Wallboard system and methods of installation and repair

Abstract

A wallboard system composed of panels having weldable joint areas is disclosed. The panels are joined together by a connector that can also be utilized to align adjacent panels. Each panel has a reinforcement grid either embedded therein or attached thereto. Preferably, the reinforcement grid is made of a network of horizontal and perpendicular conduits that extend across the panel. The connector is interposed between the sidewalls of adjacent panels and the end portions of the conduits from each panel are configured to mate with respective areas of the connector, thereby forming a flush joint between adjacent panels. The connectors may include a generally L-shaped corner bead that fills the joint areas between panels forming inside or outside corners.

1 . A wallboard system, comprising: 
 a plurality of panels, each of said panels having a plurality of conduits extending through the panel between a first edge and a second edge; and    a connector comprising a plurality of protrusions sized to fit within the respective conduits.    
   
   
       2 . The wallboard system of  claim 1 , wherein the conduits extend between opposite edges of each panel.  
   
   
       3 . The wallboard system of  claim 1 , further comprising a second plurality of conduits, wherein the second plurality of conduits are orthogonal to the first plurality of conduits.  
   
   
       4 . The wallboard system of  claim 1 , wherein the connector comprises an elongated strip from which the protrusions project.  
   
   
       5 . The wallboard system of  claim 4 , wherein the protrusions project from opposing surfaces of the strip.  
   
   
       6 . The wallboard system of  claim 1 , wherein the conduits are made of a plastic material selected from the group consisting of PVC, polycarbonate, polystyrene, ABS, nylon, PET, acrylics, or combinations thereof.  
   
   
       7 . The wallboard system of  claim 1 , wherein the protrusions on the connector and the conduits are welded together.  
   
   
       8 . The wallboard system of  claim 1 , wherein the connector has at least two surfaces that are disposed at an angle relative to each other, wherein said protrusions project from the two surfaces.  
   
   
       9 . The wallboard system of  claim 1 , wherein the panel is drywall.  
   
   
       10 . The wallboard system of  claim 1 , wherein the panel is plasterboard.  
   
   
       11 . The wallboard system of  claim 1 , wherein the panel is cement fiberboard.  
   
   
       12 . The wallboard system of  claim 1 , wherein the panel is mineral fiber.  
   
   
       13 . A drywall panel having a plurality of elongated reinforcements extending through from one edge to another.  
   
   
       14 . The drywall panel of  claim 13 , further comprising indicia on the exterior of the panel indicating position of the reinforcements.  
   
   
       15 . The drywall panel of  claim 13 , wherein said elongated reinforcements comprise a network of horizontal and perpendicular reinforcements.  
   
   
       16 . The drywall panel of  claim 13 , wherein an end portion of each reinforcement protrudes outwardly from an edge of the panel.  
   
   
       17 . The drywall panel of  claim 16 , further comprising a gusset disposed along the edge of the panel, said gusset having a plurality of openings configured to receive the end portion of the reinforcement.  
   
   
       18 . A plurality of panels comprised of gypsum, each of the panels having two opposing faces and an edge portion comprised of a material other than gypsum, said material having a bonding property which allows an edge portion of one panel to be attached to an edge portion of another panel by bonding so as to securely fasten the edge portions together.  
   
   
       19 . The panels of  claim 18 , wherein the bonding property comprises a property which allows the material to be weldable to other materials.  
   
   
       20 . The panels of  claim 18 , wherein the edge portion material is plastic.  
   
   
       21 . The panels of  claim 18 , wherein said edge portion comprises a planar surface that is perpendicular to the opposing faces of the panel.  
   
   
       22 . The panels of  claim 18 , wherein the edge portion of one panel is attached to the edge portion of another panel by bonding both edge portions to a connector that is disposed therebetween.  
   
   
       23 . A wallboard panel comprised of gypsum, said panel having an edge portion comprised of a plastic material.  
   
   
       24 . The wallboard panel of  claim 23 , wherein the edge portion comprises opposing edges of the panel, said opposing edges are interconnected by reinforcements extending across the gypsum.  
   
   
       25 . The wallboard panel of  claim 24 , wherein the edge portion comprises a frame that borders the edges of the panel.  
   
   
       26 . The wallboard panel of  claim 23 , wherein said plastic material is attached to a face of the wallboard panel.  
   
   
       27 . A corner bead for finishing a corner of abutted, non-overlapping drywall panels, said corner bead configured to fit wholly between ends of the abutted panels without overlapping onto faces of the panels.  
   
   
       28 . The corner bead of  claim 27 , further comprising two elongated surfaces disposed at an angle relative to each other, wherein each surface is configured to contact an end of a respective abutting panel.  
   
   
       29 . The corner bead of  claim 27 , further comprising a plurality of protrusions extending from each of said elongated surfaces.  
   
