CN203957095U - Slurry distributor and cementing slurry mixed distribution assembly - Google Patents

Abstract

A kind of slurry distributor and a kind of cementing slurry mixed distribution assembly, described slurry distributor can comprise distribution conduit and slurry Wiping mechanism.Distribution conduit roughly along longitudinal axis extend and comprise the portion of entering, with described in enter distribution outlets that portion's fluid is communicated with and in the described bottom surface of extending between portion and described distribution outlets that enters, described distribution outlets extends preset distance along transversal line, and described transversal line is substantially vertical with described longitudinal axis.Slurry Wiping mechanism comprises movable wiper blade, described movable wiper blade becomes contact relation with the described bottom surface of described distribution conduit, described wiper blade can removed on path and reciprocally move between primary importance and the second place, described removing path layout adjacent with described distribution outlets.Scheme of the present utility model can realize the wider distribution of even gypsum slurry and can help to control and be separated such as the air-liquid state in resistance aqueous foam gypsum slurry.

Description

Slurry distributor and cemented slurry mixing and distributing assembly

Cross Reference to Related Applications

This patent application claims the benefit of non-provisional patent application 13/659,516 entitled "road Distributor, System, and Method for Using Same" filed 24/10/2012 and continuation patent application 13/844,364 filed 15/3/15/2013.

All of the foregoing related applications are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to continuous board (e.g., wallboard) manufacturing processes, and more particularly to apparatus, systems, and methods for distribution of aqueous calcined gypsum slurry.

Background

It is well known to make gypsum board by uniformly diffusing calcined gypsum (commonly referred to as "stucco") into water to form an aqueous calcined gypsum slurry. Typically, an aqueous calcined gypsum slurry is made in a continuous manner by placing stucco and water, as well as other additives, in a mixer that includes a device for stirring the contents to form a uniform gypsum slurry. The slurry is continuously directed toward and through the discharge outlet of the mixer and into a discharge conduit connected to the discharge outlet of the mixer. The aqueous foam can be combined with the aqueous calcined gypsum slurry in the mixer and/or in the discharge conduit. The slurry stream passes through a discharge conduit from which the slurry stream is continuously deposited onto a moving web of cover sheet supported by the forming table. The slurry is allowed to spread over the advancing web. A second sheet of cover web is applied to cover the slurry and form a sandwich structure of the continuous wallboard preform, which is shaped, such as at a conventional forming station, to achieve a desired thickness. The calcined gypsum reacts with water in the wallboard preform and sets as the wallboard preform moves down the manufacturing line. The wallboard preform is cut into sections at a point along the line where the wallboard preform has sufficiently solidified, the sections are flipped over, dried (e.g., in a roaster) to drive off excess water, and processed to provide a wallboard finished product of a desired size.

Prior devices and methods for addressing some of the operational problems associated with the production of gypsum wallboard are disclosed in commonly assigned U.S. patent nos. 5,683,635, 5,643,510, 6,494,609, 6,874,930, 7,007,914 and 7,296,919, which are incorporated herein by reference.

In the art, the weight proportion of water relative to stucco combined to form a given amount of finished product is commonly referred to as "water stucco ratio" (WSR). A reduction in WSR with a constant formulation will correspondingly increase the viscosity of the slurry, thereby reducing the ability of the slurry to spread on the forming table. Reducing the use of water (e.g., reducing WSR) in the gypsum board manufacturing process can yield a number of advantages, including the potential for reducing the energy requirements of the process. However, spreading the gypsum slurry uniformly on the forming table at a desired viscosity remains a significant challenge.

Further, in some cases where the slurry is a multi-phase slurry containing air, air-liquid slurry separation may occur in the slurry discharge conduit of the mixer. As the WSR decreases, the air volume increases to maintain the same dry density. The degree of separation of the air phase from the liquid slurry phase increases, resulting in a tendency to larger mass or density variations.

It will be appreciated that this background description is made by the utility model to assist the reader and should not be taken as an indication that any of the problems noted are themselves recognized in the art. While the described principles are capable of alleviating problems inherent in other systems in some aspects and embodiments, it should be understood that the scope of the invention is defined by the appended claims rather than by the ability of any disclosed feature to solve any specific problem mentioned herein.

SUMMERY OF THE UTILITY MODEL

In one aspect, the present disclosure is directed to embodiments of a slurry distribution system for use in making gypsum products. In one embodiment, a slurry distributor may include a feed conduit and a distribution conduit in fluid communication with the feed conduit. The feed conduit may include a first feed inlet in fluid communication with the distribution conduit and a second feed inlet disposed in spaced relation to the first feed inlet and in fluid communication with the distribution conduit. The distribution conduit can extend generally along a longitudinal axis and include an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis substantially perpendicular to the longitudinal axis.

In other embodiments, the slurry distributor comprises a feed conduit and a distribution conduit. The feed conduit includes a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The first and second feed inlets each have an opening with a cross-sectional area. The inlet portion of the distribution conduit has an opening with a cross-sectional area larger than the sum of the cross-sectional areas of the openings of the first and second feed inlets.

In other embodiments, a slurry distributor includes a feed conduit, a distribution conduit, and at least one support section. The feed conduit includes a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. Each support segment is movable over a stroke to bring the support segment into a series of positions in which the support segment is in increasing compressive engagement with portions of at least one of the feed conduit and the distribution conduit.

In another aspect of the disclosure, the slurry distributor can be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. In one embodiment, the present disclosure describes a gypsum slurry mixing distribution assembly including a gypsum slurry mixer adapted to mix with calcined gypsum to form an aqueous calcined gypsum slurry. The slurry distributor is in fluid communication with the gypsum slurry mixer and is adapted to receive the first and second flows of aqueous calcined gypsum slurry from the gypsum slurry mixer and distribute the first and second flows of aqueous calcined gypsum slurry onto the advancing web.

The slurry distributor includes: a first feed inlet adapted to receive a first stream of aqueous calcined gypsum slurry from a gypsum slurry mixer; a second feed inlet adapted to receive a second stream of aqueous calcined gypsum slurry from the gypsum slurry mixer; and a distribution outlet in fluid communication with both the first and second feed inlets and adapted such that the first and second flows of aqueous calcined gypsum slurry are discharged from the slurry distributor through the distribution outlet.

In another embodiment, a slurry distributor includes a feed conduit and a distribution conduit. The feed conduit includes an entry section having a feed inlet and a feed entry outlet in fluid communication with the feed inlet. The entry section extends along a first feed flow axis. The feed conduit includes a shaped pipe having a bulbous portion in fluid communication with the feed inlet outlet of the entry segment. The feed conduit includes a transition segment in fluid communication with the bulb. The transition section extends along a second feed flow axis in non-parallel relationship with the first feed flow axis.

The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the feed inlet of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

The bulbous portion has an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a flow direction from the feed inlet toward the distribution outlet of the distribution conduit. The shaped duct has a convex inner surface in facing relationship with the feed inlet outlet of the entry segment.

In yet another embodiment, a slurry distributor includes a bifurcated feed conduit and a distribution conduit. The bifurcated feed conduit includes: first and second feed portions each having an entry section with a feed inlet and a feed entry outlet in fluid communication with the feed inlet; a shaped duct having a bulbous portion in fluid communication with a feed inlet outlet of the intake section; and a transition section in fluid communication with the bulb. The entry section extends generally along a vertical axis. The transition section extends along a longitudinal axis perpendicular to the vertical axis.

The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

The first and second bulbs each have an expanded region having a cross-sectional flow area greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a direction of flow from the respective first and second feed inlets toward the distribution outlet of the distribution conduit. The first and second shaped conduits each have a convex inner surface in facing relationship with the respective first and second feed inlet outlets of the first and second inlet sections.

In another embodiment, a slurry distributor includes a distribution conduit and a slurry wiping mechanism. The distribution conduit extends generally along a longitudinal axis, the distribution outlet is in fluid communication with the inlet portion, and the floor extends between the inlet portion and the distribution outlet. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The slurry wiping mechanism includes a movable wiping blade in contacting relationship with the bottom surface of the distribution conduit. The wiper blade is reciprocally movable in a cleaning path between a first position and a second position. The clearing path is disposed adjacent to the distribution outlet.

In yet another embodiment, a slurry distributor includes a distribution conduit and a forming mechanism. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The distribution outlet includes an outlet opening having a width along a transverse axis and a height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis.

The shaping mechanism includes a shaping member in contacting relationship with the distribution conduit. The shaping member is movable in the stroke to bring the shaping member into a series of positions in which the shaping member is in increasing compressive engagement with a portion of the distribution conduit adjacent the distribution outlet to change the shape and/or size of the outlet opening.

In another aspect of the present disclosure, a slurry distributor may be used in a cementitious slurry mixing and distribution assembly. For example, a slurry distributor can be used to distribute an aqueous calcined gypsum slurry onto an advancing web. In other embodiments, a gypsum slurry mixing and distribution assembly includes a mixer and a slurry distributor in fluid communication with the mixer. The mixer is adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. The slurry distributor includes a feed conduit and a distribution conduit.

The feed conduit includes a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet. The first feed inlet is adapted to receive a first stream of aqueous calcined gypsum slurry from the gypsum slurry mixer. The second feed inlet is adapted to receive a second stream of aqueous calcined gypsum slurry from the gypsum slurry mixer.

The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. A distribution outlet is in fluid communication with both the first and second feed inlets and is adapted to cause the first and second flows of aqueous calcined gypsum slurry to be discharged from the slurry distributor through the distribution outlet.

The first and second feed inlets each have an opening with a cross-sectional area. The entrance portion of the distribution conduit has an opening with a cross-sectional area larger than the sum of the cross-sectional areas of the openings of the first and second feed inlets.

The cementitious slurry mixing and distribution assembly comprises: a mixer adapted to agitate water and cementitious binder to form an aqueous cementitious slurry; and a slurry distributor in fluid communication with the mixer. The slurry distributor may be any of various embodiments of slurry distributors consistent with the principles of the present disclosure.

In yet another aspect of the present disclosure, the slurry distribution system can be used in a method of making a cementitious product. For example, a slurry distributor can be used to distribute an aqueous calcined gypsum slurry onto an advancing web.

In some embodiments, the method of distributing an aqueous calcined gypsum slurry onto a moving web can be performed using a slurry distributor constructed according to the principles of the present disclosure. The first and second flows of aqueous calcined gypsum slurry pass through the first and second feed inlets, respectively, of the slurry distributor. The first and second aqueous calcined gypsum slurry streams are combined in a slurry distributor. The first and second flows of aqueous calcined gypsum slurry are discharged from the distribution outlet of the slurry distributor on the moving web.

In other embodiments, methods of preparing gypsum products can be performed using a slurry distributor constructed according to the principles of the present disclosure. A first stream of aqueous calcined gypsum slurry is passed through a first feed inlet of a slurry distributor at an average first feed speed. A second stream of the aqueous calcined gypsum slurry is passed through a second feed inlet of the slurry distributor at an average second feed speed. The second feed inlet is in spaced relationship to the first feed inlet. The first and second aqueous calcined gypsum slurry streams are combined in a slurry distributor. The combined first and second flows of aqueous calcined gypsum slurry are discharged from the distribution outlet of the slurry distributor at an average discharge velocity onto a cover web sheet moving in the machine direction. The average discharge velocity is less than the average first feed velocity and the average second feed velocity.

In another embodiment, a method of making a cementitious product can be performed using a slurry distributor constructed according to the principles of the present disclosure. A stream of aqueous cementitious slurry is discharged from the mixer. A flow of aqueous cementitious slurry is passed through a feed inlet of a slurry distributor along a first feed flow axis at an average feed velocity. The aqueous cementitious slurry stream is passed into the bulb of the slurry distributor. The bulbous portion has an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region with respect to a direction of flow from the feed inlet. The bulbous portion is configured to reduce the average velocity of the flow of aqueous cementitious slurry moving from the feed inlet through the bulbous portion. The shaped pipe has a convex inner surface in facing relationship with the first feed flow axis to move the flow of aqueous cementitious slurry in a radial flow in a plane substantially perpendicular to the first feed flow axis. The flow of aqueous cementitious slurry is passed into a transition section extending along a second feedstream axis in a non-parallel relationship to the first feedstream axis. The aqueous cementitious slurry stream is delivered into a distribution conduit. The distribution conduit includes a distribution outlet extending a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

In another embodiment, a method of making a cementitious product includes discharging a stream of aqueous cementitious slurry from a mixer. A flow of aqueous cementitious slurry is passed through an entry portion of a distribution conduit of a slurry distributor. A stream of aqueous cementitious slurry is discharged from a distribution outlet of the slurry distributor onto a cover web sheet moving in the machine direction. The wiping sheet is reciprocally movable along the bottom surface of the distribution conduit between a first position and a second position on a removal path to remove aqueous cementitious slurry therefrom. A purge path is disposed adjacent the distribution outlet.

In yet another embodiment, a method of making a cementitious product comprises: a stream of aqueous cementitious slurry is discharged from the mixer. A flow of aqueous cementitious slurry is passed through an entry portion of a distribution conduit of a slurry distributor. The flow of aqueous cementitious slurry is discharged from the outlet opening of the distribution outlet of the slurry distributor onto a cover web sheet moving in the machine direction. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The outlet opening has a width along a transverse axis and a height along a vertical axis that is relatively perpendicular to the longitudinal axis and the transverse axis. Portions of the distribution conduit adjacent the distribution outlet are compressibly engaged to change the shape and/or size of the outlet opening.

Also disclosed herein are embodiments of a mold used in a method of making a slurry distributor according to the principles of the present disclosure. Also disclosed herein are embodiments of a support for a slurry distributor according to the principles of the present disclosure.

Further and alternative aspects and features of the disclosed principles will be understood from the following detailed description and the accompanying drawings. It will be understood that the slurry distribution system disclosed herein is capable of implementation and use in other and different embodiments, and is capable of modification in various respects. Accordingly, it is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the scope of the appended claims.

Drawings

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the office upon request and payment of the necessary fee.

Fig. 1 is a perspective view of an embodiment of a slurry distributor constructed according to the principles of the present disclosure.

Fig. 2 is a perspective view of the slurry distributor of fig. 1 and an embodiment of a slurry distributor support constructed in accordance with the principles of the present disclosure.

Fig. 3 is a front elevational view of the slurry distributor of fig. 1 and the slurry distributor support of fig. 2.

Fig. 4 is a perspective view of an embodiment of a slurry distributor constructed in accordance with the principles of the present disclosure, which defines an internal geometry similar to that of fig. 1, but constructed of a rigid material and having a two-piece construction.

Fig. 5 is another perspective view of the slurry distributor of fig. 4, but with the forming system removed for illustrative purposes.

Fig. 6 is an isometric view of another embodiment of a slurry distributor constructed in accordance with the principles of the present disclosure, including a first feed inlet and a second feed inlet arranged at a feed angle of about sixty degrees with respect to the longitudinal axis or machine direction of the slurry distributor.

Fig. 7 is a top plan view of the slurry distributor of fig. 6.

Fig. 8 is a rear elevation view of the slurry distributor of fig. 6.

Fig. 9 is a top plan view of a first piece of the slurry distributor of fig. 6 having a two-piece construction.

Fig. 10 is a front perspective view of the slurry distribution device of fig. 9.

Fig. 11 is an exploded view of the slurry distributor of fig. 6 and a support system of the slurry distributor constructed in accordance with the principles of the present disclosure.

Fig. 12 is a perspective view of the slurry distributor and support system of fig. 11.

Fig. 13 is an exploded view of another embodiment of the slurry distributor of fig. 6 and a support system constructed in accordance with the principles of the present disclosure.

Fig. 14 is a perspective view of the slurry distributor and support system of fig. 13.

Fig. 15 is a perspective view of an embodiment of a slurry distributor constructed in accordance with the principles of the present disclosure, which defines an internal geometry similar to that of fig. 6, but constructed of a rigid material and having a unitary construction.

Fig. 16 is a top plan view of the slurry distributor of fig. 15.

Fig. 17 is an enlarged perspective view of the internal geometry defined by the slurry distributor of fig. 15, illustrating the progressive cross-sectional flow area of portions of the feed conduits of the slurry distributor.

Fig. 18 is an enlarged perspective view of the internal geometry of the slurry distributor of fig. 15, showing another progressive cross-sectional flow area of the feed conduit.

Fig. 19 is an enlarged perspective view of the internal geometry of the slurry distributor of fig. 15, showing yet another progressive cross-sectional flow area of the feed conduit aligned with one-half of the entry portion of the distribution conduit of the slurry distributor of fig. 15.

Fig. 20 is a perspective view of another embodiment of the slurry distributor of fig. 15 and a support system constructed in accordance with the principles of the present disclosure.

Fig. 21 is a perspective view of fig. 20 but with the support frame removed for exemplary purposes to show a plurality of retention plates in a distributing relationship with the slurry distributor of fig. 15.

Fig. 22 is a front perspective view of another embodiment of a slurry distributor and another embodiment of a support system constructed in accordance with the principles of the present disclosure.

Fig. 23 is a rear perspective view of the slurry distributor and support system of fig. 22.

Fig. 24 is a top plan view of the slurry distributor and support system of fig. 22.

Fig. 25 is a side elevational view of the slurry distributor and support system of fig. 22.

Fig. 26 is a front elevational view of the slurry distributor and support system of fig. 22.

Fig. 27 is a rear elevation view of the slurry distributor and support system of fig. 22.

Fig. 28 is an enlarged detailed view of a distal portion of a slurry distributor illustrating an embodiment of a slurry wiping mechanism constructed in accordance with the principles of the present disclosure.

Fig. 29 is a perspective view of a forming mechanism constructed in accordance with the principles of the present disclosure and used in the slurry distributor of fig. 22.

FIG. 30 is a front elevational view of the forming mechanism of FIG. 29.

FIG. 30A is a view as in FIG. 30 showing the forming members of the forming mechanism in a compressed position.

Fig. 30B is a view as in fig. 30, showing the forming members of the forming mechanism in a pivoted position.

Fig. 30C is an enlarged detailed exploded view of the forming member showing the connection technique between the translating bar and the forming section.

Fig. 31 is a side elevational view of the forming mechanism of fig. 29.

Fig. 32 is a top plan view of the forming mechanism of fig. 29.

Fig. 33 is a bottom elevation view of the forming mechanism of fig. 29.

Fig. 34 is a top plan view of the slurry distributor and support system of fig. 22 with the support frame removed for illustrative purposes.

Fig. 35 is an enlarged detailed view taken from the side of the bulbous portion of the slurry distributor of fig. 22.

Fig. 36 is a perspective view of a pair of rigid support inserts resting on the bottom support member of the support system of fig. 22.

Fig. 37 is a side elevational view of the rigid support insert of fig. 36.

Fig. 38 is a front elevational view of the rigid support insert of fig. 36.

Fig. 39 is a rear elevational view of the rigid support insert of fig. 36.

Fig. 40 is a front elevational view of the slurry distributor of fig. 22.

Fig. 41 is a rear elevation view of the slurry distributor of fig. 22.

Fig. 42 is a bottom perspective view of the slurry distributor of fig. 22.

Fig. 43 is a bottom plan view of the slurry distributor of fig. 22.

Fig. 44 is a top plan view of a half of the slurry distributor of fig. 22.

Fig. 45 is a cross-sectional view taken along line 45-45 in fig. 44.

Fig. 46 is a cross-sectional view taken along line 46-46 of fig. 44.

Fig. 47 is a cross-sectional view taken along line 47-47 of fig. 44.

Fig. 48 is a cross-sectional view taken along line 48-48 of fig. 44.

Fig. 49 is a cross-sectional view taken along line 49-49 of fig. 44.

FIG. 50 is a cross-sectional view taken along line 50-50 in FIG. 44.

FIG. 51 is a cross-sectional view taken along line 51-51 of FIG. 44.

Fig. 52 is a cross-sectional view taken along line 52-52 of fig. 44.

Fig. 53 is a cross-sectional view taken along line 53-53 in fig. 44.

Fig. 54 is a perspective view of an embodiment of a multi-piece mold for making a slurry distributor as in fig. 1 constructed according to the principles of the present disclosure.

Fig. 55 is a top plan view of the mold of fig. 54.

Fig. 56 is an exploded view of an embodiment of a multi-piece mold for making the slurry distributor of fig. 15 constructed in accordance with the principles of the present disclosure.

Fig. 57 is a perspective view of another embodiment of a mold for making one piece of a two-piece slurry distributor constructed in accordance with the principles of the present disclosure.

Fig. 58 is a top plan view of the mold of fig. 57.

Fig. 59 is a schematic plan view of an embodiment of a gypsum slurry mixing and distribution assembly including a slurry distributor according to the principles of the present disclosure.

Fig. 60 is a schematic plan view of another embodiment of a gypsum slurry mixing and distribution assembly including a slurry distributor according to the principles of the present disclosure.

Fig. 61 is a schematic elevation view of an embodiment of a wet end of a gypsum wallboard manufacturing line in accordance with the principles of the present disclosure.

Fig. 62 is a perspective view of an embodiment of a flow splitter constructed in accordance with the principles of the present disclosure suitable for use in a gypsum slurry mixing and distribution assembly including a slurry distributor.

Fig. 63 is a cross-sectional side elevational view of the flow diverter of fig. 62.

Fig. 64 is a side elevational view of the flow splitter of fig. 62 to which an embodiment of a compression device constructed in accordance with the principles of the present disclosure is mounted.

Fig. 65 is a top plan view of a half of a slurry distributor similar to the slurry distributor of fig. 15.

Fig. 66 is a plot of the data from table I of example 1, showing the dimensionless distance from the feed inlet versus the dimensionless area and the dimensionless hydraulic radius for the half of the slurry distributor of fig. 65.

Fig. 67 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless distance from the feed inlet versus the dimensionless velocity of the flow of the forming slurry moving through the half of the slurry distributor of fig. 65.

Fig. 68 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless distance from the feed inlet versus the dimensionless shear rate in the formed slurry moving through the half of the slurry distributor of fig. 65.

Fig. 69 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless distance from the feed inlet versus the dimensionless viscosity of the forming slurry moving through the half of the slurry distributor of fig. 65.

Fig. 70 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless distance from the feed inlet versus the dimensionless shear stress in the shaped slurry moving through the half of the slurry distributor of fig. 65.

Fig. 71 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless distance from the feed inlet versus the dimensionless reynolds number of the shaped slurry moving through the half of the slurry distributor of fig. 65.

Fig. 72 is a top plan view of a slurry distributor similar to the slurry distributor of fig. 22.

Fig. 73 is a top perspective view of a Computational Fluid Dynamics (CFD) model output for the half of the slurry distributor of fig. 72.

