BUILDING SURFACE PRODUCT INCLUDING ATTACHMENT STRUCTURES, BUILDING SURFACE SYSTEM, AND METHOD OF ASSEMBLY

The present disclosure relates generally to building surface systems, for example, suitable for forming an internal or external surface of a building. The present disclosure relates more particularly to a building surface product that includes a panel and a first attachment post extending outward from a rear surface of the panel. The first attachment post includes a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel. The first attachment post also includes a lip extending radially outward from the shaft that is configured to hold the first attachment post in an aperture of a support structure. The disclosure also relates to a building surface system including a plurality of rails configured to panels that include an attachment post.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Patent Application No. 63/289,398 , filed Dec. 14, 2021, and U.S. Provisional Patent Application no. 63/387,215, filed Dec. 13, 2022, each of which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE DISCLOSURE 1. Field of the Disclosure

The present disclosure relates generally to building surface systems, for example, suitable for forming an internal or external surface of a building. The present disclosure relates more particularly to a building surface system formed by panels that are secured to a support structure.

2. Technical Background

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

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

While the mounting of gypsum panels is straightforward, most panels are finished by covering the joints between the panels and the fasteners in order to create a smooth surface. The panels are then painted or covered with wall paper to create a pleasing aesthetic. The process of finishing the building surface is time consuming, as each application of joint compound or paint should be dried before the subsequent step can be performed. Moreover, the finishing steps require uncommon skills.

Further, after traditional gypsum panels are installed, removing the panels requires damaging a portion of the panels and the surface finish. Accordingly, when mechanical, electrical, and plumbing components behind the building surface need to be repaired, the building surface is at least partially damaged to gain access to the components. After the work on the hidden components is completed, the building surface needs to be repaired and finished once again. For these reasons, the present inventors have determined that a building surface product that can be installed more quickly would be attractive to both builders and customers.

SUMMARY OF THE DISCLOSURE

In one aspect, the present disclosure provides a building surface product comprising:

a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface;

a first attachment post extending outward from the rear surface of the panel, the first attachment post including:

    • a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and
    • a lip extending radially outward from the shaft and configured to hold the first attachment post in an aperture of a support structure.

In another aspect, the disclosure provides a method of forming the building surface system according to the disclosure, the method comprising:

positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail; and

securing the first building surface product to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.

In another aspect, the disclosure provides a building surface system comprising:

a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate; and

a first building surface product according to the disclosure attached to the support structure, wherein the first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.

Additional aspects of the disclosure will be evident from the disclosure herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.

FIG. 1A is a schematic perspective view of a building surface product according to an embodiment of the disclosure.

FIG. 1B is a schematic perspective view of a portion of the building surface product of FIG. 1A.

FIG. 1C is a schematic cross-sectional view of a portion of the building surface product of FIG. 1A.

FIG. 2 is a schematic cross-sectional view of a portion of a building surface product according to another embodiment of the disclosure.

FIG. 3 is a schematic cross-sectional view of a portion of a building surface product according to another embodiment of the disclosure.

FIG. 4A is a schematic cross-sectional perspective view of a building surface system according to an embodiment of the disclosure.

FIG. 4B is a schematic front plan view of a portion of a rail of the building surface system of FIG. 4A.

FIG. 4C is a schematic cross-sectional top view of a portion of the building surface system of FIG. 4A.

FIG. 4D is a schematic cross-sectional side view of a portion of the building surface system of FIG. 4A.

FIG. 5A is a schematic perspective view of a portion of a vertical framing member according to an embodiment of the disclosure.

FIG. 5B is a schematic perspective view of a rail attached to the vertical framing member of FIG. 5A.

FIG. 6 is a schematic perspective view of a building surface system according to an embodiment of the disclosure.

FIG. 7A is a schematic side view of an assembly of a portion of a building surface product according to an embodiment of the disclosure.

FIG. 7B is a schematic side view of an assembly of another portion of the building surface product of FIG. 7A.

FIG. 7C is a schematic side view of the building surface product of FIGS. 7A and 7B secured to a support structure.

FIG. 7D is a schematic side view of the building surface product of FIG. 7C and a spacer.

FIG. 7E is a schematic side view of the building surface product of FIG. 7C and a portion of another building surface product.

FIG. 7F is a schematic side view of the building surface product of FIG. 7C and additional portions of the other building surface product of FIG. 7E.

FIG. 7G is a schematic side view of a portion of a building surface product being removed from a support structure.

FIG. 8 is a schematic cross-sectional view of a portion of a building surface product according to an embodiment of the disclosure.

FIG. 9 is a schematic cross-sectional view of a portion of a building surface product according to an embodiment of the disclosure.

FIG. 10 is a schematic cross-sectional view of a panel of a building surface product according to an embodiment of the disclosure.

FIGS. 11A and 11B are a schematic cross-sectional views of a panel of a building surface product according to another embodiment of the disclosure.

FIG. 12A is a schematic perspective view of a pair of attachment structures according to an embodiment of the disclosure.

FIG. 12B is a schematic perspective view of a first attachment structure of the pair of FIG. 12A.

FIG. 12C is a schematic perspective view of the a second attachment structure of the pair of FIG. 12A.

FIG. 12D is a schematic side view of a building surface product secured to a support structure that includes the pair of attachment structures of FIG. 12A.

FIG. 13A is a schematic perspective view of a pair of attachment structures according to an embodiment of the disclosure.

FIG. 13B is a schematic side view of a building surface product secured to a support structure that includes the pair of attachment structures of FIG. 13A.

FIG. 14A is a schematic perspective view of a pair of attachment structures according to an embodiment of the disclosure.

FIG. 14B is a schematic side view of a building surface product secured to a support structure that includes the pair of attachment structures of FIG. 14A.

FIG. 15A is a schematic perspective view of building surface products secured to a support structure in accordance with an embodiment of the disclosure.

FIG. 15B is a schematic side view of the building surface products of FIG. 15A in a disconnected state.

FIG. 15C is a schematic side view of the building surface products of FIG. 15A in a connected state.

FIG. 16A is a schematic perspective view of a pair of building surface products secured to a support structure in accordance with an embodiment of the disclosure.

FIG. 16B is a schematic side view of a building surface product secured to a support structure that includes the pair of attachment structures of FIG. 16A.

FIG. 16C is an exploded view of the building surface products of FIG. 16A.

FIG. 17A is a schematic perspective view of a pair of attachment structures according to an embodiment of the disclosure.

FIG. 17B is a schematic front view of the building surface product of FIG. 17A secured to a first support structure.

FIG. 17C is a schematic front view of the building surface product of FIG. 17A secured to a second support structure.

 DETAILED DESCRIPTION

As described above, the present inventors have noted that conventional building surface products are time-consuming to install and require skill to finish. The present inventors have determined that a building surface product that can be installed more quickly and without requiring specific skills to finish would be attractive to builders and customers.

Accordingly, one aspect of the disclosure is a building surface product that includes a substantially planar panel and a first attachment post extending outward from a rear surface of the panel. The panel has a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface. The first attachment post includes a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel. A lip extends radially outward from the shaft and is configured to hold the first attachment post in an aperture of a support structure, as described in more detail below.

The rear surface of such a building surface product is shown in perspective view in FIG. 1A. Building surface product 100 includes a planar panel 102 in the form of a rectangle that has a first side 104, a second side 105, a first end 106, a second end 107, a front surface 108, and a rear surface 109. Further, panel 102 includes a gypsum body 110 (see FIG. 1C) that is disposed between the front surface 108 and the rear surface 109. Building surface product 100 also includes a number of attachment posts 130 extending outward from rear surface 109 of panel 102. FIG. 1B shows greater detail of two of the attachment posts 130 extending from rear surface 109 of panel 102, and FIG. 1C shows a cross-sectional view of a first attachment post 130 embedded in the rear surface 109 of panel 102.

As illustrated in FIG. 1C, first attachment post 130 includes a shaft 132 extending outward from rear surface 109 of panel 102 and a lip 138 extending radially outward from shaft 132. Lip 138 is configured to engage part of a support structure so as to couple building surface product 100 to the support structure, as described in further detail below.

In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer. For example, as shown in FIGS. 1A through 1C, gypsum body 110 of panel 102 includes a front layer 113 that extends across the width and length of panel 102 from first side 104 to second side 105 and from first end 106 to second end 107. In addition, a reinforcing layer 114 extends around the perimeter of panel 102 behind front layer 113. The reinforcing layer 114 provides a greater thickness to gypsum body 110 around the perimeter of panel 102, and may increase the strength of the panel 102.

In other embodiments, the gypsum body of the panel includes a single layer. Such an embodiment is shown in FIG. 2. Panel 202 of building surface product 200 includes a gypsum body 210 having a single layer that extends from the front surface 208 of panel 202 to the rear surface 209 of panel 202. A plurality of attachment posts including a first attachment post 230 extend into rear surface 209 and are configured to secure building surface product 200 to a support structure.

In certain embodiments of the building surface product as otherwise described herein, the panel includes a first receiver sleeve and the first attachment post extends into the first receiver sleeve. For example, panel 102 of FIGS. 1A to 1C includes a first receiver sleeve 140 that is held in gypsum body 110. As shown in FIG. 1C, first attachment post 130 extends into first receiver sleeve 140 from rear surface 109 and is held in place by engaging with first receiver sleeve 140.

In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve extends through the reinforcing layer to the front layer. For example, in panel 102, as shown in FIG. 1C, first receiver sleeve 140 extends from rear surface 109 entirely through reinforcing layer 114 so as to abut front layer 113. In other embodiments, the first receiver sleeve extends only partially through the reinforcing layer of the panel body. For example, in some embodiments, the first receiver sleeve is position at the rear surface of the panel and does not extend all the way to the front layer. In other embodiments, the first receiver sleeve is positioned at the interface between the front layer and the reinforcing layer and does not extend all the way to the rear surface. Further in some embodiments, the first receiver sleeve extends into the front surface of the panel. For example, in some embodiments, the first receiver sleeve extends at least partially through the reinforcing layer and into the front layer.

In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve includes a threaded interior surface configured to engage the first attachment post. For example, in some embodiments, the shaft of the first attachment post is threaded and the first receiver sleeve includes a complementary thread to receive the first attachment post. Such a threaded engagement may help secure the first attachment post in the panel. In other embodiments, the first receiver sleeve is configured to capture the first attachment post in another manner. For example, in some embodiments, the shaft of the first attachment post is threaded and the first receiver sleeve has a deformable interior surface. Accordingly, the threaded shaft of the first attachment post can cut into the first receiver sleeve in order to form a secure connection between the first attachment post and first receiver sleeve.

In certain embodiments of the building surface product as otherwise described herein, the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer of the panel. For example, first receiver sleeve 140 of building surface product 100 includes an external flange 142 that extends radially outward from an axis of the receiver sleeve. The external flange 142 is positioned between the front layer 113 and the reinforcing layer 114 so as to capture the receiver sleeve in the gypsum body 110 and prevent first receiver sleeve 140 from separating from panel 102.

In other embodiments, the panel is constructed without a receiver sleeve. For example, in some embodiments, the first attachment post extends directly into the material of the gypsum body. A cross section of such an embodiment is shown in FIG. 3. Building surface product 300 includes a panel 302 with a gypsum body 310 formed between front surface 308 and rear surface 309 of panel 302. Gypsum body 310 includes a front layer 313 and a reinforcing layer 314. A first attachment post 330 extends through rear surface 309 of panel 302 to directly engage gypsum body 310.

In certain embodiments of the building surface product as otherwise described herein, the first attachment post extends through the reinforcing layer and into the front layer. For example, as shown in FIG. 3, first attachment post 330 penetrates rear surface 309 of panel 302 and extends entirely through reinforcing layer 314 and into front layer 313. First attachment post 330 extends only partially into front layer 313 and thus, the end of first attachment post 330 is disposed within the front layer 313. Accordingly, first attachment post 330 is not visible on the front surface 308 of panel 302. In other embodiments, the first attachment post extends through both the front layer and the reinforcing layer to the front surface of the panel. Still, in other embodiments, the first attachment post extends only partially through the reinforcing layer and does not extend to the front layer.

