WO2008142684A2

WO2008142684A2 - Method for patterning plasterboard and plasterboard products produced thereby

Info

Publication number: WO2008142684A2
Application number: PCT/IL2008/000686
Authority: WO
Inventors: Moshe Korndrexler
Original assignee: Rlbd Yazamut Iskit Ltd.
Priority date: 2007-05-21
Filing date: 2008-05-20
Publication date: 2008-11-27
Also published as: IL183364A0; WO2008142684A3; IL183364A

Abstract

A method for producing a patterned plasterboard product including providing a computer-controlled engraving machine and employing the computer-controlled machine to engrave a sheet of plasterboard.

Description

METHOD FOR PATTERNING PLASTERBOARD AND PLASTERBOARD PRODUCTS PRODUCED THEREBY

FIELD OF THE INVENTION

The present invention relates to methods of patterning plasterboard and to plasterboard products produced thereby.

BACKGROUND OF THE INVENTION

The following patent documents are believed to represent the current state of the art.

U.S. Patents 6,857,241 and 6,822,192.

SUMMARY OF THE INVENTION

The present invention seeks to provide methodology for patterning plasterboard as well as patterned plasterboard products.

There is thus provided in accordance with a preferred embodiment of the present invention a method for producing a patterned plasterboard product including providing a computer-controlled engraving machine and employing the computer- controlled machine to engrave a sheet of plasterboard. Preferably, the method also includes pre-treating the sheet of plasterboard to enhance its suitability for engraving using the computer-controlled machine. Additionally, the pre-treating enhances the mechanical strength of the sheet of plasterboard.

Preferably, the employing the computer-controlled machine to engrave a sheet of plasterboard includes selectably configuring at least one edge of the sheet of plasterboard. Alternatively or additionally, the employing the computer-controlled machine to engrave a sheet of plasterboard includes selectably configuring at least one interior area of the sheet of plasterboard. Additionally or alternatively, the employing the computer-controlled machine to engrave a sheet of plasterboard includes employing a cutting implement which has at least one forwardly facing helical cutting edge.

In accordance with a preferred embodiment of the present invention the method also includes coating at least one surface of the sheet of plasterboard prior to employing the computer-controlled machine to engrave the sheet of plasterboard.

Preferably, the selectably configuring at least one edge of the sheet of plasterboard includes employing a two stage milling tool, including a relatively narrow drill bit portion and a relatively wider, edge definition cutting portion.

There is also provided in accordance with another preferred embodiment of the present invention a patterned plasterboard product including at least one sheet of plasterboard bearing a decorative design formed by use of a computer-controlled engraving machine. Preferably, the decorative design is formed on at least one edge of the sheet of plasterboard. Alternatively or additionally, the decorative design is formed in at least one interior area of the sheet of plasterboard.

In accordance with a preferred embodiment of the present invention, the decorative design is formed by employing a cutting implement which has at least one forwardly facing helical cutting edge. Additionally or alternatively, the decorative design is at least partially formed by employing a laser.

Preferably, at least one edge of the product is formed by employing a two stage milling tool, including a relatively narrow drill bit portion and a relatively wider, edge definition cutting portion.

There is further provided in accordance with yet another preferred embodiment of the present invention a building structure including at least one interior architectural surface formed of plasterboard bearing a decorative engraved design.

Preferably, the decorative engraved design is formed by use of a computer-controlled engraving machine. In accordance with a preferred embodiment, the computer-controlled engraving machine is a CNC milling machine.

Preferably, the at least one interior architectural surface includes at least one sheet of plasterboard having at least one edge which is configured with an engraved design. Additionally or alternatively, the at least one interior architectural surface includes at least one sheet of plasterboard part of which defines an undecorated flat portion and part of which defines a decorated edge portion.

