The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

An electrically conductive sandwich panel (10) supplies at least one electrical device to be pushed into the panel. The sandwich panel (10) has two electrically conductive layers (13, 15) insulated from each other and a layer (11) formed by a board (12, 14) insulated from said electrical layers. The board has two sheets (111, 112) of cardboard enclosing an electrically insulating material, such as plaster. Connectors are used to connect the electrically conductive layers to a power supply. The panel may be screw-fastened on a support by means of suitable screws and may be fitted with a suitable electrical device. A punch tool facilitates pushing the electrical device into the panel.

This disclosure is directed to a multilayered laminate, comprising (a) a support substrate having at least one releasable major surface; (b) a transparent overcoat formed of a first coating composition on the releasable major surface of the support substrate, wherein the first coating composition comprises an aqueous polymer dispersion having a particle size in the range of 30 to 400 nm; (c) a stone-like topcoat system on the transparent overcoat, wherein the stone-like topcoat system comprises a multicolored spot layer and a background color layer; (d) an adhesive primer coat formed of a second coating composition on the stone-like topcoat system, wherein the second coating composition comprises an aqueous polymer dispersion selected from aqueous acrylic dispersions, aqueous organic silicone dispersions and aqueous vinyl acetate dispersions, wherein the transparent overcoat in the multilayered laminate, when released from the support substrate, a gloss of at least 60% at 60.

Embodiments of a system and a method for manufacturing a gypsum board can be used to produce a gypsum board having at least one perforated cover sheet via a cover sheet perforator system. The cover sheet perforator system can include a perforator roller is disposed downstream of a forming station along a machine direction, a roller support frame for rotatably supporting the perforator roller such that its rotational axis extends along the cross-machine direction, and a motor arranged with the perforator roller to rotate the perforator roller about the rotational axis. The drive motor can be adapted to rotate the perforator roller with a tangential speed substantially equal to the line speed to produce a series of perforation holes in an upwardly-facing cover sheet as the gypsum board moves past the perforator roller.

A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard includes a gypsum layer having a first side with a first gypsum surface, a first encasing layer at least partially covering the first gypsum surface to form a first encasing layer portion, and a sound damping layer on the first side covering at least part of the first encasing layer portion.

The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

The present invention is directed to a gypsum panel with an enhanced gypsum core to facing material bond and a method of making such gypsum panel. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. The first facing material and/or the second facing material having a nucleating composition applied to a surface thereof. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry onto the first facing material, providing a second facing material on the gypsum slurry, and providing a nucleating composition on the first facing material before depositing the gypsum slurry onto the first facing material, on the gypsum slurry before providing the second facing material on the gypsum slurry, on the second facing material before providing the second facing material on the gypsum slurry, or a combination thereof.

A building board, particularly a gypsum board, can have a high fastener sealability if protected by the combination of thin layers of an extruded polymer film and a thermoplastic coating layer. The combination of extruded polymer film and thermoplastic coating layer is designed such that the gypsum board can also tolerate overdriven fasteners, thus exceeding the requirements of ASTM D1970-15.

The tape incudes a water vapor-permeable air and water barrier article and a pressure sensitive adhesive layer. The air and water barrier article includes a fibrous layer having first and second major surfaces and a polymeric layer on a first major surface of the fibrous layer that penetrates into the fibrous layer but leaves at least some fibers exposed on the second major surface. The pressure sensitive adhesive layer is on the polymeric layer of the air and water barrier article. The tape can retain greater than 50 percent by weight of mortar applied according to the Vertical Mortar Receptivity Evaluation. The article includes a substrate, the tape, and a composite layer comprising at least one of gypsum, lime, or cement. The composite layer is at least one of dried or cured on the second major surface of the fibrous layer. Methods of making the article are also described.

A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard includes a gypsum layer having a first side with a first gypsum surface, a first encasing layer at least partially covering the first gypsum surface to form a first encasing layer portion, and a sound damping layer on the first side covering at least part of the first encasing layer portion.