US20110314759A1 - Drywall product - Google Patents

Drywall product Download PDF

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Publication number
US20110314759A1
US20110314759A1 US12/823,542 US82354210A US2011314759A1 US 20110314759 A1 US20110314759 A1 US 20110314759A1 US 82354210 A US82354210 A US 82354210A US 2011314759 A1 US2011314759 A1 US 2011314759A1
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US
United States
Prior art keywords
drywall
product
sheet
nail
side
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/823,542
Inventor
NICHOLAS W. McCULLOUGH
Original Assignee
Mccullough Nicholas W
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mccullough Nicholas W filed Critical Mccullough Nicholas W
Priority to US12/823,542 priority Critical patent/US20110314759A1/en
Publication of US20110314759A1 publication Critical patent/US20110314759A1/en
Application status is Abandoned legal-status Critical

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/002Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form ; Layered products having particular features of form
    • B32B3/02Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form ; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/20Inorganic coating
    • B32B2255/205Metallic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/26Polymeric coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/714Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145Rot proof, resistant to bacteria, mildew, mould, fungi
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/724Permeability to gases, adsorption
    • B32B2307/7242Non-permeable
    • B32B2307/7246Water vapor barrier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/732Dimensional properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00Buildings or parts thereof

Abstract

A drywall product may inhibit the formation of mold, may hold a nail securely, may provide insulation, and may be strong and durable. The drywall product may include one or more of the following features: a vapor barrier on a stud side of a sheet of the drywall product, a nailing and fastening member on at least a portion of the sheet of the drywall product, a drywall-type mixture covering a wall side of the sheet of the drywall product, and a paper face for a smooth finish.