In accordance with a preferred embodiment, the at least one interior architectural surface includes at least one sheet of plasterboard including a decorated portion formed in at least one interior area of the at least one sheet of plasterboard. Preferably, the decorative design is formed by employing a cutting implement which has at least one forwardly facing helical cutting edge. Additionally or alternatively, the decorative design is at least partially formed by employing a laser. hi accordance with a preferred embodiment of the present invention at least one edge of the product is formed by employing a two stage milling tool, including a relatively narrow drill bit portion and a relatively wider, edge definition cutting portion. BRIEF DESCRIPTION OF THE INVENTION

The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

Figs. IA & IB are simplified pictorial illustrations of methodologies for patterning plasterboard operative in accordance with a preferred embodiment of the present invention; Fig. 2 is a simplified pictorial illustration , of various patterned plasterboard products constructed in accordance with a preferred embodiment of the present invention;

Fig. 3 is a simplified pictorial illustration of the manufacture of plasterboard ceiling tiles in accordance with a preferred embodiment of the present invention;

Figs. 4A - 4H are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with a preferred embodiment of the present invention;

Figs. 5A - 51 are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with another preferred embodiment of the present invention;

Figs. 6A - 6G are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with yet another preferred embodiment of the present invention; and Figs. 7A - 7D are simplified pictorial illustrations of a methodology for desired edge definition of plasterboard products in accordance with a preferred embodiment of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference is now made to Figs. IA & IB, which are simplified pictorial illustrations of methodologies for patterning plasterboard operative in accordance with a preferred embodiment of the present invention.^' As seen in Figs. IA and IB, plasterboard 10, which may be conventional plasterboard comprising a layer of plaster

12, sandwiched between two layers of paper 14, such as plasterboard commercially available from Orbond Ltd. of Israel, or any other suitable type of plasterboard, is patterned using a CNC milling machine 16, preferably a CNC engraving table commercially available from Multicam of China. The pattern may be any suitable pattern and need not be repeated. Typically the pattern is formed on one or more edges of a layer of plasterboard.

It is appreciated that full sheets of plasterboard may be patterned in accordance with the present invention or alternatively partial sheets of plasterboard may be employed.

Optionally, prior to machining, the plasterboard may be sprayed with an adhesive or other substance on one or both surfaces thereof to enhance the mechanical strength thereof and thus to enable enhancement of the resolution of the pattern formed therein by the CNC milling machine 16. A suitable optional spraying station is shown at reference numeral 18. Inasmuch as a significant amount of dust is produced by operation of the CNC milling machine 16 on the plasterboard 10, a dust removal assembly 20 is preferably provided.

As seen in Fig IB, the pattern formed in the plasterboard in accordance with the present invention may include a pattern formed on one or more edges of a layer of plasterboard, such as a pattern 22, or a pattern formed by patterning an interior area of the plasterboard, such as a pattern 24.

It is a particular feature of the present invention that patterned plasterboard is produced in a highly efficient and cost effective manner. Patterned plasterboard has significant advantages over patterned metal, plastic and wood for certain applications both in terms of cost and usability. A particularly beneficial application of patterned plasterboard manufactured in accordance with a preferred embodiment of the present invention is in interior construction, to create peripherally patterned ceiling and window spaces. In accordance with a preferred embodiment of the present invention, as seen in Fig. 2, a ceiling may be made of patterned plasterboard using conventional techniques. As seen, for example, at reference numeral 30, the patterned edges 32, of sheets 34 of plasterboard, define a decorative cornice. Similarly, as also seen in Fig. 2 at reference number 40, patterned edges 42 of sheets 44 of plasterboard define a decorative window frame. It is appreciated that a single sheet of plasterboard may form part of a wall and part of a cornice or window frame.

Fig. 2 also shows at reference numeral 50 a decorative screen 52, including patterned areas 54, for recessed lighting, which screen 52 can be integrally

_? formed with a wall, using the same sheet of plasterboard. At reference numeral 60 there is seen a light shade 62, including patterned areas 64, also formed of a piece of patterned plasterboard.

As seen in Fig 2, the pattern formed in the plasterboard in accordance with the present invention may include a pattern formed on one or more edges of a layer of plasterboard, such as patterned areas 64, or a pattern formed by patterning an interior area of the plasterboard, such as patterned areas 54. Reference is now made to Fig. 3, which is a simplified pictorial illustration of a methodology for manufacturing engraved plasterboard ceiling tiles in accordance with a preferred embodiment of the present invention. As seen in Fig. 3, plasterboard 110, which may be conventional plasterboard comprising a layer of plaster 112, sandwiched between layers of paper 114, such as plasterboard commercially available from Orbond Ltd. of Israel, or any other suitable type of plasterboard, is patterned using a CNC milling machine 116, preferably a CNC engraving table commercially available from Multicam of China. The pattern may be any suitable pattern and need not be repeated. Typically the pattern is formed on one or more edges of a layer of plasterboard. It is appreciated that full sheets of plasterboard may be patterned in accordance with the present invention or alternatively partial sheets of plasterboard may be employed. Optionally, prior to machining, the plasterboard may be sprayed with an adhesive or other substance on one or both surfaces thereof to enhance the mechanical strength thereof and thus to enable enhancement of the resolution of the pattern formed therein by the CNC milling machine 116. A suitable optional spraying station is shown at reference numeral 118. Inasmuch as a significant amount of dust is produced by operation of the CNC milling machine 116 on the plasterboard 110, a dust removal assembly (not shown) is preferably provided.

