Tapered plasterboards and methods for making them

Patent metadata

Field	Value
Publication number	US-11976465-B2
Application number	US-202217567733-A
Country	US
Kind code	B2
Filing date	Jan 3, 2022
Priority date	Sep 30, 2017
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

Disclosed herein are plaster boards having a first surface and an opposing second surface, and a first edge and an opposing second edge that bound the first surface and the second surface. The first surface includes a first section and a second section, the first section being raised compared to the second section, the second section abutting the second edge. The second surface includes a first section and a second section that are separated by a boundary between the first edge and the second edge. The first section of the second surface is substantially parallel to the first section of the first surface. The second section of the second surface slopes toward the first surface from the boundary toward the second edge. Methods for making the plaster boards involve forming wet plaster material and drying the wet plaster material such that the wet plaster material hardens into a plasterboard.

First claim

What is claimed is:

1. A sound-dampening plasterboard having a first surface and a second surface opposing the first surface, the sound-dampening plasterboard comprising:
a first plasterboard comprising:
a first surface facing toward an interior of the sound-dampening plasterboard and a second surface opposing the first surface of the first plasterboard and facing toward the first surface of the sound-dampening plasterboard,
a body of hardened plaster and a facing layer disposed at the first surface of the first plasterboard,
a first edge and an opposing second edge that bound the first surface of the first plasterboard and the second surface of the first plasterboard,
the first surface of the first plasterboard comprising a first section and a second section, the first section being raised compared to the second section, the second section abutting the second edge,
the second surface of the first plasterboard comprising a first section and a second section disposed between the first section and the second edge, the first section and the second section being separated by a boundary between the first edge and the second edge, the first section of the second surface of the first plasterboard being substantially parallel to the first section of the first surface of the first plasterboard, the second section of the second surface of the first plasterboard sloping toward the first surface of the first plasterboard from the boundary toward the second edge,
wherein the facing layer is not substantially present on the first section of the first surface, but is substantially present on the second section of the first surface of the plasterboard;

a second plasterboard having a first surface facing the toward the interior of the sound-dampening plasterboard and a second surface opposing the first surface of the second plasterboard and facing toward the second surface of the sound-dampening plasterboard; and
a sound-dampening layer disposed between the first surface of the first plasterboard and the first surface of the second plasterboard.

2. The sound-dampening plasterboard of claim 1 , wherein the second section of the second surface of the first plasterboard abuts the second edge.

3. The sound-dampening plasterboard of claim 1 , wherein the first section of the first surface of the first plasterboard is substantially parallel to the second section of the first surface of the first plasterboard.

4. The sound-dampening plasterboard of claim 1 , wherein the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard are separated by a step-shaped boundary.

5. The sound-dampening plasterboard of claim 4 , wherein the step-shaped boundary is substantially perpendicular to the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard.

6. The sound-dampening plasterboard of claim 1 , wherein the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard are separated by a sloped boundary.

7. The sound-dampening plasterboard of claim 1 , wherein the first section of the first surface of the first plasterboard is raised above the second section of the first surface of the first plasterboard by at least 0.02 inches.

8. The sound-dampening plasterboard of claim 1 , wherein the first section of the first surface of the first plasterboard is raised above the second section of the first surface of the first plasterboard by no more than 0.1 inches.

9. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the first surface of the first plasterboard is no more than 4 inches, the width spanning between (i) a boundary that separates the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard and (ii) the second edge.

10. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the second surface of the first plasterboard is no more than 4 inches, the width of the second section of the second surface of the first plasterboard spanning between (i) the boundary that separates the first section of the second surface of the first plasterboard and the second section of the second surface of the first plasterboard and (ii) the second edge.

11. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the first surface of the first plasterboard is no more than 50% different, from a width of the second section of the second surface of the first plasterboard,
wherein the width of the second section of the first surface of the first plasterboard spans between (i) a boundary that separates the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard and (ii) the second edge, and
wherein the width of the second section of the second surface of the first plasterboard spans between (i) the boundary that separates the first section of the second surface of the first plasterboard and the second section of the second surface of the first plasterboard and (ii) the second edge.

12. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the first surface of the first plasterboard is no more than 20% different from a width of the second section of the second surface,
wherein the width of the second section of the first surface of the first plasterboard spans between (i) a boundary that separates the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard and (ii) the second edge, and
wherein the width of the second section of the second surface of the first plasterboard spans between (i) the boundary that separates the first section of the second surface of the first plasterboard and the second section of the second surface of the first plasterboard and (ii) the second edge.

13. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the first surface of the first plasterboard is at least twice as large as a width of the second section of the second surface of the first plasterboard,
wherein the width of the second section of the first surface of the first plasterboard spans between (i) a boundary that separates the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard and (ii) the second edge, and
wherein the width of the second section of the second surface of the first plasterboard spans between (i) the boundary that separates the first section of the second surface of the first plasterboard and the second section of the second surface of the first plasterboard and (ii) the second edge.

14. The sound-dampening plasterboard of claim 1 , wherein a width of the second section of the second surface of the first plasterboard is at least twice as large as a width of the second section of the first surface of the first plasterboard,
wherein the width of the second section of the first surface of the first plasterboard spans between (i) a boundary that separates the first section of the first surface of the first plasterboard and the second section of the first surface of the first plasterboard and (ii) the second edge, and
wherein the width of the second section of the second surface of the first plasterboard spans between (i) the boundary that separates the first section of the second surface of the first plasterboard and

Assignees

• Certainteed Gypsum Inc

Inventors

• Bridenstine John
• Riley Christopher G
• Dimitrakopoulos James

Classifications

• E04C2/043 Primary

  of plaster (E04C2/049 takes precedence) · CPC title

• B28B1/002

  assembled from preformed elements · CPC title

• B28B7/0085

  with surfaces for moulding chamfers · CPC title

• B28B11/0845

  for smoothing · CPC title

• B28B19/0092

  to webs, sheets or the like, e.g. of paper, cardboard · CPC title