Building board with acoustical foam

A method for making a composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:

• opposed upper and lower mats, the opposed upper and lower mats having interior and exterior faces;
• a core layer of set gypsum having a thickness extending between the upper and lower mats;
• and
• a polymer sheet positioned within the core layer such that the set gypsum of the core layer contacts both upper and lower surfaces of the polymer sheet, the polymer sheet having a thickness less than the thickness of the core layer, the polymer sheet having sound-absorbing characteristics;
• the method comprising
• providing the polymer sheet wound on a first roll;
• providing the lower mat wound on a second roll;
• continuously unwinding the lower mat from the second roll onto a forming table and moving the lower mat along the forming table in a first direction;
• in a first zone continuously forming a core slurry layer on the lower mat and continuously unwinding the polymer sheet from the first roll thereof and continuously disposing the polymer sheet centrally within the core slurry layer;
• providing the upper mat wound on a third roll;
• continuously unwinding the upper mat from the third roll and disposing the upper mat on the core slurry layer having the polymer sheet disposed within;
• and
• after disposing the upper mat thereon, causing the core slurry layer to set.