In certain embodiments of the building surface product as otherwise described herein, the reinforcing layer includes a first section along a first edge of the panel, and the first section is disposed behind the front layer along the first edge. For example, as shown in FIG. 1A, reinforcing layer 114 of panel 102 includes a first section 115 along a first edge 116 of panel 102. Specifically, first section 115 of reinforcing layer 114 extends along the length of panel 102 from first end 106 to second end 107, thereby reinforcing the entire first side 104 of panel 102. In other embodiments, the first section of the reinforcing layer extends across the width of the panel, rather than the length. Moreover, in some embodiments, the first section of the reinforcing layer extends over only a portion of the respective side or end, rather than over its entirety.

In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes a first edge section between the front layer and the first section of the reinforcing layer at the first edge. For example, as shown in FIG. 1C, gypsum body 110 includes a first edge section 120 that is positioned along first edge 116 of panel 102 between front layer 113 and the first section 115 of reinforcing layer 114. Accordingly, first edge section 120 forms the outer surface of panel 102 along first edge 116.

In certain embodiments of the building surface product as otherwise described herein, the front layer has a first tapered face along the first edge, the first section of the reinforcing layer has a tapered face along the first edge, and the first edge section has a triangular shape including a front face that is adjacent to the first tapered face of the front layer and a rear face that is adjacent to the tapered face of the first section of the reinforcing layer. For example, first edge section 120 of gypsum body 110 has a triangular cross-section with an outer face 121 along first edge 116, a front face 122 that is presented toward front layer 113, and a rear face 123 that is presented toward first section 115 of reinforcing layer 114. To match the shape of first edge section 120, front layer 113 has a first tapered face 124 that is opposes front face 122 of first edge section 120. Likewise, first section 115 of reinforcing layer 114 also has a tapered face 125 that opposes rear face 123 of first edge section 120. In the embodiment of shown in FIGS. 1A-1C, gypsum body 110 has similar edge sections around the rest of the perimeter of panel 102.

In certain embodiments of the building surface product as otherwise described herein, the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet. For example, the configuration shown in FIG. 1C is formed by routing two adjacent V-shaped grooves on one face of a gypsum panel. The space between the two grooves is a triangular ridge of gypsum material that forms first edge section 120. The outer sides of the two grooves form the first tapered face 124 of the front layer 113 and the tapered face 125 of the first section 115 of reinforcing layer 114. The first section 115 of reinforcing layer 114 is then folded over front layer 113 so that the tapered faces 124, 125 oppose the front and rear faces 122, 123 of first edge section 120, respectively.

In certain embodiments of the building surface product as otherwise described herein, a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer. For example, when the first section 115 of reinforcing layer 114 is folded behind front layer 113, the facing sheet 126 that extended along the original gypsum panel on the face opposite the grooves wraps around the first edge 116 so as to cover the front surface 108 of the gypsum body 110, the outer face 121 of the first edge section 120 and the rear face of the first section 115 of the reinforcing layer 114. In other embodiments, the facing sheet may be applied to the gypsum body after the reinforcing layer is formed over the front layer. Still, in some embodiments, separate facing sheets cover the front layer and reinforcing layer. Further still, in some embodiments, at least some portions of the gypsum body are not covered by a facing sheet.

In certain embodiments of the building surface product as otherwise described herein, an adhesive layer is provided between the first tapered face of the front layer and the front face of the first edge section. Likewise, in certain embodiments, an adhesive layer is provided between the tapered face of the first section of the reinforcing layer and the rear face of the first edge section. For example, in some embodiments, a layer of adhesive may be disposed on either or both of the front face 122 or rear face 123 of first edge section 120 so as to adhere the first edge section 120 to the respective tapered face 124, 125 of the front layer 113 or first section 115 of the reinforcing layer 114. The adhesive layer may help strengthen the edge of the gypsum body 110 and maintain the folded shape of the panel 102.

In certain embodiments of the building surface product as otherwise described herein, an adhesive layer is provided between the between the front layer and the first section of the reinforcing layer. For example, in some embodiments, a layer of adhesive may be disposed on the rear face of the front layer 113 of gypsum body 110 and on the front face of first section 115 of reinforcing layer 114. The adhesive layer may help hold the first section 115 of reinforcing layer 114 against front layer 113 and strengthen the edge of panel 102. In some embodiments, the layer of adhesive is a continuous layer that extends across the entire front surface of the reinforcing layer. In other embodiments, the layer of adhesive may be formed by spots or traces of adhesive on the faces between the two layers. Still, in other embodiments, the layers may be attached to one another in another manner, such as bonding of the gypsum material of the layers to each other or to a material sheet between the two layers.

In certain embodiments of the building surface product as otherwise described herein, the first attachment post extends through the adhesive layer provided between the front layer and the first section of the reinforcing layer. For example, in some embodiments, the first attachment post may pass through the interface between the front layer and the first section of the reinforcing layer in an area where adhesive is provided between these layers. In some embodiments, the engagement of the first attachment post to the panel may be strengthened by the extension of the first attachment post through the adhesive. On the other hand, in some embodiments, the first attachment post extends through the interface between the front layer and the first section of the reinforcing layer in an area where there is no adhesive positioned between the two layers of the gypsum body.

In certain embodiments of the building surface product as otherwise described herein, a pair of facing sheets are provided between the front layer and the first section of the reinforcing layer. For example, in gypsum body 310 of panel 302 a first intermediate facing sheet 327 is secured to the rear face of front layer 313 and a second intermediate facing sheet 328 is secured to the front face of first section 315 of reinforcing layer 314. Each of the intermediate facing sheets 327, 328 can help increase the strength of the corresponding layer 313, 314 of gypsum body 310. Moreover, the intermediate facing sheets 327, 328 may also help secure the first attachment post 330 in the gypsum body 310.

In certain embodiments of the building surface product as otherwise described herein, the reinforcing layer extends around a perimeter of the panel. For example, in certain embodiments, the reinforcing layer includes a section along each edge of the panel. Moreover, in some embodiments, the gypsum body includes an edge section along each edge of the panel between the front layer and respective section of the reinforcing layer. For example, as shown in FIG. 1A, reinforcing layer 114 of panel 102 is formed by four sections positioned around the perimeter of the panel. The four sections of reinforcing layer 114 cooperate using miter joints to form a frame around the perimeter of panel 102. In other embodiments, the reinforcing layer is formed by another number of sections. For example, in some embodiments, the reinforcing layer is formed by two sections along the sides or ends of the panel. In other embodiments, the reinforcing layer is formed by more sections. Further, in some embodiments, the reinforcing layer is formed by a single section that is folded behind the reinforcing layer. For example, in some embodiments, the reinforcing layer is formed by a single section that extends over the entire front layer of the panel.

In certain embodiments of the building surface system as otherwise described herein, the lip of the first attachment post is formed as a portion of a head at the second end of the shaft. For example, as shown in FIG. 1C, the lip 138 of first attachment post 130 is disposed on a head 136 positioned at the second end of shaft 132.

In certain embodiments of the building surface system as otherwise described herein, the first attachment post includes a collar surrounding the shaft that engages the rear surface of the panel. For example, first attachment post 130 includes a collar 134 extending outward from shaft 132 at an intermediate point along the length of shaft 132. The collar 134 defines the depth that first attachment post 130 is inserted into the rear surface 109 of panel 102. Accordingly, the lip 138 formed by head 136 is set at a distance from panel 102, allowing the lip 138 of attachment post 130 to easily engage a support structure.

In certain embodiments of the building surface product as otherwise described herein, the first attachment post is one of a plurality of attachment posts extending from the rear surface of the panel. For example, building surface product 100 includes four attachment posts 130 extending from the rear surface 109 of panel 102. Further, in some embodiments, all of the attachment posts have the same configuration, such as in building surface product 100. For example, in some embodiments, each of the plurality of attachment posts includes a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip that extends radially outward from the respective shaft and is configured to hold the respective attachment post in a respective aperture of the support structure.

In other embodiments, the attachment posts have different configurations. For example, in some embodiments, the attachment posts at one end of the panel have a different configuration than attachment posts at the other end. Likewise, in some embodiments, the attachment posts at the top of the panel have a different configuration than those at the bottom. Further, while building surface product 100 includes four attachment posts 130, as shown in FIG. 1A, in other embodiments, the building surface product may include more or fewer attachment posts. For example, in some embodiments, the building surface product includes several columns of attachment posts across the width of the panel. Likewise, in some embodiments, the building surface product includes several rows of attachment posts over the height of the panel. Further, in some embodiments, the building surface product includes attachment posts along only one side of the panel, while the other side of the panel is secured in another manner. Further still, in some embodiments, the building surface product includes a single attachment post.

In another aspect, the disclosure provides a building surface system including a support structure and a first building surface product according to the disclosure attached to the support structure. The support structure includes a plurality of rails that form a support surface. The plurality of rails includes a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate. The first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.

Such a building surface system is shown in FIG. 4A. Building surface system 450 includes a support structure 452 and a plurality of building surface products, including first building surface product 400A and second building surface product 400B, attached to support structure 452. The support structure 452 includes a group of vertical framing members 454 and a plurality of rails 460, including first rail 460A and second rail 460B, that extend across vertical framing members 454 and form a support surface. The first building surface product 400A is secured to support structure 452 by securing attachment posts of first building surface product 400A to first rail 460A.

FIG. 4B shows an enlarged plan view of a section of a rail 460. As illustrated in FIG. 4B, rail 460 includes a longitudinal plate 462 and a first receiving slot 470A in the longitudinal plate 462. The first receiving slot 470A is configured to receive the first attachment post of the first building surface product. For example, FIG. 4C shows a schematic cross-sectional top view of a portion of a first building surface product 400A secured to the rail 460. As shown in FIG. 4C, a first attachment post 430A extending outward from a rear surface 409 of first building surface product 400A is attached to rail 460. In particular, first attachment post 430A is disposed within first receiving slot 470A so that first building surface product 400 is secured to rail 460.

While the embodiment shown in FIGS. 4A and 4C includes a building surface product having a panel with a single layer, in other embodiments, the building surface system includes building surface products with panels that have a front layer and a reinforcement layer, such as those shown in FIGS. 1A-1C and 3.

In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes a first engagement edge extending along one side of the slot, the shaft of the first attachment post extends through the first receiving slot, and the lip of the first attachment post abuts the first engagement edge of the longitudinal plate. For example, as shown in FIG. 4C, the shaft 432 of first attachment post 430A extends through first receiving slot 470 and the head 436 of first attachment post 430A engages rail 460. In particular, the head 436 of first attachment post 430A forms a lip 438 that hooks behind a first engagement edge 472 that extends along the length of first receiving slot 470. Accordingly, lip 438 prevents first attachment post 430A from being pulled through first receiving slot 470A such that first building surface product 400 is held securely against first rail 460.

In certain embodiments of the building surface system as otherwise described herein, a first end of the first receiving slot is wider than a second end of the first receiving slot, and the first attachment post is held at the second end of the first receiving slot. Further, in some embodiments, the first end of the first receiving slot has a width that is larger than a width of the first attachment post, such that the first attachment post is removable from the first receiving slot at the first end. For example, as shown in FIG. 4B, first receiving slot 470A extends along the length of longitudinal plate 462 from a first end 474 to a second end 476. The width of first receiving slot 470A tapers inward toward the second end 476. Accordingly, the first end 474 of first receiving slot 470A may be wide enough to receive the head 436 of first attachment post 430A, while the second end 476 is sized to prevent the head 436 from passing back through first receiving slot 470A. For example, the width of first receiving slot may be slightly larger than the head of first attachment post at the first end and smaller than the head but slightly larger than the shaft at the second end.

