KR20150074054A - Slurry distributor with a profiling mechanism, system, and method for using same - Google Patents

Abstract

The slurry dispenser may include a distribution conduit and a profiling mechanism. The distribution conduit generally includes a dispensing outlet extending in the longitudinal axis and in fluid communication with the entry portion and the entry portion. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The dispensing outlet includes an exit 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. The profiling mechanism is in contact with the distribution conduit and includes a portion of the distribution conduit adjacent the dispensing outlet to vary the shape and / or size of the outlet opening, And a movable profiling member in the proceeding range.

Description

TECHNICAL FIELD [0001] The present invention relates to a slurry distributor having a profiling mechanism, a slurry distributor having a profiling mechanism,

Cross-references to related applications

This patent application is filed on October 24, 2012, and is filed on March 15, 2013, and assigned to the assignee of the present invention, Patent application Ser. No. 13 / 844,550 entitled " Slurry Distributor with a Profiling Mechanism, System, and Method for Using Same ".

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

The present disclosure relates to continuous board (e.g. wallboard) manufacturing processes, and more particularly to an apparatus, system and method for dispensing aqueous calcined gypsum slurry.

It is well known to produce gypsum boards by uniformly dispersing fired gypsum (commonly referred to as "stucco") in water to form an aqueous fired gypsum slurry. The aqueous fired gypsum slurry is typically produced in a continuous manner by inserting stucco and water and other additives into a mixer that includes means for agitating the contents to form a uniform gypsum slurry. The slurry is continuously directed to the discharge outlet of the mixer and through it and into the discharge conduit connected to the discharge outlet of the mixer. The aqueous bubbles may be combined with an aqueous fired gypsum slurry in a mixer and / or discharge conduit. The stream of slurry passes through a discharge conduit that is continuously deposited on a moving web of cover sheet material supported by a forming table. The slurry is allowed to diffuse on the advancing web. A second web of cover sheet material is applied to cover the slurry and form a sandwich structure of a continuous wallboard preform, which is molded, for example, in a conventional foaming station to obtain the desired thickness. The calcined gypsum reacts with water in the wallboard preform and solidifies as the wallboard preform moves below the manufacturing line. The wallboard preform is cut into segments at one point along the line where the wallboard preform has been sufficiently solidified, the segments are inverted, dried (e.g., in kiln) to remove the excess, Lt; / RTI >

Conventional devices and methods for handling some of the operational problems associated with the manufacture of gypsum board 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.

The weight ratio of water to stucco combined to form a given amount of finished product is often referred to in the art as "water-to-stocco ratio" (WSR). The reduction in WSR without formula changes will correspondingly increase the slurry viscosity, thereby reducing the ability of the slurry to diffuse on the forming table. Reducing water usage (i. E., Lowering WSR) in the gypsum board manufacturing process can bring many advantages, including opportunities to reduce energy demands in the process. However, uniform diffusion of increasing viscosity gypsum slurries on the forming table remains a great challenge.

Moreover, in some situations where the slurry is a multiphasic slurry comprising air, the air-liquid slurry separation can be developed in the slurry discharge conduit from the mixer. As the WSR decreases, the air content increases to maintain the same dry density. The degree of vapor phase separated from the liquid slurry phase increases, thereby causing a tendency for a larger mass or density change.

It will be appreciated that this background description has been devised by the inventors to assist the reader and that the problems pointed out themselves should not be construed as an instruction recognized in the art. While the principles described may alleviate the problems inherent in other systems in some aspects and embodiments, the scope of protected innovation is not limited to any particular problem as defined by the appended claims, It is to be understood that the invention is not defined by the ability of any disclosed feature to be resolved.

In one aspect, this disclosure relates to embodiments of a slurry dispensing system for use in making gypsum products. In one embodiment, the slurry dispenser 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 may extend generally along the longitudinal axis and include an entry port and a dispensing outlet in fluid communication therewith. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

In other embodiments, the slurry dispenser includes a feed conduit and a distribution conduit. The feed conduit comprises a first incoming segment having a first feed inlet and a second incoming segment having a second feed inlet arranged in spaced relation to the first feed inlet. The distribution conduit generally includes a dispensing outlet extending along the longitudinal axis and in fluid communication with the entry and exit portions. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. The dispensing outlet extends a predetermined distance along the abscissa. The horizontal axis is substantially perpendicular to the vertical axis. Each of the first and second feed openings has an opening having a cross-sectional area. The entry portion of the distribution conduit has an opening having a cross-sectional area greater than the sum of the cross-sectional areas of the openings of the first and second feed openings.

In other embodiments, the slurry dispenser includes a feed conduit, a distribution conduit, and at least one support segment. The feed conduit comprises a first incoming segment having a first feed inlet and a second incoming segment having a second feed inlet arranged in spaced relation to the first feed inlet. The distribution conduit generally includes a dispensing outlet extending along the longitudinal axis and in fluid communication with the entry and exit portions. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. Each support segment is moveable over an extent such that the support segment has a support segment at a portion over at least a portion of at least one of the feed conduit and the distribution conduit and locations for increasing compression engagement.

In another aspect of the disclosure, the slurry dispenser may be disposed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous fired gypsum slurry. In one embodiment, the present disclosure describes a gypsum slurry mixing and dispensing assembly comprising a gypsum slurry mixer adapted to agitate water and fired gypsum to form an aqueous fired gypsum slurry. The slurry dispenser is in fluid communication with the gypsum slurry mixer and is adapted to receive the first and second streams of aqueous fired gypsum slurry from the gypsum slurry mixer and distribute the first and second streams of the aqueous fired gypsum slurry to the advancing web.

The slurry dispenser comprises a first feed inlet adapted to receive a first flow of the aqueous fired gypsum slurry from the gypsum slurry mixer, a second feed inlet adapted to receive a second flow of the aqueous fired gypsum slurry from the gypsum slurry mixer, And a distribution outlet in fluid communication with both the second feed inlets and wherein the first and second streams of aqueous fired gypsum slurry are adapted to be discharged from the slurry distributor through the distribution outlet.

In another embodiment, the slurry dispenser includes a feed conduit and a distribution conduit. The feed conduit includes an entry segment having a feed inlet and a feed inlet exit in fluid communication with the feed inlet. The entry segment extends along the first feed flow axis. The feed conduit includes a forming duct having a bulb portion in fluid communication with the feed inlet exit of the entry segment. The delivery conduit includes a transition segment in fluid communication with the bulb portion. The transition segment extends along a second feed flow axis that is non-parallel to the first feed flow axis.

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

The bulb portion has an enlarged region having a cross sectional flow region that is larger than the cross sectional flow region of the adjacent region upstream from the expanded region with respect to the flow direction from the feed inlet toward the distribution outlet distribution conduit. The forming duct has a convex inner surface that is in face-to-face relationship with the incoming inlet of the incoming segment.

In another embodiment, the slurry dispenser includes a quarter feed conduit and a distribution conduit. The branch feed conduit comprises first and second feed portions each having an entry segment having a feed inlet exit in fluid communication with the feed inlet and feed inlet, a forming duct having a bulb portion in fluid communication with the feed inlet exit of the entry segment, And a transition segment in fluid communication with the portion. The entry segment extends entirely along the vertical axis. The transition segments extend along a longitudinal axis perpendicular to the vertical axis.

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

Each of the first and second bulb portions having a cross sectional flow area greater than the cross sectional flow area of the adjacent region upstream from the extended region with respect to the flow direction from the respective first and second feed inlets toward the distribution outlet distribution conduit And has an extended area. The first and second formed ducts each have a convex inner surface that is in face-to-face relationship with the first and second feed inlet outlets of each of the first and second incoming segments.

In another embodiment, the slurry dispenser includes a distribution conduit and a slurry wiping mechanism. The distribution conduit extends generally along a longitudinal axis, a dispensing outlet in fluid communication with the entry portion, and a bottom surface extending between the entry portion and the dispensing outlet. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The slurry wiping mechanism includes a movable wiper blade in contact with the lower surface of the distribution conduit. The wiper blade is reciprocable over a clearing path between the first and second positions. The clearing path is disposed adjacent to the distribution outlet.

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

The profiling mechanism includes a profiling member in contact with the distribution conduit. The profiling member may be positioned over the range of the annulus so that the profiling member has a portion of the distribution conduit adjacent the dispensing outlet to vary the shape and / or size of the outlet opening, It is movable.

In another aspect of the present disclosure, a slurry dispenser can be used in a cement slurry mixing and dispensing assembly. For example, a slurry dispenser can be used to dispense an aqueous fired gypsum slurry onto the advanced web. In other embodiments, the gypsum slurry mixing and dispensing assembly includes a slurry dispenser in fluid communication with the mixer and mixer. The mixer is adapted to agitate water and calcined gypsum to form an aqueous fired gypsum slurry. The slurry dispenser includes a feed conduit and a distribution conduit:

The feed conduit comprises a first incoming segment having a first feed inlet and a second incoming segment having a second feed inlet arranged in spaced relation to the first feed inlet. The first feed inlet is adapted to receive a first flow of the aqueous fired gypsum slurry from the gypsum slurry mixer. The second feed inlet is adapted to receive a second flow of the aqueous fired gypsum slurry from the gypsum slurry mixer.

The distribution conduit generally includes a dispensing outlet extending along the longitudinal axis and in fluid communication with the entry and exit portions. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. The dispensing outlet extends a predetermined distance along the abscissa. The horizontal axis is substantially perpendicular to the vertical axis. The dispensing outlet is in fluid communication with both the first and second feed inlets and the first and second streams of aqueous fired gypsum slurry are adapted to be discharged from the slurry dispenser through the dispensing outlet.

Each of the first and second feed openings has an opening having a cross-sectional area. The entry portion of the distribution conduit has an opening having a cross-sectional area greater than the sum of the cross-sectional areas of the openings of the first and second feed openings.

The cement slurry mixing and dispensing assembly includes a mixer adapted to agitate water and cement material to form an aqueous cement slurry and a slurry dispenser in fluid communication with the mixer. The slurry dispenser may be any one of a variety of embodiments of the slurry dispenser following the principles of the present disclosure.

In another aspect of the present disclosure, a slurry dispensing system can be used in a method of making a cement product. For example, a slurry dispenser can be used to dispense an aqueous fired gypsum slurry onto the advanced web.

In some embodiments, a method of dispensing an aqueous fired gypsum slurry onto a moving web may be performed using a slurry dispenser constructed in accordance with the principles of the present disclosure. The first stream of aqueous fired gypsum slurry and the second stream of aqueous fired gypsum slurry are respectively passed through the first feed inlet and the second feed inlet of the slurry distributor. The first and second streams of the aqueous fired gypsum slurry are combined in a slurry dispenser. The first and second streams of aqueous fired gypsum slurry are discharged from the distribution outlet of the slurry distributor on the moving web.

In other embodiments, the method of making the gypsum product may be performed using a slurry dispenser constructed in accordance with the principles of the present disclosure. The first stream of aqueous fired gypsum slurry is passed through the first feed inlet of the slurry dispenser at an average first feed rate. The second stream of aqueous fired gypsum slurry is passed through the second feed inlet of the slurry dispenser at an average second feed rate. The second feed inlet is spaced apart from the first feed inlet. The first and second streams of the aqueous fired gypsum slurry are combined in a slurry dispenser. The combined first and second flows of the aqueous fired gypsum slurry are discharged at an average discharge rate from the dispensing outlet of the slurry dispenser as the cover sheet material moves along the machine direction. The average release rate is less than the average first feed rate and the average second feed rate.

In another embodiment, a method of making a cement product may be performed using a slurry dispenser constructed in accordance with the principles of the present disclosure. The stream of aqueous cement slurry is discharged from the mixer. The flow of the aqueous cement slurry is passed along the first feed flow axis through the feed inlet of the slurry dispenser at an average feed rate. The flow of the aqueous cement slurry is transferred to the bulb portion of the slurry dispenser. The bulb portion has an enlarged area having a larger cross sectional flow area than the cross sectional flow area of the adjacent area upstream from the extended area with respect to the flow direction from the feed inlet. The bulb portion is configured to reduce the average velocity of the flow of the aqueous cement slurry through the bulb portion from the feed inlet. The forming duct has a convex inner surface that faces the first feed flow axis such that the flow of the aqueous cement slurry moves radially in a plane substantially perpendicular to the first feed flow axis. The flow of the aqueous cement slurry is transferred to a transition segment extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The flow of the aqueous cement slurry is passed through a distribution conduit. The distribution conduit includes a dispensing outlet extending a predetermined distance along a transverse axis substantially perpendicular to the longitudinal axis.

In another embodiment, a method of making a cement product includes discharging a stream of an aqueous cement slurry from a mixer. The flow of the aqueous cement slurry is passed through the entry portion of the distribution conduit of the slurry dispenser. The flow of the aqueous cement slurry is released from the dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction. The wiper blade is reciprocated along the clearing path along the lower end surface of the distribution conduit between the first and second locations to remove the aqueous cement slurry therefrom. The clearing path is disposed adjacent to the distribution outlet.

In yet another embodiment, a method of making a cement product includes discharging a stream of an aqueous cement slurry from a mixer. The flow of the aqueous cement slurry is passed through the entry portion of the distribution conduit of the slurry dispenser. The flow of the aqueous cement slurry is released from the outlet opening of the dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The exit opening has an axis along the transverse axis and a height along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis. A portion of the distribution conduit adjacent the dispensing outlet is compression-tightened to change the shape and / or size of the outlet opening.

Embodiments of a mold for use in a method of making a slurry dispenser in accordance with the principles of the present disclosure are also disclosed herein. Embodiments of supports for a slurry dispenser in accordance with the principles of the present disclosure are also disclosed herein.

Additional and alternative aspects and features of the disclosed principles will be understood from the following detailed description and the accompanying drawings. As will be appreciated, the slurry dispensing systems described herein may be performed and used in different and different embodiments, and may be otherwise modified. It is, therefore, 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.

