Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
  • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
  • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
  • E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2002/001—Mechanical features of panels
  • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
  • E04F13/04—Bases for plaster
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0801—Separate fastening elements
  • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
  • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
  • E04F13/083—Hooking means on the back side of the covering elements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
  • E04F2201/026—Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. being stepped

Definitions

• FIG. 1 is a schematic perspective view of an interlocking building surface product according to an embodiment of the disclosure
• FIG. 7 is a side view of an interlocking building surface product according to another embodiment of the disclosure.
• FIG. 11 is a perspective view of an interlocking building surface product according to another embodiment of the disclosure.
• FIG. 13 is a perspective view of an interlocking building surface product according to another embodiment of the disclosure.
• FIG. 14 is a schematic side view of an apparatus used in a method of making a building surface product according to an embodiment of the disclosure
• FIG. 18 is a schematic side view of an interlocking building surface product according to another embodiment of the disclosure.
• FIG. 25 is a schematic detailed side view of snap-fit connectors according to another embodiment of the disclosure.
• FIG. 26 is a schematic detailed side view of snap-fit connectors according to still another embodiment of the disclosure.
• FIG. 27 is a schematic detailed side view of an edge of a building surface product according to an embodiment of the disclosure.
• FIG. 28 is a schematic detailed side view of an edge of a building surface product according to another embodiment of the disclosure.
• FIG. 30 is a schematic detailed side view of an edge of a building surface product according to another embodiment of the disclosure.
• the lower interlocking structure includes a first lower projection that extends downward from the body and has a thickness that is smaller than the thickness of the body.
• the upper interlocking structure and the lower interlocking structure are configured to cooperate with neighboring gypsum panels so as to form a building surface.
• Building surface product 100 includes a gypsum panel 102 that is substantially planar and has an upper edge 104, a lower edge 106, a first end 107, and a second end 108.
• planar refers to a panel in which a plane can pass through the entirety of the panel from one end to the other. Thus, the surfaces of a planar panel are not required to be entirely flat, so long as the shape of the panel follows a plane.
• the term substantially planar refers to a shape that bows along its length or width to an extent of no more than 5 degrees.
• the building surface product is substantially planar, and in some embodiments the building surface product is planar. Still, in other embodiments, the building surface curves along its length to a greater extent than 5 degrees.
• gypsum panel 102 includes a body 114 having a front face 116 and a rear face 118. Further gypsum panel 102 has a thickness 120 that extends from front face 116 of body 114 to rear face 118 of body 114. In some embodiments, the thickness of the body is equal to the thickness of the building surface product as a whole, in other embodiments, the building surface product is thicker than the thickness of the body.
• Upper interlocking structure 110 includes a first upper projection 122 that extends upward from body 114 of gypsum panel 102.
• lower interlocking structure 112 includes a first lower projection 124 that extends downward from body 114.
• the first lower projection is coextensive with the front face of the body.
• first lower projection 124 extends downward from body 114 at the front face 116 of body 114, such that the front surface of first lower projection 124 is flush with front face 116. Accordingly, the lower projection 124 forms an extension of body 114 along front face 116, forming a continuous surface between body 114 and first lower projection 124.
• the lower interlocking structure 412 includes a first lower projection 424 extending downward from body 414 that is adjacent to and coextensive with front face 416 of body 414.
• lower interlocking structure 412 also includes a second lower projection 434 that is adjacent to rear face 418 of body 414.
• a gap is provided between first lower projection 424 and second lower projection 434 to provide a lower recess 430 in the form of a groove.
• the groove 430 provided between first lower projection 424 and second lower projection 434 is configured to receive an upwardly extending projection of a neighboring building surface product.
• the first upper projection is disposed between the front face and the rear face and forms a tongue configured for insertion into the groove of a neighboring building surface product.
• building surface product 400 shown in FIG. 4, includes an upper interlocking structure 410 that has a first upper projection 422 positioned between the front face 416 and rear face 418 of body 414 of gypsum panel 402.
• First upper projection 422 is specifically configured as a tongue to fit into a groove of a neighboring building surface product.
• the first upper projection 422 of upper interlocking structure 410 is configured so as to cooperate with the recess 430 of lower interlocking structure 412 and be received therein.
• a series of building surface products all having the same configuration as that of building surface product 400 can form a building surface wherein the upper interlocking structure of each gypsum panel fits into the lower interlocking structure of a neighboring gypsum panel.
• Each of the upper interlocking structure 510 and lower interlocking structure 512 are configured to receive an insert, such as insert 540, in the respective upper recess 538 and lower recess 530. Accordingly, neighboring building surface products having a configuration similar to that of building surface product 500 connect to one another using the upper interlocking structure and lower interlocking structure via an insert disposed in the adjacent recesses.
• the recesses of adjacent building surface products are aligned such that the insert may be a straight plank.
