The present disclosure relates generally to building surface systems, for example, suitable for forming an internal or external surface of a building. The present disclosure relates more particularly to a building surface system formed by panels that are secured to a support structure.
Prefabricated panels, for example gypsum panels that are commonly referred to as drywall, are often used to construct building surfaces. The panels are attached to a supporting structure, such as the joists of a wall frame. Once the panels are hung on the supporting structure, the surface is finished using joint compound or another material to create a smooth surface. The surface may then be painted or covered with wall paper.
Gypsum panels are advantageous for use as a building surface for various reasons. Such panels are incredibly durable, have excellent fire resistance, are easily repaired, and are easy to mount on a supporting structure. Typically, mounting gypsum panels only requires attaching the panels to an underlying supporting structure using mechanical fasteners, such as screws.
While the mounting of gypsum panels is straightforward, most panels are finished by covering the joints between the panels and the fasteners in order to create a smooth surface. The panels are then painted or covered with wall paper to create a pleasing aesthetic. The process of finishing the building surface is time consuming, as each application of joint compound or paint should be dried before the subsequent step can be performed. Moreover, the finishing steps require uncommon skills.
Further, after traditional gypsum panels are installed, removing the panels requires damaging a portion of the panels and the surface finish. Accordingly, when mechanical, electrical, and plumbing components behind the building surface need to be repaired, the building surface is at least partially damaged to gain access to the components. After the work on the hidden components is completed, the building surface needs to be repaired and finished once again. For these reasons, the present inventors have determined that a building surface product that can be installed more quickly would be attractive to both builders and customers.
In one aspect, the present disclosure provides a building surface product comprising:
a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface;
a first attachment post extending outward from the rear surface of the panel, the first attachment post including:
In another aspect, the disclosure provides a method of forming the building surface system according to the disclosure, the method comprising:
positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail; and
securing the first building surface product to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.
In another aspect, the disclosure provides a building surface system comprising:
a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate; and
a first building surface product according to the disclosure attached to the support structure, wherein the first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
As described above, the present inventors have noted that conventional building surface products are time-consuming to install and require skill to finish. The present inventors have determined that a building surface product that can be installed more quickly and without requiring specific skills to finish would be attractive to builders and customers.
Accordingly, one aspect of the disclosure is a building surface product that includes a substantially planar panel and a first attachment post extending outward from a rear surface of the panel. The panel has a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface. The first attachment post includes a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel. A lip extends radially outward from the shaft and is configured to hold the first attachment post in an aperture of a support structure, as described in more detail below.
The rear surface of such a building surface product is shown in perspective view in
As illustrated in
In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer. For example, as shown in
In other embodiments, the gypsum body of the panel includes a single layer. Such an embodiment is shown in
In certain embodiments of the building surface product as otherwise described herein, the panel includes a first receiver sleeve and the first attachment post extends into the first receiver sleeve. For example, panel 102 of
In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve extends through the reinforcing layer to the front layer. For example, in panel 102, as shown in
In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve includes a threaded interior surface configured to engage the first attachment post. For example, in some embodiments, the shaft of the first attachment post is threaded and the first receiver sleeve includes a complementary thread to receive the first attachment post. Such a threaded engagement may help secure the first attachment post in the panel. In other embodiments, the first receiver sleeve is configured to capture the first attachment post in another manner. For example, in some embodiments, the shaft of the first attachment post is threaded and the first receiver sleeve has a deformable interior surface. Accordingly, the threaded shaft of the first attachment post can cut into the first receiver sleeve in order to form a secure connection between the first attachment post and first receiver sleeve.
In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer of the panel. For example, first receiver sleeve 140 of building surface product 100 includes an external flange 142 that extends radially outward from an axis of the receiver sleeve. The external flange 142 is positioned between the front layer 113 and the reinforcing layer 114 so as to capture the receiver sleeve in the gypsum body 110 and prevent first receiver sleeve 140 from separating from panel 102.
In other embodiments, the panel is constructed without a receiver sleeve. For example, in some embodiments, the first attachment post extends directly into the material of the gypsum body. A cross section of such an embodiment is shown in
In certain embodiments of the building surface product as otherwise described herein, the first attachment post extends through the reinforcing layer and into the front layer. For example, as shown in
In certain embodiments of the building surface product as otherwise described herein, the reinforcing layer includes a first section along a first edge of the panel, and the first section is disposed behind the front layer along the first edge. For example, as shown in
In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes a first edge section between the front layer and the first section of the reinforcing layer at the first edge. For example, as shown in
In certain embodiments of the building surface product as otherwise described herein, the front layer has a first tapered face along the first edge, the first section of the reinforcing layer has a tapered face along the first edge, and the first edge section has a triangular shape including a front face that is adjacent to the first tapered face of the front layer and a rear face that is adjacent to the tapered face of the first section of the reinforcing layer. For example, first edge section 120 of gypsum body 110 has a triangular cross-section with an outer face 121 along first edge 116, a front face 122 that is presented toward front layer 113, and a rear face 123 that is presented toward first section 115 of reinforcing layer 114. To match the shape of first edge section 120, front layer 113 has a first tapered face 124 that is opposes front face 122 of first edge section 120. Likewise, first section 115 of reinforcing layer 114 also has a tapered face 125 that opposes rear face 123 of first edge section 120. In the embodiment of shown in
In certain embodiments of the building surface product as otherwise described herein, the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet. For example, the configuration shown in
In certain embodiments of the building surface product as otherwise described herein, a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer. For example, when the first section 115 of reinforcing layer 114 is folded behind front layer 113, the facing sheet 126 that extended along the original gypsum panel on the face opposite the grooves wraps around the first edge 116 so as to cover the front surface 108 of the gypsum body 110, the outer face 121 of the first edge section 120 and the rear face of the first section 115 of the reinforcing layer 114. In other embodiments, the facing sheet may be applied to the gypsum body after the reinforcing layer is formed over the front layer. Still, in some embodiments, separate facing sheets cover the front layer and reinforcing layer. Further still, in some embodiments, at least some portions of the gypsum body are not covered by a facing sheet.
In certain embodiments of the building surface product as otherwise described herein, an adhesive layer is provided between the first tapered face of the front layer and the front face of the first edge section. Likewise, in certain embodiments, an adhesive layer is provided between the tapered face of the first section of the reinforcing layer and the rear face of the first edge section. For example, in some embodiments, a layer of adhesive may be disposed on either or both of the front face 122 or rear face 123 of first edge section 120 so as to adhere the first edge section 120 to the respective tapered face 124, 125 of the front layer 113 or first section 115 of the reinforcing layer 114. The adhesive layer may help strengthen the edge of the gypsum body 110 and maintain the folded shape of the panel 102.
