Described herein is a building system comprising: a plurality of support members each comprising a support surface, a plurality of first building panels secured to the support surface of the plurality of support members, each of the plurality of first building panels comprising a non-porous body, a plurality of second building panels secured to the plurality of first building panels by an adhesive and a first plurality of mechanical fasteners, each of the plurality of the second building panels comprising a porous body.
Legal claims defining the scope of protection, as filed with the USPTO.
. A building system comprising:
. The building system according to, wherein the each of the plurality of first building panels have an elongated rectilinear shape extending along a first longitudinal axis and each of the plurality of second building panels have an elongated rectilinear shape extending along a second longitudinal axis.
. The building system according to, wherein at least one of the plurality of first building panels and at least one of the plurality of second building panels are arranged such that the first longitudinal axis of the at least one of the plurality of first building panels and the second longitudinal axis of the least one of the plurality of second building panels are not parallel.
. The building system according to, wherein the first longitudinal axis of the at least one of the plurality of first building panels is orthogonal to the second longitudinal axis of the least one of the plurality of second building panels are orthogonal.
. The building system according to any one of, wherein the adhesive is present in a plurality of stripes that extend in a direction substantially parallel to second longitudinal axis.
. The building system according to, wherein one of the plurality of stripes of adhesive extends across at least two adjacent ones of the plurality of first building panels.
. The building system according to, wherein the one of the plurality of stripes of adhesive extends across at least two adjacent ones of the plurality of first building panels in a direction substantially orthogonal to the first longitudinal axis.
. The building system according to, wherein the side surface of each of the plurality of first building panels comprise a first elongated edge opposite a second elongated edge which extend substantially parallel to the first longitudinal axis, the side surface of each of the plurality of first building panels further comprising a first transverse edge opposite a second transverse edge that intersect the first and second transverse edges of the first building panel; and
. The building system according to, wherein the first elongated edge of the second building panel overlaps at least a portion of a first one of the plurality of first building panels and a portion of a second one of the plurality of first building panels.
. A method of installing a building system comprising:
. The method according to, wherein the at least one facing building panel comprises a first major surface opposite the second major surface, and wherein during step b), the mechanical fastener is driven through the first major surface.
. The method according to, wherein after step b), a head portion of the mechanical fastener is located between the first major surface and the second major surface of the at least one facing building panel.
. The method according to, wherein after step b), the method further comprises step c) comprising a time period sufficient for the adhesive to reach full bond strength.
. The method according to, wherein after step b), a concealing composition is applied to the first major surface of the at least one building panel to conceal the at least one mechanical fastener.
. The method according to, wherein prior to step a), the plurality of backing building panels are secured to a plurality of securing members to form the pre-existing building surface.
. The method according to, wherein the plurality of backing building panels are secure to the plurality of securing members by adhesive.
. A building system comprising:
. The building system according to, wherein each of the plurality of fasteners has a fastener length as measured from a proximal end of the fastener to a distal end of the fastener, and wherein each of the plurality of building panels comprises a panel thickness as measured between the first major surface and the second major surface, wherein the proximal end of each of the plurality of fasteners is located inset of the first major surface of the building panel by a non-zero distance.
. The building system according to, wherein each of the plurality of fasteners has a fastener length as measured from a proximal end of the fastener to a distal end of the fastener, and wherein each of the plurality of building panels comprises a panel thickness as measured between the first major surface and the second major surface, wherein the proximal end of each of the plurality of fasteners is located inset of the first major surface of the building panel by a depth that is a non-zero value.
. The building system according to, wherein the plurality of building panels define a facing surface, and wherein the building system further comprises a paint composition over the facing surface.
Complete technical specification and implementation details from the patent document.
The present application is a United States Continuation Patent Application of U.S. patent application Ser. No. 17/894,562, filed on Aug. 24, 2022, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/237,325, filed Aug. 26, 2021, the entireties of which are incorporated herein by reference.
Creating an aesthetically pleasing and structurally stable building system may require both skilled labor as well as specialty building hardware that may drive up the cost of installation. Therefore, a need exists for a building system that may exhibit the desired aesthetic characteristics that may be installed without necessitating specialty hardware and/or specialized labor to create the finished system.
The present invention is directed to a building system comprising: a plurality of support members each comprising a support surface; a plurality of first building panels secured to the support surface of the plurality of support members, each of the plurality of first building panels comprising a non-porous body; a plurality of second building panels secured to the plurality of first building panels by an adhesive and a plurality of first mechanical fasteners, each of the plurality of the second building panels comprising a porous body.
