US 12,110,680 B2
Building board with acoustical foam
Christopher K. Athari, St. Petersburg, FL (US); Thomas J. Garvey, Oakville (CA); and Pamela Shinkoda, Oakville (CA)
Assigned to CertainTeed Gypsum, Inc., Malvern, PA (US)
Filed by CertainTeed Gypsum, Inc., Malvern, PA (US)
Filed on Dec. 27, 2022, as Appl. No. 18/089,258.
Application 18/089,258 is a continuation of application No. 16/984,716, filed on Aug. 4, 2020, granted, now 11,536,022.
Application 16/984,716 is a continuation of application No. 16/031,444, filed on Jul. 10, 2018, granted, now 10,731,337, issued on Aug. 4, 2020.
Application 16/984,716 is a continuation of application No. 13/837,109, filed on Mar. 15, 2013, abandoned.
Prior Publication US 2023/0139624 A1, May 4, 2023
Int. Cl. E04B 1/86 (2006.01); B32B 3/26 (2006.01); B32B 5/02 (2006.01); B32B 13/04 (2006.01); B32B 13/08 (2006.01); B32B 13/14 (2006.01); E04B 1/84 (2006.01)
CPC E04B 1/86 (2013.01) [B32B 3/266 (2013.01); B32B 5/022 (2013.01); B32B 13/045 (2013.01); B32B 13/08 (2013.01); B32B 13/14 (2013.01); B32B 2262/10 (2013.01); B32B 2266/0285 (2013.01); B32B 2266/06 (2013.01); B32B 2307/102 (2013.01); B32B 2419/00 (2013.01); E04B 2001/8461 (2013.01); Y10T 442/25 (2015.04)] 15 Claims
OG exemplary drawing
 
1. 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.