Note: Descriptions are shown in the official language in which they were submitted.
BUILDING SURFACE PRODUCT INCLUDING ATTACHMENT STRUCTURES,
BUILDING SURFACE SYSTEM, AND METHOD OF ASSEMBLY
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
[0001] 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.
2. Technical Background
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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
1
Date Recue/Date Received 2022-12-14
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.
SUMMARY OF THE DISCLOSURE
[0006] 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:
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 shaft and configured to hold the
first
attachment post in an aperture of a support structure.
[0007] 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.
[0008] 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.
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Date Recue/Date Received 2022-12-14
[0009] Additional aspects of the disclosure will be evident from the
disclosure herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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.
[0011] FIG. 1A is a schematic perspective view of a building surface product
according to an
embodiment of the disclosure.
[0012] FIG. 1B is a schematic perspective view of a portion of the building
surface product of
FIG. 1A.
[0013] FIG. 10 is a schematic cross-sectional view of a portion of the
building surface product
of FIG. 1A.
[0014] FIG. 2 is a schematic cross-sectional view of a portion of a building
surface product
according to another embodiment of the disclosure.
[0015] FIG. 3 is a schematic cross-sectional view of a portion of a building
surface product
according to another embodiment of the disclosure.
[0016] FIG. 4A is a schematic cross-sectional perspective view of a building
surface system
according to an embodiment of the disclosure.
[0017] FIG. 4B is a schematic front plan view of a portion of a rail of the
building surface
system of FIG. 4A.
[0018] FIG. 40 is a schematic cross-sectional top view of a portion of the
building surface
system of FIG. 4A.
[0019] FIG. 40 is a schematic cross-sectional side view of a portion of the
building surface
system of FIG. 4A.
[0020] FIG. 5A is a schematic perspective view of a portion of a vertical
framing member
according to an embodiment of the disclosure.
3
Date Recue/Date Received 2022-12-14
[0021] FIG. 5B is a schematic perspective view of a rail attached to the
vertical framing
member of FIG. 5A.
[0022] FIG. 6 is a schematic perspective view of a building surface system
according to an
embodiment of the disclosure.
[0023] FIG. 7A is a schematic side view of an assembly of a portion of a
building surface
product according to an embodiment of the disclosure.
[0024] FIG. 7B is a schematic side view of an assembly of another portion of
the building
surface product of FIG. 7A.
[0025] FIG. 70 is a schematic side view of the building surface product of
FIGS. 7A and 7B
secured to a support structure.
[0026] FIG. 7D is a schematic side view of the building surface product of
FIG. 7C and a
spacer.
[0027] FIG. 7E is a schematic side view of the building surface product of
FIG. 70 and a
portion of another building surface product.
[0028] FIG. 7F is a schematic side view of the building surface product of
FIG. 7C and
additional portions of the other building surface product of FIG. 7E.
[0029] FIG. 7G is a schematic side view of a portion of a building surface
product being
removed from a support structure.
[0030] FIG. 8 is a schematic cross-sectional view of a portion of a building
surface product
according to an embodiment of the disclosure.
[0031] FIG. 9 is a schematic cross-sectional view of a portion of a building
surface product
according to an embodiment of the disclosure.
[0032] FIG.10 is a schematic cross-sectional view of a panel of a building
surface product
according to an embodiment of the disclosure.
[0033] FIGS. 11A and 11B are a schematic cross-sectional views of a panel of a
building
surface product according to another embodiment of the disclosure.
[0034] FIG. 12A is a schematic perspective view of a pair of attachment
structures according
to an embodiment of the disclosure.
4
Date Recue/Date Received 2022-12-14
[0035] FIG. 12B is a schematic perspective view of a first attachment
structure of the pair of
FIG. 12A.
[0036] FIG. 12C is a schematic perspective view of the a second attachment
structure of the
pair of FIG. 12A.
[0037] FIG. 12D is a schematic side view of a building surface product secured
to a support
structure that includes the pair of attachment structures of FIG. 12A.
[0038] FIG. 13A is a schematic perspective view of a pair of attachment
structures according
to an embodiment of the disclosure.
[0039] FIG. 13B is a schematic side view of a building surface product secured
to a support
structure that includes the pair of attachment structures of FIG. 13A.
[0040] FIG. 14A is a schematic perspective view of a pair of attachment
structures according
to an embodiment of the disclosure.
[0041] FIG. 14B is a schematic side view of a building surface product secured
to a support
structure that includes the pair of attachment structures of FIG. 14A.
[0042] FIG. 15A is a schematic perspective view of building surface products
secured to a
support structure in accordance with an embodiment of the disclosure.
[0043] FIG. 15B is a schematic side view of the building surface products of
FIG. 15A in a
disconnected state.
[0044] FIG. 15C is a schematic side view of the building surface products of
FIG. 15A in a
connected state.
[0045] FIG. 16A is a schematic perspective view of a pair of building surface
products
secured to a support structure in accordance with an embodiment of the
disclosure.
[0046] FIG. 16B is a schematic side view of a building surface product secured
to a support
structure that includes the pair of attachment structures of FIG. 16A.
[0047] FIG. 16C is an exploded view of the building surface products of FIG.
16A.
[0048] FIG. 17A is a schematic perspective view of a pair of attachment
structures according
to an embodiment of the disclosure.
Date Recue/Date Received 2022-12-14
[0049] FIG. 17B is a schematic front view of the building surface product of
FIG. 17A secured
to a first support structure.
[0050] FIG. 17C is a schematic front view of the building surface product of
FIG. 17A secured
to a second support structure.
DETAILED DESCRIPTION
[0051] 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.
[0052] 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.