• the recesses are offset or have complex shapes, and the insert has a corresponding shape configured to be received in the recesses of two neighboring building surface products.
• the upper and lower recesses extend along the entire length of the building surface product, and the insert likewise extends across all or a substantial majority of the building surface product. In other embodiments, the upper and lower recesses are intermittently positioned along the length of the building surface product, and one or more inserts are positioned therein to connect neighboring building surface products.
• the first lower projection has a rounded edge.
• Building surface product 700 includes a gypsum panel 702 that has a body 714, which includes a front face 716 and a rear face 718.
• An upper interlocking structure 710 is disposed above body 714 and a lower interlocking structure 712 is disposed below body 714.
• Upper interlocking structure 710 includes a first upper projection 722 and lower interlocking structure 712 includes a first lower projection 724.
• the lower end of first lower projection 724 has a convex curved surface 742 that forms a rounded edge on first lower projection 724.
• the ends are perpendicular to the upper edge and the lower edge.
• building surface product 100 shown in FIGS. 1 and 2
• ends 107 and 108 are perpendicular to upper edge 104 and lower edge 106.
• the ends are disposed at an angle to the upper edge and lower edge.
• the phrase“at an angle” as used herein refers to an angle that is at least 3 degrees from parallel (0 degrees) or perpendicular (90 degrees). In some embodiments, the angle is in a range of 30 degrees to 80 degrees.
• building surface product 900 shown in FIG.
• the facing includes a reinforcing sheet disposed at the rear face of the gypsum panel.
• the facing includes a robust paper, board, or fiber-reinforced sheet at the rear of the gypsum panel.
• the reinforcing sheet may provide added strength for attaching the building surface product to a support structure.
• the reinforcing sheet is disposed only along the rear face of the gypsum panel.
• the reinforcing sheet may be used in combination with another facing along the front face of the gypsum panel that has a lower tear strength than the reinforcing sheet.
• the front face of the gypsum panel may be free of any facing, while the reinforcing sheet is disposed along the rear face of the gypsum panel.
• a front surface of the building surface product includes a textured surface.
• the front surface of the building surface product is sanded or roughened to provide a surface texture to the front face of the building surface product.
• a coating of a grainy or heterogeneous coating is applied to the front surface of the building surface product.
• building surface product 1200 shown in FIG. 12, includes a heterogeneous coating applied to portions of the front face 1216 of gypsum panel 1202, which provides the front surface of the building surface product with a textured surface.
• the surface texture of the front face of the building surface product may provide the product with a visual appearance similar to Venetian plaster or cast concrete.
• a front surface of the building surface product is painted.
• the building surface product is painted prior to installation on a support structure, such as in a manufacturing facility.
• the building surface product is painted before any mechanical fasteners are used to attach the building surface product to a support structure, such as wall joists.
• the building surface product is painted and is free of mechanical fasteners extending therethrough.
• a width from the upper edge to the lower edge is in a range from 3 inches to 4 feet, e.g., from 4 inches to 2 feet, e.g., from 6 inches to 1 foot.
• a width of the building surface product that is smaller than standard gypsum wallboard products, for example from a few inches up to a foot, can provide an aesthetic that is similar to shiplap.
• the joints between the building surface products form part of the aesthetic of the building surface, and do not need to be covered and hidden. This allows surfaces that are made using the building surface products according to the disclosure to be constructed without the need to cover the joints between the building surface products, which can save considerable time and effort.
• the upper interlocking structure and the lower interlocking structure are machined into the gypsum panel.
• portions of the gypsum panel can be cut, routed or otherwise removed in order to form the upper and lower interlocking structures.
• FIG. 15 Such a method is schematically illustrated in FIG. 15.
• a CNC machine 1562 is removing a portion of gypsum panel 1502 corresponding to recess 1532 so as to form upper projection 1522 of upper interlocking structure 1510.
• a machine is used to remove other portions of the gypsum panel so as to form the lower interlocking structure.
• the method further includes positioning a flexible sheet on the forming surface so as to provide a facing that lines at least a portion of the gypsum panel. In some embodiments, the method further includes positioning a second flexible sheet over the gypsum panel so as to provide the facing that lines another portion of the gypsum panel. For example, in some embodiments, a flexible sheet is positioned on the forming surface and the gypsum slurry is then dispensed over the flexible sheet. As the gypsum slurry takes the form of the panel, the flexible sheet may be wrapped around the sides of the gypsum panel using rollers or guides.
• forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product.
• forming the surface texture includes forming grooves in the front face of the body of the gypsum panel.
• the formation of the grooves may be carried out by removing material from the gypsum panel, such as by using a CNC machine as shown in FIG. 15.
• the grooves are provided by the forming surface.
