Abstract: The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material. 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, water, and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material, onto the first facing material, and providing a second facing material on the gypsum slurry.

Abstract: The present invention is directed to a gypsum board and a method of making such gypsum board. In one embodiment, the gypsum board comprises a gypsum core including a first gypsum core layer and a second gypsum core layer sandwiching a laminate layer. The laminate layer comprises two outer laminate layers sandwiching an inner laminate layer, wherein the two outer laminate layers have a higher elastic modulus than the inner laminate layer. The method of making the gypsum board includes steps of providing facing materials and corresponding gypsum slurries wherein the laminate layer is provided in-line during the manufacturing process of the gypsum board.