Patent Description:
The present disclosure relates generally to building surface products, for example, panels suitable for forming a building surface. The present disclosure relates more particularly to building surface products having overlapped edges.

Prefabricated panels, for example gypsum wallboards that are commonly referred to as drywall, are often used to construct building surfaces. The wallboards are attached to a supporting structure, such as the joists of a wall frame. Once the wallboards are hung on the supporting structure, the wall is finished using joint compound or another material to create a smooth surface. The wall may then be painted or covered with wall paper.

Gypsum wallboards are advantageous for use as a building surface for various reasons. Such wallboards are incredibly durable, have excellent fire resistance, are easily repaired, and are easy to mount on a supporting structure. Typically, mounting gypsum wallboard panels only requires attaching the wallboards to an underlying supporting structure using mechanical fasteners, such as screws.

While the mounting of gypsum wallboards is relatively easy, most wallboard panels are finished by covering the joints between the panels and the fasteners in order to create a smooth surface. The wallboards 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. Accordingly, the present inventors have determined that a building surface formed of gypsum-based products that are constructed without requiring timely finishing would be attractive to both builders and customers.

<CIT> discloses a building board for mounting on a support structure including a set of studs (<NUM>). The building board comprising a framing element (<NUM> essentially shaped as a rectangular cuboid including two opposite main sides having relatively large delimitation surfaces and four edge sides having relatively small delimitation surfaces. A first type of snap-in means (A1) are arranged along a first edge side and a second type of snap-in means (A2) are arranged along a second edge sides opposite to said first edge side. The snap-in means of the first type (A1) is, after mounting of the building board against the support structure, configured to receive a snap-in means of the second type (A2) of another building board so that this building board is connected to the mounted building board. Either the snap-in means of said first or second type (A1, A2) includes a groove (<NUM>; <NUM>) for receiving at least one clamping element (<NUM>) for fixing and holding the first and the second building boards against a stud (<NUM>) of the support structure.

<CIT> discloses cover pads for use on upright walls, wherein the pad provides an improved internal support which is of simplified construction, for example the center support and the surrounding frame being made of a one-piece monolithic support structure which permits a flexible covering to be attached to the center support and the exterior side surfaces of the edge frame while the covering and support structure are in a flat and planar condition, following which the edge frame is folded and secured into position around the center support. The internal support structure for the pad, when in a flat condition, has voids at the corners so that the covering can be tucked into the corners prior to the edge frame being folded into its frame-defining position.

In one aspect, the invention provides a fastenable building surface product comprising:.

In another aspect, the invention provides a method of making a building surface product, in accordance with claim <NUM>.

Additional aspects of the invention are subject-matter of the dependent claims and will be evident from the following embodiments of the invention.

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 invention.

As described above, the present inventors have noted that conventional building surfaces formed of gypsum products involve extensive finishing to meet customer expectations. The present inventors have determined that a building surface formed of gypsum-based products that are constructed without requiring timely finishing would be attractive to both builders and customers.

Accordingly, one aspect of the disclosure not according to the claimed invention is an interlocking building surface product including a substantially planar gypsum panel having an upper edge, a lower edge, and two ends. The gypsum panel includes a body comprising a front face, a rear face, and a thickness between the front face and the rear face. An upper interlocking structure is disposed at the upper edge of the gypsum panel and a lower interlocking structure is disposed at the lower edge of the gypsum panel. The upper interlocking structure includes a first upper projection that extends upward from the body of the gypsum panel and has a thickness that is smaller than the thickness of the body. Likewise, the lower interlocking structure includes a first lower projection that extends downward from the body and has a thickness that is smaller than the thickness of the body. The upper interlocking structure and the lower interlocking structure are configured to cooperate with neighboring gypsum panels so as to form a building surface.

Such a building surface product is shown in perspective view in <FIG>. Building surface product <NUM> includes a gypsum panel <NUM> that is substantially planar and has an upper edge <NUM>, a lower edge <NUM>, a first end <NUM>, and a second end <NUM>. The term planar, as used herein, refers to a panel in which a plane can pass through the entirety of the panel from one end to the other. Thus, the surfaces of a planar panel are not required to be entirely flat, so long as the shape of the panel follows a plane. The term substantially planar refers to a shape that bows along its length or width to an extent of no more than <NUM> degrees. In some embodiments of the present disclosure, the building surface product is substantially planar, and in some embodiments the building surface product is planar. Still, in other embodiments, the building surface curves along its length to a greater extent than <NUM> degrees.

Gypsum panel <NUM> also includes an upper interlocking structure <NUM> disposed at the upper edge <NUM> thereof. Moreover, a lower interlocking structure <NUM> is similarly disposed at the lower edge <NUM> of the gypsum panel <NUM>. Upper interlocking structure <NUM> and lower interlocking structure <NUM> are configured to cooperate with neighboring gypsum panels so as to form a building surface. For example, as explained in more detail below, the upper interlocking structure <NUM> of building surface product <NUM> may cooperate with the lower interlocking structure of a neighboring building surface product. Likewise, the lower interlocking structure <NUM> of building surface product <NUM> may cooperate with the upper interlocking structure of another neighboring building surface product. The terms upper and lower, as used herein, refer to one possible installation configuration of the building surface product on a support frame, and are used for relative directions in such a configuration. However, embodiments of the building surface product can be installed in other configurations, such as configurations in which features described as being on an upper side of the product are disposed on the bottom. Likewise, the building surface product of the disclosure can also be installed vertically, such that features described as upper and lower are disposed on the left and/or right.

As shown in the side view of building surface product <NUM>, in <FIG>, gypsum panel <NUM> includes a body <NUM> having a front face <NUM> and a rear face <NUM>. Further gypsum panel <NUM> has a thickness <NUM> that extends from front face <NUM> of body <NUM> to rear face <NUM> of body <NUM>. In some embodiments, the thickness of the body is equal to the thickness of the building surface product as a whole, in other embodiments, the building surface product is thicker than the thickness of the body. Upper interlocking structure <NUM> includes a first upper projection <NUM> that extends upward from body <NUM> of gypsum panel <NUM>. Similarly, lower interlocking structure <NUM> includes a first lower projection <NUM> that extends downward from body <NUM>. The thickness of each projection is smaller than thickness <NUM> of the body <NUM> of gypsum panel <NUM>. In particular, the thickness <NUM> of first upper projection <NUM> is smaller than thickness <NUM> of body <NUM> and thickness <NUM> of first lower projection <NUM> is smaller than thickness <NUM>. In some embodiments, the combined thickness of the first upper projection and the first lower projection is no greater than the thickness of the body of the gypsum panel. This allows the first upper projection of one panel and the first lower projection of another panel to overlap while the body of the two panels are coplanar, as described in more detail below.

In certain embodiments of the interlocking building surface product as otherwise described herein, the gypsum panel comprises a reinforced gypsum material. In some embodiments, the gypsum panel includes at least <NUM>% by weight polymer. Reference to the weight percentage of a component of the gypsum panel, as used herein, refers to the weight after the gypsum has set. In certain embodiments, the polymer includes starch and/or polyvinyl acetate.

In certain embodiments of the interlocking building surface product as otherwise described herein, the gypsum panel includes at least <NUM>% by weight of reinforcing fibers. For example, in some embodiments, the gypsum panel includes glass fibers. Further, in some embodiments, the gypsum panel includes cellulose-based fibers. Moreover, in some embodiments, the gypsum panel includes polyethylene, polypropylene or polyester fibers. Various embodiments of the building surface product include different combinations of the aforementioned fibers in the gypsum panel.

In some embodiments, the gypsum panel includes one or more additives, such as biocides, hydrophobic additives, and fire resistance additives.

In certain embodiments of the interlocking building surface product as otherwise described herein, the first lower projection is coextensive with the front face of the body. For example, in building surface product <NUM> first lower projection <NUM> extends downward from body <NUM> at the front face <NUM> of body <NUM>, such that the front surface of first lower projection <NUM> is flush with front face <NUM>. Accordingly, the lower projection <NUM> forms an extension of body <NUM> along front face <NUM>, forming a continuous surface between body <NUM> and first lower projection <NUM>.

In certain embodiments of the interlocking building surface product as otherwise described herein, the lower interlocking structure includes a lower recess formed next to the first lower projection, and the first upper projection is configured to fit in the lower recess of a neighboring building surface product. For example, in building surface product <NUM>, lower interlocking structure <NUM> includes a lower recess <NUM> adjacent to first lower projection <NUM>. As shown in <FIG>, the first upper projection of a neighboring building surface product of similar configuration is configured to fit in the lower recess <NUM> of interlocking structure <NUM>. As a result, lower interlocking structure <NUM> overlaps and cooperates with the corresponding upper interlocking structure of the neighboring building surface product.

