U.S. patent application number 10/075714 was filed with the patent office on 2003-08-14 for magnetic gypsum panel.
Invention is credited to Schroth, Michael.
Application Number | 20030150190 10/075714 |
Document ID | / |
Family ID | 27660130 |
Filed Date | 2003-08-14 |
United States Patent
Application |
20030150190 |
Kind Code |
A1 |
Schroth, Michael |
August 14, 2003 |
Magnetic gypsum panel
Abstract
Magnetic gypsum or drywall is a concept that adds value and
application to a standard gypsum drywall panel by insertion of a
various sized flat, thin gage ferrous metal sheet into the interior
face or substrate of the drywall during the drywall manufacturing
process. The drywall-finished product would then become a platform
to accept the attachment of a variety of magnets and magnetic
objects to its finished surface for display and storage.
Inventors: |
Schroth, Michael; (Mullica
Hill, NJ) |
Correspondence
Address: |
MICHAEL SCHROTH
849 FRANKLINVILLE RD
MULLICA HILL
NJ
08062
US
|
Family ID: |
27660130 |
Appl. No.: |
10/075714 |
Filed: |
February 14, 2002 |
Current U.S.
Class: |
52/794.1 |
Current CPC
Class: |
E04C 2/043 20130101 |
Class at
Publication: |
52/794.1 |
International
Class: |
E04C 002/34 |
Claims
Many other variations in feature and construction are obvious to
the inventor and to those skilled in the art that fall within the
scope of this invention. Having briefly described the invention, I
claim:
1. A panel with a flat metal insert placed internally facing one
surface to act as an attraction target for magnets and objects with
magnetic properties.
2. A panel where the flat metal insert is constructed of very high
iron concentration.
3. A panel where the flat metal insert is constructed of a
corrosion resistant coating or treatment.
4. A panel where the flat metal inserts is positioned in any
location or locations within the outside perimeter of the wall
panel.
5. A panel where the flat metal insert is sized to any dimension or
shape to accommodate a specific magnetic application.
6. A panel where the flat metal insert is positioned in any
dimension in relation to the depth or thickness of the finished
panel.
7. A panel where the metal insert is constructed of a dimension,
curvature, shape, thickness or gage to accommodate a specific
magnetic application.
8. A panel that is used in the construction of interior wall, floor
or ceiling that contains a flat metal insert for the purpose of
magnetic attraction properties.
9. A process for inserting a flat metal insert into a gypsum slurry
substrate during the panel manufacturing process.
10. A process for inserting and adhesively securing a flat metal
insert onto one surface of a gypsum panel top surface paper
covering.
Description
FIELD OF THE INVENTION
[0001] This invention relates to gypsum board used in the
construction of interior walls, and ceilings, and more specifically
to apparatus and method for inserting a flat metal sheet into the
gypsum substrate of the board during the manufacturing process for
the purpose of creating a base for magnetic attraction.
BACKGROUND OF THE INVENTION
[0002] This invention is based upon the consumer requirement for a
vertical magnetic surface that is conveniently located within a
home, office, store or school. Gypsum, plasterboard, wallboard,
sheetrock, drywall and other terms are common names given to panels
constructed of gypsum and cardboard. These panels are used
extensively in the construction of interior residential, commercial
and industrial walls, floors and ceilings. Gypsum drywall is sold
commercially in a variety of sizes, thickness and type. Gypsum
drywall is manufactured and distributed by a large number of
international manufacturers. This invention focuses primarily on
wall panels constructed of gypsum and cardboard, but has
application to other panels used in similar applications but are
constructed of similar, but not identical materials. This invention
describes a concept that addresses the creation of a new
application of "standards gypsum drywall by adding magnetic
properties to a specific section of the front or "finished" surface
of a drywall panel. The completed, finished product would show no
apparent difference to the consumer. A magnetic drywall panel and a
standard drywall panel would look identical in every respect.
