Building covering system incorporating a building panel, and methods of forming and installing the same

Patent metadata

Field	Value
Publication number	US-12404679-B2
Application number	US-202217894562-A
Country	US
Kind code	B2
Filing date	Aug 24, 2022
Priority date	Aug 26, 2021
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

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.

First claim

What is claimed is:

1. A building system comprising:
a plurality of support members located in a plenary space of an interior building space, each support member comprising a support surface;
a plurality of first building panels located below the plenary space and secured directly to the support surface of the plurality of support members, each of the plurality of first building panels comprising a non-porous body, each of the first building panels comprising a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface; and
a plurality of second building panels secured directly 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, each of the second building panels comprising a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface;
wherein the second major surface of the plurality of first building panels faces the support surface of the plurality of support members; and
wherein the second major surface of the plurality of the second building panels faces the first major surface of the plurality of first building panels.

2. The building system according to claim 1 , wherein the plurality of first mechanical fasteners each comprise a head and a threaded body, and wherein the threaded body of one of the plurality of first mechanical fasteners extends through at least a portion of the porous body of one of the plurality of second building panels and at least a portion the non-porous body of one of the plurality of first building panels, wherein the head of at least one of the plurality of first mechanical fasteners is located between the first major surface and the second major surface of the plurality of second building panels.

3. The building system according claim 1 , wherein a first interface exists between the second major surface of the plurality of first building panels and the support surface of the plurality of support members and a second interface exists between the second major surface of the plurality of second building panels and the first major surface of the plurality of first building panels, wherein the adhesive is present in the second interface, and wherein the first interface is substantially free of the adhesive.

4. The building system according to claim 3 , wherein the threaded body of the plurality of first mechanical fasteners extends through the second interface, and wherein the threaded body of at least one of the plurality of first mechanical fasteners does not extend through the first interface.

5. The building system according to claim 1 , wherein the non-porous body comprises dry-wall, gypsum board, plywood, particle board, and combinations thereof, wherein the porous body is formed of a fibrous material, wherein the fibrous material is an inorganic fiber, and wherein the inorganic fiber is selected from the group consisting of mineral wool, rock wool, stone wool, and glass fibers.

6. The building system according to claim 1 , wherein the non-porous body has a first body density and the porous body has a second body density, wherein the first body density and the second body density are not equal, wherein the first body density ranges from about 16 lb./ft 3 to about 180 lb./ft 3 , wherein the second body density ranges from about 2 lb./ft 3 to about 16 lb./ft 3 , and wherein a ratio of the first body density to second body density ranges from about 1.5:1 to about 10:1.

7. The building system according to claim 1 , further comprising a plurality of second mechanical fasteners that each comprise a head and a threaded body, and wherein the threaded body of the plurality of second mechanical fasteners extends through at least a portion of the non-porous body of one of the plurality of first building panels and the support surface of one of the plurality of support members, wherein the side surface of the first building panel defines a perimeter of the first building panel, and wherein the plurality of first mechanical fasteners are present within the perimeter of one of the second building panels in first fastener density and the plurality of second mechanical fasteners are present within the perimeter of one of the first building panels in a second fastener density, wherein the first fastener density and the second fastener density are not equal.

8. The building system according to claim 7 , wherein the second fastener density is greater than the first fastener density, wherein the first fastener density ranges from about 0.2 fasteners/ft 2 to about 0.75 fasteners/ft 2 , wherein a ratio of the second fastener density to first fastener density ranges from about 1.1:1 to about 10:1.

9. The building system according to claim 1 , wherein each of the plurality of first building panels has a first thickness as measured between the first major surface and the second major surface of the first building panels, and each of the plurality of second building panels has a second thickness as measured between the first major surface and the second major surface of the second building panels, and wherein the first thickness and the second thickness are not equal.

10. The building system according to claim 9 , wherein the first thickness ranges from about 0.3 inches to about 0.75 inches, wherein the second thickness ranges from about 0.4 inches to about 1.6 niches, wherein a ratio of the second thickness to the first thickness ranges from about 3.0:1 to about 1.25:1, wherein each of the plurality of first mechanical fasteners has a first fastener length, and wherein a ratio of first fastener length to second thickness ranges from about 1.25:1 to about 2.5:1.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Kragness Eric D
• Cavanaugh Jason T

Classifications

• E04F13/0885

  specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application · CPC title

• E04F13/16

  of fibres or chips, e.g. bonded with synthetic resins {, or with an outer layer of fibres or chips (E04F13/0864 takes precedence)} · CPC title

• E04F13/0803

  with load-supporting elongated furring elements between wall and covering elements · CPC title

• E04F13/0866 Primary

  composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence) · CPC title