In certain embodiments of the interlocking building surface product as otherwise described herein, the first upper projection is coextensive with the rear face of the body. For example, as shown in <FIG>, the first upper projection extends upward from body <NUM> at the rear face <NUM> of body <NUM>, such that the rear surface of first upper projection <NUM> is flush with rear face <NUM>. This allows upper projection <NUM> and rear face <NUM> of body <NUM> form flat surface for bracing against a support frame, as explained in more detail below. In particular, the upper projection <NUM> and rear face <NUM> are coextensive and form a continuous surface between body <NUM> and first upper projection <NUM>.

In some embodiments of the interlocking building surface product as otherwise described herein, the upper interlocking structure <NUM> includes an upper recess formed next to the first upper projection, and the first lower projection is configured to fit into the upper recess of a neighboring building surface product. For example, in building surface product <NUM>, upper interlocking structure <NUM> includes an upper recess <NUM>, similar to lower recess <NUM>, that is adjacent to first upper projection <NUM>. As shown in <FIG>, the first lower projection of a neighboring building surface product is configured to fit in the upper recess <NUM> of interlocking structure <NUM>. As a result, upper interlocking structure <NUM> overlaps and cooperates with the corresponding lower interlocking structure of the neighboring building surface product.

In certain embodiments of the interlocking building surface product as otherwise described herein, the lower interlocking structure includes a second lower projection adjacent the rear face of the body, and wherein the lower recess is in the form of a lower groove disposed between the first lower projection and the second lower projection. An example of such a building surface product is shown in <FIG>. Building surface product <NUM> includes a gypsum panel <NUM> that has a body <NUM>, which includes a front face <NUM> and a rear face <NUM>. An upper interlocking structure <NUM> is disposed above body <NUM> and a lower interlocking structure <NUM> is disposed below body <NUM>. The lower interlocking structure <NUM> includes a first lower projection <NUM> extending downward from body <NUM> that is adjacent to and coextensive with front face <NUM> of body <NUM>. In addition, lower interlocking structure <NUM> also includes a second lower projection <NUM> that is adjacent to rear face <NUM> of body <NUM>. A gap is provided between first lower projection <NUM> and second lower projection <NUM> to provide a lower recess <NUM> in the form of a groove. In order to interlock with a neighboring building surface product, the groove <NUM> provided between first lower projection <NUM> and second lower projection <NUM> is configured to receive an upwardly extending projection of a neighboring building surface product.

In certain embodiments of the interlocking building surface product as otherwise described herein, the first upper projection is disposed between the front face and the rear face and forms a tongue configured for insertion into the groove of a neighboring building surface product. For example, building surface product <NUM>, shown in <FIG>, includes an upper interlocking structure <NUM> that has a first upper projection <NUM> positioned between the front face <NUM> and rear face <NUM> of body <NUM> of gypsum panel <NUM>. First upper projection <NUM> is specifically configured as a tongue to fit into a groove of a neighboring building surface product. In particular, the first upper projection <NUM> of upper interlocking structure <NUM> is configured so as to cooperate with the recess <NUM> of lower interlocking structure <NUM> and be received therein. Thus, a series of building surface products all having the same configuration as that of building surface product <NUM> can form a building surface wherein the upper interlocking structure of each gypsum panel fits into the lower interlocking structure of a neighboring gypsum panel.

In certain embodiments of the interlocking building surface product as otherwise described herein, the upper interlocking structure includes a second upper projection, wherein an upper groove is disposed between the first upper projection and the second upper projection, and wherein the upper groove and the lower groove are each configured to receive an insert that cooperates with a corresponding groove of a neighboring building surface product. Such a building surface product is shown in <FIG>. Building surface product <NUM> includes a gypsum panel <NUM> that has a body <NUM>, which includes a front face <NUM> and a rear face <NUM>. An upper interlocking structure <NUM> is disposed above body <NUM> and a lower interlocking structure <NUM> is disposed below body <NUM>. The lower interlocking structure <NUM> includes a first lower projection <NUM> extending downward from body <NUM> that is adjacent to and coextensive with front face <NUM> and a second lower projection <NUM> that is adjacent to rear face <NUM> of body <NUM>. A lower recess <NUM> in the form of a groove is formed between first lower projection <NUM> and second lower projection <NUM>. Upper interlocking structure <NUM> has a similar configuration as lower interlocking structure <NUM> and includes a first upper projection <NUM> extending upward from body <NUM> that is adjacent to and coextensive with front face <NUM> and a second upper projection <NUM> that is adjacent to rear face <NUM> of body <NUM>. An upper recess <NUM> in the form of a groove is formed between first upper projection <NUM> and second upper projection <NUM>.

Each of the upper interlocking structure <NUM> and lower interlocking structure <NUM> are configured to receive an insert, such as insert <NUM>, in the respective upper recess <NUM> and lower recess <NUM>. Accordingly, neighboring building surface products having a configuration similar to that of building surface product <NUM> connect to one another using the upper interlocking structure and lower interlocking structure via an insert disposed in the adjacent recesses. In some embodiments, the recesses of adjacent building surface products are aligned such that the insert may be a straight plank. In other embodiments, the recesses are offset or have complex shapes, and the insert has a corresponding shape configured to be received in the recesses of two neighboring building surface products. In some embodiments, the upper and lower recesses extend along the entire length of the building surface product, and the insert likewise extends across all or a substantial majority of the building surface product. In other embodiments, the upper and lower recesses are intermittently positioned along the length of the building surface product, and one or more inserts are positioned therein to connect neighboring building surface products.

In certain embodiments of the interlocking building surface product as otherwise described herein, the first lower projection has a chamfered edge. For example, such a building surface product is shown in <FIG>. Building surface product <NUM> includes a gypsum panel <NUM> that has a body <NUM>, which includes a front face <NUM> and a rear face <NUM>. An upper interlocking structure <NUM> is disposed above body <NUM> and a lower interlocking structure <NUM> is disposed below body <NUM>. Upper interlocking structure <NUM> includes a first upper projection <NUM> and lower interlocking structure <NUM> includes a first lower projection <NUM>. The lower end of first lower projection <NUM> has an angled surface <NUM> that forms a chamfered edge on first lower projection <NUM>.

In certain embodiments of the interlocking building surface product as otherwise described herein, the first lower projection has a rounded edge. For example, such a building surface product is shown in <FIG>. Building surface product <NUM> includes a gypsum panel <NUM> that has a body <NUM>, which includes a front face <NUM> and a rear face <NUM>. An upper interlocking structure <NUM> is disposed above body <NUM> and a lower interlocking structure <NUM> is disposed below body <NUM>. Upper interlocking structure <NUM> includes a first upper projection <NUM> and lower interlocking structure <NUM> includes a first lower projection <NUM>. The lower end of first lower projection <NUM> has a convex curved surface <NUM> that forms a rounded edge on first lower projection <NUM>. Similarly, building surface product <NUM> includes a gypsum panel <NUM> that has a body <NUM>, which includes a front face <NUM> and a rear face <NUM>. An upper interlocking structure <NUM> is disposed above body <NUM> and a lower interlocking structure <NUM> is disposed below body <NUM>. Upper interlocking structure <NUM> includes a first upper projection <NUM> and lower interlocking structure <NUM> includes a first lower projection <NUM>. The lower end of first lower projection <NUM> has a concave curved surface <NUM> that forms a rounded edge on first lower projection <NUM>.

In certain embodiments of the interlocking building surface product as otherwise described herein, the upper side of the body has a chamfered edge. For example, building surface product <NUM> includes an angled surface extending from front face <NUM> of body <NUM> toward first upper projection <NUM> that forms a chamfered edge <NUM>.

In certain embodiments of the interlocking building surface product as otherwise described herein, the upper side of the body has a rounded edge. For example, building surface product <NUM> includes a convex curved surface extending from front face <NUM> of body <NUM> toward first upper projection <NUM> that forms a rounded edge <NUM>. Similarly, building surface product <NUM> includes a concave curved surface extending from front face <NUM> toward first upper projection <NUM> that forms a rounded edge <NUM>. While building surface product <NUM> includes chamfered edges <NUM>, <NUM> toward both the top and bottom of front face <NUM>, building surface product <NUM> includes convex rounded edges <NUM>, <NUM> toward both the top and bottom of front face <NUM>, and building surface product <NUM> includes concave rounded edges <NUM>, <NUM> toward both the top and bottom of front face <NUM>, in other embodiments, the building surface product may include a chamfered edge combined with a rounded edge, or a concave rounded edge combined with a convex rounded edge. Likewise, in some embodiments, the building surface product includes a straight edge combined with a rounded or chamfered edge. Other combinations and edges are also possible.

