AU2016201276B1 - Improved plasterboard and fixing method - Google Patents

Description

2016201276 01 Mar 2016 1 PATENTS ACT 1990 Section 29 Standard Patent

Applicant: Spence Hartman Address: 37 Kokoda Street Idalia Queensland 4811 Australia Inventor: Spence Hartman Address: 37 Kokoda Street Idalia Queensland 4811 Australia

Title of Invention:

IMPROVED PLASTERBOARD AND FIXING METHOD

The applicant applies for the grant of a patent for the invention described in the accompanying complete patent specification:

The following is a full description of the invention including the best method of performing the invention, known to us: specPA2022615amalMarl6 2 2016201276 29 Feb 2016

IMPROVED PLASTERBOARD AND FIXING METHOD

[0001] The present invention relates to an improved plasterboard. The present invention also relates to a fixing method of an improved plasterboard.

[0002] Plasterboard is used around the world, fitted to stud walls or battens to form walls and ceilings within rooms. Sold under various trade marks, all conventional plasterboards are formed of a sheet of gypsum plaster between two sheets of strong paper. Use of plasterboard is an economic and relatively simple way to create the internal walls and ceiling of a structure. After installation to the structure of a room the board is plastered, other room features such as cornice pieces or skirting boards added, and paint applied.

[0003] Millions of plasterboards are used around the world and all suffer the same problems, in particular a phenomenon known as “screw-popping”. The “screw popping”, is where the screws used to secure the board are not properly installed and are installed too deeply. A space is left between the top of the installed screw and the surface of the plasterboard into which plaster fills. A circular piece of plaster forms and as pressure acts on the plug of plaster it is forced up and away from the screw. The plug “pops” out over time, proud of the plaster, generally manifesting in a line of dimples on the plaster surface, easily visible on the finished surface.

[0004] During installation of the plasterboards, it is important that the screws are installed sufficiently deeply to firmly install the board to the structure. It would not be any use to have the plasterboard hanging loose or the screws sitting proud of the plasterboard surface. There is a tendency, therefore, for the person installing the screws to screw these in too deeply, creating pressure at the screw attachment point and creating an air gap between the surface of the plaster and the top of the screw. After the plasterboards have been screwed in, plaster is applied over the top to give a smooth finish and specPA2022615 3 2016201276 29 Feb 2016 to fill in the gap between the surface and the screw. It is this tiny circle of plaster that ultimately pops out, creating unsightly dimples on the surface.

[0005] Use of power tools to apply fixings is well known, and for use to screw or nail plasterboards to a ceiling. Use of power tools makes it particularly easy to apply the fixings but these may be applied too deeply.

[0006] The inventor has worked in the industry for many years and has experienced all the problems of the current form of plasterboard and the difficulties these problems cause. Over lengthy experimentation and development the inventor has come up with a surprisingly effective new plasterboard that can be installed as conventional plasterboards, but avoids the problems of the prior art of “screw popping” and screws not being installed properly. Grooves or channels are included into which the fixings can be used, including new fixings, which work together with the plasterboard to create a strong and effective fixing system.

[0007] The problems of the prior art have been considered by people in the trade for many, many years, trying to find a better way. However, the plasterboards, fixings and method of installation has remained the same in all that time. There has been no innovation, change or improvement in the area for years- until now. The inventor has solved a problem in a unique way, which once known about is likely to replace all present plasterboards and methods of use, and become the industry standard.

[0008] The invention is applicable to any form of plasterboard for use in domestic, commercial, and industrial applications or in any situation where it may be desired to install plasterboard. Other types of boards used in construction may also incorporate the novel and inventive system of the inventor, in the same way. The following description gives an illustrative example of use for plasterboard for internal rooms, and with the example of installation of a ceiling. It is not intended that the application of the invention specPA2022615 4 2016201276 29 Feb 2016 be limited in any way to use of plasterboard for internal rooms, or a ceiling rather than walls or any other surface. The invention may be readily used in many different applications and is not limited to those described.

[0009] For clarity, any prior art referred to herein, does not constitute an admission that the prior art forms part of the common general knowledge, in Australia or elsewhere.

[0010] It is an object of the present invention to provide an improved plasterboard that at least ameliorates one or more of the aforementioned problems of the prior art.

[0011] Accordingly, the present invention provides an improved plasterboard for installation on a structure: a substantially planar body; and one or more receiving portions in the substantially planar body adapted to receive one or more fixings therein, wherein, the substantially planar body may receive one or more fixings in the one or more receiving portions to install the plasterboard to the structure, for a substantially improved installation.

[0012] Preferably, the improved plasterboard includes a core formed of a layer of gyprock or other plaster which is covered in a paper covering. The core may take any suitable form. The core may include materials other than plaster. The paper preferably substantially covers both surfaces of the plasterboard. Other covering materials such as cloth or a man-made material may be used to cover the core instead of paper. specPA2022615 5 2016201276 29 Feb 2016 [0013] Preferably, the improved plasterboard is substantially rectangular in shape. Preferably, the plasterboard is similar in overall size and shape to a conventional plasterboard. The plasterboard may take any suitable shape or form. The plasterboard may be any suitable board where it is desired to install the board on a structure and it may be beneficial to include recessed portions to receive the fixings for installation. In this form of the invention the core may be made of any suitable material, not limited to plaster.

