Gypsum studs assembled by rolling scored segments

Abstract

A gypsum stud is provided, including a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween, a series of cuts formed on at least one of the first and second facing sheets and extending into the core, retaining intact an opposing one of said first and second facing sheets to form a hinge point, the panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.

1 . A gypsum stud, comprising:
 a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;   a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;   said panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.   
     
     
         2 . The gypsum stud of  claim 1  further including a layer of adhesive applied to at least one of said first and second facing sheets so that said panel is held in said rolled condition. 
     
     
         3 . The gypsum stud of  claim 1 , wherein said cuts are 90° cuts. 
     
     
         4 . The gypsum stud of  claim 3 , wherein said cuts extend up to the opposite facing sheet from where they begin. 
     
     
         5 . The gypsum stud of  claim 1 , wherein said cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm). 
     
     
         6 . The gypsum stud of  claim 5 , where the rolling begins at the 1″ end so that the resulting stud has a width of 2½″. 
     
     
         7 . The gypsum stud of  claim 1 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.). 
     
     
         8 . The gypsum stud of  claim 1 , wherein said gypsum wallboard panel is a full-size, standard panel, and said cuts are made into said first and second facing sheets to form multiple wallboard studs. 
     
     
         9 . The gypsum stud of  claim 8 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.). 
     
     
         10 . The gypsum stud of  claim 8 , wherein three said gypsum studs, including three tubular outer portions and three insert portions are created from said panel. 
     
     
         11 . The gypsum stud of  claim 1 , wherein said stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within said central opening. 
     
     
         12 . The gypsum stud of  claim 10 , wherein said insert portion is formed by creating said cuts in an alternating fashion on said first and second facing sheets. 
     
     
         13 . A method of making a gypsum stud, comprising:
 providing a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;   generating a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;   rolling said panel from a first side to a second side into a rolled condition so that a rolled up stud is formed.   
     
     
         14 . The method of  claim 13 , wherein a first spacing of said cuts on said first facing sheet is different from a second spacing of said cuts on said second facing sheet. 
     
     
         15 . The method of  claim 13 , further including generating said series of cuts to form a first outer portion defining a central opening, and generating said series of cuts to form a second, insert portion dimensioned to fit inside said opening.