U.S. patent application number 11/463780 was filed with the patent office on 2008-02-14 for wallboard panel.
Invention is credited to Michael T. Moore.
Application Number | 20080034693 11/463780 |
Document ID | / |
Family ID | 39049168 |
Filed Date | 2008-02-14 |
United States Patent
Application |
20080034693 |
Kind Code |
A1 |
Moore; Michael T. |
February 14, 2008 |
Wallboard panel
Abstract
The instant invention is directed to a wallboard panel which is
made from new or recycled paper. The panel comprises a pair of
sheet members which are parallel in alignment and a honeycomb core
sandwiched between the sheet members. The inner surfaces of the
sheet members are coated with an adhesive material and the
honeycomb core is impressed into the adhesive layers. The honeycomb
core is manufactured by a novel process. The sheet members and
honeycomb core can be coated with a phenolic resin and/or a fire
retardant material. The wallboard panel can also include insulation
and/or fire-retardant material disposed within the hollow honeycomb
core.
Inventors: |
Moore; Michael T.; (Jupiter,
FL) |
Correspondence
Address: |
MCHALE & SLAVIN, P.A.
2855 PGA BLVD
PALM BEACH GARDENS
FL
33410
US
|
Family ID: |
39049168 |
Appl. No.: |
11/463780 |
Filed: |
August 10, 2006 |
Current U.S.
Class: |
52/417 |
Current CPC
Class: |
E04C 2/365 20130101;
B31D 3/0292 20130101; B29D 99/0089 20130101; B31D 3/0238
20130101 |
Class at
Publication: |
52/417 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. A process for forming a honeycomb structure comprising:
continuously removing sheets of paper from individual rolls of
paper; applying a plurality of bands of glue to one side of each
sheet of paper; each band of glue being relatively short compared
to the length of the roll of paper and extending substantially the
entire width of the sheet of paper; spacing the bands of glue an
equal distance from each other; arranging the sheets of paper in a
stacked relationship on top of each other; the bands of glue on
adjacent sheets being spaced apart in a staggered relationship such
that the bands of glue on one sheet are spaced midway between the
bands of glue on the adjacent sheet; cutting the sheets of paper
into a plurality of strips; attaching the strips in a stacked
relationship whereby a plurality of stacked strips forms a section
which can be expanded; expanding the strips to form a honeycomb
structure.
2. A process for forming a wallboard panel comprising: forming a
pair of rigid sheet members from paper; aligning said sheet members
in parallel and in spaced relationship to each other; forming a
honeycomb core by the process of claim 1; and attaching the
honeycomb core in between said pair of rigid sheet members.
3. The process of claim 2, further including coating the inner
surfaces of each of said sheet members with an adhesive; and
impressing said honeycomb core into said adhesive layers.
4. The process of claim 2, further including filling a plurality of
cells of said honeycomb core with a solid material.
5. The process of claim 2, further including impregnating said
honeycomb core with a phenolic resin.
6. The process of claim 2, further including impregnating said
rigid sheet members with a phenolic resin.
7. The process of claim 2, further including impregnating said
rigid sheet members with plaster.
8. The process of claim 2, further including filing a plurality of
cells of said honeycomb core with an insulating material.
9. The process of claim 2, further including filing a plurality of
cells of said honeycomb core with a fire retardant material.
10. The process of claim 4, wherein said plurality of cells of said
honeycomb core comprise the cells immediately adjacent the
peripheral edges of said wallboard panel.
11. The process of claim 2, wherein the thickness of said wallboard
panel adjacent the longitudinal edges is reduced.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to the field of building
wall structures and more particularly to an improved method of
manufacturing an improved wallboard panel for attachment to studs
in a wall or ceiling.
BACKGROUND OF THE INVENTION
[0002] The most common type of wallboard used for interior wall
construction in buildings is gypsum board, also known as drywall.
It is commonly available under brand names such as
Sheetrock.COPYRGT. or Gyproc.COPYRGT.. Gypsum drywall comprises a
sheet of gypsum with a paper facing and paper backing.
[0003] Approximately 2.0 million new homes are constructed annually
in the United States, most of these employ gypsum drywall in their
construction. The gypsum drywall is used for the interior walls,
ceilings, and partitions. It has a surface which is suitable for
the reception of finish materials and decorations such as paint.
