Abstract:
A wallboard with a plaster structural substrate is provided that includes a partial or complete fastening/distributing layer that provide desirable characteristics to both mechanically hold conventional fasteners (such as screws) as well as distribute the load of the fasteners to a sufficient area of the wallboard as to eliminate the need for supplemental construction or special fasteners or anchors. The fastening/distributing layer or inserts may be imbedded within the plaster substrate or laminated to it. The paper layer may include indicia identifying the location of the fastening/distributing layer.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention is directed generally to wallboards and more particularly to wallboards that are reinforced to provide better support for structures mounted thereto. 
         [0003]    2. Description of Related Art 
         [0004]    Standard, paper-wrapped, gypsum plaster-filled, wallboard is conventionally used today in the construction of most residential and commercial buildings. However, the structural plaster substrate of conventional wallboards is generally not strong enough to support most cabinetry or other fixtures mounted thereon. Typically the gypsum filled wallboard requires special fastening devices or supplemental construction to distribute the weight from such cabinetry to both the wallboard and studs to which the wallboard is mounted. In addition, many fixtures including, shelves, brackets, mirrors, and wall hangings also require supplemental construction or special anchors or fasteners to distribute the weight of the fixtures to the surrounding area of the wallboard and supporting studs. 
         [0005]    The present invention represents an improvement over such standard wallboards by providing a reinforced wallboard substrate that eliminates the need for special devices or supplemental construction to support cabinetry and/or other fixtures. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    An object of the present invention is to provide a unique wallboard with a plaster structural substrate that includes a partial or complete fastening/distributing layer that provides desirable characteristics to both mechanically hold conventional fasteners (such as screws) as well as distribute the load of the fasteners to a sufficient area of the wallboard as to eliminate the need for supplemental construction or special fasteners or anchors. The fastening/distributing layer or inserts may be imbedded within the plaster substrate or laminated to it. The paper layer may include indicia identifying the location of the fastening/distributing layer. 
         [0007]    According to principles of the present invention, a wallboard is provided. The wallboard includes a fastening/distributing layer having a lower surface and an upper surface, a plaster substrate having an upper surface and a lower surface, the lower surface being bonded to the upper surface of the fastening/distributing layer, and a paper layer bonded to the upper surface of the plaster substrate is provided. 
         [0008]    In another aspect, the thickness of the wallboard may range from about one-half inch thick to one inch thick. 
         [0009]    In a further aspect, the fastening/distributing layer may have a thickness ranging from about one thirty-secondth inch thick to three-sixteenth inch thick. 
         [0010]    In a different aspect, the wallboard may include at least two tapered edges. 
         [0011]    In still another aspect, the fastening/distributing layer may be formed of wood. Alternatively, the fastening/distributing layer may be formed of metal, composites, synthetic material, woven material, matted material, or combinations thereof. 
         [0012]    In yet another aspect, the wallboard may include a second fastening/distributing layer between the upper surface of the plaster substrate and the paper layer. 
         [0013]    According to principles of the present invention, another wallboard is provided. The wallboard includes a plaster substrate having an upper surface and a lower surface, an upper paper layer bonded to the upper surface, a lower paper layer bonded to the lower surface, and a pair of fastening/distributing inserts located inside the wallboard between the upper and lower paper layers. 
         [0014]    In another aspect, the paper layer may include indicia identifying the location of the pair of fastening/distributing inserts. 
         [0015]    In a different aspect, the pair of fastening/distributing inserts may be located in the plaster substrate between the upper and lower surfaces. Alternatively, the pair of fastening/distributing inserts may be located on the upper surface or the lower surface. 
         [0016]    In another aspect, the pair of fastening/distributing inserts may be perforated metal sheets or metal inserts. Alternatively, the pair of fastening/distributing inserts may be formed from non-metallic sheet material. 
         [0017]    In a different aspect, the pair of fastening/distributing inserts may extend in the longitudinal direction of the wallboard. Alternatively, the pair of fastening/distributing inserts may extend in the lateral direction of the wallboard. 