[0053] The rear surface of such a building surface product is shown in
perspective view in
FIG. 1A. Building surface product 100 includes a planar panel 102 in the form
of a rectangle
that has a first side 104, a second side 105, a first end 106, a second end
107, a front surface
108, and a rear surface 109. Further, panel 102 includes a gypsum body 110
(see FIG. 1C) that
is disposed between the front surface 108 and the rear surface 109. Building
surface product
100 also includes a number of attachment posts 130 extending outward from rear
surface 109
of panel 102. FIG. 1B shows greater detail of two of the attachment posts 130
extending from
rear surface 109 of panel 102, and FIG. 1C shows a cross-sectional view of a
first attachment
post 130 embedded in the rear surface 109 of panel 102.
[0054] As illustrated in FIG. 1C, first attachment post 130 includes a shaft
132 extending
outward from rear surface 109 of panel 102 and a lip 138 extending radially
outward from shaft
132. Lip 138 is configured to engage part of a support structure so as to
couple building surface
product 100 to the support structure, as described in further detail below.
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Date Recue/Date Received 2022-12-14
[0055] 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 FIGS. 1A through 1C, gypsum body 110 of panel 102
includes a front
layer 113 that extends across the width and length of panel 102 from first
side 104 to second
side 105 and from first end 106 to second end 107. In addition, a reinforcing
layer 114 extends
around the perimeter of panel 102 behind front layer 113. The reinforcing
layer 114 provides a
greater thickness to gypsum body 110 around the perimeter of panel 102, and
may increase the
strength of the panel 102.
[0056] In other embodiments, the gypsum body of the panel includes a single
layer. Such an
embodiment is shown in FIG. 2. Panel 202 of building surface product 200
includes a gypsum
body 210 having a single layer that extends from the front surface 208 of
panel 202 to the rear
surface 209 of panel 202. A plurality of attachment posts including a first
attachment post 230
extend into rear surface 209 and are configured to secure building surface
product 200 to a
support structure.
[0057] 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 FIGS. 1A to 1C includes a first
receiver sleeve 140
that is held in gypsum body 110. As shown in FIG. 1C, first attachment post
130 extends into
first receiver sleeve 140 from rear surface 109 and is held in place by
engaging with first
receiver sleeve 140.
[0058] 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 FIG. 1C, first receiver sleeve 140 extends from rear
surface 109 entirely
through reinforcing layer 114 so as to abut front layer 113. In other
embodiments, the first
receiver sleeve extends only partially through the reinforcing layer of the
panel body. For
example, in some embodiments, the first receiver sleeve is position at the
rear surface of the
panel and does not extend all the way to the front layer. In other
embodiments, the first receiver
sleeve is positioned at the interface between the front layer and the
reinforcing layer and does
not extend all the way to the rear surface. Further in some embodiments, the
first receiver
sleeve extends into the front surface of the panel. For example, in some
embodiments, the first
receiver sleeve extends at least partially through the reinforcing layer and
into the front layer.
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Date Recue/Date Received 2022-12-14
[0059] 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.
[0060] 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.
[0061] 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 FIG. 3.
Building surface
product 300 includes a panel 302 with a gypsum body 310 formed between front
surface 308
and rear surface 309 of panel 302. Gypsum body 310 includes a front layer 313
and a
reinforcing layer 314. A first attachment post 330 extends through rear
surface 309 of panel
302 to directly engage gypsum body 310.
[0062] 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 FIG. 3, first attachment post 330 penetrates rear surface
309 of panel 302
and extends entirely through reinforcing layer 314 and into front layer 313.
First attachment
post 330 extends only partially into front layer 313 and thus, the end of
first attachment post 330
is disposed within the front layer 313. Accordingly, first attachment post 330
is not visible on the
front surface 308 of panel 302. In other embodiments, the first attachment
post extends through
both the front layer and the reinforcing layer to the front surface of the
panel. Still, in other
8
Date Recue/Date Received 2022-12-14
embodiments, the first attachment post extends only partially through the
reinforcing layer and
does not extend to the front layer.
[0063] 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 FIG. 1A,
reinforcing layer 114 of panel 102 includes a first section 115 along a first
edge 116 of panel
102. Specifically, first section115 of reinforcing layer 114 extends along the
length of panel 102
from first end 106 to second end 107, thereby reinforcing the entire first
side 104 of panel 102.
In other embodiments, the first section of the reinforcing layer extends
across the width of the
panel, rather than the length. Moreover, in some embodiments, the first
section of the
reinforcing layer extends over only a portion of the respective side or end,
rather than over its
entirety.
[0064] 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 FIG. 1C, gypsum
body 110
includes a first edge section 120 that is positioned along first edge 116 of
panel 102 between
front layer 113 and the first section 115 of reinforcing layer 114.
Accordingly, first edge section
120 forms the outer surface of panel 102 along first edge 116.
[0065] 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
FIGS. 1A-1C, gypsum body 110 has similar edge sections around the rest of the
perimeter of
panel 102.
9
Date Recue/Date Received 2022-12-14
[0066] 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 FIG. 1C is
formed by routing two adjacent V-shaped grooves on one face of a gypsum panel.
The space
between the two grooves is a triangular ridge of gypsum material that forms
first edge section
120. The outer sides of the two grooves form the first tapered face 124 of the
front layer 113
and the tapered face 125 of the first section 115 of reinforcing layer 114.
The first section 115
of reinforcing layer 114 is then folded over front layer 113 so that the
tapered faces 124, 125
oppose the front and rear faces 122, 123 of first edge section 120,
respectively.
[0067] 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.
[0068] 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.
[0069] 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
Date Recue/Date Received 2022-12-14
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.
[0070] 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.
[0071] 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.
[0072] 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 FIG. 1A, reinforcing layer 114 of panel 102 is formed by four sections
positioned around the
perimeter of the panel. The four sections of reinforcing layer 114 cooperate
using miter joints to
11
Date Recue/Date Received 2022-12-14
form a frame around the perimeter of panel 102. In other embodiments, the
reinforcing layer is
formed by another number of sections. For example, in some embodiments, the
reinforcing
layer is formed by two sections along the sides or ends of the panel. In other
embodiments, the
reinforcing layer is formed by more sections. Further, in some embodiments,
the reinforcing
layer is formed by a single section that is folded behind the reinforcing
layer. For example, in
some embodiments, the reinforcing layer is formed by a single section that
extends over the
entire front layer of the panel.