While it is a useful and ubiquitous material in building
construction, gypsum drywall is difficult to work with. The weight
of the gypsum makes the sheets of drywall unwieldy and difficult to
manipulate. In addition to its heavy weight, the drywall is
extremely fragile and panels of gypsum drywall can easily split in
two if they are mishandled.
[0004] The process of installation of the drywall panels requires
that they be cut to fit around doors, windows and other openings.
This usually results in approximately one pound of waste for every
square foot of finished house. This results in an average of nearly
one ton of gypsum drywall for each single family home built. A
reason for the large amount of waste is that walls and ceilings are
easier to tape and spackle and are less likely to develop cracks is
they are covered with large pieces of drywall from which the
openings are cut. Small pieces of drywall require significantly
more time and labor for finishing. Also, the joints between them
are susceptible to cracking over time.
[0005] Debris from construction, remolding, and demolition
activities is estimated to account for approximately 24% of the
solid waste that is discarded in the landfills across the United
States, a large percentage of which is drywall. This large volume
of waste creates serious environmental concerns. The disposal of
waste gypsum drywall is problematic. Landfill space which receive
the waste drywall is becoming less available and more expensive. A
greater concern is the face that in a landfill the moist anaerobic
conditions allow bacteria to reduce the sulfate component of the
gypsum to hydrogen sulfide gas, carbon dioxide, and water. Hydrogen
sulfide gas at low concentrations is noxious and at higher
concentrations pose serious health and safety risks. Some landfills
have already refused to accept drywall waste because of concerns
about the hydrogen sulfide gas.
[0006] An alternative to the landfills is incineration.
Incineration of drywall causes the sulfate present in the gypsum to
be converted to sulfur dioxide gas. Air pollution concerns
associated with this makes this alternative undesirable. Another
alternative is dumping the waste into the ocean. A study of this
dumping was done by the Canadian government. The conclusion of this
study was that since the materials present in drywall made with
gypsum are naturally present in the ocean environment, this method
would be environmentally benign. However, the highly negative
public perception of ocean dumping of solid waste materials makes
this option undesirable also.
[0007] While it is technically feasible to recycle drywall, the
high costs of recycling the drywall verses the relatively low costs
of the raw gypsum make this practice economically undesirable.
[0008] As a result of the grave environmental concerns associated
with drywall, there is an urgent need for an alternative building
material which can be used in place of gypsum drywall. The material
should be able to be used in the same manner as gypsum drywall yet
overcome the drawbacks and disposal problems associated with gypsum
drywall. There is also a need for a wallboard material which is
easier to handle than gypsum drywall, which can be inexpensively
produced and which is environmentally friendly.
DESCRIPTION OF THE PRIOR ART
[0009] The present invention is directed to an improved wallboard
made from an improved wallboard material and manufactured by a new
and improved process. The improved wallboard is a plurality of
paper sheets having a honeycomb core sandwiched between them and
the improved material is recycled paper. The improved process is a
novel method of manufacturing the honeycomb core. The resulting
wallboard is lightweight yet has a superior tensile strength
because of the honeycomb core. There are several examples in the
prior art of wall panels incorporating a honeycomb core. These
include U.S. Pat. Nos. 5,899,037; 4,0104,143 and 6,253,530. From a
manufacturing standpoint, honeycomb materials can be characterized
as one of two types, expanded or non-expanded. The expanded types
are formed from strips of a flexible material, such as paper or
plastic, which are stacked and bonded along staggered joint lines.
The structure is secured at the top and bottom surfaces and then
the stack is pulled apart to produce the honeycomb structure. The
stack can be fixed in its expanded form by immersion into a resin
bath, or in the case of thermoplastic materials, the stack can be
is heated to fix the cells in their expanded condition.
[0010] Another type of honeycomb material is non-expanded honeycomb
material. This material consists of discretely formed hexagonal
tubes which have been bonded together in a honeycomb formation.
Each of the prior art references cited above have honeycomb cores
which are fabricated using the expansion process.
