System and method for making wallboard

Abstract

A method of making wallboard including the steps of providing an unfinished length of wallboard that has a recess along its longitudinal edges by conveying it upon a conveyor in a first direction in a step, forming recesses in the unfinished length of wallboard at both lateral edges thereof, selecting an apparatus for forming the recess from a plurality of device for forming the recess, forming the recess with the selected apparatus, and separating the unfinished length of wallboard at a location of the recess to form finished lengths of wallboard, such that the finished lengths of wallboard have recessed lateral edges. Also disclosed is a system for performing the method.

1 . A method of making wallboard comprising: 
 providing an unfinished length of wallboard that has a recess along its longitudinal edges by conveying it upon a conveyor in a first direction; and    forming recesses in the unfinished length of wallboard at both lateral edges thereof;    selecting an apparatus for forming the recess from a plurality of devices for forming the recess;    forming the recess with the selected apparatus; and    separating the unfinished length of wallboard at a location of the recess to form finished lengths of wallboard, such that the finished lengths of wallboard have recessed lateral edges.    
   
   
       2 . The method of  claim 1  wherein the step of selecting an apparatus comprises the step of lowering the apparatus to contact the wallboard.  
   
   
       3 . The method of  claim 1  wherein the step of selecting an apparatus further comprises moving the apparatus laterally to a desired location for forming the recess.  
   
   
       4 . The method of  claim 1  wherein the wallboard provided is partially cured gypsum wallboard.  
   
   
       5 . The method of  claim 1  wherein the step of forming the recess with the selected apparatus comprises the step of gradually compressing the wallboard along the desired location of the recess as the wallboard is conveyed in a direction generally parallel to the recess.  
   
   
       6 . The method of  claim 1  wherein the step of forming the recess with the selected apparatus comprises the step of forming the recess with the selected apparatus while moving the wallboard in a direction generally perpendicular to the first direction  
   
   
       7 . The method of  claim 1  wherein the step of forming the recess with the selected apparatus comprises the step of continually increasing the recess on the wallboard as the wallboard moves in a direction parallel to the recess.  
   
   
       8 . The method of  claim 1  wherein the step of selecting an apparatus for forming the recess from a plurality of device for forming the recess comprises the step of selecting a plurality of apparatus for forming a plurality of recesses.  
   
   
       9 . A method of making wallboard comprising: 
 forming a continuous slab of wallboard having opposed face surfaces bordered by a pair of longitudinal side edges;    forming longitudinal recessed areas along the side edges on a first face of the wallboard;    cutting the wallboard to a first, unfinished length;    forming recesses in the wallboard at lateral edges of the unfinished length and forming at least one recess in the unfinished length of wallboard generally parallel to and offset from the lateral edges; and    cutting the unfinished length of wallboard at a location of the recess such that the finished lengths of wallboard have recessed lateral edges.    
   
   
       10 . The method of  claim 9  further comprising the step of selecting an apparatus for forming the recess from a plurality of device for forming the recess.  
   
   
       11 . The method of  claim 10  wherein the step of selecting an apparatus for forming the recess from a plurality of apparatus for forming the recess comprises the step of lowering the apparatus to contact the wallboard.  
   
   
       12 . The method of  claim 11  further comprising the step of selecting the apparatus from a plurality of apparatus adapted to be lowered to contact the wallboard.  
   
   
       13 . The method of  claim 9  further comprising the step of positioning the apparatus to a desired location of the recess.  
   
   
       14 . The method of  claim 13  wherein the step of positioning the apparatus further comprises moving the apparatus laterally to a desired location for forming the recess.  
   
   
       15 . The method of  claim 14  wherein the step of positioning the apparatus for forming the recess comprises the step of lowering the apparatus to contact the wallboard.  
   
   
       16 . The method of  claim 15  further comprising the step of selecting the apparatus from a plurality of apparatus adapted to be lowered to contact the wallboard.  
   
   
       17 . The method of  claim 9  wherein the wallboard provided is partially cured gypsum wallboard.  
   
   
       18 . The method of  claim 9  wherein the step of forming the recess with the selected apparatus comprises the step of gradually compressing the wallboard along the desired location of the recess as the wallboard is conveyed in a direction generally parallel to the recess.  
   
   
       19 . The method of  claim 9  wherein the step of forming the recess with the selected apparatus comprises the step of forming the recess with the selected apparatus while moving the wallboard in a direction generally perpendicular to the first direction  
   
   
       20 . The method of  claim 9  wherein the step of forming the recess with the selected apparatus comprises the step of continually increasing the on the wallboard as the wallboard moves in a direction parallel to the recess.  
   