It is a particular feature of the present invention ^■ that engraved plasterboard ceiling panels are produced in a highly efficient and cost effective manner. Reference is now made to Figs. 4A - 4H₃ which are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with a preferred embodiment of the present invention in which a special cutting implement 200 is employed. Cutting implement 200 is characterized in. that it has generally helical cutting edges 202 and 204 which are forward facing, e.g. downward facing in the sense of Figs. 4A - 4F. The use of special cutting implement 200 has a substantial advantage in that it provides a relatively clean cut of paper layers at the top of a sheet of plasterboard, since it tends to force the paper layers downwardly against the plaster layer rather than to pull them upwardly away from the plaster layer.

The methodology of Figs. 4A — 4H may be used with any conventional plasterboard, preferably plasterboard 210 including a layer 212 of gypsum, preferably of thickness between 5-18 mm, sandwiched between layers 214 and 216 of paper. A visible finish surface of the plasterboard adjacent layer 214 preferably includes an additional relatively thin layer 218 of paper.

Fig. 4A illustrates the cutting implement 200 prior to engagement with the plasterboard 210. Fig. 4B illustrates initial cutting of layer 218 by implement 200, which leaves torn portions 220 of paper, as illustrated about an aperture 222 in layer

218. Fig. 4C shows cutting of layer 214, which produces a relatively clean cut aperture

224 in layer 214, due to the presence of layer 218.

Fig. 4D shows cutting of layer 212. It is noted that the particulate gypsum 226 resulting from the action of cutting implement 200 is not forced upwardly through aperture 222 and 224 due to the particular configuration of the cutting implement. Use of a conventional cutting implement instead of cutting implement 200 would force the particulate gypsum 226 up through apertures 222 and 224, roughening the edges thereof, and tearing the paper layers 214 and 218 thereabout, producing an unaesthetic appearance.

Fig. 4E illustrates cutting of layer 216 by implement 200. This is seen to be a rough cut, with particulate gypsum 226 being forced out through the resulting aperture 228 formed in layer 216, thus tearing the paper layer 216 about aperture 228, as illustrated. It is appreciated that paper layer 216 is normally not seen when the plasterboard product is installed and thus, the appearance thereof is not problematic.

Fig. 4F illustrates further cutting of layers 218, 214, 212 and 216. As described above, it is appreciated that the use of cutting implement 200 provides a relatively clean cut of layers 214 and 218, since it tends to force the layers 214 and 218 downwardly against the plaster layer rather than to pull them upwardly away from the plaster layer.

Fig. 4G shows sanding of layer 218 adjacent aperture 222 and Fig. 4H shows the appearance of the finished product.

Reference is now made to Figs. 5A - 51, which are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with another preferred embodiment of the present invention in which a special cutting implement 300 preferably is employed. Cutting implement 300 is characterized in that it has generally helical cutting edges 302 and 304 which are downward facing in the sense of Figs. 5A - 5G.

The methodology of Figs. 5A - 51 may be used with any conventional plasterboard, preferably plasterboard 310 including a layer 312 of gypsum, preferably of thickness between 5-18 mm, sandwiched between layers 314 and 316 of paper. A visible finish surface of the plasterboard adjacent layer 314 preferably includes an additional relatively thin layer 318 of paper. In the embodiment of Figs. 5 A - 51, a layer 320 of spackling compound, such as SPACKLE®, is formed over layer 318.

Fig. 5 A illustrates the cutting implement 300 prior to engagement with layer 320 and with plasterboard 310. Fig. 5B illustrates initial cutting of layer 320 by implement 300, which produces a relatively clean cut aperture 321 in layer 320. Fig. 5C illustrates initial cutting of layer 318, which does not leave torn portions of paper about an aperture 322 in layer 318, due to the presence of layer 320. Fig. 5D shows cutting of layer 314, which produces a relatively clean cut aperture 324 in layer 314, due to the presence of layers 318 and 320.