In certain embodiments of the building surface product as otherwise described herein, an adhesive layer is provided between the between the front layer and the first section of the reinforcing layer. For example, in some embodiments, a layer of adhesive may be disposed on the rear face of the front layer 113 of gypsum body 110 and on the front face of first section 115 of reinforcing layer 114. The adhesive layer may help hold the first section 115 of reinforcing layer 114 against front layer 113 and strengthen the edge of panel 102. In some embodiments, the layer of adhesive is a continuous layer that extends across the entire front surface of the reinforcing layer. In other embodiments, the layer of adhesive may be formed by spots or traces of adhesive on the faces between the two layers. Still, in other embodiments, the layers may be attached to one another in another manner, such as bonding of the gypsum material of the layers to each other or to a material sheet between the two layers.
In certain embodiments of the building surface product as otherwise described herein, the first attachment post extends through the adhesive layer provided between the front layer and the first section of the reinforcing layer. For example, in some embodiments, the first attachment post may pass through the interface between the front layer and the first section of the reinforcing layer in an area where adhesive is provided between these layers. In some embodiments, the engagement of the first attachment post to the panel may be strengthened by the extension of the first attachment post through the adhesive. On the other hand, in some embodiments, the first attachment post extends through the interface between the front layer and the first section of the reinforcing layer in an area where there is no adhesive positioned between the two layers of the gypsum body.
In certain embodiments of the building surface product as otherwise described herein, a pair of facing sheets are provided between the front layer and the first section of the reinforcing layer. For example, in gypsum body 310 of panel 302 a first intermediate facing sheet 327 is secured to the rear face of front layer 313 and a second intermediate facing sheet 328 is secured to the front face of first section 315 of reinforcing layer 314. Each of the intermediate facing sheets 327, 328 can help increase the strength of the corresponding layer 313, 314 of gypsum body 310. Moreover, the intermediate facing sheets 327, 328 may also help secure the first attachment post 330 in the gypsum body 310.
In certain embodiments of the building surface product as otherwise described herein, the reinforcing layer extends around a perimeter of the panel. For example, in certain embodiments, the reinforcing layer includes a section along each edge of the panel. Moreover, in some embodiments, the gypsum body includes an edge section along each edge of the panel between the front layer and respective section of the reinforcing layer. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the lip of the first attachment post is formed as a portion of a head at the second end of the shaft. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the first attachment post includes a collar surrounding the shaft that engages the rear surface of the panel. For example, first attachment post 130 includes a collar 134 extending outward from shaft 132 at an intermediate point along the length of shaft 132. The collar 134 defines the depth that first attachment post 130 is inserted into the rear surface 109 of panel 102. Accordingly, the lip 138 formed by head 136 is set at a distance from panel 102, allowing the lip 138 of attachment post 130 to easily engage a support structure.
In certain embodiments of the building surface product as otherwise described herein, the first attachment post is one of a plurality of attachment posts extending from the rear surface of the panel. For example, building surface product 100 includes four attachment posts 130 extending from the rear surface 109 of panel 102. Further, in some embodiments, all of the attachment posts have the same configuration, such as in building surface product 100. For example, in some embodiments, each of the plurality of attachment posts includes a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip that extends radially outward from the respective shaft and is configured to hold the respective attachment post in a respective aperture of the support structure.
In other embodiments, the attachment posts have different configurations. For example, in some embodiments, the attachment posts at one end of the panel have a different configuration than attachment posts at the other end. Likewise, in some embodiments, the attachment posts at the top of the panel have a different configuration than those at the bottom. Further, while building surface product 100 includes four attachment posts 130, as shown in
In another aspect, the disclosure provides a building surface system including a support structure and a first building surface product according to the disclosure attached to the support structure. The support structure includes a plurality of rails that form a support surface. The plurality of rails includes a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate. The first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.
Such a building surface system is shown in
While the embodiment shown in
In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes a first engagement edge extending along one side of the slot, the shaft of the first attachment post extends through the first receiving slot, and the lip of the first attachment post abuts the first engagement edge of the longitudinal plate. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, a first end of the first receiving slot is wider than a second end of the first receiving slot, and the first attachment post is held at the second end of the first receiving slot. Further, in some embodiments, the first end of the first receiving slot has a width that is larger than a width of the first attachment post, such that the first attachment post is removable from the first receiving slot at the first end. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes a front face and a first indentation that protrudes rearward from the front face, wherein the first receiving slot is disposed in the first indentation. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, a depth of the first indentation increases from the first end of the first receiving slot to the second end of the first receiving slot. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the rear surface of the panel of the first building surface product abuts the front face of the longitudinal plate. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the first receiving slot is disposed on a first side of the longitudinal plate and a second receiving slot is disposed on a second side of the longitudinal plate. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the building surface system includes a second building surface product according to the disclosure, where an attachment post of the second building surface product is received in the second receiving slot of the longitudinal plate so as to secure the second building surface product against the support structure. For example, building surface system 450, as shown in
In the illustrated embodiment, as shown in
In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes an outwardly extending projection between the first receiving slot and the second receiving slot. Further, in some embodiments, the outwardly extending projection is disposed between the first building surface product and the second building surface product. For example, as shown in
In some embodiments, the projection may provide a support ledge for a building surface product during an installation process. For example, the panel of a building surface product may be arranged to rest on the projection while the attachment posts of the building surface product are inserted into receiving slots of the corresponding rail. Likewise, the projection may also aid in positioning the rail while it is installed. For example, as explained in more detail below, the projection may be placed on a previously-installed building surface product before the rail is secured in place as part of the support structure.
The rail 460 shown in
In certain embodiments of the building surface system as otherwise described herein, a height of the outwardly extending projection is substantially equal to a thickness of the panel of the first building surface product. The term substantially equal, as used herein, means having a deviation of no more than 10%. For example, as shown in
In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes an open path extending from the first end of the first receiving slot to an edge along the second side of the longitudinal plate. For example, as shown in
In some embodiments, the first receiving slot includes the open path to the edge of the longitudinal plate, while the second receiving slot is enclosed. On the other hand, in some embodiments, both the first receiving slot and the second receiving slot include such an open path, where the respective open paths extend to opposite edges of the longitudinal plate. Further still, in some embodiments, both receiving slots are enclosed and are not accessible by an open path to an edge of the longitudinal plate.