SUMMARY OF THE INVENTION
[0011] The instant invention is directed to a wallboard panel which
is made from new or recycled paper. The panel comprises a pair of
sheet members which are parallel in alignment and a honeycomb core
sandwiched between the sheet members. The inner surfaces of the
sheet members are coated with an adhesive material and the
honeycomb core is impressed into the adhesive layers. The honeycomb
core is manufactured by a novel process. The sheet members and
honeycomb core can be coated with a phenolic resin and/or a fire
retardant material. The wallboard panel can also include insulation
and/or fire-retardant material disposed within the hollow honeycomb
core.
[0012] Accordingly, it is an objective of the instant invention to
provide a wallboard panel which is lightweight and has a high
tensile strength.
[0013] It is a further objective of the instant invention to
provide a wallboard panel which is constructed from new or recycled
paper.
[0014] It is yet another objective of the instant invention to
provide a new process for the manufacture of a honeycomb core.
[0015] It is a still further objective of the invention to provide
a wallboard panel which is constructed from biodegradable materials
so that disposal thereof will not harm the environment.
[0016] It is a still yet further objective of the invention to
provide an improved wallboard panel which has superior
soundproofing characteristics.
[0017] Other objects and advantages of this invention will become
apparent from the following description taken in conjunction with
any accompanying drawings wherein are set forth, by way of
illustration and example, certain embodiments of this invention.
Any drawings contained herein constitute a part of this
specification and include exemplary embodiments of the present
invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 is a wallboard panel according to a preferred
embodiment of the invention in which a surface is shown partially
cut away;
[0019] FIG. 2 is a cross-sectional view taken along line 2-2 in
FIG. 1 which illustrates the wallboard panel of FIG. 1 nailed to a
wall stud;
[0020] FIG. 3 illustrates indicia on the outer surface of the
wallboard of FIG. 1;
[0021] FIG. 4 illustrates the honeycomb core in its expanded
state;
[0022] FIG. 5 is a side view of the paper layers illustrating the
spacing of the glue strips;
[0023] FIG. 6 illustrates how four rolls of paper are brought
together to form the pre-expanded honeycomb core; and
[0024] FIG. 7 is view of the rotary knives cutting the sheet of
paper into strips.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 illustrates a wallboard panel 10 according to a
preferred embodiment of the invention in which the wallboard panel
10 is shown partially cutaway for ease of description. The
wallboard panel 10 can be utilized in the same manner as standard
gypsum drywall and advantageously requires no special tools for
installation. The wallboard panel 10 is constructed from facing
sheet members 12 and 14 which sandwich a honeycomb core 16
therebetween. As seen in the cross-section view shown in FIG. 2,
the facing sheet members 12 and 14 have inner and outer surfaces
12a, 12b, 14a and 14b respectively. The inner surfaces 12b and 14b
are adhered to the honeycomb core 16. Use of the honeycomb core 16
produces a wallboard panel 10 which is lightweight and has a
tensile strength superior to standard gypsum drywall. The honeycomb
core 16 also provides superior noise suppression thereby providing
superior soundproofing qualities compared to gypsum drywall.
[0026] In a preferred embodiment of the invention the facing sheet
members 12 and 14 and the honeycomb core are constructed from
recycled paper. These elements can also be constructed from new
paper. The resultant product is "environment-friendly" from the
manufacturing standpoint as well as with regard to the ultimate
disposal of the material.
[0027] The paper to be recycled can come from a variety of sources.
Waste newspaper can be used as well as any other paper or cellulose
material. Also, any fibrous material comprised of cotton, wool,
linen or the like can be used. Any suitable process known in the
art can be employed to recycle paper products to form the
components of the wallboard 10 and the invention is not limited in
this regard.
[0028] As is known in the art, the used paper products such as
newspapers, cardboard, magazines office waste paper, etc., is
initially soaked in water to soften them. Soaking the paper makes
the beating of the wet paper easier. The paper can be initially cut
up to speed up the soaking process. The soaked paper pulp is then
beaten into a slurry. Sufficient water is added to the paper during
the beating process to create an aqueous mixture which is fairly
viscous, yet pourable. The beater should not overly chop the paper,
since chopping destroys the long paper fibers needed for strength
in the final product. The length of the beating is determined by
the type of paper being treated.