Fig. 5E shows cutting of layer 312. It is noted that the particulate gypsum 326 resulting from the action of cutting implement 300 is not forced upwardly through aperture 322 and 324 due to the particular configuration of the cutting implement. Use of a conventional cutting implement instead of cutting implement 300 would force the particulate gypsum 326 up through apertures 322 and 324, roughening the edges thereof, and tearing the paper layers 314 and 318 thereabout, producing an unaesthetic appearance. Fig. 5F illustrates cutting of layer 316 by implement 300. This is seen to be a rough cut, with particulate gypsum 326 being forced out through the resulting aperture 328 formed in layer 316, thus tearing the paper layer 316 about aperture 328, as illustrated. It is appreciated that paper layer 316 is normally not seen when the plasterboard product is installed and thus, the appearance thereof is not problematic. Fig. 5G illustrates further cutting of layers 320, 318. 314, 312 and 316. It is appreciated that, as described above, the provision of layer 320 provides for a relatively clean cut aperture in layer 320.

Fig. 5H shows optional sanding of layer 320 adjacent aperture 321 and Fig. 51 shows the appearance of the finished product. Reference is now made to Figs. 6A - 6G, which are simplified pictorial illustrations of various stages in the manufacture of engraved plasterboard products in accordance with yet another preferred embodiment of the present invention in which a laser 400 is preferably is employed.

The methodology of Figs. 6A — 6G may be used with any conventional plasterboard, preferably plasterboard 410 including a layer 412 of gypsum, preferably of thickness 5-18 mm, sandwiched between layers 414 and 416 of paper. A visible finish surface of the plasterboard adjacent layer 414 preferably includes an additional relatively thin layer 418 of paper.

In the embodiment of Figs. 6A - 6G, laser 400 provides a clean cut through layers 414 and 418, as shown in Figs. 6A and 6B. Fig. 6C illustrates a cutting implement- 419 prior to engagement with layer 412 of plasterboard- 410. Cutting implement 419 is preferably a special cutting element such as cutting elements 200 and 300 described hereinabove or alternatively can be any suitable cutting element.

Fig. 6D illustrates shows cutting of layer 412. Fig. 6E illustrates cutting of layer 416 by implement 419. This is seen to be a rough cut, with particulate gypsum 426 being forced out through the resulting aperture 428 formed in layer 416, thus tearing the paper layer 416 about aperture 428, as illustrated. It is appreciated that paper layer 416 is normally not seen when the plasterboard product is installed and thus, the appearance thereof is not problematic.

Fig. 6F illustrates further cutting of layers 412 and 416. Fig. 6G shows the appearance of the finished product.

It is appreciated that although Figs. 4A - 6G illustrate manufacture of a patterned plasterboard product wherein the cutting tool cuts entirely through the plasterboard, the present invention relates equally to manufacturing techniques wherein the cutting tool does not cut entirely through the plasterboard. Reference is now made to Figs. 7A - 7D, which are simplified pictorial illustrations of a methodology for desired edge definition of plasterboard products in accordance with a preferred embodiment of the present invention, which employs a two stage milling tool 500, preferably including a relatively narrow drill bit portion 502 and a wider, preferably tapered edge definition cutting portion 504. Drill bit portion 502 may be a special cutting tool similar to tools 200 and 300 described hereinabove or may be of any other suitable construction.

The methodology of Figs. 7A - 7D may be used with any conventional plasterboard, preferably plasterboard 510 including a layer 512 of gypsum, preferably of thickness between 5-18 mm, sandwiched between layers 514 and 516 of paper. A visible finish surface of the plasterboard adjacent layer 514 preferably includes an additional relatively thin layer 518 of paper.

In the embodiment of Figs. 7A - 7D, drill bit portion 502 cuts entirely through all of layers 512 - 518, as shown in Figs. 7B and 7C. Fig. 7A illustrates milling tool 500 prior to engagement with layer 512 of plasterboard 510. Fig. 7B illustrates cutting of plasterboard 510, it being seen that drill bit portion 502 cuts ^• entirely through all of the layers- of the plasterboard, while cutting portion 504 cuts through layers 512, 514 and 518 only. Fig. 7C shows that the cutting of layer 518 and possibly also of layer 514 may be a rough cut. Fig. 7D shows plasterboard products, such as ceiling panels 530, cut by the technique described hereinabove with reference to Figs. 7A - 1C, after sanding or other suitable finishing of the edges to remove torn paper. It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the present invention includes combinations and subcombinations of the various features described hereinabove as well as features which would occur to a person skilled in the art upon reading the foregoing description and which are not in the prior art.