In certain embodiments of the building surface system as otherwise described herein, the first receiving slot is one of a row of receiving slots positioned along a length of the longitudinal plate, and the building surface system includes a row of building surface products that engage other receiving slots in the row of receiving slots. For example, as shown in
In some embodiments, the longitudinal plate forms the entire rail. For example, in some embodiments, the upper and lower sides of the longitudinal plate form the outer edges of the rail. In other embodiments, the longitudinal plate forms a portion of the rail. For example, in some embodiments, the rail includes a structural flange extending from one side of the longitudinal plate, similar to an L-bracket. Further, in some embodiments, the rail includes structural flanges extending from both sides of the longitudinal plate, so as to have a channel configuration.
In some embodiments, the rail is formed of a metal, such as aluminum or steel. In other embodiments, the rail is formed of a polymer material, such as a reinforced polymer. Still, in other embodiments, the rail is formed of another material, such as wood, bamboo or composite material.
In certain embodiments of the building surface system as otherwise described herein, the support structure includes vertical framing members, and the first rail extends across the vertical framing members and is attached to the vertical framing members. For example, as shown in
In some embodiments, the framing members are formed of timber, such as wood studs. In other embodiments, the framing members are formed of metal, such as such as steel or aluminum studs. Other materials may also be used for the framing members.
In certain embodiments of the building surface system as otherwise described herein, the first rail is attached to the vertical framing members using mechanical fasteners that extend into the vertical framing members. For example, in some embodiments, the first rail is secured to the vertical framing members with screws or nails that extend directly into the body of the vertical framing members. In other embodiments, where the vertical framing members are metal, the first rail may be welded or otherwise affixed to the vertical framing members. Further, in other embodiments, the vertical framing members may include receptacles to receive the mechanical fasteners. For example, in some embodiments, the vertical framing members include beams and reinforcement plates secured to the beams, where the reinforcement plates include receivers configured to receive mechanical fasteners that secure the first rail to the vertical framing members.
Such an embodiment is shown in
In certain embodiments of the building surface system as otherwise described herein, the receivers have an adjustable position with respect to the reinforcement plates. For example, receiver 558 is configured to slide with respect to reinforcement plate 556, which allows the vertical position of first rail 560 to be varied as needed to align the building surface products.
In another aspect, the disclosure provides a method of forming the building surface system according to the disclosure. The method includes positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail. The first building surface product is secured to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.
For example, to add a further building surface product 400 in one of the empty positions in building surface system 450, shown in
In certain embodiments of the method as otherwise described herein, the first building surface product is positioned in front of the support structure such that a plurality of additional attachment posts of the first building surface product are inserted in respective receiving slots of the support structure, and sliding the first building surface product to the assembled position causes the additional attachment posts to be secured in the respective receiving slots. For example, when installing building surface product 100, shown in
In certain embodiments of the method as otherwise described herein, the method further includes positioning a second building surface product according to the disclosure in front of the support structure such that the rear surface of the panel of the second building surface product faces the support structure and an attachment post of the second building surface product is inserted in another receiving slot of the longitudinal plate of the first rail. The second building surface product is secured to the support structure by sliding the second building surface product to an assembled position where the attachment post of the second building surface product is secured in the other receiving slot of the longitudinal plate of the first rail, and the attachment post retains the second building surface product against the support structure. For example, when installing the building surface system 450, shown in
In some embodiments, the support structure is assembled first and the building surface products are secured to the assembled support structure. For example, in some embodiments, the rails are all attached to vertical framing members and then the building surface products of the disclosure are attached to the rails. In other embodiments, the building surface products and rails may be assembled intermittently. For example, in some embodiments, a row of building surface products may be attached to the upper side of a previously-installed rail, and then a subsequent rail may be placed behind the row of building surface products and then secured in place.
For example, in certain embodiments of the method as otherwise described herein, the method includes positioning a second rail behind the first building surface product with a second attachment post of the first building surface inserted into a receiving slot of the second rail, and securing the second rail to the first building surface product by sliding the second rail to an assembled position where the second attachment post of the first building surface product is secured in the receiving slot of the second rail. In such a method, the spacing of the rails is inherently accurate, as each rail fixed within the support structure only after being coupled to the lower row of building surface products. Accordingly, the spacing of the rails can be set without the need for careful measurements, which may reduce mistakes and inaccuracies.
In certain embodiments of the method as otherwise described herein, positioning the second rail behind the first building surface product includes introducing the second attachment post into the receiving slot of the second rail through an open path in the second rail. For example, with the first building surface product already in place there may be limited space between the vertical framing members and the building surface product to maneuver the second rail into place. However, where the receiving slots on one side of the rail include open paths to the side edge of the longitudinal plate, as shown in
In certain embodiments of the method as otherwise described herein, positioning the second rail behind the first building surface product includes placing a projection of the second rail on an upper edge of the panel of the first building surface product. For example, when placing the rail 460 shown in
In another aspect, the disclosure provides a building surface product with attachment clips. The building surface product includes a substantially planar panel having a front surface, a rear surface, a first side, a second side, a first end, and a second end. A first attachment structure includes a first base secured to the rear surface of the panel and a first clip connected to the base. A second attachment structure includes a second base configured to be attached to a support structure and a second clip connected to the second base. The second clip is adapted to couple to the first clip so as to secure the panel to the support surface.
The first attachment structure 730 includes a first base 734 that is adapted to be secured against the rear surface 709 of the panel 702 and a first clip 740 that is configured to be secured to another attachment structure (as explained further below). The first attachment structure 730 is formed by a bent metal sheet, and the first base 734 is provided by a flat section of the first attachment structure 730 that is held against the rear surface 709. The first clip 740 extends rearward from the first base 734 for engagement with the other attachment structure.
In certain embodiments as otherwise described herein, the first clip includes a first hook and the second clip includes a corresponding second hook adapted to couple to the first hook. For example, as shown in
In the illustrated embodiment, the first attachment structure 730 is positioned at the upper side of panel 702 and the leg 744 of the first attachment structure 730 extends from the upper end of the first base 734. Similarly, the arm 784 extends from the upper end of the second base 774 of the second attachment structure 770. In other embodiments, as shown in other embodiments and described in more detail below, the positioning of the first and second attachment structures and the location of the associated clips may have other positions. For example, the leg of the first attachment structure that holds the first clip may extend from the lower end of the first base, rather than from the upper end.