• mold 1664 shown in FIG. 16, includes ridges 1669 that from grooves 1650 in the front face 1616 of the gypsum panel 1602.
• the disclosure provides an interlocking building surface system comprising: a plurality of building surface products according to the disclosure secured to a support structure and arranged so as to provide a building surface, wherein the plurality of building surface products includes a first building surface product with an upper interlocking structure coupled to a lower interlocking structure of a second building surface product.
• the system further includes mechanical fasteners securing the plurality of building surface products to the support structure.
• mechanical fasteners 1796 such as screws, secure the building surface products to the framing elements 1794 of the support structure 1792.
• the mechanical fasteners pass through fastener holes in the building surface products, while in other embodiments, the fasteners are forced through the gypsum material.
• a front surface of the first building surface product and a front surface of the second building surface product are covered with a layer of paint.
• the paint covers the entire exposed front surface of each building surface product.
• the layer of paint can be applied directly to building surface products from the upper edge to the lower edge and from the first end to the second end.
• the first building surface product is painted a first color and the second building surface product is painted a second color.
• Building surface system 2090 includes a plurality of building surface products in two configurations.
• Building surface product 2100 includes a substantially planar gypsum panel 2102 including a first edge 2104, a second edge 2106, a first end 2107, and a second end 2108.
• the gypsum panel 2102 also includes a body 2114 that has a front face 2116, a rear face 2118 and a thickness between front face 2116 and rear face 2118.
• Building surface product 2100 also includes a first lapping projection 2124 that extends outward from body 2114 at second edge 2106 and that is configured to overlap a portion of a neighboring gypsum panel so as to form a building surface, as described in more detail below.
• a first press-on connector 2170 is disposed on the rear face 2118 of body 2114 near the first edge 2104 of gypsum panel 2102. The press- on connector is configured to engage a corresponding second press-on connector, as described in more detail below.
• the press-on connector and lapping projection are complementary components that allow the fastenable building surface product to have an interlocking engagement with neighboring building surface products while also being modular.
• the building surface product can be positioned so that the lapping projection extends behind a portion of a neighboring panel.
• the first press-on connector can be used to secure the building surface product in place by engaging with a complementary second press-on connector.
• the building surface product can be removable and/or re-installable. For example, the building surface product can be removed from a constructed building surface by initially disengaging the first press-on connector and then removing the lapping projection from behind the neighboring panel.
• connections formed between both adjacent building surface products as well as the connections between the building surface products and the support surface are hidden. This allows building surfaces constructed using the building surface products to be completed without the time consuming process of obscuring attachment devices, such as covering mechanical fasteners with joint compound.
• first edge of building surface product 2100 is shown at the top of the gypsum panel, and the second edge is shown at the bottom, in other embodiments the first and second edges are reversed. Furthermore, in some embodiments, the product can be rotated and installed with either edge at the top. Moreover, in some embodiments, the building surface products are installed vertically.
• corresponding second press-on connector is a second snap-fit connector.
• the first snap-fit connector includes a second flange that extends from the connector body in an opposite direction of the first flange and is configured to engage the second snap-fit connector.
• first snap-fit connector 2170 includes a second flange 2175 that extends in an opposite direction from connector body 2172 compared to first flange 2174, specifically, in a downward direction.
• second flange 2175 is configured to be secured by a second flexible hook 2185 of second snap-fit connector 2180.
• first snap-fit connector 2370 includes a connector body 2372 with a first flange 2374 extending laterally outward therefrom and a second flange 2375 extending from the connector body 2372 in a direction opposite first flange 2374.
• second snap-fit connector 2380 has a first flexible hook member 2384 that receives and retains first flange 2374 and a second hook member 2385 that receives and retains second flange 2375. Accordingly, second snap-fit connector, which is attached to framing member 2394, holds the building surface product securely against the framing member by its connection to first snap-fit connector 2370.
• Both first snap-fit connectors 2170 and 2370 have male configurations and second snap-fit connectors 2180 and 2380 have female configurations that receive the first snap-fit connectors.
• the first snap-fit connector has a female configuration that receives the second snap-fit connector.
• first snap-fit connector 2570 has a first flange 2574 and a second flange 2575 extending from connector body 2572, and cooperates with a second snap-fit connector 2580 that includes a first hook 2584 and a second hook 2585.
• first snap-fit connector 2670 shown in FIG. 26, has a removable connection with second snap-fit connector 2680.
• first snap-fit connector 2670 has a first flange 2674 and a second flange 2675 extending from connector body 2672. The first flange 2674 and second flange 2675 cooperate with a first hook 2684 and a second hook 2685 of second snap-fit connector 2680.
• first snap-fit connector 2470 and the inner surfaces of the hooks 2484 and 2485 of second snap-fit connector 2480 have sharp edges to prevent removal of the first snap-fit connector 2470 from the second snap-fit connector once installed.