FIG. 74 is a view as in FIG. 74, showing the various regions discussed in examples 4-6.

Fig. 75 is a view of the area a indicated in fig. 74.

Fig. 76 is a top plan view of region a showing radial positions for performing CFD analysis.

Fig. 77 is a plot of the data from table IV of example 4, showing the radial position at zone a versus the dimensionless average velocity of zone a moving through the half of the slurry distributor of fig. 73.

FIG. 78 is an enlarged detailed view taken from FIG. 72, showing region B of the slurry distributor with a swirling motion of the slurry flow moving therethrough.

Fig. 79 is a plot of data from table VI of example 6, showing the dimensionless distance from the feed inlet versus the dimensionless velocity of the flow of the forming slurry moving through the half of the slurry distributor of fig. 73.

Fig. 80 is a plot of data from table VI of example 6, showing dimensionless distance from the feed inlet versus dimensionless shear rate in the formed slurry moving through the half of the slurry distributor of fig. 72.

Fig. 81 is a plot of data from table VI of example 6, showing the dimensionless distance from the feed inlet versus the dimensionless viscosity of the forming slurry moving through the half of the slurry distributor of fig. 73.

Fig. 82 is a plot of data from table VI of example 6, showing the dimensionless distance from the feed inlet versus the dimensionless reynolds number for the shaped slurry moving through the half of the slurry distributor of fig. 73.

Fig. 83 is a plot of data from table VII of example 7, showing the dispersion angle of formed slurry discharged from the half of the slurry distributor of fig. 73 versus the dimensionless distance along the width of the outlet opening from the central transverse midpoint.

Detailed Description

The present disclosure provides various embodiments of a slurry distribution system that can be used to manufacture products including cementitious products, such as, for example, gypsum wallboard. Embodiments of slurry distributors constructed in accordance with the principles of the present disclosure can be used in manufacturing processes to efficiently distribute multiphase slurries, such as those containing air and a liquid phase, such as are commonly found, for example, in aqueous foamed gypsum slurries.

Embodiments of a distribution system constructed in accordance with the principles of the present disclosure can be used to distribute a slurry (e.g., an aqueous calcined gypsum slurry) onto an advancing web (e.g., paper or mat) moving on a conveyor belt during the manufacture of continuous board (e.g., wallboard). In one aspect, a slurry distribution system constructed in accordance with the principles of the present disclosure can be used in a conventional gypsum drywall manufacturing process, as or as part of a discharge conduit attached to a mixer adapted to agitate calcined gypsum and water to form an aqueous calcined gypsum slurry.

Embodiments of a slurry distribution system constructed in accordance with the principles of the present disclosure are directed to achieving a broader distribution (in the cross-machine direction) of a uniform gypsum slurry. Embodiments of the slurry distribution system of the present disclosure are suitable for use with gypsum slurries having a range of WSRs, including those conventionally used to make gypsum wallboard as well as those WSRs that are relatively low and have relatively high viscosities. In addition, the gypsum slurry distribution system of the present disclosure can be used to help control air-liquid phase separation, such as in aqueous foamed gypsum slurries (including foamed gypsum slurries having extremely high foam volumes). The dispersion of the aqueous calcined gypsum slurry on the advancing web can be controlled by routing and distributing the slurry using a distribution system as shown in the figures and as described herein.

A cementitious slurry mixing and distribution assembly according to the principles of the present disclosure can be used to form any type of cementitious product, such as, for example, a board. In some embodiments, a cementitious product can be formed, such as gypsum drywall, Portland (Portland) cement board, or acoustical panel.

The cementitious slurry can be any conventional cementitious slurry such as any cementitious slurry commonly used to produce gypsum wallboard, acoustical panels including acoustical panels such as those described in U.S. patent application publication No. 2004/0231916, or portland cement board. Thus, the cementitious slurry can optionally further comprise any additives commonly used in the production of cementitious board products. Such additives include structural additives including mineral wool, continuous or chopped glass fibers (also known as fiberglass), perlite, clay, vermiculite, calcium carbonate, polyester, and papermaking fibers, as well as chemical additives such as blowing agents, fillers, accelerators, sugars, reinforcing agents (such as phosphates, phosphonates, borates, and the like), retarders, cements (e.g., starch and latex), colorants, bactericides, biocides, hydrophobicizers, such as silicone-based materials (e.g., silane, siloxane, or silicone-resin matrices), and the like. Examples of the use of some of these and other additives are described, for example, in U.S. Pat. nos. 6,342,284, 6,632,550, 6,800,131, 5,643,510, 5,714,001, and 6,774,146, and U.S. patent applications publication nos. 2004/0231916, 2002/0045074, 2005/0019618, 2006/0035112, and 2007/0022913.

Non-limiting examples of binders include portland cement, acid film cement, slag cement, fly ash cement, calcium aluminate cement, water-soluble calcium sulfate anhydrite, calcium sulfate alpha-hemihydrate, calcium sulfate beta-hemihydrate, natural, synthetic or chemically modified calcium sulfate hemihydrate, calcium sulfate dihydrate ("gypsum," "set gypsum," or "hydrated gypsum"), and mixtures thereof. In one aspect, the cementitious binder desirably includes calcined gypsum, such as in the form of calcium sulfate alpha-hemihydrate, calcium sulfate beta-hemihydrate, and/or calcium sulfate anhydrite. In embodiments, the calcined gypsum may be cellulosic in some embodiments, and non-cellulosic in other embodiments. The calcined gypsum can include at least about 50% beta calcium sulfate hemihydrate. In other embodiments, the calcined gypsum can include at least about 86% beta calcium sulfate hemihydrate. The weight ratio of water to calcined gypsum can be any suitable ratio, but those of ordinary skill in the art will appreciate that lower ratios will be more efficient because less excess water must be driven off during the manufacturing process, thereby saving energy. In some embodiments, the gypsum can be produced by mixing water and calcined gypsum in a ratio of from about 1: 6 to about 1: 1 weight ratio, such as about 2: 3.

embodiments of methods of making cementitious products, such as gypsum products, in accordance with the principles of the present disclosure may include: an aqueous calcined gypsum slurry is distributed onto an advancing web using a slurry distributor constructed in accordance with the principles of the present disclosure. Various embodiments of a method of distributing an aqueous calcined gypsum slurry onto a moving web are described herein.

Turning now to the drawings, in fig. 1-3, an embodiment of a slurry distributor 120 according to the principles of the present disclosure is shown, and in fig. 4 and 5, another embodiment of a slurry distributor 220 according to the principles of the present disclosure is shown. Slurry distributor 120 shown in fig. 1-3 is constructed of a resiliently flexible material, while slurry distributor 220 shown in fig. 3 and 4 is made of a relatively rigid material. However, the internal flow geometry of the two slurry distributors 120, 220 in fig. 1-5 is the same, and reference should also be made to fig. 5 when considering the slurry distributor 120 of fig. 1-3.

Referring to fig. 1, the slurry distributor 120 includes: a feed conduit 122 having a first feed inlet 124 and a second feed inlet 125; and a distribution conduit 128 including a distribution outlet 130 and in fluid communication with the feed conduit 128. A shaping system 132 (see fig. 3) may also be provided, which is adapted to locally change the size of the distribution outlet 130 of the distribution conduit 128.

Referring to FIG. 1, the feed conduit 122 generally extends along a transverse axis or cross-machine direction 60, with the transverse axis or cross-machine direction 60 being substantially perpendicular to the longitudinal axis or machine direction 50. The first feed inlet 124 is in spaced relation to the second feed inlet 125. The first feed inlet 124 and the second feed inlet 125 define respective openings 134, 135 that have substantially the same area. The illustrated openings 134, 135 of the first feed inlet 124 and the second feed inlet 125 both have a circular cross-sectional shape, as illustrated in this embodiment. In other embodiments, the cross-sectional shape of the feed inlets 124, 125 can take other forms, depending on the intended application and the current processing conditions.

The first feed inlet 124 and the second feed inlet 125 are in opposing relationship to each other along the cross-machine axis 60 such that the first feed inlet 124 and the second feed inlet 125 are disposed at a substantially 90 angle to the machine axis 50. In other embodiments, the first feed inlet 124 and the second feed inlet 125 can be oriented differently with respect to the machine direction. For example, in some embodiments, the first feed inlet 124 and the second feed inlet 125 can be angled between 0 ° and about 135 ° with respect to the machine direction 50.

The feed conduit 122 includes a first entry section 136 and a second entry section 137, and a bifurcated connector section 139 disposed between the first entry section 136 and the second entry section 137. The first and second entry sections 136, 137 are generally cylindrical and extend along the transverse axis 60 such that they are substantially parallel to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. The first feed inlet 124 and the second feed inlet 125 are disposed at, and in fluid communication with, the distal ends of the first entry segment 136 and the second entry segment 137, respectively.

In other embodiments, the first and second feed inlets 124, 125 and the first and second entry sections 136, 137 can be oriented differently about the transverse axis 60, the machine direction 50, and/or the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. For example, in some embodiments, the first and second feed inlets 124, 125 and the first and second entry sections 136, 137 can each be disposed substantially in the plane 57 defined by the longitudinal or machine direction 50 at a feed angle θ about the longitudinal or machine direction 50 ranging up to about 135 ° about the machine direction 50, in other embodiments ranging from about 30 ° to about 135 °, in further embodiments ranging from about 45 ° to about 135 °, and in still further embodiments ranging from about 40 ° to about 110 °.

The bifurcated connector section 139 is in fluid communication with the first and second feed inlets 124, 125 and the first and second entry sections 136, 137. The bifurcated connector segment 139 includes a first shaped conduit 141 and a second shaped conduit 143. The first and second feed inlets 124, 125 of the feed conduit 22 are in fluid communication with the first and second shaped conduits 141, 143, respectively. The first and second shaped conduits 141, 143 of the connector section 139 are adapted to receive a first flow 190 of aqueous calcined gypsum slurry in a first feed direction and a second flow 191 of aqueous calcined gypsum slurry in a second flow direction of the first and second feed inlets 124, 125, respectively, and direct the first flow 190 and second flow 191 of aqueous calcined gypsum slurry into the distribution conduit 128.

As shown in fig. 5, the first and second shaped conduits 141, 143 of the connector segment 139 define first and second feed outlets 140, 145 in fluid communication with the first and second feed inlets 124, 125, respectively. Each feed outlet 140, 145 is in fluid communication with the distribution conduit 128. Each of the illustrated first and second feed outlets 140, 145 defines an opening 142, the opening 142 having a generally rectangular interior 147 and a generally circular side 149. The rounded side 145 is arranged adjacent to the side walls 151, 153 of the distribution duct 128.

In an embodiment, the openings 142 of the first and second feed outlets 140, 145 may have a cross-sectional area that is greater than the cross-sectional area of the respective openings 134, 135 of the first feed inlet 124 and the second feed inlet 125. For example, in some embodiments, the cross-sectional area of the openings 142 of the first and second feed outlets 140, 145 may range from greater than the cross-sectional area of the respective openings 134, 135 of the first feed inlet 124 and second feed inlet 125 to approximately 300% greater than the cross-sectional area of the respective openings 134, 135 of the first feed inlet 124 and second feed inlet 125, in other embodiments in the range from greater than the cross-sectional area of the respective openings 134, 135 of first feed inlet 124 and second feed inlet 125 to approximately 200% greater than the cross-sectional area of the respective openings 134, 135 of first feed inlet 124 and second feed inlet 125, and in further embodiments in a range from greater than the cross-sectional area of the respective openings 134, 135 of the first and second feed inlets 124, 125 to approximately 150% greater than the cross-sectional area of the respective openings 134, 135 of the first and second feed inlets 124, 125.

In an embodiment, the openings 142 of the first and second feed outlets 140, 145 may have a hydraulic diameter (4 x cross-sectional area/circumference) that is less than the hydraulic diameter of the respective openings 134, 135 of the first feed inlet 124 and the second feed inlet 125. For example, in some embodiments, the hydraulic diameter of the openings 142 of the first and second feed outlets 140, 145 may be about 80% or less, in other embodiments about 70% or less, and in still other embodiments about 50% or less of the hydraulic diameter of the respective openings 134, 135 of the first and second feed inlets 124, 125.

Referring back to fig. 1, the connector segment 139 is substantially parallel to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. In other embodiments, the connector segments 139 can be oriented differently about the transverse axis 60, the machine direction 50, and/or the plane 57 defined by the longitudinal axis 50 and the transverse axis 60.

The first feed inlet 124, the first entry section 136 and the first shaped conduit 141 are mirror images of the second feed inlet 125, the second entry section 137 and the second shaped conduit 143, respectively. Thus, it will be understood that, also in a corresponding manner, the description of one feed inlet can apply to another feed inlet, the description of one entry section can apply to another entry section, and the description of one shaped duct can apply to another shaped duct.

The first shaped conduit 141 is fluidly connected to the first feed inlet 124 and the first entry section 136. The first shaped conduit 141 is also fluidly connected with the distribution conduit 128 to thereby help fluidly connect the first feed inlet 124 and the distribution outlet 130 to enable the first slurry stream 190 to enter the first feed inlet 124, travel through the first entry segment 136, the first shaped conduit 141, and the distribution conduit 128, and exit the slurry distributor 120 through the distribution outlet 130.

The first sizing conduit 141 has a front outer curved wall 157 and an opposite rear inner curved wall 158 that define a curved guide surface 165, the guide surface 165 adapted to redirect the first slurry flow from a first feed flow direction 190 to an outlet flow direction 192, the first feed flow direction 190 being substantially parallel to the transverse or cross-machine direction 60, the outlet flow direction 192 being substantially parallel to the longitudinal or machine direction 50 and substantially perpendicular to the first feed flow direction 190. The first shaped duct 141 is adapted to receive a first slurry stream moving in the first feed flow direction 190 and to redirect the slurry stream by a change in the directional angle α as shown in fig. 9 such that the first slurry stream is conveyed into the distribution conduit 128 moving substantially in the outlet flow direction 192.

In use, a first stream of aqueous calcined gypsum slurry passes through the first feed inlet 124 in a first feed direction 190, and a second stream of aqueous calcined gypsum slurry passes through the second feed inlet 125 in a second feed direction 191. In some embodiments, the first and second feed directions 190, 191 can be symmetrical with respect to each other along the longitudinal axis 50. The first slurry flow moving in the first feed flow direction 190 is redirected in the slurry distributor 120 to an outlet flow direction 192 by a change in direction angle a in the range of up to about 135 °. The second slurry flow moving in the second feed flow direction 191 is redirected in the slurry distributor 120 to the outlet flow direction 192 by a change in direction angle a in the range of up to about 135 °. The combined first and second flows of aqueous calcined gypsum slurry 190 and 191 are discharged from the slurry distributor 120 moving generally in an outlet flow direction 192. The outlet flow direction 192 can be substantially parallel to the longitudinal axis or machine direction 50.

For example, in the illustrated embodiment, the first slurry stream is redirected from a first feed flow direction 190 along the cross-machine direction 60 to an outlet flow direction 192 along the machine direction 50 by a change in direction angle α of about ninety degrees with respect to the vertical axis 55. In some embodiments, the slurry flow can be redirected from the first feed flow direction 190 to the outlet flow direction 192 by a change in the direction angle α about the vertical axis 55 in a range up to about 135 °, and in other embodiments the direction angle α is in a range from about 30 ° to about 135 °, while in other embodiments the direction angle α is in a range from about 45 ° to about 135 °, and in other embodiments the direction angle α is in a range from about 40 ° to about 110 °.

In some embodiments, the shape of the posterior curved guide surface 165 can be generally parabolic, which in the illustrated embodiment can be defined by Ax²A parabola of the form + B. In alternative embodiments, a higher order curve may be used to define the rear curved guide surface 165, or alternatively, the rear inner wall 158 may have a generally curved shape made up of straight or linear segments oriented at their ends to collectively define a generally curved wall. Moreover, the parameters used to define the particular form factor of the outer wall can depend on the specific operating parameters of the process in which the slurry distributor will be used.

At least one of the feed conduit 122 and the distribution conduit 128 may include an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region in a direction from the feed conduit 122 toward the distribution conduit 128. The first entry section 136 and/or the first shaped conduit 141 can have a cross-section that varies along the flow direction to help distribute the first flow of slurry moving therethrough. The shaped conduit 141 may have a cross-sectional flow area that increases in the first flow direction 195 from the first feed inlet 124 toward the distribution conduit 128 such that the first slurry flow is slowed as it passes through the first shaped conduit 141. In some embodiments, the first shaped duct 141 may have a maximum cross-sectional flow area at a predetermined point along the first flow direction 195, and further decrease from the maximum cross-sectional flow area at a point along the first flow direction 195.

In some embodiments, the maximum cross-sectional flow area of the first shaped conduit 141 is about 200% or less of the cross-sectional area of the opening 134 of the first feed inlet 124. In other embodiments, the maximum cross-sectional flow area of the first shaped conduit 141 is about 150% or less of the cross-sectional area of the opening 134 of the first feed inlet 124. In other embodiments, the maximum cross-sectional flow area of the first shaped conduit 141 is about 125% or less of the cross-sectional area of the opening 134 of the first feed inlet 124. In other embodiments, the maximum cross-sectional flow area of the first shaped conduit 141 is about 110% or less of the cross-sectional area of the opening 134 of the first feed inlet 124. In some embodiments, the cross-sectional flow area is controlled such that the fluid area does not change more than a predetermined amount over a given length to help prevent large changes in flow regime.

In some embodiments, the first entry segment 136 and/or the first shaped duct 141 may include one or more guide channels 167, 168, the guide channels 167, 168 being adapted to help distribute the first slurry stream toward the outer wall 157 and/or the inner wall 158 of the feed conduit 122. The guide channels 167, 168 are adapted to increase the flow of slurry around the boundary wall layer of the slurry distributor 120.

Referring to fig. 1 and 5, the guide channels 167, 168 can be configured to have a larger cross-sectional area than an adjacent portion 171 of the feed conduit 122, which defines a restriction that facilitates flow to adjacent guide channels 167, 168 disposed at the wall regions of the slurry distributor 120, respectively. In the illustrated embodiment, the feed conduit 122 includes an outer guide channel 167 adjacent the outer wall 157 and the side wall 151 of the distribution conduit 128 and an inner guide channel 168 adjacent the inner wall 158 of the first shaping conduit 141. The cross-sectional areas of the outer guide channel 167 and the inner guide channel 168 can become progressively smaller moving in the first flow direction 195. The outer guide channel 167 can extend substantially along the sidewall 151 of the distribution conduit 128 to the distribution outlet 130. At a given cross-sectional location through the first shaped conduit 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 has a larger cross-sectional area than the inner guide channel 168 to help divert the first flow of slurry from its initial line of travel in the first feed direction 190 toward the outer wall 157.

Providing adjacent wall regions of the directing channel can help direct or direct the flow of slurry to those regions, which can be regions in conventional systems where "dead spots" of low slurry flow are found. By providing guide channels to promote slurry flow at the wall areas of the slurry distributor 120, slurry accumulation inside the slurry distributor is inhibited and cleaning inside the slurry distributor 120 can be enhanced. It also reduces the frequency of slurry accumulation breaking up into clumps, which can tear the moving lidding web sheet.

In other embodiments, the relative dimensions of the outer guide channel 167 and the inner guide channel 168 can be varied to facilitate conditioning of the slurry flow to improve flow stability and reduce the occurrence of air-liquid slurry phase separation. For example, in applications where a relatively more viscous slurry is used, the outer guide channel 167 can have a smaller cross-sectional area than the inner guide channel 168 at a given cross-sectional location through the first shaped duct 141 in a direction perpendicular to the first flow direction 195 to help squeeze the first flow of slurry toward the inner wall 158.

The inner curved walls 158 of the first and second shaped conduits 141, 142 meet to define a peak 175 proximate the entry 152 of the distribution conduit 128. The peak 175 effectively bifurcates the connector segment 139. Each feed outlet 140, 145 is in fluid communication with an inlet portion 152 of the distribution conduit 128.

In other embodiments, the location of the peak 175 along the longitudinal axis 50 can vary. For example, in other embodiments, the inner curved walls 158 of the first and second shaped conduits 141, 142 may be less curved to make the peak 175 farther from the distribution outlet 130 along the longitudinal axis 50 than as shown in the illustrated slurry distributor 120. In other embodiments, the peak 175 can be closer to the distribution outlet 130 along the longitudinal axis 50 than as shown in the illustrated slurry distributor 120.

The distribution conduit 128 is substantially parallel to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60 and is adapted to urge the combined first and second flows of hydrous calcined gypsum slurry from the first and second shaped tubes 141, 142 into a substantially two-dimensional flow pattern for enhanced stability and uniformity. The distribution outlet 130 has a width extending a predetermined distance along the transverse axis 60 and a height extending along the vertical axis 55, the vertical axis 55 being relatively perpendicular to the longitudinal axis 50 and the transverse axis 60. The height of the distribution outlet 130 is small relative to its width. The distribution conduit 128 may be oriented relative to the moving cover web sheet on the forming table such that the distribution conduit 128 is substantially parallel to the moving web.

The distribution conduit 128 extends generally along the longitudinal axis 50 and includes an inlet portion 152 and a distribution outlet 130. The entry portion 152 is in fluid communication with the first and second feed inlets 124, 125 of the feed conduit 122. Referring to fig. 5, the entry portion 152 is adapted to receive both the first and second flows of aqueous calcined gypsum slurry from the first and second feed inlets 124, 125 of the feed conduit 122. The entry portion 152 of the distribution conduit 128 includes a distribution inlet 154, the distribution inlet 154 being in fluid communication with the first and second feed outlets 140, 145 of the feed conduit 122. The illustrated distribution inlet 154 defines an opening 156 that substantially corresponds to the openings 142 of the first and second feed outlets 140, 145. The first and second flows of aqueous calcined gypsum slurry are combined in the distribution conduit 128 such that the combined flow moves generally along an outlet flow direction 192, which outlet flow direction 192 can be substantially aligned with the line of movement of the cover web sheet moving over the forming table in the wallboard manufacturing line.

The distribution outlet 130 is in fluid communication with the entry portion 152, and thus the first and second feed inlets 124, 125 and the first and second feed outlets 140, 145 of the feed conduit 122. The distribution outlet 130 is in fluid communication with the first and second shaped conduits 141, 143 and is adapted to discharge the combined first and second slurry streams therefrom along an outlet flow direction 192 as the cover web sheet advances in the machine direction 50.

Referring to FIG. 1, the illustrated distribution outlet 130 defines a generally rectangular opening 181 having semi-circular narrow ends 183, 185. The semi-circular ends 183, 185 of the opening 181 of the distribution outlet 130 may be terminal ends of the outer guide channel 167 disposed adjacent the side walls 151, 153 of the distribution duct 128.

