Building board with acoustical foam

Patent metadata

Field	Value
Publication number	US-10731337-B2
Application number	US-201816031444-A
Country	US
Kind code	B2
Filing date	Jul 10, 2018
Priority date	Mar 15, 2013
Publication date	Aug 4, 2020
Grant date	Aug 4, 2020

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.

First claim

What is claimed is:

1. 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 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 first roll;
providing the lower mat wound on a second 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;
in a first zone continuously forming a core slurry layer on the lower mat and continuously unwinding the polymer sheet from the first roll thereof and continuously disposing the polymer sheet centrally within the core slurry layer;
providing the upper mat wound on a third roll;
continuously unwinding the upper mat from the third roll and disposing the upper mat on the core slurry layer having the polymer sheet disposed within; and
after disposing the upper mat thereon, causing the core slurry layer to set.

2. The method according to claim 1 , wherein the core layer of set gypsum extends through the polymer sheet.

3. The method according to claim 1 , wherein a series of apertures is formed through the thickness of the polymer sheet, the core layer extending through the apertures to allow the polymer sheet to bond to the core layer.

4. The method according to claim 1 , wherein the polymer sheet is formed from a thermoset polymer.

5. The method according to claim 1 , wherein the polymer sheet is formed from a melamine resin.

6. The method according to claim 5 , wherein the polymer sheet has an open cell structure, the open cell structure enhancing the sound-absorbing characteristic of the building panel.

7. The method according to claim 1 , wherein the polymer sheet has an open cell structure, the open cell structure enhancing the sound-absorbing characteristic of the building panel.

8. The method according to claim 1 , wherein the composite building panel further comprises an upper layer of a set slurry coating the upper mat, and a lower layers of a set slurry coating the lower mat, wherein the upper and lower layers of set slurry have a greater density than the core layer, and wherein
the lower mat is provided with dense slurry layer formed thereon;
the core slurry layer continuously is formed on the dense slurry layer of the lower mat;
the upper mat is provided with a dense slurry layer formed thereon; and
the upper mat is continuously disposed on the core slurry layer with the dense slurry layer thereof against the core slurry layer.

9. The method according to claim 8 , wherein the set gypsum of the core layer extends from the upper set slurry coating layer to the lower set slurry coating layer.

10. The method according to claim 8 , wherein the upper and lower mats are porous mats formed from non-woven, randomly aligned inorganic fibers, wherein the upper and lower set slurry coating layers penetrate the upper and lower mats.

11. The method according to in claim 1 , wherein the set gypsum of the core layer extends continuously from the upper mat to the lower mat.

12. The method according to claim 1 , wherein the upper and lower mats are porous mats formed from non-woven, randomly aligned inorganic fibers.

13. The method according to claim 1 , wherein the upper and lower mats are paper sheets.

Assignees

• Certainteed Gypsum Inc

Inventors

• Garvey Thomas J
• Athari Christopher K
• Shinkoda Pamela

Classifications

• E04C2/288 Primary

  composed of insulating material and concrete, stone or stone-like material · CPC title

• E04C2/2885

  with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous · CPC title

• B32B2307/102

  Insulating · CPC title

• B32B3/266

  characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12 · CPC title

• E04B1/86 Primary

  slab-shaped · CPC title