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 method for making a composite, multi-layered building panel, the panel comprising:
- opposed first and second mats, the opposed first and second 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 between the first mat and the core layer of set gypsum;
- the method comprising
- providing the polymer sheet;
- providing the first mat;
- continuously providing the first mat and the polymer sheet onto a forming table, wherein the polymer sheet is provided on top of the first mat, and moving the first mat and polymer sheet along the forming table in a first direction;
- in a first zone continuously forming a core slurry layer on the polymer sheet, thereby continuously disposing the polymer sheet between the first mat and the core slurry layer;
- continuously providing the second mat and disposing the second mat on the core slurry layer;
- and
- after disposing the upper mat thereon, causing the core slurry layer to set.
Dependencies are inferred from the claim text.