Magnetic drywall panels would be used in similar applications of
standard drywall panels. In most applications the magnetic drywall
panels would be used in the construction of interior walls, but
would also have applications where other magnetic adherence is
desired. Magnetic drywall panels after erection can be treated with
paint, wallpaper or coverings in a normal fashion. After magnetic
drywall panels are treated with the final cosmetic paint or
wallpaper, the panel can be utilized as a surface to apply a wide
variety of magnets on the area that contains the flat, thin gage
metal sheet. Magnets can be applied to secure posters, drawings,
notes etc. in a similar fashion as magnets are applied to the
surface of a refrigerator or any other object made of a metallic
ferrous material. It would in fact act as a magnetic bulletin
board. A room(s) in a new home, school or office can be constructed
with magnetic drywall thereby providing a 24" high or more eye
level band of magnetic surface around the perimeter of a room (FIG.
3).
DESCRIPTION OF PRIOR ART
[0003] Gypsum board is well known and widely used in the
construction industry. A typical sheet of gypsum wallboard
comprises a gypsum core, a back cover sheet on one side of the core
and a face or front cover sheet on the other side of the core. The
face cover sheet is folded around the long edges of the core and
overlaps the side edges of the back cover sheet.
[0004] Prior art reveals a plurality of methods and practices for
the manufacture of gypsum wallboard U.S. Pat. Nos. 4,288,263
(1981); 5,116,671 (1992); 4,392,896 (1983); and 5,116,671 (1992).
Each of the inventions describes processes varying in technique and
apparatus. Most claim specific additives and ingredients that
benefit the process and/or final product.
[0005] Prior art related to magnetic gypsum includes a variety of
methods related to securing objects to the surface of the wallboard
by mechanical means that project from the wallboard allowing
magnetic attraction (U.S. Pat. No. 3,031,799). These methods are
almost all focus on installing the components after the gypsum is
installed.
[0006] Chiro (U.S. Pat. No. 5,476,559) discloses a method of
adhesively applying a metal sheet to the surface of the gypsum
wallboard and covering the metal with sheetrock compound after the
board is installed. Similar to Chiro, is Frye (U.S. Pat. No.
4,942,071) who invents a method of applying several layers of
material adhesively to a wall-like structure.
[0007] There are a number of inventions focused on "veneer"
laminations, in particular Snyder (U.S. Pat. No. 6,004,648) and
Elbey (U.S. Pat. No. 4,376,003) that provide a means of adhesively
securing material to wall-like structures.
[0008] Much work has been disclosed in inventions related to
"building panels". In these cases the panels are generally not
gypsum or related material. Panels mentioned are usually structural
in design and are intended for exterior use. Bader (U.S. Pat. No.
6,044,603) and Meyerson (U.S. Pat. Nos. 4,769,963 and 5,086,599)
each claim methods of inserting metal material into a panel during
the manufacturing process, but only for the purpose of structural
integrity and shape.
[0009] Clear (U.S. Pat. No. 6,119,422) claims a method of
adhesively securing bonded mesh to a wall-like surface for the
purpose of creating an impact resistant building panel.
[0010] Deets (U.S. Pat. No. 5,609,788) discloses a method of
creating a magnetic paint additive for the purpose of creating
magnetic signs made of various materials, including gypsum.
SUMMARY OF THE INVENTION
[0011] During the gypsum drywall manufacturing process a flat, thin
gage ferrous metal sheet with a preferred high iron content would
be placed in position within the horizontal top (finished) surface
of the panel. The metal insert is covered by a thin layer of gypsum
material and the finished cardboard-covering surface, or applied
directly by adhesive means directly to the interior surface of the
top surface cardboard. This task is performed automatically during
the gypsum wallboard manufacturing process. As stated, the
inspection of the drywall panel would reveal no visible difference
between the subject panel and a standard drywall panel with a metal
insert. The only apparent difference would be in the slight
increase of weight in the magnetic drywall panel.
[0012] The size of the metal insert can vary according to
application. It is anticipated that the most common application
will be an insert approx. 24 inches high.times.47" inches wide. The
center (12 inches) of the insert would be placed approx. at
eyelevel within a 48 inch wide by 96-inch panel when it is
positioned in a normal vertical location. Horizontally installed
panels can also accommodate metal inserts.