The opening 181 of the distribution outlet 130 has an area that is greater than the sum of the areas of the openings 134, 135 of the first and second feed inlets 124, 125 and less than the sum of the areas of the openings 142 of the first and second feed outlets 140, 145 (i.e., the openings 156 of the distribution inlet 154). Thus, the cross-sectional area of the opening 156 of the inlet portion 152 of the distribution conduit 128 is greater than the cross-sectional area of the opening 181 of the distribution outlet 130.

For example, in some embodiments, the cross-sectional area of the opening 181 of the distribution outlet 130 can be in a range from greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125 to approximately 400% greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125, in other embodiments, in a range from greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125 to approximately 200% greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125, and in still other embodiments, in a range from greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125 to approximately 150% greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125. In other embodiments, the ratio of the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125 to the cross-sectional area of the opening 181 of the distribution outlet 130 can vary based on one or more factors including the manufacturing line speed, the viscosity of the slurry distributed by the distributor 120, the width of the sheet product made by the distributor 120, and the like. In some embodiments, the cross-sectional area of the opening 156 of the entry portion 152 of the distribution conduit 128 can range from greater than the cross-sectional area of the opening 181 of the distribution outlet 130 to approximately 200% greater than the cross-sectional area of the opening 181 of the distribution outlet 130, in other embodiments from greater than the cross-sectional area of the opening 181 of the distribution outlet 130 to approximately 150% greater than the cross-sectional area of the opening 181 of the distribution outlet 130, and in further embodiments, from greater than the cross-sectional area of the opening 181 of the distribution outlet 130 to approximately 125% greater than the cross-sectional area of the opening 181 of the distribution outlet 130.

The distribution outlet 130 extends generally along the transverse axis 60. The opening 181 of the distribution outlet 130 has a width W along the transverse axis 60 of about twenty-four inches₁And a height H of about one inch along the vertical axis 55₁(see also fig. 3). In other embodiments, the size and shape of the openings 181 of the distribution outlet 130 can be varied.

The distribution outlet 130 is disposed at an intermediate position along the transverse axis 60 between the first feed inlet 124 and the second feed inlet 125 such that the first feed inlet 124 and the second feed inlet 125 are disposed at substantially the same distance D from a transverse central midpoint 187 of the distribution outlet 130₁、D₂(see also fig. 3). The distribution outlet 130 can be made of a resiliently flexible material such that its shape is adapted to be variable along the transverse axis 60, such as for example by the shaping system 32.

It is contemplated that in other embodiments, the width W of the opening 181 of the distribution outlet 130₁And/or height H₁Can vary for different operating conditions. Generally, the overall dimensions for various embodiments of a slurry distributor as disclosed herein can be scaled up or down depending on the type of product to be manufactured (e.g., the thickness and/or width of the manufactured product), the speed of the manufacturing line used, the rate at which slurry is deposited by the distributor, the viscosity of the slurry, and so forth. For example, the width W of the distribution outlet 130 along the transverse axis 60 used in the wallboard manufacturing process₁Is generally set to a nominal width of no greater than fifty-four inches, and in some embodiments, can be from about eight inches to about fifty-four inchesAnd in other embodiments, from about eighteen inches to about thirty inches. In other embodiments, the width W of the distribution outlet 130 along the transverse axis 60₁The ratio to the maximum nominal width of the board produced on a manufacturing system utilizing a slurry distributor constructed in accordance with the principles of the present disclosure can be in the range of from about 1/7 to about 1, in other embodiments in the range of from about 1/3 to about 1, in further embodiments in the range of from about 1/3 to about 2/3, and in other embodiments in the range of from about 1/2 to about 1.

In some embodiments, the height of the distribution outlet can range from about 3/16 inches to about two inches, and in other embodiments between about 3/16 inches and about one inch. In some embodiments including a rectangular distribution outlet, the rectangular width and rectangular height legs of the outlet opening can be about 4 or greater, in other embodiments about 8 or greater, in some embodiments from about 4 to about 288, in other embodiments from about 9 to about 288, in other embodiments from about 18 to about 288, and in other embodiments from about 18 to about 160.

The distribution conduit 128 includes a polymeric portion 182 in fluid communication with the inlet portion 152. The height of the converging portion 182 is less than the height at the maximum cross-sectional flow area of the first and second shaped ducts 141, 143 and less than the height of the opening 181 of the distribution outlet 130. In some embodiments, the height of the polymeric portion 182 can be approximately half the height of the opening 181 of the distribution outlet 130.

The heights of the converging portion 182 and the distribution outlet 130 can cooperate together to help control the average velocity at which the combined first and second aqueous calcined gypsum streams are distributed from the distribution conduit 128. The height and/or width of the distribution outlet 130 can be varied to adjust the average velocity at which the combined first and second slurry streams are discharged from the slurry distributor 120.

In some embodiments, the outlet flow direction 192 is substantially parallel to a plane 57 defined by the machine direction 50 and the cross-machine direction 60 of the system transporting the advancing sheet of lidding web. In other embodiments, the first and second feed directions 190, 191 and the outlet flow direction 192 are each substantially parallel to a plane 57 defined by the machine direction 50 and the cross-machine direction 60 of the system carrying the advancing cover web sheet. In some embodiments, the slurry distributor can be adapted and arranged relative to the forming table to redirect the flow of slurry in the slurry distributor 120 from the first and second feed directions 190, 191 to the outlet flow direction 192 without substantial flow direction alteration by rotation about the cross-machine direction 60.

In some embodiments, can be adapted and arranged relative to the forming table such that the first and second slurry streams are redirected in the slurry distributor from the first and second feed directions 190, 191 to the outlet flow direction 192 by rotating about the cross-machine direction 60 within an angle of about forty-five degrees or less to redirect the first and second slurry streams. In some embodiments, such rotation can be achieved by adapting the slurry distributor such that the first and second feed inlets 124, 125 and the first and second feed directions 190, 191 of the first and second streams of slurry are disposed at a vertical offset angle ω with respect to the vertical axis 55 and the plane 57 formed by the machine axis 50 and the cross-machine axis 60. In embodiments, the first and second feed inlets 124, 125 and the first and second feed directions 190, 191 of the first and second slurry streams can be arranged at a vertical offset angle ω in a range from zero to about sixty degrees to redirect the slurry streams about the machine axis 50 and move along the vertical axis 55 in the slurry distributor 120 from the first and second feed directions 190, 191 toward the outlet flow direction 192. In embodiments, at least one of the respective entry segments 136, 137 and shaped conduits 141, 143 can be adapted to facilitate redirection of the slurry about the machine axis 50 and along the vertical axis 55. In an embodiment, the first and second slurry flows can be redirected from the first and second feed directions 190, 191 to the outlet flow direction 192 to substantially align the outlet flow direction 192 with the machine direction 50 by a change in the direction angle α about an axis substantially perpendicular to the vertical offset angle ω and/or one or more other rotational axes in a range of about forty-five degrees to about one hundred fifty degrees.

In use, the first and second aqueous calcined gypsum slurry streams pass through the first and second feed inlets 124, 125 in the polymerized first and second feed directions 190, 191. The first and second shaped ducts 141, 143 redirect the first and second flows of slurry from the first feed direction 190 and the second feed direction 191 such that the first and second flows of slurry move within a change in direction angle a from being both substantially parallel to the transverse axis 60 to being both substantially parallel to the machine direction 50. The distribution conduit 128 can be positioned such that it extends along a longitudinal axis 50, the longitudinal axis 50 being substantially coincident with the machine direction 50, and the cover web sheet is moved in the machine direction 50 during the method of making gypsum board. The first and second flows of aqueous calcined gypsum slurry are combined in the slurry distributor 120 such that the combined first and second flows of aqueous calcined gypsum slurry pass through the distribution outlet 130 in an outlet flow direction 192 generally along the longitudinal axis 50 and in the machine direction.

Referring to fig. 2, a slurry distributor support 100 can be provided to help support a slurry distributor 120, which in the illustrated embodiment is made of a flexible material, such as, for example, PVC or urethane. The slurry distributor support 100 can be made of a suitable rigid material to help support the flexible slurry distributor 120. The slurry distributor support 100 may comprise a two-piece construction. The two pieces 101, 103 are pivotally movable relative to each other about a hinge 105 at their rear ends to allow easy access to the interior 107 of the support 100. The interior 107 of the support 100 can be configured such that the interior 107 substantially conforms to the exterior of the slurry distributor 120 to help limit the amount of movement the slurry distributor 120 can traverse relative to the support 100 and/or to help define the internal geometry of the slurry distributor 120 through which the slurry will flow.

Referring to fig. 3, in some embodiments, the slurry distributor support 100 can be made of a suitable resiliently flexible material that provides support and is capable of deforming in response to a forming system 132 mounted to the support 100. The forming system 132 can be mounted to the support 100 adjacent the distribution outlet 130 of the slurry distributor 120. The forming system 132 so installed can function to change the size and/or shape of the distribution outlet 130 of the distribution conduit 128, again by changing the size and/or shape of the closely conforming support 100, which in turn affects the size and/or shape of the distribution outlet 130.

Referring to fig. 3, the shaping system 132 can be adapted to selectively vary the size and/or shape of the opening 181 of the distribution outlet 130. In some embodiments, the shaping system can be used to selectively adjust the height H of the opening 181 of the distribution outlet 130₁。

The illustrated forming system 132 includes a plate 90, a plurality of mounting bolts 92 securing the plate to the distribution outlet 128, and a series of adjustment bolts 94, 95 threadably fastened to its four rows. Mounting bolts 92 are used to secure plate 90 to support 100 adjacent distribution outlet 130 of slurry distributor 120. The plate 90 extends substantially along the transverse axis 60. In the illustrated embodiment, the plate 90 is in the form of a length of angle steel. In other embodiments, the plate 90 may have a different shape and may comprise a different material. In still other embodiments, the shaping system may include other components adapted to selectively vary the size and/or shape of the opening 181 of the distribution outlet 130.

The illustrated shaping system 132 is adapted to locally vary the size and/or shape of the opening 181 of the distribution outlet 130 along the transverse axis 60. The adjustment bolts 94, 95 are in regular, spaced relation to one another along the transverse axis 60 above the distribution outlet 130. The adjustment bolts 94, 95 are independently adjustable to locally vary the size and/or shape of the distribution outlet 130.

The shaping system 132 can be used to locally alter the distribution outlet 130, thereby altering the flow pattern of the distribution of the combined first and second flows of hydrous calcined gypsum slurry from the slurry distributor 120. For example, the centerline adjustment bolt 95 can be tightened to constrain the lateral center point 187 of the distribution outlet 130 to increase the edge flow angle away from the longitudinal axis 50 to facilitate spreading in the cross-machine direction 60 and improve the uniformity of the slurry flow in the cross-machine direction 60.

The shaping system 132 can be used to change the size of the distribution outlet 130 along the transverse axis 60 and maintain the distribution outlet 130 in a new shape. The plate 90 can be made of a suitably reinforced material such that the plate 90 can withstand the relative forces applied by the adjustment bolts 94, 95 in response to adjustments made by the adjustment bolts 94, 95 when extruding the distribution outlet 130 into a new shape. The shaping system 132 can be used to help equalize variations in the flow distribution of the slurry exiting the distribution outlet 130 (e.g., due to different slurry densities and/or different feed inlet velocities) to make the pattern of slurry exiting from the distribution conduit 129 more uniform.

In other embodiments, the number of adjustment bolts can be varied to vary the spacing between adjacent adjustment bolts. In other embodiments, such as at the width W of the distribution outlet 130₁The number of adjusting bolts can also be varied to achieve the desired adjacent bolt spacing in different situations. In still other embodiments, the spacing between adjacent bolts can vary along the transverse axis 60, for example, providing greater local variation control at the side edges 183, 185 of the distribution outlet 130.

Slurry distributors constructed in accordance with the principles of the present disclosure may include any suitable material. In some embodiments, the slurry distributor can comprise any suitable substantially rigid material, which can comprise a suitable material capable of allowing the size and shape of the outlet to be adjusted using, for example, a forming system. For example, a suitable rigid plastic such as an Ultra High Molecular Weight (UHMW) plastic or metal can be used. In other embodiments, a slurry distributor constructed in accordance with the principles of the present disclosure can be made of a flexible material, such as a suitable flexible plastic material, including, for example, polyvinyl chloride (PVC) or urethane. In some embodiments, a slurry distributor constructed in accordance with the principles of the present disclosure may include a single feed inlet, an entry section, and a shaped conduit in fluid communication with a distribution conduit.

A gypsum slurry distributor constructed in accordance with the principles of the present disclosure can be used to help provide a wide cross-machine distribution of aqueous calcined gypsum slurry to facilitate the spreading of high viscosity/lower WSR gypsum slurry on a cover web sheet moving on a forming table. Also, a gypsum slurry distribution system can be used to help control air-slurry phase separation.

In accordance with another aspect of the present disclosure, a gypsum slurry mixing and distribution assembly can include a slurry distributor constructed in accordance with the principles of the present disclosure. The slurry distributor can be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. In one embodiment, the slurry distributor is adapted to receive the first and second streams of aqueous calcined gypsum slurry from the gypsum slurry mixer and distribute the first and second streams of aqueous calcined gypsum slurry onto the advancing web.

The slurry distributor may comprise part of or serve as a discharge conduit of a conventional gypsum slurry mixer (e.g., pin mixer) as is well known in the art. The slurry distributor can be used with components of a conventional discharge conduit. For example, the slurry distributor can be used with components of a gate-tank-feed hopper arrangement as is well known in the art or components of the discharge conduit arrangements described in U.S. Pat. nos. 6,494,609, 6,874,930, 7,007,914 and 7,296,919.

A slurry distributor constructed in accordance with the principles of the present disclosure can be advantageously constructed as a retrofit in existing wallboard manufacturing systems. Preferably, the slurry distributor can be used to replace conventional single-or multi-branch feed hoppers used in conventional discharge conduits. The gypsum slurry distributor can be retrofitted to existing slurry discharge conduit arrangements, such as shown in, for example, U.S. Pat. nos. 6,874,930 or 7,007,914, as a replacement for the distal dispensing launder or feed hopper. However, in some embodiments, the slurry distributor may optionally be attached to one or more feed hopper outlets.

Referring to fig. 4 and 5, the slurry distributor 220 is similar to the slurry distributor 120 of fig. 1-3, except that it is constructed of a substantially rigid material. The internal geometry 207 of the slurry distributor 220 of fig. 4 and 5 is similar to the internal geometry of the slurry distributor 120 of fig. 1-3, and like reference numerals are used to indicate like structure. The internal geometry 207 of the slurry distributor 207 is adapted to define a flow path through which the gypsum slurry travels in a streamlined flow manner, separated by a reduced or substantially air-liquid slurry phase and substantially without a vortex path.

In some embodiments, the slurry distributor 220 can comprise any suitable substantially rigid material, which can comprise a suitable material capable of allowing the size and shape of the outlet 130 to be adjusted using, for example, a forming system. For example, a suitably rigid plastic such as UHMW plastic or metal can be used.

Referring to fig. 4, the slurry distributor 220 has a two-piece construction. The upper piece 221 of the slurry distributor 220 includes a recess 227 adapted to receive the forming system 132 therein. The two pieces 221, 223 are pivotally movable relative to each other about a hinge 205 at their rear ends to allow easy access to the interior 207 of the slurry distributor 220. Mounting holes 229 are provided to facilitate the attachment of the upper piece 221 and its mating lower piece 223.

Referring to fig. 6-8, another embodiment of a slurry distributor 320 constructed in accordance with the principles of the present disclosure is shown and made of a rigid material. The slurry distributor 320 of fig. 6-8 is similar to the slurry distributor 220 of fig. 4 and 5, except that the slurry distributor 320 of fig. 6-8 has the first and second feed inlets 324, 325 and the first and second entry segments 336, 337 arranged at a feed angle θ (see fig. 7) of about 60 degrees with respect to the longitudinal axis or machine direction 50.

The slurry distributor 320 has a two-piece construction including an upper piece 321 and a mating lower piece 323. The two pieces 321, 323 of the slurry distributor 320 can be fastened together using any suitable technique, such as by using fasteners through a corresponding number of mounting holes 329 provided in each piece 321, 323, for example. The upper piece 321 of the slurry distributor 320 includes a recess 327 adapted to receive the forming system 132 therein. The slurry distributor 320 of fig. 6-8 is otherwise similar to the slurry distributor 220 of fig. 4 and 5.

Referring to fig. 9 and 10, a lower piece 323 of the slurry distributor 320 of fig. 6 is shown. The lower piece 323 defines a first portion 331 of the internal geometry 307 of the slurry distributor 320 of fig. 6. The upper piece 323 defines a symmetrical second portion of the internal geometry 307 such that when the upper piece 321 and the lower piece 323 are mated together, as shown in fig. 6, they define the complete internal geometry 307 of the slurry distributor 320 of fig. 6.

Referring to fig. 9, the first and second shaped conduits 341, 343 are adapted to receive first and second flows of slurry moving in first and second feed flow directions 390, 391 and to alter the slurry flow direction by a change in direction angle α such that the first and second flows of slurry are conveyed into a distribution conduit 328 moving substantially in an outlet flow direction 392, the outlet flow direction 392 being aligned with the machine direction or longitudinal axis 50.

Fig. 11 and 12 depict another embodiment of a slurry distributor support 300 for use with the slurry distributor 320 of fig. 6. Slurry distributor support 300 may include upper and lower support plates 301, 302 constructed of a suitably rigid material such as, for example, metal. The support plates 301, 302 can be secured to the distributor by any suitable means. In use, the support plates 301, 302 can help support the slurry distributor 320 in position over a machine line that includes a conveyor assembly that supports and conveys the moving cover sheet. The support plates 301, 302 can be mounted to suitable uprights placed on either side of the conveyor assembly.

Fig. 13 and 14 depict yet another embodiment of a slurry distributor support 310 for use with the slurry distributor 320 of fig. 6, which also includes upper and lower support plates 311, 312. The cut-outs 313, 314, 318 in the upper support plate 311 enable the support 310 to be lighter than without such cut-outs and provide access to portions of the slurry distributor 320, such as those that accommodate, for example, mounting fasteners. The slurry distributor support 310 of fig. 13 and 14 can be otherwise similar to the slurry distributor support 300 of fig. 11 and 12.

Fig. 15-19 illustrate another embodiment of a slurry distributor 420 that is similar to the slurry distributor 320 of fig. 6-8, except that it is constructed from a substantially flexible material. The slurry distributor 420 of fig. 15-19 further includes first and second feed inlets 324, 325 and first and second entry segments 336, 337 arranged at a feed angle θ of about 60 ° with respect to the longitudinal axis or machine direction 50 (see fig. 7). The internal geometry 307 of the slurry distributor 420 of fig. 15-19 is similar to the slurry distributor 320 of fig. 6-8, and like reference numerals are used to denote like structures.

Fig. 17-19 progressively depict the internal geometry of the second entry segment 337 and the second shaped duct 343 of the slurry distributor 420 of fig. 15 and 16. The cross-sectional areas 411, 412, 413, 414 of the outer guide channel 367 and the inner guide channel 368 can be gradually smaller moving in the second flow direction 397 towards the distribution outlet 330. The outer guide channels 367 can extend substantially along the outer wall 357 of the second shaped conduit 343 and along the sidewall 353 of the distribution conduit 328 to the distribution outlet 330. The inner guide channel 368 is adjacent the inner wall 358 of the second shaped conduit 343 and terminates at the peak 375 of the split connector segment 339. The slurry distributor 420 of fig. 15-19 is otherwise similar to the slurry distributor 120 of fig. 1 and the slurry distributor 320 of fig. 6.

Referring to fig. 20 and 21, the illustrated embodiment of the slurry distributor 420 is made of a flexible material such as, for example, PVC or urethane. A slurry distributor support 400 can be provided to help support the slurry distributor 420. The slurry distributor support 400 may comprise a support member, in the illustrated embodiment in the form of a bottom support tray 401 filled with a suitable support medium 402 defining a support surface 404. The support surface 404 is configured to substantially conform to at least a portion of an exterior of at least one of the feed conduit 322 and the distribution conduit 328 to help limit an amount of relative movement between the slurry distributor 420 and the support tray 401. In some embodiments, the support surface 404 can also help maintain the internal geometry of the slurry distributor 420 through which slurry will flow.

The slurry distributor support 400 can also include a movable support assembly 405 disposed in spaced relation to the bottom support tray 401. The movable support assembly 405 can be positioned above the slurry distributor 420 and adapted to be placed in supporting relation with the slurry distributor 420 to help maintain the internal geometry 307 of the slurry distributor in a desired configuration.

The movable support assembly 405 may include a support frame 407 and a plurality of support sections 415, 416, 417, 418, 419 movably supported by the support frame 407. The support frame 407 can be mounted to at least one of the bottom support tray 401 or one or more uprights suitably arranged to maintain the support frame 407 in fixed relationship with the bottom support tray 401.

In an embodiment, at least one support section 415, 416, 417, 418, 419 is independently movable relative to another support section 415, 416, 417, 418, 419. In the illustrated embodiment, each support section 415, 416, 417, 418, 419 is independently movable relative to the support frame 407 within a predetermined stroke. In an embodiment, each support section 415, 416, 417, 418, 419 is movable in the stroke to bring each support section into a series of positions in which the respective support section 415, 416, 417, 418, 419 is in partial increasingly compressive engagement with at least one of the feed conduit 322 and the distribution conduit 328.

The position of each support section 415, 416, 417, 418, 419 can be adjusted to bring the support sections 415, 416, 417, 418, 419 into compressive engagement with at least a portion of the slurry distributor 420. Each support section 415, 416, 417, 418, 419 can be independently adjusted to place each support section 415, 416, 417, 418, 419 in either further compressive engagement with at least a portion of the slurry distributor 420 to locally compress the interior of the slurry distributor, or in decompression engagement with at least a portion of the slurry distributor 420 to allow the interior of the slurry distributor 420 to expand outwardly, such as in response to aqueous gypsum slurry flowing therethrough.

In the illustrated embodiment, each of the support sections 415, 416, 417 is movable in a stroke along a vertical axis 55. In other embodiments, at least one support section is movable along different lines of action.

The movable support assembly 405 includes a clamping mechanism 408 associated with each support section 415, 416, 417, 418, 419. Each clamping mechanism 408 can be adapted to selectively secure an associated support segment 415, 416, 417, 418, 419 in a selected position relative to the support frame 407.