[0073] 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 FIG. 10, the lip 138 of first attachment post
130 is disposed on
a head 136 positioned at the second end of shaft 132.
[0074] 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.
[0075] 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.
[0076] 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.
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Date Recue/Date Received 2022-12-14
Further, while building surface product 100 includes four attachment posts
130, as shown in
FIG. 1A, in other embodiments, the building surface product may include more
or fewer
attachment posts. For example, in some embodiments, the building surface
product includes
several columns of attachment posts across the width of the panel. Likewise,
in some
embodiments, the building surface product includes several rows of attachment
posts over the
height of the panel. Further, in some embodiments, the building surface
product includes
attachment posts along only one side of the panel, while the other side of the
panel is secured
in another manner. Further still, in some embodiments, the building surface
product includes a
single attachment post.
[0077] 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.
[0078] Such a building surface system is shown in FIG. 4A. Building surface
system 450
includes a support structure 452 and a plurality of building surface products,
including first
building surface product 400A and second building surface product 400B,
attached to support
structure 452. The support structure 452 includes a group of vertical framing
members 454 and
a plurality of rails 460, including first rail 460A and second rail 460B, that
extend across vertical
framing members 454 and form a support surface. The first building surface
product 400A is
secured to support structure 452 by securing attachment posts of first
building surface product
400A to first rail 460A.
[0079] FIG. 4B shows an enlarged plan view of a section of a rail 460. As
illustrated in FIG.
4B, rail 460 includes a longitudinal plate 462 and a first receiving slot 470A
in the longitudinal
plate 462. The first receiving slot 470A is configured to receive the first
attachment post of the
first building surface product. For example, FIG. 4C shows a schematic cross-
sectional top
view of a portion of a first building surface product 400A secured to the rail
460. As shown in
FIG. 4C, a first attachment post 430A extending outward from a rear surface
409 of first building
surface product 400A is attached to rail 460. In particular, first attachment
post 430A is
disposed within first receiving slot 470A so that first building surface
product 400 is secured to
rail 460.
13
Date Recue/Date Received 2022-12-14
[0080] While the embodiment shown in FIGS. 4A and 4C includes a building
surface product
having a panel with a single layer, in other embodiments, the building surface
system includes
building surface products with panels that have a front layer and a
reinforcement layer, such as
those shown in FIGS. 1A-1C and 3.
[0081] 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 FIG. 4C, the shaft 432 of first attachment post 430A extends through
first receiving slot
470 and the head 436 of first attachment post 430A engages rail 460. In
particular, the head
436 of first attachment post 430A forms a lip 438 that hooks behind a first
engagement edge
472 that extends along the length of first receiving slot 470. Accordingly,
lip 438 prevents first
attachment post 430A from being pulled through first receiving slot 470A such
that first building
surface product 400 is held securely against first rail 460.
[0082] 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 FIG. 4B, first receiving slot 470A
extends along the
length of longitudinal plate 462 from a first end 474 to a second end 476. The
width of first
receiving slot 470A tapers inward toward the second end 476. Accordingly, the
first end 474 of
first receiving slot 470A may be wide enough to receive the head 436 of first
attachment post
430A, while the second end 476 is sized to prevent the head 436 from passing
back through
first receiving slot 470A. For example, the width of first receiving slot may
be slightly larger than
the head of first attachment post at the first end and smaller than the head
but slightly larger
than the shaft at the second end.
[0083] 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 FIGS. 4B and 40, longitudinal plate 462 includes a planar front
face 464 that
extends along the length and across the width of rail 460. A first indentation
466A extends
rearward from front face 464 so as to form a raised bulge behind front face
464. First receiving
14
Date Recue/Date Received 2022-12-14
slot 470A is positioned within first indentation 466A such that the edge
around first receiving slot
470A is spaced from front face 464.
[0084] 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 FIG. 40, the
depth of first
indentation 466A increases from the first end 474 of first receiving slot 470A
to the second end
476. Accordingly, the engagement edge 472 that surrounds first receiving slot
470A slopes
away from front face 464 toward the second end 476 of first receiving slot
470A. Thus, as first
attachment post 430A is moved from the first end 474 of first receiving slot
470A toward the
second end 476, the engagement edge 472 slopes toward head 436, thereby
tightening the fit
between first attachment post 430A of first building surface product 400A and
rail 460.
[0085] 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 FIGS. 4A and 40, first building
surface product
400A is secured against support structure 452 with the rear surface 409 of
panel 402 abutting
front face 464 of longitudinal plate 462 of rail 460.
[0086] 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 FIG. 4B,
rail 460 includes first receiving slot 470A on a first side 466 of
longitudinal plate 462 and a
second receiving slot 470B on the second side 467 of longitudinal plate 462.
Similar to first
receiving slot 470A, second receiving slot 470B is positioned in an
indentation and decreases in
width from a first end to a second end.
[0087] 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
FIG. 4A, includes a plurality of rails including first rail 460A and second
rail 460B. Each of the
rails includes a longitudinal plate with receiving slots on both the first
side and the second side
of the plate. Accordingly, one building surface product can be attached to the
first side of the
longitudinal plate while a second building surface product is attached to the
second side of the
Date Recue/Date Received 2022-12-14
longitudinal plate. For example, the lower side of first building surface
product 400A is attached
to first rail 460A and the upper side of second building surface product 400B
is also attached to
first rail 460A.
[0088] FIG. 4D shows a cross-sectional side view of rail 460 with both first
building surface
product 400A and second building surface product 400B secured to the front
face 464 of
longitudinal plate 462. In particular, first attachment post 430A of first
building surface product
400A is held in a first receiving slot 470A while an attachment post 430B of
second building
surface product 400B is held in second receiving slot 470B. Accordingly, rail
460 assists in
holding both the first building surface product 400A and second building
surface product 400B
against the support structure.