[0013] The metal insert would not significantly effect or interfere
with standard and accepted methods and practices of installing,
erecting or contouring drywall. Nails, screws and adhesive can be
used in a normal fashion.
[0014] Magnetic drywall panels after erection can be treated with
paint, wallpaper or coverings in a normal fashion.
[0015] If desired, magnetic drywall panels can be used to hang
pictures or any other object in a normal fashion using nails,
screws or adhesive. The thin gage of the metal insert would not
prevent these activities. In fact, the addition of the metal would
present an improved, stronger surface for nail or screw penetration
allowing heaver objects to be hung.
[0016] The size of the metal insert can be made larger or smaller,
or of any shape depending on the size or orientation of the drywall
panel, or the amount of surface required or desired for magnetic
application. Tests have confirmed that the covering of drywall with
its normal covering paper and the cosmetic covering of paint or
wallpaper do not interfere with the application of magnets to the
surface. The quality (high iron content) of the ferrous metal
insert and the quality, type and shape of the magnet itself, and
the depth of the metal insert in the drywall substrate determine
the magnetic strength or attraction of the magnets to the panel.
Testing indicates that vibration from door closings and other
similar activities do not affect the magnetic strength if the
quality of the insert and magnet are high.
[0017] The invention discloses two methods of inserting flat metal
sheets into a gypsum panel during the panel manufacturing process.
The invention also discloses a method of inserting a flat metal
sheet into a standard gypsum panel after it is installed.
[0018] The key to this invention is quality material. The metal
inserts must be of a grade of steel with a very high iron content.
Magnets used for holding framed objects and similar heavy items
must be commercially available high-grade Alnico magnets. Tests
have confirmed that Alnico magnets versus standard ceramic or
flexible magnets have much higher magnetic strength (gauss).
Heavier objects (up to 10 pounds) can be securely held by use of
adhesively mounted Alnico magnets to the object. The object can
then be placed against the magnetic wallboard and be repeatedly
rearranged within the perimeter of the metal insert area.
Lightweight objects held by standard magnets can be used for
everyday applications of holding notes, photographs, decorative
magnets, documents, drawings, etc.
[0019] Commercially available magnetic gypsum wallboard or drywall
would provide the consumer a choice presently not available between
standard wallboard and magnetic wallboard during the construction
stage of a building or addition. Families would find the use of
magnetic wallboard very convenient in kitchens, family rooms and
children bedrooms. Offices and schools would also contain scores of
applications for magnetic wallboard. It is not suggested that
magnetic wallboard completely replace standard wallboard in any
respect. It is estimated that after an appropriate period of market
education and introduction, magnetic wallboard would account for
approximately 5% of the wallboard market. But, due to its value
added qualities, producers of magnetic wallboard would be able to
charge consumers a premium price for the product. Standard
wallboard is a price sensitive commodity with a great deal of
competition between producers. The market for wallboard continues
to grow with no apparent cost effective replacement in sight. There
is very little difference in product or in wholesale and retail
pricing of wallboard between manufacturers. Because of this factor,
a producer of magnetic wallboard would be able to differentiate and
clearly establish themselves as an innovator. The premium cost of
magnetic wallboard would allow a producer to realize a relatively
short period of time return on investment of R&D, and process
line modifications expenditures. Although magnetic wallboard would
approximately account for less than 5% of a producer's wallboard
output, it could eventually account for 25% of the producer's sales
dollars. This is a product that appeals to the consumer. This
invention allows producers of wallboard to refine the invention and
introduce it to the marketplace.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The process of manufacturing natural or synthetic gypsum
wallboard or drywall is very similar throughout the world's gypsum
wallboard producers. In general terms the process is as
follows:
[0021] A. Gypsum rock is mined from quarries. The rock is blasted,
collected and crushed. The crushed rock is transported to a drywall
plant for processing.
[0022] B. The gypsum rock is fed into pan feeder that uniformly
meter the gypsum rock into a conveyor belt that carries it to a
crusher. The crusher then breaks up the larger rocks and sometimes
blends in recycled waste-board. The crusher smashes rocks larger
than 2 inches in diameter while allowing smaller rocks to pass
through it. The crushed rock blend in conveyed to silos that meter
the crushed rock directly to a rock dryer.