In the illustrated embodiment, a rod 409 is mounted to each support section 415, 416, 417, 418, 419 and extends upwardly through a corresponding opening in the support frame 407. Each clamping mechanism 408 is mounted to the support frame 407 and is associated with one of the rods 409 extending from the respective support section 415, 416, 417, 418, 419. Each clamping mechanism 408 can be adapted to selectively maintain the associated rod 409 in a fixed relationship with the support frame 407. The illustrated clamping mechanism 408 is a conventional lever-actuated clamp that encircles the respective rod 409 and allows infinitely variable adjustment between the clamping mechanism 408 and the associated rod 409.

Those skilled in the art will appreciate that any suitable clamping mechanism 408 can be used in other embodiments. In some embodiments, each associated rod 409 is movable via a suitable actuator (e.g., either hydraulic or electric), the actuator being controlled via a controller. By holding the associated support sections 415, 416, 417, 418, 419 in a fixed position relative to the support frame 407, the actuator can act as a clamping mechanism.

Referring to fig. 21, the support sections 415, 416, 417, 418, 419 can each include a contact surface 501, 502, 503, 504, 505 configured to substantially conform to a surface portion of a desired geometry of at least one of the feed conduit 322 and the distribution conduit 328 of the slurry distributor 420. In the illustrated embodiment, a distributor conduit support section 415 is provided that includes a contact surface 501, the contact surface 501 conforming to the outer and inner shape of the portion of the distributor conduit 328 in which the distributor conduit support section 415 is disposed. A pair of shaped pipe support sections 416, 417 are provided which comprise contact surfaces 502, 503 respectively, the contact surfaces 502, 503 conforming to the outer and inner shape of the portions of the first and second shaped pipes 341, 343, respectively, in which the shaped pipe support sections 416, 417 are arranged. A pair of entry support sections 418, 419 are provided which comprise contact surfaces 504, 505, respectively, the contact surfaces 504, 505 conforming to the outer and inner shape of the portions of the first and second entry sections 336, 337, respectively, in which the shaped pipe support sections 418, 419 are disposed. The contact surfaces 501, 502, 503, 504, 505 are adapted to be placed in contacting relation with selected portions of the slurry distributor 420 to help hold the contacting portions of the slurry distributor 420 in place to help define the internal geometry 307 of the slurry distributor 420.

In use, the movable support assembly 405 can be operated to independently place each support section 415, 416, 417, 418, 419 in a desired relationship with the slurry distributor 420. The support sections 415, 416, 417, 418, 419 can help maintain the internal geometry 307 of the slurry distributor 420 to facilitate slurry flow therethrough and to help ensure that the volume defined by the internal geometry 307 is substantially filled with slurry during use. The location of the specific contact surfaces of a given support section 415, 416, 417, 418, 419 can be adjusted to locally adjust the internal geometry of the slurry distributor 420. For example, distributor conduit support section 415 can be moved along vertical axis 55 proximate to bottom support tray 401 to lower the height of distributor conduit 328 in the area where distributor conduit support section 415 is disposed.

In other embodiments, the number of support segments can vary. In still other embodiments, the size and/or shape of a given support segment can be varied.

Fig. 22-27 illustrate another embodiment of a slurry distributor 1420 constructed in accordance with the principles of the present disclosure. The slurry distributor 1420 is made of a substantially flexible material such as, for example, PVC or urethane. The slurry distributor 1420 of fig. 22-27 also includes first and second feed inlets 1424, 1425 and first and second entry sections 1436, 1437 that are arranged at a feed angle θ that is substantially parallel to the longitudinal axis or machine direction 50 (see fig. 24).

The slurry distributor 1420 includes a bifurcated feed conduit 1422, a distribution conduit 1428, a slurry wiping mechanism 1417, and a forming mechanism 1432. A slurry distributor support 1400 can be provided to help support the slurry distributor 1420.

Referring to fig. 22 and 23, slurry distributor support 1400 can include a support member, in the illustrated embodiment in the form of a bottom support member 1401 defining a support surface 1402. The support surface 1402 can be configured to substantially conform to at least a portion of an exterior of at least one of the feed conduit 1422 and the distribution conduit 1428 to help limit an amount of relative movement between the slurry distributor 1420 and the bottom support member 1401. In some embodiments, the support surface 1402 can also help maintain the internal geometry of the slurry distributor 1420 through which slurry will flow. In embodiments, additional anchoring structures can be provided to help secure the slurry distributor 1420 to the bottom support member 1401.

Slurry distributor support 1400 may further include an upper support member 1404, the upper support member 1404 being disposed in spaced relation to the bottom support member 1401. The upper support member 1404 can be positioned above the slurry distributor 1420 and adapted to be placed in supporting relation with the slurry distributor 1420 to help maintain the internal geometry 1407 of the slurry distributor 1420 in a desired configuration.

The upper support member 1404 may include a support frame 1407 and a plurality of support segments 1413, 1415, 1416 fixedly supported by the support frame 1407. The support frame 1407 can be mounted to at least one of the bottom support member 1401 or one or more suitably arranged uprights to hold the support frame 1407 in fixed relationship with the bottom support tray 1401. The support segments 1413, 1415, 1416 can each have a contact surface configured to substantially conform to a surface portion of a desired geometry of at least one of the feed conduits 1422 and the distribution conduits 1428 of the slurry distributor 1420. In an embodiment, the support frame 1407 can be adapted to movably adjust the spatial relationship between the support segments 1413, 1415, 1416 and the slurry distributor 1420. For example, in some embodiments, the support frame 1407 is capable of moving the support segments 1413, 1415, 1416 in a stroke on the vertical axis 55.

Referring to fig. 22, the slurry wiping mechanism 1417 includes a pair of actuators 1510, 1511, the actuators 1510, 1511 being operatively arranged with a wiping blade 1514 for selectively reciprocating the wiping blade 1514. Actuators 1510, 1511 are mounted to the bottom support member 1401 adjacent the distal end 1515 of the distribution conduit 1428. A wiper blade 1514 extends laterally between the actuators 1510, 1511.

Referring to FIG. 26, the distribution outlet 1430 includes an outlet opening 1481, the outlet opening 1481 having a width W along the transverse axis 60₂. The wiping sheet 1514 extends along the transverse axis 60 for a predetermined width W₃The distance of (c). Width W of outlet opening 1481₂Is smaller than the width W of the wiping sheet 1514₃So that the wiping blade 1514 is wider than the outlet opening 1481.

Referring to fig. 28, in the illustrated embodiment, each actuator 1510, 1511 comprises a double acting pneumatic cylinder having a reciprocally movable piston 1520. The rod 1522 of the piston 1520 is connected to the wiper blade 1514. In an embodiment, a pair of pneumatic air lines can be connected to the drive port 1525 and the retract port 1526, respectively. The pressurized gas source 1530 can be controlled by a suitable control valve assembly 1532 controlled by a controller 1534 to selectively reciprocate the wiping blade 1514 along the longitudinal axis 50. In an embodiment, an air line can tie drive ports 1525 of both actuators 1510, 1511 together in parallel, and a separate air line can tie retraction ports 1526 of both actuators 1510, 1511 together in parallel. In other embodiments, the actuator can be any item capable of reciprocating the wiping blade, including, for example, a manually operated device.

The movable wiper blade 1514 is in contacting relationship with the bottom surface 1540 of the distribution conduit 1428. The wiper blade 1514 is reciprocally movable across a cleaning path (shown in phantom) between a first position and a second position. The clearing path is disposed adjacent to the distal end 1515 of the distribution conduit 1428 including the distribution outlet 1430. The wiper blade reciprocates longitudinally along the cleaning path. In the illustrated embodiment, the first position of the wiping sheet 1514 is longitudinally upstream of the distribution outlet 1430, and the second position is longitudinally downstream of the distribution outlet 1430.

The controller 1534 is adapted to selectively control the actuator to reciprocally move the wiper blade 1514. In an embodiment, the controller 1534 is adapted to move the wiper blade 1514 from a first position to a second position in a cleaning direction 1550 during a wiping stroke and to move the wiper blade from the second position to the first position in an opposite, return direction 1560 during a return stroke. In an embodiment, the controller 1534 is adapted to move the wipe blade 1514 such that the time of movement in the wipe stroke is substantially the same as the time of movement in the return stroke.

In an embodiment, the controller 1534 can be adapted to move the wiper blade 1514 reciprocally between the first and second positions in a cycle having a sweep period. The sweep cycle includes: a wiping portion that protects a time of movement on a wiping stroke; a return portion that protects the time of movement on the return stroke; and a cumulative delay portion including a predetermined period of time during which the wiping sheet 1514 is held in the first position. In embodiments, the wipe portion is substantially the same as the return portion. In an embodiment, the controller 1534 is adapted to adjustably vary the cumulative delay portion.

Referring to fig. 34, the bottom support member 1401 supporting the bottom surface of the distribution conduit 1428 includes a perimeter 1565. The distribution outlet 1430 is longitudinally offset from the bottom support member 1401 such that the distal outlet portion 1515 of the distribution conduit 1428 extends from the periphery 1565 of the bottom support member 1410. Referring back to fig. 28, when the wiper blade is in the first position, the wiper blade 1514 supports the distal outlet portion 1515 of the slurry distributor 1420.

Referring to fig. 22, the forming mechanism 1432 includes a forming member 1610 in contacting relationship with the distribution conduit 1428 and a support assembly 1620 adapted to allow the forming member 1610 to have at least two degrees of freedom. In embodiments, the forming member is translatable along at least one axis and rotatable about at least one pivot axis. In an embodiment, the shaping member is movable along a vertical axis 55 and rotatable about a pivot axis 1630, the pivot axis 1630 being substantially parallel to the longitudinal axis 50.

Referring to fig. 26, 30, and 30A, the forming member 1610 is movable in the stroke to bring the forming member 1610 into a series of positions in which the forming member 1610 is in increasing compressive engagement with portions of the distribution conduit 1428 adjacent the distribution outlet 1430 to change the shape and/or size of the outlet opening 1430.

Referring to FIG. 26, the outlet openings 1481 of the distribution outlets 1430 have a width W along the transverse axis 60₂. The contact forming section of forming member 1410 has a width W extending a predetermined distance along the transverse axis₄. In embodiments, the width W of the outlet opening 1481₂Is wider than the width W of the forming member 1410₄Is large. In other embodiments, the width W of the outlet opening 1481₂Less than or equal to the width W of the forming member 1410₄. The shaping member 1410 is positioned such that a pair of lateral portions 1631, 1632 of the distribution outlet 1430 are in laterally offset relation to the shaping member 1410 such that the shaping member does not engage the lateral portions 1631, 1632. In some implementations, the lateral portions 1631, 1632 can have a width W of the outlet opening 1481₂About one-quarter of the combined width.

Referring to fig. 23, support assembly 1620 comprises a pair of stationary uprights 1642, 1643, a transverse stationary support member 1645, and a transverse pivoting support member 1647 pivotally connected to transverse stationary support member 1645 using any suitable pivotal connection. The fixed uprights 1642, 1643 can be mounted to the bottom support member 1401. A transverse stationary support member 1645 can extend transversely between the stationary uprights 1642, 1643.

Referring to fig. 29, 30B and 31, the pivoting support member 1647 is rotatable relative to the fixed support member 1645 about the pivot axis 1630 within an arc length 1652. In an embodiment, the arc length 1652 allows the pivot end 1653 of the pivot support member 1647 to tilt both upward above the transverse axis 60 and downward below the transverse axis 60. The pivoting support member 1647 supports the forming member 1610.

In an embodiment, the forming member 1610 is translatable along a vertical axis 55 and rotatable about a pivot axis 1630 that is substantially parallel to the longitudinal axis 50. The shaping member 1610 is rotatable about a pivot axis 1630 within an arc length 1652 to position the shaping member 1610 in a series of positions in which it is in variable compressive engagement with portions of the distribution conduit 1428 intersecting the transverse axis 60 such that the height H of the outlet opening 1481₂Varies along the transverse axis 60.

Referring to fig. 29 and 33, the shaped member 1610 includes an engagement section 1660 extending generally longitudinally and transversely and a translation adjustment lever 1662 extending generally perpendicularly from the engagement section 1660. The translating adjustment lever 1662 of the shaped member 1610 is movably secured to a pivoting support member 1647 of the support assembly 1620 such that the shaped member 1610 is movable along the vertical axis 55 in a series of vertical positions. A pair of translation guide rods 1663, 1665 are connected to the engagement section 1660 and extend through respective collars 1667, 1668 mounted to a pivot support member 1647. The guide rods 1663, 1665 are movable along a vertical axis 55 relative to the collars 1667, 1668.

The support assembly 1620 may include a clamping mechanism adapted to selectively engage the translation adjustment lever 1662 to secure the shaped member 1610 in a selected vertical position over a range of vertical positions. In the illustrated embodiment, the threaded connection between the translation adjustment rod 1662 and the pivot support member 1647 serves as a clamping mechanism. A lock nut 1664 is provided to secure the threaded translational adjustment rod 1662 in place. A resilient nut 1666 is disposed proximal to the distal end 1657 of the translating adjustment rod 1662 to maintain a clearance sufficient to allow rotation of a cap screw 1669 (see fig. 30C) attached to the distal end. Referring to fig. 30C, a blind bore 1658 is defined in the shaped member 1610 to receive a cap screw 1669 to allow the cap screw to rotate about the axis of the translating adjustment rod 1662.

Referring to fig. 30B and 31, the support assembly 1620 can be adapted to rotatably support the forming member 1610 such that the forming member 1610 can rotate about the pivot axis 1630 at a series of positions along the arc length 1652. The support assembly 1620 includes a rotary adjustment rod 1670, the rotary adjustment rod 1670 extending between a fixed support member 1645 and a pivoting support member 1647 through a support bracket 1672 coupled to the fixed support member 1645 (see also fig. 31). The rotation adjustment lever 1670 is movably fixed to the fixed support member 1645 by a threaded connection with the support bracket 1672 such that moving the rotation adjustment lever 1670 relative to the fixed support member 1645 by rotating its T-handle causes the pivot support member 1647 to pivot relative to the fixed support member 1645 about the pivot axis 1630. The support bracket 1672 can be configured such that it can allow some flexure during the tilting operation. Collars 1673, 1674 that can be provided with shafts can increase reliability.

Support assembly 1620 may include a clamping mechanism adapted to selectively engage a rotary adjustment rod 1670 to secure shaping member 1610 at a selected one of a series of positions along arc length 1652. In the illustrated embodiment, a lock nut 1677 can be provided to lock the threaded rod 1670 to the barrel nut 1679.

Referring to fig. 34 and 40, the bifurcated feed conduit 1422 of the slurry distributor 1420 includes first and second feeds 1701, 1702. Each of the first and second feeding portions 1701, 1702 has: a respective entry section 1436, 1437, the entry section 1436, 1437 having a feed inlet 1424, 1425 and a feed entry outlet 1710, 1711 in fluid communication with the feed inlet 1424, 1425; shaped conduits 1441, 1443 having bulbous portions 1720, 1721 (see also fig. 41), the bulbous portions 1720, 1721 being in fluid communication with the feed inlet outlets 1710, 1711 of the respective inlet segments 1436; and transition sections 1730, 1731 in fluid communication with respective bulbous portions 1720, 1721.

Referring to fig. 34, the first and second feed inlets 1424, 1425 and the first and second entry sections 1436, 1437 can be arranged at respective feed angles θ measured as degrees of rotation relative to the vertical axis 55, which are in the range of up to 135 ° with respect to the longitudinal axis 50. The illustrated first and second feed inlets 1424, 1425 and first and second entry sections 1436, 1437 are disposed at respective feed angles θ that are substantially aligned with the longitudinal axis 50.

The first feeding portion 1701 is substantially identical to the second feeding portion 1702. Therefore, it should be understood that the description of one feeding portion applies equally to the other feeding portion. In other embodiments, there is only a single feed or in further embodiments there may be more than two feeds.

Referring to fig. 35, the entry section 1436 is generally cylindrical and extends along the first feed flow axis 1735. The first feed flow axis 1735 of the illustrated entry section 1436 extends generally along the vertical axis 55.

In other embodiments, the first feed flow axis 1735 can have a different orientation relative to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. For example, in other embodiments, the first feed flow axis 1735 may be arranged at a feed pitch angle σ measured as a degree of rotation relative to the transverse axis 60, the transverse axis 60 being non-perpendicular to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. In embodiments, the pitch angle σ, as measured from the longitudinal axis 50 upward in a direction opposite the machine direction 92 to the vertical axis 55 as shown in fig. 35, can be anywhere in the range from about zero to about one hundred thirty-five degrees, in other embodiments anywhere in the range from about fifteen to about one hundred twenty degrees, in still other embodiments anywhere in the range from about thirty to about one hundred zero five degrees, in other embodiments anywhere in the range from about forty-five to about one hundred zero five degrees, and in other embodiments anywhere in the range from about seventy-five to about one hundred zero five degrees. In other embodiments, the first feed flow axis 1735 can be arranged at a feed roller angle measured as a degree of rotation relative to the longitudinal axis 50, the longitudinal axis 50 being non-perpendicular to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60.

Referring to fig. 34, the shaped tube 1441 comprises a pair of lateral sidewalls 1740, 1741 and a bulbous portion 1720. The shaped conduit 1441 is in fluid communication with the feed inlet outlet 1722 of the inlet section 1436. Referring to fig. 35, bulb 1720 is configured to reduce the average velocity of the slurry stream moving from entry segment 1436 through bulb 1720 to transition segment 1730. In an embodiment, bulb 1720 is configured to reduce the average velocity of the slurry stream moving from entry segment 1436 through bulb 1720 to transition segment 1730 by at least twenty percent.

Referring to fig. 45-47, the bulb 1720 has an expansion region 1750, the expansion region 1750 having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expansion region relative to a flow direction 1752 from the feed inlet 1424 toward the distribution outlets 1430 of the distribution conduit 1428. In an embodiment, the bulb 1720 has a region 1752, the region 1752 having a cross-sectional area in a plane perpendicular to the first flow axis 1735 that is greater than a cross-sectional area of a feed into the outlet 1711.

The shaped duct 1441 has a convex inner surface 1758, the convex inner surface 1758 being in facing relationship with the feed inlet outlet 1711 of the inlet section 1436. The bulb 1720 has a generally radial guide channel 1460 disposed adjacent the convex inner surface. The guide channel 1460 is configured to promote radial flow in a plane substantially perpendicular to the first feed flow axis 1735. Referring to fig. 45, convex inner surface 1758 is configured to define a central restriction 1762 in the flow path, which also helps to increase the average velocity of the slurry in radial guide channels 1760.

The shaped tube 1441 can be configured such that a flow of slurry moving through a region adjacent to the convex inner surface 1758 and adjacent to at least one of the lateral sidewalls 1740, 1741 toward the distribution outlet 1430 has a swirling motion (S) from about zero to about 10 (S)_m) In other embodiments up to about 3, and in still other embodiments from about 0.5 to about 5. In an embodiment, the flow of slurry moving through a region adjacent to the convex inner surface 1758 and adjacent to at least one of the lateral sidewalls 1740, 1741 toward the distribution outlet 1430 has a swirling motion (S) from about 0 ° to about 84 ° (S)_m) And in other embodiments from about 10 ° to about 80 °.

Referring to fig. 34 and 35, transition section 1730 is in fluid communication with bulb 1720. The illustrated transition 1730 extends along the longitudinal axis 50. The transition 1730 is configured such that its width, measured along the transverse axis 60, increases in the direction of flow from the bulb 1720 to the discharge outlet 1430. The transition 1730 extends along a second feed flow axis 1770, the second feed flow axis 1770 being in a non-parallel relationship with the first feed flow axis 1735.

In an embodiment, the first feed flow axis 1735 is substantially perpendicular to the longitudinal axis 50. In an embodiment, the first feed flow axis 1735 is substantially parallel to the vertical axis 55, and the vertical axis 55 is perpendicular to the longitudinal axis 50 and the lateral axis 60. In an embodiment, the second feed flow axis 1770 is disposed at a respective feed angle θ in a range of up to about 135 ° relative to the longitudinal axis 50.

In an embodiment, the feed conduit 1422 includes a bifurcated connector section 1439 that includes first and second guide surfaces 1780, 1781. In an embodiment, the first and second guiding surfaces 1781 can be adapted to redirect the first and second flows of slurry entering the feed conduit through the first and second inlets 1424, 1425, respectively, to an outlet flow direction by a change in direction angle in a range of up to about 135 °.

Referring to fig. 41-43, each of the shaped conduits 1441, 1443 has a concave outer surface 1790, 1791, the concave outer surface 1790, 1791 being substantially complementary in shape to and in underlying relationship with its convex inner surface 1758. Each concave outer surface 1790, 1791 defines a recess 1794, 1795.

Referring to fig. 27, 35 and 36, the support inserts 1801, 1802 are disposed within respective recesses 1794, 1795 of the slurry distributor 1420. The support inserts 1801, 1802 are disposed in underlying relation to the respective convex inner surfaces of the shaped conduits 1441, 1443. The support inserts 1801, 1802 can be made of any suitable material that will help support the slurry distributor and maintain the desired shape of the overlying convex inner surface. In the illustrated embodiment, the support inserts 1801, 1802 are substantially identical. In other embodiments, a different support insert can be used, or in still other embodiments, no insert is used.

Referring to fig. 37-39, rigid support insert 1801 includes a support surface 1810 that substantially conforms to the shape of the convex inner surface of the shaped pipe. In an embodiment, the shaped conduit of the slurry distributor can be made of a material sufficiently flexible such that the convex inner surface is defined by the support surface 1810 of the support insert 1801. In these cases, the concave outer surface of the shaped pipe can be omitted.

The support insert 1801 includes a feed end 1820 and a distribution end 1822. Support insert 1801 extends along a central support axis 1825. Support insert 1801 is substantially symmetrical about support axis 1825. The support insert 1801 is asymmetric about a central axis 1830 that is perpendicular to the support axis 1825.

Virgin landing fig. 34, the distribution conduit 1428 extends generally along the longitudinal axis 50 and includes an inlet 1452 and a distribution outlet 1430 in fluid communication with the inlet 1452. The inlet 1452 is in fluid communication with first and second feed inlets 1424, 1425 of the feed conduit 1422. The distribution conduit 1428 increases in width from the inlet 1452 to the distribution outlet 1430. However, in other embodiments, the width of the distribution conduit 1428 decreases or is constant from the entry 1452 to the distribution outlet 1430.

The entry portion 1452 includes an entry opening 1453, the entry opening 1453 having a distributed entry width W along the transverse axis 60₅And an entry height H along the vertical axis 55₄Wherein the distribution has an entrance width W₅A width W of the outlet opening 1481 less than the distribution outlet 1430₂. In other embodiments, the distribution entrance width W₅Greater than or equal to the width W of the outlet opening 1481 of the distribution outlets 1430₂. In embodiments, the width to height ratio of outlet opening 1481 is about four or greater.