In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes a front face and a first indentation that protrudes rearward from the front face, wherein the first receiving slot is disposed in the first indentation. For example, as shown in FIGS. 4B and 4C, longitudinal plate 462 includes a planar front face 464 that extends along the length and across the width of rail 460. A first indentation 466A extends rearward from front face 464 so as to form a raised bulge behind front face 464. First receiving slot 470A is positioned within first indentation 466A such that the edge around first receiving slot 470A is spaced from front face 464.

In certain embodiments of the building surface system as otherwise described herein, a depth of the first indentation increases from the first end of the first receiving slot to the second end of the first receiving slot. For example, as shown in FIG. 4C, the depth of first indentation 466A increases from the first end 474 of first receiving slot 470A to the second end 476. Accordingly, the engagement edge 472 that surrounds first receiving slot 470A slopes away from front face 464 toward the second end 476 of first receiving slot 470A. Thus, as first attachment post 430A is moved from the first end 474 of first receiving slot 470A toward the second end 476, the engagement edge 472 slopes toward head 436, thereby tightening the fit between first attachment post 430A of first building surface product 400A and rail 460.

In certain embodiments of the building surface system as otherwise described herein, the rear surface of the panel of the first building surface product abuts the front face of the longitudinal plate. For example, as shown in FIGS. 4A and 4C, first building surface product 400A is secured against support structure 452 with the rear surface 409 of panel 402 abutting front face 464 of longitudinal plate 462 of rail 460.

In certain embodiments of the building surface system as otherwise described herein, the first receiving slot is disposed on a first side of the longitudinal plate and a second receiving slot is disposed on a second side of the longitudinal plate. For example, as shown in FIG. 4B, rail 460 includes first receiving slot 470A on a first side 466 of longitudinal plate 462 and a second receiving slot 470B on the second side 467 of longitudinal plate 462. Similar to first receiving slot 470A, second receiving slot 470B is positioned in an indentation and decreases in width from a first end to a second end.

In certain embodiments of the building surface system as otherwise described herein, the building surface system includes a second building surface product according to the disclosure, where an attachment post of the second building surface product is received in the second receiving slot of the longitudinal plate so as to secure the second building surface product against the support structure. For example, building surface system 450, as shown in FIG. 4A, includes a plurality of rails including first rail 460A and second rail 460B. Each of the rails includes a longitudinal plate with receiving slots on both the first side and the second side of the plate. Accordingly, one building surface product can be attached to the first side of the longitudinal plate while a second building surface product is attached to the second side of the longitudinal plate. For example, the lower side of first building surface product 400A is attached to first rail 460A and the upper side of second building surface product 400B is also attached to first rail 460A.

FIG. 4D shows a cross-sectional side view of rail 460 with both first building surface product 400A and second building surface product 400B secured to the front face 464 of longitudinal plate 462. In particular, first attachment post 430A of first building surface product 400A is held in a first receiving slot 470A while an attachment post 430B of second building surface product 400B is held in second receiving slot 470B. Accordingly, rail 460 assists in holding both the first building surface product 400A and second building surface product 400B against the support structure.

In the illustrated embodiment, as shown in FIGS. 4B and 4D, the first and second receiving slots are aligned along the length of the longitudinal plate and are both oriented similarly, so that the slots narrow in the same direction. In other embodiments, the position of the receiving slots along the length of the longitudinal plate may be staggered, rather than aligned. Further, in some embodiments, the orientation of the second slot may be opposite to that of the first slot, such that an attachment post placed in the second receiving slot is secured in the slot by moving the opposite direction as an attachment post placed in the first receiving slot.

In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes an outwardly extending projection between the first receiving slot and the second receiving slot. Further, in some embodiments, the outwardly extending projection is disposed between the first building surface product and the second building surface product. For example, as shown in FIGS. 4B and 4D, the longitudinal plate 462 of first rail 460A includes an outwardly extending projection 468 that is positioned between the first side 466 and second side 467 of longitudinal plate 462. Accordingly, the first receiving slot 470A and second receiving slot 470B are disposed on opposing sides of projection 468. Moreover, projection 468 is interposed between first building surface product 400A and second building surface product 400B.

In some embodiments, the projection may provide a support ledge for a building surface product during an installation process. For example, the panel of a building surface product may be arranged to rest on the projection while the attachment posts of the building surface product are inserted into receiving slots of the corresponding rail. Likewise, the projection may also aid in positioning the rail while it is installed. For example, as explained in more detail below, the projection may be placed on a previously-installed building surface product before the rail is secured in place as part of the support structure.

The rail 460 shown in FIGS. 4B-4D is formed from a single metal sheet that is folded, shaped and cut to form the receiving slots, indentations and projection. Accordingly, projection 468 is configured as a flange that is formed as a folded section of the metal sheet between the first side 466 and second side 467 of longitudinal plate 462. However, in other embodiments, the projection is a bump or ridge. Further, in some embodiments, the projection is a molded or cast element that extends outward from the front face of the rail. Further, while projection 468 of rail 460 runs continuously along longitudinal plate 462, in other embodiments, the projection includes discrete segments along the length of the longitudinal plate.

In certain embodiments of the building surface system as otherwise described herein, a height of the outwardly extending projection is substantially equal to a thickness of the panel of the first building surface product. The term substantially equal, as used herein, means having a deviation of no more than 10%. For example, as shown in FIG. 4D, projection 468 of rail 460 extends outward from front face 464 to a height that is equal to the thickness of the panels of first building surface product 400A and second building surface product 400B. The projection 468 thereby forms a visible ridge between first building surface product 400A and second building surface product 400B that is aligned with the front surfaces of the building surface products. In other embodiments, the height of the projection is greater than the thickness of the panels. Accordingly, the projection may extend outward past the front surfaces of the building surface products. Further, in some embodiments, the height of the projection is smaller than the thickness of the panels of the building surface products, which may obscure the projection. Still further, in some embodiments, the rail may exclude the projection entirely.

In certain embodiments of the building surface system as otherwise described herein, the longitudinal plate includes an open path extending from the first end of the first receiving slot to an edge along the second side of the longitudinal plate. For example, as shown in FIG. 4B, rail 460 includes an open path 478 that extends from the first end 474 of first receiving slot 470 to an edge of longitudinal plate 462. The open path 478 allows an attachment post to be inserted into the first receiving slot 470A by a lateral relative movement of the attachment post with respect to the rail through the open path, rather than a direct insertion into the receiving slot by a movement of the attachment post along its axial direction. As explained further below, this allows the rail to be slid into place on a previously installed building surface product.

In some embodiments, the first receiving slot includes the open path to the edge of the longitudinal plate, while the second receiving slot is enclosed. On the other hand, in some embodiments, both the first receiving slot and the second receiving slot include such an open path, where the respective open paths extend to opposite edges of the longitudinal plate. Further still, in some embodiments, both receiving slots are enclosed and are not accessible by an open path to an edge of the longitudinal plate.

In certain embodiments of the building surface system as otherwise described herein, the first receiving slot is one of a row of receiving slots positioned along a length of the longitudinal plate, and the building surface system includes a row of building surface products that engage other receiving slots in the row of receiving slots. For example, as shown in FIG. 4A, first rail 460A includes a row of receiving slots that are configured to support a row of building surface products. In particular, first rail 460A and second rail 460B are configured to cooperate to support a row of two building surface products. In other embodiments, the row may include a greater number of building surface products.

In some embodiments, the longitudinal plate forms the entire rail. For example, in some embodiments, the upper and lower sides of the longitudinal plate form the outer edges of the rail. In other embodiments, the longitudinal plate forms a portion of the rail. For example, in some embodiments, the rail includes a structural flange extending from one side of the longitudinal plate, similar to an L-bracket. Further, in some embodiments, the rail includes structural flanges extending from both sides of the longitudinal plate, so as to have a channel configuration.

In some embodiments, the rail is formed of a metal, such as aluminum or steel. In other embodiments, the rail is formed of a polymer material, such as a reinforced polymer. Still, in other embodiments, the rail is formed of another material, such as wood, bamboo or composite material.

In certain embodiments of the building surface system as otherwise described herein, the support structure includes vertical framing members, and the first rail extends across the vertical framing members and is attached to the vertical framing members. For example, as shown in FIG. 4A, support structure 452 includes a plurality of vertical framing members 454 in the form of beams or studs that extend in a row to provide support structure 452 with a planar configuration. In other embodiments, the rails extend vertically and may be coupled to horizontal supports.

In some embodiments, the framing members are formed of timber, such as wood studs. In other embodiments, the framing members are formed of metal, such as such as steel or aluminum studs. Other materials may also be used for the framing members.

In certain embodiments of the building surface system as otherwise described herein, the first rail is attached to the vertical framing members using mechanical fasteners that extend into the vertical framing members. For example, in some embodiments, the first rail is secured to the vertical framing members with screws or nails that extend directly into the body of the vertical framing members. In other embodiments, where the vertical framing members are metal, the first rail may be welded or otherwise affixed to the vertical framing members. Further, in other embodiments, the vertical framing members may include receptacles to receive the mechanical fasteners. For example, in some embodiments, the vertical framing members include beams and reinforcement plates secured to the beams, where the reinforcement plates include receivers configured to receive mechanical fasteners that secure the first rail to the vertical framing members.

Such an embodiment is shown in FIGS. 5A and 5B. FIG. 5A shows a vertical framing member 554 that includes a beam 555 with a reinforcement plate 556 secured to the front face of beam 555. Reinforcement plate 556 is secured to beam 555 using teeth that are integrally formed therein, similar to a timber connector plate. In other embodiments, the reinforcement plate may be secured to the beam using fasteners, such as screws, nails or staples, or another method. Reinforcement plate 556 includes a receiver 558 that is configured to receive a mechanical fastener for securing a rail to the vertical framing member 554. For example, receiver 558 includes internal threads for receiving a bolt or other threaded shaft that holds the rail to vertical framing member 554. FIG. 5B shows a first rail 560 secured to vertical framing member 554 using mechanical fastener 559 that is secured in reinforcement plate 556.

In certain embodiments of the building surface system as otherwise described herein, the receivers have an adjustable position with respect to the reinforcement plates. For example, receiver 558 is configured to slide with respect to reinforcement plate 556, which allows the vertical position of first rail 560 to be varied as needed to align the building surface products.

In another aspect, the disclosure provides a method of forming the building surface system according to the disclosure. The method includes positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail. The first building surface product is secured to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.

For example, to add a further building surface product 400 in one of the empty positions in building surface system 450, shown in FIG. 4A, the building surface product 400 is placed in front of support structure 452 with the rear surface of the panel of the building surface product 400 facing a rail 460 of the support structure 452. Further, a first attachment post extending from the rear surface of the panel is positioned in a corresponding receiving slot 470 of the rail. The building surface product 400 is then slid across the support structure 452 in order to move the first attachment post of the building surface product to an assembled position at a closed end of the receiving slot in the rail. The attachment post and receiving slot cooperate to retain the first building surface product 400 against the support structure 452.

In certain embodiments of the method as otherwise described herein, the first building surface product is positioned in front of the support structure such that a plurality of additional attachment posts of the first building surface product are inserted in respective receiving slots of the support structure, and sliding the first building surface product to the assembled position causes the additional attachment posts to be secured in the respective receiving slots. For example, when installing building surface product 100, shown in FIGS. 1A-1C, the building surface product 100 is positioned so that each attachment post is inserted into a respective receiving slot in the rails of the support structure, and the building surface product 100 is slid so that each attachment post moves to the second end of the respective receiving slot and is secured in place.

In certain embodiments of the method as otherwise described herein, the method further includes positioning a second building surface product according to the disclosure in front of the support structure such that the rear surface of the panel of the second building surface product faces the support structure and an attachment post of the second building surface product is inserted in another receiving slot of the longitudinal plate of the first rail. The second building surface product is secured to the support structure by sliding the second building surface product to an assembled position where the attachment post of the second building surface product is secured in the other receiving slot of the longitudinal plate of the first rail, and the attachment post retains the second building surface product against the support structure. For example, when installing the building surface system 450, shown in FIGS. 4A-4D, each of the building surface products 400 is secured to the support structure 452 in a manner similar to that described above, where attachment posts of the building surface products are secured to respective receiving slots 470 of the support structure 452.