[0029] Various additives and binders can be added to the aqueous
mixture during the beating process. In order to add desirable
properties to the finished product, fire-proofing chemicals, insect
repellents, etc. are added at this stage. The mixture can also be
impregnated with phenolic resin which provides waterproofing and
insect resistance, as well as inhibiting the growth of fungus and
molds. It is preferable to impregnate the paper with up to about
38% by weight of a resin, normally a water or other solvent-based
resin, such as a low-emission, waterborne phenolic resin of the
type sold by Georgia-Pacific Resins, Inc. of Decatur, Ga.
[0030] Plaster and cement can be added to strengthen the final
product. It has been found that a mixture including about 20-50%
plaster will produce a textured stone hard material. Use of a
plaster-impregnated material to fabricate wallboard in accordance
with the invention will produce a product suitable for outdoor use.
The slurry is then poured into a mold and compressed to form a mat.
The strength of the final product is a function of the degree of
pressure applied. Greater pressure generally results in a stronger
product. In order to obtain satisfactory strength characteristics,
it is preferable to use pressures from about 700 to 2000 pounds per
square inch (psi). If binders such as plaster and concrete are
used, the compressed slurry must be allowed to harden while under
the pressure.
[0031] The honeycomb core is formed by combining four layers of
paper 34, 36, 38 and 40 having strips of glue 42 at specific
locations, in a stacked relation with each layer on top of the
previous layer, as illustrated in FIG. 5. The glued portions of
each layer are spaced from each other in such a manner that the
glued portions of each layer are adhered to the adjacent layer of
paper below. The non-adhered portions of the layers permit the
combined layers to be pulled apart to form a honeycomb structure.
This is illustrated in FIG. 4. Each of the four layers of paper
contains a narrow band of glue 42 which extends the entire width of
each layer. The glue bands of adjacent layers of paper are offset
from each other as illustrated in FIG. 5. In a preferred embodiment
layers of paper are removed from from four rolls of paper 44, each
roll being four feet wide. Glue is applied in a narrow band to the
width of each roll by applicators 46. The bands of glue are spaced
apart approximately one inch in a preferred embodiment. The bands
of glue in adjacent rolls are offset by one half of the distance
between the bands or approximately 1/2 inch so that adjacent layers
of paper can be attached to each other as shown in FIG. 5 thereby
forming a honeycomb core. Each layer of paper is passed over a
roller 48 after the glue is applied. This roller helps to align the
layers of paper into a stacked relationship as shown in FIG. 6.
After the four layers of paper are attached to each other they are
passed over roller 52 and then through a cutter 54 which cut the
four foot wide sheets of paper into a plurality of 3/8 inch wide
strips. The cutter 54 comprises an axle 56 onto which a plurality
of rotary cutting wheels 58 are rotatably mounted. As the layers of
paper pass the cutter the cutting wheels cut the paper into strips
approximately 3/8 inch wide.
[0032] A 3/8 inch wide strip of four sheets of paper are placed on
top of another 3/8 inch wide strip of four sheets of paper such
that the bottom sheet of the first or upper group is adhered to the
top sheet of the second or lower group. This process forms a
honeycomb core material which can be expanded to twice the width of
a single group of sheets. The strips or groups of paper are
attached on top of each other until an expanded section of
honeycomb material up to 12 feet long is formed.
[0033] Referring to FIG. 2, it is seen that the inner surfaces 12b
and 14b of the sheet members are respectively coated with adhesive
layers 21 and 23. The adhesive is preferably a one component,
solvent free, moisture curing, non-volatile urethane adhesive such
as Mor-Ad.COPYRGT. M-612, produced by Morton International. Mor-Ad
division, of Chicago, Ill. Another suitable adhesive is a two
component epoxy resin such as one sold under the brand name
Stic-Bond.COPYRGT., available from Stic-Adhesive Products Co. Inc.,
of Los Angeles, Calif. The adhesive layers 21 and 23 are preferably
about 5 mm thick. To assemble the wallboard panel 10, the honeycomb
panel 16 is impressed into the adhesive layers 21 and 23. Prior to
assembly, the open cells of the honeycomb core 16 can be filled
with a desired material, such as a fiberglass insulation or a
fire-retardant material. The open cells of the honeycomb adjacent
all of the outer peripheral edges of the wallboard panel 10 are
preferably filled with a viscous material which will harden as it
dries. This prevents fraying of the edges of the wallboard. The
finished wallboard is preferably 1/2 inch thick. However,
additional wallboard panels could be formed with different
thicknesses conforming to conventional wallboard thicknesses.