         [0018]    In yet another aspect, the pair of fastening/distributing inserts may be a first pair of fastening/distributing inserts and the wallboard may further include a second pair of fastening/distributing inserts. The first pair of fastening/distributing inserts may be located on the upper surface and the second pair of fastening/distributing inserts may be located on the lower surface. 
         [0019]    In a further aspect, at least one of the first and second pair of fastening/distributing inserts may be formed from a non-metallic material. Alternatively, at least one of the first and second pair of fastening/distributing inserts may be perforated metal sheets or metal inserts. 
         [0020]    In a different aspect, the first and second pair of fastening/distributing inserts may extend in the longitudinal direction of the wallboard. Alternatively, the first and second pair of fastening/distributing inserts may extend in the lateral direction of the wallboard. 
         [0021]    In a different aspect, the wallboard may include at least two tapered edges 
         [0022]    According to principles of the present invention, another wallboard is provided. The wallboard includes a plaster substrate having an upper surface and a lower surface, an upper paper layer bonded to the upper surface, a lower paper layer bonded to the lower surface. At least three sides of the wallboard have tapered edges. 
         [0023]    With the above embodiments, the wallboard is configured to duplicate or mimic a conventional wallboard surface that will allow the secure attachment of cabinets and fixtures using conventional fasteners, such as screws, without reference to stud location or special fasteners. In addition, the wallboard is strengthened to resist any moment arms created by the mounting of cabinetry or other fixtures. 
         [0024]    Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from the detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein: 
           [0026]      FIG. 1  is a perspective view of a first exemplary embodiment of a wallboard according to principles of the present invention; 
           [0027]      FIG. 1A  is a schematic cross-sectional view of the reinforced wallboard of  FIG. 1  taken along line  1 A- 1 A, and  FIG. 1B  shows a schematic cross-sectional views of an alternative location of the fastening/distributing layer(s) within the plaster substrate of the reinforced wallboard of  FIG. 1 ; 
           [0028]      FIG. 2  is a perspective view of a second exemplary embodiment of a wallboard according to principles of the present invention where the fastening/distributing layer imbedded in the plaster substrate extends in a longitudinal direction of the wallboard; 
           [0029]      FIG. 2A  is a schematic cross-sectional view of the reinforced wallboard of  FIG. 2  taken along line  2 A- 2 A, and  FIGS. 2B-2D  show schematic cross-sectional views of alternative locations of the fastening/distributing insert(s) within the plaster substrate of the reinforced wallboard of  FIG. 2 ; 
           [0030]      FIG. 3  is a perspective view of a third exemplary embodiment of a reinforced wallboard according to principles of the invention where the fastening/distributing layer imbedded in the plaster substrate extends in a lateral direction of the wallboard; 
           [0031]      FIG. 3A  is a schematic cross-sectional view of the reinforced wallboard of  FIG. 3  taken along line  3 A- 3 A, and  FIGS. 3B-3D  show schematic cross-sectional views of alternative locations of the fastening/distributing inserts(s) within the plaster substrate of the reinforced wallboard of  FIG. 3 ; and 
           [0032]      FIG. 4  is a plan view of a fourth exemplary embodiment of a reinforced wallboard according to principles of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Generally the present invention relates to a paper covered plaster wall panel or wallboard structure having improved strength and is designed to facilitate the secure attachment of cabinets, fixtures, and/or other heavy objects to the surface thereof. The present invention allows for the elimination of supplemental construction, pre-installation blocking strips, nailers, and other special fastening schemes by providing a fastening/distributing layer that allows secure gripping of conventional fasteners, such as drywall screws, and also distributes the weight of a heavy object, such as a cabinet or other fixture to a wall surface comprised of one or more of the reinforced wallboards and studs. The wallboard may be treated to have fire retardant effects if so desired. 
         [0034]      FIGS. 1 and 1A  show an exemplary embodiment of a reinforced wallboard  100  that includes a fastening/distributing-layer  110  laminated to a plaster substrate  120 , such as, but not limited thereto, a gypsum plaster substrate, and paper layer  130 . A pair of tapered sides  122  may be formed to more closely duplicate conventional wallboards. 