In certain embodiments as otherwise described herein, an end of the first hook extends forward such that the first hook has an opening that faces the panel, and an end of the second hook extends rearward and is adapted for insertion into the opening of the first hook. For example, as shown in
In certain embodiments as otherwise described herein, the first attachment structure includes a spring extending rearward from the first base and configured to urge the first attachment structure forward so as to maintain the connection between the first hook and the second hook. For example, as shown in
In certain embodiments as otherwise described herein, the spring is positioned to press against the second base of the second attachment structure. For example, as shown in
In certain embodiments as otherwise described herein, the second attachment structure includes a shelf for supporting a portion of the panel. For example, as shown in
As shown in
As shown in
In some embodiments, the spacers may be removed after the building surface products are secured to the support structure. In other embodiments, the spacers are retained and form part of the building surface structure. For example, in some embodiments, the spacers provide a decorative element between the building surface products, such as an accent line. Further, in some embodiments, the spacers may also perform a performance function, such as sealing the space for the prevention of thermal, odor or air leakage between the spaces. The spacers may also perform additional structural benefits, such as increased mechanical strength of the structure. Alternatively, the spacers may provide a cushioning function, such as to allow for seismic vibrations to pass through the system without damage to the panels. For example, the spacers may be soft to provide acoustic benefits. Alternatively, in some embodiments, the spacers may be hard.
The spacer may also allow for movement of the building surface products so that a panel can be removed from the wall, for example, for performing maintenance inside the wall cavity. For example, as shown in
As shown in
Further, panel 802 of
In some embodiments, the first receiver sleeve includes a threaded interior surface configured to engage the first attachment post. For example, in
In some embodiments, the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer of the panel. For example, first receiver sleeve 804 of building surface product 800 includes an external flange 842 that extends radially outward from an axis of the receiver sleeve. The external flange 842 is positioned between the front layer 813 and the reinforcing layer 814 so as to capture the receiver sleeve in the gypsum body 810 and prevent first receiver sleeve 804 from separating from panel 802. In other embodiments, the panel is constructed without a receiver sleeve. For example, in some embodiments, the mechanical fastener extends directly into the material of the gypsum body.
In the embodiment shown in
The front layer 813, first edge section 820, and the first section 815 of the reinforcing layer 814 are formed from a machined and folded gypsum sheet. For example, the configuration shown in
In some embodiments, a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer. For example, when the first section 815 of reinforcing layer 814 is folded behind front layer 813, the facing sheet 826 that extended along the original gypsum panel on the face opposite the grooves wraps around the first edge 816 so as to cover the front surface 808 of the gypsum body 810, the outer face 821 of the first edge section 820 and the rear face of the first section 815 of the reinforcing layer 814. In other embodiments, the facing sheet may be applied to the gypsum body after the reinforcing layer is formed over the front layer. Still, in some embodiments, separate facing sheets cover the front layer and reinforcing layer. Further still, in some embodiments, at least some portions of the gypsum body are not covered by a facing sheet.
The embedded fastener 940 includes a threaded body 942 that extends through the first hole 922 of the gypsum body 920. Further, the threaded body 942 has a front end 943 a rear end 944. A lateral projection 946 is disposed at the front end 943 of the threaded body 942. The lateral projection 946 helps to hinder removal of the embedded fastener 940 through the first hole 922. For example, the lateral projection 946 may be configured to project beyond the diameter of the first hole 922 so that attempted removal of the embedded fastener 940 through the rear end of the first hole 922 will result in the lateral projection 946 interfering with the edge of the gypsum body 920 that surrounds the first hole 922.
The mechanical fastener 932 includes a threaded body 934 that engages the threaded body 942 of the embedded fastener 940. At the rear end of the first hole 922, the mechanical fastener 932 extends outward from the first hole 922 so that it may engage the first attachment structure 930. On the other hand, the entire embedded fastener 940 is contained behind the front surface 908 of the panel 902.
The phrase “contained behind,” as used herein means that the no portion of the fastener assembly extends past the front surface of the panel. In other words, the entirety of the structure of both the embedded fastener and mechanical fastener is behind, or rearward of, the plane formed by the front surface of the panel, and the surfaces of these components are either flush with or behind the front surface of the panel. The phrase “contained behind” does not necessitate that any part of the embedded fastener or mechanical fastener be covered or obscured by the front surface, but rather only that these components be positioned rearward of the front surface. By having the components contained behind the front surface of the panel, they can be entirely obscured when the panel is finished with coating materials or paint, as explained further below.
The threaded body 942 of embedded fastener 940 includes a hollow circular barrel with internal threads. Accordingly, the mechanical fastener 932 includes a shaft with external threads that are configured to mate with the internal threads of hollow barrel 942 so that the mechanical fastener 932 may be coupled to the embedded fastener 940.
In some embodiments, the lateral projection of the embedded fastener includes a flat base extending radially outward from the threaded body of the embedded fastener. For example, embedded fastener 940 includes a flat base 946 positioned at the front end of internally threaded hollow barrel 942. The flat base 946 extends radially outward around the circumference of hollow barrel 942. Further, the flat base 946 is larger than the diameter of first hole 922, which inhibits embedded fastener 940 from being removed from the front end of first hole 922. While, the flat base 946 of embedded fastener 940 is circular, in other embodiments, the flat base may have another shape, such as square or hexagonal. Further still, in other embodiments, the embedded fastener may have a lateral projection that has a different configuration, such as a hook or arm that extends radially from the threaded body in only one direction, rather than circumferentially.
In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is formed as a tee nut. For example, the embedded fastener 940 of building surface product 900 is formed as a standard tee nut including the base 946 and hollow threaded barrel 942.
In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is contained between the front surface and the rear surface of the panel. For example, as shown in
In certain embodiments of the building surface product as otherwise described herein, the panel includes a first projection extending along the first side of the panel and positioned at the front surface of the panel, and a second projection extending along the second side of the panel and configured to fit behind a first projection of a neighboring panel. For example, panel 902 includes a first projection 960 that extends along the first side 906 of the panel 902. A second projection is similarly arranged on the opposing side of the panel 902. As shown, the first projection 960 is located toward the front surface 908. In contrast, the second projection 970 at the opposing side 907 of the panel is located toward the rear surface 909. Accordingly, when two similarly configured panels are placed adjacent to one another, the first projection of one panel can cooperate with the second projection of the other panel, such that the first projection sits in front of the corresponding second projection, as explained further below.
In panel 902, as shown in
In certain embodiments of the building surface product as otherwise described herein, the first projection has an angled rear face and the second projection has an angled front face. For example, in panel 902, first projection 960 is formed by an upward extension of the front surface 908 of the panel 902 and an angled rear face 962 that extends down from the front surface 908 toward the rear surface 909. The second projection 970 at the opposing side 907 of panel 902 has the opposite configuration. Accordingly, the angled rear face 962 of the of the first projection 960 and the angled front face 972 of the second projection 970 are disposed at the same angle so that the respective first and second projections of neighboring panels can engage one another.
