Board Building Material, Board Building Material Producing Method, Board Building Material Installation Method

• US 20070220824A1
• Filed: 04/27/2005
• Published: 09/27/2007
• Est. Priority Date: 04/28/2004
• Status: Active Grant

• Current Assignee: Yoshino Gypsum Company Limited
• Original Assignee: Yoshino Gypsum Company Limited
• Inventors: Hasegawa, Tomoya, Wada, Masahiro, Amagai, Yasuyuki, Okazaki, Shoichi
• Granted Patent: US 7,661,511 B2
• Time in Patent Office: Days
• US Class Current: 52/506.50
• CPC Class Codes: E04B 2001/8245 Machines for manufacturing, shaping, piercing or filling sound insulating elements
• CPC Class Codes: E04B 9/001 characterised by provisions for heat or sound insulation
• CPC Class Codes: E04B 9/045 being laminated
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04F 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence

Abstract

Perforations of a board for building material are formed by a number of recesses (13), or a number of recesses (13) and through-holes (12). A bottom face (16) of the recess forms a face for screwing or driving the fixing element (70) thereto. A color of the bottom face is set to have a brightness of color decreased in comparison with a color of a surface (18) of the board. A substrate of the board is a gypsum board and the bottom face of the recess is formed by a liner paper for gypsum board. According to such a board, a region for screwing or driving the fixing element thereto can be ensured without impairing regularity, uniformity or architectural design of the perforations, and putty finishing or the like for an exposed part of the fixing element can be omitted.

Claims

1-21. -21. (canceled)

22. A board for building material which has perforations disposed on a surface of the board, the perforations being constituted from a number of recesses, or a number of recesses and through-holes,

wherein a substrate of the board is a gypsum board, a shape of the perforation is a polygon or a circle, said recess is formed on the surface of the board by compression-forming for locally compressing the substrate, and a bottom face of the recess formed by a liner paper for the gypsum board provides a face for screwing or driving the fixing element thereto.

23. The board as defined in claim 22, wherein a color of the bottom face is set to have a brightness of color decreased in comparison with a color of the surface of the board.

26. The board as defined in claim 22, wherein a sound absorption of the board is established by control of a ratio of the recesses and the through-holes.

27. The board as defined in claim 22, wherein a sheet is laid over said through-hole on a reverse face side thereof.

28. The board as defined in claim 27, wherein said sheet is a sheet of material including glass fibers and an inorganic matter.

29. The board as defined in claim 22, wherein said bottom face has a positioning index for positioning a fixing element.

30. The board as defined in claim 29, wherein said index is a dent, a small aperture or a cross-shaped groove, into which the tip of the fixing element can be inserted.

31. The board as defined in claim 29, wherein said index is positioned at a center of said bottom face.

34. The board as defined in claim 22, wherein a depth of said recess from the surface of the board is set to be in a range from 0.1 mm to 2.0 mm.

35. A method of producing the board as defined in claim 22, wherein the surface of the board is locally pressed by a flat pressing face of a male die so that the recess of a predetermined depth is formed on the surface of the board and the recess is provided with the bottom face of the recess for screwing or driving a fixing element thereto.

36. The method as defined in claim 35, wherein a guide plate provided with a guide hole for inserting the male die thereinto and an abutment face for abutment against the surface of the board is used, and the pressing face of said male die is pressed against the surface of the board in a condition that the abutment face is in contact with the surface of the board.

37. The method as defined in claim 35, wherein a penetrating member which has a profile substantially conforming to an outline of the recess and which transitionally penetrates the surface of the board for facilitating deformation of the surface is used.

38. The method as defined in claim 35, wherein a surface of a substrate of the board is colored beforehand in a color of said bottom face, and after the recess of the predetermined depth is formed, the surface of the substrate is colored in a brightness of color increased in comparison with the color of the bottom face.

39. A method of installing the board as defined in claim 22, wherein a sound absorption effect and an acoustic reverberation effect of a room are established with use of first boards which are said boards improved in their sound absorption performance by control of a ratio of the recess and the through-hole, and second boards which are said boards restricted in their sound absorption performance by control of the ratio of the recess and the through-hole.

40. The method as defined in claim 39, wherein the recesses and the through-holes have an equal dimension.

41. The method as defined in claim 35, wherein the through-holes are bored through the board.

24. A board for building material which has perforations disposed on a surface of the board, the perforations being constituted from a number of recesses, or a number of recesses and through-holes,

wherein a shape of the perforation is a polygon or a circle, said recess is formed on the surface of the board by compression-forming for locally compressing the substrate, said recesses are disposed in an area of the board to which fixing elements are to be screwed or driven, a bottom face of the recess provides a face for screwing or driving the fixing element thereto, and a color of the bottom face is set to have a brightness of color decreased in comparison with a color of the surface of the board.

32. The board as defined in claim 24, wherein a substrate of the board is a gypsum board and said bottom face of the recess is formed by a liner paper for gypsum board.

33. The board as defined in claim 32, wherein a color of said bottom face is the same as a color of said liner paper.

25. A board for building material which has perforations disposed on a surface of the board, the perforations being constituted from a number of recesses, or a number of recesses and through-holes,

wherein a shape of the perforation is a polygon or a circle, said perforations are formed on the surface of the board by compression-forming for locally compressing the substrate, the perforations are regularly and uniformly disposed on the surface of the board, and a color of a bottom face of the recess is set to have a brightness of color decreased in comparison with a color of the surface of the board.

42. The board as defined in claim 25, wherein a substrate of the board is a gypsum board and said bottom face of the recess is formed by a liner paper for gypsum board.