         [0035]    In this first exemplary embodiment, the fastening/distributing layer  110  may be formed of wood, such as, but not limited to, plywood, Oriented Strand Board (OSB), and the like. In the alternative, the fastener/distributing layer  110  may be formed of metal, synthetic material, such as plastic, melamine, woven or matted materials, such as Nylon, other composite materials, or combinations thereof. 
         [0036]    The thickness of the fastening/distributing layer  110  and plaster substrate  120  may be selected to provide a thickness in the range of a half-inch, three-quarter inch, five-eighths inch, one inch, or other desirable thicknesses. The thickness of the fastening/distributing layer may range from about one thirty-second inch thick to three-sixteenth inch thick. For example, the fastening/distributing layer  110  may be formed of one-eighth or three-sixteenth inch thick plywood. The plaster substrate  120  may be three-eighth or five-sixteenth inch thick so that the combination of the fastening/distributing layer  110 , plaster substrate  120 , and paper layer  130  form conventional wallboard thicknesses such as standard half-inch, three-quarter inch, five-eighths inch, or one inch thick wallboard  100 , as well as other thicknesses. It is understood that different thicknesses may be provided dependent on the thickness and shapes of the fastening/distributing layer. 
         [0037]    One method of manufacturing the wallboard  100  includes laminating a pre-formed plaster substrate  120  onto a fastening/distributing layer  110  by providing a layer of adhesive  115  on either the plaster substrate  120  or the fastening/distributing layer  110  and binding the two together. The paper layer  130  may be attached to the plaster substrate  120  via layer of adhesive  125  prior to or after the plaster substrate  120  is attached to the fastening/distributing layer  110 . 
         [0038]    Another method of manufacturing the wallboard  100  includes extruding slurry onto or against the fastening/distributing layer  110  and curing the slurry using known wallboard manufacturing techniques to form the plaster substrate  120  on or adhered to the fastening/distributing layer  110 . Binding agents may be applied to the fastening/distributing layer  110  to assist with bonding the plaster substrate  120  to the fastening/distributing layer  110 . Finally, the paper layer  130  may be affixed to the plaster substrate  120  by providing a layer of adhesive  125  on either the plaster substrate  120  or the paper layer  130 . 
         [0039]      FIG. 1B  shows an alternative arrangement where a second fastening/distributing layer  140  may be located between the plaster substrate  120  and the paper layer  130 . The second fastening/distributing layer  140  is similar to fastening/distributing layer  110  and may be provide in the same fashion as the fastening/distributing layer  110  so that the gypsum plaster layer is sandwiched between fastening/distributing layer  110  and the second fastening/distributing layer  140 . 
         [0040]    A second exemplary embodiment of a reinforced wallboard  200  is shown in  FIG. 2 . As shown in  FIG. 2 , the wallboard  200  includes a plaster substrate  210  surrounded by an upper paper layer  220  and a lower paper layer  222 . The plaster substrate  210  may be formed of plaster and includes an upper surface  212  and a lower surface  214 . A pair of tapered edges  216  may be formed in the upper surface  212 . 
         [0041]    One, two, or a plurality of fastening/distributing inserts  230  may be provided within the plaster substrate  210  between the upper surface  212  and lower surface  214 . They may be inserted longitudinally as shown in  FIG. 2  or perpendicular to the length of the board as will be described later. Preferably, each of the fastening/distributing inserts  230  would be formed of a metallic material, fiberglass material, synthetic material, composite material, or combinations thereof. In addition, each of the fastening/distributing inserts may be perforated so that the material of the plaster substrate  210  can penetrate through and bond to both sides of the fastening/distributing insert  230 . By providing the pair of inserts  230 , cost is reduced while the wallboard  200  is reinforced in ideal locations for attaching heavy fixtures. 
         [0042]    According to the second exemplary embodiment, a pair of inserts  230  may be extruded in the plaster substrate  210  between the upper surface  212  and lower surface  214  as seen in  FIGS. 2 and 2A . This configuration may be ideal where the wallboard will be installed horizontally. The pair of inserts  230  may be place approximately six inches in from the sides of the reinforced wallboard  200  and about halfway between the upper surface  212  and lower surface  214 . Each of the inserts  230  may be approximately 12 inches wide to allow for various sizes and spacing of cabinetry and/or other devices. It is understood that other sizes and locations may be provided. 