In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is covered at the first surface of the panel by a material layer. For example, in some embodiments, the front of the embedded fastener is covered by a joint compound, stucco, a putty, or another material that may be spread over the embedded fastener. Such a material layer may be provided over the embedded fastener during manufacture of the building surface product. Accordingly, the installers of the building surface product can avoid spending time obscuring the fastener assemblies that extend through the panel. Likewise, in some embodiments, a layer of paint extends across the front surface of the panel and over the embedded fastener so as to obscure the embedded fastener. Similar to the material layer, the layer of paint may be provided over the front surface during manufacture of the building surface product. In other embodiments, however, the layer of paint may be formed at the installation site. Further, in some embodiments, the front finishing may be accomplished by the addition of an additional layer of a material, such as a lamination or a paper, film, fabric or plastic. In this and the other embodiments, the finishing serves to obscure the fastener assemblies.
As shown in
The second base 1274 of the second attachment structure 1270 includes two layers at the upper end thereof. The two layers are formed by fold in the metal sheet that forms the second attachment structure 1270. The folded portion of the second base 1274 allows the second base 1274 to extend both above and below the arm 1284 associated with the second clip 1280.
The layered upper section of the second base 1274 includes an aperture 1276 for fixedly attaching the second base 1274 to a support structure. In contrast, the lower section of the second base 1274 that is below the arm 1284 includes a slot 1277. The slot 1277 allows the second attachment structure 1270 to be loosely coupled to the support structure while the wall panel is positioned. Once the panel is accurately positioned against the support structure, the second attachment structure 1270 may be securely fastened in place at a height that allows for engagement between the corresponding clips of the first attachment structure 1230 and second attachment structure 1270.
The first component 1371 also forms an arm 1384 that extends from the lower end of the base 1374 and a first spring 1338 that extends from the upper end of the base 1374. A second hook 1382 is formed at the end of the arm 1384. The second component 1372 forms a second spring 1339 that extends from the lower end of the base 1374.
The opening 1484 of the second hook 1482 faces upward so that the assembly of the panel 1402 and first attachment structure 1430 may be coupled to the second attachment structure 1470 by lowering the first attachment structure 1430 onto the second attachment structure 1470 such that the bulbous end of the first hook 1442 is inserted into the constricted opening 1484 of the second attachment structure 1470.
In the illustrated embodiment, the second attachment structure 1570 includes an additional clip 1585 above the second clip 1580. This additional clip 1585 is configured to couple to a corresponding clip, such as a channel, of another building surface panel, as shown in
As shown in
In some embodiments, the panel includes a gypsum body. In other embodiments, the panel is formed from another material. For example, in some embodiments, the panel includes a body that is constructed of wood, natural fibers, mineral fibers, synthetic fibers or a polymer material. In some embodiments, building surface products including a panel of wood or polymer may include attachment posts that are fastened to the rear surface of the panel with or without passing all the way through the panel. In still other embodiments, the building surface product may include composites made up of combinations of materials, such as woods and polymers, or gypsums and polymers, or fibers and gypsums.
In certain embodiments of the building surface product as otherwise described herein, the gypsum body comprises a reinforced gypsum material. The use of a reinforced gypsum material can enhance the connection between the panel and the attachment posts that are attached to the panel. Moreover, the use of a reinforced gypsum material can also provide extra stability for the panel in the vicinity of the attachment posts. For example, in some embodiments, the gypsum body includes at least 1% by weight polymer. Reference to the weight percentage of a component of the gypsum body, as used herein, refers to the weight after the gypsum has set. In certain embodiments, the polymer includes starch and/or polyvinyl acetate.
In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes at least 1% by weight of reinforcing fibers. For example, in some embodiments, the gypsum body includes glass fibers. Further, in some embodiments, the gypsum panel includes cellulose-based fibers or stone wool fibers. Moreover, in some embodiments, the gypsum panel includes polyethylene, polypropylene or polyester fibers. Various embodiments of the building surface product include different combinations of the aforementioned fibers in the gypsum panel.
In some embodiments, the gypsum body includes one or more additives, such as biocides, hydrophobic additives, and fire resistance additives.
In certain embodiments of the building surface product as otherwise described herein, the panel is rectangular. For example, as shown in
In some embodiments the building surface product is configured to form a wall surface or ceiling surface. For example, panel 102 of building surface product 100 is a panel. In other embodiments, the building surface product is configured to form a trim or decorative element. For example, in some embodiments, the panel of the building surface product is formed as a trim or decorative component that is attached to a support structure using the attachment posts of the disclosure. For example, in some embodiments the panel is a molding component, such as crown molding at the top of the building surface. In other embodiments, the panel forms a baseboard at the bottom of a building surface. Still in other embodiments, the panel forms corner trim or window trim. Various shapes for such trim configurations are possible. For example, in some embodiments, the trim may be flat, angled or curved. Likewise, such trim can be proud, flush or recessed. Still, in other embodiments the building surface product forms a decorative beam. In some embodiments, the building surface product passes over the middle of a building surface. For example, in some embodiments, the panel of the building surface product forms a chair rail, a batten or has another configuration that passes over the middle of the surface. In some embodiments, the building surface product includes a panel configured as a trim or decorative element and is formed of a polymer or wood and the first attachment post extends only partially through the panel.
In certain embodiments of the building surface product as otherwise described herein, the building surface product further includes a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface. In some embodiments, the facing sheet is a paper facing. In other embodiments, the facing sheet includes reinforcing fibers. For example, in some embodiments, the facing sheet includes a fiberglass mat. Further, in some embodiments, the gypsum material is embedded into the facing sheet.
In certain embodiments of the building surface product as otherwise described herein, the facing sheet surrounds the panel along its length covering both the front surface and the rear surface. For example, in some embodiments, the facing sheet is formed from two distinct sheets that are wrapped around the gypsum panel. The facing sheets may then be attached to one another to surround the panel. In some embodiments, the facing sheets wrap around the panel along its length. The ends of the panel may then either be left uncovered or the facing sheets may also be folded over the ends.
In certain embodiments of the building surface product as otherwise described herein, a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches. In some embodiments, the width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet. For example, in some embodiments, the width of the panel is in a range from 3 inches to 6 feet, e.g., from 4 inches to 4 feet, e.g., from 6 inches to 3 feet.