• This permanent connection can be advantageous in instances where removal of the building surface products is only permitted in instances where portions of the wall are being destroyed. In some cases, removal of the snap-fit connectors in instances using such a permanent connection requires removal of the second snap-fit connector from the framing members.
• first snap-fit connector 2670 and second snap-fit connector 2680 have inner surfaces of the flanges 2674, 2675 and hooks 2584, 2585 to allow repeated removal and reinsertion. This configuration allows maintenance to be on the building surface, or behind the building surface, without the need to replace any components of the building surface itself.
• the first snap fit connector is in the form of a rail that extends along a length of the building surface product.
• the rail extends across at least 50% of the length of the building surface product, e.g., at least 80% of the length of the building surface product, e.g., at least 90% of the length of the building surface product.
• first snap-fit connector 2170 shown in FIGS. 21 and 22 is configured as a rail and extends across a vast majority of the gypsum panel 2102 to within two inches of the first end 2107 and second end 2108.
• the first snap-fit connector is attached to the gypsum panel using adhesive.
• the adhesive is an organic adhesive, such as a curable glue, a single component epoxy, a two component epoxy, a hot-melt thermoplastic, or a polyurethane resin.
• the adhesive is an inorganic adhesive, such as cement.
• the first snap-fit connector is attached to the gypsum panel using a mechanical fastener, such as a screw.
• the first lapping projection is disposed behind the body of the gypsum panel, and wherein the first projection is configured to extend behind the body of the gypsum panel of a neighboring building surface product.
• first lapping projection 2170 is positioned behind body 2114 of gypsum panel 2102.
• the first lapping projection 2170 when installed, is positioned behind the body of the gypsum panel of a neighboring building surface product.
• the first lapping projection is coextensive with the rear face but thinner than the thickness of the panel.
• the second edge may include a second lapping projection that cooperates with the first lapping projection of a neighboring panel.
• the folded gypsum edge is a flat fold including a first folded section adhered to the body of the gypsum panel along an angled slit, where the body of the gypsum panel and the first folded section are covered by a continuous facing sheet.
• Building surface product 2700 includes first snap-fit connector 2770 attached to the rear surface 2718 of gypsum panel 2702.
• the building surface product also includes a first edge 2704 with a folded gypsum edge including a flat fold.
• the folded edge includes a first folded section 2776 that is secured to the body 2714 of gypsum panel 2702 with an adhesive.
• the body 2714 of the gypsum panel 2702 and the first folded section 2776 are covered by a continuous facing sheet 2779 that wraps around the folded edge 2704.
• the building surface product also includes a first edge 2804 with a folded gypsum edge including a corner fold.
• the folded edge includes a first folded section 2876 that is secured to the body 2814 of gypsum panel 2802 along an angled slit using an adhesive. Further, a second folded section 2877 is secured to the first folded section 2876 along another angled slit by adhesive.
• the body 2814 of the gypsum panel 2802, the first folded section 2886, and the second folded section 2877 are all covered by a continuous facing sheet 2879 that wraps around the folded edge 2804.
• the second folded section is adhered to the first snap-fit connector.
• second folded edge 2877 is attached to first snap-fit connector 2870 with an adhesive.
• the first snap-fit connector includes a base extending outward from the connector body, wherein the base is adhered to the body of the gypsum panel, and wherein the second folded section overlaps the base of the first snap-fit connector.
• Building surface product 2900 includes first snap-fit connector 2970 attached to the rear surface 2918 of gypsum panel 2902.
• First snap-fit connector 2970 includes a base 2978 extending outward from connector body 2972.
• the building surface product also includes a first edge 2904 with a folded gypsum edge including a corner fold.
• the folded edge includes a first folded section 2976 that is secured to the body 2914 of gypsum panel 2902 along an angled slit using an adhesive. Further, a second folded section 2977 is secured to the first folded section 2976 along another angled slit by adhesive. Moreover, second folded edge 2977 overlaps base 2978 of first snap-fit connector 2970. Furthermore, the body 2914 of the gypsum panel 2902, the first folded section 2986, and the second folded section 2977 are all covered by a continuous facing sheet 2979 that wraps around the folded edge 2904.
• the snap-fit connector is disposed on the body of the gypsum panel.
• snap-fit connector 3070 is disposed on the body 3014 of gypsum panel 3002.
• the snap-fit connector is disposed on the folded edge of the gypsum panel.
• building surface product 3100 shown in FIG. 31 , includes a gypsum panel 3102 with a folded edge 3104 having a first folded section 3176 and a second folded section 3177.
• First snap-fit connector 3170 is disposed on top of the second folded section 3177 of folded edge 3104.
• FIG. 32 shows the first snap-fit connector 3170 coupled to a second snap-fit connector 3180 using a first hook 3184 and a second hook 3185 that secure the respective flanges of first snap-fit connector.