In certain embodiments of the interlocking building surface product as otherwise described herein, the ends are perpendicular to the upper edge and the lower edge. For example, building surface product <NUM>, shown in <FIG> and <FIG>, has a rectangular shape, and ends <NUM> and <NUM> are perpendicular to upper edge <NUM> and lower edge <NUM>. In other embodiments, the ends are disposed at an angle to the upper edge and lower edge. The phrase "at an angle" as used herein, refers to an angle that is at least <NUM> degrees from parallel (<NUM> degrees) or perpendicular (<NUM> degrees). In some embodiments, the angle is in a range of <NUM> degrees to <NUM> degrees. For example, building surface product <NUM>, shown in <FIG>, includes a gypsum panel <NUM> that is substantially planar and has an upper edge <NUM>, a lower edge <NUM>, a first end <NUM>, and a second end <NUM>. Each of the first end <NUM> and second end <NUM> are disposed at an angle to the upper edge <NUM> and lower edge <NUM>. In particular, first end <NUM> intersects upper edge <NUM> and lower edge <NUM> at an angle of about <NUM> degrees. Likewise, second end <NUM> intersects upper edge <NUM> and lower edge <NUM> at an angle of about <NUM> degrees. While the corners of the gypsum panel <NUM> are obtuse at the upper edge <NUM> and acute at the lower edge <NUM>, in other embodiments, the corners are obtuse at the lower edge and acute at the upper edge. Further, in some embodiments, respective corners at the upper edge are obtuse and acute and respective corners at the lower edge are also obtuse and acute, such that the gypsum panel is in the shape of a parallelogram.

In certain embodiments of the interlocking building surface product as otherwise described herein, the ends are curved. For example, building surface product <NUM>, shown in <FIG>, includes a gypsum panel <NUM> that is substantially planar and has an upper edge <NUM>, a lower edge <NUM>, a first end <NUM>, and a second end <NUM>. Each of the first end <NUM> and second end <NUM> are curved. While, the curved first and second ends <NUM>, <NUM> of building surface product <NUM> form rounded corners at lower edge <NUM> and sharp corners at upper edge <NUM>, in other embodiments, the curved ends may form four rounded corners, or configurations of rounded and sharp corners.

In certain embodiments of the interlocking building surface product as otherwise described herein, a portion of a first end of the gypsum panel is configured to overlap with a portion of a neighboring building surface product. For example, building surface product <NUM>, shown in <FIG>, includes a first lateral projection <NUM> at first end <NUM> that is adjacent the rear face of gypsum panel <NUM> and a second lateral projection <NUM> at second end <NUM> that is adjacent the front face of gypsum panel <NUM>. Thus, when building surface product <NUM> is positioned laterally adjacent to a building surface product of a similar design, the second lateral projection of the neighboring product can overlap the first lateral projection <NUM> of building surface product <NUM> at first end <NUM>. Likewise, the second lateral projection <NUM> can overlap a corresponding first lateral projection of a neighboring building surface product at the second end <NUM> of building surface product <NUM>.

In certain embodiments of the interlocking building surface product as otherwise described herein, the building product further includes a facing that lines at least a portion of the gypsum panel. In some embodiments, the facing is a paper facing. In other embodiments, the facing includes reinforcing fibers. For example, in some embodiments, the facing includes a fiberglass mat. Further, in some embodiments, the gypsum product of the gypsum panel the building surface product is embedded into the facing.

In certain embodiments of the interlocking building surface product as otherwise described herein, the facing surrounds the gypsum panel along its length. For example, in some embodiments, the facing is formed from two distinct sheets that are wrapped around the gypsum panel. The facing sheets may then be attached to one another to surround the panel. In some embodiments, the facing sheets wrap around the panel along its length. The ends of the panel may then either be left uncovered or the facing sheets may also be folded over the ends.

In certain embodiments of the interlocking building surface product as otherwise described herein, the facing includes a reinforcing sheet disposed at the rear face of the gypsum panel. For example, in some embodiments, the facing includes a robust paper, board, or fiber-reinforced sheet at the rear of the gypsum panel. The reinforcing sheet may provide added strength for attaching the building surface product to a support structure. In some embodiments, the reinforcing sheet is disposed only along the rear face of the gypsum panel. For example, the reinforcing sheet may be used in combination with another facing along the front face of the gypsum panel that has a lower tear strength than the reinforcing sheet. Likewise, in some embodiments, the front face of the gypsum panel may be free of any facing, while the reinforcing sheet is disposed along the rear face of the gypsum panel.

In certain embodiments of the interlocking building surface product as otherwise described herein, a front surface of the building surface product includes a textured surface. For example, in some embodiments, the front surface of the building surface product is sanded or roughened to provide a surface texture to the front face of the building surface product. Further, in some embodiments, a coating of a grainy or heterogeneous coating is applied to the front surface of the building surface product. For example, building surface product <NUM>, shown in <FIG>, includes a heterogeneous coating applied to portions of the front face <NUM> of gypsum panel <NUM>, which provides the front surface of the building surface product with a textured surface. The surface texture of the front face of the building surface product may provide the product with a visual appearance similar to venetian plaster or cast concrete.

In certain embodiments of the interlocking building surface product as otherwise described herein, the front face of the body includes grooves along the length of the gypsum panel. For example, building surface product <NUM>, shown in <FIG>, includes grooves <NUM> that extend across the front surface of the building surface product <NUM> parallel to the upper edge <NUM> and lower edge <NUM>. In some embodiments, the grooves are disposed at regular intervals and provide a gap in the front face of the building surface product that is similar to the gap that is formed where two neighboring building surface products meet. Accordingly, the grooves may help obscure the location of the actual joints between adjacent building surface products.

In certain embodiments of the interlocking building surface product as otherwise described herein, the building product further includes fastener holes extending through the gypsum panel. For example, building surface product <NUM> includes fastener holes <NUM> that extend through the first upper projection <NUM> of the upper interlocking structure <NUM>. By placing the fastener holes within a portion of the upper interlocking structure, the fastener holes can be obscured by the first lower projection of a neighboring building surface product that hangs over the first upper projection <NUM>. The building surface product <NUM> also includes fastener holes <NUM> through the body of the gypsum panel <NUM> within grooves <NUM>. The fastener holes within the grooves are also obscured by their placement within the grooves, where lighting is reduced. In other embodiments, fastener holes are provided alternatively, or in addition, within the lower interlocking structure, or through the entire thickness of the gypsum panel.

In certain embodiments of the interlocking building surface product as otherwise described herein, the front surface of the building surface product provides acoustical dampening to the building surface product. For example, in some embodiments, the front surface of the building surface product includes baffles, ridges, protrusions or other surface features that enhance sound dampening.

In certain embodiments of the interlocking building surface product as otherwise described herein, a front surface of the building surface product is painted. For example, in some embodiments, the building surface product is painted prior to installation on a support structure, such as in a manufacturing facility. Thus, in some embodiments, the building surface product is painted before any mechanical fasteners are used to attach the building surface product to a support structure, such as wall joists. Indeed, in some embodiments the building surface product is painted and is free of mechanical fasteners extending therethrough.

In certain embodiments of the interlocking building surface product as otherwise described herein, a width from the upper edge to the lower edge is in a range from <NUM> inches to <NUM> feet, e.g., from <NUM> inches to <NUM> feet, e.g., from <NUM> inches to <NUM> foot. A width of the building surface product that is smaller than standard gypsum wallboard products, for example from a few inches up to a foot, can provide an aesthetic that is similar to shiplap. As a result, the joints between the building surface products form part of the aesthetic of the building surface, and do not need to be covered and hidden. This allows surfaces that are made using the building surface products according to the disclosure to be constructed without the need to cover the joints between the building surface products, which can save considerable time and effort.

In certain embodiments of the interlocking building surface product as otherwise described herein, a length from a first end of the gypsum panel to a second end of the gypsum panel is in a range from <NUM> foot to <NUM> feet, e.g., from <NUM> feet to <NUM> feet, e.g., from <NUM> feet to <NUM> feet. In some embodiments, thickness of the gypsum panel is in a range of ¼ inch to <NUM> inches, e.g., from ½ inch to <NUM> inches. Other thicknesses are also possible.

In another aspect not according to the claimed invention, the disclosure provides a method of making an interlocking building surface product according to any of the above-described embodiments. In various embodiments, the method includes forming the substantially planar gypsum panel with the upper edge, the lower edge, the upper interlocking structure disposed at the upper edge, the lower interlocking structure disposed at the lower edge, and the two ends. For example, a method of the disclosure includes forming gypsum panel <NUM>, shown in <FIG> to include the upper edge <NUM>, the lower edge <NUM>, the upper interlocking structure <NUM> as upper edge <NUM>, the lower interlocking structure <NUM> at lower edge <NUM>, the first end <NUM>, and the second end <NUM>. As explained in more detail below, some embodiments of the method include cutting the general shape of the gypsum panel from a larger sheet of material, and other embodiments include forming the general shape of the gypsum panel directly from a gypsum slurry. Further, in some embodiments, the upper and lower interlocking structures are machined into the gypsum panel. In other embodiments, the upper and lower interlocking structures are provided in the gypsum panel when it is formed from a slurry.