[0023] C. The rock dryer is a large rotating kiln or oven that
evaporates any surface moisture on the rocks. The dry gypsum is
then ground in a roller-type crushing mill or a heated impact mill.
These powerful mills grind the gypsum into a fine powder normally
referred to as "land plaster".
[0024] D. The plaster is then fed into a calcining system where it
is "calcined" or heated to remove remaining water or moisture that
is chemically bound in the gypsum. At this point the gypsum is
referred to as "stucco".
[0025] E. After the stucco is formed, dry additives such as
perlite, starch, fiberglass or vermiculite are mixed in depending
on the different properties the drywall needs to adopt when
finished (added water resistance, fire protection, sound properties
etc.). The stucco is then stored in large silos to await use in the
drywall manufacturing process.
[0026] F. At the beginning of the board forming process, water,
soap foam and accelerators are added in a pin-mixing machine. The
pin mixer is the first step of the "wet end" of the manufacturing
process.
[0027] G. After mixing, the stucco becomes a "slurry" or paste. The
slurry is spread on a moving stream of cream-colored paper or
cardboard and then covered, or sandwiched with top paper or
cardboard (gray paper) to be formed into wallboard or drywall. The
cream paper is used for the face of the wallboard while the gray is
used for the backside.
[0028] H. The paper is placed on racks beside the pin mixer where
the slurry is made. The edges of the paper are scored and sometimes
chamfered to allow precise folding of the paper to form the edges
of the wallboard. The rack run above and below the exit of the pin
mixer so the stucco slurry can be sandwiched.
[0029] I. The long continuous sheet of wallboard travels up to 800
feet on moving belt and roller conveyor to the knife where it is
cut into specified lengths. The long "board line" is needed to
allow the gypsum slurry to harden before it is cut (about 4
minutes). Essentially, the gypsum slurry is hardening back into a
form of gypsum rock that has been molded into sheets.
[0030] J. The cut boards or sheets are then flipped, cream side up
and sent into a multi-stage kiln to dry for about 40 minutes.
[0031] K. Upon exiting the kiln, the wallboard is sent to a bundler
where it is trimmed to an exact length, end-taped in two panel
bundles, stacked and moved to a warehouse for shipment to
customers.
[0032] This section describes two processes of inserting a flat
metal sheet into the body of a gypsum or similar material wallboard
panel during the wallboard manufacturing process.
[0033] 1. For the purpose of this description the "metal insert"
shall be described as a galvanized flat ferrous carbon steel sheet
approximately 26 gage in thickness (0.0179"), and 12 ounces per
square foot in weight. The physical size is 47-inches wide
(horizontal) by 24-inches high (vertical). These are the physical
properties used in the testing and development of this invention.
It is understood that materials of varying shape, size, thickness
and weight could be utilized to accomplish the intention of this
invention to a greater or less degree.
[0034] 2. For the purpose of this description it is desired that
the wallboard manufacturing process be described as manufacturing
the most common 48-inch by 96-inch by 1/2-inch thick sheets. It is
understood that the manufacturing process of sheets of other
perimeter and thickness dimension could be modified to accomplish
the intention of this invention.
[0035] 3. It is understood that it is highly desirable that an
existing wallboard manufacturing process line could be modified to
accept the additional process of inserting metal sheets during the
board forming process. Utilizing an exiting line for the
manufacture of "standard" and "magnetic" wallboard would be very
cost effective for the producer.
[0036] 4. A quantity of metal insert blanks with the properties
stated above shall be stacked in a commercially available
high-speed horizontal sheet metal feeder (FIG. 6).
[0037] 5. The sheet metal feeder shall be placed perpendicular or
above (FIG. 6 and FIG. 7) to the board forming process line. The
feeder shall be positioned at the line immediately before the
application of the gray or "bottom" paper to the slurry. It must be
noted that most wallboard manufacturing process lines operate with
the gray (bottom) paper being applied to the top of the slurry
board forming process (the back side of the wallboard). In this
application the paper application shall be reversed with the cream
(top) paper being applied from the top, (FIG. 7) and the gray
becoming the bottom carrier. Magnetic drywall may in fact utilize
completely different paper of color and/or composition for
technical or marketing purposes.