In some embodiments, the support structure is assembled first and the building surface products are secured to the assembled support structure. For example, in some embodiments, the rails are all attached to vertical framing members and then the building surface products of the disclosure are attached to the rails. In other embodiments, the building surface products and rails may be assembled intermittently. For example, in some embodiments, a row of building surface products may be attached to the upper side of a previously-installed rail, and then a subsequent rail may be placed behind the row of building surface products and then secured in place.

For example, in certain embodiments of the method as otherwise described herein, the method includes positioning a second rail behind the first building surface product with a second attachment post of the first building surface inserted into a receiving slot of the second rail, and securing the second rail to the first building surface product by sliding the second rail to an assembled position where the second attachment post of the first building surface product is secured in the receiving slot of the second rail. In such a method, the spacing of the rails is inherently accurate, as each rail fixed within the support structure only after being coupled to the lower row of building surface products. Accordingly, the spacing of the rails can be set without the need for careful measurements, which may reduce mistakes and inaccuracies.

In certain embodiments of the method as otherwise described herein, positioning the second rail behind the first building surface product includes introducing the second attachment post into the receiving slot of the second rail through an open path in the second rail. For example, with the first building surface product already in place there may be limited space between the vertical framing members and the building surface product to maneuver the second rail into place. However, where the receiving slots on one side of the rail include open paths to the side edge of the longitudinal plate, as shown in FIG. 4B, the rail may be slid into place with the attachment posts of the building surface products passing through the open paths to the receiving slots.

In certain embodiments of the method as otherwise described herein, positioning the second rail behind the first building surface product includes placing a projection of the second rail on an upper edge of the panel of the first building surface product. For example, when placing the rail 460 shown in FIG. 4B behind a previously installed building surface product, the rail can be positioned so that the projection 468 rests on the upper edge of the panel of the building surface product. The components can be sized so that this position aligns the receiving slots of the rail with the attachment posts of the building surface product to allow for easy insertion of the attachment posts into the receiving slots.

In another aspect, the disclosure provides a building surface product with attachment clips. The building surface product includes a substantially planar panel having a front surface, a rear surface, a first side, a second side, a first end, and a second end. A first attachment structure includes a first base secured to the rear surface of the panel and a first clip connected to the base. A second attachment structure includes a second base configured to be attached to a support structure and a second clip connected to the second base. The second clip is adapted to couple to the first clip so as to secure the panel to the support surface.

FIG. 6 illustrates a building surface system that includes several of such building surface products. Building surface system 650 includes a support structure 652 formed by a group of vertical framing members 654. A plurality of building surface products 600 are attached to the support structure 652 using attachment structures that are joined by corresponding clips. Various examples of such attachment structures are described below.

FIGS. 7A-7F illustrate a sequence in assembling an embodiment of a building surface system that includes a building surface product having a pair of attachment structures for holding the building surface product to a support structure. FIG. 7A shows portions of a building surface product 700 including a panel 702 and a first attachment structure 730 that is positioned for attachment to the panel 702. As explained in more detail below, the panel 702 includes a gypsum body 710 that is formed by a front layer 713 and a reinforcing layer 714. The front layer 713 forms the front surface 708 of the panel 702, while the rear surface 709 of the panel 702 is formed by a combination of the reinforcing layer 714 and the front layer 713. The first attachment structure 730 is positioned for attachment to the rear surface 709 using a mechanical fastener 732 that extends into the reinforcement layer. In the illustrated embodiment, the mechanical fastener 732 is in the form of a bolt.

The first attachment structure 730 includes a first base 734 that is adapted to be secured against the rear surface 709 of the panel 702 and a first clip 740 that is configured to be secured to another attachment structure (as explained further below). The first attachment structure 730 is formed by a bent metal sheet, and the first base 734 is provided by a flat section of the first attachment structure 730 that is held against the rear surface 709. The first clip 740 extends rearward from the first base 734 for engagement with the other attachment structure.

FIG. 7B illustrates a second attachment structure 770 that is positioned for attachment to a framing member 754 of a support structure 750 using a mechanical fastener 772 in the form of a screw. The framing member 754 is in the form of a wall stud. The second attachment structure 770 includes a second base 774 that is adapted to be secured to the front surface of the framing member 754 and a second clip 780 that is configured to be secured to the first attachment structure. Similar to the first attachment structure 730 shown in FIG. 7A, the second attachment structure 770 is formed by a bent metal sheet, and the second base 774 is provided by a flat section of the second attachment structure 770 that is held against the front surface of the framing member 754. The second clip 780 extends forward from the second base 774 for engagement with the first attachment structure 730, as shown in FIG. 7C.

FIG. 7C shows the first attachment structure 730 secured to the panel 702 by the bolt 732 and the second attachment structure 770 secured to the framing member 754 by the screw 772. Moreover, the first clip 740 of the first attachment structure 730 is coupled to the second clip 780 of the second attachment structure 770 such that the building surface product 700 is held securely against the framing member 754 of the support structure 750.

In certain embodiments as otherwise described herein, the first clip includes a first hook and the second clip includes a corresponding second hook adapted to couple to the first hook. For example, as shown in FIG. 7A, the first clip 740 of first attachment structure 730 is formed by a first hook 742 that is disposed at the end of a leg 744 that extends rearward from the first base 734. Likewise, as shown in FIG. 7B, the second clip 780 of the second attachment structure 770 is formed by a second hook 782 that is disposed at the end of an arm 784 that extends forward from the second base 774.

In the illustrated embodiment, the first attachment structure 730 is positioned at the upper side of panel 702 and the leg 744 of the first attachment structure 730 extends from the upper end of the first base 734. Similarly, the arm 784 extends from the upper end of the second base 774 of the second attachment structure 770. In other embodiments, as shown in other embodiments and described in more detail below, the positioning of the first and second attachment structures and the location of the associated clips may have other positions. For example, the leg of the first attachment structure that holds the first clip may extend from the lower end of the first base, rather than from the upper end.

In certain embodiments as otherwise described herein, an end of the first hook extends forward such that the first hook has an opening that faces the panel, and an end of the second hook extends rearward and is adapted for insertion into the opening of the first hook. For example, as shown in FIG. 7A, the first hook 742 of first attachment structure 730 is curved back from leg 744 such that the end of the first hook 742 extends forward toward the rear surface of the panel 702. Accordingly, the first hook 742 forms an opening 746 that faces the panel 702. Similarly, as shown in FIG. 7B, the second hook 782 of the second attachment structure 770 is curved back from arm 784 such that the end of the second hook 782 extends rearward and away from the panel 702. As a result, the second hook 782 forms an opening 786 that faces away from the panel 702. As shown in FIG. 7C, this configuration allows the end of the second hook 782 of the second attachment structure 770 to be inserted into the opening 746 of the first hook 742 in order to connect the first attachment structure 730 to the second attachment structure 770. At the same time, the end of the first hook 742 of the first attachment structure 730 may be inserted into the opening 786 formed by the second hook 782. With the first hook 742 and second hook 782 engaged, the panel 702 may be securely held against the support structure 750.

In certain embodiments as otherwise described herein, the first attachment structure includes a spring extending rearward from the first base and configured to urge the first attachment structure forward so as to maintain the connection between the first hook and the second hook. For example, as shown in FIG. 7A, first attachment structure 730 of building surface product 700 includes a spring 738 that extends rearward from the first base 734. As depicted in FIG. 7C, the spring 738 provides a spring force against the second attachment structure 770. Because the second attachment structure 770 is secured to the framing member 754 of the support structure 750, the spring force provided by the spring 738 urges the first attachment structure 730 forward. This forward force on the first attachment structure 730 helps to maintain the forward facing opening 746 of the first hook 742 engaged with the end of the second hook 782 of the second attachment structure 770.

In certain embodiments as otherwise described herein, the spring is positioned to press against the second base of the second attachment structure. For example, as shown in FIG. 7C, the configuration of the first attachment structure 730 and second attachment structure 770 is such that the spring 738 of first attachment structure 730 presses against the second base 774 of the second attachment structure 770 when the building support product 700 is mounted to the support structure.

In certain embodiments as otherwise described herein, the second attachment structure includes a shelf for supporting a portion of the panel. For example, as shown in FIG. 7C, second attachment structure 770 includes a shelf 775 extending forward from the lower end of second base 774. The shelf 775 supports the panel 702 by allowing the adjacent section of the reinforcing layer 714 of the panel 702 to rest on shelf 775. This may allow some of the load of the panel 702 to be transferred directly to the second attachment structure 770, so that the clips do not bear the entirety of the load.

As shown in FIG. 7D, once the building surface product 700 is secured to the support structure 750, a spacer 778 may be provided on the building surface product 700 for positioning another building surface product above building surface product 700. The spacer 778 rests on the upper side of the panel 702 and sets the position for another attachment structure that will hold another building surface product. For example, as shown in FIG. 7E, once the spacer 778 is placed on the first building surface product 700, another attachment structure 770A is secured to the framing member 754 above the spacer 778.

As shown in FIG. 7F, once the attachment structure 770A is secured to the framing member 754, a second panel 702A may be secured to the attachment structure 770A via another cooperative attachment structure 730A. By positioning the attachment structure 770A based on the spacer 778, the spacer 778 can assist in providing a uniform spacing between the first building surface product 700 and the second building surface product 700A.

In some embodiments, the spacers may be removed after the building surface products are secured to the support structure. In other embodiments, the spacers are retained and form part of the building surface structure. For example, in some embodiments, the spacers provide a decorative element between the building surface products, such as an accent line. Further, in some embodiments, the spacers may also perform a performance function, such as sealing the space for the prevention of thermal, odor or air leakage between the spaces. The spacers may also perform additional structural benefits, such as increased mechanical strength of the structure. Alternatively, the spacers may provide a cushioning function, such as to allow for seismic vibrations to pass through the system without damage to the panels. For example, the spacers may be soft to provide acoustic benefits. Alternatively, in some embodiments, the spacers may be hard.

The spacer may also allow for movement of the building surface products so that a panel can be removed from the wall, for example, for performing maintenance inside the wall cavity. For example, as shown in FIG. 7G, by removing the spacer 738, the panel 702 can be lifted slightly to disengage the first hook 742 of the first attachment structure 730 from the second hook 782 of the second attachment structure 770. The panel 702 and first attachment structure 730 may then be pulled away from the support structure 750 and removed from the wall.

As shown in FIGS. 8-11B, the panel may have various different configurations. Further, depending on the configuration of the panel, the connection of the first attachment structure to the panel may be achieved in different ways. In some embodiments, the first attachment structure may be secured to the panel using a fastener, as stated above. The fastener may be secured directly to the material of the panel, such as the gypsum body, or may be secured to a separate element that is secured to the panel, as explained further below. Alternatively, in some embodiments, the first attachment structure may be secured to the panel using adhesive or another manner.

FIG. 8 shows a panel 802 and a first attachment structure 830 attached thereto. Similar to panel 702 shown in FIGS. 7A-7G, panel 802 includes a gypsum body 810 formed by a front layer 813 and a reinforcing layer 814. The front layer 813 extends across the width and length of the panel 802 while the reinforcing layer 814 extends around the perimeter of the panel 802 behind front layer 813. The reinforcing layer 814 provides a greater thickness to gypsum body 810 around the perimeter of panel 802, and may increase the strength of the panel 802.

Further, panel 802 of FIG. 8 includes a first receiver sleeve 804 that is held in gypsum body 810. To secure the first attachment structure 830 to panel 802, a mechanical fastener 832 extends through the first attachment structure 830, into gypsum body 810 and into first receiver sleeve 804 from rear surface 809. The mechanical fastener 832 is held in place by engaging with first receiver sleeve 804, which may provide a stronger engagement than would be provided by engaging the gypsum directly.