In an embodiment, at least one of the feed conduit 1422 and the distribution conduit 1428 includes a flow stabilizing zone adapted to reduce the average feed velocity of the slurry stream entering the feed inlets 1424, 1425 and moving to the distribution outlet 1430 such that the slurry stream is discharged from the distribution outlet at an average discharge velocity that is at least twenty percent lower than the average feed velocity.

Fig. 44-53 progressively depict the internal geometry 1407 of the half 1504 of the slurry distributor 1420 of fig. 22. The slurry distributor 1420 of fig. 22 is otherwise similar to the slurry distributor 120 of fig. 1 and the slurry distributor 420 of fig. 20.

Any suitable technique for making a slurry distributor constructed in accordance with the principles of the present disclosure can be used. For example, in embodiments where the slurry distributor is made of a flexible material such as PVC or urethane, a multi-piece mold can be used. In some embodiments, the mold piece region is about 150% or less of the region through which the shaped slurry distributor of the mold piece is pulled out during removal, in other embodiments, the mold piece region is about 125% or less of the region through which the shaped slurry distributor of the mold piece is pulled out during removal, in still other embodiments, the mold piece region is about 115% or less of the region through which the shaped slurry distributor of the mold piece is pulled out during removal, and in still other embodiments, the mold piece region is about 110% or less of the region through which the shaped slurry distributor of the mold piece is pulled out during removal The area of the shaped slurry distributor,

referring to fig. 54 and 55, an embodiment of a multi-piece mold 550 suitable for making the slurry distributor 120 of fig. 1 from a flexible material such as PVC or urethane is shown. The illustrated multi-piece mold 550 includes five mold segments 551, 552, 553, 554, 555. The mold segments 551, 552, 553, 554, 555 of the multi-piece mold 550 can be made of any suitable material, such as, for example, aluminum.

In the illustrated embodiment, the distributor conduit die segments 551 are configured to define the internal flow geometry of the distributor conduit 128. The first and second shaped conduit mold segments 552, 553 are configured to define an internal flow geometry of the first and second shaped conduits 141, 143. The first and second entry mold segments 554, 555 define an internal flow geometry of the first entry segment 136 and the first feed inlet 124, and the second entry segment 137 and the second feed inlet 125, respectively. In other embodiments, the multi-piece mold can include a different number of mold sections and/or the mold sections can have different shapes and/or sizes.

Referring to fig. 54, the connection bolts 571, 572, 573 can be inserted through two or more mold segments to interlock and align the mold segments 551, 552, 553, 554, 555 such that a substantially continuous outer surface 580 of the multi-piece mold 550 is defined. In some embodiments, the distal portion 575 of the connection bolts 571, 572, 573 includes external threads configured to threadingly engage one of the mold segments 551, 552, 553, 554, 555 to connect at least two of the mold segments 551, 552, 553, 554, 555 to one another. The outer surface 580 of the multi-piece mold 550 is configured to define the internal geometry of the shaped slurry distributor 120 such that burn-out at the joint is reduced. During removal of the mold 550 from the interior of the molded slurry distributor 120, the connecting bolts 571, 572, 573 can be removed to disassemble the multi-piece mold 550.

The assembled multi-piece mold 550 is dipped into a solution of a flexible material, such as PVC or urethane, so that the mold 550 is completely immersed into the solution. The mold 550 can then be removed from the impregnated material. A quantity of the solution will adhere to the outer surface 580 of the multi-piece mold 550 and once the solution becomes solid form, the solution will form the shaped slurry distributor 120. In embodiments, the multi-piece mold 550 can be used in any suitable dipping process to form a molded part.

By making the mold 550 from a plurality of individual aluminum pieces, in the illustrated embodiment there are five pieces that are designed to fit together to provide the desired internal flow geometry, once they begin to solidify but are still warm, the mold segments 551, 552, 553, 554, 555 can be separated from each other and pulled out of solution. At a sufficiently high temperature, the flexible material is sufficiently compliant to pull a larger calculated area of the aluminum mold pieces 551, 552, 553, 554, 555 through a smaller calculated area of the shaped slurry distributor 120 without tearing it. In some embodiments, the maximum die piece area is up to about 150%, in other embodiments up to about 125%, in still other embodiments up to about 115%, and in still other embodiments up to about 110% of the minimum area of the shaped slurry distributor cavity region that the particular die piece traverses laterally across during removal.

Referring to fig. 56, an embodiment of a multi-piece mold 650 suitable for making the slurry distributor 320 of fig. 6 from a flexible material such as PVC or urethane is shown. The illustrated multi-piece mold 650 includes five mold segments 651, 652, 653, 654, 655. The mold segments 651, 652, 653, 654, 655 of the multi-piece mold 550 can be made of any suitable material, such as, for example, aluminum. The mold segments 651, 652, 653, 654, 655 are shown in the disassembled state in fig. 56.

Connecting bolts can be used to removably connect the mold segment mold segments 651, 652, 653, 654, 655 together to assemble the mold 650 such that a substantially continuous outer surface of the multi-piece mold 650 is defined. The outer surface of the multi-piece mold 650 defines the internal flow geometry of the slurry distributor 220 of fig. 6. The mold 650 is similar in construction to the mold 550 of fig. 54 and 55 in that each piece of the mold 650 of fig. 56 is configured such that its area is within a predetermined amount of the minimum area of the shaped slurry distributor 220 that the mold piece must traverse when it is removed (e.g., in some embodiments, up to about 150% of the minimum area of the shaped slurry distributor cavity region that the particular mold piece traverses laterally during removal, in other embodiments up to about 125%, in still other embodiments up to about 115%, and in still other embodiments up to about 110%).

Referring to fig. 57 and 58, an embodiment of a mold 750 for making one of the pieces 221, 223 of the two-piece slurry distributor 220 of fig. 4 is shown. Referring to fig. 57, a mounting bore defining member 752 may be included to define a mounting bore in the piece of the two-piece slurry distributor 220 of fig. 4 that facilitates its connection with the other piece.

Referring to fig. 57 and 58, the mold 750 includes a mold surface 754 extending from a bottom surface 756 of the mold 750. The boundary wall 756 extends along a vertical axis and defines a depth of the mold. The die surface 754 is disposed within the boundary wall 756. The boundary wall 756 is configured for filling the volume of the cavity 758 defined within the boundary wall with molten mold material such that the mold surface 754 is immersed therein. The die surface 754 is configured as a negative image of the internal flow geometry defined by the particular piece of the two-piece distributor being formed.

In use, the cavity 758 of the mold 750 can be filled with molten material such that the mold surface is submerged and the cavity 758 is filled with molten material. The molten material can be allowed to cool and be removed from the mold 750. Another mold can be used to form the mating piece of the slurry distributor 220 of fig. 4.

Referring to fig. 59, an embodiment of a gypsum slurry mixing and distribution assembly 810 includes a gypsum slurry mixer 912 in fluid communication with a slurry distributor 820, the slurry distributor 820 being similar to the slurry distributor 320 shown in fig. 6. The gypsum slurry mixer 812 is adapted to agitate the water and the calcined gypsum to form an aqueous calcined gypsum slurry. Both water and calcined gypsum can be common to the mixer 812 via one or more inlets as is well known in the art. Any suitable mixer (e.g., pin mixer) can be used with the slurry distributor.

The slurry distributor 820 is in fluid communication with the gypsum slurry mixer 812. The slurry distributor 820 includes: a first feed inlet 824 adapted to receive a first stream of aqueous calcined gypsum slurry moving in a first feed direction 890 from the gypsum slurry mixer 812; a second feed inlet 825 adapted to receive a second stream of aqueous calcined gypsum slurry moving in a second feed direction 891 from the gypsum slurry mixer 812; and a distribution outlet 830 in fluid communication with both the first and second feed inlets 824, 825 and adapted such that the first and second flows of aqueous calcined gypsum slurry are discharged from the slurry distributor 820 through the distribution outlet 830 substantially along the machine direction 50.

The slurry distributor 820 includes a feed conduit 822 in fluid communication with a distribution conduit 828. The feed conduit includes a first feed inlet 824 and a second feed inlet 825 disposed in spaced relation to the first feed inlet 824, both the first feed inlet 824 and the second feed inlet 825 being disposed at a feed angle θ of about 60 ° with respect to the machine direction 50. The feed conduit 822 includes structure therein adapted to receive first and second flows of slurry moving in first and second feed flow directions 890, 891 and redirect the flows of slurry through a change in direction angle a (see fig. 9) such that the first and second flows of slurry are delivered into the distribution conduit 828 moving substantially in an outlet flow direction 892, the outlet flow direction 892 being substantially aligned with the machine direction 50. The first and second feed inlets 824, 825 each comprise an opening having a cross-sectional area, and the entry portion 852 of the distribution conduit 828 comprises an opening having a cross-sectional area that is greater than the sum of the cross-sectional areas of the openings of the first and second feed inlets 824, 825.

The distribution conduits 828 extend generally along a longitudinal or machine direction 50 that is substantially perpendicular to the transverse axis 60. Distribution conduit 828 includes an entry portion 852 and a distribution outlet 830. The entry portion 852 is in fluid communication with the first and second feed inlets 824, 825 of the feed conduit 822 such that the entry portion 852 is adapted to receive the first and second streams of aqueous calcined gypsum slurry therefrom. Distribution outlet 830 is in fluid communication with inlet 852. The distribution outlet 830 of the distribution conduit 828 extends a predetermined distance along the transverse axis 60 to facilitate discharge of the combined first and second flows of aqueous calcined gypsum slurry in the cross-machine direction or along the transverse axis 60. The slurry distributor 820 is otherwise similar to the slurry distributor 320 of fig. 6.

The delivery conduit 814 is disposed between and in fluid communication with the gypsum slurry mixer 812 and the slurry distributor 820. The delivery conduit 814 includes a main delivery trunk 815, a first delivery branch 817 in fluid communication with a first feed inlet 824 of the slurry distributor 820, and a second delivery branch 818 in fluid communication with a second feed inlet 825 of the slurry distributor 820. Main delivery trunk 815 is in fluid communication with both first and second delivery branches 817, 818. In other embodiments, the first and second delivery branches 817, 818 can be in independent fluid communication with the gypsum slurry mixer 812.

The delivery catheter 814 can be made of any suitable material and can have different shapes. In some embodiments, the delivery catheter 814 may comprise a flexible catheter.

The aqueous foam supply conduit 821 can be in fluid communication with at least one of the gypsum slurry mixer 812 and the delivery conduit 814. Aqueous foam from a source can be added to the constituent materials through the foam supply conduit 821 at any suitable location downstream of the mixer 812 and/or in the mixer 812 itself to form the foamed gypsum slurry that is provided to the slurry distributor 220. In the illustrated embodiment, the foam supply conduit 821 is disposed downstream of the gypsum slurry mixer 812. In the illustrated embodiment, the aqueous foam supply conduit 821 has a manifold-type arrangement for supplying foam to the spray ring or block associated with the delivery conduit 814 as described, for example, in U.S. patent 6,874,930.

In other embodiments, one or more foam supply conduits can be provided in fluid communication with the mixer 812. In further embodiments, the aqueous foam supply conduit can be in fluid communication with the gypsum slurry mixer alone. As will be understood by those skilled in the art, the means for directing the aqueous foam into the gypsum slurry mixing and distribution assembly 810, including its relative position in the assembly, can be varied and/or optimized to provide uniform dispersion of the aqueous foam in the gypsum slurry to produce a board suitable for its intended use.

Any suitable blowing agent can be used. Preferably, the aqueous foam is produced in a continuous manner as follows: a mixed stream of foaming agent and water is directed to a foam generator, and a resultant aqueous foam stream exits the generator and is directed to and mixed with the calcined gypsum slurry. Some examples of suitable blowing agents are described in, for example, U.S. Pat. Nos. 5,683,635 and 5,643,510.

When the foamed gypsum slurry sets and is dried, the foam dispersed in the slurry creates air voids therein for reducing the overall density of the wallboard. The amount of foam and/or the amount of air in the foam can be varied to adjust the dry board density so that the resulting wallboard product is within a desired weight range.

One or more flow adjustment elements 823 can be associated with the delivery conduit 814 and adapted to control the first and second flows of aqueous calcined gypsum slurry from the gypsum slurry mixer 812. The flow adjustment elements 823 can be used to control the operating characteristics of the first and second flows of aqueous calcined gypsum slurry. In the illustrated embodiment of FIG. 59, the flow adjustment element 823 is associated with a main delivery trunk 815. Examples of suitable flow adjustment elements include volume restrictors, pressure reducers, constrictor valves, canisters, and the like, including those described in, for example, U.S. Pat. Nos. 6,494,609, 6,874,930, 7,007,914, and 7,296,919.

Main delivery trunk 815 can be coupled to first and second delivery branches 817, 818 via a suitable Y-splitter 819. Flow splitters 819 are disposed between main delivery trunk 815 and first delivery branch 817 and between main delivery trunk 815 and second delivery branch 818. In some embodiments, the flow splitter 819 can be adapted to help split the first and second gypsum slurry streams so that they are substantially equal. In other embodiments, additional components can be added to help regulate the first and second slurry streams.

In use, the aqueous calcined gypsum slurry is discharged from the mixer 812. The aqueous calcined gypsum slurry from the mixer 812 is split into a first stream of aqueous calcined gypsum slurry and a second stream of aqueous calcined gypsum slurry in a splitter 819. The aqueous calcined gypsum slurry from the mixer 812 can be split to substantially equalize the first and second aqueous calcined gypsum slurry streams.

Referring to fig. 60, another embodiment of a gypsum slurry mixing and distribution assembly 910 is shown. The gypsum slurry mixing and distribution assembly 910 includes a gypsum slurry mixer 912 in fluid communication with a slurry distributor 920. The gypsum slurry mixer 912 is adapted to agitate the water and the calcined gypsum to form an aqueous calcined gypsum slurry. The slurry distributor 920 is similar in construction and function to the slurry distributor 320 of fig. 6.

The delivery conduit 914 is disposed between the gypsum slurry mixer 912 and the slurry distributor 920 and is in fluid communication with the gypsum slurry mixer 912 and the slurry distributor 920. The delivery conduit 914 includes a main delivery trunk 915, a first delivery branch 917 in fluid communication with the first feed inlet 924 of the slurry distributor 920, and a second delivery branch 918 in fluid communication with the second feed inlet 925 of the slurry distributor 920.

The main delivery trunk 915 is disposed between the gypsum slurry mixer 912 and both the first and second delivery branches 917, 918 and is in fluid communication with both the gypsum slurry mixer 912 and the first and second delivery branches 917, 918. The aqueous foam supply conduit 921 can be in fluid communication with at least one of the gypsum slurry mixer 912 and the delivery conduit 914. In the illustrated embodiment, the aqueous foam supply conduit 912 is associated with the main delivery trunk 915 of the delivery conduit 914.

The first delivery branch 917 is disposed between the gypsum slurry mixer 912 and the first feed inlet 924 of the slurry distributor 920 and is in fluid communication with the gypsum slurry mixer 912 and the first feed inlet 924 of the slurry distributor 920. At least one first flow adjustment element 923 is associated with the first delivery branch 917 and is adapted to control a first flow of aqueous calcined gypsum slurry from the gypsum slurry mixer 912.

The second delivery branch 918 is disposed between the second feed inlets 925 of the gypsum slurry mixer 912 and the slurry distributor 920 and is in fluid communication with the second feed inlets 925 of the gypsum slurry mixer 912 and the slurry distributor 920. At least one second flow adjustment element 927 is associated with the second conveying branch 918 and is adapted to control a second flow of aqueous calcined gypsum slurry from the gypsum slurry mixer 912.

The first and second flow conditioning elements 923, 927 are operable to control operating characteristics of the first and second streams of hydrous calcined gypsum slurry. The first and second flow adjustment elements 923, 927 are independently operable. In some embodiments, the first and second flow adjustment elements 923, 927 can be actuated to alternate the first and second slurry flows in an opposite manner between a relatively slower average speed and a relatively faster average speed such that at a given time the first slurry flow has a faster average speed than the second slurry flow and at another point in time the first slurry flow has a slower average speed than the second slurry flow.

As will be appreciated by those of ordinary skill in the art, one or both of the cover web sheets can be pretreated with a very thin and relatively dense layer of gypsum slurry (relative to the gypsum slurry comprising the core) and/or a hard edge, as desired, the very thin and relatively dense layer of gypsum slurry commonly referred to in the art as a skim coat. To this end, the mixer 912 includes a first auxiliary conduit 929, the first auxiliary conduit 929 being adapted to deposit a dense aqueous calcined gypsum slurry stream that is relatively denser than the first and second aqueous calcined gypsum slurry streams delivered to the slurry distributor (i.e., a "face skim coat/hard edge stream"). The first subsidiary conduit 929 is capable of depositing a front skim coat/hard edge stream onto the moving sheet of cover web upstream of a skim coat roller 931, the skim coat roller 931 being adapted to apply a skim coat to the moving sheet of cover web and to define a hard edge at the periphery of the moving web by the width of the roller 931 being less than the width of the moving web, as is well known in the art. By guiding the portion of dense slurry around the end of the roll for applying the dense layer onto the wire, the hard edge can be formed from the same dense slurry forming a thinner dense layer.

The mixer 912 can also include a second auxiliary conduit 933, the second auxiliary conduit 933 being adapted to deposit a dense aqueous calcined gypsum slurry stream that is relatively denser than the first and second aqueous calcined gypsum slurry streams delivered to the slurry distributor (i.e., a "back skim surface layer stream"). A second subsidiary conduit 933 is capable of depositing a back skim coat stream onto a second moving cover web sheet upstream (in the direction of movement of the second web) of a skim coat roller 937, the skim coat roller 937 being adapted to apply a skim coat onto the second moving cover web sheet as is known in the art (see also fig. 61).

In other embodiments, a separate secondary conduit can be connected to the mixer to deliver one or more separate edge streams to the moving lidding web sheet. Other suitable equipment, such as an auxiliary mixer, can be provided in the auxiliary conduit to help make the slurry therein denser, such as by mechanically breaking foam in the slurry and/or by chemically decomposing the foam with a suitable de-foaming agent.

In other embodiments, the first and second delivery branches can each include a foam supply conduit therein, the foam supply conduits being adapted to independently direct aqueous foam into the first and second aqueous calcined gypsum slurry streams delivered to the slurry distributor, respectively. In still other embodiments, a plurality of mixers are provided to provide separate slurry streams to first and second feed inlets of a slurry distributor constructed in accordance with the principles of the present disclosure. It will be appreciated that other embodiments are possible.

The gypsum slurry mixing distribution assembly 910 of fig. 60 is otherwise similar to the gypsum slurry mixing distribution assembly 810 of fig. 59. It is further contemplated that other slurry distributors constructed in accordance with the principles of the present disclosure can be used in other embodiments of cementitious slurry mixing and distribution assemblies as described herein.

Referring to fig. 61, an exemplary embodiment of a wet end 1011 of a gypsum wallboard manufacturing line is shown. The wet end 1011 includes a gypsum slurry mixing and distribution assembly 1010 having: a gypsum slurry mixer 1012 in fluid communication with a slurry distributor 1020, the slurry distributor 1020 being similar in construction and function to the slurry distributor 320 of fig. 6; a hard edge/front skim coat roller 1031 disposed upstream of the slurry distributor 1020 and supported above the forming table 1038 with the first moving cover web sheet 1039 disposed therebetween; a back skim coat roller 1037 disposed above the support element 1041 such that the second moving cover web sheet 1043 is disposed therebetween; and a forming station 1045 adapted to shape the preform to a desired thickness. The skimming surface rollers 1031, 1037, forming table 1038, support elements 1041 and forming station 1045 can each comprise conventional equipment known in the art suitable for their intended purpose. The wet end 1011 can be equipped with other conventional equipment known in the art.

In another aspect of the present disclosure, a slurry distributor constructed in accordance with the principles of the present disclosure can be used in a variety of manufacturing processes. For example, in one embodiment, the slurry distribution system can be used in a method of making a gypsum product. A slurry distributor can be used to distribute the aqueous calcined gypsum slurry onto the first advancing screen 1039.

The water and calcined gypsum can be mixed in mixer 1012 to form first and second aqueous calcined gypsum slurry streams 1047, 1048. In some embodiments, the water and calcined gypsum can be continuously added to the mixer at a water-calcined gypsum ratio of from about 0.5 to about 1.3, and in other embodiments the water-calcined gypsum ratio is about 0.75 or less.

Gypsum board products are typically formed "face down" so that the advancing web 1039 serves as a "face" cover sheet for the finished board. A front skim coat/hard edge stream 1049 (a denser layer of aqueous calcined gypsum slurry relative to at least one of the first and second streams of aqueous calcined gypsum slurry) can be applied to the first moving web 1039 upstream of the hard edge/front skim coat roller 1031 relative to the machine direction 1092 to apply a skim coat to the first web 1039 and define a hard edge of the board.

The first stream 1047 and the second stream 1048 of aqueous calcined gypsum slurry pass through the first feed inlet 1024 and the second feed inlet 1025, respectively, of the slurry distributor 1020. The first and second aqueous calcined gypsum slurry streams 1047, 1048 are combined in a slurry distributor 1020. The first and second aqueous calcined gypsum slurry streams 1047, 1048 move in a streamlined flow along the flow path through the slurry distributor 1020 with minimal or substantially no air-liquid slurry phase separation and substantially no vortex flow path.

The first mobile network 1039 moves along the longitudinal axis 50. The first stream 1047 of aqueous calcined gypsum slurry passes through a first feed inlet 1024 and the second stream 1048 of aqueous calcined gypsum slurry passes through a second feed inlet 1025. The distribution conduit 1028 is positioned such that it extends along a longitudinal axis 50, the longitudinal axis 50 being substantially coincident with the machine direction 1092, the first sheet of lidding material 1039 moving in the machine direction 1092. Preferably, the central midpoint of the distribution outlet 1030 (taken along the transverse axis/cross-machine direction 60) substantially coincides with the central midpoint of the first moving cover sheet 1039. The first and second flows of aqueous calcined gypsum slurry 1047, 1048 are combined in the slurry distributor 1020 such that the combined first and second flows of aqueous calcined gypsum slurry 1051 pass through the distribution outlet 1030 in a distribution direction 1093 generally along the machine direction 1092.

