Polyester Laminated Building Boards With Improved Surface Characteristics

A composite, multi-layered building panel comprising:

• opposed upper and lower fiber mats, the mats being porous and each mat having an interior and an exterior surface;
• a set gypsum core extending between and bonded to the interior surfaces of the upper and lower fiber mats, the portion of the set gypsum core proximate the upper and lower fiber mats having a density that is greater than the remainder of the set gypsum core;
• a polyethylene terephthalate (PET) film having an interior and an exterior surface;
• a polymer adhesive adhering the interior surface of the PET film to the exterior surface of the upper fiber mat, whereby the PET film is bonded to the upper fiber mat;
• and
• an acrylic coating applied to the exterior surface of the PET film, the acrylic coating providing a surface finish to the composite, multi-layered building panel;
• wherein the polymer adhesive forms a smooth outer stratum on the upper and lower fiber mats, the outer stratum being substantially free of the fibers that make up the upper and lower fiber mats.