Patent Abstract:
A panel includes a core and a layer of adhesive on top of a core of the panel. A release liner covers the layer of adhesive. The release liner includes segments configured so that any of the segments can be selectively individually removed, exposing corresponding sections of the layer of adhesive.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     The present invention claims the benefit of U.S. Provisional Application Ser. No. 61/727,381 filed Nov. 16, 2012, which is hereby incorporated by reference as if it were set forth in its entirety. 
    
    
     BACKGROUND 
     The present invention relates to self-adhesive panels and an associated method. 
     Traditionally, drywall can be installed using a drywall panel, studs, and screws or nails. Studs are placed with the centers of the studs 16 or 24 inches apart (“on center”) on each wall requiring drywall installation. Drywall panels are installed with minimal joints and with the edges of each panel aligned with stud centers. Drywall panels are mounted onto corresponding studs and secured to the studs using nails or screws. 
     SUMMARY 
     A panel includes a core and a layer of adhesive on top of a core of the panel. A release liner covers the layer of adhesive. The release liner includes segments configured so that any of the segments can be selectively individually removed, exposing corresponding sections of the layer of adhesive. 
     An assembly includes studs spaced apart and a panel adhered to the studs. The panel includes a core and a layer of adhesive on top of the core. A release liner covers the layer of adhesive and includes segments configured, sized, and spaced so that any of the segments can be selectively individually removed, exposing corresponding sections of the layer of adhesive for adhering the panel horizontally or vertically onto the studs. 
     A method includes removing segments of a release liner of a panel to expose segments of adhesive on the panel. The method further includes aligning the panel studs such that the segments of adhesive are facing the studs and adhering the panel to the studs. 
     A method of manufacturing includes applying an adhesive to a panel, applying a release liner on top of the adhesive, and perforating the release liner to define removable segments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an embodiment of a drywall panel according to the present invention. 
         FIG. 2  is a front view of a first embodiment of a release liner of a drywall panel. 
         FIG. 3  is a front view of a second embodiment of a release liner of a drywall panel. 
         FIG. 4  is a front view of a drywall panel installed vertically on studs. 
         FIG. 5  is a front view of a drywall panel installed horizontally on studs. 
         FIG. 6  is an exploded side view of installation of a drywall panel using a two part adhesive. 
     
    
    
     DETAILED DESCRIPTION 
     In general, a panel of the present invention is typically made from a core, base, or body of gypsum or another material but can be made of other materials based on applications such as fireproofing and bathroom installation where moisture is a greater concern. For instance, the panel can be drywall, plasterboard, wallboard, sheetrock, gypsum board, plywood, DensGlass® fiberglass mat gypsum panels (available from Georgia-Pacific Gypsum LLC, Atlanta, Ga.), or other type of rigid panel. The drywall panel can be ½ inch thick or ⅝ inch thick, based on commercial or residential application. One or more sides of the drywall panel can be covered with paper (or other materials) like standard drywall panels. One side of the drywall panel includes a layer of adhesive on top of the paper (if any), the adhesive covered by a release liner, eliminating the need for coating the drywall panel with adhesive prior to installation. In a preferred embodiment, the release liner is segmented or perforated such that it can be removed in sections, exposing corresponding sections of adhesive underneath. 
     Adhesive layered on the drywall panel of the present invention can be contact cement, construction adhesive such as PL 200 (manufactured by Henkel of Westlake, Ohio), liquid glue, or any other suitable adhesive, glue, cement or building material. Adhesive used with the drywall panel of the present invention can be one part, where the only adhesive used is the layer on the drywall panel itself. In an alternative embodiment, a two part adhesive (or cement) can be used, with adhesive both on the drywall panel and on the installation location (e.g. on the studs) of the wall on which the drywall panel is installed. 
       FIG. 1  is a side view of one embodiment of drywall panel  10 . Drywall panel  10  is primarily made of gypsum board  12 . Gypsum board  12  is typically covered by a paper layer on both sides with gypsum in between the two paper layers. For simplicity, the paper layers are not specifically delineated. Gypsum board  12  is covered by a layer of adhesive  14 . Adhesive  14  is covered by release liner  16 . Release liner  16  of drywall panel  10  extends past adhesive  14  and gypsum board  12  for ease of installation. In one embodiment, release liner  16  extends past adhesive  14  and gypsum board  12  by a desired amount, such as ¼ of an inch, which provides a gripping surface  16 G that allows a person installing drywall panel  10  to pull on the extended portion of release liner  16  to remove release liner  16  and expose at least a portion of adhesive  14 . 