In some embodiments, the distribution conduit 1028 is positioned such that it is substantially parallel to a plane defined by the longitudinal axis 50 and the transverse axis 60 of the first web 1039 moving along the forming table. In other embodiments, the entry portion of the distribution conduit can be disposed vertically lower or higher relative to the first mesh 1039 than the distribution outlet 1030.

The combined first and second aqueous calcined gypsum slurry streams 1051 are discharged from the slurry distributor 1020 onto a first moving web 1039. The front skim coat/hard edge stream 1049 can be deposited from the mixer 1012 onto the first moving web 1039 at a point upstream of the point at which the first and second aqueous calcined gypsum slurry streams 1047, 1048 are discharged from the slurry distributor 1020 in the machine direction 1092 relative to the direction of movement of the first moving web 1039. The combined first and second flows of aqueous calcined gypsum slurry 1047, 1048 can be discharged from the slurry distributor in the cross-machine direction at a reduced momentum per unit to help prevent "wash-off" of the front skim coat/hard edge flow 1049 deposited onto the first moving web 1039 (in the event that portions of the deposited skim coat are displaced from their positions on the moving web 339 in response to impingement of slurry deposited thereon) relative to conventional feed hopper designs.

The first and second flows of aqueous calcined gypsum slurry 1047, 1048 through the first and second feed inlets 1024, 1025, respectively, of the slurry distributor 1020 can be selectively controlled by at least one flow-modifying element 1023. For example, in some embodiments, the first and second flows of aqueous calcined gypsum slurry 1047, 1048 are selectively controlled such that the average velocity of the first flow of aqueous calcined gypsum slurry 1047 through the first feed inlet 1024 is substantially equal to the average velocity of the second flow of aqueous calcined gypsum slurry 1048 through the second feed inlet 1025.

In an embodiment, the first aqueous calcined gypsum slurry stream 1047 passes through the first feed inlet 1024 of the slurry distributor 1020 at an average first feed velocity. The second flow of aqueous calcined gypsum slurry 1048 passes through the second feed inlet 1025 of the slurry distributor 1020 at an average second feed rate. The second feed entry 1025 is in spaced relation to the first feed entry 1024. The first and second aqueous calcined gypsum slurry streams 1051 are combined in a slurry distributor 1020. The combined first and second flows 1051 of aqueous calcined gypsum slurry are discharged from the distribution outlets 1030 of the slurry distributor 1020 at an average discharge velocity onto the cover web sheet 1039 moving in the machine direction 1092. The average discharge velocity is less than the average first feed velocity and the average second feed velocity.

In some embodiments, the average discharge velocity is less than about 90% of the average first feed velocity and the average second feed velocity. In some embodiments, the average discharge velocity is less than about 80% of the average first feed velocity and the average second feed velocity.

The combined first and second aqueous calcined gypsum slurry streams 1051 are discharged from the slurry distributor 1020 through a distribution outlet 1030. The opening of the distribution outlet 1030 has a width extending along the transverse axis 60 and is dimensioned such that the ratio of the width of the first moving cover web sheet 1039 to the width of the opening of the distribution outlet 1030 is between about 1: 1 and about 6: 1 and ranges inclusive of these. In some embodiments, the ratio of the average velocity of the combined first and second aqueous calcined gypsum slurry streams 1051 discharged from the slurry distributor 1020 to the velocity of the moving cover web sheet 1039 moving in the machine direction 1092 can be about 2: 1 or less, and in other embodiments may be from about 1: 1 to about 2: 1.

the combined first and second aqueous calcined gypsum slurry streams 1051 discharged from the slurry distributor 1020 form a spreading pattern on a moving web 1039. At least one of the size and shape of the distribution outlet 1030 can be adjusted, which in turn can change the dispersion pattern.

Thus, the slurry is fed into the two feed inlets 1024, 1025 of the feed conduit 1022 and then exits through the distribution outlet 1030 at an adjustable gap. The polymeric portion 1082 can provide a slight increase in slurry velocity, thereby reducing undesirable exit effects and thus further improving flow stability at the free surface. By utilizing a forming system for cross machine (CD) forming control at the discharge outlet 1030, side-to-side flow variations and/or any local variations can be reduced. The distribution system can help prevent air-liquid slurry separation in the slurry, making the material delivered to the forming station 1038 more uniform and consistent.

A back skim coat stream 1053 (a denser layer of aqueous calcined gypsum slurry relative to at least one of the first and second streams of aqueous calcined gypsum slurry 1047, 1048) can be applied to the second moving web 1043. The back skim coat layer stream 1053 can be deposited from the mixer 1012 at a point upstream of the back skim coat roller 1037 relative to the direction of movement of the second moving web 1043.

In other embodiments, the average velocity of the first and second aqueous calcined gypsum slurry streams 1047, 1048 is varied. In some embodiments, the slurry velocity at the feed inlets 1024, 1025 of the feed conduit 1022 can periodically oscillate between relatively higher and lower average velocities (one inlet having a higher velocity at a point in time than the other inlet and then at a predetermined point in time, or vice versa) to help reduce the potential for agglomeration within its geometry.

In an embodiment, the first flow of aqueous calcined gypsum slurry 1047 through the first feed inlet 1024 has a lower shear rate than the shear rate of the combined first and second flows 1051 discharged from the distribution outlet 1030, and the second flow of aqueous calcined gypsum slurry 1048 through the second feed inlet 1025 has a lower shear rate than the shear rate of the combined first and second flows 1051 discharged from the distribution outlet 1030. In embodiments, the shear rate of the combined first and second streams 1051 discharged from the distribution outlet 1030 can be greater than about 150%, in still other embodiments greater than about 175%, and in still other embodiments greater than or greater than twice the shear rate of the first aqueous calcined gypsum slurry 1047 through the first feed inlet 1024 and/or the second aqueous calcined gypsum slurry stream 1048 through the second feed inlet 1025. It should be appreciated that the viscosities of the first and second aqueous calcined gypsum slurry streams 1047, 1048 and the combined first and second streams 1051 can be inversely related to the shear rate present at a given location such that as the shear rate increases, the viscosity decreases.

In an embodiment, the first flow of hydrous calcined gypsum slurry 1047 through the first feed inlet 1024 has a shear stress lower than the shear stress of the combined first and second flows 1051 discharged from the distribution outlet 1030, and the second flow of hydrous calcined gypsum slurry 1048 through the second feed inlet 1025 has a shear stress lower than the shear stress of the combined first and second flows 1051 discharged from the distribution outlet 1030. In an embodiment, the shear stress of the combined first and second streams 1051 discharged from the distribution outlet 1030 can be greater than about 110% of the shear rate of the first stream 1047 of aqueous calcined gypsum slurry through the first feed inlet 1024 and/or the second stream 1048 of aqueous calcined gypsum slurry through the second feed inlet 1025.

In an embodiment, the first flow of aqueous calcined gypsum slurry 1047 through the first feed inlet 1024 has a reynolds number higher than the reynolds number of the combined first and second flows 1051 discharged from the distribution outlet 1030, and the second flow of aqueous calcined gypsum slurry 1048 through the second feed inlet 1025 has a reynolds number higher than the reynolds number of the combined first and second flows 1051 discharged from the distribution outlet 1030. In embodiments, the reynolds number of the combined first and second streams 1051 discharged from the distribution outlet 1030 can be less than about 90%, in still other embodiments less than about 80%, and in other embodiments less than about 70% of the reynolds number of the first stream 1047 of aqueous calcined gypsum slurry through the first feed inlet 1024 and/or the second stream 1048 of aqueous calcined gypsum slurry through the second feed inlet 1025.

Referring to fig. 62 and 63, an embodiment of a Y-splitter 1100 suitable for use in a gypsum slurry mixing and distribution assembly constructed according to the principles of the present disclosure is shown. The diverter 1100 can be placed in fluid communication with a gypsum slurry mixer and a slurry distributor such that the diverter 1100 receives a single stream of aqueous calcined gypsum slurry from the mixer and discharges two separate streams of aqueous calcined gypsum slurry therefrom to the first and second feed inlets of the slurry distributor. One or more flow conditioning elements can be disposed between the mixer and the flow splitter 1100 and/or between one or both delivery branches that lead between the flow splitter 1100 and an associated slurry distributor.

The flow splitter 1100 has a substantially circular inlet 1102 arranged in a main branch 1103 and a pair of substantially circular outlets 1104, 1106 arranged in first and second outlet branches 1105, 1107 respectively, the main branch 1103 being adapted to receive a single flow of slurry, the outlets 1104, 1106 allowing two flows of slurry to be discharged from the flow splitter 1100. The cross-sectional area of the openings of the inlet 1102 and outlets 1104, 1106 can be varied depending on the desired flow rate. In embodiments where the cross-sectional area of the openings of the outlets 1104, 1106 are each substantially equal to the cross-sectional area of the opening of the inlet 1102, the flow rate of the slurry exiting each outlet 1104, 1106 can be reduced to about 50% of the velocity of the single flow of slurry entering the inlet 1102, where the volumetric flow through the inlet 1102 and the two outlets 1104, 1106 is substantially the same.

In some embodiments, the outlets 1104, 1106 can be made smaller in diameter than the inlet 1102, thereby maintaining a relatively high flow rate throughout the flow splitter 1100. In embodiments where the cross-sectional area of the openings of the outlets 1104, 1106 are respectively smaller than the cross-sectional area of the opening of the inlet 1102, the flow rate is maintained in the outlets 1104, 1106, or at least reduced to a lesser degree than if the outlets 1104, 1106 and the inlet 1102 were all of substantially equal cross-sectional area. For example, in some embodiments, the flow splitter 1100 has an inlet 1102, and the inlet 1102 has an Inner Diameter (ID) of about 3 inches₁) And each outlet 1104, 1106 has an ID of about 2.5 inches₂(although other inlet and outlet diameters can be used in other embodiments). In embodiments having these dimensions at a linear velocity of 350fpm, the smaller diameter of the outlets 1104, 1106 reduces the flow velocity at each outlet by about 28% of the flow velocity of the single slurry stream at the inlet 1102.

The flow splitter 110 may include a central contoured portion 1114 and a junction 1120 between the first and second outlet branches 1105, 1107. The central profile 1114 forms a restriction 1108 in a central interior region of the flow splitter 1100 upstream of the junction 1120, the restriction 1108 helping to promote flow to the outer edges 1110, 1112 of the flow splitter to reduce slurry buildup at the junction 1120. Center profile part 1114 are shaped such that guide channels 1111, 1113 are formed adjacent to the outer edges 1110, 1112 of the flow splitter 1100. The restrictions 1108 in the central profile 1114 have a height H which is greater than the height of the guide channels 1111, 1113₃Smaller height H₂. The guide channels 1111, 1113 have a cross-sectional area larger than the cross-sectional area of the central restriction 1108. As a result, the flowing slurry encounters less flow resistance through the guide channels 1111, 1113 than through the central restriction 1108 and is directed toward the outer edge of the diverter junction 1120.

The junction 1120 establishes an opening to the first and second outlet branches 1105, 1107. Junction 1120 is comprised of a planar wall surface 1123 that is substantially perpendicular to inlet flow direction 1125.

Referring to fig. 64, in some embodiments, an automated device 1150 for squeezing the shunt 1100 at adjustable and regular intervals can be provided to prevent solids from collecting inside the shunt 1100. In some embodiments, the pressing device 1150 may include a pair of plates 1152, 1154 disposed on opposite sides 1142, 1143 of the central profile 1114. The plates 1152, 1154 are movable relative to each other by means of a suitable actuator 1160. The actuator 1160 can be automatically or selectively operated to move the plates 1152, 1154 together relative to each other to apply a compressive force on the shunt 1100 at the central profile 1114 and junction 1120.

When the compression device 1150 compresses the shunt, the compression action applies a compressive force to the shunt 1100, and the shunt 1100 flexes inwardly in response. This pressure force can help prevent solids from accumulating inside the flow splitter 1100, which could disrupt a substantially equal split through the outlets 1104, 1106 to the slurry distributor. In some embodiments, the squeezing device 1150 is designed to automatically pulse through the use of a programmable controller operatively arranged with an actuator. The duration of the application of the compressive force by the squeezing means 1150 and/or the interval between the pulsations can be adjusted. Further, the stroke length of travel of plates 1152, 1154 relative to each other in the compression direction can be adjusted.

In embodiments, a method of making a cementitious product can be performed using a slurry distributor constructed according to the principles of the present disclosure. A stream of aqueous cementitious slurry is discharged from the mixer. A flow of aqueous cementitious slurry is passed through the feed inlet of the slurry distributor along a first feed flow axis at an average feed velocity. The aqueous cementitious slurry stream is passed into the bulb of the slurry distributor. The bulbous portion has an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region with respect to a flow direction from the feed inlet. The bulbous portion is configured to reduce the average velocity of the flow of aqueous cementitious slurry moving from the feed inlet through the bulbous portion. The shaped pipe has a convex inner surface in facing relationship with the first feed flow axis to move the flow of aqueous cementitious slurry in radial flow in a plane substantially perpendicular to the first feed flow axis. The flow of aqueous cementitious slurry is passed into a transition section extending along a second feedstream axis in a non-parallel relationship to the first feedstream axis.

The flow of aqueous cementitious slurry is delivered into a distribution conduit that includes a distribution outlet extending a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

In an embodiment, the flow of slurry moving through the region adjacent to the convex inner surface and adjacent to the at least one lateral sidewall toward the distribution outlet has a swirling motion (S) from zero to about 10_m) And in other embodiments from about 0.5 to about 5. In an embodiment, the flow of slurry moving through the region adjacent to the convex inner surface and adjacent to the at least one lateral sidewall toward the distribution outlet has a swirl angle (S) of from 0 ° to about 84 ° (S)_m）。

In embodiments, the flow of aqueous cementitious slurry passes through a flow stabilization zone adapted to reduce the average feed velocity of the flow of aqueous cementitious slurry entering the feed inlet and moving to the distribution outlet. The aqueous cementitious slurry stream is discharged from the distribution outlet at an average discharge velocity that is at least twenty percent less than the average feed velocity.

In another embodiment, a method of making a cementitious product comprises: a stream of aqueous cementitious slurry is discharged from the mixer. The aqueous cementitious slurry stream passes through the entry portion of the distribution conduit of the slurry distributor. A stream of aqueous cementitious slurry is discharged from a distribution outlet of the slurry distributor onto a cover web sheet moving in the machine direction. The wiping sheet is reciprocally movable along the bottom surface of the distribution conduit between a first position and a second position on a removal path to remove aqueous cementitious slurry therefrom. The clearing path is arranged adjacent to the distribution outlet.

In an embodiment, the distribution conduit extends generally along the longitudinal axis between the entry portion and the distribution outlet. The wiper blade reciprocates longitudinally along the cleaning path.

In an embodiment, the wiping blade moves in a cleaning direction from the first position to the second position during a wiping stroke, and the wiping blade moves in an opposite, return direction from the second position to the first position during a return stroke. The wiper blade is reciprocally moved so that the time of movement in the wiping stroke is substantially the same as the time of movement in the return stroke.

In an embodiment, the wiping blade moves in a cleaning direction from the high and low pressure position to the second position during a wiping stroke, and the wiping blade moves in an opposite, return direction from the second position to the first position during a return stroke. The wiper blade is reciprocally movable between a first position and a second position in a cycle having a sweep period. The sweep cycle includes: a wiping portion that protects a time of movement within a wiping stroke; a return portion that protects the time of movement within the return stroke; and an accumulated delay section that protects the wiper blade from remaining at the first position for a predetermined period of time. In embodiments, the wipe portion is substantially equal to the return portion. In an embodiment, the cumulative delay portion is adjustable.

In additional embodiments, a method of making a cementitious product comprises: a stream of aqueous cementitious slurry is discharged from the mixer. A flow of aqueous cementitious slurry is passed through an entry portion of a distribution conduit of a slurry distributor. The flow of aqueous cementitious slurry is discharged from the outlet opening of the distribution outlet of the slurry distributor onto a cover web sheet moving in the machine direction. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The outlet opening has a width along a transverse axis and a height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis. Portions of the distribution conduit adjacent the distribution outlet are compressibly engaged to change the shape and/or size of the outlet opening. In embodiments, the distribution conduit is compressibly engaged by the forming mechanism to cause the flow of aqueous cementitious slurry to exit the outlet opening at an increased spread angle relative to the machine direction.

In embodiments, the distribution conduit is compressibly engaged by a shaping mechanism having a shaping member in contacting relationship with the distribution conduit. The forming member is movable through a stroke to bring the forming member into a series of positions in which the forming member is in increasing compressive engagement with the distribution conduit. In an embodiment, a method comprises: the shaping member is moved along a vertical axis to adjust the size and/or shape of the outlet opening. In an embodiment, a method comprises: moving the shaping member to translate the shaping member along and/or rotate the shaping member about at least one axis to adjust the size and/or shape of the outlet opening.

Embodiments of slurry distributors, cementitious slurry mixing distribution assemblies, and methods of using the same are provided herein that can provide a number of enhanced process features that facilitate the manufacture of cementitious products, such as gypsum wallboard, in commercial settings. A slurry distributor constructed in accordance with the principles of the present disclosure can facilitate the spreading of aqueous calcined gypsum slurry on a moving cover web as the moving cover web passes through a mixer located at the wet end of a manufacturing line toward a forming station.

A gypsum slurry mixing and distribution assembly constructed in accordance with the principles of the present disclosure is capable of splitting a stream of aqueous calcined gypsum slurry from a mixer into two separate streams of aqueous calcined gypsum slurry, which can be recombined downstream of a slurry distributor constructed in accordance with the principles of the present disclosure to provide a desired pattern of dispersion. The dual inlet configuration and the design of the distribution outlet can allow for a wider spread of the more viscous slurry in the cross-machine direction on the moving lidding web sheet. The slurry distributor can be adapted such that two separate streams of aqueous calcined gypsum slurry enter the slurry distributor along a feed inlet direction that includes a cross-machine direction component, are redirected within the slurry distributor to move the two streams substantially in the machine direction, and are recombined in the distributor in a manner that improves cross-directional uniformity of the combined aqueous calcined gypsum slurry stream discharged from the distribution outlet of the slurry distributor to help reduce mass flow variation over time along the transverse axis or cross-machine direction. Directing the first and second flows of aqueous calcined gypsum slurry in first and second feed directions that include cross-machine direction components can facilitate discharge of the recombined slurry flow from the slurry distributor with reduced momentum and/or energy.

The internal flow cavity of the slurry distributor can be configured such that each of the two slurry streams moves through the slurry distributor in a streamlined flow. The internal flow cavity of the slurry distributor can be configured such that each of the two slurry streams moves through the slurry distributor with minimal or substantially air-liquid slurry phase separation. The internal flow cavity of the slurry distributor can be configured such that each of the two slurry streams moves through the slurry distributor substantially without passing through a vortex flow path.

A gypsum slurry mixing distribution assembly constructed in accordance with the principles of the present disclosure may include a flow geometry upstream of the distribution outlet of the slurry distributor to reduce the slurry velocity in one or more steps. For example, a flow splitter can be disposed between the mixer and the slurry distributor to reduce the velocity of the slurry entering the slurry distributor. As another example, the flow geometry in the gypsum slurry mixing distribution assembly can include an expanded region upstream of and within the slurry distributor to slow the slurry so that it is controllable as it exits the distribution outlet of the slurry distributor.

The geometry of the distribution outlet can also help to control the discharge velocity and momentum of the slurry as it is discharged from the slurry distributor onto the moving cover web sheet. The flow geometry of the slurry distributor can be adapted such that slurry discharged from the distribution outlet is maintained in a substantially two-dimensional flow pattern having a relatively small height compared to the outlet being wider in the cross-machine direction to help improve stability and uniformity.

Under similar operating conditions, a relatively wide discharge outlet produces a lower momentum per unit width of the slurry discharged from the distribution outlet than the momentum per unit width of the slurry discharged from a conventional feed hopper. The reduced momentum per unit width can help prevent washout of the skim coat of the dense layer applied to the sheet of cover web upstream of the point where the slurry is discharged from the slurry distributor onto the web.

Where a conventional hopper outlet 6 inches wide and 2 inches thick is used, the average velocity of the outlet can be about 761ft/min for high volume products. In embodiments where a slurry distributor constructed in accordance with the principles of the present disclosure includes a distribution outlet having openings that are 24 inches wide and 0.75 inches thick, the average velocity can be about 550 ft/min. The mass flow was the same for both devices, 3,437 lb/min. For both cases, the momentum of the slurry (mass flow rate average velocity) was-2,618,000 and 1,891,000 lb-ft/min for conventional feed hopper and slurry distributor, respectively². The corresponding calculated momentum was divided by the width of the conventional hopper outlet and the slurry distributor outlet, and the slurry discharged from the conventional hopper had a momentum per unit width of 402,736 (lb-ft/min)²) /(inches across the width of the feed hopper) and the momentum per unit width of the slurry discharged from a slurry distributor constructed in accordance with the principles of the present disclosure is 78,776 (lb-ft/min 2)/(inches across the width of the slurry distributor). In this case, the slurry discharged from the slurry distributor has a momentum per unit width of about 20% compared to a conventional feed hopper.

A slurry distributor constructed in accordance with the principles of the present disclosure is capable of achieving a desired spreading pattern while using an aqueous calcined gypsum slurry over a wide range of water-stucco ratios, including relatively low WSR or more conventional WSR, such as a water-calcined gypsum ratio from about 0.4 to about 1.2 (e.g., less than 0.75) in some embodiments, and between about 0.4 and about 0.8 in other embodiments. Embodiments of slurry distributors constructed in accordance with the principles of the present disclosure can include an internal flow geometry adapted to produce a controlled shearing effect on the first and second flows of aqueous calcined gypsum slurry as they progress through the slurry distributor from the first and second feed inlets toward the distribution outlet. The application of controlled shear in the slurry distributor can selectively reduce the viscosity of the slurry as a result of being subjected to such shear. Under the effect of controlled shear in the slurry distributor, slurries with lower water-stucco ratios can be distributed from the slurry distributor in a spread pattern along the cross-machine direction as compared to slurries with conventional WSRs.

The internal flow geometry of the slurry distributor can be adapted to further accommodate slurries of various water-stucco ratios to provide enhanced flow adjacent the boundary wall region of the internal geometry of the slurry distributor. By including flow geometry features in the slurry distributor adapted to increase the degree of flow around the boundary wall layer, the tendency of the slurry to recirculate and/or stop flowing and setting in the slurry distributor is reduced. The result is therefore a reduced build-up of set slurry in the slurry distributor.