   
       30 . The corner bead of  claim 27 , wherein said corner bead is configured to attach to the panels without taping or nailing.  
   
   
       31 . The corner bead of  claim 27 , wherein said corner bead is configured for finishing an inside corner.  
   
   
       32 . The corner bead of  claim 27 , wherein said corner is configured for finishing an outside corner.  
   
   
       33 . The corner bead of  claim 28 , wherein the angle between the elongated surfaces of the corner bead is adjustable.  
   
   
       34 . A wallboard system comprising: 
 a pair of panels comprised of gypsum core, each of the panels having an edge portion comprised of material other than gypsum; and    a corner bead between edges of adjacent panels, said corner bead having a pair of surfaces disposed at an angle relative to each other, said corner bead comprised of a material, wherein the edge portion material and the corner bead material have bonding properties which allow respective edge portions of the panels to be attached to respective surfaces of the corner bead by bonding.    
   
   
       35 . A method of installing a plurality of wallboard panels, comprising: 
 positioning a first drywall panel having an edge portion comprised of a material other than drywall to a second drywall panel having an edge portion comprised of a material other than drywall; and    attaching the edge portion of the first drywall panel to the edge portion of the second drywall panel by a method selected from the group consisting of cement bonding, adhesive bonding, solvent welding, heat welding, ultrasonic welding, and combinations thereof.    
   
   
       36 . The method of  claim 35 , wherein the step of attaching the edge portions of the drywall panels comprises placing a connector adjacent a respective edge portion of each drywall panel and adhering said connector to said respective edge portions.  
   
   
       37 . The method of  claim 36 , wherein placing a connector adjacent a respective edge portion comprises placing a connector having spaced protrusions extending therefrom adjacent an edge of the first drywall panel, inserting a plurality of the protrusions into the edge portion of the first panel, and inserting another plurality of the protrusions into the edge portion of the second drywall panel, and adhering the inserted plurality of protrusions to the drywall material.  
   
   
       38 . The method of  claim 37 , further comprising inserting a fastener into a face of the drywall panel, through one of a plurality of conduits embedded in the drywall, and into a support frame.  
   
   
       39 . A method of repairing a drywall panel, comprising: 
 cutting an opening in a drywall panel having a plurality of conduits extending therethrough;    preparing a drywall insert sized to fit within the opening such that a plurality of conduits through the insert is parallel to the plurality of conduits in the panel; and    inserting at least one connector into at least some of the conduits so as to fasten the insert into the panel.    
   
   
       40 . The method of  claim 39 , further comprising orienting the inserts so that a second plurality of conduits of the insert orthogonal to the first plurality of the insert is parallel to a second plurality of conduits of the panel orthogonal to the plurality of conduits to the panel.  
   
   
       41 . A frame for mounting gypsum drywall, comprising: 
 a perimeter edge portion configured to retain a panel of said gypsum drywall with plural edges of the panel adjacent respective plural edges of said perimeter edge portion; and    a backing portion attached to said edge portion and disposed within a space defined by the perimeter of the edge portion.    
   
   
       42 . The frame of  claim 41 , wherein said edge portion comprises a plurality of elongated sections defining a substantially rectangular area.  
   
   
       43 . The frame of  claim 42 , wherein at least one elongated section is made of a plastic material.  
   
   
       44 . The frame of  claim 42 , wherein at least two of the elongated sections are disposed orthogonally to each other thereby forming a corner.  
   
   
       45 . The frame of  claim 42 , wherein plural openings are formed in at least one elongated section.  
   
   
       46 . The frame of  claim 41 , wherein said edge portion is approximately 4 feet wide and 8 feet long.  
   
   
       47 . The frame of  claim 41 , wherein the backing portion extends cross the space defined by the perimeter of the edge portion.  
   
   
       48 . The frame of  claim 41 , wherein the backing portion comprises a plurality of conduits.  
   
   
       49 . A method of applying a frame to a gypsum drywall panel, comprising: 
 providing a substantially rigid frame having a backing material disposed within a space defined by said frame; and    attaching said gypsum drywall panel to said frame.    
   
   
       50 . The method of  claim 49 , wherein providing said frame comprises joining a plurality of elongated legs together in a manner such that at least two of the legs are disposed orthogonally to each other.  
   
   
       51 . The method of  claim 50 , wherein attaching said gypsum drywall panel to said frame comprises attaching a face of said gypsum drywall panel to said elongated legs.  
   
   
       52 . The method of  claim 49 , wherein forming said frame comprises attaching a backing material to at least one edge of the frame.  
   
   
       53 . The method of  claim 52 , wherein said backing material comprises a conduit.  
   
   
       54 . The method of  claim 52 , wherein attaching said gypsum drywall panel comprises attaching a face of the panel to said backing material.