       FIG. 2  is a front view of a first embodiment of release liner  16  of drywall panel  10 . Release liner  16  includes tabs  18 ,  20 ,  22 ,  24 , and  26 . Tabs  18 ,  20 ,  22 ,  24 , and  26  are sized, spaced, and coded such that drywall panel  10  can be installed horizontally or vertically by selectively removing individual tabs to expose desired portions of adhesive  14 . Tabs  18 ,  20 , and  22  can each be 4 inches wide. In between tabs  18  and  20 , tabs  24  and  26  can each be 5 inches wide. In between tabs  20  and  22 , tabs  24  can each be 4 inches wide. Tabs  18  are generally removed for installation whether drywall panel  10  is installed horizontally or vertically, and regardless of stud spacing. Tabs  20  and tabs  18  are removed when drywall panel  10  is installed vertically onto a wall with studs that are  16  inches on center. Tab  22  and tabs  18  are removed when drywall panel  10  is installed vertically onto a wall with studs that are 24 inches on center. Remaining tabs can be left in place for installation. Tabs  24  and tabs  18  are removed when drywall panel  10  is installed horizontally onto a wall with studs that are either 16 inches or 24 inches on center. In an alternative embodiment, when drywall panel  10  is installed horizontally and vertically, if needed, tabs  18 ,  20 ,  22 ,  24 , and  26  can all be removed, exposing all of adhesive  14 . 
     Drywall panel  10  can be manufactured starting with a typical drywall panel, such as gypsum board  12  of  FIG. 1 . Gypsum board  12  is typically covered by a paper or polymer film layer on both sides with gypsum in between the two paper or polymer film layers. Adhesive  14  can then be pre-applied to gypsum board  12  on top of one of the paper or polymer film layers. Release liner  16  is then applied on top of adhesive  14 . Release liner  16  can be pre-perforated or pre-segmented prior and subsequently applied on top of adhesive  14 . In an alternative embodiment, release liner  16  can be perforated or segmented after release liner  16  is applied on top of adhesive  14 . The perforations in release liner  16  define tabs, such as tabs  18 ,  20 ,  22 ,  24 , and  26  as shown in  FIG. 2 . Each tab can be color-coded, signifying when it is appropriate to remove the tab during horizontal or vertical installation of drywall panel  10 . 
       FIG. 3  is a front view of a second embodiment of release liner  16 ′ of drywall panel  10 . Release liner  16 ′ includes tabs  28 ,  30 ,  32 ,  34 , and  36 . Tabs  28 ,  30 ,  32 ,  34 , and  36  are sized, spaced, and marked with symbols such that drywall panel  10  can be installed horizontally or vertically by selectively removing individual tabs to expose desired portions of adhesive  14 . Tabs  28 ,  30 , and  32  can each be 4 inches wide. In between tabs  28  and  30 , tabs  34  and  36  can each be 5 inches wide. In between tabs  30  and  32 , tabs  34  can each be 4 inches wide. The symbols marked on tabs  28 ,  30 ,  32 ,  34 , and  36  are for illustration purposes only. Tabs  28 ,  30 ,  32 ,  34 , and  36  can be marked with symbols, Arabic numerals corresponding to stud spacing dimensions (such as the Arabic numerals shown on tabs  30  and  32 ), and/or any suitable visual indicia or tactile indicia (such as Braille). 
     Tabs  28  are marked with triangles and are removed whether drywall panel  10  is installed horizontally or vertically. Tabs  30  are marked with circles and are removed in addition to tabs  28  when drywall panel  10  is installed vertically onto a wall with studs that are 16 inches on center. Tab  32  is marked with a star and is removed in addition to tabs  28  when drywall panel  10  is installed vertically onto a wall with studs that are 24 inches on center. Tabs  34  are marked with a rectangle and are removed when drywall panel  10  is installed horizontally onto a wall with studs that are either 16 inches or 24 inches on center. In an alternative embodiment, when drywall panel  10  is installed horizontally, tabs  28 ,  30 ,  32 ,  34 , and  36  can all be removed, exposing all of adhesive  14 . 
     Drywall should be installed with as few joints as possible, therefore depending on the shape and size of the wall, vertical or horizontal installation can be more appropriate. For vertical installation, the layout of the wall should be checked to determine the distance between the centers of studs, for example whether studs are 16 inches or 24 inches on center. For walls taller than 10 feet, horizontal bridging between studs should be installed to keep studs on center. Prior to installing drywall panel  10 , drywall panel  10  is measured to see if drywall panel  10  will line up with the center of a stud. If drywall panel  10  does not line up, drywall panel  10  is cut to line up with a center of the nearest stud. Once drywall panel  10  is aligned with the center of a stud, that stud is the layout stud. 