[0014] It is envisaged that multiple plasterboards will be used to create a surface. The plasterboards, pieces or sections of plasterboard may be any size of shape. However, the invention is equally applicable to where a single board is installed. Further, numerous plasterboards may be installed together and fall within the scope of the invention. Preferably, a large surface area is created by using repeating plasterboards according to the invention. The repeating plasterboards may create a regular repeating sequence of receiving portions.

[0015] Installation may take any suitable form. Installation may be through permanent or removable fixings. The installation may be in a domestic home, commercial or retail building or other building. The installation may be part of the construction of a room. The installation may be part of a renovation.

[0016] Any suitable fixings may be used. The fixings may be screws. The fixings may be nails. A combination of suitable fixings may be used to install the plasterboard. Preferably, a plurality of screws are used to install the plasterboard to the structure. Preferably, a plurality of fixings are used to install a plurality of plasterboards to create a large surface.

[0017] Accordingly, the present invention also provides an improved fixing for use with a surface, the improved fixing including: a head; a shaft, connected to the head; and specPA2022615 6 2016201276 29 Feb 2016 a plurality of recesses in the head, able to receive material therein, wherein the shaft of the improved fixing may be used to penetrate a surface and the recesses are adapted to receive material therein, and the material adhere thereto.

[0018] Preferably, the head includes an upper surface and recesses are formed in the upper surface of the head. The recesses may alternatively be formed any suitable part of the head of the fixing.

[0019] Preferably, the improved fixing is made of a strong material. The strong material may be metal. Preferably, the improved fixing is made of a steel. Preferably, the steel is high carbon steel with a zinc coating. Any suitable material may be used including natural materials, plastics or composite materials.

[0020] The fixing may be a fixing suitable to join materials together. The fixing may be suitable to be installed on a surface, used to hang objects. The fixing may be used for any suitable purpose. Preferably, the improved fixing is one suitable to install plasterboards or similar.

[0021] The surface may be any suitable surface. The surface may be a wall, ceiling or floor. The surface may be a stud wall. The surface may be the surface of an object.

[0022] The head may have any suitable shape. Preferably, the head is a wide head. Preferably, the head has a width of at least 10 millimetres. Preferably, the head has a width of at least 12 millimetres. The head may be very wide, over 20 millimetres, in another form of the invention.

[0023] Preferably, the head has a substantially flat or level upper surface. The surface may be textured, include holes, recesses or depressions or be specPA2022615 7 2016201276 29 Feb 2016 shaped but in overall appearance is flat so as to be able to lie flush with a surface when installed. Preferably, the head is adapted so once installed it can lie substantially flush with the surface in which it is installed. Preferably, the upper surface is substantially flat. The upper surface may be flat and smooth. The upper surface may include a textured surface. The upper surface may be a knurled surface.

[0024] Preferably, the head includes means for engagement with a tool. The engagement means may be any suitable engagement means. The means may be a slot. The means may be a cross-threaded slot. The tools used may be a screwdriver. A manual or power driven screw driver may be used. Any suitable tool may be used to install the improved fittings.

[0025] The shaft may take any suitable form. Preferably, the shaft is a threaded shaft. Alternatively, the threads may be omitted and the fixing may be in the form of a tack or nail. Preferably, a pointed end is included. Preferably, the pointed end is a self-tapping end. The improved fixing may be similar to a self-tapping screw, excepting the form of the head.

[0026] The shaft may be connected to the head in any suitable manner. The shaft and head may be joined together. Preferably, the head and the shaft are made integrally during manufacture.

[0027] The plurality of recesses may be any suitable number of recesses. The number of recesses may be chosen from the group: 4; 8; or 12. In a different form of the invention the plurality of recesses may run together. For example, to form a ring shape around the centre. Most preferably, eight recesses are included.

[0028] The recesses may be arranged in any suitable manner on the head of the fixing. The recesses may be arranged in a ring formation. The recesses specPA2022615 8 2016201276 29 Feb 2016 may be arranged in a square or other shape. Any suitable arrangement of recesses may be used.

[0029] Preferably, in one form of the invention, the recesses are depression. The recesses are adapted to receive material therein and adhere thereto. Preferably, depressions are included in the upper surface of the head. The depressions may be positioned at any suitable position on the head of the fixing.

[0030] Recesses may be included at any suitable position on the improved fixing. Recesses may be included at any suitable position on the head of the fixing. Recesses may be included on the under surface of the head. The under surface of the head may be tapered to improve adhesion to material. The tapered part may itself include recesses to assist in adhesion of material thereto.

[0031] The recesses may extend part way through the head. The recesses may extend most of the way through the head. On one form of the invention the recesses may extend all the way through the head. The recesses may be holes in the head of the fixing. Preferably, the holes enable communication between the upper surface and an under surface of the head of the fixing. Preferably, the holes allow the material therethrough. The material may be applied over the upper surface and pass through the holes to the under surface. The material under the head may assist to fix the fixing to the underlying surface. Alternatively, adhesive on the underlying surface may adhere to the under surface when used in other manners.

[0032] The recesses may be spaces between dimples or other shaped parts.

[0033] In one form of the invention the recesses form a textured surface of the head. The textured surface may be a knurled surface. In this form of the invention the knurled surface may be any suitable knurled surface. The specPA2022615 9 2016201276 29 Feb 2016 recesses forming the knurled surface may be configured to be very small or larger in other forms of the invention. The knurled surface may be formed of a repeating pattern of recesses. The knurled surface may have an irregular pattern of recesses.

