Building Board with Acoustical Foam
AssigneeCertainTeed Gypsum, Inc.
InventorsThomas J. Garvey, Christopher K. Athari, 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.
Claims21
1-12. (canceled)
A method for making a composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:
- opposed upper and lower mats, the paper sheets 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 roll;
- providing the lower mat;
- on the lower mat, forming a core slurry layer, the polymer sheet being dispensed from the roll thereof and positioned centrally within the core slurry layer;
- providing the upper mat;
- disposing the upper mat on the core slurry layer;
- and
- causing the core slurry layer to set.
A method for making a composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:
- opposed upper and lower mats, the paper sheets having interior and exterior faces;
- a core layer of set gypsum having a thickness extending between the upper and lower mats;
- and
- a plurality of individual polymer pieces made of open-celled foam, the polymer pieces disposed within the core layer, the set gypsum of the core layer extending around the polymer pieces, the polymer pieces having sound-absorbing characteristics,
- the method comprising
- providing the lower mat;
- on the lower mat, separately dispensing the core slurry and the plurality of individual polymer pieces in order to form a core slurry layer having the plurality of individual polymer pieces disposed therewithin, the core slurry layer extending around the polymer pieces;
- providing the upper mat;
- disposing the upper mat on the core slurry layer;
- and
- causing the core slurry layer to set.
Dependencies are inferred from the claim text.