   
       21 . A device for forming recesses in an unfinished length of wallboard: 
 a first press located at a first lateral edge of the unfinished length of wallboard;    a second press located at a second lateral edge of the unfinished length of wallboard opposite the first lateral edge;    a third press located between the first and second press;    whereby as unfinished length of wallboard is fed into the first, second and third presses the first press forms a recess along the first lateral edge, the second press forms a recess along the second lateral edge and the third press forms a recess in the wallboard generally parallel to the first recess and between the first and second lateral edges.    
   
   
       22 . The device of  claim 21  further comprising one or more additional presses for forming one or more additional recesses in the unfinished length of wallboard.  
   
   
       23 . The device of  claim 21  wherein the presses provide gradually increasing pressure to the wallboard as the wallboard is conveyed toward the presses.  
   
   
       24 . The device of  claim 21  wherein the presses each comprise an upper and lower surface that taper toward one another gradually over not less than 6 inches of length.  
   
   
       25 . The device of  claim 24  wherein the surfaces are attached to moving chains which support and compress the wallboard.  
   
   
       26 . The device of  claim 24  wherein the upper surface defines the desired taper to be imprinted into the wallboard and the lower surface is a generally flat surface.  
   
   
       27 . The device of  claim 24  wherein the upper surfaces may be selectively raised and lowered to bring the upper surface into and out of contact with the wallboard.  
   
   
       28 . The device of  claim 24  wherein at least one of the upper surfaces are moveable laterally to place the press in a desired location.  
   
   
       29 . A device for forming recesses in an unfinished length wallboard: 
 a casting conveyor for forming a continuous slab of wallboard from a slurry, the wallboard having inner and outer paper surfaces bordered by a pair of longitudinal side edges, the conveyor having shaped recess formers along the sides thereof to form recesses in the longitudinal edges;    a cutting system adjacent to the end of the conveyor for cutting the wallboard slab to unfinished lengths;    a lateral edge forming system for forming lateral recessed areas on the unfinished lengths at the cut lateral edges;    a first press located at a first lateral edge of the unfinished length of wallboard;    a second press located at a second lateral edge of the unfinished length of wallboard opposite the first lateral edge;    a third press located between the first and second press;    whereby when an unfinished length of wallboard is fed into the first, second and third presses the first press forms a recess along the first lateral edge, the second press forms a recess along the second lateral edge and the third press forms a recess in the wallboard generally parallel to the first recess and between the first and second lateral edges.    
   
   
       30 . The device of  claim 29  further comprising one or more additional presses for forming one or more additional recesses in the unfinished length of wallboard.  
   
   
       31 . The device of  claim 29  wherein the presses provide gradually increasing pressure to the wallboard as the wallboard is conveyed toward the presses.  
   
   
       32 . The device of  claim 29  wherein the presses each comprise an upper and lower surface that taper toward one another gradually over not less than 6 inches of length.  
   
   
       33 . The device of  claim 32  wherein the surfaces are attached to moving chains which support and compress the wallboard.  
   
   
       34 . The device of  claim 32  wherein the upper surface defines the desired taper to be imprinted into the wallboard and the lower surface is a generally flat surface.  
   
   
       35 . The device of  claim 32  wherein the upper surfaces may be selectively raised and lowered to bring the upper surface into and out of contact with the wallboard.  
   
   
       36 . The device of  claim 32  wherein at least one of the upper surfaces are moveable laterally to place the press in a desired location.  
   
   
       37 . A method of making wallboard comprising: 
 providing an unfinished length of wallboard;    providing a press assembly comprising an upper assembly and a lower assembly, wherein the upper assembly comprises an infinite loop having an exterior surface rotatable about the upper press assembly and the lower press assembly comprises an infinite loop having an exterior surface rotatable about the lower assembly, wherein the upper and lower press assemblies are placed opposite one another wherein a gap between the exterior surfaces of the loops of the upper and lower press assemblies gradually tapers from a first distance at a first end of the press assembly to a second, closer distance;    rotating the loops of the upper and lower press assemblies; and    moving the unfinished length of wallboard between the upper and lower press assemblies by contacting the wallboard between rotating loops and moving the wallboard through the tapered gap.    
   
   
       38 . A device for forming recesses in a length of wallboard comprising: 
 a press assembly comprising an upper press assembly and a lower press assembly, the upper press assembly comprising an infinite loop with an exterior surface and the lower assembly comprising an infinite loop with an exterior surface, the infinite loops being rotatable about their respective upper or lower press assembly, the press assemblies being placed adjacent one another to define a gap therebetween, the gap being tapered such that it is wider at a first end of the press assembly and narrows to a smaller dimension.