A slurry distributor constructed in accordance with the principles of the present disclosure may include a shaping system mounted adjacent to the distribution outlet to vary the cross-machine velocity component of the combined slurry stream discharged from the distribution outlet to selectively control the spread angle and spread width in the cross-machine direction of the slurry on a substrate moving down the manufacturing line toward the forming station. The forming system can help the slurry discharged from the distribution outlet achieve a desired spreading pattern while being less sensitive to slurry viscosity and WSR. The forming system can be used to alter the flow dynamics of the slurry discharged from the distribution outlet of the slurry distributor to direct the flow of the slurry such that the slurry has a more uniform velocity in the cross-machine direction. The use of a forming system can also facilitate the use of a gypsum slurry mixing and distribution assembly constructed in accordance with the principles of the present disclosure in gypsum wall manufacturing equipment to produce wallboard of different types and volumes.

Accordingly, in an embodiment, a slurry distributor, comprises: a distribution conduit extending generally along a longitudinal axis and including an inlet portion, a distribution outlet in fluid communication with the inlet portion, and a floor extending between the inlet portion and the distribution outlet, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis. A slurry wiping mechanism including a movable wiping blade in contacting relationship with the bottom surface of the distribution conduit, the wiping blade reciprocally movable between a first position and a second position over a purge path disposed adjacent the distribution outlet.

In another embodiment, the distribution outlet comprises an outlet opening having a width along the transverse axis and a height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis, wherein the outlet opening has an aspect ratio of about 4 or greater.

In another embodiment, the distribution outlet includes an outlet opening having a width along the transverse axis, the wiping sheet extends along the transverse axis a predetermined second distance, the width of the outlet opening is less than the second distance along the transverse axis such that the wiping sheet is wider than the outlet opening.

In another embodiment, the wiping blade reciprocates longitudinally along the purge path, and the first position of the wiping blade is longitudinally upstream of the distribution outlet and the second position is longitudinally downstream of the distribution outlet.

In another embodiment, the slurry wiping mechanism includes an actuator operatively arranged with the wiping blade to selectively reciprocate the wiping blade.

In another embodiment, the actuator comprises a pneumatic cylinder having a reciprocally movable piston connected to the wiper blade.

In another embodiment, the slurry wiping mechanism includes a controller adapted to selectively control the actuator to reciprocally move the wiping blade.

In another embodiment, the controller is adapted to move the wiping blade in a cleaning direction over a wiping stroke from the first position to the second position, and the controller is adapted to move the wiping blade in an opposite, return direction over a return stroke from the second position to the first position, and wherein the controller is adapted to move the wiping blade such that the time of movement over the wiping stroke is substantially the same as the time of movement over the return stroke.

In another embodiment, the controller is adapted to move the wiper blade in a cleaning direction over a wiping stroke from the first position to the second unknown and in an opposite, return direction over a return stroke from the second position to the first position, and wherein the controller is adapted to move the wiper blade back and forth between the first position and the second position in a cycle having a wiping cycle comprising: a wiping portion containing a time of movement over the wiping stroke; a return portion including a time of movement on the return stroke; and a cumulative delay portion that contains a predetermined period of time during which the wiper blade is held at the first position.

In another embodiment, the wipe portion is substantially identical to the return portion.

In another embodiment, the cumulative delay portion is adjustable.

In another embodiment, a slurry distributor comprises: a feed conduit including a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit.

In another embodiment, the first and second feed inlets and the first and second entry sections are arranged at respective feed angles in a range up to about 135 ° relative to the longitudinal axis.

In another embodiment, a cementitious slurry mixing and distribution assembly comprising: a mixer adapted to agitate water and cementitious binder to form an aqueous cementitious slurry; a slurry distributor in fluid communication with the mixer. The slurry distributor includes: a distribution conduit extending generally along a longitudinal axis and including an inlet portion, a distribution outlet in fluid communication with the inlet portion, and a floor extending between the inlet portion and the distribution outlet, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis. A slurry wiping mechanism including a movable wiping blade in contacting relationship with the bottom surface of the distribution conduit, the wiping blade reciprocally movable over a purge path between a first position and a second position, the purge path disposed adjacent the distribution outlet.

In another embodiment, the distribution outlet includes an outlet opening having a width along the transverse axis, the wiping blade extends a predetermined second distance along the transverse axis, and wherein the wiping blade reciprocates longitudinally along the purge path.

In another embodiment, the cementitious slurry mixing and distribution assembly further comprises: a bottom support member supporting the bottom surface of the distribution conduit, the bottom support member having a perimeter, the distribution outlet being longitudinally offset from the bottom support member such that a distal outlet portion of the distribution conduit extends from the perimeter of the bottom support member. Wherein the wiping blade supports the distal outlet portion of the slurry distributor when the wiping blade is in the first position.

In another embodiment, the cementitious slurry mixing and distribution assembly further comprises: a delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor. A flow conditioning element associated with the delivery conduit and adapted to control flow of the aqueous cementitious slurry from the mixer. An aqueous foam supply conduit in fluid communication with at least one of the mixer and the delivery conduit.

In another embodiment, the slurry distributor comprises a feed conduit comprising a first entry section and a second entry section, the first entry section having a first feed inlet, the second entry section having a second feed inlet, said second feed inlet being disposed in spaced relation to said first feed inlet, said entry portion of said distribution conduit being in fluid communication with said first and second feed inlets of said feed conduit, the first feed inlet is adapted to receive a first flow of aqueous cementitious slurry from the mixer, the second feed inlet is adapted to receive a second flow of aqueous cementitious slurry from the mixer, and the distribution outlet is in fluid communication with both the first and second feed inlets and is adapted to cause the first and second flows of aqueous cementitious slurry to be discharged from the slurry distributor through the distribution outlet.

In another embodiment, the cementitious slurry mixing and distribution assembly further comprises: a delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor, the delivery conduit including a main delivery trunk and first and second delivery branches. A diverter joining the main delivery trunk and the first and second delivery branches, the diverter disposed between the main delivery trunk and the first delivery branch and between the main delivery trunk and the second delivery branch. Wherein the first conveying branch is in fluid communication with the first feed inlet of the slurry distributor and the second conveying branch is in fluid communication with the second feed inlet of the slurry distributor.

In another embodiment, a method of making a cementitious product comprises: (a) discharging a stream of aqueous cementitious slurry from the mixer; (b) passing the aqueous cementitious slurry stream through an entry portion of a distribution conduit of a slurry distributor; (c) discharging the flow of aqueous cementitious slurry from a distribution outlet of the slurry distributor as the cover web sheet moves in the machine direction; and (d) reciprocally moving a wiping blade along the bottom surface of the distribution conduit between a first position and a second position on a removal path to remove aqueous cementitious slurry therefrom, the removal path being disposed adjacent the distribution outlet.

In another embodiment, a method of making a cementitious product comprises: the distribution conduit extends generally along a longitudinal axis between the entry portion and the distribution outlet, and wherein the wiper blade reciprocates longitudinally along the purge path.

In another embodiment, a method of making a cementitious product comprises: the wiper blade moves in a cleaning direction on a wiping stroke from the first position to the second position and the wiper blade moves in an opposite, return direction on a return stroke from the second position to the first position, and wherein the wiper blade moves reciprocally such that the time of movement on the wiping stroke is substantially the same as the time of movement on the return stroke.

In another embodiment, a method of making a cementitious product comprises: the wiper blade moves in a cleaning direction from the first position to the second position on a wiping stroke and the wiper blade moves in an opposite, return direction from the second position to the first position on a return stroke, and wherein the wiper blade moves back and forth between the first position and the second position in a cycle having a sweep cycle comprising: a wiping portion containing a time of movement over the wiping stroke; a return portion including a time of movement on the return stroke; and a cumulative delay portion that contains a predetermined period of time during which the wiper blade is held at the first position.

In another embodiment, a method of making a cementitious product comprises: the wipe portion is substantially identical to the return portion.

In another embodiment, a method of making a cementitious product comprises: the cumulative delay portion is adjustable.

Examples

Referring to fig. 65, the geometry and flow characteristics of an embodiment of a slurry distributor constructed according to the principles of the present disclosure were evaluated in examples 1-3. Fig. 65 shows a top plan view of a half 1205 of a slurry distributor. The slurry distributor halves 1205 include the feed conduit 320 half 1207 and the distribution conduit 328 half 1209. The half 1207 of the feed conduit 322 includes a second feed inlet 325 defining a second opening 335, a second entry section 337, and a half 1211 of a bifurcated connector section 339. The half 1209 of the distribution conduit 328 includes the half 1214 of the inlet portion 352 of the distribution conduit 328 and the half 1217 of the distribution outlet 330.

It should be understood that the other half of the slurry distributor, which is a mirror image of half 1205 of fig. 65, can be integrally joined and aligned with half 1205 of fig. 65 at the transverse central midpoint 387 of the distribution outlet 330 to form a slurry distributor substantially similar to slurry distributor 420 of fig. 15. Thus, the geometry and flow characteristics described below apply equally to the mirrored half of the slurry distributor.

Referring to fig. 72, the geometry and flow characteristics of another embodiment of a slurry distributor 2020 constructed in accordance with the principles of the present disclosure are evaluated in examples 4-6. The slurry distributor 2020 shown in fig. 72 is substantially the same as the slurry distributor 1420 of fig. 34. The flow characteristics of the slurry distributor 2020 of fig. 72 using a forming mechanism constructed in accordance with the principles of the present disclosure were evaluated in example 7. The forming mechanism evaluated in example 7 was substantially the same as the forming mechanism 1432 of fig. 22.

Thus, in an embodiment, a slurry distributor comprises a feed conduit comprising an entry section having a feed inlet and a feed entry outlet in fluid communication with the feed inlet. The entry section extends along a first feed flow axis. The feed conduit includes a shaped tube having a bulbous portion in fluid communication with the feed inlet outlet of the entry segment. The feed conduit includes a transition segment in fluid communication with the bulb. The transition section extends along the second feed flow axis. The second feed flow axis is in a non-parallel relationship to the first feed flow axis. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the feed inlet of the feed conduit. The distribution outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The bulbous portion has an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a flow direction from the feed inlet toward the distribution outlet of the distribution conduit. The shaped duct has a convex inner surface in facing relationship with the feed entry outlet of the entry segment.

In another embodiment, the first feed flow axis of the slurry distributor is substantially perpendicular to the longitudinal axis.

In another embodiment, the first feed flow axis of the slurry distributor is substantially parallel to a vertical axis that is perpendicular to the longitudinal axis and the lateral axis.

In another embodiment, the second feed flow axis of the slurry distributor is arranged at a respective feed angle in a range of up to about 135 ° with respect to the longitudinal axis.

In another embodiment, the feed conduit of the slurry distributor comprises: a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet; a second shaped duct having a bulbous portion in fluid communication with the feed inlet outlet of the second inlet section; and a second transition segment in fluid communication with the bulb portion of the second shaped duct. The entry portion of the distribution conduit is in fluid communication with the first and second feed inlets of the feed conduit.

In another embodiment, the feed conduit of the slurry distributor comprises a bifurcated connector section comprising first and second guide surfaces. The first and second guide surfaces are adapted to redirect a first flow of slurry entering the feed conduit through the first inlet to an outlet flow direction by a change in direction angle in a range up to about 135 ° and to redirect a second flow of slurry entering the feed conduit through the second inlet to an outlet flow direction by a change in direction angle in a range up to about 135 °, respectively.

In another embodiment, the bulbous portion of the slurry distributor comprises a cross-sectional area in a plane perpendicular to the first flow axis that is greater than the cross-sectional area fed into the outlet.

In another embodiment, the bulbous portion of the slurry distributor comprises a generally radial guide channel disposed adjacent the convex inner surface. The guide channel is configured to promote radial flow in a plane substantially perpendicular to the first feed flow axis.

In another embodiment, the bulbous portion of the slurry distributor is configured to reduce the average velocity of the slurry stream passing through the bulbous portion from the entry section to the transition section.

In another embodiment, the bulbous portion of the slurry distributor is configured to reduce the average velocity of the slurry stream passing through the bulbous portion from the entry section to the transition section by at least twenty percent.

In another embodiment, a slurry distributor includes a rigid support insert having a support surface that substantially conforms to the shape of the convex inner surface of the shaped conduit. The support insert is disposed in underlying relation to the convex interior surface.

In another embodiment, the shaped conduit of the slurry distributor has a concave outer surface that is substantially complementary in shape to the convex inner surface. The shaped duct is in underlying relationship with the concave outer surface defining the recess. The support insert is disposed within the recess.

In another embodiment, a support insert of a slurry distributor includes a feed end and a distribution end. The support insert extends along a central support axis and is substantially symmetrical about the support axis.

In another embodiment, the support insert of the slurry distributor is asymmetric about a central axis perpendicular to the support axis.

In another embodiment, the shaped duct of the slurry distributor comprises a pair of lateral sidewalls. The shaped conduit is configured such that a flow of slurry moving through a region adjacent the convex inner surface and adjacent the at least one lateral sidewall toward the distribution outlet has a swirling motion (S) from about zero to about 10_m）。

In another embodiment, the slurry stream moving toward the distribution outlet through the region adjacent the convex inner surface and adjacent the at least one lateral sidewall has a swirling motion (S) from about 0.5 to about 5_m）。

In another embodiment, the flow of slurry moving through the region adjacent to the convex inner surface and adjacent to the at least one lateral sidewall toward the distribution outlet has a swirl angle (S) of from about 0 ° to about 84 ° (S)_m）。

In another embodiment, the distribution outlet of the slurry distributor comprises an outlet opening having an outlet width along a transverse axis and a distribution outlet height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis. The entry portion includes an entry opening having a distribution entry width along the lateral axis and an entry height along the vertical axis, wherein the distribution entry width is less than the distribution exit width.

In another embodiment, the width to height ratio of the outlet openings of the slurry distributor is about 4 or greater.

In another embodiment, at least one of the feed conduit and the distribution conduit of the slurry distributor includes a flow stabilizing zone adapted to reduce the average feed velocity of the slurry stream entering the feed inlet and moving to the distribution outlet such that the slurry stream is discharged from the distribution outlet at an average discharge velocity that is at least twenty percent lower than the average feed velocity.

In another embodiment, a slurry distributor includes a bifurcated feed conduit including first and second feed portions each having an entry section with a feed inlet and a feed entry outlet in fluid communication with the feed inlet. The entry segment extends generally along a vertical axis. The shaped pipe with the bulb is in fluid communication with the feed inlet outlet of the inlet section. The transition section is in fluid communication with the bulb and extends along a longitudinal axis, and the longitudinal axis is perpendicular to the vertical axis. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The first and second bulbs each have an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a direction of flow from the respective first and second feed inlets toward the distribution outlet of the distribution conduit. The first and second shaped conduits each have a convex inner surface in facing relationship with the respective first and second feed inlet outlets of the first and second inlet sections.

In another embodiment, the slurry distributor includes first and second rigid support inserts each having a support surface that substantially conforms to the shape of the convex inner surfaces of the first and second shaped conduits. The support inserts are respectively disposed in underlying relationship with the convex inner surfaces.

In another embodiment, the first and second feed inlets and the first and second entry sections are arranged at respective feed angles relative to the longitudinal axis in a range up to about 135 °.

In another embodiment, the first and second feed inlets and the first and second entry sections are arranged at respective feed angles that are substantially aligned with the longitudinal axis.

In another embodiment, the cementitious slurry mixing and distribution assembly includes a mixer adapted to agitate water and cementitious slurry to form an aqueous cementitious slurry. The slurry distributor is in fluid communication with the mixer. The slurry distributor includes a feed conduit including an entry section having a feed inlet and a feed entry outlet in fluid communication with the feed inlet. The entry section extends along a first feed flow axis. The feed conduit includes a shaped pipe having a bulbous portion in fluid communication with the feed inlet outlet of the entry segment. The feed conduit also includes a transition segment in fluid communication with the bulb. The transition section extends along the second feed flow axis. The second feed flow axis is in a non-parallel relationship to the first feed flow axis. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The inlet portion is in fluid communication with the feed inlet of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The bulbous portion has an expanded region having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a flow direction from the feed inlet toward the distribution outlet of the distribution conduit. The shaped duct has a convex inner surface in facing relationship with the feed inlet outlet of the entry segment.

In another embodiment, a method of making a cementitious product comprises: (a) discharging a stream of aqueous cementitious slurry from the mixer; (b) passing a flow of aqueous cementitious slurry through a feed inlet of a slurry distributor along a first feed flow axis at an average feed speed; (c) passing the flow of aqueous cementitious slurry into a bulbous portion of the slurry distributor, the bulbous portion having an expanded region with a cross-sectional flow area greater than a cross-sectional flow area of an adjacent region upstream of the expanded region relative to a direction of flow from the feed inlet, the bulbous portion being configured to reduce an average velocity of the flow of aqueous cementitious slurry moving from the feed inlet through the bulbous portion; (d) passing the flow of aqueous cementitious slurry into a transition section extending along a second feedstream axis, the second feedstream axis being in a non-parallel relationship to the first feedstream axis; and (e) passing the flow of aqueous cementitious slurry into a distribution conduit comprising a distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis. The shaped pipe has a convex inner surface in facing relationship with the first feed flow axis to move the flow of aqueous cementitious slurry in a radial flow in a plane substantially perpendicular to the first feed flow axis.

In another embodiment, the method of making a cementitious product further comprises: the slurry stream moving through the region adjacent the convex inner surface and adjacent the at least one lateral sidewall toward the distribution outlet has a swirling motion (S) of from about zero to about 10_m）。

In another embodiment, the slurry stream moving toward the distribution outlet through the region adjacent the convex inner surface and adjacent the at least one lateral sidewall has a swirling motion (S) of from about 0.5 to about 5_m）。

In another embodiment, the flow of slurry moving through the region adjacent the convex inner surface and adjacent the at least one lateral sidewall toward the distribution outlet has a swirl angle (S) of from about 0 ° to about 84 ° (S)_m）。

In another embodiment, the method of making a cementitious product further comprises: passing the flow of aqueous cementitious slurry through a flow stabilization zone adapted to reduce the average feed velocity of the flow of aqueous cementitious slurry entering the feed inlet and moving to the distribution outlet; and discharging the stream of aqueous cementitious slurry from the distribution outlet at an average discharge velocity that is at least twenty percent lower than the average feed velocity.

Example 1

In this embodiment and referring to FIG. 65, in the first position L of the second feed inlet 325₁And sixteenth position L of half 1207 of distribution outlet 330₁₆Sixteen different positions L therebetween_1-16The specific geometry of the half 1205 of the slurry distributor is evaluated. Each position L_1-16A cross-sectional slice of the half 1205 of the slurry distributor as indicated by the corresponding line is shown. The flow line 1212 along the center of the geometry of each cross-sectional slice is used to determine the adjacent location L_1-16The distance between them. Eleventh position L₁₁Corresponding to the half 1214 of the inlet portion 352 of the distribution conduit 328, which corresponds to the opening 342 of the second feeding outlet 345 of the half 1207 of the feeding conduit 320. Thus, the first to tenth positions L_1-10Are taken in the half 1207 of the feed conduit 320 and the eleventh through sixteenth positions are taken in the half 1209 of the distribution conduit 328.

For each position L_1-16The following geometry values were determined: at the second feed inlet 325 and a specific location L_1-16The distance along flow line 1212; the opening being in position L_1-16The cross-sectional area of; position L_1-16The circumference of (a); and position L_1-16Hydraulic diameter of (2). The hydraulic diameter is calculated using the following formula:

D_hyd=4 × A/P (equation 1)

Wherein D_hydIn order to be the hydraulic diameter,

a is a specific position L_1-16And an area of

P is a specific position L_1-16The circumference of (a).

Using the entry conditions, each location L can be determined_1-16To describe the internal flow geometry, as shown in table 1. A curve fitting equation is used to describe the dimensionless geometry of the half 1205 of the slurry distributor in fig. 66, with fig. 66 showing the dimensionless distance from the inlet versus the dimensionless area and hydraulic diameter.

For each position L_1-16Indicates that the cross-sectional flow area is from the first location L at the second feed inlet 325₁To the eleventh position L at the half 1214 of the entry portion 352 (also at the opening 342 of the second feed outlet 345)₁₁And (4) increasing. In the exemplary embodiment, the cross-sectional flow area at half 1214 of entry 352 is approximately 1/3 greater than the cross-sectional flow area at second feed inlet 325. In the first position L₁And an eleventh position L₁₁From position to position L, the cross-sectional flow area of the second entry land 337 and the second shaped duct 339_1-11And (4) changing. In the region, at least two adjacent positions L₆、L₇A position L configured to be positioned farther from the second feed inlet 325₇Having an adjacent position L closer to the second feed inlet 325₆Smaller cross-sectional flow area.

In the first position L₁And an eleventh position L₁₁In between, in the half 1207 of the feed conduit 322, there is an expansion region (e.g., L)_4-6) Having an adjacent area (e.g., L) upstream of the expanded area in a direction from the second inlet 335 toward the half 1217 of the distribution outlet 330₃) Has a large cross-sectional flow area. The second entry land 337 and the second shaped conduit 341 have cross-sectional areas that vary along the flow direction 1212 to help distribute the second flow of slurry moving therethrough.

The cross-sectional area extends from an eleventh location L at a half 1214 of the entry portion 352 of the distribution conduit 328₁₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In thatIn the exemplary embodiment, the cross-sectional flow area of half 1214 of inlet portion 352 is approximately 95% of the cross-sectional flow area of half 1217 of distribution outlet 330.

A first position L at the second feed inlet 325₁At a cross-sectional flow area ratio of the sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The cross-sectional flow area is small. In the exemplary embodiment, the cross-sectional flow area at the half 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately 1/4 greater than the cross-sectional flow area at the second feed inlet 325.

The hydraulic diameter is measured from a first location L at the second feed inlet 325₁To an eleventh location L at the half 1214 of the entry portion 352 of the distribution conduit 328₁₁And decreases. In the exemplary embodiment, the hydraulic diameter at half 1214 of entry portion 352 of distribution conduit 328 is approximately 1/2 of the hydraulic diameter at second feed inlet 325.

The hydraulic diameter is measured from the eleventh location L at the half 1214 of the entry portion 352 of the distribution conduit 328₁₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the exemplary embodiment, the hydraulic diameter of the half 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately 95% of the hydraulic diameter of the half 1214 of the inlet portion 352 of the distribution conduit 328.

A first position L at the second inlet 325₁At a hydraulic diameter ratio of the sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The hydraulic diameter of the (C) is large. In the exemplary embodiment, the hydraulic diameter at the half 1217 of the distribution outlet 330 of the distribution conduit 328 is less than approximately half of the hydraulic diameter of the second feed inlet 325.