In some embodiments, the first receiver sleeve includes a threaded interior surface configured to engage the first attachment post. For example, in FIG. 8, the shaft of the mechanical fastener 832 is threaded and the first receiver sleeve 804 includes a complementary thread to receive the mechanical fastener 832. Such a threaded engagement may help secure the mechanical fastener in the panel. In other embodiments, the first receiver sleeve is configured to capture the first attachment post in another manner. For example, in some embodiments, the shaft of the mechanical fastener is threaded and the first receiver sleeve has a deformable interior surface. Accordingly, the threaded shaft of the mechanical fastener can cut into the first receiver sleeve in order to form a secure connection between the mechanical fastener and first receiver sleeve.

In some embodiments, the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer of the panel. For example, first receiver sleeve 804 of building surface product 800 includes an external flange 842 that extends radially outward from an axis of the receiver sleeve. The external flange 842 is positioned between the front layer 813 and the reinforcing layer 814 so as to capture the receiver sleeve in the gypsum body 810 and prevent first receiver sleeve 804 from separating from panel 802. In other embodiments, the panel is constructed without a receiver sleeve. For example, in some embodiments, the mechanical fastener extends directly into the material of the gypsum body.

In the embodiment shown in FIG. 8, gypsum body 810 includes a first edge section 820 that is positioned along first edge 816 of panel 802 between front layer 813 and the first section 815 of reinforcing layer 814. Accordingly, first edge section 820 forms the outer surface of panel 802 along first edge 816. The first edge section 820 has a triangular cross-section with an outer face 821 along first edge 816, a front face 822 that is presented toward front layer 813, and a rear face 823 that is presented toward first section 815 of reinforcing layer 814. To match the shape of first edge section 820, front layer 813 has a first tapered face 824 that opposes front face 822 of first edge section 820. Likewise, first section 815 of reinforcing layer 814 also has a tapered face 825 that opposes rear face 823 of first edge section 820.

The front layer 813, first edge section 820, and the first section 815 of the reinforcing layer 814 are formed from a machined and folded gypsum sheet. For example, the configuration shown in FIG. 8 is formed by routing two adjacent V-shaped grooves on one face of a gypsum panel. The space between the two grooves is a triangular ridge of gypsum material that forms first edge section 820. The outer sides of the two grooves form the first tapered face 824 of the front layer 813 and the tapered face 825 of the first section 815 of reinforcing layer 814. The first section 815 of reinforcing layer 814 is then folded over front layer 813 so that the tapered faces 824, 825 oppose the front and rear faces 822, 823 of first edge section 820, respectively.

In some embodiments, a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer. For example, when the first section 815 of reinforcing layer 814 is folded behind front layer 813, the facing sheet 826 that extended along the original gypsum panel on the face opposite the grooves wraps around the first edge 816 so as to cover the front surface 808 of the gypsum body 810, the outer face 821 of the first edge section 820 and the rear face of the first section 815 of the reinforcing layer 814. In other embodiments, the facing sheet may be applied to the gypsum body after the reinforcing layer is formed over the front layer. Still, in some embodiments, separate facing sheets cover the front layer and reinforcing layer. Further still, in some embodiments, at least some portions of the gypsum body are not covered by a facing sheet.

FIG. 9 shows a panel 902 with a gypsum body 920 that is formed as a single layer. A first attachment structure 930 is attached to the rear surface 909 of panel 902 using a mechanical fastener 932. The mechanical fastener 932 extends into gypsum body 920 through a hole 922 in the gypsum body 920. Inside the hole 922, the mechanical fastener 932 engages an embedded fastener 940.

The embedded fastener 940 includes a threaded body 942 that extends through the first hole 922 of the gypsum body 920. Further, the threaded body 942 has a front end 943 a rear end 944. A lateral projection 946 is disposed at the front end 943 of the threaded body 942. The lateral projection 946 helps to hinder removal of the embedded fastener 940 through the first hole 922. For example, the lateral projection 946 may be configured to project beyond the diameter of the first hole 922 so that attempted removal of the embedded fastener 940 through the rear end of the first hole 922 will result in the lateral projection 946 interfering with the edge of the gypsum body 920 that surrounds the first hole 922.

The mechanical fastener 932 includes a threaded body 934 that engages the threaded body 942 of the embedded fastener 940. At the rear end of the first hole 922, the mechanical fastener 932 extends outward from the first hole 922 so that it may engage the first attachment structure 930. On the other hand, the entire embedded fastener 940 is contained behind the front surface 908 of the panel 902.

The phrase “contained behind,” as used herein means that the no portion of the fastener assembly extends past the front surface of the panel. In other words, the entirety of the structure of both the embedded fastener and mechanical fastener is behind, or rearward of, the plane formed by the front surface of the panel, and the surfaces of these components are either flush with or behind the front surface of the panel. The phrase “contained behind” does not necessitate that any part of the embedded fastener or mechanical fastener be covered or obscured by the front surface, but rather only that these components be positioned rearward of the front surface. By having the components contained behind the front surface of the panel, they can be entirely obscured when the panel is finished with coating materials or paint, as explained further below.

The threaded body 942 of embedded fastener 940 includes a hollow circular barrel with internal threads. Accordingly, the mechanical fastener 932 includes a shaft with external threads that are configured to mate with the internal threads of hollow barrel 942 so that the mechanical fastener 932 may be coupled to the embedded fastener 940.

In some embodiments, the lateral projection of the embedded fastener includes a flat base extending radially outward from the threaded body of the embedded fastener. For example, embedded fastener 940 includes a flat base 946 positioned at the front end of internally threaded hollow barrel 942. The flat base 946 extends radially outward around the circumference of hollow barrel 942. Further, the flat base 946 is larger than the diameter of first hole 922, which inhibits embedded fastener 940 from being removed from the front end of first hole 922. While, the flat base 946 of embedded fastener 940 is circular, in other embodiments, the flat base may have another shape, such as square or hexagonal. Further still, in other embodiments, the embedded fastener may have a lateral projection that has a different configuration, such as a hook or arm that extends radially from the threaded body in only one direction, rather than circumferentially.

In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is formed as a tee nut. For example, the embedded fastener 940 of building surface product 900 is formed as a standard tee nut including the base 946 and hollow threaded barrel 942.

In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is contained between the front surface and the rear surface of the panel. For example, as shown in FIG. 9, the length of embedded fastener 940 is about half of the thickness of panel 902, and embedded fastener 940 is positioned just behind the front surface 908. Accordingly, the rear end of embedded fastener 940, which is formed by the rear end of threaded body 942, is about halfway between the front surface 908 and rear surface 909 of panel 902, such that the entire embedded fastener 940 is contained between the front surface 908 and rear surface 909.

In certain embodiments of the building surface product as otherwise described herein, the panel includes a first projection extending along the first side of the panel and positioned at the front surface of the panel, and a second projection extending along the second side of the panel and configured to fit behind a first projection of a neighboring panel. For example, panel 902 includes a first projection 960 that extends along the first side 906 of the panel 902. A second projection is similarly arranged on the opposing side of the panel 902. As shown, the first projection 960 is located toward the front surface 908. In contrast, the second projection 970 at the opposing side 907 of the panel is located toward the rear surface 909. Accordingly, when two similarly configured panels are placed adjacent to one another, the first projection of one panel can cooperate with the second projection of the other panel, such that the first projection sits in front of the corresponding second projection, as explained further below.

In panel 902, as shown in FIG. 9, the first side 906 of panel 902 is positioned at the top of the panel, such that the projection at the front of the panel 902 is on the top of the panel. In other embodiments, the first side of the panel may be positioned at the bottom of the panel. In various embodiments, each of the first and second projections extend in a direction that is parallel to the front and rear surfaces of the panel. For example, in panel 902, the first projection 960 extends upward and the second projection 970 extends downward.

In certain embodiments of the building surface product as otherwise described herein, the first projection has an angled rear face and the second projection has an angled front face. For example, in panel 902, first projection 960 is formed by an upward extension of the front surface 908 of the panel 902 and an angled rear face 962 that extends down from the front surface 908 toward the rear surface 909. The second projection 970 at the opposing side 907 of panel 902 has the opposite configuration. Accordingly, the angled rear face 962 of the of the first projection 960 and the angled front face 972 of the second projection 970 are disposed at the same angle so that the respective first and second projections of neighboring panels can engage one another.

In certain embodiments of the building surface product as otherwise described herein, the embedded fastener is covered at the first surface of the panel by a material layer. For example, in some embodiments, the front of the embedded fastener is covered by a joint compound, stucco, a putty, or another material that may be spread over the embedded fastener. Such a material layer may be provided over the embedded fastener during manufacture of the building surface product. Accordingly, the installers of the building surface product can avoid spending time obscuring the fastener assemblies that extend through the panel. Likewise, in some embodiments, a layer of paint extends across the front surface of the panel and over the embedded fastener so as to obscure the embedded fastener. Similar to the material layer, the layer of paint may be provided over the front surface during manufacture of the building surface product. In other embodiments, however, the layer of paint may be formed at the installation site. Further, in some embodiments, the front finishing may be accomplished by the addition of an additional layer of a material, such as a lamination or a paper, film, fabric or plastic. In this and the other embodiments, the finishing serves to obscure the fastener assemblies.

FIG. 10 shows another embodiment of a panel with angled edges. Panel 1002 includes a front layer 1013 and a reinforcing layer 1014. Similar to the panel 802, shown in FIG. 8, panel 1002 is formed by machining grooves into a gypsum body 1010. The shapes of the notches are neither uniform nor symmetrical. Accordingly, when the gypsum body 1010 is folded around the notches, the gypsum body 1010 forms edges with differing angles so that both the upper side 1004 and lower side 1005 of the panel 1002 are angled downward from the front surface 1008.

FIGS. 11A and 11B show another embodiment of a panel where the gypsum body is formed as a single layer and the upper and lower sides are angled. As shown in FIG. 11A, panel 1102 includes notches 1103 that are formed in the gypsum body 1110. But the notches do not form a reinforcing layer behind a front layer. Instead, as shown in FIG. 11B, the when the gypsum body 1110 is folded around the notches, the folded sections only form the angled surfaces at the upper side 1104 and lower side 1105. In addition to forming the angled surfaces at the upper and lower sides of the panel 1102, folding the edges over can also provide a facing sheet along the upper side 1104 and lower side 1105 that is continuous with a facing sheet extending over a front surface 1108 of the panel 1102.

FIGS. 12A-17C show various attachment structures having different configurations in accordance with embodiments of the disclosure. FIG. 12A shows a pair of attachment structures configured to hold a panel to a support structure. The pair includes a first attachment structure 1230 that is configured to be secured to a panel and a second attachment structure 1270 configured to be secured to a support structure. As shown in FIG. 12B, the first attachment structure 1230 includes a first base 1234 that is adapted to be set against a surface of a panel and a leg 1244 extending from an upper end of the first base 1234. A first clip 1240 in the form of a first hook 1242 is provided at the end of the leg 1244. A spring 1238 extends outward from the lower end of the first base 1234 and is configured to push the first attachment structure 1230 forward and maintain engagement with the second attachment structure 1270, as explained above with respect to building surface product 700.

As shown in FIG. 12C, the second attachment structure 1270 includes a second base 1274 that is configured to be set against a support structure and an arm 1284 extending forward from the second base 1274. A second clip 1280 in the form of a second hook 1282 is provided at the end of the arm 1284 for engagement with the first attachment structure 1230.

The second base 1274 of the second attachment structure 1270 includes two layers at the upper end thereof. The two layers are formed by fold in the metal sheet that forms the second attachment structure 1270. The folded portion of the second base 1274 allows the second base 1274 to extend both above and below the arm 1284 associated with the second clip 1280.