         [0043]    As seen in  FIG. 2 , the wallboard  200  may include a marker or other indicia  240  identifying the location of the fastening/distributing inserts  230  within the plaster gypsum plaster. These markers  240  assist installers in mounting cabinetry or other fixtures to the wallboard  200  appropriately. 
         [0044]    One method for manufacturing the wallboard  200  includes providing first and second continuous sheets of paper that are separated by a predetermined distance and a sheet of perforated material arranged between the two continuous sheets of paper. Slurry or other mixture is then extruded into the space between the two continuous sheets of paper such that the slurry is allowed to penetrate through the perforated material. Next, the slurry is cured and the resulting stock is cut into the appropriate sized wallboards. Finally, a marker may be applied to a surface of the paper indicating the location of the fastening/distributing insert material in the wallboard. Alternatively, the paper may already carry the marker thereon. 
         [0045]      FIGS. 2B-2D  show placement of fastening/distributing inserts  230  at various locations within the reinforced wallboard  200  different to that shown in  FIG. 2A .  FIGS. 2B and 2C  show the pair of inserts  230  located in either the upper surface  212  or lower surface  214 , respectively.  FIG. 2D  shows a pair of inserts  230  located in the upper surface  212  and a second pair of inserts  250  located in the lower surface  214 . The second pair of inserts  250  is similar to the pair of inserts  230  described above. 
         [0046]    The method of manufacturing the wallboards illustrated in  FIGS. 2B-2D  may be the same as described above. Alternatively, the fastening/distributing inserts may be attached by adhesive to the upper surface  212 , to the lower surface  214 , to the upper paper layer  220 , and/or to the lower paper layer  222 . 
         [0047]    While the above embodiment may be more appropriate for horizontal installation of the wallboard  200 , the present invention is not limited to horizontal orientations. In a third exemplary embodiment, as seen in  FIG. 3 , wallboard  300  may be more appropriate for vertical installation of the wallboard. In this exemplary embodiment, the wallboard  300  includes a plaster substrate  310  surrounded by an upper paper layer  320  and a lower paper layer  322 . The plaster substrate  310  may be formed of plaster and includes an upper surface  312  and a lower surface  314 . A pair of tapered edges  316  may be formed in the upper surface  312 . 
         [0048]    One, two, or a plurality of fastening/distributing inserts  330  may be provided within the plaster substrate  310  between the upper surface  312  and lower surface  314  and are oriented in the lateral direction of the wallboard. Preferably, each of the fastening/distributing inserts  330  would be formed of a metallic material, fiberglass material, synthetic material, composite material, or combinations thereof. In addition, each of the fastening/distributing inserts may be perforated so that the material of the plaster substrate  310  can penetrate through and bond to both sides of the fastening/distributing insert  330 . By providing the pair of inserts  330 , cost is reduced while the wallboard  300  is reinforced in ideal locations for attaching heavy fixtures. 
         [0049]    According to the third exemplary embodiment, a pair of inserts  330  may be extruded in the plaster substrate  310  between the upper surface  312  and lower surface  314  as seen in  FIGS. 3 and 3A . One of the pair of inserts  330  may be placed approximately ten inches in from the top of the reinforced wallboard  300  and about halfway between the upper surface  312  and lower surface  314  while the other is placed approximately thirty-five inches from the top. Each of the inserts  230  may be approximately 12 inches wide to allow for various sizes and spacing of cabinetry and/or other devices. While this configuration may be appropriate for forty inch tall cabinets, it is understood that different sized inserts and spacings may be used. 
         [0050]    As seen in  FIG. 3 , the wallboard  300  may include a marker or other indicia  340  identifying the location of the fastening/distributing inserts  330  within the plaster gypsum plaster. These markers  340  assist installers in mounting cabinetry or other fixtures to the wallboard  200  appropriately. 