The patent or application file includes at least one drawing performed in color. Copies of such patents or patent application publications with color drawing (s) will be provided by the Patent Office upon request and payment of the required fees.
1 is a perspective view of one embodiment of a slurry dispenser constructed in accordance with the principles of the present disclosure;
Figure 2 is a perspective view of one embodiment of a slurry distributor support and a perspective view of the slurry dispenser of Figure 1 constructed in accordance with the principles of the present disclosure.
3 is a front elevational view of the slurry dispenser of FIG. 1 and the slurry dispenser support of FIG. 2;
4 is a perspective view of one embodiment of a slurry dispenser similar to the slurry dispenser of FIG. 1, but constructed in accordance with the principles of the present disclosure, which defines an internal shape comprised of a rigid material and having a two-piece construction.
5 is another perspective view of the slurry dispenser of FIG. 4 where the profiling system is removed for illustrative purposes.
6 is an isometric view of another embodiment of a slurry dispenser constructed in accordance with the principles of the present disclosure which includes a first feed inlet and a second feed inlet disposed at a feed angle of approximately 60 degrees relative to the longitudinal axis or machine direction of the slurry dispenser, .
Figure 7 is a top plan view of the slurry dispenser of Figure 6;
8 is a rear elevational view of the slurry dispenser of FIG.
Figure 9 is a top plan view of the first piece of the slurry dispenser of Figure 6, which has a two-piece construction.
10 is a front perspective view of the slurry dispenser piece of FIG.
Figure 11 is an exploded view of the slurry dispenser and slurry dispenser support system of Figure 6 constructed in accordance with the principles of the present disclosure.
Figure 12 is a perspective view of the slurry dispenser and support system of Figure 11;
Figure 13 is an exploded view of another embodiment of the slurry dispenser and support system of Figure 6 constructed in accordance with the principles of the present disclosure.
Figure 14 is a perspective view of the slurry dispenser and support system of Figure 13;
15 is a perspective view of one embodiment of a slurry dispenser similar to the slurry dispenser of FIG. 6, but constructed in accordance with the principles of the present disclosure, which defines an internal shape comprised of a flexible material and having an integral construction.
Figure 16 is a top plan view of the slurry dispenser of Figure 15;
Figure 17 is an enlarged perspective view of the internal shape defined by the slurry dispenser of Figure 15 illustrating progressive cross-sectional flow areas of a portion of its feed conduit.
18 is an enlarged perspective view of the internal shape of the slurry dispenser of FIG. 15 illustrating another progressive cross-sectional flow area of the feed conduit.
FIG. 19 is an enlarged perspective view of the internal shape of the slurry dispenser of FIG. 15 illustrating another progressive cross-sectional flow area of the feed conduit aligned with a half of the entry section for the distribution conduit of the slurry dispenser of FIG. 15;
Figure 20 is a perspective view of another embodiment of the slurry dispenser and support system of Figure 15 constructed in accordance with the principles of the present disclosure;
Figure 21 is similar to Figure 20 but with the support frame removed for illustrative purposes to illustrate a plurality of retaining plates in a dispensing relationship with the slurry dispenser of Figure 15;
22 is a front perspective view of another embodiment of a slurry dispenser constructed in accordance with the principles of the present disclosure and another embodiment of a support system.
Figure 23 is a rear perspective view of the slurry dispenser and support system of Figure 22;
Figure 24 is a top plan view of the slurry dispenser and support system of Figure 22;
Figure 25 is a side elevation view of the slurry dispenser and support system of Figure 22;
26 is a front elevational view of the slurry dispenser and support system of FIG. 22;
Figure 27 is a rear elevation view of the slurry dispenser and support system of Figure 22;
28 is an enlarged detail view of a distal portion of a slurry dispenser illustrating one embodiment of a slurry wiping mechanism constructed in accordance with the principles of the present disclosure;
Figure 29 is a perspective view of a profiling mechanism constructed in accordance with the principles of the present disclosure and used in the slurry dispenser of Figure 22;
30 is a front elevational view of the profiling mechanism of FIG. 29;
30A is a view as in FIG. 30, illustrating a profiling member of a profiling mechanism in a compressed position.
30B is a view as in FIG. 30, illustrating a profiling member of a profiling mechanism in a pivoted position;
30C is an enlarged detail exploded view of the profiling member illustrating a connection technique between the translation rod and the profiling segment;
31 is a side elevational view of the profiling mechanism of FIG. 29;
32 is a top plan view of the profiling mechanism of FIG. 29;
33 is a bottom front view of the profiling mechanism of Fig. 29;
Figure 34 is a top plan view of the slurry dispenser and support system of Figure 22 with the support frame removed for illustrative purposes.
Figure 35 is an enlarged detail view taken from the side of the bulb portion of the slurry dispenser of Figure 22;
Figure 36 is a perspective view of a pair of rigid support inserts that rest on the lower support member of the support system of Figure 22;
37 is a side elevation of a side view of the rigid support insert of Fig. 36;
38 is a front elevational view of the front surface of the rigid support insertion portion of Fig.
39 is a rear elevational front view of the rigid support insertion portion of Fig.
FIG. 40 is a front elevational view of the slurry dispenser of FIG. 22; FIG.
41 is a rear elevational view of the slurry dispenser of Fig. 22;
42 is a bottom perspective view of the slurry dispenser of Fig.
Figure 43 is a bottom plan view of the slurry dispenser of Figure 22;
Figure 44 is a top plan view of the half portion of the slurry dispenser of Figure 22;
45 is a cross-sectional view taken along line 45-45 of Fig.
46 is a cross-sectional view taken along line 46-46 of Fig.
47 is a cross-sectional view taken along line 47-47 of Fig.
Figure 48 is a cross-sectional view taken along lines 48-48 of Figure 44;
49 is a cross-sectional view taken along line 49-49 of Fig.
50 is a cross-sectional view taken along line 50-50 of FIG.
51 is a cross-sectional view taken along line 51-51 in Fig.
52 is a cross-sectional view taken along line 52-52 of Fig.
53 is a cross-sectional view taken along line 53-53 of Fig.
54 is a perspective view of one embodiment of a multi-piece mold for making a slurry dispenser as in FIG. 1 constructed in accordance with the principles of the present disclosure;
55 is a top plan view of the mold of FIG. 54;
Figure 56 is an exploded view of one embodiment of a multi-piece mold for making a slurry dispenser as in Figure 15 constructed in accordance with the principles of the present disclosure.
57 is a perspective view of another embodiment of a mold for making a two-piece slurry dispenser 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 one embodiment of a gypsum slurry mixing and dispensing assembly including a slurry dispenser in accordance with the principles of the present disclosure;
60 is a schematic plan view of another embodiment of a gypsum slurry mixing and dispensing assembly including a slurry dispenser in accordance with the principles of the present disclosure;
61 is a schematic front view of one embodiment of a wet end of a gypsum board manufacturing line in accordance with the principles of the present disclosure;
62 is a perspective view of one embodiment of a flow divider constructed in accordance with the principles of the present disclosure, suitable for use in a gypsum slurry mixing and dispensing assembly including a slurry dispenser.
Fig. 63 is a side elevational front view of the flow divider of Fig. 62; Fig.
Figure 64 is a side elevational view of the flow divider of Figure 62 with a compression device constructed in accordance with the principles of the present disclosure;
65 is a top plan view of a half portion of a slurry dispenser similar to the slurry dispenser of FIG.
66 is a plot of the data from Table I of Example 1 showing the dimensionless area and the dimensionless hydraulic radius of the half portion of the slurry dispenser of FIG. 65 versus the dimensionless distance from the feed inlet.
67 is a plot of data from Tables II and III of Examples 2 and 3, respectively, illustrating the dimensionless velocity of the flow of the modeled slurry moving through the half portion of the slurry dispenser of Figure 65 versus the dimensionless distance from the feed inlet; to be.
68 is a plot of data from Tables II and III of Examples 2 and 3, respectively, illustrating the dimensionless shear rate in the modeled slurry moving through the half-portion of the slurry dispenser of Figure 65 versus the dimensionless distance from the feed inlet; to be.
Figure 69 is a plot of data from Tables II and III of Examples 2 and 3, respectively, illustrating the dimensionless viscosity of the modeled slurry moving through the half portion of the slurry dispenser of Figure 65 versus the dimensionless distance from the feed inlet.
Figure 70 is a plot of the data from tables II and III of examples 2 and 3, respectively, showing the dimensionless shear stresses in the modeled slurry moving through the half-section of the slurry dispenser of Figure 65, to be.
Figure 71 plots the data from tables II and III of Examples 2 and 3, respectively, representing the dimensionless Reynolds number in the modeled slurry moving through the half-way portion of the slurry dispenser of Figure 65 versus the dimensionless distance from the feed inlet to be.
72 is a top plan view of a slurry dispenser similar to the slurry dispenser of FIG. 22;
73 is a top perspective view of a computational fluid dynamics (CFD) model output for the half portion of the slurry dispenser of FIG. 72;
74 is a view as in FIG. 73, illustrating various areas discussed in Examples 4-6.
Fig. 75 is a diagram of area A shown in Fig.
76 is a top plan view of region A illustrating radial positions used to perform CFD analysis.
77 is a plot of the data from Table IV of Example 4 showing the dimensionless average velocity moving through region A of the half portion of the slurry dispenser of FIG. 73 versus the radial position in Region A. FIG.
78 is an enlarged detail view taken from FIG. 72, illustrating the region B of the slurry dispenser in which the flow of the moving slurry has swirl motion;
79 is a plot of the data from Table VI of Example 6 showing the dimensionless velocity from the feed inlet versus the dimensionless velocity of the modeled slurry moving through the half portion of the slurry dispenser of FIG. 73;
80 is a plot of the data from Table VI of Example 6 showing the dimensionless shear rate in the modeled slurry moving through the half portion of the slurry dispenser of FIG. 73 versus the dimensionless distance from the feed inlet.
FIG. 81 is a plot of the data from Table VI of Example 6 showing the dimensionless viscosity of the modeled slurry moving through the half-portion of the slurry dispenser of FIG. 73 versus the dimensionless distance from the feed inlet.
82 is a plot of the data from Table VI of Example 6 showing the dimensionless Reynolds number of the modeled slurry moving through the non-dimensional distance from the feed inlet versus the half portion of the slurry dispenser of FIG. 73;
83 is a plot of the data from Table VII of Example 7 showing the non-dimensional distance along the width of the exit opening from the mid-central mid-point to the diffuse angle of the modeled slurry emanating from the half portion of the slurry dispenser of FIG. 73;

The present disclosure provides various embodiments of a slurry dispensing system that can be used in the manufacture of products, including, for example, cement products such as gypsum board. Embodiments of a slurry dispenser constructed in accordance with the principles of the present disclosure can be used in a manufacturing process to effectively dispense a multiphasic slurry, such as those containing gaseous and liquid phases, for example, as found in aqueous gaseous gypsum slurries .

Embodiments of a dispensing system constructed in accordance with the principles of the present disclosure may include an advancing web (e. G., A sintered gypsum slurry) that moves a slurry (e. G., An aqueous fired gypsum slurry) onto a conveyor during a continuous board For example, paper, or mat. In one aspect, a slurry dispensing system constructed in accordance with the principles of the present disclosure includes a gypsum gypsum slurry and a conventional gypsum dry wall preparation as part of it, as a discharge conduit attached to a mixer that stirs water. Process.

Embodiments of the slurry distribution system constructed in accordance with the principles of the present disclosure aim at achieving a wider distribution of the uniform gypsum slurry (along the cross machine direction). Embodiments of the slurry distribution system of the present disclosure are suitable for use with gypsum slurries having a range of WSRs, including WSRs conventionally used for making gypsum wallboards and those having relatively lower and relatively higher viscosities. Moreover, the gypsum slurry dispensing system of the present disclosure can be used to help control air-liquid separation in aqueous gaseous gypsum slurries, including, for example, a bubble gypsum slurry having a very high bubble volume. The diffusion of the aqueous fired gypsum slurry onto the advanced web can be controlled by dispensing and dispensing the slurry using a dispensing system as shown and described herein.

Cement slurry mixing and dispensing assemblies in accordance with the principles of the present disclosure may be used to form any type of cement gel, such as, for example, a board. In some embodiments, a cement board, such as a gypsum drywall, a Portland cement board, or an acoustic panel may be formed, for example.

The cement slurry may be any conventional cement slurry, such as the soundproofing panels described in U. S. Patent Application Publication 2004/0231916, or gypsum wallboards including a Portland cement board, any It can be a cement slurry. As such, the cement slurry may optionally further comprise any additives commonly used to produce cement board products. Such additives include structural additives including mineral surfaces, continuous or cut glass fibers (also referred to as fiberglass), perlite, clay, vermiculite, calcium carbonate, polyester, and paper fibers, as well as foams, (For example, starch and latex), colorants, fungicides, insecticides, hydrophobing agents, such as, for example, antioxidants, antioxidants, Silicon-based materials (e.g., silane, siloxane, or silicon-resin matrix), and the like. Examples of the use of these and some of the other additives are described, for example, in U.S. Patent Nos. 6,342,284; 6,632,550; 6,800,131; 5,643,510; 5,714,001; And 6,774,146; And U.S. Patent Application Publication No. 2004/0231916; 2002/0045074; 2005/0019618; 2006/0035112; And 2007/0022913.

Non-limiting examples of cement materials include Portland cement, Sorel cement, slack cement, fly ash cement, calcium alumina cement, water soluble calcium sulfate anhydride, potassium sulfate alpha-hemihydrate, calcium sulfate beta-hemihydrate, natural, Calcium hypohalite, calcium sulfate dihydrate ("gypsum", "set gypsum", or "hydrated gypsum"), and mixtures thereof. In one embodiment, the cement material preferably comprises calcined gypsum in the form of, for example, calcium sulfate alpha hemihydrate, calcium sulfate beta hemihydrate, and / or calcium sulfate anhydride. In embodiments, the calcined gypsum may be fibrous in some embodiments and non-fibrous in other embodiments. The calcined gypsum may comprise at least about 50% beta calcium sulfate hemi-hydrate. In other embodiments, the calcined gypsum may comprise at least about 86% beta calcium sulfate hemi-hydrate. The weight ratio of water to calcined gypsum may be any suitable ratio, but as will be appreciated by those of ordinary skill in the art, lower ratios are more efficient because less excess water must be released during manufacture, You can save. In some embodiments, the cement slurry can be prepared by combining water and calcined gypsum in a ratio of about 1: 6 weight ratio to about 1: 1 ratio, for example, up to about 2: 3, respectively, during board manufacturing according to the products have.

Embodiments of a method of making a cement product, such as a gypsum product in accordance with the principles of the present disclosure, include the steps of dispensing an aqueous fired gypsum slurry on an advanced web using a slurry dispenser constructed in accordance with the principles of the present disclosure . Various embodiments of a method for dispensing an aqueous fired gypsum slurry on a moving web are described herein.

Referring now to the drawings, FIGS. 1-3 illustrate one embodiment of a slurry dispenser 120 according to the principles of the present disclosure, and FIGS. 4 and 5 illustrate slurry dispenser 220 according to principles of the present disclosure, ≪ / RTI > The slurry dispenser 120 shown in Figures 1 - 3 is made of a resiliently flexible material, while the slurry dispenser 220 shown in Figures 3 and 4 is made of a relatively rigid material. However, the internal flow shapes of both of the slurry dispensers 120 and 220 are the same in FIGS. 1 to 5, and also reference should be made to FIG. 5 when considering the slurry dispenser 120 of FIGS.

1, a slurry dispenser 120 includes a feed conduit 122 having first and second feed inlets 124, 125 and a distribution outlet 130 and is in fluid communication with the feed conduit 128, And a distribution conduit 128, A profiling system 132 (see FIG. 3) may be provided that is adapted to vary the size of the dispensing outlet 130 of the dispensing conduit 128 locally.

Referring to Figure 1, the feed conduit 122 extends generally along a transverse axis or cross machine direction 60 that is substantially perpendicular to the longitudinal axis or machine direction 50. The first feed inlet 124 is spaced apart from the second feed inlet 125. The first feed inlet 124 and the second feed inlet 125 define respective openings 134, 135 having substantially the same area. Both of the illustrated openings 134, 135 of the first and second feed openings 124, 125 have a circular cross-sectional shape as illustrated in this example. In other embodiments, the cross-sectional shape of the feed inlets 124, 125 may take other forms depending on the current intended applications and process conditions.

The first and second feed inlets 124 and 125 are formed along the cross machine axis 60 such that the first and second feed inlets 124 and 125 are disposed at a substantially 90 angle to the machine axis 50 Are in opposing relation to each other. In other embodiments, the first and second feed inlets 124, 125 may be oriented in different ways for the machine direction. For example, in some embodiments, the first and second feed inlets 124,125 may be at an angle between 0 [deg.] And about 135 [deg.] Relative to the machine direction 50. [

The feed conduit 122 includes a branch connector segment 139 disposed between the first and second incoming segments 136,137 and the first and second incoming segments 136,137. The first and second infeed segments 136 and 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 and second feed inlets 124, 125 are disposed at, and in fluid communication with, the distal ends of the first and second incoming segments 136, 137, respectively.

In other embodiments, the first and second feed inlets 124, 125 and the first and second incoming segments 136, 137 may be disposed on the transverse axis 60, the machine direction 50, and / 50 and the transverse axis 60, as will be described in greater detail below. For example, in some embodiments, the first and second feed inlets 124, 125 and the first and second incoming segments 136, Range, and in other embodiments from about 30 degrees to about 135 degrees, and in still other embodiments from about 45 degrees to about 135 degrees, and in still other embodiments from about 40 degrees to about 110 degrees, Can be disposed substantially in the plane 57 defined by the longitudinal axis 50 and the transverse axis 60 at the feeding angle [theta] with respect to the machine direction 50 or the longitudinal axis being an angle in the range of up to 50 [deg.].