[0034] Preferably, the plaster is applied over the surface of the installed fixing. The material may be any suitable material. Where the fixings are used to install plasterboards the material may be plaster to provide a substantially smooth finish to the surface. Preferably, plaster is smoothed over the improved fixing and adheres thereto to provide a substantially smooth surface. Preferably, plaster can strongly adhere to the head of the improved fitting.

[0035] Preferably, the plaster is applied and is received in the recesses, dimples, holes or knurled surface of the fixing. Preferably, the plaster engages strongly with the surface of the head of the fixing. It is envisaged that use of the improved fitting will be a significant improvement, as the plaster will contribute positively to the installation and keep the installation strong. This compares to use of conventional screws the surface of which does not assist to grab the plaster or hold on to the plaster after installation, and in fact may repel the plaster as a smooth surface.

[0036] Preferably, use of the improved fixing resists “screw popping”. Preferably, plaster is used to fill over and around the fixing to present a smooth surface.

[0037] Preferably, the plaster is applied to the channel of the improved plasterboard over the improved fixing avoiding the creating of a plug of plaster which may be prone to “screw popping”. Preferably, when the fixing is properly installed and plaster applied a smooth surface is created which resists “screw popping”, over time. specPA2022615 10 2016201276 29 Feb 2016 [0038] Preferably, the improved fixing in any of its forms and variants is used with the improved plasterboard of the invention.

[0039] The invention also relates to a method of use of an improved fixing including a head, shaft and recesses for receipt of material, the method including the following steps: a) screwing the improved fixing into a surface so that the head is substantially flush with the surface; b) applying the material over head of the improved fixing; c) adhering material in the recesses, wherein a substantially smooth finish may be achieved.

[0040] Preferably, the fixing is installed so that the top of the head is slightly below the surface. Preferably, a plurality of improved fixings are used to install an item. The item may be plasterboards. Preferably, the material applied is plaster.

[0041] The invention also provides a method of installation of fixings with a plasterboard.

[0042] The structure to which the plasterboard may be attached may be any suitable structure, such as part of home, office or shop. Preferably, the structure is formed of battens or stud wall and the plasterboard is fixed to the battens or stud wall during installation. The structure may be a part of a stud wall. The structure may be a stud wall, frame of battens, trusses or crossbeams to which panels of plasterboard can be attached to create a wall or ceiling. Preferably, the structure is in the form of battens to which the plasterboard is to be attached to create a surface. Preferably, the structure is a stud wall. Preferably, the structure is formed of battens and the plasterboard is fixed to the battens during installation. Preferably, the battens specPA2022615 11 2016201276 29 Feb 2016 form a regular structure to which plasterboard can be attached to create a surface. In other forms of the invention the plasterboard could be attached to any structure. The plasterboard may be attached to a flat surface, in another form of the invention.

[0043] Preferably, the structure includes attachment points to which the plasterboards may be mounted. Preferably, the structure includes attachment points and the plasterboard is mounted by attachment through use of fixings to the attachment points of the structure. Preferably, the attachment points of the structure may take any suitable form. The attachment points may simply be the point where the fixing contacts or crosses the structure. Preferably, the attachment points are on battens or a stud wall to which a plasterboard can be attached to create a surface. The battens or stud wall may be attachment points or may include one or more attachment points along their length. The structure may be a stud wall of a known kind. The structure may include one or more cross beams and the attachment points are any points of suitable contact on these cross-beams. In other forms of the invention the attachment points may be part of a flat surface to which a plasterboard may be attached.

[0044] The substantially planar body may take any form. Preferably the substantially planar body is a rectangular shape. Preferably, the substantially planar body is formed of a sheet of plaster. Preferably, the sheet of plaster includes a surface covering. There may be a plurality of parts which make up the substantially planar body in use. For example, a series of longitudinal parts may be included, or other formation of parts to create the whole. The substantially planar body may include form or structure to create features of a room in some forms of the invention. Preferably, the substantially planar body is similar in form to a standard plasterboard sheet, however including the inventive features creating a significantly improved plasterboard. specPA2022615 12 2016201276 29 Feb 2016 [0045] There may be any suitable number of receiving portions. The receiving portions may take any suitable form to receive fixings during installation of the plasterboard. Most preferably, the receiving portions are adapted to be of a suitable depth to contain the heads of the fixings once installed and not interfere with the surface of the plasterboard once installed.

[0046] Preferably, there are a plurality of receiving portions. Any suitable number of receiving portions may be used. Preferably, at least two receiving portions are included. Preferably, at least two receiving portions are included, spaced across the body. The spacing may be even. Preferably, one or more edge may form a receiving portion. Preferably, a pair of opposed edges are adapted to form a receiving portion whereby the edges of different boards may correspond to form a common receiving portion. Preferably, the pair of long edges are adapted to form receiving portions. Most preferably, there are at least two receiving portions in the substantially planar body and the edges also form receiving portions.

[0047] The receiving portions are a significant advance on a simple flat board being attached to create a wall or ceiling. The receiving portions are particularly useful to assist in aligned, accurate installation to the attachment points, to prevent the need to use additional fixings. Further the risk of cracking or other damage to the panel is reduced by use of the receiving portions, particularly noting the reinforcement described below. Overall, the receiving portions create a very useful improvement on the art.

