Abstract: A photovoltaic module includes an encapsulated photovoltaic element and an infrared-transmissive decorative overlay simulating conventional roofing.

Abstract: The present disclosure relates generally to a ceiling tile, for example, suitable for use in a ceiling grid. The present disclosure relates more particularly to a ceiling tile including a light housing extending across a first portion of a width of the ceiling tile, and a panel extending across a remaining portion of the width of the ceiling tile.

Abstract: One aspect of the disclosure is a method of installing siding to a siding accessory using an installation aid. The method includes mounting and fastening at least one siding accessory to a surface, placing a siding panel onto the surface, the siding panel having a first side, a second side, a top edge, and a bottom edge, locking the siding panel into place, placing at least one installation aid between the first side and/or the second side of the siding panel and the at least one siding accessory, the installation aid having at least one projection spaced to create a gap between the first or second side of the siding panel and the at least one siding accessory to allow for expansion and contraction of the siding panel, sliding the siding panel over to the at least one siding accessory, and fastening the siding panel to the surface. Various embodiments of installation aids are also disclosed.

Abstract: Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

Abstract: Disclosed is a building board construction that provides enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in an continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.

Abstract: One aspect of the disclosure is a shingle including a first bituminous sheet at the bottom surface of the shingle, the first bituminous sheet having a lower edge disposed at the lower end of the shingle, the first bituminous sheet having one or more slits extending from the lower edge of the first bituminous sheet toward the upper end of the shingle; and a second bituminous sheet at least partially laminated to a top surface of the first bituminous sheet, the second bituminous sheet having a lower edge disposed adjacent the lower end of the shingle, the second bituminous sheet having one or more tabs being defined by one or more notches formed in the second bituminous sheet, each notch extending away from the lower edge of the second bituminous sheet.

Abstract: The present disclosure relates generally to an insulation-retaining sheet, e.g., for blown-in insulation, that includes an integral vapor-retarding membrane. In one aspect, the disclosure provides an insulation-retaining sheet including a sheet of mesh having an air permeability of at least 200 cfm per square foot; and one or more strips of vapor-retarding membrane, the one or more strips of vapor-retarding membrane being laminated to the sheet of mesh, the first side edge each of the strips of vapor-retarding membrane extending to the first side edge of the sheet of mesh, the second side edge each of the strips of vapor-retarding membrane extending to the second side edge of the sheet of mesh, wherein the insulation-retaining sheet has a plurality of open zones extending laterally from the first side edge of the sheet of mesh to the second side edge of the sheet of mesh in which no vapor-retarding membrane is laminated to the mesh.

Abstract: The present invention relates generally to electrical systems. The present invention relates more particularly to electrical wiring systems suitable for use in roofing applications. One aspect of the invention is a wiring system on a roof comprising a roof deck having a slope and one or more roofing elements disposed on the roof deck, the wiring system including one or more wires extending along the roof on top of the roofing elements; and a wire covering disposed over the one or more wires.

Abstract: Photocatalytic roofing granules include a binder and inert mineral particles, with photocatalytic particles dispersed in the binder.

Abstract: A method of making the asphalt shingles includes applying a substrate to a layer of shingle-forming material, the substrate having indicators at predetermined spaced-apart distances, with the indicators being sensed as the shingle-forming layer is moved along a predetermined path, with adhesive zones being applied to the shingle such that the application of the adhesive zones is synchronized in response to sensing the locations of the indicators, and with the shingle-forming layer then being cut into individual shingles.

Abstract: The present invention relates generally to roofing products. The present invention relates more particularly to roofing products for use with photovoltaic elements, and to photovoltaic systems that include one or more photovoltaic elements is joined to a roofing substrate. In one embodiment, a roofing product includes a flexible roofing substrate having a top surface, the top surface having one or more receptor zones thereon, each receptor zone being adapted to receive one or more photovoltaic elements, each receptor zone having a different surfacing than the area of the top surface adjacent to it.

Abstract: The present disclosure relates particularly to photovoltaic roofing systems for use in photovoltaically generating electrical energy, specifically, the use of bottom flashings in such systems. Methods for installing such systems and replacing non-photovoltaic roofing elements in such systems are also described.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: A cross member of a T bar ceiling system is designed to be part of the ceiling grid system and adapted to releasably receive a strip light beneath the cross T member. The strip light provides support flanges beneath the T member for supporting a ceiling panel edge at the conventional height. With this arrangement the grid system can be installed in the normal manner with these cross T's at positions where strip lights are to be secured. The strip lights can be installed at a later point in time. Preferably a push type releasable connection is used.

Abstract: A lighting system for ceiling grid systems advantageously uses a grid member designed to cooperate with a strip light to secure the strip light generally aligned beneath the grid system. The grid system can be initially installed with the cooperating grid members at specified locations. The strip lights can then be installed to the grid system. This arrangement simplifies installation particularly installations in commercial type spaces and larger scale architectural projects.

Abstract: A ceiling panel according to the present invention has opposed translucent membranes secured in a tensioned state across a perimeter frame. The frame includes frame members that are designed to oppose inward bowing of the perimeter frame caused by the tensioned membranes. The frame members have a side profile shaped to conceal a grid support network with the lower translucent member extending across and about a lower edge of the perimeter frame. The invention also includes a modified structure for supporting of translucent panels below a grid network.

Abstract: A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., water temperature, pH, mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions.

Abstract: The present invention relates to an improved method for using heat energy in a gypsum board plant. More specifically, the method contemplates taking heat from a gasifier, or other alternative heat source, and using it to dry gypsum boards. In order to control humidity levels, this heat is delivered to one or more board dryers via a heat exchanger.

Abstract: A composition and process for the manufacture thereof for use in a hybrid building material comprising at least in part Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4·6H2O). Specified constituents, including magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate) are mixed in predetermined ratios and the reaction proceeds through multiple phases reactions which at times are proceeding simultaneously and in parallel and reaction may even compete with each other for reagents if the Struvite-K reaction is not buffered to slow down the reaction rate). A number of variable factors, such as water temperature, pH mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined and specified ratios of Struvite-K and Syngenite may be provided for specified purposes, optimized in respect of stoichiometry to reduce the combined heat of formation to non-destructive levels.

Abstract: Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the undissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.