A branch connector segment 139 is in fluid communication with the first and second feed inlets 124, 125 and the first and second incoming segments 136, 137. The branch connector segment 139 includes first and second formed ducts 141, 143. The first and second feed inlets 124, 125 of the feed conduit 22 are in fluid communication with the first and second formed ducts 141, 143, respectively. The first and second shaping ducts 141 and 143 of the connector segment 139 extend from the first and second feed inlets 124 and 125 to the first feed direction 190 of the aqueous fired gypsum slurry, And to direct the first and second streams 190, 191 of the aqueous fired gypsum slurry to the distribution conduit 128, respectively, in a first flow direction 191 and a second flow direction in the second flow direction 191, respectively.

5, the first and second forming ducts 141, 143 of the connector segment 139 are connected to the first and second feed openings 124, 125, respectively, in fluid communication with the first and second feed openings 124, 2 feed outlets 140 and 145, 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 having a generally right angled inner portion 147 and a substantially circular side portion 149. Circular side portions 145 are disposed adjacent sidewalls 151, 153 of the distribution conduit 128.

The openings 142 of the first and second feed outlets 140 and 145 are formed in the first feed opening 124 and the second feed opening 125 in the cross sectional area Each having a larger cross-sectional area. For example, in some embodiments, the cross-sectional area of the openings 142 of the first and second feed outlets 140, 145 is greater than the cross-sectional area of the openings 142 of the first feed inlet 124 and the second feed inlet 125 Greater than about 300% greater than the cross-sectional area of the openings 134, 135, greater than about 200% greater in other embodiments, and greater than about 150% greater in yet other embodiments.

The openings 142 of the first and second feed outlets 140 and 145 are formed by the hydraulic forces of the openings 134 and 135 of the first feed inlet 124 and the second feed inlet 125 And a hydraulic diameter smaller than the hydraulic diameter (4x cross-sectional area / perimeter), respectively. For example, in some embodiments, the hydraulic diameters of the openings 142 of the first and second feed outlets 140, 145 are greater than the hydraulic diameters of the first feed inlet 124 and the second feed inlet 125, About 80% or less of the hydraulic diameter of the openings 134, 135, about 70% or less in other embodiments, and about 50% or less in other embodiments.

Referring again to FIG. 1, connector segment 139 is substantially parallel to plane 57 defined by longitudinal axis 50 and transverse axis 60. In other embodiments, the connector segment 139 may be oriented in a different manner for the plane 57 defined by the transverse axis 60, the machine direction 50, and / or the longitudinal axis 50 and the transverse axis 60 have.

The first feed inlet 124, the first incoming segment 136 and the first formed duct 141 are connected to the second feed inlet 125, the second incoming segment 137 and the second formed duct 143, Is a mirror image of. Thus, it is also possible, in a corresponding manner, that the description of one feed inlet is applicable to different feed openings, the description of one entry segment is applicable to different entry segments, and the description of one forming duct is applicable to other forming ducts Will be understood.

The first shaped duct 141 is fluidly connected to the first feed inlet 124 and the first incoming segment 136. The first forming duct 141 also has a first stream 190 of slurry entering the first feed inlet 124; Travel through the first entry segment 136, the first forming duct 141, and the distribution conduit 128; Is fluidly connected to the distribution conduit 128 so that it can be discharged from the slurry dispenser 120 through the distribution outlet 130 thereby helping to fluidly connect the first feed inlet 124 and the distribution outlet 130.

The first shaping duct 141 is configured to direct the first flow of slurry substantially parallel to the longitudinal or machine direction 50 from the first feed flow direction 190 substantially transverse to the transverse or machine direction 60, An outer curved wall 157 and an opposing rear surface defining a curved guide surface 165 that is adapted to redirect to an exit flow direction 192 that is substantially perpendicular to the feed flow direction 190, (158). The first shaping duct 141 is positioned in the first feed flow direction 190 as shown in Figure 9 so that the first stream of slurry is conveyed to the distribution conduit 128 that is substantially moving in the outlet flow direction 192. [ And to forward the slurry flow direction by a change in direction angle [alpha].

In use, the first stream of the aqueous fired gypsum slurry passes through the first feed inlet 124 in the first feed direction 190 and the second stream of aqueous fired gypsum slurry passes through the second feed direction 191 in the second feed direction 191, Passes through feed inlet 125. The first and second feeding directions 190, 191 may be symmetrical with respect to each other along the longitudinal axis 50 in some embodiments. The first flow of slurry moving in the first feed flow direction 190 is diverted to the outlet flow direction 192 through a change in the directional angle a within a range of approximately 135 degrees in the slurry distributor 120. [ The second flow of slurry moving in the second feed flow direction 191 is diverted to the outlet flow direction 192 through a change in the directional angle a in the range of about 135 占 from the slurry distributor 120. [ The combined first and second streams 190, 191 of the aqueous fired gypsum slurry are discharged from the slurry distributor 120, which travels generally in the outlet flow direction 192. The outlet flow direction 192 may be substantially parallel to the longitudinal axis or machine direction 50.

For example, in the illustrated embodiment, the first flow of slurry is a change in the direction angle alpha of about 90 degrees about the vertical axis 55 from the first feed flow direction 190 along the cross- To the outlet flow direction 192 along the machine direction 50 through the second flow path. In some embodiments, the flow of slurry may range from about 30 degrees to about 135 degrees in the exit flow direction 192, up to about 135 degrees, in other embodiments from about 45 degrees in other embodiments Through a variation of directional angle a about the vertical axis 55 in the range of up to about 135 degrees and in other embodiments in the range of about 40 degrees to about 110 degrees in the first feed flow direction 190, Lt; / RTI >

In some embodiments, the shape of the back curve guide surface 165 may be entirely parabolic, which may be defined by the parabola of the formula Ax ² + B in the illustrated embodiment. In alternate embodiments, higher order curves can be used to define the back curve guide surface 165, or alternatively, the back wall, the inner wall 158, And may have a general curved shape consisting of straight or linear segments that have been oriented in the < RTI ID = 0.0 > Moreover, the parameters used to define the specific form factors of the outer wall may depend on the particular operating parameters of the process in which the slurry dispenser is to be used.

At least one of the feed conduit 122 and the distribution conduit 128 has an enlarged cross sectional flow region that is larger than the cross sectional flow region of the adjacent region upstream from the expanded region in the direction toward the distribution conduit 128 from the feed conduit 122. [ Region. ≪ / RTI > The first ingress segment 136 and / or the first shaping duct 141 may have a cross-section that varies along the direction of the flow to assist in dispensing the first flow of slurry moving therethrough. The forming duct 141 is configured to increase the cross sectional flow that increases in the first flow direction from the first feed inlet 124 toward the distribution conduit 128 to decelerate as the first flow of slurry passes through the first forming duct 141. [ Area. In some embodiments, the first formed duct 141 has a maximum cross-sectional flow area at a predetermined point along the first flow direction 195 and a maximum cross-sectional flow area at points that further follow the first flow direction 195. In some embodiments, Area. ≪ / RTI >

In some embodiments, the maximum cross sectional flow area of the first shaped duct 141 is less than about 200% of the cross sectional area of the opening 134 of the first feed inlet 124. In still other embodiments, the maximum cross-sectional flow area of the forming duct 1410 is less than or equal to about 150% of the cross-sectional area of the opening 134 of the first feed inlet 124. In still other embodiments, The maximum cross sectional flow area of the forming duct 141 is less than or equal to about 125% of the cross sectional area of the opening 134 of the first feed inlet 124. In still other embodiments, Sectional flow area is less than or equal to about 110% of the cross-sectional area of the opening 134 of the flow region 124. In some embodiments, the cross-sectional flow region is greater than a predetermined amount over a given length, Controlled.

In some embodiments, the first inlet segment 136 and / or the first forming duct 141 may distribute the first flow of slurry toward the outer and / or inner walls 157, 158 of the feed conduit 122 One or more guide channels 167, 168 that are adapted to help the user to do so. The guide channels 167, 168 are adapted to increase the flow of slurry around the boundary wall layers of the slurry distributor 120.

Referring to Figures 1 and 5, the guide channels 167 and 168 are configured in a feed conduit (not shown) that defines a restriction that facilitates flow to adjacent guide channels 167 and 168, respectively, disposed in the wall region of the slurry distributor 120 Sectional area greater than the adjacent portion 71 of the first and second portions 122, 122. In the illustrated embodiment, the feed conduit 122 includes an outer guide channel 167 adjacent the outer wall 157 and the sidewall 151 of the distribution conduit 128 and an inner guide channel 166 adjacent to the inner wall of the first forming duct 141 And a guide channel 168. The cross-sectional areas of the outer and inner guide channels 167 and 168 may move in the first flow direction 195 and continue to be smaller. The outer guide channel 167 may extend substantially along the sidewall 151 of the distribution conduit 128 to the distribution outlet 130. At a given cross-sectional position through the first forming duct 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 extends from its initial line of travel in a first feeding direction Has a larger cross-sectional area than the inner guide channel (168) to assist in switching the first flow of slurry into the slurry (190).

Providing the guide channels adjacent to the wall areas may help direct or guide the slurry flow to such areas, which may be beneficial in conventional systems where "dead spots" of low slurry flow are found / RTI > By promoting the slurry flow in the wall regions of the slurry distributor 120 through the provision of the guide channels, the slurry accumulation within the slurry distributor can be impeded and the cleanliness within the slurry distributor 120 can be increased. The frequency of slurry accumulation which separates into lumps capable of tearing the moving web of cover sheet material may be reduced.

In other embodiments, the relative sizes of the outer and inner guide channels 167, 168 may be varied to help adjust the slurry flow to improve flow stability and reduce the occurrence of air-liquid slurry phase separation . For example, in applications that use a relatively viscous slurry at a given cross-sectional location through the first forming duct 141 in a direction perpendicular to the first flow direction 195, May have a smaller cross-sectional area than the inner guide channel (168) to help propel the first flow of slurry toward the first guide channel (158).

The inner curved walls 158 of the first and second formed ducts 141 and 142 are facing to define a peak 175 adjacent the entry portion 152 of the distribution conduit 128. Peak 175 effectively branches connector segment 139. Each feed outlet 140, 145 is in fluid communication with the entry portion 152 of the distribution conduit 128.

The position of the peak 175 along the longitudinal axis 50 may be varied in other embodiments. For example, the inner curved walls 158 of the first and second formed ducts 141, 142 may extend along the longitudinal axis 50, as shown in the slurry distributor 120 in which the peaks 175 are illustrated, Lt; RTI ID = 0.0 > 130 < / RTI > In other embodiments, the peaks 175 may be closer to the distribution outlet 130 along the longitudinal axis 50 than 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 receive the combined first and second flows of the aqueous fired gypsum slurry for increased stability and uniformity Dimensional flow pattern from the first and second formed ducts 141 and 142. [ The dispensing outlet 130 has a width that extends a predetermined distance along the transverse axis 60 and a height that extends along a vertical axis 55 that is perpendicular to the transverse axis 60 and to the longitudinal axis 50. The height of the dispensing outlet 130 is small relative to its width. The distribution conduit 128 may be oriented relative to the moving web of the cover sheet on the forming table such that the distribution conduit 128 is substantially parallel to the moving web.

The distribution conduit 128 generally extends along the longitudinal axis 50 and includes an entry portion 152 and a dispensing outlet 130. The entry portion 152 is in fluid communication with the first and second feed inlets 124, 125 of the feed conduit 122. 5, the entry portion 152 is adapted to receive both the first and second streams of aqueous fired 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 in fluid communication with the first and second feed outlets 140 and 145 of the feed conduit 122. The illustrated dispensing 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 streams of the aqueous fired gypsum slurry may be collected in the outlet flow direction 192, which may be substantially aligned with the line of movement of the web of cover sheet material through which the combined flows travel across the forming table in the wallboard manufacturing line And is coupled to the distribution conduit 128 for movement.

The dispensing outlet 130 is in fluid communication with the first and second feed inlets 124 and 125 and the first and second feed outlets 140 and 145 of the entry portion 152 and thus of the feed conduit 122 . The dispensing outlet 130 is in fluid communication with the first and second formed ducts 141 and 143 and extends along the exit flow direction 192 as it advances along the machine direction 50 And is adapted to release the combined first and second streams of slurry.

Referring to FIG. 1, the illustrated dispensing outlet 130 defines a generally rectangular opening 181 having semicircular narrow ends 183, 185. The semicircular ends 183 and 185 of the opening 181 of the dispensing outlet 130 may be the terminating ends of the outer guide channels 167 disposed adjacent the sidewalls 151 and 153 of the distribution conduit 128 have.

The opening 181 of the dispensing outlet 130 is larger than the sum of the areas of the openings 134 and 135 of the first and second feed openings 124 and 125 and the first and second feed outlets 140, (That is, the opening 156 of the distribution inlet 154) of the first and second openings 145, The cross sectional area of the opening 156 of the entry 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 dispensing outlet 130 is greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed openings 124, Greater than about 400% greater, in other embodiments greater than about 200% greater, and in yet other embodiments greater than about 150% greater. The ratio of the cross-sectional areas of the openings 134,135 of the first and second feed inlets 124,125 to the sum of the cross-sectional area of the openings 181 of the distribution outlet 130, in other embodiments, The speed, the viscosity of the slurry dispensed by the dispenser 120, the width of the board product produced by the dispenser 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 is greater than about 200% greater than the cross-sectional area of the opening 181 of the dispensing outlet 130, In a range of greater than about 150%, and in other embodiments greater than about 125%.

The dispensing outlet 130 extends substantially along the transverse axis 60. The opening 181 of the dispensing outlet 130 has a width W ₁ of approximately 24 inches along the transverse axis 60 and a height H ₁ of approximately one inch along the vertical axis 55 ). In other embodiments, the size and shape of the opening 181 of the dispensing outlet 130 may be varied.

The dispensing outlet 130 is positioned such that the first feed inlet 124 and the second feed inlet 125 are substantially located at a distance D ₁ , D ₂ equal to the transverse center midpoint 187 of the dispensing outlet 130 Is disposed intermediate the first feed inlet 124 and the second feed inlet 125 along the transverse axis 60 (see also Fig. 3). The dispensing outlet 130 may be made from an elastic flexible material such that its shape is variably adapted along the transverse axis 60, such as by, for example, the profiling system 32.

It is contemplated that the width W ₁ and / or height H ₁ of the opening 181 of the dispensing outlet 130 may be varied for different operating conditions in other embodiments. In general, the overall dimensions of the various embodiments for slurry dispensers as disclosed herein may vary depending on the type of product being manufactured (e.g., the thickness and / or width of the product manufactured), the speed of the manufacturing line being used, The deposition rate of the slurry through the slurry, the viscosity of the slurry, and the like. For example, the width (W ₁ ) of the dispensing outlet 130 for use in a wallboard manufacturing process, typically provided in nominal widths not greater than 54 inches along the transverse axis 60, is approximately 8 in some embodiments In the range of up to about 54 inches, and in other embodiments from about 18 inches to about 30 inches. In other embodiments, the width (W ₁ ) along the transverse axis 60 of the distribution outlet 130 to the maximum nominal double of the panel produced on the manufacturing system using a slurry dispenser constructed in accordance with the principles of the present disclosure The ratio ranges from about 1/7 to about 1, in other embodiments from about 1/3 to about 1, in other embodiments from about 1/3 to about 2/3, and In other embodiments from about one half to about one.