     After drywall panel  10  is properly measured, tabs  18  are removed regardless of stud spacing. If drywall panel  10  is cut such that one of tabs  18  is no longer on drywall panel  10 , remaining tab  18  and whichever tab ( 20 ,  22 ,  24 , or  26 ) is nearest the cut edge are removed. If a wall contains studs  38  that are 16 inches on center, tabs  20  and tabs  18  are removed, as shown in  FIG. 4 . If a wall contains studs  38  that are 24 inches on center, tab  22  and tab  18  are removed. Drywall panel  10  now contains exposed sections of adhesive  14  that line up in parallel with studs onto which drywall panel  10  is mounted. The exposed sections of adhesive  14  can be discontinuous, that is, separated by tabs that remain in contact with adhesive  14 . 
     Drywall panel  10  can be carried over to the wall and stood up at a distance (e.g. 1 to 2 inches or 3 to 4 inches) away from the wall. If drywall panel  10  is installed on a wall from left to right, the left edge of drywall panel  10  is the leading edge. If drywall panel  10  is installed from right to left, the right edge of drywall panel  10  is the leading edge. The leading edge of drywall panel  10  should be aligned on and in contact with the wall such that drywall panel  10  is snug to any adjacent wall, stud, or sheetrock. The rest of drywall panel  10  is then pressed against the wall with, in one embodiment, at least 45 pounds of pressure while ensuring that the outside edge of drywall panel  10  is in the center of the layout stud. Once one drywall panel  10  is installed, additional drywall panels  10  are installed along the length of the wall in the same manner until the wall is adequately covered. Fasteners, such as nails or screws, can optionally be attached to further secure drywall panel  10 ; however, such fasteners are made unnecessary by adhesive  14 . 
       FIG. 4  is a front view of an embodiment of drywall panel  10  having release liner  16 , with drywall panel  10  shown broken away to reveal studs  38 . Drywall panel  10  is installed vertically on studs  38 . Studs  38  are spaced 16 inches on center. Tabs  18  and  20  have been removed from drywall panel  10  to reveal adhesive  14 . Drywall panel  10  is aligned with the center of layout stud  38 L such that adhesive  14  binds drywall panel  10  to studs  38 , with adhesive  14  aligned in parallel with studs  38 . Adhesive  14  may be in continuous contact with studs  38  along substantially an entire length of drywall panel  10 . 
     For horizontal installation from the ground up, the highest point of the floor in front of the wall is found using a laser level taking measurements every ten feet. The stud closest to the highest point of the floor should be marked at 48.5 inches. That stud is then used as a reference point to measure off a level laser line and mark the rest of the studs. This ensures that when drywall panel  10  is installed, drywall panel  10  stays on center of the studs. Once the rest of the studs are marked, a level line is drawn across all of the studs, such as using a chalk line. A guide bar can be installed along the top of the line to more easily align drywall panel  10  on studs. After the wall is properly marked, drywall panel  10  is measured to see if drywall panel  10  will line up with the center of a stud. If drywall panel  10  does not line up, drywall panel  10  is cut to line up with the center of a stud. Once drywall panel  10  is aligned with the center of a stud, that stud is the layout stud. 
     After drywall panel  10  is properly measured, tabs  18  are removed. If drywall panel  10  is cut such that one of tabs  18  is no longer on drywall panel  10 , remaining tab  18  and whichever tab ( 20 ,  22 ,  24 , or  26 ) is nearest the cut edge are removed. Tabs  24  are also removed. The exposed sections of adhesive  14  can be discontinuous, that is, separated by tabs that remain in contact with adhesive  14 . In an alternative embodiment (not shown), all tabs ( 18 ,  20 ,  22 ,  24 , and  26 ) are removed, exposing all of adhesive  14 . 
     Once the tabs are removed and the desired sections of adhesive  14  are exposed, drywall panel  10  can be carried over to the wall and stood up at a distance (e.g. 1 to 2 inches or 3 to 4 inches) away from the wall. A person should stand on each end of drywall panel  10  and lift drywall panel  10  such that the top edge of drywall panel  10  leans toward the wall. Drywall panel  10  is then aligned with the chalk line or guide bar and should be snug to any adjacent wall, stud, or sheetrock. When drywall panel  10  is properly aligned, the top edge of drywall panel  10  is pressed into the studs. The rest of drywall panel  10  is subsequently pressed into the wall, applying, for example, greater than or equal to 45 pounds of pressure from the top edge down, ensuring that the vertical edge of drywall panel  10  is aligned on the center of the layout stud. Once one drywall panel  10  is installed, additional drywall panels  10  are installed along the length of the wall adjacent to the first drywall panel  10 . 