Other embodiments of the present invention include a building system comprising: a plurality of support members; a plurality of first building panels each having a first major surface opposite a second major surface and a side surface extending there-between; a plurality of second building panels each having a first major surface opposite a second major surface and a side surface extending there-between; wherein the plurality of first building panels are secured to the plurality of support members; wherein the plurality of second building panels are secured to the plurality of first building panels by an adhesive; and wherein the plurality of second building panels and the plurality of first building panels arranged in an offset pattern such that the side surface of at least one of the plurality of first building panels and the side surface of at least one of the plurality of second building panels are not co-planar.
Other embodiments of the present invention include a method of installing a building system comprising: a) bringing into contact a second major surface of at least one facing building panel and a pre-existing building surface of a pre-existing building layer to form a building interface, whereby adhesive is present in the interface; and b) driving at least one mechanical fastener into the at least one facing building panel such that the at least one mechanical fastener is located at least in a portion of the at least one facing building panel and the pre-existing building surface; wherein the at least one building panel comprises a porous body.
Other embodiments of the present invention include a method of installing a building system comprising: a) bringing into contact a plurality of facing building panels with a pre-existing building layer to form a building interface, whereby adhesive is present in the interface; and b) driving at least one mechanical fastener into the at least one facing building panel such that the at least one mechanical fastener is located at least in a portion of the at least one building panel and the pre-existing building surface; wherein the pre-existing building layer is formed of a plurality of backing building panels located immediately adjacent to each other; and wherein the plurality of facing building panels are arranged in an offset pattern relative to the plurality of backing building panels such that at least one edge of the facing building panels and at least one edge of the backing building panels are not co-planar.
Other embodiments of the present invention include a building system comprising: a plurality of support members comprising a support surface; a plurality of building panels each having a first major surface opposite a second major surface and a side surface extending there-between; wherein the plurality of building panels are secured to the plurality of support members by an adhesive and a plurality of fasteners; and wherein each of the plurality of building panels comprises a porous body, the porous body comprising a fibrous material.
Other embodiments of the present invention include a building system comprising: a plurality of support members comprising a support surface; a plurality of building panels each having a first major surface opposite a second major surface and a side surface extending there-between, each of the plurality of building panels having a panel thickness as measured from the first major surface to the second major surface of each of the plurality of building panels; wherein the plurality of building panels are secured to the plurality of support members by an adhesive and a plurality of fasteners; and wherein each of the plurality of fasteners has a fastener length as measured from a proximal end of the fastener to a distal end of the fastener and each of the plurality of fasteners has a head having an outer diameter; and wherein the distal end of each of the plurality of fasteners is located in the support member and the proximal end of each of the plurality of fasteners is located inset of the first major surface of the building panel by a depth that is a non-zero value.
Other embodiments of the present invention include a method of installing a building system comprising: a) bringing into contact a plurality of building panels with a pre-installed support grid comprising a support surface to form a first interface there-between, whereby adhesive is present in the first interface and each of the plurality of building panels has a panel thickness; and b) driving at least one mechanical fastener into the at least one building panel such that a distal end of the mechanical faster is inset of the first major surface by a depth that is a non-zero value, whereby the mechanical fastener extends through the first interface;
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top,” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such.
Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. According to the present application, the term “about” means +/−5% of the reference value. According to the present application, the term “substantially free” less than about 0.1 wt. % based on the total of the referenced value.
Referring to, the building systemof the present invention may comprise a plurality of first building panels, a plurality of second building panels, and one or more support elements(also referred to as a “support member”). The support elementmay comprise a support surface.
Non-limiting examples of support structures include suspended ceiling grids, wall-studs (also called framing studs), and structural walls (e.g., ceiling formed by an adjacent subfloor in a multi-floor building, roof). In the non-limiting exemplified embodiment, the support structureis a ceiling joist—whereby the ceiling joist forms the support surface. Although not shown, in other embodiments, the support elementmay comprise an inverted T-bar having a horizontal flange and a vertical web—whereby the horizontal flange may form the support surface.
The building systemmay be installed in an interior space, whereby the interior space comprises a plenary spaceand an active room environment. The plenary spaceprovides space for mechanical lines within a building (e.g., HVAC, plumbing, etc.). The active spaceprovides room for the building occupants during normal intended use of the building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.). The plenary spacemay exist above the first building panelsand the active room environmentmay exist below the second building panels.
Referring to, other embodiments of the present invention include a building systemcomprising a plurality of the second building panelsand one or more support elements(also referred to as a “support member”)—as discussed in greater detail herein.
Referring now to, the first building panel(also referred to as a “backing building panel”) may comprise a first major surfaceopposite a second major surfaceand a side surfaceextending between the first and second major surfaces,.