In particular, in certain embodiments of the method as otherwise described herein, forming the gypsum panel includes depositing a gypsum slurry over a forming surface and allowing the gypsum slurry to set. An embodiment of a method including this stage is shown in <FIG>. Slurry <NUM> is dispensed from a mixer <NUM> onto a forming surface <NUM> positioned on a conveyor <NUM>. The forming surface <NUM> is a flat plane that allows the gypsum slurry <NUM> to set in the form of a flat sheet of gypsum. In some embodiments, the forming surface includes sidewalls that contain the outer sides of the gypsum material as it sets. Further, in some embodiments, the method further includes the use one or more rollers or dies to further form the gypsum panel into its desired shape, such as a flat sheet. In some embodiments of the method the gypsum product passes through one or more ovens to facilitate drying of the gypsum material.

In certain embodiments of the method as otherwise described herein, the forming surface is configured to form a sheet of gypsum material, and the gypsum panel is cut from the sheet of gypsum material. For example, in <FIG>, the conveyor <NUM> moves the gypsum material to a blade <NUM> that cuts the gypsum material into the general shape of the gypsum panel. The blade can take various forms, for example, a circular saw. In other embodiments, other cutting devices are also possible, such as a laser cutting device, or a water-jet cutting device. In some embodiments, the width of the sheet of gypsum material is the same as the length of the gypsum panels, and the gypsum panels are cut from the sheet of gypsum material along their upper and lower edges. In other embodiments, the width of the sheet of gypsum material is the same as the width of the gypsum panels, and the gypsum panels are cut from the sheet of gypsum material along their ends.

In other embodiments, the forming surface is configured to form the gypsum panel. For example, in some embodiments, the forming surface is part of a mold and the shape of the gypsum panel is formed in mold. Thus, the mold may include boundaries corresponding to the upper edge, the lower edge, the first end and the second end of the gypsum panel. Further, in some embodiments, the mold may include a cover. In other embodiments, the upper surface of the mold is open.

In certain embodiments of the method as otherwise described herein, the upper interlocking structure and the lower interlocking structure are machined into the gypsum panel. For example, portions of the gypsum panel can be cut, routed or otherwise removed in order to form the upper and lower interlocking structures. Such a method is schematically illustrated in <FIG>. In the illustrated method, a CNC machine <NUM> is removing a portion of gypsum panel <NUM> corresponding to recess <NUM> so as to form upper projection <NUM> of upper interlocking structure <NUM>. In other embodiments, a machine is used to remove other portions of the gypsum panel so as to form the lower interlocking structure. Further, in some embodiments, material is removed from the front and/or rear face of the gypsum panel, such as is shown in <FIG>. In some embodiments, material is removed from the upper edge and/or lower edge of the gypsum panel. Likewise, in some embodiments, material is removed from the ends.

In certain embodiments of the method as otherwise described herein, the forming surface is part of a mold that includes a first portion configured to form the upper interlocking structure and a second portion configured to form the lower interlocking structure. For example, such a method is shown in <FIG>, in which a gypsum slurry is dispensed onto forming surface <NUM>, which is part of a mold <NUM>. The mold <NUM> includes a first portion <NUM> shaped as a step that occupies a recess of the final gypsum panel <NUM> in order to form the first upper projection <NUM> of upper interlocking structure <NUM>. On the opposite end of mold <NUM> is a second portion <NUM> shaped as an overhang that occupies another recess of the final gypsum panel in order to form the first lower projection <NUM> of lower interlocking structure <NUM>.

In the illustrated embodiment, mold <NUM> is open at the ends, so as to form a continuous sheet of the gypsum material that includes the upper interlocking structure <NUM> and the lower interlocking structure <NUM>. The sheet of gypsum material is then cut at intervals to create the gypsum panels. In other embodiments, the mold includes boundaries at the ends and forms a single gypsum panel.

In certain embodiments of the method as otherwise described herein, the method further includes positioning a flexible sheet on the forming surface so as to provide a facing that lines at least a portion of the gypsum panel. In some embodiments, the method further includes positioning a second flexible sheet over the gypsum panel so as to provide the facing that lines another portion of the gypsum panel. For example, in some embodiments, a flexible sheet is positioned on the forming surface and the gypsum slurry is then dispensed over the flexible sheet. As the gypsum slurry takes the form of the panel, the flexible sheet may be wrapped around the sides of the gypsum panel using rollers or guides. A second flexible sheet may cover the opposing side of the gypsum panel. In some embodiments, the flexible sheet is paper. In other embodiments, the flexible sheet is a mat, for example a glass fiber mat. In some embodiments, the flexible sheet includes reinforcing fibers, as described above.

In some embodiments, the method further includes connecting the flexible sheet and the second flexible sheet such that the facing surrounds the gypsum panel. For example, with the flexible sheet wrapped around the sides of the gypsum panel, the flexible sheet may be secured to the second flexible sheet on the opposite side of the panel. When secured on the gypsum panel, the flexible sheet forms a facing around the surface of the panel. The two flexible sheets may be secured to one another, for example, using a combination of folds and adhesive, as will be appreciated by those of ordinary skill in the art.

In certain embodiments of the method as otherwise described herein, the method further includes forming a surface texture on a front surface of the building surface product. In some embodiments, forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product. In other embodiments, forming the surface texture includes forming grooves in the front face of the body of the gypsum panel. For example, the formation of the grooves may be carried out by removing material from the gypsum panel, such as by using a CNC machine as shown in <FIG>. In other embodiments, the grooves are provided by the forming surface. For example, mold <NUM>, shown in <FIG>, includes ridges <NUM> that from grooves <NUM> in the front face <NUM> of the gypsum panel <NUM>.

In certain embodiments of the method as otherwise described herein, the method further includes providing fastener holes through the gypsum panel. For example, in some embodiments, fastener holes are drilled through the gypsum panel. The fastener holes promote proper placement of mechanical fasteners to secure the building surface product to a support structure. Further, the fastener holes may also assist in maintaining the structural integrity of the gypsum panel.

In another aspect not according to the claimed invention, the disclosure provides an interlocking building surface system comprising: a plurality of building surface products according to the disclosure secured to a support structure and arranged so as to provide a building surface, wherein the plurality of building surface products includes a first building surface product with an upper interlocking structure coupled to a lower interlocking structure of a second building surface product. Such a system is schematically shown in <FIG>. Building surface system <NUM> includes a plurality of building surface products secured to a support structure <NUM>. The support structure <NUM> is in the form of a wall frame including a plurality of periodically spaced studs <NUM>. In other embodiments, the support structure includes other framing elements. Further, in some embodiments, the support structure is in the form sheathing or panels. The building surface products of system <NUM> include a first building surface product <NUM> and a second building surface product <NUM>. The first building surface product <NUM> includes an upper interlocking structure <NUM> that is coupled to a lower interlocking structure <NUM> of the second building surface product <NUM>.

In certain embodiments of the interlocking system as otherwise described herein, the first upper projection of the upper interlocking structure of the first building surface product is covered by a first lower projection of the lower interlocking structure of the second building surface product. For example, first lower projection <NUM> of lower interlocking structure <NUM> of second building surface product <NUM> covers first upper projection <NUM> of upper interlocking structure <NUM> of first building surface product <NUM>.

In certain embodiments of the interlocking system as otherwise described herein, the system further includes mechanical fasteners securing the plurality of building surface products to the support structure. For example, mechanical fasteners <NUM>, such as screws, secure the building surface products to the framing elements <NUM> of the support structure <NUM>. In some embodiments, the mechanical fasteners pass through fastener holes in the building surface products, while in other embodiments, the fasteners are forced through the gypsum material.

In certain embodiments of the interlocking system as otherwise described herein, a first group of the mechanical fasteners extend through the first upper projection of the upper interlocking structure of the first building surface product into the support structure, and the first lower projection of the lower interlocking structure of the second building surface product covers the first group of mechanical fasteners. For example, the mechanical fasteners <NUM> which attach first building surface product <NUM> to support structure <NUM> are shown with dotted lines, as they are positioned behind first lower projection <NUM> of second building product <NUM>. Accordingly, because each building surface product overlaps the lower neighboring building surface product, the system may be installed with the mechanical fasteners obscured without the need for any joint compound to cover the mechanical fasteners.

In certain embodiments of the interlocking system as otherwise described herein, each of the building surface products includes a cleat disposed on the rear face of the body, and wherein the support structure includes corresponding cleats adapted to engage the cleats of the building surface products. For example, such a system is shown in <FIG>. Building surface product <NUM> includes a body <NUM> with a front face <NUM> and a rear face <NUM>. A cleat <NUM> is attached to the rear face <NUM> of body <NUM>. Likewise a corresponding cleat <NUM> is attached to a framing element <NUM> of support structure <NUM>. Accordingly, building surface product <NUM> is secured to support structure <NUM> using the cooperative cleats <NUM> and <NUM>.

In other embodiments, the building surface products are attached to the support structure using various other methods. For example, in some embodiments, the building surface products are attached to the support structure using an adhesive, such as a pressure sensitive adhesive.