Description

    BACKGROUND OF THE INVENTION
  • The present invention relates to drywall products and, more particularly, to drywall products that may resist mold, allow the direct nailing of trim thereto and add insulation value.
  • Current drywall will grow mold if any moisture exists behind the walls. The paper on the back of current drywall feeds the mold and allows it to grow, potentially making people sick. Current drywall also does not securely hold nails. This feature may be especially useful when trim is installed along a floor edge and/or a ceiling edge of a wall. Current drywall has minimal insulation value (for example, ½ inch drywall has an R-value of about 0.45) and may be broken or damaged easily.
  • As can be seen, there is a need for a drywall product that may inhibit the formation of mold, may hold a nail or fastener securely, may provide insulation and may be strong and durable.
  • SUMMARY OF THE INVENTION
  • In one aspect of the present invention, a drywall product comprises a drywall type mixture disposed as a sheet having a wall side and a stud side; and a nail and fastener layer attached to or incorporated into at least a portion of the stud side of the drywall type mixture.
  • In another aspect of the present invention, a drywall product comprises a drywall type mixture disposed as a sheet having a wall side and a stud side; a nail and fastener layer attached or incorporated into at least a portion of the stud side of the drywall type mixture; and a vapor barrier entirely covering the stud side of the sheet.
  • These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a side view of a drywall product according to an embodiment of the present invention;
  • FIG. 2 is a front view of a drywall product according to another embodiment of the present invention;
  • FIG. 3 is a side view of a drywall product according to still another embodiment of the present invention;
  • FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3; and
  • FIG. 5 is a perspective view of the drywall product of FIG. 3 installed on a wall.
  • DETAILED DESCRIPTION OF THE INVENTION
  • The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
  • Various inventive features are described below that can each be used independently of one another or in combination with other features.
  • Broadly, an embodiment of the present invention provides a drywall product that may inhibit the formation of mold, may hold a nail and other fasteners securely, may provide insulation and may be strong and durable. The drywall product, according to embodiments of the present invention, may include one or more of the following features: a vapor barrier on a stud side of a sheet of the drywall product, a nailing and fastening member on at least a portion of the sheet of the drywall product, a drywall-type mixture covering a wall side of the sheet of the drywall product, and a paper face for a smooth finish. As used herein, “stud side” refers to the side of the sheet of drywall product that may be installed facing wall studs. “Wall side” of a sheet of drywall product refers to the side of the sheet of drywall product that may be installed facing an interior of a room.
  • Referring to FIG. 1, a drywall product sheet 10 may have a thickness 12 that is equivalent to conventional drywall. For example, the thickness 12 may be, for example ½ inch. Alternatively, the overall thickness 12 may be ⅜ inch or ⅝ inch or the like. The drywall product sheet 10 may have overall dimensions similar to conventional drywall. For example, the drywall product sheet 10 may be a 4-foot by 8-foot sheet, a 4-foot by 12-foot sheet or a 4-foot by 16 foot sheet or like that. The drywall product sheet 10 may include a vapor barrier 14 on a stud side 16 of the drywall product sheet 10. The vapor barrier 14 may be a plastic or rubberized layer. In one embodiment of the present invention, the vapor barrier 14 may be a plastic sheeting, such as a 6 mil plastic sheeting. In an alternate embodiment, the vapor barrier 14 may be sprayed on as a rubberized coating onto the drywall product sheet 10. In a further alternate embodiment, the vapor barrier 14 may be a metalized film or foil. The vapor barrier 14 may cover the entire stud side of the drywall product sheet 10.
  • On a wall side 18 of the drywall product sheet, a smooth paper face 20 may be disposed. The smooth paper face 20 may be similar to the paper face of conventional drywall. Between the smooth paper face 20 and the vapor barrier 14 may be installed a drywall-type mixture 22. The drywall-type mixture 22 may be similar to conventional drywall mixtures. A waterproofing chemical, as may be known in the art, may be added to the drywall-type mixture 22. The drywall-type mixture 22 may be designed in a manner similar to conventional drywall. For example, the wall side of the drywall-type mixture 22 may include indentations (not shown) along one or more edges thereof for creating smooth seams when the drywall product sheets 10 abut one another. The thickness of the drywall-type mixture 22 may be from about 3/16 inch to about ½ inch, for example, and typically is between about 5/16 inch to about ½ inch, as discussed in greater detail below. A mesh may be optionally formed in the drywall-type mixture 22.
  • A nail and fastener layer 24 may be disposed between the drywall-type mixture 22 and the vapor barrier 14. In one embodiment of the present invention, the nail and fastener layer 24 may be disposed along an entire surface of the drywall product sheet 10. In an alternate embodiment, the nail and fastener layer 24 may be disposed around a perimeter of a drywall product sheet 10-1, as shown in FIG. 2. In a further alternate embodiment, the nail and fastener layer 24 may be disposed on one or more edges 26 of a drywall product sheet 10-2, as shown in FIG. 3. By having the nail and fastener layer 24 cover a portion of at least one edge of the drywall product sheet 10, the edge 26 having the nail and fastener layer 24 may be disposed at a position to secure trim and/or molding to the drywall product sheet 10. Trim and/or molding may be secured to the nail and fastener layer 24 by, for example, a nail, screw or other similar fastener. The nail and fastener layer 24 may be attached to the drywall-type mixture 22 or may be incorporated into the drywall-type mixture 22.
  • As shown in FIG. 5, the drywall product sheet 10-2 may be positioned with the edge 26 having the nail and fastener layer 24 facing a floor 32 and a ceiling 28 of a wall 30 to be drywalled. Such a configuration may permit molding to be installed and secured to the drywall product sheet 10-2 at the floor 32 and the ceiling 28.
  • The nail and fastener layer 24 may be made of a material that may secure a nail therewithin. For example, the nail and fastener layer 24 may be wood, plastic or a composite material. In other embodiments, the nail and fastener layer 24 may be made of post-consumer recycled material. The nail and fastener layer 24 may be from about ⅛ inch to about ¼ inch thick. In one embodiment of the present invention, the drywall type mixture 22 may be about 5/16 inch thick, while the nail and fastener layer 24 may be about 3/16 inch thick, resulting in an overall thickness 12 of about ½ inch, thereby approximating the thickness of a conventional sheet of ½ inch drywall.
  • When the nail and fastener layer 24 does not cover the entire surface of the drywall product sheet 10, the thickness of the drywall type mixture 22 may vary so that the combination of the nail and fastener layer 24 and the drywall type mixture 22 may result in a drywall product sheet 10 that may have a flat stud side 16, as shown in FIG. 4. The nail and fastener layer 24 may have a width 34 from about 2 inches to about 16 inches, typically from about 8 inches to about 14 inches.
  • It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims (10)

