US 11,851,874 B2
Interlocking gypsum building surface products, methods of manufacture, and interlocking gypsum building surface systems
Robert L. Jenkins, Honey Brook, PA (US); Garrett Loomis, Newton, MA (US); Kim Dupont-Madinier, Somerville, MA (US); Brock Jacobites, Northboro, MA (US); David Knutson, Lunenburg, MA (US); James Dimitrakopoulos, Conshohocken, PA (US); Stephen W. Reynolds, Malvern, PA (US); Douglas J. Wambaugh, Bend, OR (US); Rachel Z. Pytel, Newton, MA (US); and Dennis Michaud, Groton, MA (US)
Assigned to CertainTeed Gypsum, Inc., Malvern, PA (US)
Filed by CertainTeed Gypsum, Inc., Malvern, PA (US)
Filed on Jul. 17, 2020, as Appl. No. 16/931,978.
Claims priority of provisional application 63/037,485, filed on Jun. 10, 2020.
Claims priority of provisional application 62/875,238, filed on Jul. 17, 2019.
Prior Publication US 2021/0017764 A1, Jan. 21, 2021
Int. Cl. E04C 2/04 (2006.01); C04B 14/38 (2006.01); C04B 28/14 (2006.01); C04B 111/00 (2006.01)
CPC E04C 2/043 (2013.01) [C04B 14/38 (2013.01); C04B 28/14 (2013.01); C04B 2111/0062 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A building surface system comprising:
a support structure;
a plurality of second press-on connectors disposed on a front side of the support structure, and
a plurality of building surface products secured to the support structure and arranged so as to provide a building surface, each building surface product of the plurality comprising:
a substantially planar gypsum panel having a first edge, a second edge, and two ends, wherein the gypsum panel includes:
a body comprising a front face, a rear face, and a thickness between the front face and the rear face, and
a first lapping projection extending outward from the body at the second edge, the first lapping projection being configured to overlap a portion of a neighboring gypsum panel so as to form a building surface; and
a first press-on connector disposed on the rear face of the body toward the first edge of the gypsum panel, the press-on connector being configured to engage a corresponding second press-on connector,
wherein the first press-on connector of each building surface product is coupled to at least one of the second press-on connectors,
wherein the first edge of the gypsum panel of each building surface product overlaps the first lapping projection of a neighboring building surface product, and
wherein in each building surface product of the plurality the first edge includes a folded gypsum edge that is a flat fold including a first folded section adhered to the body of the gypsum panel along an angled slit, and wherein the body of the gypsum panel and the first folded section are covered by a continuous facing sheet.