In certain embodiments of the interlocking system as otherwise described herein, a portion of the second building surface product is attached to a portion of the first building surface product using an adhesive. For example, in some embodiments the front surface of the upper projection of the first building surface product is attached to a rear surface of the lower projection of the second building surface product using an adhesive.

In certain embodiments of the interlocking system as otherwise described herein, a rear surface of a portion of the second building surface product is attached to a front surface of a portion of the first building surface product using a fastener. For example, in some embodiments the front surface of the upper projection of the first building surface product is attached to a rear surface of the lower projection of the second building surface product using hook and loop fastener.

In certain embodiments of the interlocking system as otherwise described herein, the plurality of building surface products have different shapes that are arranged in a pattern, and wherein the first building surface product has a first shape and the second building surface product has a second shape. Such as building surface system is shown in <FIG>. Building surface system <NUM> includes a plurality of building surface products in two configurations. Some of the building surface products are wider at the upper edge than at the lower edge, while some are wider at the lower edge than at the upper edge. In particular, building surface system <NUM> includes a first building surface product <NUM> that is wider at the upper edge and a second building surface product <NUM> that is wider at the lower edge.

In certain embodiments of the interlocking system as otherwise described herein, a joint between the first building surface product and the second building surface product is free of any joint compound. For example, the upper interlocking structure and the lower interlocking structure may be configured to have an attractive appearance when the building surface products are adjacent, without the need of any joint compound to hide the joints. Accordingly, the building surface system can be constructed without the need to apply or finish any joint compound, which can save considerable effort in preparing the building surface.

In certain embodiments of the interlocking system as otherwise described herein, a front surface of the first building surface product and a front surface of the second building surface product are covered with a layer of paint. In some embodiments, the paint covers the entire exposed front surface of each building surface product. For example, if the building surface is constructed without the use of joint compound, the layer of paint can be applied directly to building surface products from the upper edge to the lower edge and from the first end to the second end.

In certain embodiments of the interlocking system as otherwise described herein, the first building surface product is painted a first color and the second building surface product is painted a second color. Such a building surface system is shown in <FIG>. Building surface system <NUM> includes a plurality of building surface products in two configurations. Some of the building surface products are wider at the upper edge than at the lower edge, while some are wider at the lower edge than at the upper edge. Further, some of the building surface products are painted a first color while some of the building surface products are painted a second color. In particular, building surface system <NUM> includes a first building surface product <NUM> that is painted a first color and a second building surface product <NUM> that is painted a second color.

Only the following embodiments are embodiments of the invention.

In one aspect according to the claimed invention, the disclosure provides a fastenable building surface product including a substantially planar gypsum panel having a first edge, a second edge, and two ends. The gypsum panel includes a body comprising a front face, a rear face, and a thickness between the front face and the rear face. A first lapping projection extends outward from the body at the second edge and is configured to overlap a portion of a neighboring gypsum panel so as to form a building surface. The building surface product also includes a first press-on connector disposed on and attached to the rear face of the body toward the first edge of the gypsum panel. The press-on connector is configured to engage a corresponding second press-on connector.

The phrase "toward the first edge," refers to the position of the press-on connector being disposed closer to the first edge than the second edge.

Such a building surface product is shown, for example, in <FIG>. Building surface product <NUM> includes a substantially planar gypsum panel <NUM> including a first edge <NUM>, a second edge <NUM>, a first end <NUM>, and a second end <NUM>. The gypsum panel <NUM> also includes a body <NUM> that has a front face <NUM>, a rear face <NUM> and a thickness between front face <NUM> and rear face <NUM>. Building surface product <NUM> also includes a first lapping projection <NUM> that extends outward from body <NUM> at second edge <NUM> and that is configured to overlap a portion of a neighboring gypsum panel so as to form a building surface, as described in more detail below. A first press-on connector <NUM> is disposed on the rear face <NUM> of body <NUM> near the first edge <NUM> of gypsum panel <NUM>. The press-on connector is configured to engage a corresponding second press-on connector, as described in more detail below.

The press-on connector and lapping projection are complementary components that allow the fastenable building surface product to have an interlocking engagement with neighboring building surface products while also being modular. The building surface product can be positioned so that the lapping projection extends behind a portion of a neighboring panel. Subsequently, the first press-on connector can be used to secure the building surface product in place by engaging with a complementary second press-on connector. Further, depending on the construction of the first press-on connector, as explained in more detail below, in some embodiments, the building surface product can be removable and/or re-installable. For example, the building surface product can be removed from a constructed building surface by initially disengaging the first press-on connector and then removing the lapping projection from behind the neighboring panel.

Furthermore, by using a lapping projection and press-on connector, the connections formed between both adjacent building surface products as well as the connections between the building surface products and the support surface are hidden. This allows building surfaces constructed using the building surface products to be completed without the time consuming process of obscuring attachment devices, such as covering mechanical fasteners with joint compound.

While the first edge of building surface product <NUM> is shown at the top of the gypsum panel, and the second edge is shown at the bottom, in other embodiments the first and second edges are reversed. Furthermore, in some embodiments, the product can be rotated and installed with either edge at the top. Moreover, in some embodiments, the building surface products are installed vertically.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first press-on connector is a first snap-fit connector and the corresponding second press-on connector is a second snap-fit connector. For example, <FIG> shows a more detailed view of first press-on connector <NUM> of <FIG>, in the form of a first snap-fit connector attached to the rear face <NUM> of the body <NUM> of gypsum panel <NUM>. The first snap-fit connector <NUM> is coupled to a corresponding second snap-fit connector <NUM> that is secured to a framing member <NUM>.

The term snap-fit, as used herein, is defined as a connection between components where at least one of the components undergoes a deflection as the components are connected. Accordingly, if the connection is detachable, a corresponding deflection is needed in order to disconnect the assembled components. Such a snap-fit connection can provide a relatively stable attachment without the need for any additional fasteners. The deformation that occurs may be elastic, such that the components return to their original shape after the connection is made or after the components are disconnected. Alternatively, the deformation can be plastic and a permanent connection can be established.

A snap-fit connection, as the term is used herein, encompasses connections where either or both of the components being attached can undergo the deformation. Thus, the first snap-fit connector of the building surface product can undergo a deformation as it is attached to the corresponding second snap-fit connector, or the second snap-fit connector can undergo a deflection as it is attached to the first snap-fit connector.

In other embodiments, the first press-on connector can have another configuration, such as a component of a hook and loop fastener, or another recloseable fastener.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first snap-fit connector includes a connector body and a first flange that extends laterally outward from the connector body and is configured to engage the second snap-fit connector. For example, as shown in <FIG>, first snap-fit connector <NUM> includes a body <NUM> with a first flange <NUM> extending laterally outward therefrom. In particular, first flange <NUM> extends upward from body <NUM>. Further, second snap-fit connector <NUM> has a first flexible hook member <NUM> that receives and retains first flange <NUM>.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first snap-fit connector includes a second flange that extends from the connector body in an opposite direction of the first flange and is configured to engage the second snap-fit connector. For example, first snap-fit connector <NUM> includes a second flange <NUM> that extends in an opposite direction from connector body <NUM> compared to first flange <NUM>, specifically, in a downward direction. Like first flange <NUM>, second flange <NUM> is configured to be secured by a second flexible hook <NUM> of second snap-fit connector <NUM>.

Another embodiment of a first snap-fit connector and a second snap-fit connector is shown in <FIG>. Similar to first snap-fit connector <NUM>, first snap-fit connector <NUM> includes a connector body <NUM> with a first flange <NUM> extending laterally outward therefrom and a second flange <NUM> extending from the connector body <NUM> in a direction opposite first flange <NUM>. Further, second snap-fit connector <NUM> has a first flexible hook member <NUM> that receives and retains first flange <NUM> and a second hook member <NUM> that receives and retains second flange <NUM>. Accordingly, second snap-fit connector, which is attached to framing member <NUM>, holds the building surface product securely against the framing member by its connection to first snap-fit connector <NUM>.

Both first snap-fit connectors <NUM> and <NUM> have male configurations and second snap-fit connectors <NUM> and <NUM> have female configurations that receive the first snap-fit connectors. However, in other embodiments, the first snap-fit connector has a female configuration that receives the second snap-fit connector.