[0048] Preferably, the receiving portions shape and position correspond to the position of potential underlying attachment points whereby in use the plasterboard may be readily installed on the structure through applying fixings through the receiving points into the attachment points of the structure. Preferably, the receiving portions cross the attachment points of the structure. Preferably, the receiving portions are adapted to overlie the specPA2022615 13 2016201276 29 Feb 2016 positions of the attachment points of the structure in use. For example, by crossing and attaching to a batten or stud wall.

[0049] Where the attachment points are along a batten the receiving portions may generally correspond in dimensions to the batten and cross at points for attachment.

[0050] Preferably, the receiving portions include one or more channels. Preferably, in one form of the invention one or more receiving portions are included which are channels. Preferably, the receiving portions shape and position correspond to the position of potential underlying attachment points whereby in use the plasterboard may be readily installed on the structure through applying fixings through the receiving points into the attachment points of the structure.

[0051] The channel may include a substantially flat base with sloping sides from the plasterboard surface. Preferably, the channel is narrow. Preferably, the channel is a suitable size to comfortably receive the fixings. Preferably, the channel can receive fixings along its length to attach the plasterboard to the underlying structure. Preferably, the channel is readily filled with plaster to cover the fixings after installation. The dimensions and particular configuration of the channel may be varied. Preferably, the channel is approximately 5 millimetres in depth. Other suitable depths may be used to suit different sizes of fixings and fixing heads.

[0052] Preferably, the receiving portion is adapted to be of a dimension suitable to receive the head of a fixing such as a nail or screw such that on installation the head of the fixing does not substantially protrude above the surface of the receiving portion. The height of the receiving portion may be any suitable height. The height of the receiving portion is most preferably configured to substantially contain the head of a fixing when installed to a correct depth. Preferably, once installed the head of the fixing does not specPA2022615 14 2016201276 29 Feb 2016 substantially protrude out of the receiving portion once the fixing is installed. Where the receiving portion is a channel preferably, the head of the fixing does not protrude above the upper surface of the channel once installed.

[0053] Most preferably, the dimensions of the channel facilitate the installation of a the improved plasterboard to the underlying structure at a suitable depth for firm installation of the board but such that the head of the fixing is fully received within the channel, whereby on apply plaster to finish the installation a smooth surface can be achieved and “screw popping” is substantially avoided. Overall, the new improved board is a significant improvement as it will assist the person installing the board to install it in the best manner and to produce the most professional finish possible in the short and long term. The invention is likely to be widely adopted through the industry as these inventions become known to the public.

[0054] The channel may be of variable height and or width in some forms of the invention. Preferably, the channel corresponds to some extent to the underlying structure to which the plasterboard is to be attached, either at cross-points or along the length depending on the nature of the installation. Preferably, a pair of channels is included running substantially the length of the body. Fixings may be used along the channels to attach to the underlying structure at any suitable point. There may be structure crossing at points along the channel and the fixings may be applied at these points. The channels may, in other forms of the invention may be positioned in any suitable form. In one preferred form of the invention there are a pair of channels spaced approximately 400 millimetres from the edge of the body. Any number or channels or pairs of channels may be formed in the plasterboard body.

[0055] The receiving portions may take any suitable shape in cross section. There may be a plurality of receiving portions along the length of the body. One or more rows of the plurality of receiving portions may be included. Most specPA2022615 15 2016201276 29 Feb 2016 preferably, channels form the receiving portions to facilitate alignment with underlying attachment points of the structure and enable fixings to be applied at any suitable position along the length of the channel to install the panel to the structure.

[0056] The edge of the plasterboard may also include receiving portions in a preferred form of the invention. The edges may form a channel in one form of the invention. The edges of the board may include a recessed portion suitable for receipt of fixings. Preferably, a plurality of boards are used, each including channels and edges which when abutted form channels so that a repeating series of channels is created across the whole surface. Therefore the edges of different plasterboards can abut to form channels at either end. In this way a repeating series of channels is made, at each abutting edge and two running along the panel, giving suitable points to apply fixings and fix the panel to the structure. Preferably, fixings installed in the recessed portions substantially fit within the recess whereby the heads of the fixing do not protrude. Preferably, the fixings when installed properly lie within the channel and do not interfere with the surface of the panel.

[0057] Preferably, the receiving portions are adapted to facilitate the installation of fixings to the correct depth. The channels may be adapted to be of a depth to receive the fixings to be suitable installed on the structure. The edges may be configured to be of a depth suitable to receive fixings installed to a suitable depth whereby the plasterboard is installed on the structure.

[0058] Preferably, reinforcement is included at any suitable part of the plasterboard. Preferably, reinforcement is included in the plasterboard at points where fixings may be applied. Preferably, reinforcement is included in the receiving portions to substantially act against damage to the plasterboard during installation by application of fixings. Most preferably, the reinforcement resists cracking of the plasterboard. The reinforcement may be fibreglass. specPA2022615 16 2016201276 29 Feb 2016

Fibreglass sheet may be included around at or around the receiving portions to assist to resist against damage to the plasterboard during installation. Any suitable reinforcement or strengthening may be used to assist to resist cracking or damage to the panels at the points of attachment.

