Building board with acoustical foam
AssigneeCertainTeed Gypsum, Inc.
InventorsChristopher K. Athari, Thomas J. Garvey, Pamela Shinkoda
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Abstract
Disclosed is a building board construction that provides enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in an continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.
Claims15
A building 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 disposed between the interior faces of the upper and lower mats;
- and
- a plurality of polymer pieces, the polymer pieces distributed within the core slurry layer, each polymer piece containing a plurality of opened cells, the core layer extending around but not penetrating the polymer pieces,
- wherein the plurality of polymer pieces is provided as a plurality of polymer cubes, a granulated polymer, a powdered polymer, or a grated polymer.
Dependencies are inferred from the claim text.