The first and second snap-fit connectors may be configured according to different design constraints to have a permanent installation, a re-installable installation, or a removable installation. Various embodiments of such snap-fit connectors are shown in <FIG>. First snap-fit connector <NUM>, shown in <FIG>, provides a permanent connection to second snap-fit connector <NUM>. First snap-fit connector <NUM> has a first flange <NUM> and a second flange <NUM> extending from connector body <NUM>. The first flange <NUM> and second flange <NUM> respectively cooperate with a first hook <NUM> and a second hook <NUM> of second snap-fit connector <NUM>. On the other hand, first snap-fit connector <NUM>, shown in <FIG>, provides a re-installable connection with second snap-fit connector <NUM>. Like that of <FIG>, first snap-fit connector <NUM> has a first flange <NUM> and a second flange <NUM> extending from connector body <NUM>, and cooperates with a second snap-fit connector <NUM> that includes a first hook <NUM> and a second hook <NUM>. Furthermore, first snap-fit connector <NUM>, shown in <FIG>, has a removable connection with second snap-fit connector <NUM>. Like the others, first snap-fit connector <NUM> has a first flange <NUM> and a second flange <NUM> extending from connector body <NUM>. The first flange <NUM> and second flange <NUM> cooperate with a first hook <NUM> and a second hook <NUM> of second snap-fit connector <NUM>.

The removability or permanence of the connection between the first snap-fit connector and second snap-fit connector is dependent upon the angles and edges of the mating components. In the embodiments shown in each of <FIG>, the outer surfaces of the flanges and hooks are slanted or curved so as to allow the respective components to flex so that a connection of the first snap-fit connector and second snap-fit is possible. In contrast, the inner surfaces and edges have differing shapes to provide various different permanence and removability. For example, the inner surfaces of the flanges <NUM> and <NUM> of first snap-fit connector <NUM> and the inner surfaces of the hooks <NUM> and <NUM> of second snap-fit connector <NUM> have sharp edges to prevent removal of the first snap-fit connector <NUM> from the second snap-fit connector once installed. This permanent connection can be advantageous in instances where removal of the building surface products is only permitted in instances where portions of the wall are being destroyed. In some cases, removal of the snap-fit connectors in instances using such a permanent connection requires removal of the second snap-fit connector from the framing members.

In contrast, first snap-fit connector <NUM> and second snap-fit connector <NUM> are configured to allow disconnection of the two components, so that a new building surface product can be installed. However, the inner surfaces of the flanges <NUM>, <NUM> and hooks <NUM>, <NUM> have an appropriate shape to allow disconnection so long as sufficient force is used. In some embodiments, this force is sufficiently high to damage the building surface products, but maintain the function of the second snap-fit connector. Such a configuration allows new building surface products to be installed when one is damaged, but prevents inadvertent or accidental removal upon moderate forces applied to the panels.

Further, first snap-fit connector <NUM> and second snap-fit connector <NUM> have inner surfaces of the flanges <NUM>, <NUM> and hooks <NUM>, <NUM> to allow repeated removal and reinsertion. This configuration allows maintenance to be on the building surface, or behind the building surface, without the need to replace any components of the building surface itself.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first snap fit connector is in the form of a rail that extends along a length of the building surface product. For example, in some embodiments, the rail extends across at least <NUM>% of the length of the building surface product, e.g., at least <NUM>% of the length of the building surface product, e.g., at least <NUM>% of the length of the building surface product. It should be understood that the length of the building surface product is the longest dimension of the product extending from the first end to the second end. For example, first snap-fit connector <NUM>, shown in <FIG> and <FIG> is configured as a rail and extends across a vast majority of the gypsum panel <NUM> to within two inches of the first end <NUM> and second end <NUM>.

In certain embodiments of the fastenable building surface product as otherwise described herein, a distance between the first snap-fit connector and the first edge is less than <NUM>% of the width of the gypsum panel body, e.g., less than <NUM>%, e.g., less than <NUM>%. For example, in some embodiments, the first snap-fit connector is disposed in a range of ¼ inch to <NUM> inches from the first edge of the building surface product.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first snap-fit connector is attached to the gypsum panel using adhesive. In some embodiments, the adhesive is an organic adhesive, such as a curable glue, a single component epoxy, a two component epoxy, a hot-melt thermoplastic, or a polyurethane resin. In other embodiments, the adhesive is an inorganic adhesive, such as cement. Further, in other embodiments, the first snap-fit connector is attached to the gypsum panel using a mechanical fastener, such as a screw.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first lapping projection is disposed behind the body of the gypsum panel, and wherein the first projection is configured to extend behind the body of the gypsum panel of a neighboring building surface product. For example, as shown in <FIG> and <FIG>, first lapping projection <NUM> is positioned behind body <NUM> of gypsum panel <NUM>. Accordingly, as shown in <FIG>, when installed, the first lapping projection <NUM> is positioned behind the body of the gypsum panel of a neighboring building surface product.

In other embodiments, the first lapping projection is coextensive with the rear face but thinner than the thickness of the panel. In such embodiments, the second edge may include a second lapping projection that cooperates with the first lapping projection of a neighboring panel.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first lapping projection extends outward from the body in a direction of the plane of the gypsum panel a distance in a range of ¼ inch to <NUM> inches, e.g., <NUM>/<NUM> inch to <NUM> inches, e.g., ½ inch to <NUM> inches.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first edge includes a folded gypsum edge. Likewise, in some embodiments, the second edge also includes a folded gypsum edge. Further, in some embodiments, the first and second ends also include folded gypsum edges. In certain embodiments, the folded gypsum edge is a flat fold including a first folded section adhered to the body of the gypsum panel along an angled slit, where the body of the gypsum panel and the first folded section are covered by a continuous facing sheet. Such a folded edge is shown in <FIG>. Building surface product <NUM> includes first snap-fit connector <NUM> attached to the rear surface <NUM> of gypsum panel <NUM>. The building surface product also includes a first edge <NUM> with a folded gypsum edge including a flat fold. The folded edge includes a first folded section <NUM> that is secured to the body <NUM> of gypsum panel <NUM> with an adhesive. The body <NUM> of the gypsum panel <NUM> and the first folded section <NUM> are covered by a continuous facing sheet <NUM> that wraps around the folded edge <NUM>.

In certain embodiments of the fastenable building surface product as otherwise described herein, the folded edge is a corner fold including a first folded section and a second folded section. The first folded section is adhered to the body of the gypsum panel along a first angled slit and the second folded section is adhered to the first folded section along a second angled slit. Further, the body of the gypsum panel, the first folded section, and the second folded section are all covered by a continuous facing sheet. Such a folded edge is shown in <FIG>. Building surface product <NUM> includes first snap-fit connector <NUM> attached to the rear surface <NUM> of gypsum panel <NUM>. The building surface product also includes a first edge <NUM> with a folded gypsum edge including a corner fold. The folded edge includes a first folded section <NUM> that is secured to the body <NUM> of gypsum panel <NUM> along an angled slit using an adhesive. Further, a second folded section <NUM> is secured to the first folded section <NUM> along another angled slit by adhesive. The body <NUM> of the gypsum panel <NUM>, the first folded section <NUM>, and the second folded section <NUM> are all covered by a continuous facing sheet <NUM> that wraps around the folded edge <NUM>.

In certain embodiments of the fastenable building surface product as otherwise described herein, the second folded section is adhered to the first snap-fit connector. For example, second folded edge <NUM> is attached to first snap-fit connector <NUM> with an adhesive.

In certain embodiments of the fastenable building surface product as otherwise described herein, the first snap-fit connector includes a base extending outward from the connector body, wherein the base is adhered to the body of the gypsum panel, and wherein the second folded section overlaps the base of the first snap-fit connector. Such a folded edge is shown in <FIG>. Building surface product <NUM> includes first snap-fit connector <NUM> attached to the rear surface <NUM> of gypsum panel <NUM>. First snap-fit connector <NUM> includes a base <NUM> extending outward from connector body <NUM>. The building surface product also includes a first edge <NUM> with a folded gypsum edge including a corner fold. The folded edge includes a first folded section <NUM> that is secured to the body <NUM> of gypsum panel <NUM> along an angled slit using an adhesive. Further, a second folded section <NUM> is secured to the first folded section <NUM> along another angled slit by adhesive. Moreover, second folded edge <NUM> overlaps base <NUM> of first snap-fit connector <NUM>. Furthermore, the body <NUM> of the gypsum panel <NUM>, the first folded section <NUM>, and the second folded section <NUM> are all covered by a continuous facing sheet <NUM> that wraps around the folded edge <NUM>.

In certain embodiments of the fastenable building surface product as otherwise described herein, the connector body of the first snap-fit connector is solid. For example, connector body <NUM> of first snap-fit connector <NUM>, shown in <FIG> is a solid body. In other embodiments, the connector body of the first snap-fit connector is hollow. Such an embodiment is shown in <FIG>. Building surface product <NUM> includes a first snap-fit connector <NUM> includes a hollow connector body <NUM> having a "U" shaped cross-section and including first flange <NUM> and second flange <NUM> extending outward from the upper ends of connector body <NUM>. In some embodiments, the snap-fit connector has a standard rail configuration, such as DIN rail. As will be appreciated by those of ordinary skill in the art, the rail can be formed of metal, such as cold-rolled steel or a polymer, such as an extruded plastic.