[0038] 6. Utilizing commercially available indexing and sensor
components, the sheet metal feeder will deliver the metal insert in
its proper orientation to the surface and direction of the slurry
at the appropriate speed and accuracy to match the speed and
accuracy of the board forming process line.
[0039] 7. If required, the metal insert, before it is conveyed onto
the slurry can be treated with a viscous adhesive application on
one or two surfaces with a commercially available product that
would increase friction of the metal insert to the slurry once it
is in position (FIG. 6 & 7, Item 67). This would reduce
potential movement of the metal insert before the top paper is
applied.
[0040] 8. Another method to prevent the metal insert from moving in
the slurry is to design the metal insert with 1/4" flanges at each
end of the 47-inch dimension. The flanges would act as anchors and
reduce the possibility of shifting.
[0041] 9. The position of the metal insert in relation to a
standard sized 48-inch by 96-inch wallboard is critical. The
centerlines of the metal inert must be located precisely at 231/2"
side to side and 36" from either end. (FIG. 1 & 2).
[0042] 10. The position of the insert into the slurry shall be
precisely coordinated between the ends of the sheet relative to the
cutting or knifepoint further along the board forming line that
determines the finished length of the sheet.
[0043] 11. Delivery of the metal inert into the slurry at the
correct depth is also critical. If the insert is placed too deep,
the gypsum thickness over the metal will reduce magnetic adhesion.
Off line tests have confirmed that a depth of a minimum of 0.0625"
to a maximum of 0.125" is satisfactory.
[0044] 12. Depth control of the metal insert into the gypsum slurry
can be accomplished by a commercially available high-speed
precision electromagnetic delivery system (FIG. 7, Item 68) that is
coordinated with the sheet metal feeding system. The precision of
the delivery system will insure accurate and repeatable depth
insertion.
[0045] 13. It is understood that due to the surface displacement
area of the metal insert the insert would tend to "float" on top of
the slurry mixture. This is why the delivery system must be capable
of "pushing" the metal insert to the desired depth. After the
desired depth is attained and before the paper is applied, a method
of applying or spreading additional slurry on top of the metal
insert is required. This can be accomplished by a series of
standard controlled, high-speed wiper/rollers mechanisms. Uneven
slurry would be smoothed further along the process by standard
compression rollers.
[0046] 14. In order to have a continuous process that operates at
cost effective line speeds it is crucial to coordinate the timing
of the metal insert delivery to the slurry bed. It is anticipated
that the "Magnetic Wallboard" line will be an unknown factor slower
than "standard" wallboard speeds.
[0047] 15. After the placement of the metal insert into the slurry
and the application of the paper, the process of manufacturing
"Magnetic Wallboard" is identical to the manufacture of "Standard"
wallboard.
[0048] 16. A second process, in addition to the process described
above is for placing a metal insert directly onto the inner surface
of the cream or "top" paper of the gypsum board. Retaining the
cream color (front or top side) on the bottom of the board forming
process as the carrier it is proposed that the cream color paper
delivery system be lengthen to accommodate the addition of a sheet
metal feeder as described above. The sheet metal feeder (FIG. 8,
Item 64) would deliver the metal inserts as described in the prior
process, including use of a adhesive application directly to the
inner surface of the cream colored paper at specific locations
coordinated with the knife/cutting operation. The adhesive applied
to the inner surface would insure positive adherence and alignment
of the metal insert to the cream paper. The cream paper would then
be introduced to the bottom of the board forming line where the
gypsum slurry would be applied to the inner surface of the paper
and thus the metal insert. This alternative solves several problems
(simpler delivery and placement of the metal insert, better
magnetic attraction). Tests have confirmed that placing the metal
insert directly under a paper covering without a thin layer of
gypsum between the metal and the paper reveal no major problems as
long as the metal insert is absolutely flat.
[0049] 17. The addition of a metal insert into the gypsum substrate
and the covering with paper will not affect the "standard
manufacturing operation" process. Conversely, the standard
manufacturing process will not adversely affect the metal insert.