[0089] In the illustrated embodiment, as shown in FIG. 4B and 4D, the first
and second
receiving slots are aligned along the length of the longitudinal plate and are
both oriented
similarly, so that the slots narrow in the same direction. In other
embodiments, the position of
the receiving slots along the length of the longitudinal plate may be
staggered, rather than
aligned. Further, in some embodiments, the orientation of the second slot may
be opposite to
that of the first slot, such that an attachment post placed in the second
receiving slot is secured
in the slot by moving the opposite direction as an attachment post placed in
the first receiving
slot.
[0090] 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 FIGS. 4B and 4D, the longitudinal plate 462
of first rail 460A
includes an outwardly extending projection 468 that is positioned between the
first side 466 and
second side 467 of longitudinal plate 462. Accordingly, the first receiving
slot 470A and second
receiving slot 470B are disposed on opposing sides of projection 468.
Moreover, projection 468
is interposed between first building surface product 400A and second building
surface product
400B.
[0091] 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
16
Date Recue/Date Received 2022-12-14
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.
[0092] The rail 460 shown in FIGS. 4B-4D is formed from a single metal sheet
that is folded,
shaped and cut to form the receiving slots, indentations and projection.
Accordingly, projection
468 is configured as a flange that is formed as a folded section of the metal
sheet between the
first side 466 and second side 467 of longitudinal plate 462. However, in
other embodiments,
the projection is a bump or ridge. Further, in some embodiments, the
projection is a molded or
cast element that extends outward from the front face of the rail. Further,
while projection 468
of rail 460 runs continuously along longitudinal plate 462, in other
embodiments, the projection
includes discrete segments along the length of the longitudinal plate.
[0093] 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 FIG. 4D, projection
468 of rail 460
extends outward from front face 464 to a height that is equal to the thickness
of the panels of
first building surface product 400A and second building surface product 400B.
The projection
468 thereby forms a visible ridge between first building surface product 400A
and second
building surface product 400B that is aligned with the front surfaces of the
building surface
products. In other embodiments, the height of the projection is greater than
the thickness of the
panels. Accordingly, the projection may extend outward past the front surfaces
of the building
surface products. Further, in some embodiments, the height of the projection
is smaller than the
thickness of the panels of the building surface products, which may obscure
the projection. Still
further, in some embodiments, the rail may exclude the projection entirely.
[0094] 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 FIG. 4B,
rail 460 includes an open path 478 that extends from the first end 474 of
first receiving slot 470
to an edge of longitudinal plate 462. The open path 478 allows an attachment
post to be
inserted into the first receiving slot 470A by a lateral relative movement of
the attachment post
with respect to the rail through the open path, rather than a direct insertion
into the receiving slot
by a movement of the attachment post along its axial direction. As explained
further below, this
allows the rail to be slid into place on a previously installed building
surface product.
17
Date Recue/Date Received 2022-12-14
[0095] 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.
[0096] 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 FIG.
4A, first rail 460A includes a row of receiving slots that are configured to
support a row of
building surface products. In particular, first rail 460A and second rail 460B
are configured to
cooperate to support a row of two building surface products. In other
embodiments, the row
may include a greater number of building surface products.
[0097] 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.
[0098] 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.
[0099] 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 FIG. 4A, support structure 452 includes a plurality of vertical
framing members 454 in
the form of beams or studs that extend in a row to provide support structure
452 with a planar
configuration. In other embodiments, the rails extend vertically and may be
coupled to
horizontal supports.
18
Date Recue/Date Received 2022-12-14
[0100] 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.
[0101] 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.
[0102] Such an embodiment is shown in FIGS. 5A and 5B. FIG. 5A shows a
vertical framing
member 554 that includes a beam 555 with a reinforcement plate 556 secured to
the front face
of beam 555. Reinforcement plate 556 is secured to beam 555 using teeth that
are integrally
formed therein, similar to a timber connector plate. In other embodiments, the
reinforcement
plate may be secured to the beam using fasteners, such as screws, nails or
staples, or another
method. Reinforcement plate 556 includes a receiver 558 that is configured to
receive a
mechanical fastener for securing a rail to the vertical framing member 554.
For example,
receiver 558 includes internal threads for receiving a bolt or other threaded
shaft that holds the
rail to vertical framing member 554. FIG. 5B shows a first rail 560 secured to
vertical framing
member 554 using mechanical fastener 559 that is secured in reinforcement
plate 556.
[0103] 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.
[0104] 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
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Date Recue/Date Received 2022-12-14
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.
[0105] For example, to add a further building surface product 400 in one of
the empty
positions in building surface system 450, shown in FIG. 4A, the building
surface product 400 is
placed in front of support structure 452 with the rear surface of the panel of
the building surface
product 400 facing a rail 460 of the support structure 452. Further, a first
attachment post
extending from the rear surface of the panel is positioned in a corresponding
receiving slot 470
of the rail. The building surface product 400 is then slid across the support
structure 452 in
order to move the first attachment post of the building surface product to an
assembled position
at a closed end of the receiving slot in the rail. The attachment post and
receiving slot
cooperate to retain the first building surface product 400 against the support
structure 452.
[0106] 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 FIGS. 1A-1C,
the building
surface product 100 is positioned so that each attachment post is inserted
into a respective
receiving slot in the rails of the support structure, and the building surface
product 100 is slid so
that each attachment post moves to the second end of the respective receiving
slot and is
secured in place.
[0107] 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
Date Recue/Date Received 2022-12-14
structure. For example, when installing the building surface system 450, shown
in FIGS. 4A-4D,
each of the building surface products 400 is secured to the support structure
452 in a manner
similar to that described above, where attachment posts of the building
surface products are
secured to respective receiving slots 470 of the support structure 452.
[0108] 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.
[0109] 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.
[0110] 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 FIG. 4B, the rail may be
slid into place with
the attachment posts of the building surface products passing through the open
paths to the
receiving slots.