• the ends are perpendicular to the upper edge and the lower edge. In other embodiments, the ends are disposed at an angle to the upper edge and lower edge. For example, in some embodiments of the fastenable building surface product, the ends are at an angle in a range of 30 degrees to 80 degrees from the upper edge or lower edge.
• a front surface of the building surface product includes a textured surface.
• the front surface of the building surface product is sanded or roughened to provide a surface texture to the front face of the building surface product.
• a coating of a grainy or heterogeneous coating is applied to the front surface of the building surface product.
• the surface texture of the front face of the building surface product may provide the product with a visual appearance similar to Venetian plaster or cast concrete, for example.
• forming the gypsum panel includes depositing a gypsum slurry over a forming surface and allowing the gypsum slurry to set.
• the forming surface is configured to form a sheet of gypsum material, and the gypsum panel is cut from the sheet of gypsum material.
• the method includes positioning a flexible sheet on the forming surface so as to provide a facing that lines at least a portion of the gypsum panel. A similar method including these steps shown in FIG. 14 and described above.
• the method further includes forming the first edge of the gypsum panel as a folded edge with a corner fold by: cutting a first notch in the sheet of gypsum material so as to form a first folded section adjacent to the body of the gypsum panel, cutting a second notch in the sheet of gypsum material so as to form a second folded section adjacent to the first folded section, folding the second folded section toward the first folded section so as to close the second notch, adhering the second folded section to the first folded section, folding the first folded section toward the body of the gypsum panel so as to close the first notch and to place the second folded section over the body of the gypsum panel, and adhering the first folded section to the body of the gypsum panel.
• first edge 2804 is formed by cutting a first notch in the gypsum material to form first folded section 2876 adjacent body 2814 of gypsum panel 2802, and cutting a second notch in the gypsum material to form a second folded section 2877 adjacent to the first folded section 2876.
• the first folded section 2876 is folded toward second folded section 2877 and adhered thereto.
• the second folded section 2877 is then folded toward first folded section 2876 in order to close the second notch and the two sections are attached with adhesive.
• the first folded section 2876 is then folded toward the body 2814 to close the first notch and the first folded section 2876 is attached to the body with more adhesive.
• the snap-fit connector includes a base extending outward from the connector body, and the method further includes folding the second folded section over the base of the snap- fit connector so as to place the base of the snap-fit connector between the second folded section and the body of the gypsum panel.
• second folded section 2977 is folded over the base 2978 of first snap-fit connector 2970 in order to place the base 2978 between second folded section 2977 and body 2914 of gypsum panel 2902.
• the method further includes forming a surface texture on a front surface of the building surface product.
• forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product.
• forming the surface texture includes forming grooves in the front face of the body of the gypsum panel. For example, the formation of the grooves may be carried out by removing material from the gypsum panel, such as by using a CNC machine as shown in FIG. 15. In other embodiments, the grooves are provided by the forming surface.
• Second building surface product 2103 is presented as it is being installed.
• Second building surface product 2103 includes first lapping projection 2124 that is being inserted behind the gypsum panel of a lowering neighbor building surface product.
• second building surface product 2103 includes a first press-on connector 2170 that is prepared to connect to a plurality of second press-on connectors 2180.
• the first press-on connectors are first snap-fit connectors and the second press-on connectors are second snap-fit connectors.
• first press-on connectors 2170 are second press-on connectors 2180 are both complementary snap-fit connectors.
• each first flexible hook includes a sharp inner edge configured to inhibit removal of the first snap-fit connector from the clip of the second snap-fit connector.
• flexible hooks 2484 and 2485 of second snap-fit connector 2480 shown in FIG. 24 have sharp inner edges. The sharp inner edge of each flexible hook 2484 and 2485 promote a permanent connection of first snap-fit connector 2470 and second snap-fit connector 2480 when they are attached to one another.
• each first flexible hook includes an angled inner edge configured to deflect the flexible hook as the first snap-fit connector is removed from the clip.
• flexible hooks 2684 and 2685 of second snap-fit connector 2680 shown in FIG. 26 have angled inner edges, which promote a removable connection of the first and second snap-fit connectors.
• the angled inner edges of flexible hooks 2684 and 2685 allow the hooks to be flexed outward so that first snap-fit connector 2670 can be removed from the second snap-fit connector 2680.
• the plurality of building surface products have different shapes that are arranged in a pattern, and wherein the first building surface product has a first shape and the second building surface product has a second shape.
• a building surface system with such a construction is shown in FIG. 19, and described above.
• a joint between the first building surface product and the second building surface product is free of any joint compound.
• the first and second edges of the building surface products may be configured to have an attractive appearance when the building surface products are adjacent, without the need of any joint compound to hide the joints. Accordingly, the building surface system can be constructed without the need to apply or finish any joint compound, which can save considerable effort in preparing the building surface.