Example 2

In this example, the half 1205 of the slurry distributor of fig. 65 is used to model the flow of gypsum slurry therethrough under different flow conditions. The density (. rho.) of the aqueous gypsum slurry was set to 1,000kg/m for all flow conditions³. The aqueous gypsum slurry is a shear-thinning material such that its viscosity can be reduced as shear is applied thereto. The viscosity (μ) pa.s of the gypsum slurry was calculated using a power law fluid model with the following equation:

<math><mrow> <mi>&mu;</mi> <mo>=</mo> <mi>K</mi> <msup> <mover> <mi>&gamma;</mi> <mo>&CenterDot;</mo> </mover> <mrow> <mi>n</mi> <mo>-</mo> <mn>1</mn> </mrow> </msup> </mrow></math> (equation 2)

Wherein,

k is a constant, and K is a constant,

to a shear rate, and

in this case N is a constant equal to 0.133.

Under first flow conditions, the gypsum slurry has a viscosity coefficient K of 50 in the power law model and enters the second feed inlet 325 at 2.5 m/s. Computational fluid dynamics techniques using finite volume methods are used to determine flow characteristics in the distributor. At each position L_1-16The following flow characteristics were determined: area weighted average velocity(U), area weighted average shear rateViscosity, shear stress, and Reynolds number (Re) calculated using the power law model (equation 2).

The shear stress was calculated using the following equation:

wherein

μ is the viscosity calculated using the power law model (equation 2), an

Is the shear rate.

The reynolds number is calculated using the equation:

Re==ρ×U×D_hydmu (equation 4)

Wherein

ρ is the density of the gypsum slurry,

u is the area-weighted average velocity,

D_hydis the hydraulic diameter, and

μ is the viscosity calculated using the power law model (equation 2).

In the second flow condition, the feed rate of the gypsum slurry into the second feed inlet 325 is increased to 3.55 m/s. All other conditions were the same as the first fluid conditions of this example. For each position L, both for the first fluid condition with an inlet velocity of 2.5m/s and for the second fluid condition with an inlet velocity of 3.55m/s_1-16Of (2) aDimensionless values of the dynamic characteristics are modeled. Determining each position L using entry conditions_1-16As shown in table II.

For two fluid conditions where K is set equal to 50, the average velocity is from the first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the average velocity is reduced by about 1/5, as shown in fig. 67.

For both fluid conditions, the shear rate is from the first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And (4) increasing. In the illustrated embodiment, the shear rate is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆Approximately doubled as shown in fig. 68.

For both fluid conditions, the calculated viscosity is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the calculated viscosity is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The reduction is approximately half as shown in fig. 69.

For both flow conditions in FIG. 70, shear stress is induced from the first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And (4) increasing. In the illustrated embodiment, the shear stress is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The increase is approximately 10%.

Reynolds number in FIG. 71 for two fluid conditions is from the secondA first position L at the two feed inlets 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the Reynolds number is from the first position L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The approximation 1/3 is reduced. For both fluid conditions, a sixteenth position L at half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆In the laminar flow region.

Example 3

In this example, the half 1205 of the slurry distributor of fig. 65 was used to model the flow of gypsum slurry therethrough under similar fluid conditions as in example 2, except that the value of the coefficient K in the power law model (equation 2) was set to 100. The flow conditions were otherwise similar to those in example 2.

Also, the flow characteristics were evaluated for both a feed rate of 2.50m/s and 3.55m/s of gypsum slurry into the second feed inlet 325. At each position L_1-16The following flow characteristics were determined: area weighted average velocity (U), area weighted average shear rateViscosity, shear stress (eq. 3), and reynolds number (Re) (eq. 4) calculated using a power law model (eq. 2). Determining each position L using entry conditions_1-16As shown in table III.

For two flow conditions with K set equal to 100, the average velocity is from the first position at the second feed inlet 325Put L₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the average velocity is reduced by about 1/5. On a dimensionless basis, the results for the average velocities were essentially the same as those in example 2 and fig. 67.

For both flow conditions, the shear rate is from the first location L at the second feed inlet 324₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And (4) increasing. In the illustrated embodiment, the shear rate is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆Approximately doubled. On a dimensionless basis, the shear rate results were essentially the same as those in example 2 and figure 68.

For both flow conditions, the viscosity is calculated from the first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the viscosity is calculated from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆Reduced by approximately half. On a dimensionless basis, the results of calculating viscosity were essentially the same as those in example 2 and fig. 69.

For both flow conditions, the shear stress is from the first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And (4) increasing. In the illustrated embodiment, the shear stress is from a first location L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆The increase is about 10%. On a dimensionless basis, the results for shear stress are essentially the same as those in example 2 and fig. 70.

Reynolds number is fed in from the second feed for both flow conditionsFirst position L at port 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆And decreases. In the illustrated embodiment, the Reynolds number is from the first position L at the second feed inlet 325₁To a sixteenth position L at the half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆A reduction of about 1/3. For both flow conditions, a sixteenth position L at half 1217 of the distribution outlet 330 of the distribution conduit 328₁₆In the laminar flow region. On a dimensionless basis, the results for reynolds numbers are essentially the same as those in example 2 and figure 71.

Fig. 67-71 are graphs of flow characteristics calculated for different flow conditions of examples 2 and 3. A curve fitting equation is used to describe the change in flow characteristics over the distance from the feed inlet to the half of the distribution outlet. Thus, examples 2 and 3 demonstrate that the flow characteristics are consistent with respect to changes in inlet velocity and/or viscosity.

Example 4

In this embodiment, the slurry distributor 2020 of fig. 72 is used to model the flow of gypsum slurry at one of the bulbous portions 2120 of the feed conduit 2022. Referring to fig. 72, the first and second entry sections 2036, 2037 of the slurry distributor 2020 each have a diameter D. The slurry distributor 2020 has a length along the longitudinal axis that is about 12 xd. The slurry distributor 2020 is symmetric about a central longitudinal axis 50 that extends generally in the machine direction 2192. The slurry distributor 2020 can be divided into two halves 2004, 2005, which are substantially symmetrical about a central longitudinal axis.

Referring to fig. 73, the half 2004 of the slurry distributor of fig. 72 was used to model the flow of gypsum slurry therethrough under similar flow conditions as in example 2 except that a different dimensionless viscosity expression was used. The inlet diameter D (x × = x/D) is selected as a length scale to non-dimensionalize the position vector x (x × = x/D), and the average inlet velocity (U) is used as a velocity scale to non-dimensionalize the velocity vector U (U × = U/U). The flow conditions were otherwise similar to those in example 2.

Referring to fig. 73-76, a Computational Fluid Dynamics (CFD) technique using a finite volume method is used to determine flow characteristics in the half of the distributor. In particular, the average velocities from different vertical positions in the area a are calculated. The analysis was performed for a region extending approximately 0.75D from the center of the entry segment in region a. Twelve radially spaced vertical slices were analyzed to calculate twelve different average slurry velocities radially around the bulb. The twelve locations are substantially radially spaced apart such that adjacent radial locations are separated by approximately 30. Referring to fig. 75 and 76, radial position 1 corresponds to a direction in an opposite relationship to the machine direction 2192, and radial position 7 corresponds to the machine direction 2192. Radial positions 4 and 10 are substantially aligned with transverse axis 60.

The CFD technique is used with two different inlet velocity conditions, U1= U and U2= 1.5U. The results of the CFD analysis are seen in table IV. Velocity magnitude is expressed as a dimensionless absolute value (| U | = | U |/U). The data are also plotted in fig. 77. It should be understood that the other half 2005 of the slurry distributor 2020 will exhibit similar flow characteristics.

For both flow conditions, the average velocity at each radial position 1-12 is less than the inlet velocity, but greater than zero. Ranging from about half the inlet velocity to about 7/8 (u x-0.48 to 0.83 of the inlet velocity). The contoured convex dimple surface in the bulb helps redirect flow from the intake section radially outward in all directions.

The slurry velocity is also slowed relative to the inlet velocity. The average velocities for all twelve radial positions are substantially similar (0.65 or 65% of the inlet velocity) for a given flow condition.

Furthermore, the highest average velocities occur at radial positions 3-5 and 9-11 under each flow condition. Higher average velocities along the cross-axis or along the cross-machine direction 60 help provide more edge flow to the lateral sidewalls.

Thus, this embodiment shows that the bulb 2120 helps to slow down the slurry and change the direction of the slurry from a downward vertical direction to a radially outward horizontal plane. In addition, the bulbous portion 2120 helps divert the flow of slurry to the lateral inner and outer sidewalls of the shaped conduit of the half 2004 of the slurry distributor 2020 to facilitate slurry movement in the cross-machine direction 60.

Example 5

In this embodiment, the slurry distributor 2020 of fig. 72 is used to model the gypsum slurry flow at one of the shaped tubes 2041 of the feed conduit 2022. Referring to fig. 78, the half 2004 of the slurry distributor 2020 of fig. 72 was used to model the flow of gypsum slurry therethrough under similar flow conditions as in example 2, except using a dimensionless velocity expression similar to that of example 4. In particular, the swirling motion of the slurry at the lateral inner and outer walls of the shaped pipe is analyzed.

Referring to fig. 73, 74 and 78, a Computational Fluid Dynamics (CFD) technique using a finite volume method is used to determine flow characteristics in the half 2004 of the distributor 2020. In particular, the swirling motion of the slurry near the lateral inner and outer sidewalls of the shaped conduit 2041 is analyzed. Referring to fig. 73, as the slurry enters the shaped conduit 2041, the slurry moves in a swirling manner. As the slurry moves in the machine direction 2192 toward the distribution outlet 2030, the slurry streamlines become more orderly. As shown in fig. 74 and 78, the swirling motion of the slurry is analyzed in a region of the shaped conduit 2041 at a longitudinal position of approximately 1-3/4D (1.72D) in regions B1 and B2.

The swirling motion of the slurry is a function of its tangential velocity and its axial (or machine) velocity. Referring to FIG. 78, the degree of swirl for a vortical flow is generally characterized by the swirl number (S) as angular flux and linear momentum using the following formula:

and r denotes the radial position.

If the average of the tangential velocity and the axial velocity is used in equation 5, it becomes:

for this embodiment, the characteristic swirling motion (S) is expressed by the following equation_m）：

In this embodiment, the calculated vortical motion is used to calculate the vortical angle using the following formula:

vortex angle tan^-1(S_m) (equation 8)

The CFD technique is used with two different dimensionless inlet velocity conditions, u₁= U and U₂= 1.5U. The results of the CFD analysis are shown in table V. It should be understood that the other half of the slurry distributor will exhibit similar flow characteristics. From this analysis, it has been found that, in embodiments, the slurry distributor can be configured to produce a slurry flow rate ranging from about zero to about largeA swirling motion S in the range of about 10_mAnd a swirl angle in the range from about zero degrees to about 84 degrees.

For both flow conditions, the maximum tangential velocity at the edge is at least approximately half the inlet velocity in the edge region of the entry portion of the shaped duct. It is desirable that the swirling motion near the lateral side walls helps to maintain cleanliness of the internal geometry of the slurry distributor while in use. As shown in fig. 73, the swirling motion of the slurry is attenuated along the machine axis 50 in a direction flowing toward the distribution outlet 2030.

Example 6

In this embodiment, the slurry distributor 2020 of fig. 72 is used to model the flow of gypsum slurry through the feed conduit 2022 and the distribution conduit 2028. Referring to fig. 73 and 74, the half 2004 of the slurry distributor 2020 of fig. 72 was used to model the flow of gypsum slurry therethrough under similar flow conditions as in example 2 except using a dimensionless velocity expression similar to that of example 4.

The density (. rho.) of the aqueous gypsum slurry was set to 1,000kg/m for all flow conditions³And the viscosity factor K is set to 50. Also, the flow characteristics were evaluated for both the dimensionless feed rates of the gypsum slurry into feed inlets 2024 of B and 1.5B. The following flow characteristics are determined at each successive dimensionless location downstream of the entry of the shaped duct 2041 in the machine direction 2192 expressed as a function of the inlet diameter D: area weighted average velocity (U), planeProduct weighted average shear rateViscosity calculated using a power law model (equation 2), and reynolds number (Re) (equation 4). The hydraulic diameter is also calculated at the noted successive dimensionless locations along the longitudinal axis 50 (equation 1). Using the inlet flow conditions, dimensionless values of flow characteristics were determined for each location as shown in table VI.

Fig. 79-82 are graphs of the calculated flow characteristics for different flow conditions of example 6. A curve fitting equation is used to describe the change in flow characteristics over the distance between the halves 2004 from the feed inlet to the distribution outlet 2030. Thus, the embodiments show that the flow characteristics are consistent with respect to changes in inlet velocity.

For both flow conditions, the average velocity decreases from the first location in the feed conduit (about 3D) to the last location at half 2117 of the distribution outlet 2030 of the distribution conduit 2028 (about 12D). The average velocity generally decreases gradually as the slurry moves in the machine direction 2192. In the illustrated embodiment, the average velocity is reduced from the inlet velocity by about 1/3, as shown in fig. 79.

For both flow conditions, the shear rate increases from the first location in the feed conduit (about 3D) to the last location at half 2117 of the distribution outlet 2030 of the distribution conduit 2028 (about 12D). The shear rate varies from one location to another. In the illustrated embodiment, the shear rate increases at the half 2117 of the distribution outlet 2030 of the distribution conduit 2028 relative to the inlet, as shown in fig. 80.

For both flow conditions, the calculated viscosity decreases from the first location in the feed conduit (about 3D) to the last location at half 2117 of the distribution outlet 2030 of the distribution conduit 2028 (about 12D). The calculated viscosity varies from one location to another. In the illustrated embodiment, the calculated viscosity decreases relative to the inlet at the half 2117 of the distribution outlet 2030 of the distribution conduit 2028, as shown in fig. 81.

For both flow conditions, the Reynolds number decreases in FIG. 82 from the first position in the feed conduit (about 3D) to the last position at the half 2117 of the distribution outlet 2030 of the distribution conduit 2028 (about 12D). In the illustrated embodiment, the reynolds number is reduced by about 1/2 relative to the entrance at the half 2117 of the distribution outlet 2030 of the distribution conduit 2028. For both flow conditions, the reynolds number at the half 2117 of the distribution outlet 2030 of the distribution conduit 2028 is in the laminar flow region.

Thus, it has been found that the distal half of the slurry distributor (between about 6D and about 12D) is configured to provide a steady flow zone in which the average velocity and reynolds number of the slurry is substantially stable and reduced relative to the feed inlet conditions. As shown in fig. 73. The slurry moves through the flow stabilization zone in a generally streamlined pattern in the machine direction 2192.

Example 7

In this embodiment, the slurry distributor 2020 of fig. 72 is used to model the gypsum slurry flow at the distribution outlet 2030 of the distribution conduit 2028. In this example, the half 2004 of the slurry distributor of fig. 73 was used to model the flow of gypsum slurry therethrough under similar flow conditions as in example 2 except using a dimensionless expression of the width of the outlet opening 2081. A dimensionless width (W/W) of a half 2119 of the outlet opening 2081 across the distribution outlet 2030 (centerline at the transverse central midpoint 2187, equal to zero as shown in FIG. 72). In other respects, the flow conditions were similar to those in example 2.

CFD techniques using finite volume methods are used to determine flow characteristics in the halves 2004 of the distributor 2020. In particular, the spread angle of the slurry discharged from the outlet opening 2081 at various locations across the width of the half 2119 of the outlet opening 2081 of the distribution outlet 2030 was analyzed. The scatter angle is determined using the following formula:

spread angle = tan^-1(V_x/V_z) (equation 9)

Wherein V_xIs the average velocity in the cross-machine direction, and

V_zis the average speed in the machine direction.

The scatter angle is calculated for two different conditions: one not compressing outlet opening 2081 for the forming mechanism ("non-profiled") and one compressing outlet opening 2018 for the forming mechanism ("profiled"). In the modeled slurry distributor 2020, the outlet openings 2018 have a height of approximately 3/4 inches across their total width of approximately ten inches for each half 2004, 2005 and a total height of twenty inches for the total width of the outlet openings 2081. The modeled forming mechanism had a forming member that was approximately 15 inches wide and aligned with the lateral central midpoint such that the lateral portion of the distribution outlet was in an offset relationship with the forming member and was not compressed. In the modeled "contoured" condition, the forming mechanism compressed the outlet opening by about 1/8 inches such that the outlet opening was about 5/8 inches in the area below the forming member. The scatter angles for both conditions were determined as shown in table VII.

In both conditions, the spread angle increases as the position moves further outward from the lateral central midpoint 2187 (width = 0). The spread angle is greatest at the lateral edges of the outlet opening 2081.

The dispersion angle is increased using a shaping mechanism to compress the discharge outlet 2030, thereby decreasing the height of the outlet opening 2081. Under the modeled "profiled" condition, the maximum spread angle at the lateral edge (width = 0.466) increased by more than twenty-five percent relative to the "non-profiled" condition. Under "profiled" conditions, the average spread angle increases by more than fifty percent relative to the "non-profiled" condition.

All citations, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each citation were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The utility model discloses the people expects technical staff to adopt such variant appropriately, and utility model's people expects the utility model to implement in a way other than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims (19)

1. A slurry distributor, characterized in that the slurry distributor comprises:

a distribution conduit extending generally along a longitudinal axis and including an inlet portion, a distribution outlet in fluid communication with the inlet portion, and a floor extending between the inlet portion and the distribution outlet, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis;

a slurry wiping mechanism including a movable wiping blade in contacting relationship with the bottom surface of the distribution conduit, the wiping blade reciprocally movable between a first position and a second position over a purge path disposed adjacent the distribution outlet.

2. The slurry distributor of claim 1, wherein the distribution outlet comprises an outlet opening having a width along the transverse axis and a height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis, wherein the outlet opening has an aspect ratio of 4 or greater.

3. The slurry distributor of claim 1, wherein the distribution outlet includes an outlet opening having a width along the transverse axis, the wiping sheet extending a predetermined second distance along the transverse axis, the width of the outlet opening being less than the second distance along the transverse axis such that the wiping sheet is wider than the outlet opening.

4. The slurry distributor of claim 1, wherein the wiping blade reciprocates longitudinally along the purge path, and the first position of the wiping blade is longitudinally upstream of the distribution outlet and the second position is longitudinally downstream of the distribution outlet.

5. The slurry distributor of claim 1, wherein the slurry wiping mechanism includes an actuator operatively arranged with the wiping blade to selectively reciprocate the wiping blade.

6. The slurry distributor of claim 5, wherein the actuator comprises a pneumatic cylinder having a reciprocally movable piston connected to the wiper blade.

7. The slurry distributor of claim 5, wherein the slurry wiping mechanism includes a controller adapted to selectively control the actuator to reciprocally move the wiping blade.

8. The slurry distributor of claim 7, wherein the controller is adapted to move the wiping blade in a cleaning direction over a wiping stroke from the first position to the second position and in an opposite, return direction over a return stroke from the second position to the first position, and wherein the controller is adapted to move the wiping blade such that the time of movement over the wiping stroke is substantially the same as the time of movement over the return stroke.

9. The slurry distributor of claim 1, wherein the controller is adapted to move the wiping blade in a cleaning direction over a wiping stroke from the first position to the second position and in an opposite, return direction over a return stroke from the second position to the first position, and wherein the controller is adapted to move the wiping blade back and forth between the first position and the second position in a cycle having a sweep period comprising: a wiping portion containing a time of movement over the wiping stroke; a return portion including a time of movement on the return stroke; and a cumulative delay portion that contains a predetermined period of time during which the wiper blade is held at the first position.

10. The slurry distributor of claim 9, wherein the wiping portion is substantially identical to the return portion.

11. The slurry distributor of claim 9, wherein the cumulative delay portion is adjustable.

12. The slurry distributor of claim 1, further comprising:

a feed conduit including a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet;

wherein the entry portion is in fluid communication with the first and second feed inlets of the feed conduit.

13. The slurry distributor of claim 12, wherein the first and second feed inlets and the first and second entry sections are arranged at respective feed angles in a range of up to 135 ° relative to the longitudinal axis.

14. A cementitious slurry mixing and distribution assembly, comprising:

a mixer adapted to agitate water and cementitious binder to form an aqueous cementitious slurry;

a slurry distributor in fluid communication with the mixer, the slurry distributor comprising:

a distribution conduit extending generally along a longitudinal axis and including an entry portion, a distribution outlet in fluid communication with the entry portion, and a floor extending between the entry portion and the distribution outlet, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis, an

A slurry wiping mechanism including a movable wiping blade in contacting relationship with the bottom surface of the distribution conduit, the wiping blade reciprocally movable over a purge path between a first position and a second position, the purge path disposed adjacent the distribution outlet.

15. The cementitious slurry mixing and distribution assembly of claim 14 wherein the distribution outlet includes an outlet opening having a width along the transverse axis, the wiper blade extending a predetermined second distance along the transverse axis, and wherein the wiper blade reciprocates longitudinally along the cleaning path.

16. The cementitious slurry mixing and distribution assembly of claim 15 further comprising:

a bottom support member supporting the bottom surface of the distribution conduit, the bottom support member having a perimeter, the distribution outlet being longitudinally offset from the bottom support member such that a distal outlet portion of the distribution conduit extends from the perimeter of the bottom support member;

wherein the wiping blade supports the distal outlet portion of the slurry distributor when the wiping blade is in the first position.

17. The cementitious slurry mixing and distribution assembly of claim 14 further comprising:

a delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor;

a flow conditioning element associated with the delivery conduit and adapted to control flow of the aqueous cementitious slurry from the mixer;

an aqueous foam supply conduit in fluid communication with at least one of the mixer and the delivery conduit.

18. A cementitious slurry mixing and distribution assembly as set forth in claim 14 wherein the slurry distributor includes a feed conduit including a first entry section having a first feed inlet and a second entry section having a second feed inlet disposed in spaced relation to the first feed inlet; the entry portion of the distribution conduit is in fluid communication with the first and second feed inlets of the feed conduit, the first feed inlet is adapted to receive a first flow of aqueous cementitious slurry from the mixer, the second feed inlet is adapted to receive a second flow of aqueous cementitious slurry from the mixer, and the distribution outlet is in fluid communication with both the first and second feed inlets and is adapted to cause the first and second flows of aqueous cementitious slurry to be discharged from the slurry distributor through the distribution outlet.

19. The cementitious slurry mixing and distribution assembly of claim 18 further comprising:

a delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor, the delivery conduit including a main delivery trunk and first and second delivery branches;

a diverter joining the main delivery trunk and first and second delivery branches, the diverter disposed between the main delivery trunk and the first delivery branch and between the main delivery trunk and the second delivery branch;

wherein the first conveying branch is in fluid communication with the first feed inlet of the slurry distributor and the second conveying branch is in fluid communication with the second feed inlet of the slurry distributor.