         [0051]    One method for manufacturing the wallboard  300  includes placing the fastening/distributing inserts  330  by machine for embedding them in the plaster substrate  310  periodically simultaneously as the plaster substrate  310  is extruded between the upper paper layer  320  and bottom paper layer  322 . Placement can be timed to the speed of the extruding line to thereby control the position of the fastening/distributing inserts  330  in the wallboard. For example, coordinated with the speed of the extruded line in an standard 4×8 wallboard a ten inch fastening/distributing insert could be placed and embedded so that after cutting the wallboard  300 , it would be positioned ten inches from the top of the wallboard and likewise a second seven inch fastening/distributing insert could be placed and embedded at approximately forty inches from the top of the wallboard which in this example would make the fastening/distributing insert available to receive screw attachment at the top and bottom of standard sized wall cabinets. It is understood that many different sizes of inserts and spacing within the wallboard can be provided. 
         [0052]    Subsequent to the placement and imbedding of the fastening/distributing inserts  330  within the wallboard  330 , two additional steps may occur in the manufacturing process. One is the cutting of the wallboard sheets so as to cause appropriately positioning of the fastening/distributing insert(s) at the desired locations along the length of each sheet after the kiln hardened wallboard has been cut. The second is the stamping or printing of the paper surface of the kiln-hardened wallboard signaling to the wallboard installer the location of the fastening/distributing insert(s) imbedded within the wallboard sheet. 
         [0053]    Both the appropriate cutting of the board as well as markings signaling the location(s) of the fastening/distributing insert(s) can be accomplished in a number of ways such as the incorporation of metal detectors or other sensing devices which sense the location of the fastening/distributing insert and trigger the correct marking and cutting of the boards as they travel down the manufacturing line. In the instance where the fastening/distributing insert(s) are not of a material innately detectable, a metallic thread or strip can be woven into or printed on the non-detectable fastening/distributing insert(s) material to provide an electronically detectable ‘trigger’. 
         [0054]      FIGS. 3B-3D  show placement of fastening/distributing inserts  330  at various locations within the reinforced wallboard  300  different to that shown in  FIG. 3A .  FIGS. 3B and 3C  show the pair of inserts  330  located in either the upper surface  312  or lower surface  314 , respectively.  FIG. 3D  shows a pair of inserts  330  located in the upper surface  312  and a pair of inserts  350  located in the lower surface  314 . The pair of inserts  350  is similar to the pair of inserts  330  described above. 
         [0055]    The method of manufacturing the wallboards illustrated in  FIGS. 3B-3D  may be the same as described above. Alternatively, the fastening/distributing inserts may be attached by adhesive to the upper surface  312 , to the lower surface  314 , to the upper paper layer  320 , and/or to the lower paper layer  322 . 
         [0056]    According to a fourth exemplary embodiment of the present invention, as seen in  FIG. 4 , a wallboard  400  is provided. The wallboard  400  includes at least three tapered edges  416 , in this case all four edges are tapered. The wallboard may be reinforced as shown and described in the preceding embodiments. 
         [0057]    One method of manufacturing wallboard  400  would be to modify the one or both rollers utilized in extruding the plaster substrate and/or applying the paper layers to have a spool shape with one or more runners connecting each edge. With such a configuration, the edges of the spool would provide tapered edges extending in the direction of extrusion. The runner(s) would provide the tapered edge extending transverse to the direction of extrusion. By controlling the speed of extrusion and/or rotational speed of the spool shaped roller, the size of the wallboard can be controlled. 
         [0058]    The various embodiments of reinforced wallboard described above provide an advantage over existing wallboards by making it both easier to install cabinetry and fixtures, and substantially more securely. Pre-installation preparation of blocking strips, nailers, and/or other special fasteners can be avoided. In addition, the wallboards are strengthened such that they resist shear and moment arm loads created by the weight of cabinetry or other devices mounted thereto. As a result, the cabinetry or other devices are less likely to pull free from the wall. 
         [0059]    The invention thus being described, it will be obvious that the same may be varied in many ways. For example, there are many different processing techniques that can be used to assemble the various layers of the reinforced wallboards. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.