The standard wallboard manufacturing process parameters of
temperature, pressure, speed and handling would have no effect on
the implanted metal insert.
[0050] 18. Moisture affect on the metal insert would be negligible
due to the low moisture content of the process and the final curing
process which would drive out remaining moisture on the metal
insert. Nevertheless, it is recommended that the metal insert be
specified to be treated with a galvanized or equivalent corrosion
resistant surface treatment due to the possibility of a
moist--humid atmosphere or conditions on the wallboard while in
storage or in its final installation. The corrosion resistant
treatment of the metal insert will prevent a possible "bleeding"
effect of rust or the like through the thin layer of gypsum and
cardboard covering.
[0051] 19. The placement of the metal insert into the gypsum
substrate would not affect the structural integrity of the
wallboard in its final application. Wallboard generally is fragile
when handled roughly. Most of its collective strength is supported
and reinforced by the cardboard covering. Without the cardboard
encapsulation, wallboard would be very difficult to handle or
install. Once installed, wallboard is very stable and strong. The
addition of a metal insert would not decrease the strength or
handling properties of wallboard. The only physical difference
would be the slight increase in overall weight. The increase in
weight would not affect the wallboards performance in any know
application.
[0052] 20. The placement of a metal insert into the gypsum
substrate would not affect the fire rating of a "standard"
wallboard product. The metal itself would be more resistant to fire
than the gypsum/paper product itself.
[0053] 21. Installation of magnetic wallboard would be handled in
the same fashion as standard wallboard. Most applications of
magnetic wallboard would be directed specifically toward flat whole
wall sections. Use of magnetic wallboard for closets and other
non-flat wall configurations would not be recommended, due to the
extra time it would take to trim the material. If time or money is
not a factor, magnetic wallboard could be utilized in every
application that standard wallboard is used. In most cases
installing magnetic wallboard--whole sheets of magnetic wallboard
would be utilized. Because of this, there would be minimal cutting
and trimming. Due to the metal insert's left to right dimension of
47-inches and a standard wallboard outside dimension of 48-inches
the possibility of trimming the metal edge is reduced. In cases
where trimming or cutting sheets in half is necessary, the use of
standard sheet metal shears would adequately perform the task in
acceptable time limits. In addition, the very thin gage of the
metal insert would also allow scoring, bending and breaking of the
steel for straight line cuts.
[0054] 22. This invention also claims a process for adding metal
inserts to existing previously installed wallboard (claim 10). This
process requires the measuring and marking of an area that is
targeted for the metal insert (FIG. 4). After marking the area (any
area, up to one inch of the perimeter of the wallboard can be
utilized) a utility knife is used to score the perimeter of the
targeted area (FIG. 4, Item 40). After the perimeter is scored
(scoring means cutting through the paper and approximately 1/8"
into the gypsum substrate), the interior surface of the scored area
must then be scored with intersecting horizontal and vertical lines
(FIG. 4) creating small blocks ranging from 1/2 to 1 inch square.
After the scoring is complete it is necessary to remove the paper
and gypsum from the targeted area to create a "pocket" for the
metal insert to be placed. This is accomplished by utilizing a
stiff, sharp putty knife, or chisel and hammer. The putty knife is
placed within one of the perimeter score lines at a slight angle
and hammered into a depth of approximately 1/8". Using the putty
knife in a chisel-like fashion, the gypsum material is removed from
the targeted area to a uniform depth of no less than 1/8" (FIG. 5,
Item 50).
[0055] The pocket is now ready to accept the metal insert. The flat
metal insert is placed into the pocket. Tests have confirmed that
the metal insert will not sit in the pocket without tilting out and
falling. To eliminate this problem, small holes are drilled (the
number of holes will vary according to the size of the insert. On a
24" by 47" insert, five holes were drilled, one in each comer and
one in the center). After the holes are drilled, small, flathead
screws are screwed through the metal into the gypsum. This keeps
the insert in place. After the insert is secured in place, adhesive
fiberglass tape commonly used as joint tape for wallboard is
applied in horizontal strips completely covering the metal insert.