Claims

1. A method for producing a patterned plasterboard product comprising: providing a computer-controlled engraving machine; and employing said computer-controlled machine to engrave a sheet of plasterboard.

2. A method for producing a patterned plasterboard product according to claim 1 and also comprising pre-treating said sheet of plasterboard to enhance its suitability for engraving using said computer-controlled machine.

3. A method for producing a patterned plasterboard product according to claim 2 and wherein said pre-treating enhances the mechanical strength of said sheet of plasterboard.

4. A method for producing a patterned plasterboard product according to any of the preceding claims and wherein said employing said computer-controlled machine to engrave a sheet of plasterboard comprises selectably configuring at least one edge of said sheet of plasterboard.

5. A method for producing a patterned plasterboard product according to any of the preceding claims and wherein said employing said computer-controlled machine to engrave a sheet of plasterboard comprises selectably configuring at least one interior area of said sheet of plasterboard.

6. A patterned plasterboard product comprising: at least one sheet of plasterboard bearing a decorative design formed by use of a computer-controlled engraving machine.

7. A patterned plasterboard product according to claim 6 and wherein said decorative design is formed on at least one edge of said sheet of plasterboard.

8. A patterned plasterboard product according to claim 6 or claim 7 and wherein said decorative design is formed in at least one interior area of said sheet of plasterboard.

9. A building structure comprising: at least one interior architectural surface formed of plasterboard bearing a decorative engraved design.

10. A building structure according to claim 9 and wherein said decorative engraved design is formed by use of a computer-controlled engraving machine.

11. A building structure according to claim 10 and wherein said computer- controlled engraving machine is a CNC milling machine.

12. A building structure according to any of claims 9-11 and wherein said at least one interior architectural surface includes at least one sheet of plasterboard having at least one edge which is configured with an engraved design.

13. A building structure according to any of claim 9-12 and wherein said at least one interior architectural surface comprises at least one sheet of plasterboard part of which defines an undecorated flat portion and part of which defines a decorated edge portion.

14. A building surface according to any of claims 9-13 and wherein said at least one interior architectural surface comprises at least one sheet of plasterboard including a decorated portion formed in at least one interior area of said at least one sheet of plasterboard.

15. A method for producing a patterned plasterboard product according to

^' any of claims 1 - 5 and wherein said employing said computer-controlled machine to engrave a sheet of plasterboard comprises employing a cutting implement which has at least one forwardly facing helical cutting edge.

16. A method for producing a patterned plasterboard product according to any of claims 1 - 5 and 15 and also comprising coating at least one surface of said sheet of plasterboard prior to employing said computer-controlled machine to engrave said sheet of plasterboard.

17. A method for producing a patterned plasterboard product according to any of the preceding claims 4, 5, 15 & 16 and wherein said selectably configuring at least one edge of said sheet of plasterboard comprises employing a two stage milling tool, including a relatively narrow drill bit portion and a relatively wider, edge definition cutting portion. .

18. A patterned plasterboard product according to any of claims 6 - 8 and wherein said decorative design is formed by employing a cutting implement which has at least one forwardly facing helical cutting edge.

19. A patterned plasterboard product according to any of claims 6 - 8 and wherein said decorative design is at least partially formed by employing a laser.

20. A patterned plasterboard product according to any of claims 6 - 8 and wherein at least one edge of said product is formed by employing a two stage milling tool, including a relatively narrow drill bit portion . and a relatively wider, edge definition cutting portion.

21. A building surface according to any of claims 9 - 14 and wherein said decorative design is formed by employing a cutting implement which has at least one forwardly facing helical cutting edge.

22. A building surface according to any of claims 9 - 14 and wherein said decorative design is at least partially formed by employing a laser.

23. A building surface according to any of claims 9 - 14 and wherein at least one edge of said product is formed by employing a two stage milling tool, including a relatively narrow drill bit portion and a relatively wider, edge definition cutting portion.