The height of the dispensing outlet may be in the range of about 3/16 inches to about 2 inches in some embodiments, and between about 3/16 inches and about 1 inch in other embodiments. In some embodiments including a rectangular distribution outlet, the ratio of the rectangular width of the exit opening to the rectangular height is greater than or equal to about 4, in other embodiments greater than or equal to about 8, in some embodiments from about 4 to about 288, From about 9 to about 288 in the examples, from about 18 to about 288 in other embodiments, and from about 18 to about 160 in other embodiments.

The distribution conduit 128 includes a converging portion 182 in fluid communication with the entry portion 152. The height of the converging portion 182 is smaller than the height in the maximum cross sectional flow region of the first and second formed ducts 141 and 143 and smaller than the height of the opening 181 of the dispensing outlet 130. In some embodiments, the height of the converging portion 182 may be approximately half the height of the opening 181 of the dispensing outlet 130.

The height of the converging portion 182 and the distribution outlet 130 may cooperate with each other to help control the average velocity of the combined first and second flows of aqueous fired gypsum dispensed from the distribution conduit 128. The height and / or width of the distribution outlet 130 may be varied to adjust the average velocity of the combined first and second flows of slurry discharged from the slurry distributor 120.

In some embodiments, the outlet flow direction 192 is substantially parallel to the plane 57 defined by the machine direction 50 and transverse cross machine direction 60 of the system for conveying the advancing web of cover sheet material Do. In other embodiments, the first and second feed directions 190, 191 and the exit flow direction 192 may be selected from the machine direction 50 and the transverse cross machine direction of the system for conveying the advancing web of cover sheet material 60). ≪ / RTI > In some embodiments, the slurry dispenser is configured such that the flow of slurry rotates about the cross machine direction 60 so that it does not undergo a substantial flow change and flows from the first and second feed directions 190, 191 to the exit flow direction 192 Can be adapted and arranged for the forming table to be directed at the slurry dispenser 120.

In some embodiments, the slurry dispenser is configured such that the first and second streams of slurry are rotated about the cross machine direction 60 over an angle of about 45 degrees or less, thereby directing the first and second streams of slurry, Can be adapted and arranged for the forming table to be directed at the slurry dispenser from the second feeding directions (190, 191) to the outlet flow direction (192). Such rotation may be accomplished in some embodiments by 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, And a vertical axis 55 formed by the cross machine axis 60 and a vertical offset angle [omega] with respect to the plane 57. In the embodiments, 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 such that the flow of slurry is directed to the machine axis 50 To move along the vertical axis 55 in the slurry dispenser 120 from the first and second feed directions 190, 191 to the outlet flow direction 192, Can be arranged at a vertical offset angle ([omega]). At least one of each of the entry segments 136 and 137 and the shaping ducts 141 and 143 is adapted to facilitate orientation of the slurry around the machine axis 50 and along the vertical axis 55. In one embodiment, . In embodiments, the first and second flows of the slurry may have an axial and / or outlet flow direction 192 substantially perpendicular to the vertical offset angle? Such that the outlet flow direction 192 is generally aligned with the machine direction 50 (190, 191) through a change in the direction angle (alpha) about one or more other rotational axes within a range of about 45 degrees to about 150 degrees with respect to the first rotational axis

In use, the first and second streams of aqueous fired gypsum slurry pass through the first and second feed inlets 124, 125 at the time of converging the first and second feed directions 190, 191 . The first and second shaping ducts 141 and 143 are oriented at a directional angle from both the first and second streams of slurry to both substantially parallel to the machine direction 50 the first and second flows of the slurry from the first feeding direction 190 and the second feeding direction 191 are moved so as to move over the change of the slurry direction. The distribution conduit 128 may be positioned so that the web of cover sheet material extends along the longitudinal axis 50 substantially coinciding with the machine direction 50 through which the gypsum board is moved. The first and second streams of aqueous fired gypsum slurry are separated by the combined first and second streams of aqueous fired gypsum slurry in an outlet flow direction 192 generally along the longitudinal axis 50 and in a machine direction In the slurry dispenser 120. The slurry dispenser 120 may be a single-

2, a slurry distributor support 100 may be provided to assist in supporting the slurry distributor 120, which is made of a flexible material, such as, for example, PVC or urethane, in the illustrated embodiment . The slurry distributor support 100 may be made of a suitable rigid material to help support the flexible slurry distributor 120. The slurry dispenser support 100 may comprise a two-piece construction. The two pieces 101,103 can be pivotable relative to each other with respect to the hinge 105 at its rear end to permit ready connection to the interior 107 of the support 100. [ The interior 107 of the support 100 may be used to assist in limiting the amount of movement that the slurry dispenser 120 may experience against the support 100 or to define the internal shape of the slurry dispenser 120 through which the slurry flows The interior 107 may be configured to substantially conform to the exterior of the slurry dispenser 120. [

Referring to Figure 3, in some embodiments, the slurry distributor support 100 may be made of a suitable resiliently flexible material that provides support and may be deformed in response to a profiling system 132 mounted to the support 100. [ . The profiling system 132 may be mounted to the support 100 adjacent the dispensing outlet 130 of the slurry dispenser 120. The profiling system 132 thus installed may also serve to change the size and / or shape of the dispensing outlet 130 of the dispensing conduit 128 by also changing the size and / or shape of the conforming support 100 Which in turn affects the size and / or shape of the dispensing outlet 130.

Referring to FIG. 3, the profiling system 132 may be adapted to selectively vary the size and / or shape of the opening 181 of the dispensing outlet 130. In some embodiments, the profiling system can be used to selectively adjust the height H ₁ of the opening 181 of the dispensing outlet 130.

The illustrated profiling system 132 includes a plate 90, a plurality of mounting bolts 92 that secure the plate to the distribution conduit 128, and a series of adjustment bolts 94, 95 threaded thereto do. Mounting bolts 92 are used to secure the plate 90 to the support 100 adjacent to the dispensing outlet 130 of the slurry dispenser 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 iron. In other embodiments, the plate 90 may have different shapes and may include different materials. In yet other embodiments, the profiling system may include other components adapted to selectively vary the size and / or shape of the opening 181 of the dispensing outlet 130.

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

The profiling system 132 can be used to locally vary the distribution outlet 130 to alter the flow pattern of the combined first and second flows of aqueous fired gypsum slurry dispensed from the slurry distributor 120. [ For example, the median line adjustment bolt 95 may increase the edge flow angle away from the longitudinal axis 50 to facilitate diffusion in the cross machine direction 60 and improve slurry flow uniformity in the cross machine direction 60 And to tighten the transverse center midpoint 187 of the dispensing outlet 130 to allow the dispensing outlet 130 to move.

The profiling system 132 may be used to vary the size of the dispensing outlet 130 along the abscissa 60 and to maintain the dispensing outlet 130 in a new shape. The plate 90 is urged by the adjustment bolts 94 and 95 in response to adjustments made by the adjustment bolts 94 and 95 when the plate 90 urges the dispensing outlet 130 to the new configuration It can be made of a suitably strong material so as to withstand the opposing forces. The profiling system 132 can provide stable changes in the flow profile of the slurry discharged from the distribution outlet 130 (e.g., different slurry densities and / or different slurry densities) from the distribution conduit 128 As a result of feeding inlet velocities).

In other embodiments, the number of adjustment bolts may be varied to change the spacing between adjacent adjustment bolts. For example, in other embodiments where the width (W ₁ ) of the distribution outlet 130 is different, the number of adjustment bolts may be varied to achieve the desired adjacent bolt spacing. In still other embodiments, the spacing between adjacent bolts may be varied along transverse axis 60 to provide greater local change control at, for example, lateral edges 184, 185 of distribution outlet 130 .

The slurry dispenser constructed in accordance with the principles of the present disclosure may comprise any suitable material. In some embodiments, the slurry dispenser may comprise any suitable substantially rigid material that may include any suitable material that may permit the size and shape of the outlet to be modified using, for example, a profile system. For example, suitable rigid plastics, such as ultrahigh molecular weight (UHMW) plastics, or metals may be used. In other embodiments, the slurry dispenser constructed in accordance with the principles of the present disclosure may be made of a fusible material, such as a suitable flexible plastic material, including, for example, polyvinyl chloride (PVC) or urethane. In some embodiments, the slurry dispenser constructed in accordance with the principles of the present disclosure may include a single feed inlet, an entry segment, and a forming duct in fluid communication with the distribution conduit.

The gypsum slurry dispenser constructed in accordance with the principles of the present disclosure provides a wide cross machine distribution of the aqueous fired gypsum slurry to facilitate diffusion of the high viscosity / low WSR gypsum slurries on the web of cover sheet material moving on the forming table Can be used to help. The gypsum slurry distribution system can also be used to help control the air-slurry phase separation.

According to another aspect of the present disclosure, the gypsum slurry mixing and dispensing assembly may comprise a slurry dispenser constructed in accordance with the principles of the present disclosure. The slurry dispenser may be positioned in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous fired gypsum slurry. In one embodiment, the slurry dispenser is adapted to receive the first and second streams of aqueous fired gypsum slurry from a gypsum slurry mixer and dispense the first and second streams of aqueous fired gypsum slurry onto the advancing web.

The slurry dispenser may include or act as part of a discharge conduit of a conventional gypsum slurry mixer (e.g., a pin mixer) as is known in the art. The slurry dispenser can be used with the components of conventional discharge conduits. For example, the slurry dispenser may be a gate-canister-boot arrangement, as known in the art, or alternatively, as disclosed in U.S. Patent Nos. 6,494,609; 6,874, 930; 7,007,914; And 7,296,919, which are incorporated herein by reference in their entirety.

The slurry dispenser constructed in accordance with the principles of the present disclosure may be advantageously configured as retrofit in existing wallboard manufacturing systems. The slurry dispenser may preferably be used to replace conventional single or multiple branch boots used in conventional discharge conduits. Such gypsum slurry dispensers may be reinforced with existing slurry discharge conduit arrangements, such as those shown in U.S. Patent No. 6,874,930 or 7,007,914 as a replacement for a distal dispense spout or boot, for example. However, in some embodiments, the slurry dispenser may alternatively be attached to one or more boot outlets (s).

4 and 5, the slurry dispenser 220 is similar to the slurry dispenser 120 of FIGS. 1-3 except that it is constructed of a substantially rigid material. The internal shape 207 of the slurry dispenser 220 of FIGS. 4 and 5 is similar to that of the slurry dispenser 120 of FIGS. 1-3 and the same reference numerals are used to denote the same structure. The inner shape 207 of the slurry dispenser 207 is adapted to define a flow path for the running gypsum slurry that is a type of stream line flow to undergo air-liquid slurry phase separation that is reduced or substantially absent, .

In some embodiments, the slurry dispenser 220 may include any suitable substantially rigid material that may include any suitable material that permits the size and shape of the outlet 130 to be modified using, for example, a profile system. . For example, a suitable rigid plastic such as UHMW plastic, or a metal may be used.

Referring to Figure 4, the slurry dispenser 220 has a two-piece construction. The top piece 221 of the slurry dispenser 220 includes a recess 227 adapted to receive the profiling system 132 therein. The two pieces 221 and 223 may be pivotable relative to each other with respect to the hinge 205 at its rear end to permit ready connection to the interior 207 of the slurry dispenser 220. Mounting holes 229 are provided to facilitate connection of the upper piece 221 and its mating lower piece 223.

Referring to Figs. 6-8, another embodiment of a slurry dispenser 320 (constructed of rigid material) constructed in accordance with the principles of the present disclosure is shown. The slurry dispenser 320 of Figures 6-8 includes first and second feed inlets 324 and 325 and first and second incoming segments 336 and 337 of the slurry dispenser 320 of Figures 6-8 (See Fig. 7), except that the slurry dispenser 220 is disposed at a feed angle [theta] relative to the machine direction 50 or a longitudinal axis of approximately 60 [deg.].

The slurry dispenser 320 has a two piece construction comprising an upper piece 321 and a mating lower piece 323 thereof. The two pieces 321 and 323 of the slurry dispenser 320 may be used to form any one of the pieces 321 and 323 of any of the pieces 321 and 323 such as by using fasteners through a corresponding number of mounting holes 329 provided in each piece 321 and 323, Can be secured together using appropriate techniques. The top piece 321 of the slurry dispenser 320 includes a recess 327 adapted to receive the profiling system 132 therein. The slurry dispenser 320 of FIGS. 6-8 is otherwise similar to the slurry dispenser 220 of FIGS. 4 and 5.

Referring to Figs. 9 and 10, the lower piece 323 of the slurry dispenser 320 of Fig. 6 is shown. The lower piece 323 defines a first portion 331 of the inner shape 307 of the slurry dispenser 320 of FIG. The top piece 323 is configured to define the complete interior shape 307 of the slurry dispenser 320 of Figure 6 when the top and bottom pieces 321 and 323 mate together, And defines a symmetrical second portion of the shape 307.

Referring to FIG. 9, first and second formed ducts 341 and 343 move substantially in an outlet flow direction 392 in which the first and second flows of the slurry are aligned with the machine direction or longitudinal axis 50 Receiving first and second flows of slurry moving in first and second feed flow directions 390 and 391 to be conveyed to distribution conduit 328 and forwarding the slurry flow direction by a change in direction angle [ .

Figures 11 and 12 illustrate another embodiment of a slurry dispenser support 300 for use with the slurry dispenser 320 of Figure 6. The slurry dispenser support 300 can include upper and lower support plates 301, 302, which are constructed of a suitable rigid material, such as, for example, a metal. The support plates 301, 302 may be secured to the dispenser via any suitable means. In use, the support plates 301, 302 support the moving cover sheet and transport can assist in supporting the slurry dispenser 320 at a location across the machine line that includes the conveyor assembly. The support plates 301, 302 may be mounted on appropriate uplites disposed on either side of the conveyor assembly.

Figures 13 and 14 illustrate another embodiment of a slurry dispenser support 310 for use with the slurry dispenser 320 of Figure 6 which also includes upper and lower support plates 311 and 312 . The cutouts 313, 314 and 318 in the upper support plate 311 are connected differently to portions of the slurry distributor 320, such as those portions that accommodate the creative fasteners, It is possible to make the support 310 lighter. The slurry distributor support 310 of FIGS. 13 and 14 may be otherwise similar to the slurry distributor support 300 of FIGS. 11 and 12 in other respects.

FIGS. 15-19 illustrate another embodiment of slurry dispenser 420, which is similar to slurry dispenser 320 of FIGS. 6-8, except that it is constructed of a substantially flexible material. The slurry dispenser 420 of Figs. 15-19 also includes first and second feed inlets 324, 325 disposed at a 60 占 longitudinal axis or feed angle [theta] to the machine direction 50, And second entry segments 336 and 337 (see FIG. 7). The internal shape 307 of the slurry dispenser 420 of FIGS. 15-19 is similar to that of the slurry dispenser 320 of FIGS. 6-8, and the same reference numerals are used to denote the same structure.

Figs. 17-19 continue to illustrate the internal shapes of the second entry segment 337 and the second forming duct 343 of the slurry dispenser 420 of Figs. 15 and 16. Sectional areas 411, 412, 413 and 414 of the outer and inner guide channels 367 and 368 may continue to move in the second flow direction 397 toward the distribution outlet 330 and continue to become smaller. The outer guide channel 367 can extend substantially along the outer wall 357 of the second forming duct 343 and along the sidewall 353 of the distribution conduit 328 to the dispensing outlet 330. The inner guide channel 368 is adjacent to the inner wall 358 of the second forming duct 343 and terminates at the peak 375 of the branch connector segment 339. The slurry dispenser 420 of FIGS. 15-19 is otherwise similar to the slurry dispenser 120 of FIG. 1 and the slurry dispenser 320 of FIG. 6 in different respects.