In some embodiments, the snap-fit connector is disposed on the body of the gypsum panel. For example, snap-fit connector <NUM> is disposed on the body <NUM> of gypsum panel <NUM>. In other embodiments, the snap-fit connector is disposed on the folded edge of the gypsum panel. For example, building surface product <NUM>, shown in <FIG>, includes a gypsum panel <NUM> with a folded edge <NUM> having a first folded section <NUM> and a second folded section <NUM>. First snap-fit connector <NUM> is disposed on top of the second folded section <NUM> of folded edge <NUM>. <FIG> shows the first snap-fit connector <NUM> coupled to a second snap-fit connector <NUM> using a first hook <NUM> and a second hook <NUM> that secure the respective flanges of first snap-fit connector.

In certain embodiments of the fastenable building surface product as otherwise described herein, the gypsum panel comprises a reinforced gypsum material. In some embodiments, the gypsum panel includes at least <NUM>% by weight polymer. Further, in some embodiments, the polymer includes starch and/or polyvinyl acetate.

In certain embodiments of the fastenable building surface product as otherwise described herein, the gypsum panel includes at least <NUM>% by weight of reinforcing fibers. For example, in some embodiments, the gypsum panel includes glass fibers. Further, in some embodiments, the gypsum panel includes cellulose-based 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. Further, in some embodiments of the fastenable building surface product, the gypsum panel includes one or more additives, such as biocides, hydrophobic additives, and fire resistance additives.

In certain embodiments of the fastenable building surface product as otherwise described herein, the ends are perpendicular to the upper edge and the lower edge. In other embodiments, the ends are disposed at an angle to the upper edge and lower edge. For example, in some embodiments of the fastenable building surface product, the ends are at an angle in a range of <NUM> degrees to <NUM> degrees from the upper edge or lower edge. Further, in some embodiments of the fastenable building surface product, the ends are curved.

In certain embodiments of the fastenable building surface product as otherwise described herein, a portion of a first end of the gypsum panel is configured to overlap with a portion of a neighboring building surface product.

In certain embodiments of the fastenable building surface product as otherwise described herein, the fastenable building surface product further includes a facing that lines at least a portion of the gypsum panel. In some embodiments, the facing is a paper facing. In other embodiments, the facing includes reinforcing fibers. For example, in some embodiments, the facing includes a fiberglass mat. Further, in some embodiments, the gypsum product of the gypsum panel the building surface product is embedded into the facing.

In certain embodiments of the fastenable building surface product as otherwise described herein, a front surface of the building surface product includes a textured surface. For example, in some embodiments, the front surface of the building surface product is sanded or roughened to provide a surface texture to the front face of the building surface product. Further, in some embodiments, a coating of a grainy or heterogeneous coating is applied to the front surface of the building surface product. The surface texture of the front face of the building surface product may provide the product with a visual appearance similar to venetian plaster or cast concrete, for example.

In certain embodiments of the fastenable building surface product as otherwise described herein, the front face of the body includes grooves along the length of the gypsum panel. In some embodiments, the grooves are disposed at regular intervals and provide a gap in the front face of the building surface product that is similar to the gap that is formed where two neighboring building surface products meet. Accordingly, the grooves may help obscure the location of the actual joints between adjacent building surface products.

In certain embodiments of the fastenable building surface product as otherwise described herein, the front surface of the building surface product provides acoustical dampening to the building surface product. For example, in some embodiments, the front surface of the building surface product includes baffles, ridges, protrusions or other surface features that enhance sound dampening.

In certain embodiments of the fastenable building surface product as otherwise described herein, a front surface of the building surface product is painted. For example, in some embodiments, the building surface product is painted prior to installation on a support structure, such as in a manufacturing facility.

In certain embodiments of the fastenable building surface product as otherwise described herein, a width from the upper edge to the lower edge is in a range from <NUM> inches to <NUM> feet, e.g., from <NUM> inches to <NUM> feet, e.g., from <NUM> inches to <NUM> foot. A width of the building surface product that is smaller than standard gypsum wallboard products, for example from a few inches up to a foot, can provide an aesthetic that is similar to shiplap. As are result, the joints between the building surface products form part of the aesthetic of the building surface, and do not need to be covered and hidden. This allows surfaces that are made using the building surface products according to the disclosure to be constructed without the need to cover the joints between the building surface products, which can save considerable time and effort.

In certain embodiments of the fastenable building surface product as otherwise described herein, a length from a first end of the gypsum panel to a second end of the gypsum panel is in a range from <NUM> foot to <NUM> feet, e.g., from <NUM> feet to <NUM> feet, e.g., from <NUM> feet to <NUM> feet. In certain embodiments of the fastenable building surface product as otherwise described herein, the thickness of the gypsum panel is in a range of ¼ inch to <NUM> inches, e.g., from ½ inch to <NUM> inches. Other thicknesses are also possible.

In another aspect according to the claimed invention, the disclosure provides a method of making a fastenable building surface product according to the disclosure. The method includes forming the substantially planar gypsum panel with the first edge, the second edge, the first lapping projection extending outward from the body at the second edge, and the two ends. The method also includes attaching the first press-on connector to the rear face of the body of the gypsum panel. For example, a method of the disclosure includes forming gypsum panel <NUM>, shown in <FIG> and <FIG> to include the upper edge <NUM>, the lower edge <NUM>, the first lapping projection extending from the body <NUM> of gypsum panel <NUM> at second edge <NUM>, the first end <NUM>, and the second end <NUM>. Press-on connector <NUM> is then attached to the rear face <NUM> of gypsum panel <NUM>. As explained in more detail below, some embodiments of the method include cutting the general shape of the gypsum panel from a larger sheet of material, and other embodiments include forming the general shape of the gypsum panel directly from a gypsum slurry. Further, in some embodiments, the lapping projection is attached to the rear face of the gypsum panel. In other embodiments the lapping projection is machined into the gypsum panel. Still in other embodiments, the lapping projection is provided in the gypsum panel when it is formed from a slurry.

In certain embodiments of the method of making the fastenable building surface product, forming the gypsum panel includes depositing a gypsum slurry over a forming surface and allowing the gypsum slurry to set. In some embodiments the forming surface is configured to form a sheet of gypsum material, and the gypsum panel is cut from the sheet of gypsum material. Further, in some embodiments, the method includes positioning a flexible sheet on the forming surface so as to provide a facing that lines at least a portion of the gypsum panel. A similar method including these steps shown in <FIG> and described above.

In certain embodiments of the method of making the fastenable building surface product, the method further includes positioning a second flexible sheet over the gypsum panel so as to provide a facing that lines another portion of the gypsum panel.

In certain embodiments of the method of making the fastenable building surface product, the method further includes forming the first edge of the gypsum panel as a folded edge with a flat fold by: cutting a first notch in the sheet of gypsum material so as to form a first folded section adjacent to the body of the gypsum panel, folding the first folded section toward the body of the gypsum panel so as to close the notch, and adhering the first folded section to the body of the gypsum panel. For example, first edge <NUM>, shown in <FIG>, is formed by cutting a notch in the gypsum material to form first folded section <NUM> next to the body <NUM> of gypsum panel <NUM>. First folded section <NUM> is then folded toward body <NUM> so as to close the notch, such that first folded section <NUM> abuts body <NUM>. An adhesive is provided between first folded section <NUM> and body <NUM> to hold the folded edge closed.

In certain embodiments of the method of making the fastenable building surface product, the method further includes forming the first edge of the gypsum panel as a folded edge with a corner fold by: cutting a first notch in the sheet of gypsum material so as to form a first folded section adjacent to the body of the gypsum panel, cutting a second notch in the sheet of gypsum material so as to form a second folded section adjacent to the first folded section, folding the second folded section toward the first folded section so as to close the second notch, adhering the second folded section to the first folded section, folding the first folded section toward the body of the gypsum panel so as to close the first notch and to place the second folded section over the body of the gypsum panel, and adhering the first folded section to the body of the gypsum panel. For example, first edge <NUM>, shown in <FIG>, is formed by cutting a first notch in the gypsum material to form first folded section <NUM> adjacent body <NUM> of gypsum panel <NUM>, and cutting a second notch in the gypsum material to form a second folded section <NUM> adjacent to the first folded section <NUM>. The first folded section <NUM> is folded toward second folded section <NUM> and adhered thereto. The second folded section <NUM> is then folded toward first folded section <NUM> in order to close the second notch and the two sections are attached with adhesive. The first folded section <NUM> is then folded toward the body <NUM> to close the first notch and the first folded section <NUM> is attached to the body with more adhesive.

In certain embodiments of the method of making the fastenable building surface product, the first press-on connector is a snap-fit connector, and the method further includes adhering the second folded section to the snap-fit connector. For example, in forming building surface product <NUM>, second folded section <NUM> is attached to first snap-fit connector <NUM> using adhesive.