In certain embodiments of the building surface product as otherwise described herein, a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet. In some embodiments, the length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet. For example, in some embodiments, the length of the panel is in a range from 1 foot to 20 feet, e.g., from 2 feet to 15 feet, e.g., from 4 feet to 12 feet.
In certain embodiments of the building surface product as otherwise described herein, a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch. In some embodiments, the thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches. For example, in some embodiments, the thickness of the panel is in a range from ⅜ inch to 4 inches, e.g., from ½ inch to 3 inches, e.g., from ¾ inch to 2 inches.
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Embodiment 1. A building surface product comprising:
a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface;
a first attachment post extending outward from the rear surface of the panel, the first attachment post including:
wherein the first attachment post extends at least partially through the reinforcing layer.
Embodiment 3. The building surface product according to embodiment 2, wherein the reinforcing layer includes a first section along a first edge of the panel, and wherein the first section is disposed behind the front layer along the first edge.
Embodiment 4. The building surface product according to embodiment 3, wherein the gypsum body includes a first edge section between the front layer and the first section of the reinforcing layer at the first edge.
Embodiment 5. The building surface product according to embodiment 4, wherein the front layer has a first tapered face along the first edge, the first section of the reinforcing layer has a tapered face along the first edge, and the first edge section has a triangular shape including a front face that is adjacent to the first tapered face of the front layer and a rear face that is adjacent to the tapered face of the first section of the reinforcing layer.
Embodiment 6. The building surface product according to embodiment 4 or embodiment 5 wherein the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet.
Embodiment 7. The building surface product according to any of embodiments 4 to 6, wherein a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer.
Embodiment 8. The building surface product according to any of embodiments 5 to 7, wherein an adhesive layer is provided between the first tapered face of the front layer and the front face of the first edge section.
Embodiment 9. The building surface product according to any of embodiments 5 to 8, wherein an adhesive layer is provided between the tapered face of the first section of the reinforcing layer and the rear face of the first edge section.
Embodiment 10. The building surface product according to any of embodiments 3 to 9, wherein an adhesive layer is provided between the front layer and the first section of the reinforcing layer.
Embodiment 11. The building surface product according to embodiment 10, wherein the shaft of the first attachment post extends through the adhesive layer provided between the front layer and the first section of the reinforcing layer.
Embodiment 12. The building surface product according to any of embodiments 3 to 11, wherein a pair of facing sheets is provided between the front layer and the first section of the reinforcing layer.
Embodiment 13. The building surface product according to any of embodiments 2 to 12, wherein the reinforcing layer extends around a perimeter of the panel.
Embodiment 14. The building surface product according to any of embodiments 12 to 13, wherein the reinforcing layer includes a section along each edge of the panel.
Embodiment 15. The building surface product according to embodiment 14, wherein the gypsum body includes an edge section along each edge of the panel between the front layer and respective section of the reinforcing layer.
Embodiment 16. The building surface product according to any of embodiments 1 to 15, wherein the panel includes a first receiver sleeve and the shaft of the first attachment post extends into the first receiver sleeve.
Embodiment 17. The building surface product according to embodiment 16, wherein the first receiver sleeve extends through the reinforcing layer.
Embodiment 18. The building surface product according to embodiment 16 or embodiment 17, wherein the first receiver sleeve includes a threaded interior surface configured to engage the shaft of the first attachment post.
Embodiment 19. The building surface product according to any of embodiments 16 to 18, wherein the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer.
Embodiment 20. The building surface product according to any of embodiments 1 to 19, wherein at least a portion of the shaft of the first attachment post is threaded.
Embodiment 21. The building surface product according to any of embodiments 1 to 20, wherein the lip is formed as a portion of a head disposed at the second end of the shaft.
Embodiment 22. The building surface product according to any of embodiments 1 to 21, wherein the first attachment post includes a collar surrounding the shaft that engages the rear surface of the panel.
Embodiment 23. The building surface product according to embodiment 22, wherein the collar is spaced from the lip.
Embodiment 24. The building surface product according to any of embodiments 1 to 23, wherein the first attachment post is one of a plurality of attachment posts extending from the rear surface of the panel, each of the plurality of attachment posts including a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip extending radially outward from the respective shaft and configured to hold the respective attachment post in a respective aperture of the support structure.
Embodiment 25. The building surface product according to any of embodiments 1 to 24, wherein the gypsum body comprises a reinforced gypsum material.
Embodiment 26. The building surface product according to any of embodiments 1 to 25, wherein the gypsum body includes at least 1% by weight polymer.
Embodiment 27. The building surface product according to embodiment 26, wherein the polymer includes starch and/or polyvinyl acetate.
Embodiment 28. The building surface product according to any of embodiments 1 to 27, wherein the gypsum body includes at least 1% by weight of reinforcing fibers.
Embodiment 29. The building surface product according to any of embodiments 1 to 28, further comprising a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface.
Embodiment 30. The building surface product according to embodiment 29, wherein the facing sheet is a paper facing.
Embodiment 31. The building surface product according to any of embodiments 1 to 30, wherein a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches.
Embodiment 32. The building surface product according to any of embodiments 1 to 31, wherein a width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet.
Embodiment 33. The building surface product according to any of embodiments 1 to 32, wherein a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet.
Embodiment 34. The building surface product according to any of embodiments 1 to 33, wherein a length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet.
Embodiment 35. The building surface product according to any of embodiments 1 to 34, wherein a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch.
Embodiment 36. The building surface product according to any of embodiments 1 to 35, wherein a thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches.
Embodiment 37. A building surface system comprising:
a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate; and
a first building surface product according to any of embodiments 1 to 36 attached to the support structure, wherein the first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.
Embodiment 38. The building surface system according to embodiment 37, wherein the longitudinal plate includes a first engagement edge extending along one side of the slot, wherein the shaft of the first attachment post extends through the first receiving slot and the lip of the first attachment post abuts the first engagement edge of the longitudinal plate.
Embodiment 39. The building surface system according to embodiment 37 or embodiment 38, wherein a first end of the first receiving slot is wider than a second end of the first receiving slot, and wherein the first attachment post is held at the second end of the first receiving slot.
Embodiment 40. The building surface system according to any of embodiments 37 to 39, wherein the first end of the first receiving slot has a width that is larger than a width of the first attachment post, such that the first attachment post is removable from the first receiving slot at the first end.
Embodiment 41. The building surface system according to any of embodiments 37 to 40, wherein the longitudinal plate includes a front face and a first indentation that protrudes rearward from the front face, wherein the first receiving slot is disposed in the first indentation.