[0059] Preferably, the plasterboard is adapted to receive the fixings whereby the fixings lie flush within the receiving portions when installed. Most preferably, use of the invention makes installation easier and less prone to damage to the plasterboard. Most preferably, the design of the plasterboard facilitates proper installation of the plasterboard in an attractive manner.

[0060] Accordingly, the invention also provides a method of installing a plasterboard, the plasterboard including a substantially planar body with one or more receiving portions adapted to receive fixings to attach the plaster board to a structure at attachment points, the method including the following steps :- a) positioning the board at a suitable position on the structure for installation; b) aligning the receiving portions with the attachment points of the structure; c) attaching the board to the attachment points through use of fixings through the receiving portions, whereby the plasterboard is attached to the structure and the risk of damage to the plasterboard during installation is significantly reduced.

[0061] Preferably, the receiving portions are adapted to receive the heads of the fixings so that on installation to a suitable depth the heads of the fixings do not substantially protrude above the surface of the body. specPA2022615 17 2016201276 29 Feb 2016 [0062] The plasterboard may be attached at cross-points, along the length or to a flat structure, depending on application. Where the improved plasterboards are attached to a stud wall or batten arrangement points preferably, the plasterboard is attached to a stud wall structure and the attachment points are battens and the receiving portions correspond to the battens so that installation of the plasterboard can be achieved by application of fixings through the receiving points into the attachment points.

[0063] The plasterboard of the method may be the plasterboard of the invention, in any of its forms or variations, as described above. Preferably, the fixing used is the inventive fixing described above in any of its forms or variants.

[0064] The invention will now be described in connection with a non-limiting preferred embodiment with reference to the accompanying drawings, in which: [0065] Figure 1 is a side view from above of a plasterboard according to a preferred embodiment of the invention, before installation; [0066] Figure 2 is a detailed view of part of the plasterboard of Figure 1, illustrating the receiving part; [0067] Figure 3 is a perspective view of an improved fixing or screw for use with the improved plasterboard; [0068] Figure 4 is a front view of the improved fixing of Figure 3; [0069] Figure 5 is a plan view from above of the improved fixing of Figures 3 and 4, illustrating the head. specPA2022615 18 2016201276 29 Feb 2016 [0070] Referring to Figures 1 to 2, a preferred embodiment of the invention will be described, where improved plasterboard 1, has rectangular body 10. As illustrated body 10 comprises a central planar sheet of gyprock plaster with a paper covering to both sides, both conventional features of a plasterboard sheet. Other materials or combinations of materials could also be used, and other covering materials. Body 10 is similar to conventional plasterboard sheets in dimensions and general form, excepting for the inventive features described in detail below.

[0071] Body 10, as illustrated, has similar dimensions to standard plasterboard being 10 millimetres in thickness, with dimensions of 6 metres by 1.2 metres. Throughout the description the application of the board for a ceiling is described as a useful example. Clearly, other sizes of boards, and for use on walls or other purposes is also applicable for the invention, not limited to standard plasterboard size or dimension. However, it is useful to supply plasterboard 1, having body 10 similar to standard plasterboards. In this way the plasterboards of the invention can be substituted for standard plasterboards to minimise disruption, but with the improved installation process, as described further below.

[0072] Rectangular body 10 has first edge 12, having recessed part 14, and second edge 16, with recessed part 18. Edges 12 and 16 define the long edges of rectangular plasterboard body 10, the short edges are not labelled for convenience of illustration. In other forms of the invention the short edges could also include a recessed part. Similarly, the recessed parts may be inset slightly in a channel, in another form of the invention, on either the long or short sides of body 10. Recessed parts 14 and 18 are in the form of a channel that runs the length of long edges 12 and 16, open along the outermost edges. Recessed parts 14 and 18 are approximately 25 millimetres across, as is suitable to correspond to suitable attachment points of the underlying wall or ceiling structure to which plasterboard 1 is to be attached. specPA2022615 19 2016201276 29 Feb 2016 [0073] Centre 20 of body 10 is defined between channel area 22 and channel area 24, each surrounding channel 26, and 28 respectively. Centre 20, is the central portion of approximately 200 millimetres across surrounding the 600 millimetre point from outer edge. Part 30 is defined between recess 14 and channel area 22, and similarly part 32 is defined between recess 18 and channel area 24. Each of parts 30 and 32 are approximately 400 millimetres across including the recesses, and channel area 22 and 24 are both approximately 100 millimetres across. In this way body 10 is divided into sections generally corresponding to the attachment points on a ceiling. As illustrated channel areas 22 and 24 correspond precisely to the underlying attachment points for the ceiling or other structure to which plasterboard 1 is to be installed. Ideally, these dimensions are 400 millimetres from the outer perimeter of the board, with a similar distance between them. Other dimensions such as 800 millimetres between the edges and channel areas may also be particular suitable. A regular pattern of channels is created across the body and formed as the long sides of each panel abut.

[0074] In other forms of the invention it is envisaged that there may be many channels running along the length of body 10 to provide a range of attachment points to the ceiling. Similarly, the channels may run along the short side of the panel in other forms of the invention or in both directions in yet another form, to assist in the alignment and installation.