20 and 21, the illustrated embodiment of the slurry dispenser 420 is made of a flexible material, such as, for example, PVC or urethane. The slurry distributor support 400 may be provided to assist in supporting the slurry distributor 420. Slurry distributor support 400 may include a support member which is in the form of a lower support tray 401 that is filled with a suitable support medium 402 defining a support surface 404 in the illustrated embodiment. The support surface 404 may be formed on at least a portion of the exterior to at least one of the feed conduit 322 and the distribution conduit 328 to aid in limiting the amount of relative movement between the slurry distributor 420 and the support tray 401. [ Substantially conform to each other. In some embodiments, the support surface 404 may help maintain the internal shape of the slurry distributor 420 through which the slurry will flow.

The slurry dispenser support 400 may include a movable support assembly 405 disposed in spaced relation to the lower support tray 401. The movable support assembly 405 may be positioned over the slurry dispenser 420 and arranged to be supported in relation to the slurry dispenser 420 to help maintain the interior shape 307 of the slurry dispenser in a desired configuration.

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

In embodiments, the at least one support segment 415, 416, 417, 418, 419 is independently movable relative to the other support segment 415, 416, 417, 418, 419. In the illustrated embodiment, each support segment 415, 416, 417, 418, 419 is independently movable relative to the support frame 407 over a predetermined range of travel. Each of the support segments 415,416, 417,418 and 419 is configured such that each support segment 415,416, 417,418 and 419 has at least one of the feed conduit 322 and the distribution conduit 328 A portion for one, and a respective support segment in a range over positions that increase compression engagement.

The position of each support segment 415, 416, 417, 418, 419 can be adjusted to place the support segments 415, 416, 417, 418, 419 in compression engagement with at least a portion of the slurry distributor 420 have. Each support segment 415, 416, 417, 418, 419 places each support segment 415, 416, 417, 418, 419 in at least a portion of the slurry distributor 420 with additional compression engagement, The slurry dispenser 420 is disposed locally with a reduced compression fit with at least a portion of the slurry dispenser 420 so as to compress the interior of the slurry dispenser 420 locally, And can be independently adjusted to allow it to expand in response to flowing through it.

In the illustrated embodiment, each of the support segments 415, 416, 417 is movable over a range of travel along a vertical axis 55. In other embodiments, at least one of the support segments may be movable along a different line of action.

The movable support assembly 405 includes a clamping mechanism 408 associated with each support segment 415, 416, 417, 418, 419. Each clamping mechanism 408 may be adapted to selectively retain the associated support segments 415, 416, 417, 418, 419 at a selected position relative to the support frame 407.

In the illustrated embodiment, a rod 409 is mounted to each support segment 415, 416, 417, 418, 419 and extends upwardly through a corresponding opening in the support frame 407. Each clamping mechanism 408 is associated with one of the rods 409 mounted to the support frame 407 and projecting from each support segment 415, 416, 417, 418, 419. Each clamping mechanism 408 may be adapted to selectively retain the associated rod 409 in a fixed relationship to the support frame 407. [ The illustrated clamping mechanisms 408 are conventional lever actuated clamps that enclose each rod 409 and allow infinitely variable adjustment between the rod 409 associated with the clamping mechanism 408.

As will be appreciated by one of ordinary skill in the art, any suitable clamping mechanism 408 may be used in other embodiments. In some embodiments, each associated load 409 may be moved through a suitable actuator (e.g., hydraulic or electric) controlled through a controller. The actuator can function as a clamping mechanism by keeping the associated support segments 415, 416, 417, 418, 419 in a fixed position relative to the support frame 407.

Referring to Figure 21, the support segments 415, 416, 417, 418, 419 are disposed on the surface portion of the desired geometric shape for at least one of the feed conduit 322 and the distribution conduit 328 of the slurry distributor 420 502, 503, 504, 505, respectively, which are configured to substantially conform to one another. In the illustrated embodiment, a distributor conduit support segment 415 is provided that includes a contact surface 501 that conforms to the external and internal configuration of a portion of the distributor conduit 328 in which the distributor conduit support segment 415 is disposed. A pair of contact surfaces 502, 503 each corresponding to an outer and an inner shape of a portion of each of the first and second forming ducts 341, 343 in which the forming duct support segments 416, 417 are disposed, Molding duct support segments 416 and 417 are provided. Each of which includes a contact surface 504 and 505 that conforms to the external and internal shape of a portion of each of the first and second entry segments 336 and 337 in which the forming duct support segments 418 and 419 are disposed, Entry support segments 418 and 419 are provided. The contact surfaces 501, 502, 503, 504 and 505 are connected to a slurry distributor 420 to assist in maintaining the contacted portion of the slurry distributor 420 in a position to assist in defining the interior shape 307 of the slurry distributor 420 Quot;). ≪ / RTI >

In use, the movable support assembly 405 may be operated to independently position each support segment 415, 416, 417, 418, 419 in a desired relationship with the slurry distributor 420. The support segments 415, 416, 417, 418, 419 facilitate the flow of slurry therethrough and assist in ensuring that the volume defined by the inner shape 307 is substantially filled with the slurry during use. Can help maintain the inner shape (307) of the dispenser (420). The location of a particular contact surface of a given support segment 415, 416, 417, 418, 419 may be adjusted to locally modify the internal shape of the slurry distributor 420. [ For example, the distributor conduit support segment 415 may extend along a vertical axis 55 closer to the lower support tray 401 to reduce the height of the distribution conduit 328 in the region where the distributor conduit support segment 415 is located. Can be moved.

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

22-27 illustrate another embodiment of a slurry dispenser 1420 constructed in accordance with the principles of the present disclosure. Slurry dispenser 1420 is made of a substantially flexible material, such as, for example, PVC or urethane. The slurry dispenser 1420 of Figs. 22-27 also has a feed angle &thetas;, which is substantially parallel to the first and second feed inlets 1424,1425 and the longitudinal or machine direction 50 (see Fig. 24) And includes first and second incoming segments 1436 and 1437 which are arranged.

Slurry distributor 1420 includes a branch feed conduit 1422, a distribution conduit 1428, a slurry wiping mechanism 1417, and a profiling mechanism 1432. The slurry distributor support 1400 may be provided to assist in supporting the slurry distributor 1420.

22 and 23, the slurry distributor support 1400 can include a support member, which is in the form of a lower support member 1401 defining a support surface 1402 in the illustrated embodiment. The support surface 1402 may be formed on at least a portion of the exterior to at least one of the feed conduit 1422 and the distribution conduit 1428 to aid in limiting the amount of relative movement between the slurry distributor 1420 and the bottom support member 1401 And can be configured to substantially match. In some embodiments, the support surface 1402 may help maintain the internal shape of the slurry distributor 1420 through which the slurry flows. In embodiments, an additional fusing structure may be provided to help secure the slurry dispenser 1420 to the lower support member 1401.

The slurry distributor support 1400 may include an upper support member 1404 disposed in spaced relation to the lower support member 1401. The upper support member 1404 can be adapted to be positioned above the slurry distributor 1420 and in support relationship with the slurry distributor 1420 to help keep the interior shape 1407 of the slurry distributor 1420 in a desired configuration have.

The upper support member 1404 may include a support frame 1407 and a plurality of support segments 1413,1415 and 1416 fixedly supported by the support frame 1407. [ The support frame 1407 may be mounted to at least one of the lower support member 1401 or one or more appropriately arranged uprights to maintain the support frame 1407 in a fixed relationship with the lower support tray 1401. [ The support segments 1413,1415 and 1416 define a contact surface configured to substantially conform to the surface portion of the desired geometric shape for at least one of the feed conduit 1422 and the distribution conduit 1428 of the slurry distributor 1420, Lt; / RTI > In embodiments, the support frame 1407 may be adapted to moveably 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 can move the support segments 1413, 1415, 1416 over a range of travel over the vertical axis 55. [

22, the slurry wiping mechanism 1417 includes a pair of actuators 1510, 1511 operatively arranged with a wiper blade 1514 to selectively reciprocate the wiper blade 1514 . Actuators 1510 and 1511 are mounted on the lower support member 1401 adjacent the distal end 1515 of the distribution conduit 1428. The wiper blade 1514 extends transversely between the actuators 1510, 1511.

Referring to Figure 26, the dispensing outlet 1430 includes an exit opening 1481 having a width W ₂ along the transverse axis 60. The wiper blade 1514 extends a predetermined width W ₃ along the transverse axis 60. The width W ₂ of the outlet opening 1481 is smaller than the width W ₃ of the wiper blade 1514 so that the wiper blade 1514 is wider than the outlet opening 1481.

28, in the illustrated embodiments, each of the actuators 1510, 1511 includes a double acting pneumatic cylinder having a reciprocable piston 1520. The rod 1522 of the piston 1520 is connected to the wiper blade 1514. In embodiments, a pair of pneumatic air lines may be connected to drive port 1525 and retract port 1526, respectively. The source of compressed gas 1530 may be controlled using an appropriate control valve assembly 1532 controlled by a controller 1534 to selectively reciprocate the wiper blade 1514 along the longitudinal axis 50. The air line may restrain the drive ports 1525 of both actuators 1510 and 1511 in parallel and the individual air line may be retracted to the retract ports 1510 and 1511 of both actuators 1510 and 1511 1526 can be constrained together in parallel. In other embodiments, the actuators may be anything that can reciprocate, for example, a wiper blade including passive devices.

The movable wiper blade 1514 is in contact with the lower end surface 1540 of the distribution conduit 1428. The wiper blade 1514 is reciprocatable over the clearing path between the first position and the second position (shown as phantom lines). The clearing path is disposed adjacent the distal end 1515 of the distribution conduit 1428 including the distribution outlet 1430. [ The wiper blade reciprocates vertically along the clearing path. In the illustrated embodiment, the first position of the wiper blade 1514 is vertically upstream of the dispensing outlet 1430 and the second position is vertically downstream of the dispensing outlet 1430.

A controller 1534 is adapted to selectively control the actuators to reciprocate the wiper blade 1514. In embodiments, the controller 1534 moves the wiper blade 1514 in the clearing direction 1550 from the first position to the second position throughout the wiping stroke and moves the wiper blade from the second position to the first position Opposite direction 1560 in the return direction. In embodiments, the controller 1534 is adapted to move the wiper blade 1514 to substantially the same amount of time traveled over the wiping stroke as it travels over the return stroke.

In embodiments, the controller 1534 may be adapted to move the wiper blade 1514 in a reciprocating cycle with a sweep period between the first and second positions. The sweep period includes a wiping portion that includes the time to travel across the wiping stroke, a return portion that includes the time to travel across the return stroke and a predetermined period of time that the wiper blade 1514 holds in the first position Lt; / RTI > In embodiments, the wiping portion is substantially the same as the return portion. In embodiments, the controller 1534 is adapted to adaptively vary the accumulation delay portion.

34, the lower support member 1401, which supports the lower end surface of the distribution conduit 1428, includes a perimeter 1565. The dispensing outlet 1430 is vertically offset from the bottom support member 1401 such that the distal exit portion 1515 of the distribution conduit 1428 extends from the perimeter 1565 of the bottom support member 1401. 28, the wiper blade 1514 supports the distal exit portion 1515 of the slurry dispenser 1420 when the wiper blade is in the first position.

22, the profiling mechanism 1432 includes a profiling member 1610 in contact with the distribution conduit 1428 and a support assembly 1610 adapted to allow the profiling member 1610 to have at least two degrees of freedom 1620). In embodiments, the profiling member is translatable along at least one axis and rotatable with respect to the at least one pivot axis. In embodiments, the profiling member is rotatable about a pivot axis 1630 that is movable along a vertical axis 55 and is substantially parallel to the longitudinal axis 50. [

Referring to Figures 26, 30 and 30A, the profiling member 1610 is configured to allow the profiling member 1610 to be positioned in the dispensing conduit 1610 adjacent the dispensing outlet 1430 to change the shape and / or size of the outlet opening 1430. [ Such that there is a portion of the first portion 1428 and a portion of the profile that increases the compression tightening.

26, outlet opening 1481 of dispensing outlet 1430 has a width W ₂ along transverse axis 60. Touch profiled segments of the profiled member (1410) has a width (W ₄₎ to extend a predetermined distance along the horizontal axis. In embodiments, the width W ₂ of the exit opening 1481 is greater than the width W ₄ of the profiling member 1410. In other embodiments, the width W ₂ of the exit opening 1481 is less than or equal to the width W ₄ of the profiling member 1410. The profiling member 1410 is configured such that a pair of side portions 1631 and 1632 of the distribution outlet 1430 are spaced apart from the side of the profiling member 1410 by the side of the profiling member 1410 so that the profiling member does not engage the side portions 1631 and 1632. [ Offset relationship. In some embodiments, the side portions 1631, 1632 can have a combined width of about 1/4 of the width W ₂ of the exit opening 1481.

23, the support assembly 1620 is pivotally mounted to the transverse support member 1645 using a pair of stationary uplites 1642, 1643, a transverse support member 1645, and any suitable pivot connection, And a horizontal pivot support member 1647 connected thereto. The fixed uplites 1642 and 1643 may be mounted on the lower support member 1401. [ The transverse fixing support member 1645 may extend laterally between the fixed uplites 1642 and 1643.

29, 30, 30B, and 31, the pivot support member 1647 is rotatable about the pivot axis 1630 over the arc length 1652 with respect to the fixed support member 1645. [ The arc length 1652 allows the pivot end 1653 of the pivot support member 1647 to be tilted both upwardly above the transverse axis 60 and downwardly below the transverse axis 60. [ The pivot support member 1647 supports the profiling member 1610.

In embodiments, the profiling member 1610 is rotatable about a pivot axis 1630 that is translatable along a vertical axis 55 and substantially parallel to the longitudinal axis 50. Fastening part and the variable compression of the profiling member (1610) is the outlet opening (1481), the height (H ₂₎ the horizontal axis represents the distribution profile member to be changed according to (60) across the transverse axis 60, the conduit 1428 of And is rotatable about the pivot axis 1630 over an arc length 1652 such that there is a profiling member 1610 in a range of positions where the profile is located.

29 and 33, the profiling member 1610 includes a fastening segment 1660 extending generally longitudinally and transversely, and a translation adjustment rod 1662 extending generally vertically from the fastening segment 1660 . The translation adjustment rod 1662 of the profiling member 1610 is configured such that the profiling member 1610 is movable relative to the pivot support member 1647 of the support assembly 1620 such that the profiling member 1610 is movable along a vertical axis 55 over a range of vertical positions And is fixed movably. A pair of translation guide rods 1663 and 1665 extend through each collar 1667 and 1668 that is connected to the fastening segment 1660 and mounted to the pivot support member 1647. The guide rods 1663 and 1665 are movable relative to the collar 1667 and 1668 along the vertical axis 55.

The support assembly 1620 may include a clamping mechanism adapted to selectively fasten the translation adjustment rod 1662 to secure the profiling member 1610 to a selected one of 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 lock the thread translation adjustment rod 1662 in place. The resilient nut 1666 is disposed near the distal end 1657 of the translation adjustment rod 1662 to maintain a sufficient clearance for the push screw 1669 (see FIG. 30C) that is attached to the distal end to be allowed to rotate. 30C, a blind hole 1658 is defined in the profiling member 1610 to receive the push screw 1669 to allow the push screw to rotate about the axis of the translation adjustment rod 1662. [

30B and 31, a support assembly 1620 includes a profiled member 1610 to allow the profiling member 1610 to rotate about a pivot axis 1630 over a range of locations along an arc length 1652 1610). ≪ / RTI > The support assembly 1620 includes a rotation adjustment rod 1670 extending between the stationary support member 1645 and the pivot support member 1647 via a support bracket 1672 connected to the stationary support member 1645 (see also Figure 31) . The rotation adjustment rod 1670 is configured such that moving the rotation adjustment rod 1670 relative to the fixed support member 1645 causes the pivot shaft 1630 to rotate about the pivot axis 1630 relative to the fixed support member 1645 by rotating its T- And is movably secured to stationary support member 1645 through a threaded connection with support bracket 1672 to pivot support member 1647. The support bracket 1672 can be configured to allow some bending during tilting operation. Shaft collars 1673 and 1674 may be provided for added reliability.