Embodiment 42. The building surface system according to embodiment 41, wherein a depth of the first indentation increases from the first end of the first receiving slot to the second end of the first receiving slot.
Embodiment 43. The building surface system according to any of embodiments 37 to 42, wherein the rear surface of the panel of the first building surface product abuts the front face of the longitudinal plate.
Embodiment 44. The building surface system according to any of embodiments 37 to 43, wherein the first receiving slot is disposed on a first side of the longitudinal plate and wherein a second receiving slot is disposed on a second side of the longitudinal plate.
Embodiment 45. The building surface system according to embodiment 44, further comprising a second building surface product according to any of embodiments 1 to 36, wherein an attachment post of the second building surface product is received in the second receiving slot of the longitudinal plate so as to secure the second building surface product against the support structure.
Embodiment 46. The building surface system according to embodiment 44 or embodiment 45, wherein the longitudinal plate includes an outwardly extending projection between the first receiving slot and the second receiving slot.
Embodiment 47. The building surface system according to embodiment 46, wherein the outwardly extending projection is disposed between the first building surface product and the second building surface product.
Embodiment 48. The building surface system according to embodiment 46 or embodiment 47, wherein a height of the outwardly extending projection is substantially equal to a thickness of the panel of the first building surface product.
Embodiment 49. The building surface system according to any of embodiments 37 to 48, wherein the longitudinal plate includes an open path extending from the first end of the first receiving slot to an edge along the second side of the longitudinal plate.
Embodiment 50. The building surface system according to any of embodiments 37 to 49, wherein the first receiving slot is one of a row of receiving slots positioned along a length of the longitudinal plate, and wherein the building surface system includes a row of building surface products that engage other receiving slots in the row of receiving slots.
Embodiment 51. The building surface system according to any of embodiments 37 to 50, wherein the support structure includes vertical framing members, and wherein the first rail extends across the vertical framing members and is attached to the vertical framing members.
Embodiment 52. The building surface system according to embodiment 51, wherein the first rail is attached to the vertical framing members using mechanical fasteners that extend into the vertical framing members.
Embodiment 53. The building surface system according to embodiment 51, wherein the vertical framing members include beams and reinforcement plates secured to the beams, and wherein the reinforcement plates include receivers configured to receive mechanical fasteners that secure the first rail to the vertical framing members.
Embodiment 54. The building surface system according to embodiment 53, wherein the receivers have an adjustable position with respect to the reinforcement plates.
Embodiment 55. A method of forming the building surface system according to any of embodiments 37 to 54, the method comprising:
positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail; and
securing the first building surface product to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.
Embodiment 56. The method according to embodiment 55 wherein the first building surface product is positioned in front of the support structure such that a plurality of additional attachment posts of the first building surface product are inserted in respective receiving slots of the support structure, and wherein sliding the first building surface product to the assembled position causes the additional attachment posts to be secured in the respective receiving slots.
Embodiment 57. The method according to embodiment 55 or 56, further comprising:
positioning a second building surface product according to any of embodiments 1 to 36 in front of the support structure such that the rear surface of the panel of the second building surface product faces the support structure and an attachment post of the second building surface product is inserted in another receiving slot of the longitudinal plate of the first rail; and
securing the second building surface product to the support structure by sliding the second building surface product to an assembled position where the attachment post of the second building surface product is secured in the other receiving slot of the longitudinal plate of the first rail, and the attachment post retains the second building surface product against the support structure.
Embodiment 58. The method according to embodiment 55, further comprising;
positioning a second rail behind the first building surface product with a second attachment post of the first building surface inserted into a receiving slot of the second rail; and
securing the second rail to the first building surface product by sliding the second rail to an assembled position where the second attachment post of the first building surface product is secured in the receiving slot of the second rail.
Embodiment 59. The method according to embodiment 58, wherein positioning the second rail behind the first building surface product includes introducing the second attachment post into the receiving slot of the second rail through an open path in the second rail.
Embodiment 60. The method according to embodiment 58 or embodiment 59, wherein positioning the second rail behind the first building surface product includes placing a projection of the second rail on an upper edge of the panel of the first building surface product.
Embodiment 61. The method according to any of embodiments 58 to 60, further comprising attaching the second rail to vertical framing members of the support structure after sliding the second rail into the assembled position.
Embodiment 62. A building surface product comprising:
a substantially planar panel having a front surface, a rear surface, a first side, a second side, a first end, and a second end;
a first attachment structure including a first base secured to the rear surface of the panel and a first clip connected to the base; and
a second attachment structure including a second base configured to be attached to a support structure and a second clip connected to the second base, the second clip being adapted to couple to the first clip so as to secure the panel to the support surface.
Embodiment 63. The building surface product according to embodiment 62, wherein the first clip includes a first hook and the second clip includes a corresponding second hook adapted to couple to the first hook.
Embodiment 64. The building surface product according to embodiment 63, wherein an end of the first hook extends forward such that the first hook has an opening that faces the panel, and wherein an end of the second hook extends rearward and is adapted for insertion into the opening of the first hook.
Embodiment 65. The building surface product according to embodiment 63, wherein the first hook has a first bulbous end a constricted opening, and wherein the second hook has a second bulbous end that fits in the constricted opening of the first hook.
Embodiment 66. The building surface product according to embodiment 65, wherein the constricted opening of the second hook faces upward.
Embodiment 67. The building surface product according to any of embodiments 63 to 66, wherein the first attachment structure includes a leg extending rearward from the first base and the first hook is disposed on the leg.
Embodiment 68. The building surface product according to any of embodiments 63 to 67, wherein the second attachment structure includes an arm extending forward from the second base and the second hook is disposed on the arm.
Embodiment 69. The building surface product according to any of embodiments 63 to 68, wherein the first attachment structure includes a spring extending rearward from the first base and configured to urge the first attachment structure forward so as to maintain the connection between the first hook and the second hook.
Embodiment 70. The building surface product according to embodiment 69, wherein the spring is positioned to press against the second base of the second attachment structure.
Embodiment 71. The building surface product according to any of embodiments 62 to 70, wherein the second attachment structure includes a shelf for supporting a portion of the panel.
Embodiment 72. The building surface product according to any of embodiments 62 to 68, wherein the second attachment structure includes a spring extending forward from the second base and configured to urge the panel away from the second attachment structure so as to maintain connection between the first hook and the second hook.
Embodiment 73. The building surface product according to any of embodiments 62 to 72, wherein the second base of the second attachment structure includes a plurality of layers.