[0111] 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
21
Date Recue/Date Received 2022-12-14
rail on an upper edge of the panel of the first building surface product. For
example, when
placing the rail 460 shown in FIGS. 4B behind a previously installed building
surface product,
the rail can be positioned so that the projection 468 rests on the upper edge
of the panel of the
building surface product. The components can be sized so that this position
aligns the receiving
slots of the rail with the attachment posts of the building surface product to
allow for easy
insertion of the attachment posts into the receiving slots.
[0112] 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.
[0113] FIG. 6 illustrates a building surface system that includes several of
such building
surface products. Building surface system 650 includes a support structure 652
formed by a
group of vertical framing members 654. A plurality of building surface
products 600 are
attached to the support structure 652 using attachment structures that are
joined by
corresponding clips. Various examples of such attachment structures are
described below.
[0114] FIGS. 7A-7F illustrate a sequence in assembling an embodiment of a
building surface
system that includes a building surface product having a pair of attachment
structures for
holding the building surface product to a support structure. FIG. 7A shows
portions of a building
surface product 700 including a panel 702 and a first attachment structure 730
that is positioned
for attachment to the panel 702. As explained in more detail below, the panel
702 includes a
gypsum body 710 that is formed by a front layer 713 and a reinforcing layer
714. The front layer
713 forms the front surface 708 of the panel 702, while the rear surface 709
of the panel 702 is
formed by a combination of the reinforcing layer 714 and the front layer 713.
The first
attachment structure 730 is positioned for attachment to the rear surface 709
using a
mechanical fastener 732 that extends into the reinforcement layer. In the
illustrated
embodiment, the mechanical fastener 732 is in the form of a bolt.
[0115] 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
22
Date Recue/Date Received 2022-12-14
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.
[0116] FIG. 7B illustrates a second attachment structure 770 that is
positioned for attachment
to a framing member 754 of a support structure 750 using a mechanical fastener
772 in the form
of a screw. The framing member 754 is in the form of a wall stud. The second
attachment
structure 770 includes a second base 774 that is adapted to be secured to the
front surface of
the framing member 754 and a second clip 780 that is configured to be secured
to the first
attachment structure. Similar to the first attachment structure 730 shown in
FIG. 7A, the second
attachment structure 770 is formed by a bent metal sheet, and the second base
774 is provided
by a flat section of the second attachment structure 770 that is held against
the front surface of
the framing member 754. The second clip 780 extends forward from the second
base 774 for
engagement with the first attachment structure 730, as shown in FIG. 7C.
[0117] FIG. 70 shows the first attachment structure 730 secured to the panel
702 by the bolt
732 and the second attachment structure 770 secured to the framing member 754
by the screw
772. Moreover, the first clip 740 of the first attachment structure 730 is
coupled to the second
clip 780 of the second attachment structure 770 such that the building surface
product 700 is
held securely against the framing member 754 of the support structure 750.
[0118] 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 FIG. 7A, the first clip 740 of first attachment
structure 730 is
formed by a first hook 742 that is disposed at the end of a leg 744 that
extends rearward from
the first base 734. Likewise, as shown in FIG. 7B, the second clip 780 of the
second
attachment structure 770 is formed by a second hook 782 that is disposed at
the end of an arm
784 that extends forward from the second base 774.
[0119] 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
23
Date Recue/Date Received 2022-12-14
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.
[0120] 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 FIG. 7A, the first hook 742 of first attachment
structure 730 is curved
back from leg 744 such that the end of the first hook 742 extends forward
toward the rear
surface of the panel 702. Accordingly, the first hook 742 forms an opening 746
that faces the
panel 702. Similarly, as shown in FIG. 7B, the second hook 782 of the second
attachment
structure 770 is curved back from arm 784 such that the end of the second hook
782 extends
rearward and away from the panel 702. As a result, the second hook 782 forms
an opening 786
that faces away from the panel 702. As shown in FIG. 7C, this configuration
allows the end of
the second hook 782 of the second attachment structure 770 to be inserted into
the opening
746 of the first hook 742 in order to connect the first attachment structure
730 to the second
attachment structure 770. At the same time, the end of the first hook 742 of
the first attachment
structure 730 may be inserted into the opening 786 formed by the second hook
782. With the
first hook 742 and second hook 782 engaged, the panel 702 may be securely held
against the
support structure 750.
[0121] 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 FIG. 7A, first attachment structure 730
of building
surface product 700 includes a spring 738 that extends rearward from the first
base 734. As
depicted in FIG. 7C, the spring 738 provides a spring force against the second
attachment
structure 770. Because the second attachment structure 770 is secured to the
framing member
754 of the support structure 750, the spring force provided by the spring 738
urges the first
attachment structure 730 forward. This forward force on the first attachment
structure 730 helps
to maintain the forward facing opening 746 of the first hook 742 engaged with
the end of the
second hook 782 of the second attachment structure 770.
[0122] 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
FIG. 7C, the configuration of the first attachment structure 730 and second
attachment structure
770 is such that the spring 738 of first attachment structure 730 presses
against the second
24
Date Recue/Date Received 2022-12-14
base 774 of the second attachment structure 770 when the building support
product 700 is
mounted to the support structure.
[0123] 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
FIG. 70, second attachment structure 770 includes a shelf 775 extending
forward from the
lower end of second base 774. The shelf 775 supports the panel 702 by allowing
the adjacent
section of the reinforcing layer 714 of the panel 702 to rest on shelf 775.
This may allow some
of the load of the panel 702 to be transferred directly to the second
attachment structure 770, so
that the clips do not bear the entirety of the load.
[0124] As shown in FIG. 70, once the building surface product 700 is secured
to the support
structure 750, a spacer 778 may be provided on the building surface product
700 for positioning
another building surface product above building surface product 700. The
spacer 778 rests on
the upper side of the panel 702 and sets the position for another attachment
structure that will
hold another building surface product. For example, as shown in FIG. 7E, once
the spacer 778
is placed on the first building surface product 700, another attachment
structure 770A is secured
to the framing member 754 above the spacer 778.