The support assembly 1620 may include a clamping mechanism adapted to selectively fasten the rotation adjusting rod 1670 to secure the profiling member 1610 to a selected one of a range of positions along the arc length 1652. In the illustrated embodiment, a jam nut 1677 may be provided to lock the threaded rod 1670 to the barrel nut 1679.

34 and 40, the branch feed conduit 1422 of the slurry distributor 1420 includes first and second feed portions 1701, Each of the first and second feed portions 1701 and 1702 has a feed inlet 1424 and 1425 and a respective entry segment 1436 having feed inlet inlets 1710 and 1711 in fluid communication with the feed inlets 1424 and 1425, 1437 having bulb portions 1720, 1721 (see also Figure 41) in fluid communication with the feed inlet / outlet 1710, 1711 of each entry segment 1436, And transition segments 1730, 1731 in fluid communication with the bulb portions 1720, 1721.

Referring to Figure 34, first and second feed inlets 1424,1425 and first and second incoming segments 1436,1437 extend substantially in the range of up to 135 占 with respect to the longitudinal axis 50, Can be arranged at each feeding angle [theta], which is measured as the degree of rotation relative to the feeding roller 55. [ The illustrated first and second feed inlets 1424 and 1425 and the first and second incoming segments 1436 and 1437 are disposed at respective feed angles? That are substantially aligned with the longitudinal axis 50.

The first feeding portion 1701 is substantially the same as the second feeding portion 1702. Thus, it should be understood that the description of one feeding part is also equally applicable to the other feeding part. In other embodiments there may be only a single feed portion or there may be more than two feed portions in yet other embodiments.

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

In other embodiments, the first feed flow axis 1735 may 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 is not perpendicular to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60, but rather by a degree of rotation relative to the transverse axis 60 Can be arranged at a delivery pitch angle (?), As measured. In embodiments, the pitch angle [sigma] measured from the longitudinal axis 50 in a direction facing the machine direction 92 upwardly on the vertical axis 55 as shown in Figure 35 is about 0 to about 135 degrees From about 15 to about 120 degrees in other embodiments, from about 30 to about 105 degrees in yet another embodiment, from about 45 to about 105 degrees in yet another embodiment, and from about 75 To about 105 degrees. In other embodiments, the first feed flow axis 1735 may be a feed (not shown) perpendicular to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60, Roll angle.

Referring to Figure 34, the forming duct 1441 includes a pair of lateral sides 1740, 1741 and a bulb portion 1720. The forming duct 1441 is in fluid communication with the feed inlet / outlet 1711 of the entry segment 1436. 35, the bulb portion 1720 is configured to reduce the average velocity of the flow of slurry moving from the entry segment 1436 to the transition segment 1730 through the bulb portion 1720. In embodiments, the bulb portion 1720 is configured to reduce the average velocity of the slurry moving from the entry segment 1436 through the bulb portion 1720 to the transition segment 1730 by at least 20 percent.

Referring to Figures 45-47, the bulb portion 1720 has a cross-section of the adjacent region upstream from the expanded region, as compared to the flow direction 1752 from the feed inlet 1424 to the distribution outlet 1430 of the distribution conduit 1428. [ And an extended region 1750 having a larger cross sectional flow region than the flow region. In embodiments, the bulb portion 1720 has a region 1752 having a cross-sectional area in a plane perpendicular to the first flow axis 1735, which is larger than the cross-sectional area of the feed-in entry exit 1711.

The forming duct 1441 has a convex inner surface 1758 that is in face-to-face relationship with the feed inlet / outlet 1711 of the entry segment 1436. The bulb portion 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. 45, the convex inner surface 1758 is also configured to define a center rest portion 1762 in the flow path that aids in increasing the average velocity of the slurry in the radial guide channel 1760. [

The forming duct 1441 extends from about 0 to about 10 in flow of the slurry moving adjacent the convex inner surface 1758 toward the dispensing outlet 1430 and through the opposite side to one or more of the lateral sides 1740 and 1741 and it may be configured to have other embodiments about swirl motion (s _m) of from approximately 5 to 0.5 at up to about 3, and in yet another embodiment. The flow of slurry moving through the region adjacent to the convex inner surface 1758 and adjacent to at least one of the lateral sides 1740 and 1741 toward the distribution outlet 1430 is approximately 0 ° to approximately 84 ° in to, and another embodiment has a swirl angle (S _m) of approximately 80 ° to approximately 10 °.

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

In embodiments, the first feed flow axis 1735 is substantially perpendicular to the longitudinal axis 50. In the embodiments, the first feed flow axis 1735 is substantially parallel to the vertical axis 55, which is perpendicular to the longitudinal axis 50 and the transverse axis 60. In embodiments, the second feed flow axis 1770 is disposed at each feed angle [theta] in the range of up to approximately 135 [deg.] With respect to the longitudinal axis 50. [

In embodiments, the feed conduit 1422 includes a branch connector segment 1439 that includes first and second guide surfaces 1780, 1781. In embodiments, the first and second guide surfaces 1781 are configured to direct the first and second streams of slurry entering the feed conduit through the first and second inlets 1424 and 1425, And may be respectively adapted to divert in the direction of the outlet flow by changing the directional angle.

41-43, each of the forming ducts 1441, 1443 has a concave outer surface 1790, 1791 that is substantially complementary to and in base relation to the shape of its convex inner surface 1758 . Each recessed outer surface 1790, 1791 defines a recess 1794, 1795.

Referring to Figures 27, 35 and 36, support inserts 1801, 1802 are disposed within respective recesses 1794, 1795 of slurry dispenser 1420. The support inserts 1801 and 1802 are placed in an underlying relationship to the respective convex inner surfaces of the forming ducts 1441 and 1443. [ The support inserts 1801 and 1802 can be made of any suitable material that supports the slurry dispenser and helps maintain the desired shape for the overlying inner convex surface. In the illustrated embodiment, the support inserts 1801 and 1802 are substantially identical. In other embodiments, different support inserts may be used or inserts are not used in yet another embodiment.

37-39, the rigid support insert 1801 includes a support surface 1810 that substantially conforms to the shape of the convex inner surface of the forming duct. In embodiments, the forming duct of the slurry dispenser may be made of a flexible material that is sufficiently flexible such that the convex inner surface is defined by the support surface 1810 of the support insert 1801. In such cases, the concave outer surface of the forming duct may be omitted.

The support insert 1801 includes a feed end 1820 and a distribution end 1822. The support insertion portion 1801 extends a center support shaft 1825. The support insertion portion 1801 is substantially symmetrical around the support shaft 1825. The support insert 1801 is asymmetric around a central axis 1830 perpendicular to the support axis 1825.

34, the distribution conduit 1428 includes a distribution outlet 1430 that extends generally along the longitudinal axis 50 and is in fluid communication with the entry portion 1452 and the entry portion 1452. The entry portion 1452 is in fluid communication with the first and second feed openings 1424 and 1425 of the feed conduit 1422. The width of the distribution conduit 1428 increases from the entry portion 1452 to the distribution outlet 1430. However, in other embodiments, the width of the distribution conduit 1428 is reduced or constant from the entry portion 1452 to the dispensing outlet 1430.

Entry section 1452 enters the distribution along the horizontal axis 60, a width (W _5), and along a vertical axis (55) comprises an entry opening (1453) having a penetration height (H _4), distribution entry width (W ₅ is less than the width (W ₂ ) of the outlet opening 1481 of the dispensing outlet 1430. In other embodiments, the dispense entry width W ₅ is greater than the width W ₂ of the exit opening 1481 of the dispensing exit 1430. In embodiments, the width-to-height ratio of the exit opening 1481 is approximately 4 or greater.

In embodiments, at least one of the feed conduit 1422 and the distribution conduit 1428 is configured to receive the feeds from the feed outlets 1424, 1425 (or 1425) so that the flow of slurry is discharged from the distribution outlet at an average release rate of at least 20 percent, And a flow stabilization zone adapted to reduce the average feed rate of the slurry flow into the distribution outlet 1430. [

Figs. 44-53 continue to show the interior shape 1407 of the half portion 1504 of the slurry dispenser 1420 of Fig. The slurry dispenser 1420 of FIG. 22 is otherwise similar to the slurry dispenser 120 of FIG. 1 and the slurry dispenser 420 of FIG. 20 in other respects.

Any suitable technique for manufacturing a slurry dispenser constructed in accordance with the principles of the present disclosure may be used. For example, in embodiments where the slurry dispenser is made of a flexible material, such as PVC or urethane, a multi-piece mold may be used. In some embodiments, the mold-piece areas may be less than or equal to about 150% of the area of the molded slurry dispenser being pumped during removal, about 125% or less in other embodiments, and about 115% or less in other embodiments , And about 110% or less of yet other embodiments.

54 and 55, one embodiment of a multi-piece mold 550 suitable for use in making the slurry dispenser 120 of FIG. 1 with a flexible material, such as PVC or urethane, is shown. The illustrated multi-piece mold 550 includes five mold segments 551, 552, 553, 554, and 555. The mold segments 551, 552, 553, 554, 555 of the multi-piece mold 550 may be made of any suitable material, such as, for example, aluminum.

In the illustrated embodiment, the distributor conduit mold segment 551 is configured to define the internal flow shape of the distributor conduit 128. [ The first and second formed duct mold segments 552 and 553 are configured to define an internal flow shape of the first and second formed ducts 141 and 143. The first and second incoming mold segments 554 and 555 are configured to communicate with the first incoming segment 136 and the first incoming feed 124 and the second incoming segment 137 and the second feed inlet 125, Respectively. In other embodiments, the multi-piece mold may include a different number of mold segments and / or the mold segments may have different shapes and / or sizes.

Referring to Figure 54, the connecting bolts 571, 572 and 573 are used to define the mold segments 551, 552, 553, 554 and 555 to define a substantially continuous outer surface 580 of the multi- May be inserted through two or more mold segments to interlock and align. In some embodiments, the distal portion 575 of the connecting bolts 571, 572, 573 may be used to form mold segments (e. ≪ RTI ID = 0.0 > 551, 552, 553, 554, 555). The outer surface 580 of the multi-piece mold 550 is configured to define the internal shape of the molded slurry dispenser 120 to reduce flashing at the joints. The connection bolts 571, 572 and 573 may be removed to disassemble the multi-piece mold 550 during removal of the mold 550 from the interior of the molded slurry dispenser 120.

The assembled multi-piece mold 550 is immersed in a solution of a flexible material, such as PVC or urethane, so that the mold 550 is completely submerged in solution. The mold 550 can then be removed from the immersed material. The amount of solution can be adhered to the outer surface 580 of the multi-piece mold 550 constituting the molded slurry dispenser 120 when the solution is changed to a solid form. In embodiments, the multi-piece mold 550 may be used in any suitable immersion process to form the molded piece.

A plurality of separate aluminum pieces that are designed to fit together to provide the desired internal flow shape-in the illustrated embodiment, by fabricating the mold 550 from the five pieces- the mold segments 551, 552, 553 , 554, 555 may be separated from each other and drawn out of the solution while it is still warm, if it has begun to be set. At sufficiently high temperatures, the flexible material is transferred to the larger calculated regions of the aluminum mold pieces 551, 552, 553, 554, and 555 through the smaller calculated regions of the molded slurry dispenser 120 without tearing it It is flexible enough to pull. In some embodiments, the largest mold piece area is defined as the area where the particular mold piece is approximately 150% of the smallest area of the molded slurry dispenser cavity area transversely during the removal process, up to approximately 125% in other embodiments, Up to about 115% in embodiments, and up to about 110% in other embodiments.

56, one embodiment of a multi-piece mold 650 suitable for use in making the slurry dispenser 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, and 655. The mold segments 651, 652, 653, 654, 655 of the multi-piece mold 550 may be made of any suitable material, such as, for example, aluminum. The mold segments 651, 652, 653, 654, 655 are shown in the condition disassembled in Fig.

The connecting bolts may be used to removably connect the mold segments 651, 652, 653, 654, 655 together to assemble the mold 650 to define a substantially continuous outer surface of the multi- . The outer surface of the multi-piece mold 650 defines the internal flow shape of the slurry dispenser 220 of FIG. The mold 650 is positioned within a predetermined amount of the smallest area of the molded slurry dispenser 220 that must be traversed when the mold piece is being removed (e.g., in certain embodiments, Up to about 150%, in other embodiments up to about 125%, in other embodiments up to about 115%, and in other embodiments up to about 110%, of the smallest area of the cross-over molded mold slurry distributor cavity region 54 and 55 in that each piece of mold 650 of FIG. 56 is constructed such that there is an area of the mold 550 of FIG.

57 and 58, one embodiment of a mold 750 for use in producing one of the pieces 221, 223 of the two-piece slurry dispenser 220 of FIG. 4 is shown. 57, mounting bore defining elements 752 may be included to define mounting bores in the piece of two-piece slurry dispenser 220 of FIG. 4, which is configured to facilitate connection with other pieces.

57 and 58, the mold 750 includes a mold surface 754 that protrudes from the lower end surface 756 of the mold 750. The boundary wall 756 extends along the vertical axis and defines the depth of the mold. The mold surface 754 is disposed within the boundary wall 756. The boundary wall 756 is configured to allow the volume of the cavity 758 defined in the boundary wall to be filled with molten mold material so that the mold surface 754 is immersed. The mold surface 754 is configured to be a negative image of the internal flow shape defined by a particular piece of the two-piece dispenser being molded.

In use, the cavity 758 of the mold 750 can be filled with molten material such that the mold surface is immersed and the cavity 758 is filled with the molten material. The molten material is allowed to cool and may be removed from the mold 750. Other molds may be used to form the mating piece of the slurry dispenser 220 of FIG.

59, one embodiment of a gypsum slurry mixing and dispensing assembly 810 includes a gypsum slurry mixer 912 in fluid communication with a slurry dispenser 820 similar to the slurry dispenser 320 shown in FIG. 6 . The gypsum slurry mixer 812 is adapted to agitate water and calcined gypsum to form an aqueous fired gypsum slurry. Both water and calcined gypsum may be fed to mixer 812 through one or more inlets as is known in the art. Any suitable mixer (e. G., A pin mixer) may be used with the slurry dispenser.

The slurry dispenser 820 is in fluid communication with the gypsum slurry mixer 812. Slurry dispenser 820 includes a first feed inlet 824 adapted to receive a first stream of aqueous fired gypsum slurry moving in a first feed direction 890 from a gypsum slurry mixer 812, a gypsum slurry mixer 812, A second feed inlet 825 adapted to receive a second flow of the aqueous fired gypsum slurry moving in a second feed direction 891 from the first feed inlet 824 and the second feed inlet 824, And a dispensing outlet 830 through which the first and second streams of aqueous fired gypsum slurry are adapted to be discharged from the slurry dispenser 820 through the dispensing outlet 830 substantially along the machine direction 50.

The slurry dispenser 820 includes a feed conduit 822 in fluid communication with the 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 which has a feed angle < RTI ID = 0.0 > ([theta]). The feed conduit 822 is configured to deliver the first and second streams of slurry to the first and second feed streams 824 to substantially move into the outlet flow direction 892 that is transported to the distribution conduit 828 and substantially aligned with the machine direction 50. [ And includes therein a structure adapted to receive the first and second flows of slurry moving in the feed flow direction 890, 891 and to deflect the slurry flow direction by a change in the direction angle [alpha] (see Figure 9) . Each of the first and second feed inlets 824 and 825 has an opening having a cross sectional area and an entry portion 852 of the distribution conduit 828 is defined by the openings of the first and second feed openings 824 and 825 Sectional area larger than the sum of the cross-sectional areas.