• Embodiment 1 A building surface product comprising:
• an upper interlocking structure disposed at the upper edge of the gypsum panel, the upper interlocking structure including a first upper projection extending upward from the body and having a thickness that is smaller than the thickness of the body;
• Embodiment 2 The building surface product according to embodiment 1 , wherein the gypsum panel comprises a reinforced gypsum material.
• Embodiment 3 The building surface product according to embodiment 1 or embodiment 2, wherein the gypsum panel includes at least 1% by weight polymer.
• Embodiment 4 The building surface product according to any of embodiments 1 to 3, wherein the polymer includes starch and/or polyvinyl acetate.
• Embodiment 6 The building surface product according to any of embodiments 1 to 5, wherein the first lower projection is coextensive with the front face of the body.
• Embodiment 7 The building surface product according to any of embodiments 1 to 6, wherein the lower interlocking structure includes a lower recess formed next to the first lower projection, and wherein the first upper projection is configured to fit in the lower recess of a neighboring building surface product.
• Embodiment 8 The building surface product according to any of embodiments 1 to 7, wherein the first upper projection is coextensive with the rear face of the body.
• Embodiment 9 The building surface product according to any of embodiments 1 to 7, wherein the lower interlocking structure includes a second lower projection adjacent the rear face of the body, and wherein the lower recess is in the form of a lower groove disposed between the first lower projection and the second lower projection.
• Embodiment 10 The building surface product according to embodiment 9, wherein the first upper projection is disposed between the front face and the rear face and forms a tongue configured for insertion into the groove of a neighboring building surface product.
• Embodiment 12 The building surface product according to any of embodiments 1 to 11 , wherein the first lower projection has a chamfered edge.
• Embodiment 13 The building surface product according to any of embodiments 1 to 11 , wherein the first lower projection has a rounded edge.
• Embodiment 14 The building surface product according to any of embodiments 1 to 13, wherein the upper side of the body has a chamfered edge.
• Embodiment 18 The building surface product according to embodiment 17, wherein the angle is in a range of 30 degrees to 80 degrees.
• Embodiment 19 The building surface product according to any of embodiments 1 to 15, wherein the ends are curved.
• Embodiment 20 The building surface product according to any of embodiments 1 to 11 , wherein a portion of a first end of the gypsum panel is configured to overlap with a portion of a neighboring building surface product.
• Embodiment 23 The building surface product according to embodiment 21 or embodiment 22, wherein the facing surrounds the gypsum panel along its length.
• Embodiment 24 The building surface product according to any of embodiments 21 to 21.
• Embodiment 25 The building surface product according to any of embodiments 1 to
• a front surface of the building surface product includes a textured surface.
• Embodiment 28 The building surface product according to embodiment 25, wherein the front surface of the building surface product is roughened.
• Embodiment 29 The building surface product according to any of embodiments 25 to
• Embodiment 31 The building surface product according to any of embodiments 1 to
• a width from the upper edge to the lower edge is in a range from 3 inches to 4 feet, e.g., from 4 inches to 2 feet, e.g., from 6 inches to 1 foot.
• a length from a first end of the gypsum panel to a second end of the gypsum 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.
• Embodiment 33 The building surface product according to any of embodiments 1 to 32, wherein the thickness of the gypsum panel is in a range of 1 ⁇ 4 inch to 3 inches, e.g., from 1 ⁇ 2 inch to 2 inches.
• Embodiment 34 A method of making a building surface product according to any of embodiments 1 to 33, the method comprising:
• the substantially planar gypsum panel with the upper edge, the lower edge, the upper interlocking structure disposed at the upper edge, the lower interlocking structure disposed at the lower edge, and the two ends.
• Embodiment 35 The method according to embodiment 34, wherein forming the gypsum panel includes depositing a gypsum slurry over a forming surface and allowing the gypsum slurry to set.
• Embodiment 36 The method according to embodiment 35, wherein the forming surface is configured to form a sheet of gypsum material, and
• gypsum panel is cut from the sheet of gypsum material.
• Embodiment 37 The method according to embodiment 35, wherein the forming surface is configured to form the gypsum panel.
• Embodiment 39 The method according to any of embodiments 35 to 37, wherein the forming surface is part of a mold that includes a first portion configured to form the upper interlocking structure and a second portion configured to form the lower interlocking structure.
• Embodiment 41 The method according to embodiment 40, further comprising positioning a second flexible sheet over the gypsum panel so as to provide the facing that lines another portion of the gypsum panel.
• Embodiment 42 The method according to embodiment 41 , further comprising connecting the flexible sheet and the second flexible sheet such that the facing surrounds the gypsum panel.
