present invention comprises a press 20 for forming of one or more recessed lengths in partially cured gypsum wallboard such that when the partially cured wallboard is cut into finished lengths, the lateral edges of the finished lengths have recessed edges on all four edges of the board. For the purposes of the present invention, a recess can be a tapered or non-tapered recess. The invention preferably performs this press function in partially cured gypsum wallboard panels after gypsum slurry has been applied to paper ba...
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Abstract
A method of making wallboard including the steps of providing an unfinished length of wallboard that has a recess along its longitudinal edges by conveying it upon a conveyor in a first direction in a step, forming recesses in the unfinished length of wallboard at both lateral edges thereof, selecting an apparatus for forming the recess from a plurality of device for forming the recess, forming the recess with the selected apparatus, and separating the unfinished length of wallboard at a location of the recess to form finished lengths of wallboard, such that the finished lengths of wallboard have recessed lateral edges. Also disclosed is a system for performing the method.
Description
RELATED APPLICATIONS [0001] The present application claims priority to U.S. Provisional Patent Application No. 60 / 736,123, filed Nov. 9, 2005, the contents of which are incorporated herein by reference.FIELD OF THE INVENTION [0002] This invention relates generally to gypsum board, and more specifically to a method and apparatus for providing recessed portions on the lateral edges of wallboard. BACKGROUND OF THE INVENTION [0003] Conventional gypsum wallboard or drywall is typically manufactured from a gypsum plaster slurry which is put between two layers of paper. More specifically, in the conventional method, a wet slurry of gypsum is poured on a conveyor between two layers of paper, and the slurry is allowed a certain amount of time to set. In gypsum wallboard, the two layers of paper contain the slurry and provide the tensile strength required in installation and use. [0004] In at least some known fabrication methods, the conveyor is a closed loop conveyor that can travel at speed...
Claims
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IPC IPC(8): E04B1/00
CPCB28B11/10B28B11/14
Inventor CONBOY, JOHN S.
Owner CONBOY JOHN S