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US 2024/0278458 A1Published application
Dry wall manufacturing method and apparatus
OwnerRoger A. Mayinventor
Life of this patent
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OwnerRoger A. Mayinventor
Estimating the term…
As an elongated laminate of paper faced gypsum being produced into drywall boards is advanced along a conveyor to a point at which the gypsum is dried to a water content such that the laminate can be embossed by an embossing roller which can be pressed into the laminate for a sufficient time and depth to form a embossed channel which is about the lateral width of a piece of drywall tape which would be used to tape the ends of two separate abutting drywall pieces when being hung and taped, and a depth sufficient to accommodate a strip of drywall tape within said embossed channel. The embossing step is done on the underside of said advancing laminate at a distance from a shear used for shearing the laminate into pieces of drywall, that the center line of the embossed channel bottom wall formed by said embossing roller is located the distance the advancing laminate has to travel to shear the individual drywall pieces being produced to a desired length, or a multiple thereof.
A method of producing drywall board having a face layer which will be exposed when said drywall board is installed, and a back layer on the opposite side of said drywall board, comprising:
An apparatus used in a drywall manufacturing line for producing drywall board having a face layer which will be exposed when said drywall board is installed, and a back layer on the opposite side of said drywall board, comprising:
The apparatus of claim 12 in which said lift acts to lift said embossing roller into said surface of said advancing laminate for sufficient time to form said lateral embossed channel to a width which is about the width of a piece of drywall tape which would be used to tape the ends of two separate abutting drywall pieces together when being hung and taped, and to a depth sufficient to accommodate a strip of drywall tape between said embossed channel walls;
The apparatus of claim 13 in which said lift is designed to press said embossing roller into said underside surface of said laminate for sufficient time to form said embossed channel to a lateral width just sufficiently wider than the drywall tape intended for use that said drywall tape can be readily positioned in said embossed channel without requiring time consuming precision, and said embossing step is performed to a depth in said surface which is sufficient to accommodate a strip of drywall tape and at least one layer of drywall mud below it and another layer above it.
The apparatus of claim 12 in which said embossing station is located at a point along the length of said advancing laminate where the moisture content of the gypsum core is between about 10% and about 25%.
The apparatus of claim 12 in which said embossing station includes a backing roller extending laterally all the way across said back faced side of said laminate directly opposite said embossing roller, whereby said backing roller resists deformation of said laminate at said back faced side.
Dependencies are inferred from the claim text.