This provides an adhesive base for the joint compound to stick to.
After the tape is applied, joint compound can be applied into the
pocket and "feathered" over the outside edges of the pocket
perimeter following standard wallboard finishing techniques. After
cure and sanding, one or two additional coats of joint compound can
be applied, if necessary. The finished area can then be painted or
covered with wallpaper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] The invention will be better understood upon reference to
the following detailed description and the drawings in which:
[0057] FIG. 1 is an orthographic front view of a standard sized
4'.times.8' gypsum panel illustrating the typical location of a
24".times.47" metal insert.
[0058] FIG. 2 is an orthographic side view of a standard sized
4'.times.8'.times.1/2" thick (not to scale) gypsum panel
illustrating the typical location and depth of the metal insert in
the front side of the panel.
[0059] FIG. 3 is a perspective of wall sections with a window and
doorway illustrating the perimeter location of the metal inserts in
combination of multiple wall panels.
[0060] FIG. 4 is an orthographic front view of a standard sized
4'.times.8' gypsum panel illustrating the typical location of score
lines for inserting a metal insert into an existing installed
gypsum wallboard.
[0061] FIG. 5 is an orthographic side view of a standard sized
4'.times.8' gypsum panel illustrating the typical location of
excavated or removes gypsum material for the purpose of inserting a
metal insert into an existing installed gypsum wallboard.
[0062] FIG. 6 is an orthographic end view of a portion of a gypsum
board forming line showing the location of an overhead sheet metal
feeder-positioning system and an adhesive application spray system.
The view also illustrates the metal insert being lowered into the
gypsum slurry.
[0063] FIG. 7 is an orthographic side view of a portion of a gypsum
board forming line showing the top and bottom paper rolls applying
paper to the gypsum slurry and the position of the sheet metal
feeder-positioning system and the slurry application device and the
adhesive spray system and the metal insert depth placement system
in relation to one another.
[0064] FIG. 8 is an orthographic side view of a portion of a gypsum
board forming line showing the top and bottom paper rolls applying
paper to the gypsum slurry and the position of the sheet metal
feeder-positioning system and the slurry application device and the
adhesive spray system in relation to one another.
DETAILED DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 illustrates a typical 4'.times.8' gypsum panel with a
hidden view (Item 11) that outlines the position of a typical metal
insert in relation to the panels overall perimeter (Item 10). In
the cases where 4'.times.8' gypsum panels are installed vertically,
the preferred location of the metal insert would be at approximate
eye level (around 5'). The horizontal centerline of the insert
would be placed into the uncured gypsum slurry approximately 36"
from either end of the panel and positioned in the center of the
panel's vertical centerline. The depth of the metal insert shall be
as close to the "front" of the panel as possible. This illustration
depicts the most common configuration. Other configurations can be
developed to accommodate specific or custom requirements.
[0066] FIG. 2 illustrates the side view of a 4'.times.8' gypsum
panel (Item 21) showing the location of the metal insert (Item 20)
relative to the top and bottom of the panel. It also illustrates
the approximate location of the depth of the metal insert relative
to the "front" or the facing side of the gypsum panel. The two
processes explained within the invention define two methods for
inserting the metal insert into the gypsum panel. Process one
positions the metal insert into the gypsum slurry to a maximum
depth of 1/8". Process two positions the metal insert directly onto
the inner surface of the front facing paper by means of a delivery
system and adhesive spray system. The illustration shows the
approximate location of the metal insert for both processes.
[0067] FIG. 3 illustrates two wall sections of a room. The wall
section depicts one window on one wall and one door opening on the
second wall. The wall sections also depict vertical hidden lines
(Item 31) that represent individual 4'.times.8' gypsum wall panels
in an erected, finished position. The horizontal hidden lines (Item
30) represent the location of the metal inserts within the multiple
gypsum wall panels. As each wall panel is erected and placed in
adjoining positions to each other, a continuous perimeter of metal
inserts at approximately eyelevel is achieved.