• Embodiment 43 The method according to any of embodiments 34 to 43, further comprising forming a surface texture on a front surface of the building surface product.
• Embodiment 44 The method according to embodiment 43, wherein forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product.
• Embodiment 46 The method according to embodiment 45, wherein the grooves are machined into the front face of the body of the gypsum panel.
• Embodiment 47 The method according to embodiment 45, wherein the grooves are provided by the forming surface.
• Embodiment 48 The method according to any of embodiments 34 to 47, further comprising providing fastener holes through the gypsum panel.
• a building surface system comprising:
• a plurality of building surface products secured to a support structure and arranged so as to provide a building surface, wherein the plurality of building surface products includes a first building surface product with an upper interlocking structure coupled to a lower interlocking structure of a second building surface product.
• Embodiment 51 The building surface system according to embodiment 49 or embodiment 50, further comprising mechanical fasteners securing the plurality of building surface products to the support structure.
• Embodiment 55 The building surface system according to any of embodiments 49 to 53, wherein a rear surface of a portion of the second building surface product is attached to a front surface of a portion of the first building surface product using a fastener.
• Embodiment 56 The building surface system according to any of embodiments 49 to
• Embodiment 57 The building surface product according to any of embodiments 49 to
• Embodiment 58 The building surface system according to any of embodiments 49 to
• Embodiment 59 The building surface system according to embodiment 58, wherein the first building surface product is painted a first color and the second building surface product is painted a second color.
• Embodiment 60 A building surface product comprising:
• gypsum panel having a first edge, a second edge, and two ends, wherein the gypsum panel includes:
• a body comprising a front face, a rear face, and a thickness between the front face and the rear face
• Embodiment 62 The building surface product according to embodiment 61 , wherein the first snap-fit connector includes a connector body and a first flange that extends laterally outward from the connector body and is configured to engage the second snap-fit connector.
• Embodiment 66 The building surface product according to any of embodiments 61 to
• a distance between the first snap-fit connector and the first edge is less than 30% of the width of the gypsum panel body, e.g., less than 20%, e.g., less than 10%.
• Embodiment 67 The building surface product according to any of embodiments 61 to
• Embodiment 69 The building surface product according to any of embodiments 60 to
• the first lapping projection extends outward from the body in a direction of the plane of the gypsum panel a distance in a range of 1 ⁇ 4 inch to 3 inches, e.g., 3/8 inch to 2.5 inches, e.g., 1 ⁇ 2 inch to 2 inches.
• Embodiment 70 The building surface product according to any of embodiments 60 to
• Embodiment 73 The building surface product according to embodiment 72, wherein the second folded section is adhered to the first snap-fit connector.
• Embodiment 74 The building surface product according to embodiment 72 or embodiment 73, wherein the first snap-fit connector includes a base extending outward from the connector body, wherein the base is adhered to the body of the gypsum panel, and wherein the second folded section overlaps the base of the first snap-fit connector.
• Embodiment 75 The building surface product according to embodiment 72 or embodiment 73, wherein the first snap-fit connector is disposed on the folded edge of the gypsum panel.
• Embodiment 76 The building surface product according to any of embodiments 60 to
• the gypsum panel comprises a reinforced gypsum material.
• Embodiment 77 The building surface product according to any of embodiments 60 to
• the gypsum panel includes at least 1 % by weight polymer.
• Embodiment 78 The building surface product according to any of embodiments 60 to
• polymer includes starch and/or polyvinyl acetate.
• Embodiment 79 The building surface product according to any of embodiments 60 to
• the gypsum panel includes at least 1 % by weight of reinforcing fibers.
• Embodiment 80 The building surface product according to any of embodiments 60 to
• Embodiment 81 The building surface product according to any of embodiments 60 to 79, wherein the ends are disposed at an angle to the upper edge and lower edge.
• Embodiment 82 The building surface product according to embodiment 81 , wherein the angle is in a range of 30 degrees to 80 degrees.
• Embodiment 83 The building surface product according to any of embodiments 60 to 79, wherein the ends are curved.
• Embodiment 84 The building surface product according to any of embodiments 60 to
• a portion of a first end of the gypsum panel is configured to overlap with a portion of a neighboring building surface product.
• Embodiment 85 The building surface product according to any of embodiments 60 to
• Embodiment 86 The building surface product according to embodiment 85, wherein the facing is a paper facing.
• Embodiment 87 The building surface product according to any of embodiments 60 to 86, wherein a front surface of the building surface product includes a textured surface.
• Embodiment 88 The building surface product according to embodiment 87, wherein the front face of the body includes grooves along the length of the gypsum panel.
• Embodiment 89 The building surface product according to embodiment 7, wherein the front surface of the building surface product is roughened.