The side surfaceof the first building panelmay define a perimeter of the first building panel. The side surfaceof the first building panelmay define a perimeter of the first major surfaceof the first building panel. The side surfaceof the first building panelmay define a perimeter of the second major surfaceof the first building panel.
Depending on the shape of the first building panel, there may be a plurality of side surfaces. The first building panelmay be rectilinear in shape. The first building panelmay be elongated and extend along a first longitudinal axis A-A.
According to such embodiments, the side surfaceof the first building panelmay comprise a first side surface, a second side surface, a third side surface, and a fourth side surface. The first side surfacemay be substantially parallel to the second side surface. The third side surfacemay be substantially parallel to the fourth side surface. The first side surfaceand the second side surfacemay intersect the third side surfaceand the fourth side surface. The first side surfaceand the second side surfacemay each be substantially orthogonal to each of the third side surfaceand the fourth side surface
The first longitudinal axis A-A may intersect the third side surfaceand the fourth side surface. The first longitudinal axis A-A may extend substantially parallel to the first side surfaceand the second side surface. The first longitudinal axis A-A may extend substantially orthogonal to the third side surfaceand the fourth side surface
The first side surfacemay be referred to as a first elongated side surface or a first elongated edge. The second side surfacemay be referred to as a second elongated side surface or a second elongated edge. The third side surfacemay be referred to as a first transverse side surface or a first transverse edge. The fourth side surfacemay be referred to as a second transverse side surface or a second transverse edge.
The first building panelmay have a first thickness tas measured from the first major surfaceto the second major surfaceof the first building panel. The first thickness tmay range from about 0.3 inches to about 0.75 inches—including all thicknesses and sub-ranges there-between. In some embodiments, the first thickness tmay range from about 0.375 inches to about 0.625 inch—including all lengths and sub-ranges there-between.
The first building panelmay have a first length Las measured from the third side surfaceto the fourth side surface. The first length Lmay range from about 84 inches to about 156 inches—including all lengths and sub-ranges there-between. In some embodiments, the first length Lmay range from about 96 inches to about 144 inches—including all lengths and sub-ranges there-between. In some embodiments, the first length Lis about 96 inches. In some embodiments, the first length Lis about 120 inches.
The first building panelmay have a first width Was measured from the first side surfaceto the second side surface. The first width Wmay range from about 36 inches to about 60 inches—including all widths and sub-ranges there-between. In some embodiments, the first width Wmay range from about 46 inches to about 50 inches—including all widths and sub-ranges there-between. In some embodiments, the first width Wis about 48 inches.
The first building panelmay comprise a first body. The first bodymay form the first major surface, the second major surface, and the side surfaceof the first building panel.
The first bodymay be a non-porous body. The term non-porous refers to the first bodypreventing airflow through the first building panelbetween the first major surfaceand the second major surfaceunder atmospheric conditions.
The first building panelmay exhibit a CAC value of 30 or greater, preferably 35 or greater.
The first bodyof the first building panelmay be formed of gypsum, plywood, particle board, drywall, or the combinations thereof.
The first building panelmay have a first density. The first density may range from about 16 lb./ftto about 180 lb./ft—including all densities and sub-ranges there-between. In some embodiments, the first density may range from about 25 lb./ftto about 100 lb./ft—including all densities and sub-ranges there-between.
Referring now to, the second building panel(also referred to as a “facing building panel”) may comprise a first major surfaceopposite a second major surfaceand a side surfaceextending between the first and second major surfaces,.
The side surfaceof the second building panelmay define a perimeter of the second building panel. The side surfaceof the second building panelmay define a perimeter of the first major surfaceof the second building panel. The side surfaceof the second building panelmay define a perimeter of the second major surfaceof the second building panel.
Depending on the shape of the second building panel, there may be a plurality of side surfaces. The second building panelmay be rectilinear in shape. The second building panelmay be elongated and extend along a second longitudinal axis B-B.
According to such embodiments, the side surfaceof the second building panelmay comprise a first side surface, a second side surface, a third side surface, and a fourth side surface. The first side surfacemay be substantially parallel to the second side surface. The third side surfacemay be substantially parallel to the fourth side surface. The first side surfaceand the second side surfacemay intersect the third side surfaceand the fourth side surface. The first side surfaceand the second side surfacemay each be substantially orthogonal to each of the third side surfaceand the fourth side surface
The second longitudinal axis B-B may intersect the third side surfaceand the fourth side surface. The second longitudinal axis B-B may extend substantially parallel to the first side surfaceand the second side surface. The second longitudinal axis B-B may extend substantially orthogonal to the third side surfaceand the fourth side surface
The first side surfacemay be referred to as a first elongated side surface or a first elongated edge. The second side surfacemay be referred to as a second elongated side surface or a second elongated edge. The third side surfacemay be referred to as a first transverse side surface or a first transverse edge. The fourth side surfacemay be referred to as a second transverse side surface or a second transverse edge.