1. A drywall product comprising:
a drywall type mixture disposed as a sheet having a wall side and a stud side; and
a nail and fastener layer attached to or incorporated into at least a portion of the stud side of the drywall type mixture.
2. The drywall product of claim 1, further comprising a vapor barrier covering the stud side of the sheet.
3. The drywall product of claim 2, wherein the vapor barrier is selected from a plastic sheeting, a spray-on coating, an extruded or laminated sheet, a vapor deposited layer, a vacuum thermoformed, a furnace sintered layer or an enrobing-formed layer.
4. The drywall product of claim 1, wherein the nail and fastener layer is attached to or incorporated into the entire stud side of the drywall type mixture.
5. The drywall product of claim 1, wherein the nail and fastener layer is attached to or incorporated into at least one edge of the drywall type mixture.
6. The drywall product of claim 5, wherein the nail and fastener layer has a width from about 8 inches to about 14 inches.
7. The drywall product of claim 1, wherein the width of the drywall product is uniform in surface topography on a stud side.
8. The drywall product of claim 1, further comprising a smooth paper face on the wall side of the sheet.
9. A drywall product comprising:
a drywall type mixture disposed as a sheet having a wall side and a stud side;
a nail and fastener layer attached to or incorporated into at least a portion of the stud side of the drywall type mixture; and
a vapor barrier entirely covering the stud side of the sheet.
10. The drywall product of claim 9, wherein the nail and fastener layer is selected from the group consisting of wood, plastic, composite, and post consumer recycled material.
US12/823,542 2010-06-25 2010-06-25 Drywall product Abandoned US20110314759A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/823,542 US20110314759A1 (en) 2010-06-25 2010-06-25 Drywall product

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/823,542 US20110314759A1 (en) 2010-06-25 2010-06-25 Drywall product

Publications (1)

Publication Number Publication Date
US20110314759A1 true US20110314759A1 (en) 2011-12-29

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US12/823,542 Abandoned US20110314759A1 (en) 2010-06-25 2010-06-25 Drywall product

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140115988A1 (en) * 2011-06-17 2014-05-01 Basf Se Prefabricated Wall Assembly Having An Insulating Foam Layer
US9702152B2 (en) 2011-06-17 2017-07-11 Basf Se Prefabricated wall assembly having an outer foam layer

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2200750A (en) * 1938-06-15 1940-05-14 James T Kenney Wallboard
US3842551A (en) * 1969-07-24 1974-10-22 Nat Gypsum Co Drywall joint systems and method for making the same
US4209954A (en) * 1977-12-05 1980-07-01 Scheid Lloyd J Panel construction having lateral edge members
US6061995A (en) * 1996-03-04 2000-05-16 National Gypsum Company Composite structural member and wall assembly method
US6205729B1 (en) * 1998-11-18 2001-03-27 William H. Porter Asymmetric structural insulated panel
US6269595B1 (en) * 1999-05-20 2001-08-07 David A. Blubaugh Gridwall
US6524679B2 (en) * 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US20060134371A1 (en) * 2004-12-16 2006-06-22 United States Gypsum Company Building panels with aesthetic edges
US20070175126A1 (en) * 2005-12-29 2007-08-02 United States Gypsum Company Reinforced Cementitious Shear Panels
US7568318B1 (en) * 2000-08-08 2009-08-04 Thermocore Structural Insulated Panel Systems Pre-fabricated wall paneling

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2200750A (en) * 1938-06-15 1940-05-14 James T Kenney Wallboard
US3842551A (en) * 1969-07-24 1974-10-22 Nat Gypsum Co Drywall joint systems and method for making the same
US4209954A (en) * 1977-12-05 1980-07-01 Scheid Lloyd J Panel construction having lateral edge members
US6061995A (en) * 1996-03-04 2000-05-16 National Gypsum Company Composite structural member and wall assembly method
US6205729B1 (en) * 1998-11-18 2001-03-27 William H. Porter Asymmetric structural insulated panel
US6269595B1 (en) * 1999-05-20 2001-08-07 David A. Blubaugh Gridwall
US7568318B1 (en) * 2000-08-08 2009-08-04 Thermocore Structural Insulated Panel Systems Pre-fabricated wall paneling
US6524679B2 (en) * 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US20060134371A1 (en) * 2004-12-16 2006-06-22 United States Gypsum Company Building panels with aesthetic edges
US20070175126A1 (en) * 2005-12-29 2007-08-02 United States Gypsum Company Reinforced Cementitious Shear Panels

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140115988A1 (en) * 2011-06-17 2014-05-01 Basf Se Prefabricated Wall Assembly Having An Insulating Foam Layer
US9702152B2 (en) 2011-06-17 2017-07-11 Basf Se Prefabricated wall assembly having an outer foam layer

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