Embodiment 74. The building surface product according to embodiment 73, wherein the layers of the second base structure are formed by a folded material strip.
Embodiment 75. The building surface product according to embodiment 73, wherein the second attachment structure includes a first component that forms a first layer of the second base and a second component that forms a second layer of the second base.
Embodiment 76. The building surface product according to any of embodiments 1 to 75, wherein the second base includes an aperture for fixing the second attachment structure to the support surface.
Embodiment 77. The building surface product according to embodiment 76, wherein the second base includes a slot positioned below the aperture for holding the second attachment structure against the support surface.
Embodiment 78. The building surface product according to embodiment 62, wherein the first clip includes a channel having a constricted opening.
Embodiment 79. The building surface product according to embodiment 78, wherein the second clip is formed as a spring clip that is configured to be inserted into the channel of the first clip.
Embodiment 80. The building surface product according to embodiment 79, the spring clip includes a pair of prongs that flex upon insertion into the channel.
Embodiment 81. The building surface product according to embodiment 79 or embodiment 80, wherein the second attachment structure includes an additional clip above the second clip that is configured to couple to a corresponding clip of another building surface panel.
Embodiment 82. The building surface product according to embodiment 81, wherein the additional clip extends vertically so as to allow vertical adjustment of the other building surface panel relative to the second attachment structure.
Embodiment 83. The building surface product according to embodiment 78, wherein the second clip includes a post and a ball disposed at the end of the post, wherein the ball is configured to be inserted into the constricted opening of the channel so as to secure the first attachment structure to the second attachment structure.
Embodiment 84. The building surface product according to embodiment 83, wherein the ball of the second clip allows rotational adjustment between the first attachment structure and the second attachment structure.
Embodiment 85. The building surface product according any of embodiments 78 to 84, wherein the channel of the first clip includes a side wall extending rearward from the first base, and wherein the side wall of the channel is positioned against a section of a reinforcing layer of the panel.
Embodiment 86. The building surface product according to any of embodiments 62 to 85 wherein the panel includes a gypsum body extending from the front surface to the rear surface.
Embodiment 87. The building surface product according to embodiment 86, wherein the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer.
Embodiment 88. The building surface product according to embodiment 87, wherein the reinforcing layer includes a first section along a first edge of the panel, and wherein the first section is disposed behind the front layer along the first edge.
Embodiment 89. The building surface product according to embodiment 87 or embodiment 88 wherein the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet.
Embodiment 90. The building surface product according to embodiment 88 or embodiment 89, wherein a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer.
Embodiment 91. The building surface product according to any of embodiments 87 to 90, wherein the first attachment structure is secured to the rear surface of the panel using a mechanical fastener that extends into the reinforcing layer.
Embodiment 92. The building surface product according to embodiment 91, wherein the panel includes a first receiver sleeve and the mechanical fastener extends into the first receiver sleeve.
Embodiment 93. The building surface product according to embodiment 92, wherein the first receiver sleeve includes a threaded interior surface configured to engage a shaft of the mechanical fastener.
Embodiment 94. The building surface product according to embodiment 92 or embodiment 93, wherein the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer.
Embodiment 95. The building surface product according to any of embodiments 62 to 86, wherein the first attachment structure is secured to the rear surface of the panel using a mechanical fastener that extends into the gypsum body.
Embodiment 96. The building surface product according to embodiment 95, wherein the gypsum body includes a hole, wherein an embedded fastener including a threaded body is disposed in the hole, and wherein the mechanical fastener engages the embedded fastener.
Embodiment 97. The building surface product according to embodiment 96, wherein threaded body of the embedded fastener includes a hollow barrel with internal threads, and the threaded body of the linking fastener includes a shaft with external threads.
Embodiment 98. The building surface product according to 96 or embodiment 97, wherein the embedded fastener includes a flat base extending radially outward from the threaded body of the embedded fastener.
Embodiment 99. The building surface product according to any of embodiments 96 to 98, wherein the embedded fastener is formed as a tee nut.
Embodiment 100. The building surface product according to any of embodiments 96 to 99, wherein the embedded fastener is contained between the front surface and the rear surface of the panel.
Embodiment 101. The building surface product according to any of embodiments 96 to 100, wherein the embedded fastener is covered at the first surface of the panel by a material layer.
Embodiment 102. The building surface product according to embodiment 101, wherein the material layer is joint compound, a lamination, paper, film, fabric or plastic.
Embodiment 103. The building surface product according to any of embodiments 96 to 102, wherein a layer of paint extends across the front surface of the panel and over the embedded fastener so as to obscure the embedded fastener.
Embodiment 104. The building surface product according to any of embodiments 62 to 103, wherein the panel includes a first projection extending along the first side of the panel and positioned at the front surface of the panel, and a second projection extending along the second side of the panel and configured to fit behind a first projection of a neighboring panel.
Embodiment 105. The building surface product according to embodiment 104, wherein the first projection has an angled rear face and the second projection has an angled front face.
Embodiment 106. The building surface product according to any of embodiments 62 to 105, wherein the gypsum body comprises a reinforced gypsum material.
Embodiment 107. The building surface product according to any of embodiments 62 to 106, wherein the gypsum body includes at least 1% by weight polymer.
Embodiment 108. The building surface product according to embodiment 107, wherein the polymer includes starch and/or polyvinyl acetate.
Embodiment 109. The building surface product according to any of embodiments 62 to 108, wherein the gypsum body includes at least 1% by weight of reinforcing fibers.
Embodiment 110. The building surface product according to any of embodiments 62 to 109, further comprising a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface.
Embodiment 111. The building surface product according to embodiment 110, wherein the facing sheet is a paper facing.
Embodiment 112. The building surface product according to any of embodiments 62 to 11, wherein a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches.
Embodiment 113. The building surface product according to any of embodiments 62 to 112, wherein a width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet.
Embodiment 114. The building surface product according to any of embodiments 62 to 113, wherein a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet.
Embodiment 115. The building surface product according to any of embodiments 62 to 114, wherein a length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet.
Embodiment 116. The building surface product according to any of embodiments 62 to 115 wherein a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch.
Embodiment 117. The building surface product according to any of embodiments 62 to 116 wherein a thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches.
This application claims the benefit of priority of U.S. Provisional Patent Application No. 63/289,398 , filed Dec. 14, 2021, and U.S. Provisional Patent Application no. 63/387,215, filed Dec. 13, 2022, each of which is hereby incorporated herein by reference in its entirety.
Number | Date | Country | |
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63289398 | Dec 2021 | US | |
63387215 | Dec 2022 | US |