[0125] As shown in FIG. 7F, once the attachment structure 770A is secured to
the framing
member 754, a second panel 702A may be secured to the attachment structure
770A via
another cooperative attachment structure 730A. By positioning the attachment
structure 770A
based on the spacer 778, the spacer 778 can assist in providing a uniform
spacing between the
first building surface product 700 and the second building surface product
700A.
[0126] 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.
Date Recue/Date Received 2022-12-14
[0127] 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 FIG. 7G, by removing the spacer 738, the
panel 702 can be
lifted slightly to disengage the first hook 742 of the first attachment
structure 730 from the
second hook 782 of the second attachment structure 770. The panel 702 and
first attachment
structure 730 may then be pulled away from the support structure 750 and
removed from the
wall.
[0128] As shown in FIGS 8-11B, the panel may have various different
configurations.
Further, depending on the configuration of the panel, the connection of the
first attachment
structure to the panel may be achieved in different ways. In some embodiments,
the first
attachment structure may be secured to the panel using a fastener, as stated
above. The
fastener may be secured directly to the material of the panel, such as the
gypsum body, or may
be secured to a separate element that is secured to the panel, as explained
further below.
Alternatively, in some embodiments, the first attachment structure may be
secured to the panel
using adhesive or another manner.
[0129] FIG. 8 shows a panel 802 and a first attachment structure 830 attached
thereto.
Similar to panel 702 shown in FIGS. 7A-7G, panel 802 includes a gypsum body
810 formed by
a front layer 813 and a reinforcing layer 814. The front layer 813 extends
across the width and
length of the panel 802 while the reinforcing layer 814 extends around the
perimeter of the
panel 802 behind front layer 813. The reinforcing layer 814 provides a greater
thickness to
gypsum body 810 around the perimeter of panel 802, and may increase the
strength of the
panel 802.
[0130] Further, panel 802 of FIG. 8 includes a first receiver sleeve 804 that
is held in gypsum
body 810. To secure the first attachment structure 830 to panel 802, a
mechanical fastener 832
extends through the first attachment structure 830, into gypsum body 810 and
into first receiver
sleeve 804 from rear surface 809. The mechanical fastener 832 is held in place
by engaging
with first receiver sleeve 804, which may provide a stronger engagement than
would be
provided by engaging the gypsum directly.
[0131] In some embodiments, the first receiver sleeve includes a threaded
interior surface
configured to engage the first attachment post. For example, in FIG. 8, the
shaft of the
mechanical fastener 832 is threaded and the first receiver sleeve 804 includes
a complementary
thread to receive the mechanical fastener 832. Such a threaded engagement may
help secure
26
Date Recue/Date Received 2022-12-14
the mechanical fastener 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 mechanical fastener is threaded and the first
receiver sleeve has
a deformable interior surface. Accordingly, the threaded shaft of the
mechanical fastener can
cut into the first receiver sleeve in order to form a secure connection
between the mechanical
fastener and first receiver sleeve.
[0132] 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.
[0133] In the embodiment shown in FIG. 8, gypsum body 810 includes a first
edge section
820 that is positioned along first edge 816 of panel 802 between front layer
813 and the first
section 815 of reinforcing layer 814. Accordingly, first edge section 820
forms the outer surface
of panel 802 along first edge 816. The first edge section 820 has a triangular
cross-section with
an outer face 821 along first edge 816, a front face 822 that is presented
toward front layer 813,
and a rear face 823 that is presented toward first section 815 of reinforcing
layer 814. To match
the shape of first edge section 820, front layer 813 has a first tapered face
824 that opposes
front face 822 of first edge section 820. Likewise, first section 815 of
reinforcing layer 814 also
has a tapered face 825 that opposes rear face 823 of first edge section 820.
[0134] 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 FIG. 8 is formed by routing two adjacent V-shaped
grooves on one face
of a gypsum panel. The space between the two grooves is a triangular ridge of
gypsum
material that forms first edge section 820. The outer sides of the two grooves
form the first
tapered face 824 of the front layer 813 and the tapered face 825 of the first
section 815 of
reinforcing layer 814. The first section 815 of reinforcing layer 814 is then
folded over front layer
813 so that the tapered faces 824, 825 oppose the front and rear faces 822,
823 of first edge
section 820, respectively.
27
Date Recue/Date Received 2022-12-14
[0135] 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.
[0136] FIG. 9 shows a panel 902 with a gypsum body 920 that is formed as a
single layer. A
first attachment structure 930 is attached to the rear surface 909 of panel
902 using a
mechanical fastener 932. The mechanical fastener 932 extends into gypsum body
920 through
a hole 922 in the gypsum body 920. Inside the hole 922, the mechanical
fastener 932 engages
an embedded fastener 940.
[0137] 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.
[0138] 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.
[0139] 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
28
Date Recue/Date Received 2022-12-14
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.
[0140] 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.
[0141] 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.
[0142] 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.
[0143] 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 FIG. 9, the length of embedded fastener 940 is about
half of the
thickness of panel 902, and embedded fastener 940 is positioned just behind
the front surface
908. Accordingly, the rear end of embedded fastener 940, which is formed by
the rear end of
threaded body 942, is about halfway between the front surface 908 and rear
surface 909 of
29
Date Recue/Date Received 2022-12-14
panel 902, such that the entire embedded fastener 940 is contained between the
front surface
908 and rear surface 909.
[0144] 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.
[0145] In panel 902, as shown in FIG. 9, the first side 906 of panel 902 is
positioned at the top
of the panel, such that the projection at the front of the panel 902 is on the
top of the panel. In
other embodiments, the first side of the panel may be positioned at the bottom
of the panel. In
various embodiments, each of the first and second projections extend in a
direction that is
parallel to the front and rear surfaces of the panel. For example, in panel
902, the first
projection 960 extends upward and the second projection 970 extends downward.