The layered upper section of the second base 1274 includes an aperture 1276 for fixedly attaching the second base 1274 to a support structure. In contrast, the lower section of the second base 1274 that is below the arm 1284 includes a slot 1277. The slot 1277 allows the second attachment structure 1270 to be loosely coupled to the support structure while the wall panel is positioned. Once the panel is accurately positioned against the support structure, the second attachment structure 1270 may be securely fastened in place at a height that allows for engagement between the corresponding clips of the first attachment structure 1230 and second attachment structure 1270.

FIG. 12D shows the first attachment structure 1230 secured to a wall panel 1202 with an angled upper side 1204. The second attachment structure 1270 is secured to a support structure 1250. The first hook 1242 of the first attachment structure 1230 engages the second hook 1282 of the second attachment structure 1270 so as to secure the panel 1202 to the support structure 1250. Further, the spring 1238 urges the first attachment structure 1230 forward to maintain the engagement between the first hook 1242 and the second hook 1282.

FIG. 13A shows a pair of cooperating attachment structures including a first attachment structure 1330 and a second attachment structure 1370. The first attachment structure 1330 includes a first base 1334 that is adapted to be set against a surface of a panel and a leg 1344 extending from an upper end of the first base 1334. A first clip 1340 in the form of a first hook 1342 is provided at the end of the leg 1344. The second attachment structure 1370 is formed by a first component 1371 and a second component 1372. The two components 1371 and 1372 form two layers of the second base 1374.

The first component 1371 also forms an arm 1384 that extends from the lower end of the base 1374 and a first spring 1338 that extends from the upper end of the base 1374. A second hook 1382 is formed at the end of the arm 1384. The second component 1372 forms a second spring 1339 that extends from the lower end of the base 1374.

FIG. 13B shows the first attachment structure 1330 secured to a wall panel 1302 and both components 1371 and 1372 of the second attachment structure 1370 secured to a support structure 1350. The first hook 1342 of the first attachment structure 1330 engages the second hook 1382 of the second attachment structure 1370 so as to secure the panel 1302 to the support structure 1350. Further, the first spring 1338 and second spring 1339 cooperate to urge the first attachment structure 1330 forward to maintain the engagement between the first hook 1342 and the second hook 1382.

FIG. 14A shows a pair of cooperating attachment structures including a first attachment structure 1430 and a second attachment structure 1470. The first attachment structure 1430 includes a first base 1434 that is adapted to be set against a surface of a panel and a first hook 1442 configured to engage the second attachment structure 1470. Likewise, the second attachment structure includes a second base 1474 that is configured to be set against a support structure. The second attachment structure 1479 includes a second hook 1482 provided to engage the first hook 1442 and a spring 1438 for helping to maintain the connection between the attachment structures. The first hook 1442 includes a bulbous end 1443 and a constricted opening 1444. Further, the second hook 1482 also includes a bulbous end 1483 and a constricted opening 1484. The attachment structures are configured so that the bulbous ends pass through the constricted openings when the attachment structures are coupled in order to form a strong connection between the attachment structures.

The opening 1484 of the second hook 1482 faces upward so that the assembly of the panel 1402 and first attachment structure 1430 may be coupled to the second attachment structure 1470 by lowering the first attachment structure 1430 onto the second attachment structure 1470 such that the bulbous end of the first hook 1442 is inserted into the constricted opening 1484 of the second attachment structure 1470.

FIG. 14B shows the first attachment structure 1430 secured to a wall panel 1402 and the second attachment structure 1470 secured to a support structure 1450. The first hook 1442 of the first attachment structure 1430 engages the second hook 1482 of the second attachment structure 1470 so as to secure the panel 1402 to the support structure 1450. Further, the spring 1438 pushes an upper neighboring panel forward, which in turn pushes the panel 1402 forward. This helps maintain the engagement between the first hook 1442 and the second hook 1482.

FIG. 15A shows a panel 1502 with a first attachment clip 1530 that includes a channel 1540 and a second attachment clip 1570 that includes a spring clip 1580. As shown in FIG. 15B, the bottom of the channel 1540 forms a base 1534 that is secured against a surface of the panel. Further, the channel 1540 has a constricted opening 1542 that is configured to retain the spring clip 1580 within the channel 1540 having a constricted opening. The spring clip 1580 includes a pair of prongs 1582 that flex upon insertion into the channel 1540. Once the spring clip 1580 is inserted into the channel 1540, as shown in FIG. 15C, the prongs 1582 are hindered from being removed, which may prevent accidental decoupling of the panel from the support structure.

In the illustrated embodiment, the second attachment structure 1570 includes an additional clip 1585 above the second clip 1580. This additional clip 1585 is configured to couple to a corresponding clip, such as a channel, of another building surface panel, as shown in FIG. 15C.

FIGS. 16A-16C illustrate a similar construction as FIGS. 15A-15C, where the second attachment structure 1670 includes a first spring clip 1680 configured to hold a first panel 1602 as well as an additional spring clip 1685 configured to hold another panel 1603 against a support structure. However, unlike the configuration shown in FIGS. 15A-15C, as shown in FIG. 16A, the additional spring clip 1685 is oriented vertically, so that the height of the connection between the additional spring clip 1685 and the second panel 1603 is adjustable. Accordingly, the spacing between the panel 1602 and the second panel 1603 can be adjusted after the second panel 1603 is secured to the second attachment structure 1670, as shown in FIGS. 16B and 16C.

FIGS. 17A-17C illustrate another pair of attachment structures that are configured to couple a panel to a support structure. As shown in FIG. 17A, the first attachment structure 1730 includes a rounded channel 1740 with a constricted opening 1742. An inner side of the channel 1740 forms a base 1734 that is adapted for securing the first attachment structure 1730 to a panel. The second attachment structure 1770 has a corresponding design that includes a base 1774 configured to be attached to a support structure and a clip 1780 formed by a ball 1784 positioned at the end of a post 1782. The ball 1784 is configured to be inserted into the rounded channel 1740 to secure the second attachment structure 1770 to the first attachment structure. While the illustrated ball has a spherical shape, in other embodiments it may have an elliptical or oval shape. As will be appreciated by one skilled in the art, additional matched shapes of protuberances and receivers can be adapted to carry out the engagement function.

As shown in FIGS. 17B and 17C, the ball of the second clip allows rotational adjustment between the first attachment structure and the second attachment structure 1770. Accordingly, for example, the second attachment structure 1770 may be rotated to accommodate variations in the distances between framing members 1754 of a support structure 1750. For example, in FIG. 17B the distance between framing members 1754 of the support structure and the ends of the panel 1702 are the same. Accordingly, the panel may be secured to the support structure without any modification. In FIG. 17C, in contrast, the length of the panel 1702 is greater than the distance between neighboring framing members 1754. Rather than having to resize the panel 1702 or move the first attachment structure (see FIG. 17A), the panel 1702 may still be secured to the framing members 1754 by rotating one of the second attachment structures 1770. The rotationally symmetrical design of the second attachment structure 1770 allows the second attachment structure 1770 to couple to the first attachment structure at various different angles.

In some embodiments, the panel includes a gypsum body. In other embodiments, the panel is formed from another material. For example, in some embodiments, the panel includes a body that is constructed of wood, natural fibers, mineral fibers, synthetic fibers or a polymer material. In some embodiments, building surface products including a panel of wood or polymer may include attachment posts that are fastened to the rear surface of the panel with or without passing all the way through the panel. In still other embodiments, the building surface product may include composites made up of combinations of materials, such as woods and polymers, or gypsums and polymers, or fibers and gypsums.

In certain embodiments of the building surface product as otherwise described herein, the gypsum body comprises a reinforced gypsum material. The use of a reinforced gypsum material can enhance the connection between the panel and the attachment posts that are attached to the panel. Moreover, the use of a reinforced gypsum material can also provide extra stability for the panel in the vicinity of the attachment posts. For example, in some embodiments, the gypsum body includes at least 1% by weight polymer. Reference to the weight percentage of a component of the gypsum body, as used herein, refers to the weight after the gypsum has set. In certain embodiments, the polymer includes starch and/or polyvinyl acetate.

In certain embodiments of the building surface product as otherwise described herein, the gypsum body includes at least 1% by weight of reinforcing fibers. For example, in some embodiments, the gypsum body includes glass fibers. Further, in some embodiments, the gypsum panel includes cellulose-based fibers or stone wool fibers. Moreover, in some embodiments, the gypsum panel includes polyethylene, polypropylene or polyester fibers. Various embodiments of the building surface product include different combinations of the aforementioned fibers in the gypsum panel.

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

In certain embodiments of the building surface product as otherwise described herein, the panel is rectangular. For example, as shown in FIG. 1A, the shape of building surface product 100 is governed by panel 102 which has a rectangular form. In particular, the first edge 116 along first side 104 is parallel to the edge along second side 105 and the two edges run across the width of panel 102. Likewise, the edge at first end 106 is parallel to edge at second end 107. Moreover, the sides and ends of panel 102 are perpendicular to one another such that the shape of panel 102 is that of a rectangle. In other embodiments, the building surface product has another shape. For example, in some embodiments, the building surface product is formed as a trapezoid, triangle, or other polygon.

In some embodiments the building surface product is configured to form a wall surface or ceiling surface. For example, panel 102 of building surface product 100 is a panel. In other embodiments, the building surface product is configured to form a trim or decorative element. For example, in some embodiments, the panel of the building surface product is formed as a trim or decorative component that is attached to a support structure using the attachment posts of the disclosure. For example, in some embodiments the panel is a molding component, such as crown molding at the top of the building surface. In other embodiments, the panel forms a baseboard at the bottom of a building surface. Still in other embodiments, the panel forms corner trim or window trim. Various shapes for such trim configurations are possible. For example, in some embodiments, the trim may be flat, angled or curved. Likewise, such trim can be proud, flush or recessed. Still, in other embodiments the building surface product forms a decorative beam. In some embodiments, the building surface product passes over the middle of a building surface. For example, in some embodiments, the panel of the building surface product forms a chair rail, a batten or has another configuration that passes over the middle of the surface. In some embodiments, the building surface product includes a panel configured as a trim or decorative element and is formed of a polymer or wood and the first attachment post extends only partially through the panel.

In certain embodiments of the building surface product as otherwise described herein, the building surface product further includes a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface. In some embodiments, the facing sheet is a paper facing. In other embodiments, the facing sheet includes reinforcing fibers. For example, in some embodiments, the facing sheet includes a fiberglass mat. Further, in some embodiments, the gypsum material is embedded into the facing sheet.

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

In certain embodiments of the building surface product as otherwise described herein, a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches. In some embodiments, the width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet. For example, in some embodiments, the width of the panel is in a range from 3 inches to 6 feet, e.g., from 4 inches to 4 feet, e.g., from 6 inches to 3 feet.

In certain embodiments of the building surface product as otherwise described herein, a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet. In some embodiments, the length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet. For example, in some embodiments, the length of the panel is in a range from 1 foot to 20 feet, e.g., from 2 feet to 15 feet, e.g., from 4 feet to 12 feet.

In certain embodiments of the building surface product as otherwise described herein, a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch. In some embodiments, the thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches. For example, in some embodiments, the thickness of the panel is in a range from ⅜ inch to 4 inches, e.g., from ½ inch to 3 inches, e.g., from ¾ inch to 2 inches.

It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

EMBODIMENTS

Embodiment 1. A building surface product comprising:

a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface;

a first attachment post extending outward from the rear surface of the panel, the first attachment post including:

    • a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and
    • a lip extending radially outward from the shaft and configured to hold the first attachment post in an aperture of a support structure.
      Embodiment 2. The building surface product according to embodiment 1, wherein the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer,

wherein the first attachment post extends at least partially through the reinforcing layer.