The distribution conduit 828 extends generally along a longitudinal axis or machine direction 50 that is substantially perpendicular to the transverse axis 60. The distribution conduit 828 includes an entry portion 852 and a dispensing outlet 830. The entry portion 852 is configured to allow the first and second feed inlets 824, 822 of the feed conduit 822 to be adapted to receive both the first and second streams of the aqueous fired gypsum slurry from the entry portion 852, 825, respectively. The dispensing outlet 830 is in fluid communication with the entry portion 852. The distribution outlet 830 of the distribution conduit 828 is configured to pre-empt along the transverse axis 60 to facilitate the discharge of the combined first and second flows of the aqueous fired gypsum slurry in the cross machine direction or along the transverse axis 60 Extend the determined distance. Slurry dispenser 820 may be otherwise similar to slurry dispenser 320 of FIG.

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

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

The aqueous bubble supply conduit 821 may be in fluid communication with at least one of the gypsum slurry mixer 812 and the delivery conduit 814. The aqueous bubbles from the source may be introduced into the bubble supply conduit 821 at any suitable location downstream of the mixer 812 and / or in the mixer 812 itself to form a bubbling gypsum slurry provided to the slurry distributor 220. [ Lt; / RTI > to the constituent materials. In the illustrated embodiment, bubble supply conduit 821 is disposed downstream of gypsum slurry mixer 812. In the illustrated embodiment, the aqueous bubble supply conduit 821 has a manifold type arrangement that supplies bubbles to an injection ring or block associated with the delivery conduit 814, for example, as described in U.S. Patent No. 6,874,930.

In other embodiments, one or more bubble supply conduits may be provided in fluid communication with the mixer 812. In yet other embodiments, the aqueous bubble supply conduit (s) may be in fluid communication with the gypsum slurry mixer alone. As will be appreciated by those skilled in the art, the means for introducing aqueous bubbles into the gypsum slurry in the gypsum slurry mixing and dispensing assembly 810, including relative positions in the assembly, May be varied and / or optimized to provide a uniform dispersion of aqueous bubbles in the gypsum slurry to produce a fitted board.

Any suitable foaming agent may be used. Preferably, the aqueous bubbles are produced in a continuous manner in which a stream of a mixture of foam and water is directed to the bubbler, and the stream of final aqueous bubbles leaves the generator and is directed and mixed into the fired gypsum slurry. Some examples of suitable foaming agents are described, for example, in U.S. Patent Nos. 5,683,635 and 5,643,510.

When the gasified gypsum slurry solidifies and dries, the bubbles dispersed in the slurry produce air voids that serve to lower the overall density of the wallboard. The amount of bubbles and / or the amount of air in the bubbles may be varied to adjust the dry board density to be within the desired weight range of the finished wallboard product.

One or more flow modifying elements 823 may be described to control the first and second flows of the aqueous fired gypsum slurry from the gypsum slurry mixer 812 associated with the delivery conduit 814. [ Flow correction element (s) 823 may be used to control the operating characteristics of the first and second streams of aqueous fired gypsum slurry. In the illustrated embodiment of FIG. 59, flow correction element (s) 823 is associated with main delivery trunk 815. Examples of suitable flow modifying elements are described, for example, in U.S. Patent Nos. 6,494,609; 6,874, 930; 7,007,914; Pressure reducers, compression valves, canisters, and the like, including those described in U. S. Patent Nos. 7,296, 919 and 7,296, 919.

The main delivery trunk 815 may be connected to the first and second delivery branches 817 and 818 via a suitable Y-shaped flow divider 819. [ The flow divider 819 is disposed between the main delivery trunk 815 and the first delivery branch 817 and between the main delivery trunk 815 and the second delivery branch 818. In some embodiments, the flow divider 819 may be adapted to help split the first and second streams of gypsum slurry so that they are substantially the same. In other embodiments, additional components may be added to help control the first and second flows of the slurry.

In use, the aqueous fired gypsum slurry is discharged from the mixer 812. The aqueous fired gypsum slurry from mixer 812 is split into a first stream of aqueous fired gypsum slurry and a second stream of aqueous fired gypsum slurry in a flow divider 819. The aqueous fired gypsum slurry from the mixer 812 can be divided so that the first and second streams of the aqueous fired gypsum slurry are substantially balanced.

Referring to Figure 60, another embodiment of a gypsum slurry mixing and dispensing assembly 910 is shown. The gypsum slurry mixing and dispensing assembly 910 includes a gypsum slurry mixer 912 in fluid communication with the slurry dispenser 920. The gypsum slurry mixer 912 is adapted to agitate water and calcined gypsum to form an aqueous fired gypsum slurry. The slurry dispenser 920 may be similar in construction and function to the slurry dispenser 320 of FIG.

The delivery conduit 914 is disposed between and in fluid communication with the gypsum slurry mixer 912 and the slurry dispenser 920. The delivery conduit 914 includes a main delivery trunk 915, a first delivery branch 917 in fluid communication with the first delivery inlet 924 of the slurry dispenser 920 and a second delivery inlet 916 of the slurry dispenser 920 And a second transmission branch 918 in fluid communication with the second transmission branch 925.

The main delivery trunk 915 is disposed and in fluid communication with both the gypsum slurry mixer 912 and the first and second transmission branches 917, 918. The aqueous bubble supply conduit 921 may 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 bubble supply conduit 921 is associated with the main delivery trunk 915 of the delivery conduit 914.

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

The second transmission branch 918 is disposed between and in fluid communication with the gypsum slurry mixer 912 and the second feed inlet 925 of the slurry dispenser 920. At least one second flow correction element 927 is adapted to control a second flow of the aqueous fired gypsum slurry associated with the second transmission branch 918 and from the gypsum slurry mixer 912.

The first and second flow modifying elements 923, 927 can be operated to control operating characteristics of the first and second flows of the aqueous fired gypsum slurry. The first and second flow modifying elements 923, 927 may be independently operable. In some embodiments, the first and second flow modifying elements 923 and 927 are configured such that at a given time the first slurry has an average velocity that is faster than that of the second flow of slurry, The first and second flows of alternating slurries in an opposing manner between a relatively slower and a relatively faster average speed so as to have a slower average speed than that of the first flow of slurry.

As one of ordinary skill in the art will appreciate, one or both of the webs of the cover sheet material are very thin relative to the gypsum slurry (as compared to the gypsum slurry comprising the core), often referred to in the art as a scheme coat A dense layer, and / or, if desired, hard edges. For that purpose, mixer 912 mixes the stream of aqueous fired gypsum slurry, which is relatively more dense than the first and second streams of aqueous fired gypsum slurry delivered to the slurry dispenser (i.e., the "face skim coat / hard edge stream & skim coat / hard edge stream "). < / RTI > The first secondary conduit 929 is configured to apply the coating coat layer to the moving web of cover sheet material by the width of the roller 931 being less than the width of the moving web as known in the art, A face scheme coat / hard edge stream may be deposited on a moving web of cover sheet material upstream of a scheme coat roller 931 adapted to define a perimeter. The hard edges can be formed from the same dense slurry forming a thin dense layer by directing portions of the dense slurry around the ends of the rollers used to apply the dense layer to the web.

The mixer 912 is configured to mix a stream of dense aqueous fired gypsum slurry (i.e., a "back skim coat stream") that is relatively more dense than the first and second streams of aqueous fired gypsum slurry delivered to the slurry dispenser And a second secondary conduit 933 adapted to deposit. The second secondary conduit 933 is connected to a second moving web of cover sheet material upstream of the scheme coat roller 937 adapted to apply the scheme coat layer to the second moving web of cover sheet material as is known in the art (In the direction of movement of the second web) (see also Fig. 61).

In other embodiments, individual auxiliary conduits may be connected to the mixer to deliver one or more separation edge streams to the moving web of cover sheet material. Other suitable equipment (e.g., submixers) may be used to assist in making the slurry more dense therein, for example, by mechanically breaking the bubble into the slurry and / or by chemically breaking down the bubble through the use of a suitable defoaming agent May be provided to the conduits.

In still other embodiments, the first and second transmission branches each include a respective bubble supply conduit to independently introduce the aqueous bubbles into the first and second streams of aqueous fired gypsum slurry delivered to the slurry dispenser can do. In yet another embodiment, a plurality of mixers may be provided above providing the independent streams of slurry constructed according to the principles of this disclosure to the first and second feed inlets of the slurry distributor. It will be appreciated that other embodiments are possible.

The gypsum slurry mixing and dispensing assembly 910 of FIG. 60 may be similar to the gypsum slurry mixing and dispensing assembly 810 of FIG. 59 in other respects. It is further contemplated that other slurry dispensers constructed in accordance with the principles of the present disclosure may be used in other embodiments of the cement slurry mixing and dispensing assembly as described herein.

Referring to Figure 61, an exemplary embodiment of the wet end 1011 of a gypsum board manufacturing line is shown. The wet end 1011 includes a gypsum slurry mixing and dispensing assembly 1010 having a gypsum slurry mixer 1012 in fluid communication with a slurry dispenser 1020 similar in construction and function to the slurry dispenser 320 of Figure 6, A hard edge / face skimming roller 1031 disposed upstream of the slurry distributor 1020 and supported over the forming table 1038 such that a first moving web of material 1039 is disposed therebetween, A backscratch coater 1037 disposed over the support element 1041 such that the two moving webs 1043 are disposed therebetween and a forming station 1045 adapted to shape the preform to a desired thickness. The scheme coater rollers 1031 and 1037, the forming table 1038, the support element 1041 and the forming station 1045 all include conventional equipment suitable for its intended purposes as is known in the art can do. The wet end 1011 may be provided with other conventional equipment as is known in the art.

In another aspect of the disclosure, a slurry dispenser constructed in accordance with the principles of the present disclosure may be used in a variety of manufacturing processes. For example, in one embodiment, a slurry dispensing system may be used in a method of making a gypsum product. The slurry dispenser can be used to dispense the aqueous fired gypsum slurry onto the first advancing web 1039.

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

Gypsum board products are typically formed "face down" such that the advanced web 1039 serves as the "face" cover sheet of the finished board. The face skim coat / hard edge stream 1049 (a layer of a more dense aqueous fired gypsum slurry relative to at least one of the first and second streams of aqueous fired gypsum slurry) is applied to the first web 1039 And may be applied to a first moving web 1039 upstream of the hard edge / face scheme coater roller 1031 relative to the machine direction 1092 to define the hard edges of the board.

The first stream 1047 and the second stream 1048 of the aqueous fired gypsum slurry are passed through the first feed inlet 1024 and the second feed inlet 1025 of the slurry distributor 1020, respectively. The first and second streams 1047 and 1048 of the aqueous fired gypsum slurry are combined in a slurry dispenser 1020. The first and second streams 1047 and 1048 of the aqueous fired gypsum slurry move in a stream line flow manner through a slurry distributor 1020 along the flow path to provide a minimum or substantially no air- And does not substantially experience the vortex flow path.

The first moving web 1039 moves along the longitudinal axis 50. The first stream 1047 of the aqueous fired gypsum slurry passes through the first feed inlet 1024 and the second stream 1048 of the aqueous fired gypsum slurry passes through the second feed inlet 1025. The distribution conduit 1028 is positioned to extend along a longitudinal axis 50 substantially coinciding with the machine direction 1092 through which the first web 1039 of cover sheet material is moving. Preferably, the center midpoint of the dispensing outlet 1030 (taken along the transverse axis / cross machine direction 60) substantially coincides with the center midpoint of the first moving cover sheet 1039. The first and second streams 1047 and 1048 of the aqueous fired gypsum slurry are formed such that the combined first and second streams 1051 of the aqueous fired gypsum slurry flow generally in the dispensing direction 1093 along the machine direction 1092 Is coupled at the slurry dispenser 1020 to pass through the distribution outlet 1030.

In some embodiments, the distribution conduit 1028 is positioned substantially parallel to the plane 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 may be positioned vertically lower or higher than the distribution outlet 1030 relative to the first web 1039. [

The combined first and second streams 1051 of the aqueous fired gypsum slurry are discharged from the slurry distributor 1020 on the first moving web 1039. The face skim coat / hard edge stream 1049 is formed so that the first and second streams 1047 and 1048 of the aqueous fired gypsum slurry are separated from the direction of movement of the first moving web 1039 in the machine direction 1092, May be deposited from the mixer 1012 at a point upstream of where it is discharged from the slurry dispenser 1020 on the one moving web 1039. [ The combined first and second streams 1047 and 1048 of the aqueous fired gypsum slurry are transferred to a "washout" (not shown) of the face scheme coat / hard edge stream 1049 deposited on the first transfer web 1039 That is, a situation where a portion of the deposited scheme coat layer is displaced from its position on the moving web 339 in response to the impact of the slurry deposited thereon), as compared to a conventional boot design Can be released from the slurry dispenser at a reduced momentum per unit width.

The first and second streams 1047 and 1048 of the aqueous fired gypsum slurry that are respectively passed through the first and second feed inlets 1024 and 1025 of the slurry distributor 1020 are passed through at least one flow modifying element 1023 ). ≪ / RTI > For example, in some embodiments, the first and second streams 1047 and 1048 of the aqueous fired gypsum slurry are mixed with the first stream 1047 of the aqueous fired gypsum slurry passing through the first feed inlet 1024 The average velocity and the average velocity of the second stream 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025 are substantially equal.

In embodiments, the first stream 1047 of aqueous fired gypsum slurry is passed through the first feed inlet 1024 of the slurry distributor 1020 at an average first feed rate. The second stream 1048 of the aqueous fired gypsum slurry is passed through the second feed inlet 1025 of the slurry distributor 1020 at an average second feed rate. The second feed inlet 1025 is spaced apart from the first feed inlet 1024. The first and second streams 1051 of the aqueous fired gypsum slurry are combined in a slurry dispenser 1020. The combined first and second streams 1051 of the aqueous fired gypsum slurry are collected from the distribution outlet 1030 of the slurry distributor 1020 as the web 1039 of the cover sheet material moves along the machine direction 1092 Release rate. The average release rate is less than the average first feed rate and the average second feed rate.

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

The combined first and second streams 1051 of the aqueous fired gypsum slurry are discharged from the slurry distributor 1020 through the distribution outlet 1030. The opening of the dispensing outlet 1030 has a width extending along the transverse axis 60 and the ratio of the width of the first moving web 1039 of the cover sheet material to the width of the opening of the dispensing outlet 1030 is approximately 1: Approximately 6: 1 and are sized to be between them. In some embodiments, a moving web of cover sheet material that moves along the average speed versus machine direction 1092 of the combined first and second streams 1051 of aqueous fired gypsum slurry discharged from the slurry dispenser 1020 The ratio of the speed of the motor 1039 may be up to about 2: 1 or less in some embodiments, and from about 1: 1 to about 2: 1 in other embodiments.

The combined first and second streams 1051 of the aqueous fired gypsum slurry discharged from the slurry dispenser 1020 form a diffusion pattern on the moving web 1039. At least one of the size and shape of the dispensing outlet 1030 can be adjusted, which in turn can change the diffusion pattern.