     After the bottom row of drywall panels  10  is installed, a second row of drywall panels  10  is installed above the bottom row. In order to stagger vertical joints, the first drywall panel  10  installed in the second row should be cut such that the first drywall panel  10  aligns with the center of the stud that is closest to the center of the first drywall panel  10  installed in the bottom row; this is the layout stud. The desired tabs on the first drywall panel  10  in the second row are unzipped (i.e., removed) and drywall panel  10  is installed aligning the bottom edge with the top edge of the panel underneath drywall panel  10  and ensuring that drywall panel  10  is snug to any adjacent wall, stud, or sheetrock. Drywall panel  10  in the second row is then installed from the bottom up, pressing the bottom edge into the wall and working up drywall panel  10 , applying, for example, greater than or equal to 45 pounds of pressure and ensuring that the vertical edge is aligned on the center of the layout stud. Additional drywall panels  10  are installed along the length of the wall adjacent to the first drywall panel  10  in the second row. If necessary, subsequent rows of drywall panels  10  are installed above the second row until the wall is covered in drywall panels  10  as desired. 
     Drywall panel  10  can also be horizontally installed on exterior framing. 48 inch increments are measured from the roof edge down at both ends of the building. A reference line is made using a chalk line, and a guide bar should be installed on the bottom side of the chalk line. Drywall panel  10  is measured to see if drywall panel  10  will line up with the center of a stud. If drywall panel  10  does not line up, drywall panel  10  is cut to line up with the center of the nearest stud. Once drywall panel  10  is aligned with the center of a stud, that stud is the layout stud. After drywall panel  10  is properly measured, tabs  18  are removed. If drywall panel  10  is cut such that one of tabs  18  is no longer on drywall panel  10 , remaining tab  18  and whichever tab nearest the cut edge are removed. Tabs  24  are also removed. In an alternative embodiment, all tabs are removed, exposing all of adhesive  14 . 
     After the tabs are removed and the desired sections of adhesive  14  are exposed, two people can each lift one end of drywall panel  10  while leaning the top edge of drywall panel  10  away from the wall slightly. The bottom edge of drywall panel  10  should be aligned on the guide bar while ensuring that drywall panel  10  is snug to any adjacent wall, stud, or sheetrock. The bottom edge of drywall panel  10  is then pressed on to the wall, and the rest of drywall panel  10  is subsequently pressed into the wall from the bottom up and with, for example, greater than or equal to 45 pounds of pressure. To ensure maximum holding strength, fasteners, such as nails or screws can be installed around the perimeter of drywall panel  10 . Additional drywall panels  10  are installed along the length of the wall adjacent to the first drywall panel  10 . Subsequent rows of drywall panels  10  are installed until the wall is covered in drywall panels  10  as desired. 
       FIG. 5  is a front view of drywall panel  10  having release liner  16 , with drywall panel  10  shown broken away to reveal studs  38 . Drywall panel  10  is installed horizontally on studs  38 . Tabs  18  and  24  have been removed from drywall panel  10  to reveal adhesive  14 . Drywall panel  10  is aligned with the center of layout stud  38 L. Adhesive  14  binds drywall panel  10  to studs  38 . Adhesive  14  is substantially perpendicular to studs  38 . 
       FIG. 6  is an exploded side view of installation of drywall panel  10  using a two part adhesive such as contact cement, one part of which is on drywall panel  10  and the other part of which is on stud  38 . Drywall panel  10  includes gypsum board  12  and adhesive  14  from which the appropriate portion of release liner  16  has been removed. The paper of gypsum board  12  is not shown for simplicity. Stud  38  includes two-by-four  40  and adhesive  42 , which is applied to stud  38  prior to installation of drywall panel  10 . Drywall panel  10  is mounted onto stud  38  such that adhesive  14  and adhesive  42  are in contact. Subsequently, at least 45 pounds of pressure is applied to drywall panel  10  such that adhesive  14  and adhesive  42  are sufficiently bonded, securing drywall panel  10  to stud  38 . 
     While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, features or steps described with respect to one embodiment can be readily utilized in conjunction with another embodiment, as desired for particular applications.

Technology Classification (CPC): 1