[0146] 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.
[0147] 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.
Date Recue/Date Received 2022-12-14
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.
[0148] FIG. 10 shows another embodiment of a panel with angled edges. Panel
1002
includes a front layer 1013 and a reinforcing layer 1014. Similar to the panel
802, shown in FIG.
8, panel 1002 is formed by machining grooves into a gypsum body 1010. The
shapes of the
notches are neither uniform nor symmetrical. Accordingly, when the gypsum body
1010 is
folded around the notches, the gypsum body 1010 forms edges with differing
angles so that
both the upper side 1004 and lower side 1005 of the panel 1002 are angled
downward from the
front surface 1008.
[0149] FIGS. 11A and 11B show another embodiment of a panel where the gypsum
body is
formed as a single layer and the upper and lower sides are angled. As shown in
FIG. 11A,
panel 1102 includes notches 1103 that are formed in the gypsum body 1110. But
the notches
do not form a reinforcing layer behind a front layer. Instead, as shown in
FIG. 11B, the when
the gypsum body 1110 is folded around the notches, the folded sections only
form the angled
surfaces at the upper side 1104 and lower side 1105. In addition to forming
the angled surfaces
at the upper and lower sides of the panel 1102, folding the edges over can
also provide a facing
sheet along the upper side 1104 and lower side 1105 that is continuous with a
facing sheet
extending over a front surface 1108 of the panel 1102.
[0150] FIGS. 12A-170 show various attachment structures having different
configurations in
accordance with embodiments of the disclosure. FIG. 12A shows a pair of
attachment
structures configured to hold a panel to a support structure. The pair
includes a first attachment
structure 1230 that is configured to be secured to a panel and a second
attachment structure
1270 configured to be secured to a support structure. As shown in FIG. 12B,
the first
attachment structure 1230 includes a first base 1234 that is adapted to be set
against a surface
of a panel and a leg 1244 extending from an upper end of the first base 1234.
A first clip 1240
31
Date Recue/Date Received 2022-12-14
in the form of a first hook 1242 is provided at the end of the leg 1244. A
spring 1238 extends
outward from the lower end of the first base 1234 and is configured to push
the first attachment
structure 1230 forward and maintain engagement with the second attachment
structure 1270,
as explained above with respect to building surface product 700.
[0151] As shown in FIG. 12C, the second attachment structure 1270 includes a
second base
1274 that is configured to be set against a support structure and an arm 1284
extending forward
from the second base 1274. A second clip 1280 in the form of a second hook
1282 is provided
at the end of the arm 1284 for engagement with the first attachment structure
1230.
[0152] 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.
[0153] 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.
[0154] FIG. 12D shows the first attachment structure 1230 secured to a wall
panel 1202 with
an angled upper side 1204. The second attachment structure 1270 is secured to
a support
structure 1250. The first hook 1242 of the first attachment structure 1230
engages the second
hook 1282 of the second attachment structure 1270 so as to secure the panel
1202 to the
support structure 1250. Further, the spring 1238 urges the first attachment
structure 1230
forward to maintain the engagement between the first hook 1242 and the second
hook 1282.
[0155] FIG. 13A shows a pair of cooperating attachment structures including a
first
attachment structure 1330 and a second attachment structure 1370. The first
attachment
structure 1330 includes a first base 1334 that is adapted to be set against a
surface of a panel
and a leg 1344 extending from an upper end of the first base 1334. A first
clip 1340 in the form
of a first hook 1342 is provided at the end of the leg 1344. The second
attachment structure
32
Date Recue/Date Received 2022-12-14
1370 is formed by a first component 1371 and a second component 1372. The two
components
1371 and 1372 form two layers of the second base 1374.
[0156] 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.
[0157] FIG. 13B shows the first attachment structure 1330 secured to a wall
panel 1302 and
both components 1371 and 1372 of the second attachment structure 1370 secured
to a support
structure 1350. The first hook 1342 of the first attachment structure 1330
engages the second
hook 1382 of the second attachment structure 1370 so as to secure the panel
1302 to the
support structure 1350. Further, the first spring 1338 and second spring 1339
cooperate to urge
the first attachment structure 1330 forward to maintain the engagement between
the first hook
1342 and the second hook 1382.
[0158] FIG. 14A shows a pair of cooperating attachment structures including a
first
attachment structure 1430 and a second attachment structure 1470. The first
attachment
structure 1430 includes a first base 1434 that is adapted to be set against a
surface of a panel
and a first hook 1442 configured to engage the second attachment structure
1470. Likewise,
the second attachment structure includes a second base 1474 that is configured
to be set
against a support structure. The second attachment structure 1479 includes a
second hook
1482 provided to engage the first hook 1442 and a spring 1438 for helping to
maintain the
connection between the attachment structures. The first hook 1442 includes a
bulbous end
1443 and a constricted opening 1444. Further, the second hook 1482 also
includes a bulbous
end 1483 and a constricted opening 1484. The attachment structures are
configured so that the
bulbous ends pass through the constricted openings when the attachment
structures are
coupled in order to form a strong connection between the attachment
structures.
[0159] 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.
[0160] FIG. 14B shows the first attachment structure 1430 secured to a wall
panel 1402 and
the second attachment structure 1470 secured to a support structure 1450. The
first hook 1442
33
Date Recue/Date Received 2022-12-14
of the first attachment structure 1430 engages the second hook 1482 of the
second attachment
structure 1470 so as to secure the panel 1402 to the support structure 1450.
Further, the spring
1438 pushes an upper neighboring panel forward, which in turn pushes the panel
1402 forward.
This helps maintain the engagement between the first hook 1442 and the second
hook 1482.
[0161] FIG. 15A shows a panel 1502 with a first attachment clip 1530 that
includes a channel
1540 and a second attachment clip 1570 that includes a spring clip 1580. As
shown in FIG.