Embodiment 3. The building surface product according to embodiment 2, wherein the reinforcing layer includes a first section along a first edge of the panel, and wherein the first section is disposed behind the front layer along the first edge.
Embodiment 4. The building surface product according to embodiment 3, wherein the gypsum body includes a first edge section between the front layer and the first section of the reinforcing layer at the first edge.
Embodiment 5. The building surface product according to embodiment 4, wherein the front layer has a first tapered face along the first edge, the first section of the reinforcing layer has a tapered face along the first edge, and the first edge section has a triangular shape including a front face that is adjacent to the first tapered face of the front layer and a rear face that is adjacent to the tapered face of the first section of the reinforcing layer.
Embodiment 6. The building surface product according to embodiment 4 or embodiment 5 wherein the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet.
Embodiment 7. The building surface product according to any of embodiments 4 to 6, wherein a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer.
Embodiment 8. The building surface product according to any of embodiments 5 to 7, wherein an adhesive layer is provided between the first tapered face of the front layer and the front face of the first edge section.
Embodiment 9. The building surface product according to any of embodiments 5 to 8, wherein an adhesive layer is provided between the tapered face of the first section of the reinforcing layer and the rear face of the first edge section.
Embodiment 10. The building surface product according to any of embodiments 3 to 9, wherein an adhesive layer is provided between the front layer and the first section of the reinforcing layer.
Embodiment 11. The building surface product according to embodiment 10, wherein the shaft of the first attachment post extends through the adhesive layer provided between the front layer and the first section of the reinforcing layer.
Embodiment 12. The building surface product according to any of embodiments 3 to 11, wherein a pair of facing sheets is provided between the front layer and the first section of the reinforcing layer.
Embodiment 13. The building surface product according to any of embodiments 2 to 12, wherein the reinforcing layer extends around a perimeter of the panel.
Embodiment 14. The building surface product according to any of embodiments 12 to 13, wherein the reinforcing layer includes a section along each edge of the panel.
Embodiment 15. The building surface product according to embodiment 14, wherein the gypsum body includes an edge section along each edge of the panel between the front layer and respective section of the reinforcing layer.
Embodiment 16. The building surface product according to any of embodiments 1 to 15, wherein the panel includes a first receiver sleeve and the shaft of the first attachment post extends into the first receiver sleeve.
Embodiment 17. The building surface product according to embodiment 16, wherein the first receiver sleeve extends through the reinforcing layer.
Embodiment 18. The building surface product according to embodiment 16 or embodiment 17, wherein the first receiver sleeve includes a threaded interior surface configured to engage the shaft of the first attachment post.
Embodiment 19. The building surface product according to any of embodiments 16 to 18, wherein the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer.
Embodiment 20. The building surface product according to any of embodiments 1 to 19, wherein at least a portion of the shaft of the first attachment post is threaded.
Embodiment 21. The building surface product according to any of embodiments 1 to 20, wherein the lip is formed as a portion of a head disposed at the second end of the shaft.
Embodiment 22. The building surface product according to any of embodiments 1 to 21, wherein the first attachment post includes a collar surrounding the shaft that engages the rear surface of the panel.
Embodiment 23. The building surface product according to embodiment 22, wherein the collar is spaced from the lip.
Embodiment 24. The building surface product according to any of embodiments 1 to 23, wherein the first attachment post is one of a plurality of attachment posts extending from the rear surface of the panel, each of the plurality of attachment posts including a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip extending radially outward from the respective shaft and configured to hold the respective attachment post in a respective aperture of the support structure.
Embodiment 25. The building surface product according to any of embodiments 1 to 24, wherein the gypsum body comprises a reinforced gypsum material.
Embodiment 26. The building surface product according to any of embodiments 1 to 25, wherein the gypsum body includes at least 1% by weight polymer.
Embodiment 27. The building surface product according to embodiment 26, wherein the polymer includes starch and/or polyvinyl acetate.
Embodiment 28. The building surface product according to any of embodiments 1 to 27, wherein the gypsum body includes at least 1% by weight of reinforcing fibers.
Embodiment 29. The building surface product according to any of embodiments 1 to 28, further comprising a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface.
Embodiment 30. The building surface product according to embodiment 29, wherein the facing sheet is a paper facing.
Embodiment 31. The building surface product according to any of embodiments 1 to 30, wherein a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches.
Embodiment 32. The building surface product according to any of embodiments 1 to 31, wherein a width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet.
Embodiment 33. The building surface product according to any of embodiments 1 to 32, wherein a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet.
Embodiment 34. The building surface product according to any of embodiments 1 to 33, wherein a length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet.
Embodiment 35. The building surface product according to any of embodiments 1 to 34, wherein a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch.
Embodiment 36. The building surface product according to any of embodiments 1 to 35, wherein a thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches.
Embodiment 37. A building surface system comprising:

a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate; and

a first building surface product according to any of embodiments 1 to 36 attached to the support structure, wherein the first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.

Embodiment 38. The building surface system according to embodiment 37, wherein the longitudinal plate includes a first engagement edge extending along one side of the slot, wherein the shaft of the first attachment post extends through the first receiving slot and the lip of the first attachment post abuts the first engagement edge of the longitudinal plate.
Embodiment 39. The building surface system according to embodiment 37 or embodiment 38, wherein a first end of the first receiving slot is wider than a second end of the first receiving slot, and wherein the first attachment post is held at the second end of the first receiving slot.
Embodiment 40. The building surface system according to any of embodiments 37 to 39, wherein the first end of the first receiving slot has a width that is larger than a width of the first attachment post, such that the first attachment post is removable from the first receiving slot at the first end.
Embodiment 41. The building surface system according to any of embodiments 37 to 40, wherein the longitudinal plate includes a front face and a first indentation that protrudes rearward from the front face, wherein the first receiving slot is disposed in the first indentation.
Embodiment 42. The building surface system according to embodiment 41, wherein a depth of the first indentation increases from the first end of the first receiving slot to the second end of the first receiving slot.
Embodiment 43. The building surface system according to any of embodiments 37 to 42, wherein the rear surface of the panel of the first building surface product abuts the front face of the longitudinal plate.
Embodiment 44. The building surface system according to any of embodiments 37 to 43, wherein the first receiving slot is disposed on a first side of the longitudinal plate and wherein a second receiving slot is disposed on a second side of the longitudinal plate.
Embodiment 45. The building surface system according to embodiment 44, further comprising a second building surface product according to any of embodiments 1 to 36, wherein an attachment post of the second building surface product is received in the second receiving slot of the longitudinal plate so as to secure the second building surface product against the support structure.
Embodiment 46. The building surface system according to embodiment 44 or embodiment 45, wherein the longitudinal plate includes an outwardly extending projection between the first receiving slot and the second receiving slot.
Embodiment 47. The building surface system according to embodiment 46, wherein the outwardly extending projection is disposed between the first building surface product and the second building surface product.
Embodiment 48. The building surface system according to embodiment 46 or embodiment 47, wherein a height of the outwardly extending projection is substantially equal to a thickness of the panel of the first building surface product.
Embodiment 49. The building surface system according to any of embodiments 37 to 48, wherein the longitudinal plate includes an open path extending from the first end of the first receiving slot to an edge along the second side of the longitudinal plate.
Embodiment 50. The building surface system according to any of embodiments 37 to 49, wherein the first receiving slot is one of a row of receiving slots positioned along a length of the longitudinal plate, and wherein the building surface system includes a row of building surface products that engage other receiving slots in the row of receiving slots.
Embodiment 51. The building surface system according to any of embodiments 37 to 50, wherein the support structure includes vertical framing members, and wherein the first rail extends across the vertical framing members and is attached to the vertical framing members.
Embodiment 52. The building surface system according to embodiment 51, wherein the first rail is attached to the vertical framing members using mechanical fasteners that extend into the vertical framing members.
Embodiment 53. The building surface system according to embodiment 51, wherein the vertical framing members include beams and reinforcement plates secured to the beams, and wherein the reinforcement plates include receivers configured to receive mechanical fasteners that secure the first rail to the vertical framing members.
Embodiment 54. The building surface system according to embodiment 53, wherein the receivers have an adjustable position with respect to the reinforcement plates.
Embodiment 55. A method of forming the building surface system according to any of embodiments 37 to 54, the method comprising:

positioning the first building surface product in front of the support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail; and

securing the first building surface product to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.

Embodiment 56. The method according to embodiment 55 wherein the first building surface product is positioned in front of the support structure such that a plurality of additional attachment posts of the first building surface product are inserted in respective receiving slots of the support structure, and wherein sliding the first building surface product to the assembled position causes the additional attachment posts to be secured in the respective receiving slots.
Embodiment 57. The method according to embodiment 55 or 56, further comprising:

positioning a second building surface product according to any of embodiments 1 to 36 in front of the support structure such that the rear surface of the panel of the second building surface product faces the support structure and an attachment post of the second building surface product is inserted in another receiving slot of the longitudinal plate of the first rail; and

securing the second building surface product to the support structure by sliding the second building surface product to an assembled position where the attachment post of the second building surface product is secured in the other receiving slot of the longitudinal plate of the first rail, and the attachment post retains the second building surface product against the support structure.

Embodiment 58. The method according to embodiment 55, further comprising;

positioning a second rail behind the first building surface product with a second attachment post of the first building surface inserted into a receiving slot of the second rail; and

securing the second rail to the first building surface product by sliding the second rail to an assembled position where the second attachment post of the first building surface product is secured in the receiving slot of the second rail.

Embodiment 59. The method according to embodiment 58, wherein positioning the second rail behind the first building surface product includes introducing the second attachment post into the receiving slot of the second rail through an open path in the second rail.
Embodiment 60. The method according to embodiment 58 or embodiment 59, wherein positioning the second rail behind the first building surface product includes placing a projection of the second rail on an upper edge of the panel of the first building surface product.
Embodiment 61. The method according to any of embodiments 58 to 60, further comprising attaching the second rail to vertical framing members of the support structure after sliding the second rail into the assembled position.
Embodiment 62. A building surface product comprising:

a substantially planar panel having a front surface, a rear surface, a first side, a second side, a first end, and a second end;

a first attachment structure including a first base secured to the rear surface of the panel and a first clip connected to the base; and

a second attachment structure including a second base configured to be attached to a support structure and a second clip connected to the second base, the second clip being adapted to couple to the first clip so as to secure the panel to the support surface.

