Interior wallboard and method of making same
AssigneeGP Gypsum Corporation
InventorsFrancis J. Koval, David J. Neal, Richard Silversides, Joseph Riccio JR., Charles J. Raymond, Felmer F. Cummins
Life of this patent
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Abstract
A gypsum wallboard may have a paper-covered first face with shaped regions formed along side portions near the wallboard edges, and a fibrous mat-covered second face. The fibrous mat material covering the second face extends around the wallboard edges and is overlapped by portions of the paper on the first face. The wallboard can be manufactured by depositing a gypsum slurry onto a moving web of the fibrous mat material, applying a web of the paper to the deposited gypsum slurry, and forming shaped regions in the side portions of the top surface.
Claims35
A gypsum wallboard comprising:
- a gypsum core having a planar first face, a planar second face, and at least two edges, the first face having shaped regions in side portions located on margins of the first face proximate to the edges;
- a paper facing material adhered to the first face;
- and
- a fibrous mat facing material adhered to and covering the second face, the edges and at least a portion of each shaped region.
A process for continuously manufacturing a gypsum wallboard, comprising:
- forming a gypsum slurry;
- continuously depositing the slurry onto a moving surface of a continuously fed bottom web of facing material, the bottom web having two lateral portions;
- forming a substantially planar horizontal upper surface on the deposited slurry, the upper surface having two edges separating the upper surface from a substantially parallel lower surface in contact with the bottom web;
- folding, as the slurry and bottom web advance, the lateral portions of the bottom web up and around the two edges so as to terminate on the upper surface;
- applying a continuously fed top web onto the upper surface;
- and
- forming shaped regions in marginal side portions of the upper surface.
A gypsum wallboard comprising:
- a gypsum core having a planar first face, a planar second face, and at least two edges, the first face having shaped regions formed in margins of the first face proximate to the edges;
- a first facing material adhered to the first face;
- and
- a continuous second facing material adhered to and covering the second face, the edges and a portion of the first face.
Dependencies are inferred from the claim text.