The second building panelmay have a second thickness tas measured from the first major surfaceto the second major surfaceof the second building panel. The second thickness tmay range from about 0.4 inches to about 1.6 inches—including all thicknesses and sub-ranges there-between. In some embodiments, the second thickness tmay range from about 0.75 inches to about 1.0 inch—including all lengths and sub-ranges there-between. In some embodiments, the second thickness tis about 0.88 inches.
The second building panelmay have a second length Las measured from the third side surfaceto the fourth side surface. The second length Lmay range from about 60 inches to about 84 inches—including all lengths and sub-ranges there-between. In some embodiments, the second length Lmay range from about 70 inches to about 74 inches—including all lengths and sub-ranges there-between. In some embodiments, the second length Lis about 72 inches.
The second building panelmay have a second width Was measured from the first side surfaceto the second side surface. The second width Wmay range from about 36 inches to about 60 inches—including all widths and sub-ranges there-between. In some embodiments, the second width Wmay range from about 46 inches to about 50 inches—including all widths and sub-ranges there-between. In some embodiments, the second width Wis about 48 inches.
The first major surfaceof the second building panelmay comprise a central region Rand a perimeter region R. The central region Rmay be at least partially circumscribed by the perimeter region R. The central region Rmay be fully circumscribed by the perimeter region R. The perimeter region Rmay extend from the central region Rto the perimeter of the second building panel(the perimeter of the second building panelbeing located at the intersection of the side surfaceand the first major surfaceof the second building panel). The perimeter region Rmay extend from the central region Rto the perimeter of the second building panelby a perimeter distance D.
The perimeter distance Dmay range from about 0.5 inches to about 6.0 inches—including all distances and sub-ranges there-between. According to the embodiments, of, the perimeter distance Dmay range from about 3.5 inches to about 4.5 inches—including all distances and sub-ranges there-between. According to the embodiments, of, the perimeter distance Dmay range from about 0.5 inches to about 1.0 inches—including all distances and sub-ranges there-between.
The first major surfaceof the second building panelmay occupy a first surface area. The central region Rof the first major surfaceof the second building panelmay occupy a second surface area. The perimeter region Rof the first major surfaceof the second building panelmay occupy a third surface area. The summation of the second surface area and the third surface area may be substantially equal to the first surface area. Stated otherwise, the third surface area may be equal to the difference between the first surface area and the second surface area.
The second surface area may range from about 3% to about 30% of the first surface area—including all percentages and sub-ranges there-between. According to the embodiments, of, the second surface area may range from about 20% to about 30% of the first surface area—including all percentages and sub-ranges there-between. According to the embodiments, of, the second surface area may range from about 24% to about 26% of the first surface area—including all percentages and sub-ranges there-between. According to the embodiments, of, the second surface area may range from about 3% to about 10% of the first surface area—including all percentages and sub-ranges there-between. According to the embodiments, of, the second surface area may range from about 3% to about 7% of the first surface area—including all percentages and sub-ranges there-between.
The second building panelmay comprise a second body. In some embodiments, the second building panelmay comprise a non-woven scrim. The non-woven scrimmay be bonded to the second bodysuch that the non-woven scrimforms the first major surfaceof the second building panel. The second bodymay form the second major surfaceof the second building panel. The second bodymay form the side surfaceof the second building panel.
The second bodymay be a fibrous body. The second bodymay be comprised of a binder and fibers. In some embodiments, the second bodymay further comprise a filler and/or additive. Non-limiting examples of filler may include powders of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, perlite, polymers, gypsum, wollastonite, expanded-perlite, calcite, aluminum trihydrate, pigments, zinc oxide, or zinc sulfate.
The fibers may be organic fibers, inorganic fibers, or a blend thereof. Non-limiting examples of inorganic fibers mineral wool (also referred to as slag wool), rock wool, stone wool, and glass fibers. Non-limiting examples of organic fiber include fiberglass, cellulosic fibers (e.g. paper fiber—such as newspaper, hemp fiber, jute fiber, flax fiber, wood fiber, or other natural fibers), polymer fibers (including polyester, polyethylene, aramid—i.e., aromatic polyamide, and/or polypropylene), protein fibers (e.g., sheep wool), and combinations thereof.
Non-limiting examples of binder may include a starch-based polymer, polyvinyl alcohol (PVOH), a latex, polysaccharide polymers, cellulosic polymers, protein solution polymers, an acrylic polymer, polymaleic anhydride, epoxy resins, or a combination of two or more thereof.
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December 4, 2025
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