[0075] Each channel area 22 and 24 is reinforced by inclusion of a fibreglass backing or similar material, labelled generally 34 and 36. The reinforcement is applied to the plaster sheet before the application of the paper covering to provide a strong reinforcement to the channel areas 22 and 24. It is particularly useful to reinforce channel areas 22 and 24 as it is here that the main strain is applied when screws or nails are applied. In conventional plasterboard it is at the point of attachment that there is a very high risk of specPA2022615 20 2016201276 29 Feb 2016 damage to the surface of the board or to cracking of the board-more on this below. Any suitable reinforcement may be used in and around channel area 22 and 24. Fibreglass is particularly suitable as its fine structure can adapt to the installation and continue to reinforce, even if damaged through application of a fixing. Recess 14 and 18 along edges 12 and 16 could similarly be reinforced, in some forms of the invention.

[0076] In conventional use of standard plasterboards, a T-square, tape measure, pencil and knife are used to measure up the area where the board is to be installed, mark it and cut to size. Cutting of the board must be completed very carefully to make a piece of plasterboard that will accurately fit the space, with precisely squared edges to fit against the other pieces without gaps. Further, the paper covering to the plasterboard is very easily torn or damaged at this stage, particularly by inexperienced workers or “do-it-yourself” installers.

[0077] The fixings must be aligned properly and fitted exactly the right depth into the structure and through the plasterboard, so that the finished screw lies below the surface of the board. If the fixing protruded this would interfere with the smooth surface of the finished ceiling. Further plaster applied to the installed panel is at risk of popping out or being unsightly if the fixings are not installed to a suitable depth.

[0078] The method of use of the improved plasterboard as illustrated in the drawings is as follows. The person who wishes to install, say a ceiling panel, measures the location where the panel is to be installed using a tape measure. It may be that the standard size of board is suitable for use without further adjustment of the length, may need to be reduced. Using a T-square and pencil body 10 is marked to be cut to the appropriate length. Using a knife body 10 is scored along the drawn line, the board snapped back against the scored line and then cut on the other side to remove the extraneous length of body 10. specPA2022615 21 2016201276 29 Feb 2016 [0079] Once the length of body 10 is appropriate, plasterboard 1 is ready for installation to form the ceiling. A structure of wooden battens is the usual underlying structure for a ceiling with the battens corresponding to the attachment points for the board. For walls plasterboard 1 is affixed to a stud wall as would be readily understood by the person skilled in the art. In the case of the subject invention plasterboard 1, channel areas 22 and 24 are configured to be aligned with suitable attachment points of the structure.

[0080] Adhesive is applied to points along the battens to assist to hold plaster board 1 in place. The adhesive may be omitted. Channels 26 and 28 cross the battens ready for application of the fixings.

[0081] Referring to Figures 3 to 5, an improved fixing or screw is described for use with plasterboard 1 as these work together to create an improved plasterboard installation. Conventional screws could, however, be used instead.

[0082] Improved fixing 38, includes shaft 40 and head 42, similar to a conventional screw. Improved fixing 38 is made of high carbon steel with a zinc coating. Alternative strong materials may also be used, and other metals. The improved fixing is illustrated similar to a conventional screw with a threaded shaft. The improved fixing could, instead be similar to a nail or tack, nut and arrangement, or any suitable fixing as the invention relates to the head in particular. Clearly, the fixing has wide applications in many trades and industries.

[0083] Improved fixing 38, in the illustrated form includes shaft 40 with threads 44 between pointed end 46 and head 42. Pointed end 46 is shown as a selftapping point. The form of improved fixing 38 is much as a conventional screw below head 42, however head 42 has been carefully devised to be very different. Head 42, importantly includes recesses 48, and these are arranged specPA2022615 22 2016201276 29 Feb 2016 around a central cross-thread 50. Central cross-thread 50 is of a conventional form to receive the end of a screwdriver therein for installation. Central crossthread 50 could readily be replaced with a single slot, for use with a flat head screw driver or otherwise. The particular manner in which the improved fixing is applied may be varied within the scope of the invention.

[0084] As illustrated improved fixing 38 is 26 millimetres tall a suitable height to be used to install plasterboards so head 42 can be positioned to lie generally flush with the surface. Shaft 40 is shown as 19 millimetres long with end a further 5 millimetres long. Head 42 as illustrated is much wider than a conventional screw head being 12 millimetres across, which is beneficial as described below. These dimensions are particularly suitable for use in the described application to install plasterboards. Clearly these dimensions can also be varied to any suitable dimensions.

[0085] Wide head 42 is functionally useful as the wide head assists to provide additional pull down force during installation. It also reduces the likelihood of cracking as the force and tension of the screwing into the surface is disposed over a wider area. By dispersing the tension it is less likely that surface will be damaged due to the tension and generally improves the quality of installation.

[0086] Recesses 48, as illustrated, are four circular dimples arranged around central cross-thread 50. Recesses 48 are 2 millimetres across and less than 2 millimetres in depth so as not to allow material to pass through head 42, in this particular embodiment. The particular dimensions of recesses 48 can be varied to suit the application, as can their number. For example, there may be 6, 8, 10 or 12 recesses or any number.

