US 11,654,595 B2
Devices and methods for building panel deformation
Joseph W Davidson, Pittsburgh, PA (US); and Kenneth J Wolff, Murrysville, PA (US)
Assigned to TAPERED END, LP, Murrysville, PA (US)
Appl. No. 16/956,752
Filed by Tapered End, LP, Murrysville, PA (US)
PCT Filed Dec. 24, 2018, PCT No. PCT/US2018/067447
§ 371(c)(1), (2) Date Jun. 22, 2020,
PCT Pub. No. WO2019/133571, PCT Pub. Date Jul. 4, 2019.
Claims priority of provisional application 62/612,324, filed on Dec. 30, 2017.
Prior Publication US 2021/0060817 A1, Mar. 4, 2021
Int. Cl. B28B 17/02 (2006.01); B28B 11/00 (2006.01); C04B 41/46 (2006.01); C04B 41/62 (2006.01); B05D 1/02 (2006.01); C04B 41/00 (2006.01)
CPC B28B 17/023 (2013.01) [B05D 1/02 (2013.01); B28B 11/003 (2013.01); C04B 41/009 (2013.01); C04B 41/463 (2013.01); C04B 41/62 (2013.01); B05D 2252/00 (2013.01); B05D 2401/21 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method for modifying a building panel, the building panel including a first surface comprising a facing paper and a second surface comprising a backing paper, the building panel including a core comprising calcium sulfate hemihydrate operatively arranged between the facing paper and the backing paper, the method comprising the following steps:
applying a solution comprising at least one alcohol and water to at least a predetermined portion of the facing paper, the backing paper, or the facing paper and the backing paper of the building panel for at least partially hydrating at least a predetermined portion of the calcium sulfate hemihydrate core for converting the predetermined hydrated portion of the calcium sulfate hemihydrate core which is brittle and nondeformable to calcium sulfate dihydrate which is deformable to form a deformable portion of the building panel;
applying a predetermined force to the deformable portion of the building panel substantially normal to a horizontal plane of the building panel for causing a desired deformation of the deformable portion of the building panel;
removing the predetermined force from the deformable portion of the building panel; and
drying the building panel to convert the hydrated core of the deformable portion of the building panel back to the nondeformable calcium sulfate hemihydrate,
wherein the at least one alcohol is selected from the group consisting of methanol, ethanol, propanol, isopropanol, n-butanol, sec-butanol, isobutanol, and tert-butanol.