Reinforced wallboard

Abstract

A wallboard with a plaster structural substrate is provided that includes a partial or complete fastening/distributing layer that provide desirable characteristics to both mechanically hold conventional fasteners (such as screws) as well as distribute the load of the fasteners to a sufficient area of the wallboard as to eliminate the need for supplemental construction or special fasteners or anchors. The fastening/distributing layer or inserts may be imbedded within the plaster substrate or laminated to it. The paper layer may include indicia identifying the location of the fastening/distributing layer.

1 . A wallboard comprising:
 a fastening/distributing layer having a lower surface and an upper surface;   a plaster substrate having an upper surface and a lower surface, the lower surface being bonded to the upper surface of the fastening/distributing layer; and   a paper layer bonded to the upper surface of the plaster substrate.   
   
   
       2 . The wallboard according to  claim 1 , wherein the thickness of the wallboard ranges from about one-half inch thick to one inch thick. 
   
   
       3 . The wallboard according to  claim 2 , wherein the fastening/distributing layer has a thickness ranging from about one thirty-secondth inch thick to three-sixteenth inch thick. 
   
   
       4 . The wallboard according to  claim 1 , wherein the wallboard includes at least two tapered edges. 
   
   
       5 . The wallboard according to  claim 1 , wherein the wallboard includes four tapered edges. 
   
   
       6 . The wallboard according to  claim 1 , wherein the fastening/distributing layer is formed of wood. 
   
   
       7 . The wallboard according to  claim 1 , wherein the fastening/distributing layer is formed of metal, composites, synthetic material, woven material, matted material, or combinations thereof. 
   
   
       8 . The wallboard according to  claim 1 , further comprising a second fastening/distributing layer between the upper surface of the plaster substrate and the paper layer. 
   
   
       9 . A wallboard comprising:
 a plaster substrate having an upper surface and a lower surface;   an upper paper layer bonded to the upper surface;   a lower paper layer bonded to the lower surface; and   a pair of fastening/distributing inserts located inside the wallboard between the upper and lower paper layers.   
   
   
       10 . The wallboard according to  claim 9 , wherein the paper layer includes indicia identifying the location of the pair of fastening/distributing inserts. 
   
   
       11 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts are located in the plaster substrate between the upper and lower surfaces. 
   
   
       12 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts are located on the upper surface. 
   
   
       13 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts is located on the lower surface. 
   
   
       14 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts is perforated metal sheets or metal inserts. 
   
   
       15 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts is formed from non-metallic sheet material. 
   
   
       16 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts extends in the longitudinal direction of the wallboard. 
   
   
       17 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts extends in the lateral direction of the wallboard. 
   
   
       18 . The wallboard according to  claim 9 , wherein the pair of fastening/distributing inserts are a first pair of fastening/distributing inserts and the wallboard further comprises a second pair of fastening/distributing inserts, the first pair of fastening/distributing inserts is located on the upper surface and the second pair of fastening/distributing inserts is located on the lower surface. 
   
   
       19 . The wallboard according to  claim 18 , wherein at least one of the first and second pair of fastening/distributing inserts is formed from a non-metallic material. 
   
   
       20 . The wallboard according to  claim 18 , wherein at least one of the first and second pair of fastening/distributing inserts is perforated metal sheets or metal inserts. 
   
   
       21 . The wallboard according to  claim 18 , wherein the first and second pair of fastening/distributing inserts extend in the longitudinal direction of the wallboard. 
   
   
       22 . The wallboard according to  claim 18 , wherein the first and second pair of fastening/distributing inserts extend in the lateral direction of the wallboard. 
   
   
       23 . The wallboard according to  claim 9 , wherein the wallboard includes at least two tapered edges. 
   
   
       24 . The wallboard according to  claim 9 , wherein the wallboard includes four tapered edges. 
   
   
       25 . A wallboard comprising:
 a plaster substrate having an upper surface and a lower surface;   an upper paper layer bonded to the upper surface;   a lower paper layer bonded to the lower surface,   wherein the wallboard includes at least three tapered edges.