15B, the bottom of the channel 1540 forms a base 1534 that is secured against
a surface of the
panel. Further, the channel 1540 has a constricted opening 1542 that is
configured to retain the
spring clip 1580 within the channel 1540 having a constricted opening. The
spring clip 1580
includes a pair of prongs 1582 that flex upon insertion into the channel 1540.
Once the spring
clip 1580 is inserted into the channel 1540, as shown in FIG. 15C, the prongs
1582 are hindered
from being removed, which may prevent accidental decoupling of the panel from
the support
structure.
[0162] 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 FIG. 15C.
[0163] FIGS. 16A-16C illustrate a similar construction as FIGS. 15A-15C, where
the second
attachment structure 1670 includes a first spring clip 1680 configured to hold
a first panel 1602
as well as an additional spring clip 1685 configured to hold another panel
1603 against a
support structure. However, unlike the configuration shown in FIGS. 15A-15C,
as shown in FIG.
16A, the additional spring clip 1685 is oriented vertically, so that the
height of the connection
between the additional spring clip 1685 and the second panel 1603 is
adjustable. Accordingly,
the spacing between the panel 1602 and the second panel 1603 can be adjusted
after the
second panel 1603 is secured to the second attachment structure 1670, as shown
in FIGS. 16B
and 16C.
[0164] FIGS. 17A-17C illustrate another pair of attachment structures that are
configured to
couple a panel to a support structure. As shown in FIG. 17A, the first
attachment structure 1730
includes a rounded channel 1740 with a constricted opening 1742. An inner side
of the channel
1740 forms a base 1734 that is adapted for securing the first attachment
structure 1730 to a
panel. The second attachment structure 1770 has a corresponding design that
includes a base
1774 configured to be attached to a support structure and a clip 1780 formed
by a ball 1784
34
Date Recue/Date Received 2022-12-14
positioned at the end of a post 1782. The ball 1784 is configured to be
inserted into the
rounded channel 1740 to secure the second attachment structure 1770 to the
first attachment
structure. While the illustrated ball has a spherical shape, in other
embodiments it may have an
elliptical or oval shape. As will be appreciated by one skilled in the art,
additional matched
shapes of protuberances and receivers can be adapted to carry out the
engagement function.
[0165] As shown in FIGS. 17B and 17C, the ball of the second clip allows
rotational
adjustment between the first attachment structure and the second attachment
structure 1770.
Accordingly, for example, the second attachment structure 1770 may be rotated
to
accommodate variations in the distances between framing members 1754 of a
support structure
1750. For example, in FIG. 17B the distance between framing members 1754 of
the support
structure and the ends of the panel 1702 are the same. Accordingly, the panel
may be secured
to the support structure without any modification. In FIG. 17C, in contrast,
the length of the
panel 1702 is greater than the distance between neighboring framing members
1754. Rather
than having to resize the panel 1702 or move the first attachment structure
(see FIG. 17A), the
panel 1702 may still be secured to the framing members 1754 by rotating one of
the second
attachment structures 1770. The rotationally symmetrical design of the second
attachment
structure 1770 allows the second attachment structure 1770 to couple to the
first attachment
structure at various different angles.
[0166] 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.
[0167] 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
Date Recue/Date Received 2022-12-14
after the gypsum has set. In certain embodiments, the polymer includes starch
and/or polyvinyl
acetate.
[0168] 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.
[0169] In some embodiments, the gypsum body includes one or more additives,
such as
biocides, hydrophobic additives, and fire resistance additives.
[0170] In certain embodiments of the building surface product as otherwise
described herein,
the panel is rectangular. For example, as shown in FIG. 1A, the shape of
building surface
product 100 is governed by panel 102 which has a rectangular form. In
particular, the first edge
116 along first side 104 is parallel to the edge along second side 105 and the
two edges run
across the width of panel 102. Likewise, the edge at first end 106 is parallel
to edge at second
end 107. Moreover, the sides and ends of panel 102 are perpendicular to one
another such that
the shape of panel 102 is that of a rectangle. In other embodiments, the
building surface
product has another shape. For example, in some embodiments, the building
surface product is
formed as a trapezoid, triangle, or other polygon.
[0171] 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
36
Date Recue/Date Received 2022-12-14
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.
[0172] 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.
[0173] 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.
[0174] 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.
[0175] 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.
[0176] In certain embodiments of the building surface product as otherwise
described herein,
a thickness of the panel is at least 3/8 inch, e.g., at least 1/2 inch, e.g.,
at least 3/4 inch. In some
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Date Recue/Date Received 2022-12-14
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 3/8 inch to 4 inches, e.g., from 1/2 inch to 3 inches, e.g.,
from 1/4 inch to 2 inches.
[0177] 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.
EMBODIMENTS
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:
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 shaft and configured to hold the
first
attachment post in an aperture of a support structure.
Embodiment 2. The building surface product according to embodiment 1,
wherein the
gypsum body includes a front layer and a reinforcing layer disposed behind the
front layer,
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
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Date Recue/Date Received 2022-12-14
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
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.
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Date Recue/Date Received 2022-12-14
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
Date Recue/Date Received 2022-12-14
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.
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Date Recue/Date Received 2022-12-14
Embodiment 35. The building surface product according to any of embodiments
1 to 34,
wherein a thickness of the panel is at least 3/8 inch, e.g., at least 1/2
inch, e.g., at least 3/4 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.
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Date Recue/Date Received 2022-12-14
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.
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Date Recue/Date Received 2022-12-14
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:
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Date Recue/Date Received 2022-12-14
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
Date Recue/Date Received 2022-12-14
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.
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Date Recue/Date Received 2022-12-14
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.
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Date Recue/Date Received 2022-12-14
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.
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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.
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Date Recue/Date Received 2022-12-14
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.
Date Recue/Date Received 2022-12-14
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 3/8 inch, e.g., at least 1/2
inch, e.g., at least 1/4 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.
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Date Recue/Date Received 2022-12-14