• Embodiment 90 The building surface product according to any of embodiments 87 to
• Embodiment 91 The building surface product according to any of embodiments 60 to
• Embodiment 92 The building surface product according to any of embodiments 60 to
• a width from the upper edge to the lower edge is in a range from 3 inches to 4 feet, e.g., from 4 inches to 2 feet, e.g., from 6 inches to 1 foot.
• Embodiment 93 The building surface product according to any of embodiments 60 to
• Embodiment 94 The building surface product according to any of embodiments 60 to
• Embodiment 95 A method of making a building surface product according to any of embodiments 60 to 94, the method comprising:
• Embodiment 96 The method according to embodiment 95, wherein forming the gypsum panel includes depositing a gypsum slurry over a forming surface and allowing the gypsum slurry to set.
• gypsum panel is cut from the sheet of gypsum material.
• Embodiment 98 The method according to any of embodiment 96 or embodiment 97, further comprising positioning a flexible sheet on the forming surface so as to provide a facing that lines at least a portion of the gypsum panel.
• Embodiment 99 The method according to embodiment 98, further comprising positioning a second flexible sheet over the gypsum panel so as to provide a facing that lines another portion of the gypsum panel.
• Embodiment 100 The method according to any of embodiments 97 to 99, further comprising forming the first edge of the gypsum panel as a folded edge with a flat fold by: cutting a first notch in the sheet of gypsum material so as to form a first folded
• Embodiment 101 The method according to any of embodiments 97 to 99, further comprising forming the first edge of the gypsum panel as a folded edge with a corner fold by: cutting a first notch in the sheet of gypsum material so as to form a first folded
• Embodiment 104 The method according to any of embodiments 101 to 103, wherein the method further comprises adhering the snap-fit connector onto the folded edge of the gypsum panel.
• Embodiment 105 The method according to any of embodiments 95 to 104, wherein the first lapping projection is machined into the gypsum panel.
• Embodiment 108 The method according to embodiment 107, wherein forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product.
• Embodiment 109 The method according to embodiment 107, wherein the forming the surface texture includes forming grooves in the front face of the body of the gypsum panel.
• Embodiment 110 The method according to embodiment 109, wherein the grooves are machined into the front face of the body of the gypsum panel.
• Embodiment 111 The method according to embodiment 109, wherein the grooves are provided by the forming surface.
• Embodiment 112. A building surface system comprising: a support structure;
• Embodiment 113 The building surface product according to embodiment 112, wherein the first press-on connectors are first snap-fit connectors and the second press-on connectors are second snap-fit connectors.
• Embodiment 114 The building surface product according to embodiment 113, wherein each of the first snap-fit connectors includes a connector body and a first flange that extends laterally outward from the connector body, and wherein each of the second snap-fit connectors includes a clip having a first flexible hook configured to engage the first flange.
• Embodiment 115 The building surface product according to embodiment 114, wherein each of the first snap-fit connectors includes a second flange that extends from the connector body in an opposite direction of the first flange, and wherein the second snap-fit connector includes a second flexible hook configured to engage the second flange.
• Embodiment 116 The building surface product according to embodiment 114 or 115, wherein each first flexible hook includes an outer angled ramp surface configured to deflect the flexible hook as the first snap-fit connector is inserted into the clip.
• Embodiment 117 The building surface product according to any of embodiments 114 to 116, wherein each first flexible hook includes a sharp inner edge configured to inhibit removal of the first snap-fit connector from the clip of the second snap-fit connector.
• Embodiment 118 The building surface product according to any of embodiments 114 to 116, wherein each first flexible hook includes an angled inner edge configured to deflect the flexible hook as the first snap-fit connector is removed from the clip.
• Embodiment 119 The building surface product according to any of embodiments 113 to 118, wherein each of the second snap-fit connectors is secured to the support structure with at least one mechanical fastener.
• Embodiment 120 The building surface product according to any of embodiments 113 to 118, wherein each of the second snap fit connectors includes a support platform, and wherein each support platform provides a contact surface for a respective first lapping projection of a building surface product.
• Embodiment 121 The building surface system according to any of embodiments 112 to
• the plurality of building surface products have different shapes that are arranged in a pattern, and wherein the first building surface product has a first shape and the second building surface product has a second shape.
• Embodiment 122 The building surface product according to any of embodiments 112 to
• Embodiment 123 The building surface system according to any of embodiments 112 to
• Embodiment 124 The building surface system according to embodiment 123, wherein a first of the building surface products is painted a first color and a second of the building surface products is painted a second color.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Panels For Use In Building Construction (AREA)
• Finishing Walls (AREA)

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• 2020
  • 2020-07-17 WO PCT/US2020/042501 patent/WO2021011860A1/en unknown
  • 2020-07-17 EP EP20840960.7A patent/EP3999696A4/de active Pending
  • 2020-07-17 CN CN202080058308.5A patent/CN114269998B/zh active Active

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