In certain embodiments of the method of making the fastenable building surface product, the snap-fit connector includes a base extending outward from the connector body, and the method further includes folding the second folded section over the base of the snap-fit connector so as to place the base of the snap-fit connector between the second folded section and the body of the gypsum panel. For example, in forming building surface product <NUM>, shown in <FIG>, second folded section <NUM> is folded over the base <NUM> of first snap-fit connector <NUM> in order to place the base <NUM> between second folded section <NUM> and body <NUM> of gypsum panel <NUM>.

In certain embodiments of the method of making the fastenable building surface product, the method includes adhering the first snap-fit connector onto the folded edge of the gypsum panel. For example, in forming building surface product <NUM>, shown in <FIG>, the first snap-fit connector <NUM> is adhered to the second folded section <NUM> of folded edge <NUM> of gypsum panel <NUM>.

In certain embodiments of the method of making the fastenable building surface product, the first lapping projection is machined into the gypsum panel. For example, in some embodiments, the first lapping projection is formed in the gypsum panel using a CNC machine, as shown in <FIG>.

In certain embodiments of the method of making the fastenable building surface product, the first lapping projection is adhered to the body of the gypsum panel. For example, in some embodiments, a layer of adhesive is placed on an inside surface of the first lapping projection, and the first lapping projection is attached to the rear face of the gypsum panel. In some embodiments, the adhesive is an organic adhesive, such as a curable glue, a single component epoxy, a two component epoxy, a hot-melt thermoplastic, or a polyurethane resin. In other embodiments, the adhesive is an inorganic adhesive, such as cement.

In certain embodiments of the method of making the fastenable building surface product, the method further includes forming a surface texture on a front surface of the building surface product. In some embodiments, forming the surface texture includes spraying a heterogeneous coating on the front surface of the building surface product. In other embodiments, forming the surface texture includes forming grooves in the front face of the body of the gypsum panel. For example, the formation of the grooves may be carried out by removing material from the gypsum panel, such as by using a CNC machine as shown in <FIG>. In other embodiments, the grooves are provided by the forming surface.

In another aspect according to the claimed invention, the disclosure provides a fastenable building surface system including a support structure, a plurality of second press-on connectors disposed on a front side of the support structure, and a plurality of fastenable building surface products according to the disclosure secured to the support structure and arranged so as to provide a building surface. The first press-on connector of each building surface product is coupled to at least one of the second press-on connectors. Further, the first edge of the gypsum panel of each building surface product overlaps the first lapping projection of a neighboring building surface product. Such a system is schematically shown in <FIG>. Building surface system <NUM> includes a plurality of building surface products <NUM>, such as that shown in <FIG> and <FIG> secured to a support structure <NUM>. The support structure <NUM> is in the form of a wall frame including a plurality of periodically spaced studs <NUM>. In other embodiments, the support structure includes other framing elements. Further, in some embodiments, the support structure is in the form of sheathing or panels. Each of the building surface products <NUM> of system <NUM> include a first building surface product <NUM> and a second building surface product <NUM>. The first building surface product <NUM> includes a first press-on connector <NUM> that is coupled to a plurality of second press-on connectors <NUM> attached to the support structure <NUM>. The first and second press-on connectors <NUM> and <NUM> of first building surface product <NUM> are positioned behind the gypsum panel <NUM> and therefore are schematically depicted using dashed lines. The first building surface product <NUM> also includes a first lapping projection <NUM> that is configured to be positioned behind second building surface product <NUM>.

The second building surface product <NUM> is presented as it is being installed. Second building surface product <NUM> includes first lapping projection <NUM> that is being inserted behind the gypsum panel of a lowering neighbor building surface product. Further, second building surface product <NUM> includes a first press-on connector <NUM> that is prepared to connect to a plurality of second press-on connectors <NUM>.

In certain embodiments of the fastenable building surface system as otherwise described herein, the first press-on connectors are first snap-fit connectors and the second press-on connectors are second snap-fit connectors. For example, in the embodiment depicted in <FIG>, <FIG> and <FIG>, first press-on connectors <NUM> are second press-on connectors <NUM> are both complementary snap-fit connectors.

In certain embodiments of the fastenable building surface system as otherwise described herein, each of the first snap-fit connectors includes a connector body and a first flange that extends laterally outward from the connector body, and each of the second snap-fit connectors includes a clip having a first flexible hook configured to engage the first flange. For example, as shown in <FIG> and explained above, first snap-fit connector <NUM> includes a body <NUM> with a first flange <NUM> extending laterally outward therefrom, and second snap-fit connector <NUM> is formed as a clip and has a first flexible hook member <NUM> that receives and retains first flange <NUM>.

In certain embodiments of the fastenable building surface system as otherwise described herein, each of the first snap-fit connectors includes a second flange that extends from the connector body in an opposite direction of the first flange, and wherein the second snap-fit connector includes a second flexible hook configured to engage the second flange. For example, as explained above, first snap-fit connector <NUM> includes a second flange <NUM> that extends in an opposite direction from connector body <NUM> compared to first flange <NUM>. Further, second flange <NUM> is configured to be secured by a second flexible hook <NUM> of second snap-fit connector <NUM>.

In certain embodiments of the fastenable building surface system as otherwise described herein, each first flexible hook includes an outer angled ramp surface configured to deflect the flexible hook as the first snap-fit connector is inserted into the clip. For example, first flexible hook <NUM> of second snap-fit connector includes an outer surface that has the shape of an angled ramp so as to allow the insertion of first snap-fit connector to push the flexible hook laterally as the first snap-fit connector is inserted into the clip.

In certain embodiments of the fastenable building surface system as otherwise described herein, each first flexible hook includes a sharp inner edge configured to inhibit removal of the first snap-fit connector from the clip of the second snap-fit connector. For example, flexible hooks <NUM> and <NUM> of second snap-fit connector <NUM>, shown in <FIG> have sharp inner edges. The sharp inner edge of each flexible hook <NUM> and <NUM> promote a permanent connection of first snap-fit connector <NUM> and second snap-fit connector <NUM> when they are attached to one another.

In certain embodiments of the fastenable building surface system as otherwise described herein, each first flexible hook includes an angled inner edge configured to deflect the flexible hook as the first snap-fit connector is removed from the clip. For example, flexible hooks <NUM> and <NUM> of second snap-fit connector <NUM>, shown in <FIG> have angled inner edges, which promote a removable connection of the first and second snap-fit connectors. As a retraction force is exerted on first snap-fit connector <NUM>, the angled inner edges of flexible hooks <NUM> and <NUM> allow the hooks to be flexed outward so that first snap-fit connector <NUM> can be removed from the second snap-fit connector <NUM>.

In certain embodiments of the fastenable building surface system as otherwise described herein, each of the second snap-fit connectors is secured to the support structure with at least one mechanical fastener. For example, in some embodiments the second snap-fit connectors are coupled to framing members or a surface of the support structure using screws or nails. In other embodiments, the second snap-fit connectors are secured to the support structure using an adhesive.

In certain embodiments of the fastenable building surface system as otherwise described herein, each of the second snap fit connectors includes a support platform, and wherein each support platform provides a contact surface for a respective first lapping projection of a building surface product. For example, second snap fit connector <NUM>, as shown in <FIG>, includes a platform <NUM>. The platform serves as contact surface for the first lapping projection of the neighboring building surface product.

In certain embodiments of the fastenable building surface system as otherwise described herein, the plurality of building surface products have different shapes that are arranged in a pattern, and wherein the first building surface product has a first shape and the second building surface product has a second shape. A building surface system with such a construction is shown in <FIG>, and described above.

In certain embodiments of the fastenable building surface system as otherwise described herein, a joint between the first building surface product and the second building surface product is free of any joint compound. For example, the first and second edges of the building surface products may be configured to have an attractive appearance when the building surface products are adjacent, without the need of any joint compound to hide the joints. Accordingly, the building surface system can be constructed without the need to apply or finish any joint compound, which can save considerable effort in preparing the building surface.

In certain embodiments of the fastenable building surface system as otherwise described herein, a front surface of each of the building surface products is covered with a layer of paint. In some embodiments, a first of the building surface products is painted a first color and a second of the building surface products is painted a second color. A building surface system with such a construction is shown in <FIG>, and described above.

Claim 1:
A building surface product (<NUM>) comprising:
a substantially planar gypsum panel (<NUM>) having a first edge (<NUM>), a second edge (<NUM>), and two ends (<NUM>, <NUM>), wherein the gypsum panel (<NUM>) includes:
a body (<NUM>) comprising a front face (<NUM>), a rear face (<NUM>), and a thickness between the front face (<NUM>) and the rear face (<NUM>), and
a first lapping projection (<NUM>) extending outward from the body (<NUM>) at the second edge (<NUM>), the first lapping projection (<NUM>) being configured to overlap a portion of a neighboring gypsum panel so as to form a building surface; and
a first press-on connector (<NUM>) disposed on and attached to the rear face (<NUM>) of the body (<NUM>) toward the first edge (<NUM>) of the gypsum panel (<NUM>), the press-on connector (<NUM>) being configured to engage a corresponding second press-on connector.