[0068] FIG. 4 illustrates a 4'.times.8' gypsum panel (Item 41) in a
front and side view showing a series of squares (Item 40) that
depicts the amount of score lines made by a utility knife that is
necessary to allow chisel removal of approximately 1/8" of the
gypsum material and paper covering from the surface of the front
facing of the panel. The removal of the materials from this area
allows the insertion of the flat metal sheet into the area. After
insertion the sheet is screwed into place. Finally, a layer(s) of
gypsum compound can be applied over the metal and sanded smooth and
painted or papered to match existing conditions.
[0069] FIG. 5 illustrates a side view of a 4'.times.8'.times.1/2"
thick gypsum panel (Item 51) with a section (Item 50) of the
material removed necessary to accommodate a metal insert. The depth
of the material removed cannot exceed 1/8" or a reduction in
magnetic strength will occur.
[0070] FIG. 6 illustrates an end view of a portion of a typical
gypsum forming board process manufacturing line. Shown is the
actual conveyor (Item 60) that conveys the gypsum panel throughout
the operation. Above the conveyor a cutaway section (Item 70) of a
gypsum (slurry) board with bottom paper, laying flat on the
conveyor is shown. Above the gypsum board (slurry) a metal insert
(Item 61) is shown being lowered into the gypsum slurry. Above the
metal insert is a commercially available sheet metal
feeder-positioning system (Item 64). Attached to the sheet metal
feeder on each side are adhesive housings (Item 71) that are
attached internally to powered spray nozzles (not shown). The
nozzles deposit adhesive to the bottom of the metal insert to
assist in preventing the insert from moving after placement in the
slurry mixture. On the front face of the sheet metal feeder (Item
72) is an opening depicting the layers of metal inserts in position
for processing. Above the sheet metal feeder (Item 73) is the
loading area for the metal inserts.
[0071] FIG. 7 illustrates a side elevation view of a portion of a
typical gypsum forming board process manufacturing line. Shown is
the actual conveyor (Item 60) that conveys the gypsum panel
throughout the operation. Above the conveyor shows a gypsum panel
in the process of being formed. To the left, a dispensing roll of
"bottom" paper (Item 62) is shown delivering the paper (Item 80) to
the top surface of the conveyor. To the right of the paper
dispenser, the gypsum slurry delivery system (Item 65) is shown. To
the right of the slurry delivery system is the sheet metal
feeder-positioning system (Item 64). On the side surface of the
sheet metal feeder the adhesive housing (Item 67) is shown for
clarity. Under the sheet metal feeder and above the conveyor, a
metal insert (Item 61) is shown being positioned into place into
the gypsum slurry (Item 70). To the right of the sheet metal feeder
is the metal insert depth positioner (Item 68), which controls the
depth of the insert into the slurry. To the right of the depth
positioner is the "top" or "face" paper roll dispenser, which
applies the top paper the gypsum slurry, completing the board
assembly. It must be noted that this illustration reverses the
position of the paper compared to traditional gypsum board
manufacturing process lines. Tradition lines apply the "top" paper
on the bottom of the board during processing. This illustration
applies "top" paper to the upper surface of the board during the
process.
[0072] FIG. 8 illustrates a second process for inserting a metal
insert into a gypsum board manufacturing line. The illustration
shows a side elevation view of a portion of a typical gypsum
forming board process manufacturing line. Shown is the actual
conveyor (Item 60) that conveys the gypsum panel throughout the
operation. Above the conveyor shows a gypsum panel in the process
of being formed (Item 70). To the left, a dispensing roll of "top"
or "face" paper (Item 62) is shown delivering the paper (Item 80)
to the top surface of the conveyor. To the right of the paper
dispenser, a spray adhesive system applies adhesive to the inner
surface of the top paper incrementally. To the right of the
adhesive spray system the sheet metal feeder-positioning system
(Item 64) is shown. Under the sheet metal feeder and above the
conveyor, a metal insert (Item 61) is shown being positioned into
place onto the sticky top paper (item 80). To the right of the
sheet metal feeder system is the gypsum slurry delivery system
(Item 65). The slurry is applied over the metal insert. After this
operation the "bottom" paper (Item 63) is applied to the slurry
mixture, completing the board assembly.
* * * * *