[0087] Recesses 48 can be arranged differently in other forms of the invention and different numbers such as 8 could be used instead. In another form of the invention the recesses may be in the form of a knurled surface. specPA2022615 23 2016201276 29 Feb 2016 [0088] Improved fixings 38 are used in channels 26 and 28 screwed in as conventional screws. As shafts 40 of fixings 38 pass though channels 26 and 28 they are forced through reinforced areas 34 and 36. The reinforced areas at this point resist against the cracking or breaking of body 10 due to the installation of the screws. Further, once installed reinforcing areas 34 and 36 continue to act to resist against cracking or other damage at the attachment point, the usual start point for damage to panels. Use of fibreglass is shown, but other materials or reinforcement could be used instead.

[0089] Improved fixings 38 applied at intervals along channels 26 and 28 suitable to hold plasterboard 1 in place. Each channel 26 and 28 has a fall of 2.5 millimetres on each side and has a depth similar to heads 42 of screw 38. It is a further advantage of the invention that the screws fit neatly within channels 26 and 28. The person installing the panel does not need to judge where to put the screws, or how deep to screw the fixings into the panel, this is predetermined and dictated by the form of the channels, making it far easier to install the panels correctly than a conventional panel.

[0090] Plasterboard 1 makes installation very straightforward whereby the position and depth of the fixings is indicated on body 10. If a person were to install screws somewhere along channel 26 or 28, provided this corresponded to where it crosses the structure underneath, the panel will be attached. Use of channels means that the fixings are applied naturally in a straight-line direct into the batten below. Each fixing 38 can be spaced to suit the particular application and either measured to be spaced evenly or judged by the eye. The depth of the channels again is suitable to receive the fixings so that the person installing will know when the fixing is flush in channel 26, 28 and that the depth is suitable to hold body 10 to the structure but also that the head does not protrude. It is tempting to screw or nail the fixings into the board too deeply and too hard to be sure that the panel will not fall down, and specPA2022615 24 2016201276 29 Feb 2016 that the screw heads do not stick above the surface. However, if screws are installed too far into the panel this can lead to cracking of the panel due to stains and stresses at the fixing point. It can also lead to the “screw popping” of a plug of the plaster applied over the head of the screw, over time, which is unsightly. Channels 26 and 28 are particularly configured so that once the screw head is received in the channel it is immediately evident how far the screw should be fixed in, and so the person can stop at the right point.

[0091] Where more than one plasterboard 1 is used edges 12 and 16 may abut on one another, creating a further channel from recesses 14 and 18. Again the channel created is suitable such that screws or improved fixings 38 can be applied to attach body 10 to the underlying structure without strain or stress being applied.

[0092] After installation of the board plaster is applied over the top to fill the channels, cover fixings 38 and provide a smooth surface for the ceiling. As improved fixings 38 fit within channels 26 and 28 these are fully contained and completely covered by the plaster. The wide head 42 fills the channel and spreads the force at the point of attachment. Depressions 48 of fixings 38 are adapted to receive and hold the applied plaster firmly. It is most advantageous that plaster can be engaged in the wider head of the improved fixing and in the recesses, which contacts with the smooth or domed head of a normal screw which would not in any way engage with the plaster or improve the installation. In this way the smooth plaster finish is achieved and maintained while the fixing is firm in place and will not be likely to cause “screw popping” or other damage to the plaster due to the particular configuration used. In other forms of the invention the plaster may engage a knurled surface, or go through holes in the head of the improved fixings. specPA2022615 25 2016201276 29 Feb 2016 [0093] Any suitable fixing, including conventional screws may be used instead. It is an advantage of these inventions that they may be used together or separately.

[0094] Overall, use of the invention provides a vastly improved plasterboard and method of installation that is likely to be widely adopted. Less experienced workers may be able to install wall and ceiling panels more quickly, efficiently and with a far better result than previously. There is a further advantage when used with the improved fixing of the invention.

[0095] It will be apparent to a person skilled in the art that changes may be made to the embodiment disclosed herein without departing from the spirit and scope of the invention in its various aspects. specPA2022615 26 2016201276 29 Feb 2016 REFERENCE SIGNS LIST: 1 Plasterboard 10 Body 12 First edge 14 Recessed part 16 Second edge 18 Recessed part 20 Centre 22 Channel area 24 Channel area 26 Channel 28 Channel 30 Part 32 Part 34 Reinforcement 36 Reinforcement 38 Screw 40 Shaft 42 Head 44 Threads 46 Pointed end 48 Recesses 50 Cross-thread Dated this 29th day of February 2016

Spence Hartman

By his Patent Attorney TJIP Patents, Trade Marks & Designs

Suite 4, 45-49 Bundock Street Belgian Gardens, Townsville Queensland 4810 specPA2022615

Claims (26)

