Building Board with Acoustical Foam

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 set gypsum body, extending between the upper and lower mats, the set gypsum body comprising a core layer of gypsum having a thickness;
• and
• a sheet of material positioned between the first mat and the core layer of set gypsum;
• the method comprising
• continuously providing the first mat, the sheet of material, and the second mat and the onto a forming table, wherein the sheet of material is provided between the first mat, and the second mat, and moving the first mat, the sheet of material and the second mat along the forming table in a first direction, while
• continuously forming a body of gypsum slurry between the first mat and the second mat while continuously disposing the sheet of material within the body of gypsum slurry;
• and then
• 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 opposed upper and lower mats having interior and exterior faces;
• a set gypsum body extending between the upper and lower mats, the set gypsum body comprising a core layer of gypsum having a thickness;
• and
• a sheet of material positioned within the core layer such that the set gypsum body contacts both upper and lower surfaces of the polymer sheet, the sheet having a thickness less than the thickness of the core layer;
• the method comprising
• providing the sheet of material wound on a first roll;
• providing the lower mat wound on a second roll;
• providing the upper mat wound on a third 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;
• continuously unwinding the upper mat from the third roll and moving the upper mat along the forming table in the first direction;
• and
• continuously forming a body of gypsum slurry on the lower mat while continuously unwinding the sheet of material from the first roll and disposing it within the and disposing the upper mat on top of the body of gypsum slurry;
• and then
• causing the body of gypsum slurry to set.

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 set gypsum layer extending between the upper and lower mats;
• and
• a polymer layer positioned between the upper and lower mats within the set gypsum layer;
• the method comprising
• continuously providing the first mat, the polymer layer, and the second mat onto a forming table, wherein the polymer layer is provided between the first mat and the second mat, and moving the first mat, the polymer layer and the second mat along the forming table in a first direction, while
• continuously forming a body of gypsum slurry between the first mat and the second mat, thereby continuously disposing the polymer layer between the first mat and the second mat;
• and then
• causing the core slurry layer to set.