Abstract: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

Abstract: The present invention is directed to a gypsum panel with enhanced hail resistance and a method of making such gypsum panel. For instance, in one aspect, the gypsum panel comprises a gypsum core and a first facing material and a second facing material, the first facing material and the second facing material sandwiching the gypsum core, the first facing material, the second facing material, or both comprising glass fibers and one or more binders, the glass fibers being bound by the one or more binders. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum and water onto the first facing material, and providing a second facing material on the gypsum slurry.

Abstract: Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

Abstract: Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard comprises a gypsum layer with a gypsum surface having an encasing layer. The encasing layer is partially removed to expose the gypsum surface and form a gypsum surface portion and a first encasing layer portion on the gypsum layer. A sound damping layer is applied to the gypsum layer to cover at least part of the gypsum surface portion and the encasing layer portion.

Abstract: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

Abstract: Provided are cementitious panels that include a cementitious core material and a plurality of sheets of facing material surrounding the cementitious core material, in which at least one of the plurality of sheets of facing material includes a polymeric-film. The polymeric film may include a thermoplastic composition that has a polymeric matrix including one or more polymeric materials. Additionally, the thermoplastic composition may optionally include a filler material. Additionally, provided are methods of manufacturing such cementitious panels.

Abstract: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

Abstract: A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard includes a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a first sound damping layer disposed at the gypsum layer inner surface and having a first sound damping layer inner surface opposite the gypsum layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, a second encasing layer disposed at the first sound damping layer inner surface, and a second sound damping layer disposed at the second encasing layer opposite the first sound damping layer inner surface.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard comprises a gypsum layer with a gypsum surface having an encasing layer. The encasing layer is partially removed to expose the gypsum surface and form a gypsum surface portion and a first encasing layer portion on the gypsum layer. A sound damping layer is applied to the gypsum layer to cover at least part of the gypsum surface portion and the encasing layer portion.

Abstract: A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard includes a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a first sound damping layer disposed at the gypsum layer inner surface and having a first sound damping layer inner surface opposite the gypsum layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, a second encasing layer disposed at the first sound damping layer inner surface, and a second sound damping layer disposed at the second encasing layer opposite the first sound damping layer inner surface.

Abstract: In general, the present invention is directed to the use of particular phosphorus containing compounds for making a glass mat faced gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a glass mat faced gypsum board including a gypsum core that is formed from a gypsum slurry comprising such phosphorus containing compound. The present invention is also directed to a method of making a glass mat faced gypsum board.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard comprises a gypsum layer with a gypsum surface having an encasing layer. The encasing layer is partially removed to expose the gypsum surface and form a gypsum surface portion and a first encasing layer portion on the gypsum layer. A sound damping layer is applied to the gypsum layer to cover at least part of the gypsum surface portion and the encasing layer portion.

Abstract: Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

Abstract: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

Abstract: Provided are cementitious panels that include a cementitious core material and a plurality of sheets of facing material surrounding the cementitious core material, in which at least one of the plurality of sheets of facing material includes a polymeric-film. The polymeric film may include a thermoplastic composition that has a polymeric matrix including one or more polymeric materials. Additionally, the thermoplastic composition may optionally include a filler material. Additionally, provided are methods of manufacturing such cementitious panels.

Abstract: A sound damping wallboard and methods of forming a sound damping wallboard are disclosed. The sound damping wallboard comprises a gypsum layer with a gypsum surface having an encasing layer. The encasing layer is partially removed to expose the gypsum surface and form a gypsum surface portion and a first encasing layer portion on the gypsum layer. A sound damping layer is applied to the gypsum layer to cover at least part of the gypsum surface portion and the encasing layer portion.

Abstract: The present disclosure embraces cementitious panels, and systems and methods of manufacturing cementitious panels. An exemplary cementitious panel includes a cementitious core material, a plurality of sheets of facing material surrounding the cementitious core material, and a radiation-cured adhesive. An exemplary method of manufacturing a cementitious panel includes conveying a slurry of cementitious core material and a plurality of sheets of facing material, applying a radiation-curable adhesive to at least one of the sheets of facing material, forming a continuous length of cementitious panel material, at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, and cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.

Abstract: 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.

Abstract: The present disclosure embraces cementitious panels, and systems and methods of manufacturing cementitious panels. An exemplary cementitious panel includes a cementitious core material, a plurality of sheets of facing material surrounding the cementitious core material, and a radiation-cured adhesive. An exemplary method of manufacturing a cementitious panel includes conveying a slurry of cementitious core material and a plurality of sheets of facing material, applying a radiation-curable adhesive to at least one of the sheets of facing material, forming a continuous length of cementitious panel material, at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, and cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.