1. The claims defining the invention are as follows:

   1. An improved plasterboard and fixing for installation on a structure: a substantially planar body; and one or more receiving portions in the substantially planar body adapted to receive one or more fixings therein the height of the receiving portion is configured to substantially contain the head of a fixing, when installed to a correct depth into the underlying structure, so that on installation the head of the fixing is installed in the receiving portion, the depth of the receiving portion indicating an appropriate depth of installation of the fixing into the underlying structure, and the upper surface of the head of the fixing lies substantially flush with the upper opening of the receiving portion therewith, wherein, the substantially planar body may receive one or more fixings in the one or more receiving portions to install the plasterboard to the structure, and plaster or similar finishing material applied over the surface of the fixings in the receiving portions creates a smooth finish, which resists “screw popping” due to the precise installation of the fixing in the receiving portion, for a substantially improved installation, as the fixings are installed at an appropriate depth and hence pressure so as resist creation of air gaps or pressure which may later cause the “screw pop” of circles of plaster overlying the head of the fixing.
2. 2. The improved plasterboard of claim 1 wherein there are a plurality of receiving portions.
3. 3. The improved plasterboard of claim 2, wherein at least two receiving portions are included, spaced across the body.
4. 4. The improved plasterboard of any one of claims 1 to 3, wherein a pair of opposed edges are adapted to form a receiving portion whereby the edges of different boards correspond to form a common receiving portion.
5. 5. The improved plasterboard of any one of claims 1 to 4, wherein the receiving portions include one or more channels.
6. 6. The improved plasterboard of claim 5, wherein the channels include a substantially flat base with sloping sides from the plasterboard surface.
7. 7. The improved plasterboard of claims 5 or 6, wherein the channel is a suitable size to comfortably receive the fixings.
8. 8. The improved plasterboard of any one of claims 5 to 7, wherein the channel is approximately 5 millimetres in depth.
9. 9. The improved plasterboard of any one of claims 4 to 8, wherein the head of the fixing does not substantially protrude above the upper surface of the channel once installed and the dimensions of the channel facilitate the installation of a the improved plasterboard to the underlying structure at a suitable depth for firm installation of the board such that the head of the fixing is fully received within the channel, whereby on applying a plaster finish the installation has smooth surface can be achieved and “screw popping” is substantially avoided.
10. 10. The improved plasterboard of any one of claims 1 to 9, wherein a plurality of boards are used, each including channels and edges which when abutted form channels so that a repeating series of channels are created across the whole surface.
11. 11. The improved plasterboard of any one of claims 1 to 10, wherein reinforcement is included in the plasterboard at points where fixings may be applied to substantially act against damage to the plasterboard during installation by application of fixings.
12. 12. The improved plasterboard of any one of claims 1 to 11, wherein the fixing is an improved fixing including a head; a shaft, connected to the head; and a plurality of recesses in the head, able to receive material therein, wherein the shaft of the improved fixing may be used to penetrate the improved plasterboard and the recesses are adapted to receive material therein, and the material adhere thereto to improve the finish of the surface, as the fixings are installed at an appropriate depth and hence pressure so as resist creation of air gaps or pressure which may later cause the “screw pop” of circles of plaster overlying the head of the fixing..
13. 13. The improved plasterboard and improved fixing of claim 12, wherein use substantially prevents “screw popping” on application of plaster over the installed fixing in the receiving portion of the improved plasterboard due to the significant reductions in pressure build up on the properly installed fixing.
14. 14. The improved plasterboard and improved fixing of claim 12 or 13, wherein the head of the improved fixing includes an upper surface and recesses are formed in the upper surface of the head.
15. 15. The improved plasterboard and improved fixing of any one of claims 12 to 14, wherein the head has a width of at least 12 millimetres.
16. 16. The improved plasterboard and improved fixing of claim15 wherein the head is very wide, over 20 millimetres.
17. 17. The improved plasterboard and improved fixing of any one of claims 12 to 16 wherein the head has a substantially flat or level upper surface.
18. 18. The improved plasterboard and improved fixing of any one of claims 12 to 17,wherein the surface is textured, including holes, recesses or depressions.
19. 19. The improved plasterboard and improved fixing of any one of claims 12 to 18wherein the upper surface may be a knurled surface.
20. 20. The improved plasterboard and improved fixing of any one of claims 12 to 19, wherein the number of recesses are chosen from the group: 4; 8; or 12.
21. 21. The improved plasterboard and improved fixing of any one of claims 12 to 20,wherein the recesses are depressions.
22. 22. The improved plasterboard and improved fixing of any one of claims 12 to 21 wherein the recesses are adapted to receive plaster therein and adhere thereto.
23. 23. The improved plasterboard and improved fixing of any one of claims 12 to 22 wherein the recesses are holes in the head of the fixing which enable communication between the upper surface and an under surface of the head of the fixing and allow the material therethrough.
24. 24. The improved plasterboard and improved fixing of any one of claims 12 to 23 wherein plaster is smoothed over the improved fixing and adheres strongly thereto to provide a substantially smooth surface.
25. 25. A method of installing a plasterboard, the plasterboard including a substantially planar body; and one or more receiving portions in the substantially planar body adapted to receive one or more fixings therein the height of the receiving portion is configured to substantially contain the head of a fixing, when installed to a correct depth into the underlying structure, so that on installation the head of the fixing is installed in the receiving portion, the depth of the receiving portion indicating an appropriate depth of installation of the fixing into the underlying structure, and the upper surface of the head of the fixing lies substantially flush with the upper opening of the receiving portion therewith adapted to receive fixings, to attach the plaster board to a structure at attachment points, the method including the following steps:- a) positioning the board at a suitable position on the structure for installation; b) aligning the receiving portions with the attachment points of the structure; c) attaching the board to the attachment points through use of fixings to an appropriate depth so as prevent pressure build up that may lead to screw popping, dictated by the depth of the receiving portions of the board, such that the top of the improved fixing lies substantially flush with the surface of the improved plasterboard; and d) applying plaster or the like over the fixings installed in the improved plaster board creates a smooth finish, with minimal risk of screw popping.
26. 26. The method of claim 25wherein, the improved plaster board and fixing is of any of one of claims 1 to 25.