Embodiment 63. The building surface product according to embodiment 62, wherein the first clip includes a first hook and the second clip includes a corresponding second hook adapted to couple to the first hook.
Embodiment 64. The building surface product according to embodiment 63, wherein an end of the first hook extends forward such that the first hook has an opening that faces the panel, and wherein an end of the second hook extends rearward and is adapted for insertion into the opening of the first hook.
Embodiment 65. The building surface product according to embodiment 63, wherein the first hook has a first bulbous end a constricted opening, and wherein the second hook has a second bulbous end that fits in the constricted opening of the first hook.
Embodiment 66. The building surface product according to embodiment 65, wherein the constricted opening of the second hook faces upward.
Embodiment 67. The building surface product according to any of embodiments 63 to 66, wherein the first attachment structure includes a leg extending rearward from the first base and the first hook is disposed on the leg.
Embodiment 68. The building surface product according to any of embodiments 63 to 67, wherein the second attachment structure includes an arm extending forward from the second base and the second hook is disposed on the arm.
Embodiment 69. The building surface product according to any of embodiments 63 to 68, wherein the first attachment structure includes a spring extending rearward from the first base and configured to urge the first attachment structure forward so as to maintain the connection between the first hook and the second hook.
Embodiment 70. The building surface product according to embodiment 69, wherein the spring is positioned to press against the second base of the second attachment structure.
Embodiment 71. The building surface product according to any of embodiments 62 to 70, wherein the second attachment structure includes a shelf for supporting a portion of the panel.
Embodiment 72. The building surface product according to any of embodiments 62 to 68, wherein the second attachment structure includes a spring extending forward from the second base and configured to urge the panel away from the second attachment structure so as to maintain connection between the first hook and the second hook.
Embodiment 73. The building surface product according to any of embodiments 62 to 72, wherein the second base of the second attachment structure includes a plurality of layers.
Embodiment 74. The building surface product according to embodiment 73, wherein the layers of the second base structure are formed by a folded material strip.
Embodiment 75. The building surface product according to embodiment 73, wherein the second attachment structure includes a first component that forms a first layer of the second base and a second component that forms a second layer of the second base.
Embodiment 76. The building surface product according to any of embodiments 1 to 75, wherein the second base includes an aperture for fixing the second attachment structure to the support surface.
Embodiment 77. The building surface product according to embodiment 76, wherein the second base includes a slot positioned below the aperture for holding the second attachment structure against the support surface.
Embodiment 78. The building surface product according to embodiment 62, wherein the first clip includes a channel having a constricted opening.
Embodiment 79. The building surface product according to embodiment 78, wherein the second clip is formed as a spring clip that is configured to be inserted into the channel of the first clip.
Embodiment 80. The building surface product according to embodiment 79, the spring clip includes a pair of prongs that flex upon insertion into the channel.
Embodiment 81. The building surface product according to embodiment 79 or embodiment 80, wherein the second attachment structure includes an additional clip above the second clip that is configured to couple to a corresponding clip of another building surface panel.
Embodiment 82. The building surface product according to embodiment 81, wherein the additional clip extends vertically so as to allow vertical adjustment of the other building surface panel relative to the second attachment structure.
Embodiment 83. The building surface product according to embodiment 78, wherein the second clip includes a post and a ball disposed at the end of the post, wherein the ball is configured to be inserted into the constricted opening of the channel so as to secure the first attachment structure to the second attachment structure.
Embodiment 84. The building surface product according to embodiment 83, wherein the ball of the second clip allows rotational adjustment between the first attachment structure and the second attachment structure.
Embodiment 85. The building surface product according any of embodiments 78 to 84, wherein the channel of the first clip includes a side wall extending rearward from the first base, and wherein the side wall of the channel is positioned against a section of a reinforcing layer of the panel.
Embodiment 86. The building surface product according to any of embodiments 62 to 85 wherein the panel includes a gypsum body extending from the front surface to the rear surface.
Embodiment 87. The building surface product according to embodiment 86, wherein the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer.
Embodiment 88. The building surface product according to embodiment 87, wherein the reinforcing layer includes a first section along a first edge of the panel, and wherein the first section is disposed behind the front layer along the first edge.
Embodiment 89. The building surface product according to embodiment 87 or embodiment 88 wherein the front layer, the first edge section, and the first section of the reinforcing layer are formed from a machined and folded gypsum sheet.
Embodiment 90. The building surface product according to embodiment 88 or embodiment 89, wherein a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer.
Embodiment 91. The building surface product according to any of embodiments 87 to 90, wherein the first attachment structure is secured to the rear surface of the panel using a mechanical fastener that extends into the reinforcing layer.
Embodiment 92. The building surface product according to embodiment 91, wherein the panel includes a first receiver sleeve and the mechanical fastener extends into the first receiver sleeve.
Embodiment 93. The building surface product according to embodiment 92, wherein the first receiver sleeve includes a threaded interior surface configured to engage a shaft of the mechanical fastener.
Embodiment 94. The building surface product according to embodiment 92 or embodiment 93, wherein the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer.
Embodiment 95. The building surface product according to any of embodiments 62 to 86, wherein the first attachment structure is secured to the rear surface of the panel using a mechanical fastener that extends into the gypsum body.
Embodiment 96. The building surface product according to embodiment 95, wherein the gypsum body includes a hole, wherein an embedded fastener including a threaded body is disposed in the hole, and wherein the mechanical fastener engages the embedded fastener.
Embodiment 97. The building surface product according to embodiment 96, wherein threaded body of the embedded fastener includes a hollow barrel with internal threads, and the threaded body of the linking fastener includes a shaft with external threads.
Embodiment 98. The building surface product according to 96 or embodiment 97, wherein the embedded fastener includes a flat base extending radially outward from the threaded body of the embedded fastener.
Embodiment 99. The building surface product according to any of embodiments 96 to 98, wherein the embedded fastener is formed as a tee nut.
Embodiment 100. The building surface product according to any of embodiments 96 to 99, wherein the embedded fastener is contained between the front surface and the rear surface of the panel.
Embodiment 101. The building surface product according to any of embodiments 96 to 100, wherein the embedded fastener is covered at the first surface of the panel by a material layer.
Embodiment 102. The building surface product according to embodiment 101, wherein the material layer is joint compound, a lamination, paper, film, fabric or plastic.
Embodiment 103. The building surface product according to any of embodiments 96 to 102, wherein a layer of paint extends across the front surface of the panel and over the embedded fastener so as to obscure the embedded fastener.
Embodiment 104. The building surface product according to any of embodiments 62 to 103, wherein the panel includes a first projection extending along the first side of the panel and positioned at the front surface of the panel, and a second projection extending along the second side of the panel and configured to fit behind a first projection of a neighboring panel.
Embodiment 105. The building surface product according to embodiment 104, wherein the first projection has an angled rear face and the second projection has an angled front face.
Embodiment 106. The building surface product according to any of embodiments 62 to 105, wherein the gypsum body comprises a reinforced gypsum material.
Embodiment 107. The building surface product according to any of embodiments 62 to 106, wherein the gypsum body includes at least 1% by weight polymer.
Embodiment 108. The building surface product according to embodiment 107, wherein the polymer includes starch and/or polyvinyl acetate.
Embodiment 109. The building surface product according to any of embodiments 62 to 108, wherein the gypsum body includes at least 1% by weight of reinforcing fibers.
Embodiment 110. The building surface product according to any of embodiments 62 to 109, further comprising a facing sheet that lines the gypsum body along at least one of the front surface and the rear surface.
Embodiment 111. The building surface product according to embodiment 110, wherein the facing sheet is a paper facing.
Embodiment 112. The building surface product according to any of embodiments 62 to 11, wherein a width of the panel from the first side to the second side is at least 3 inches, e.g., at least 4 inches, e.g., at least 6 inches.
Embodiment 113. The building surface product according to any of embodiments 62 to 112, wherein a width of the panel from the first side to the second side is no more than 6 feet, e.g., no more than 4 feet, e.g., no more than 3 feet.
Embodiment 114. The building surface product according to any of embodiments 62 to 113, wherein a length of the panel from the first end to the second end is at least 1 foot, e.g., at least 2 feet, e.g., at least 4 feet.
Embodiment 115. The building surface product according to any of embodiments 62 to 114, wherein a length of the panel from the first end to the second end is no more than 20 feet, e.g., no more than 15 feet, e.g., no more than 12 feet.
Embodiment 116. The building surface product according to any of embodiments 62 to 115 wherein a thickness of the panel is at least ⅜ inch, e.g., at least ½ inch, e.g., at least ¾ inch.
Embodiment 117. The building surface product according to any of embodiments 62 to 116 wherein a thickness of the panel is no more than 4 inches, e.g., no more than 3 inches, e.g., no more than 2 inches.

Claims

1. A building surface product comprising:

a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface;
a first attachment post extending outward from the rear surface of the panel, the first attachment post including: a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip extending radially outward from the shaft and configured to hold the first attachment post in an aperture of a support structure.

2. The building surface product according to claim 1, wherein the gypsum body includes a front layer and a reinforcing layer disposed behind the front layer,

wherein the first attachment post extends at least partially through the reinforcing layer.

3. The building surface product according to claim 2, wherein the reinforcing layer includes a first section along a first edge of the panel, and wherein the first section is disposed behind the front layer along the first edge.

4. The building surface product according to claim 3, wherein the gypsum body includes a first edge section between the front layer and the first section of the reinforcing layer at the first edge.

5. The building surface product according to claim 4, wherein the front layer has a first tapered face along the first edge, the first section of the reinforcing layer has a tapered face along the first edge, and the first edge section has a triangular shape including a front face that is adjacent to the first tapered face of the front layer and a rear face that is adjacent to the tapered face of the first section of the reinforcing layer.

6. The building surface product according to claim 4, wherein a continuous facing sheet extends around the first edge so as to cover a rear face of the first section of the reinforcing layer, an outer face of the first edge section, and the front face of the front layer.

7. The building surface product according to claim 2, wherein the panel includes a first receiver sleeve and the shaft of the first attachment post extends into the first receiver sleeve.

8. The building surface product according to claim 7, wherein the first receiver sleeve includes an external flange disposed between the front layer and the reinforcing layer.

9. The building surface system according to claim 1, wherein the first attachment post includes a collar spaced from the lip and surrounding the shaft, and wherein the collar engages the rear surface of the panel.

10. A building surface system comprising:

a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate; and
a first building surface product according to claim 1 attached to the support structure, wherein the first attachment post of the first building surface product is received in the first receiving slot so as to secure the first building surface product against the support structure.

11. The building surface system according to claim 10, wherein the longitudinal plate includes a first engagement edge extending along one side of the slot, wherein the shaft of the first attachment post extends through the first receiving slot and the lip of the first attachment post abuts the first engagement edge of the longitudinal plate.

12. The building surface system according to claim 10, wherein a first end of the first receiving slot is wider than a second end of the first receiving slot, and wherein the first attachment post is held at the second end of the first receiving slot.

13. The building surface system according to claim 10, wherein the longitudinal plate includes a front face and a first indentation that protrudes rearward from the front face, wherein the first receiving slot is disposed in the first indentation.

14. A method of forming a building surface system, the method comprising:

providing a support structure including a plurality of rails that form a support surface, wherein the plurality of rails comprises a first rail including a longitudinal plate and a first receiving slot in the longitudinal plate;
providing a first building surface product comprising: a substantially planar panel having a first side, a second side, a first end, a second end, a front surface, a rear surface, and a gypsum body between the front surface and rear surface, and a first attachment post extending outward from the rear surface of the panel, the first attachment post including: a shaft having a first end that penetrates the rear surface of the panel and second end that is spaced from the panel, and a lip extending radially outward from the shaft and configured to hold the first attachment post in an aperture of a support structure;
positioning the first building surface product in front of a support structure such that the rear surface of the panel of the first building surface product faces the support structure and the first attachment post is inserted in the first receiving slot of the longitudinal plate of the first rail; and
securing the first building surface product to the support structure by sliding the first building surface product to an assembled position where the first attachment post is secured in the first receiving slot of the longitudinal plate of the first rail, and the first attachment post retains the first building surface product against the support structure.

15. The method according to claim 14, further comprising:

positioning a second building surface product in front of the support structure such that a rear surface of a panel of the second building surface product faces the support structure and an attachment post of the second building surface product is inserted in another receiving slot of the longitudinal plate of the first rail; and
securing the second building surface product to the support structure by sliding the second building surface product to an assembled position where the attachment post of the second building surface product is secured in the other receiving slot of the longitudinal plate of the first rail, and the attachment post retains the second building surface product against the support structure.

16. The method according to claim 14, further comprising;

positioning a second rail behind the first building surface product with a second attachment post of the first building surface inserted into a receiving slot of the second rail; and
securing the second rail to the first building surface product by sliding the second rail to an assembled position where the second attachment post of the first building surface product is secured in the receiving slot of the second rail.

17. The method according to claim 16, wherein positioning the second rail behind the first building surface product includes placing a projection of the second rail on an upper edge of the panel of the first building surface product.

18. The method according to claim 16, further comprising attaching the second rail to vertical framing members of the support structure after sliding the second rail into the assembled position.

Patent History
Publication number: 20230183985
Type: Application
Filed: Dec 14, 2022
Publication Date: Jun 15, 2023
Inventors: Aaron Bruckerhoff (Medfield, MA), William Lentlie (Worcester, MA), Hannah Polster (Marblehead, MA), Marcus Hanna (Marblehead, MA), Evan Molony (Milford, MA), Flavien Fremy (Belmont, MA), Michael Hull (Cambridge, MA), Emily Moreau (Framingham, MA)
Application Number: 18/066,090
Classifications
International Classification: E04F 13/08 (20060101); E04F 13/14 (20060101);