[0034] Along each longitudinal edge of the wallboard the thickness
of the wallboard is reduced to allow for the use of tape and
spackle to finish the installed wallboard. Normally the abutting
edges of wallboard result in a visible joint therebetwen which must
be hidden to produce a finished wall. The joint in normally covered
with a tape and spackling compound. To allow for the tape and
spackle to be placed on the wall without increasing the overall
thickness of wall, the thickness of conventional wallboard adjacent
these edges is reduced. Accordingly, the thickness along the
longitudinal edges of the wallboard of the instant invention will
also be reduced.
[0035] In use, the wallboard panel 10 is attached to adjoining
studs in a wall or joists in a ceiling using an attachment means
such as nails or screws. In order to provide a stable anchor for
the attachment means a portion of the honeycomb cells 19 can be
formed with reinforcing material. As can be seen in FIG. 2, the
honeycomb core includes a solid cell 25. The solid cell 25 can be
formed by filling hollow cells 19 with a suitable viscous material
which will harden as it dries. The solid cell 25 is preferably
comprised of a material having a sufficient hardness to hold a
nail, or other attachment element, in place, but not so hard as to
require pre-drilling of the cell prior to penetration by the nail.
FIG. 2 illustrates the wallboard panel 10 attached to a wall stud
50 by a nail 60 which penetrates the solid cell 25.
[0036] The solid cells 25 are arranged in a regular pattern within
the honeycomb core 16. The solid cells 25 are preferably arranged
in vertical and horizontal lines to facilitate attachment of the
wallboard 10 to the wall studs 50. The frequency of placement of
the solid cells 25 within the honeycomb core can be varied
depending on the particular application. As shown in FIG. 3, the
outer surfaces 12a and 14a are marked with indicia 30 illustrating
the location of the solid cells 25 within the wallboard panel 10 to
enable someone installing the wallboard to readily located the
solid cells 25 during the installation process.
[0037] The wallboard panel 10 can be manufactured in various sizes
depending on application requirements. The wallboard preferably has
a standard depth and the width and length can have any desired
dimensions. For example, the width of the wallboard panel 10 can be
a standard 4 feet and teh lengths can be in multiples of one foot.
Also, papermaking techniques may be used to make the panels in a
continuous running length by pouring the slurry onto a moving weir
screen wire to a particular depth and delivering the wet material
to pressure rolls for compaction and drying, the continuous batt
goes through punching rolls which may have a pattern of punches.
The areas not punched contain the solid material. Various materials
may be added to the punched batt to fill other apertures.
Continuous sheets of paper are delivered to both sides of the batt
with adhesives applied to the batt or the sheets. The complete
panel is compressed again to set the adhesives, then the continuous
panel is delivered to a cutter for sizing.
[0038] All patents and publications mentioned in this specification
are indicative of the levels of those skilled in the art to which
the invention pertains. All patents and publications are herein
incorporated by reference to the same extent as if each individual
publication was specifically and individually indicated to be
incorporated by reference.
[0039] It is to be understood that while a certain form of the
invention is illustrated, it is not to be limited to the specific
form or arrangement herein described and shown. It will be apparent
to those skilled in the art that various changes may be made
without departing from the scope of the invention and the invention
is not to be considered limited to what is shown and described in
the specification and any drawings/figures included herein.
[0040] One skilled in the art will readily appreciate that the
present invention is well adapted to carry out the objectives and
obtain the ends and advantages mentioned, as well as those inherent
therein. The embodiments, methods, procedures and techniques
described herein are presently representative of the preferred
embodiments, are intended to be exemplary and are not intended as
limitations on the scope. Changes therein and other uses will occur
to those skilled in the art which are encompassed within the spirit
of the invention and are defined by the scope of the appended
claims. Although the invention has been described in connection
with specific preferred embodiments, it should be understood that
the invention as claimed should not be unduly limited to such
specific embodiments. Indeed, various modifications of the
described modes for carrying out the invention which are obvious to
those skilled in the art are intended to be within the scope of the
following claims.
* * * * *