Thus, the slurry is fed to both feed inlets 1024 and 1025 of the feed conduit 1022 and then exits through a dispensing outlet 1030 with an adjustable gap. Converging portion 1082 may provide a slight increase in slurry rate to reduce unwanted exit effects and thereby improve flow stability at the free surface. Side-to-side flow variations and / or any local variations may be reduced by performing cross-machine (CD) profiling control at the discharge outlet 1030 using a profiling system. This dispensing system can help prevent air-liquid slurry separation in the slurry resulting in a more uniform flocculating material being delivered to the forming table 1038. [

The backscratch coat stream 1053 (a layer of a more dense aqueous fired gypsum slurry than at least one of the first and second streams 1047 and 1048 of the aqueous fired gypsum slurry) is applied to the second transfer web 1043 . The backscratch coat stream 1053 may be deposited from the mixer 1012 at a point upstream of the backscratch 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 streams 1047, 1048 of the aqueous fired gypsum slurry is varied. In some embodiments, the slurry velocities at the feed inlets 1024, 1025 of the feed conduit 1022 may be adjusted periodically between relatively higher and lower average velocities to help reduce the opportunity for accumulation within the shape itself (At a time when one entrance has a higher speed than the other entrance, and then at a predetermined time on the opposite side).

The first stream 1047 of the aqueous fired gypsum slurry passing through the first feed inlet 1024 has a shear velocity of the combined first and second streams 1051 emitted from the distribution outlet 1030, The second stream 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025 has a lower shear rate than the combined first and second streams 1051 discharged from the distribution outlet 1030, Lt; RTI ID = 0.0 > shear < / RTI > In embodiments, the shear rate of the combined first and second streams 1051 discharged from the distribution outlet 1030 is greater than the shear rate of the first flow 1047 of aqueous fired gypsum slurry passing through the first feed inlet 1024, Greater than about 150% of the shear rate of the second flow 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025 and / or greater than about 175% in yet another embodiment, But may be approximately double or more in embodiments. The viscosity of the first and second streams 1047, 1048 and the combined first and second streams 1051 of the aqueous fired gypsum slurry is such that the shear rate present at a given location such that the viscosity decreases as the shear rate increases As will be appreciated by those skilled in the art.

In embodiments, the first stream 1047 of aqueous fired gypsum slurry passing through the first feed inlet 1024 has a shear stress of the combined first and second streams 1051 discharged from the distribution outlet 1030 The second stream 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025 has a lower shear stress than the combined first and second streams 1051 discharged from the distribution outlet 1030, Lt; RTI ID = 0.0 > shear < / RTI > Shear stress of the combined first and second flows 1051 discharged from the distribution outlet 1030 is greater than the shear stress of the first flow 1047 of the aqueous fired gypsum slurry passing through the first feed inlet 1024, And / or greater than about 110% of the shear rate of the second flow 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025.

The first stream 1047 of the aqueous fired gypsum slurry passing through the first feed inlet 1024 has a Reynolds number of combined first and second streams 1051 discharged from the distribution outlet 1030 The second stream 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025 has a higher Reynolds number than the combined first and second streams 1051 discharged from the distribution outlet 1030, Lt; RTI ID = 0.0 > Reynolds < / RTI > In embodiments, the Reynolds number of the combined first and second streams 1051 discharged from the distribution outlet 1030 is greater than the first flow 1047 of the aqueous fired gypsum slurry passing through the first feed inlet 1024, Less than about 90% of the Reynolds number of the second stream 1048 of the aqueous fired gypsum slurry passing through the second feed inlet 1025, and less than about 80% in yet another embodiment, Gt; 70% < / RTI >

62 and 63, one embodiment of a Y-shaped flow divider 1100 suitable for use in a gypsum slurry mixing and dispensing assembly constructed in accordance with the principles of the present disclosure is shown. The flow divider 1100 allows the flow divider 1100 to receive a single stream of aqueous fired gypsum slurry from the mixer and to discharge the two separate streams of aqueous fired gypsum slurry therefrom to the first and second feed inlets of the slurry distributor A gypsum slurry mixer, and a slurry dispenser. One or more flow correction elements may be disposed between the mixer and the flow divider 1100 and / or between one or both of the transfer branches connected between the divider 1100 and the associated slurry distributor.

The flow divider 1100 includes a substantially circular inlet 1102 disposed in the main branch 1103 adapted to receive a single flow of slurry and a first and a second inlet 1102 that allow the two streams of slurry to be discharged from the divider 1100. [ 2 outlet branches 1105, 1107, respectively. The cross sectional areas of the openings of the inlet 1102 and the outlets 1104 and 1106 may vary according to the desired flow rate. In embodiments in which the cross-sectional areas of the openings of the outlets 1104 and 1106 are substantially equal to the cross-sectional areas of the openings of the inlet 1102 respectively, the flow rate of the slurry discharged from the respective outlets 1104 and 1106, The volumetric flow rates through the two outlets 1104 and 1106 can be reduced to about 50% of the velocity of the single flow of slurry entering the substantially identical inlet 1102.

In some embodiments, the diameter of the outlets 1104,1106 may be made smaller than the diameter of the inlet 1102 to maintain a relatively high flow rate throughout the divider 1100. [ In embodiments in which the cross sectional areas of the openings of the outlets 1104 and 1106 are smaller than the cross sectional areas of the openings of the inlet 1102 respectively, the flow rate is maintained at the outlets 1104 and 1106, Can be reduced at least to a lesser extent than if inlet 1102 had substantially the same cross-sectional areas. For example, in some embodiments, the flow divider 1100 includes an inlet 1102 having an inner diameter (ID ₁ ) of approximately 3 inches and a respective outlet 1104, 1106 having an ID ₂ of approximately 2.5 inches. (Although other inlet and outlet diameters may be used in other embodiments). In one embodiment having these dimensions at a line speed of 350 fpm, the smaller diameter of the outlets 1104, 1106 is such that the flow velocity at each outlet is approximately equal to the flow velocity of the single flow of slurry at the inlet 1102 28%.

The flow divider 1100 may include a junction 1120 between the central contour portion 1114 and the first and second outlet branches 1105 and 1107. The central contour portion 1114 is configured to define a constraining portion 1108 that facilitates flow to the outer edges 1110 and 1112 of the divider to reduce the occurrence of slurry accumulation at the junction 1120, In the center internal region of the flow divider 1100 having the same function. The shape of the central contour portion 1114 causes guide channels 1111 and 1113 adjacent to the outer edges 1110 and 1112 of the flow divider 1100. The constraining portion 1108 in the central contour portion 1114 has a height H _{2 that} is smaller than the height H ₃ of the guide channels 1111 and 1113. The guide channels 1111 and 1113 have a larger cross-sectional area than the cross-sectional area of the center rest portion 1108. [ As a result, the flowing slurry encounters less flow resistance through the guide channels 1111, 1113 than through the central restricting portion 1108, and the flow is directed toward the outer edges of the divider junction 1120.

The junction point 1120 provides openings in the first and second outlet branches 1105 and 1107. The junction 1120 is comprised of a planar wall surface 1123 that is substantially perpendicular to the inlet flow direction 1125.

Referring to Figure 64, in some embodiments, an automatic device 1150 that squeezes the divider 1100 at adjustable and regular time intervals can be provided to prevent accumulations of solids within the divider 1100 have. In some embodiments, the compression device 1150 may include a pair of plates 1152, 1154 disposed on opposite sides 1142, 1143 of the central contour portion 1114. The plates 1152 and 1154 are moveable relative to each other by a suitable actuator 1160. The actuator 1160 is automatically or selectively operated to move the plates 1152 and 1154 together with respect to each other to apply a compressive force on the central contour portion 1114 and the splitter 1100 at the junction 1120 .

When the crimping apparatus 1150 squeezes the flow divider, the crimping action applies a compressive force to the flow divider 1100, which is correspondingly flexible inward. This compressive force can help prevent the accumulation of solids within the divider 1100 that can interfere with the slurry distribution through the outlets 1104 and 1106 in substantially the same flow. In some embodiments, the compression device 1150 is designed to automatically pulsewise through the use of a programmable controller operably arranged with the actuators. The duration of the application of the compressive force by the compression device 1150 and / or the interval between the pulses can be adjusted. Furthermore, the stroke lengths in which the plates 1152 and 1154 travel with respect to each other in the compression direction can be adjusted.

In one embodiment, a method of making a cement product may be performed using a slurry dispenser constructed in accordance with the principles of the present disclosure. The stream of aqueous cement slurry is discharged from the mixer. The flow of the aqueous cement slurry is passed along the first feed flow axis through the feed inlet of the slurry dispenser at an average feed rate. The flow of the aqueous cement slurry is transferred to the bulb portion of the slurry dispenser. The bulb portion has an enlarged cross-sectional flow region that is larger than the cross-sectional flow region of the adjacent region upstream from the expanded region with respect to the flow direction from the feed inlet. The bulb portion is configured to reduce the average velocity of the flow of the aqueous cement slurry through the bulb portion from the feed inlet. The forming duct has a convex inner surface that faces the first feed flow axis such that the flow of the aqueous cement slurry moves radially in a plane substantially perpendicular to the first feed flow axis. The flow of the aqueous cement slurry is transferred to a transition segment extending along a second feed flow axis in non-parallel relationship with the first feed flow axis.

The flow of the aqueous cement slurry is transferred to the distribution conduit. The distribution conduit includes a dispensing outlet extending a predetermined distance along a transverse axis substantially perpendicular to the longitudinal axis.

In embodiments, the flow of slurry moving through the region adjacent to at least one of the lateral sides adjacent to the convex inner surface and toward the distribution outlet is from about 0 to about 10, and in other embodiments from about 0.5 to about 5 (S _m ). Carried out in the example, the flow of the slurry which are adjacent to the convex inner surface and moving through a region adjacent to at least one of the dispensing outlet directed lateral side has a swirl angle (S _m) of up to about 84 ° at about 0 °.

In embodiments, the flow of the aqueous cement slurry is passed through a flow stabilization zone that is adapted to enter the feed inlet and reduce the average feed rate of the stream of aqueous cement slurry moving to the distribution outlet. The flow of the aqueous cement slurry is discharged from the distribution outlet at an average discharge rate of at least 20 percent, which is less than the average discharge rate.

In another embodiment, a method of making a cement product includes discharging a stream of an aqueous cement slurry from a mixer. The flow of the aqueous cement slurry is passed through the entry portion of the distribution conduit of the slurry dispenser. The flow of the aqueous cement slurry is released from the dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction. The wiper blade is reciprocated along the clearing path along the lower surface of the distribution conduit between the first and second locations to remove the aqueous cement slurry therefrom. The clearing path is disposed adjacent to the distribution outlet.

In embodiments, the distribution conduit extends generally along the longitudinal axis between the entry portion and the dispensing outlet. The wiper blade reciprocates vertically along the clearing path.

In embodiments, the wiper blade moves across the wiping stroke in the clearing direction from the first position to the second position, and the wiper blade faces the second position to the first position, Move. The wiper blade reciprocates such that the time it takes to travel across the wiping stroke is substantially equal to the time it travels over the return stroke.

In embodiments, the wiper blade moves across the wiping stroke in the clearing direction from the first position to the second position, and the wiper blade faces the second position to the first position, Move. The wiper blade reciprocates in a cycle having a sweep period between the first position and the second position. The sweep period includes a wiping portion that includes the time to travel across the wiping stroke, a return portion that includes the time to travel across the return stroke, and a predetermined period of time that the wiper blade holds in the first position And an accumulation delay portion. In embodiments, the wiping portion is substantially the same as the return portion. In embodiments, the accumulation delay portion is adjustable.

In yet another embodiment, a method of making a cement product includes discharging a stream of an aqueous cement slurry from a mixer. The flow of the aqueous cement slurry is passed through the entry portion of the distribution conduit of the slurry dispenser. The flow of the aqueous cement slurry is released from the outlet opening of the dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis. The exit opening has 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. A portion of the distribution conduit adjacent the dispensing outlet is compression-tightened to change the shape and / or size of the outlet opening. In embodiments, the distribution conduit is compression-tightened by a profiling mechanism such that the flow of the aqueous cement slurry is released from the exit opening at an increased diffusion angle relative to the machine direction.

In embodiments, the distribution conduit is compression-tightened by a profiling mechanism having a profiling member in contact with the distribution conduit. The profiling member is moveable over a range so that the profiling member has a profiling member in a range over positions that increase the distribution conduit and compression tightening. In embodiments, the method includes moving the profiling member along a vertical axis to adjust the size and / or shape of the exit opening. In embodiments, the method includes moving the profiling member such that the profiling member translates along at least one axis and / or rotates relative to at least one axis to adjust the size and / or shape of the exit opening .

Examples of slurry dispensers, cement slurry mixing and dispensing assemblies, and methods of use thereof that can provide many of the increased process features that are useful in making cement products, such as gypsum wallboard in commercial environments, are provided herein do. A slurry dispenser constructed in accordance with the principles of the present disclosure may facilitate the diffusion of the aqueous fired gypsum slurry onto a moving web of cover sheet material as it advances past the mixer and toward the forming station at the wet end of the manufacturing line.

Gypsum slurry mixing and dispensing assemblies constructed in accordance with the principles of the present disclosure may be used to provide a flow of an aqueous fired gypsum slurry from a mixer that can be recombined downstream of a slurry dispenser constructed in accordance with the principles of the present disclosure to provide a desired diffusion pattern Can be divided into two separate streams of aqueous fired gypsum slurry. The design of dual inlet configurations and distribution outlets allows for wider diffusion of more viscous slurry across the moving web of cover sheet material in the cross machine direction. The slurry dispenser is characterized in that the two separate streams of aqueous fired gypsum slurry enter the slurry dispenser along the feed inlet directions including the cross-machine direction components, and the two streams of slurry move substantially in the machine direction, And recombining in the distributor in such a way as to increase the cross-directional uniformity of the combined flows of the aqueous fired gypsum slurry discharged from the distribution outlet of the slurry distributor to assist in reducing the mass flow change over time along the transverse or cross machine direction, Can be adapted. Introducing the first and second streams of aqueous fired gypsum slurry in first and second feed directions comprising cross machine direction components is advantageous in that the recombined flows of slurry are discharged from the slurry distributor with reduced momentum and / Can help.

The inner flow cavity of the slurry dispenser can be configured so that each of the two streams of slurry is moved through the slurry distributor into the stream line flow. The internal flow cavity of the slurry dispenser can be configured to move each of the two streams of slurry into an air-liquid slurry phase separation with minimal or substantially no slurry dispenser. The inner flow cavity of the slurry dispenser can be configured so that each of the two flows of slurry travels through the slurry distributor substantially without experiencing a swirl flow path.

The gypsum slurry mixing and dispensing assembly constructed in accordance with the principles of the present disclosure may include a flow configuration upstream of the dispensing outlet of the slurry dispenser to reduce the slurry speed in one or more steps. For example, a flow divider may be provided between the mixer and the slurry distributor to reduce the slurry velocity entering the slurry distributor. As another example, the flow geometry in the gypsum slurry mixing and dispensing assembly may include expansion areas upstream and inward of the slurry dispenser to slow down the slurry, so that it is manageable when released from the dispensing outlet of the slurry dispenser.

The shape of the dispensing outlet may help control the rate and rate of release of the slurry as it is being discharged from the slurry dispenser on the moving web of cover sheet material. The flow profile of the slurry dispenser can be adapted so that the slurry discharged from the distribution outlet is substantially maintained in a two-dimensional flow pattern having a relatively small height as compared to a wider outlet in the cross-machine direction to help improve stability and uniformity have.

The relatively broad discharge outlet yields the momentum per unit width of the slurry discharged from the distribution outlet lower than the momentum per unit width of the slurry discharged from the conventional boot under similar operating conditions. The reduced momentum per unit width can help prevent wash-out of the dense layer of the dense layer that is applied to the web of cover sheet material upstream from the position at which the slurry is discharged from the slurry dispenser on the web.

In the situation where conventional boot outlets are used, which are 6 inches wide and 2 inches thick, the average speed of the outlet for the product may be approximately 761 ft / min. In embodiments where the slurry dispenser constructed in accordance with the principles of the present disclosure includes a dispensing outlet having an opening that is 24 inches wide and 0.75 inches thick, the average speed may be approximately 550 ft / min. The mass flow rate is the same for both devices at 3,437 lb / min. The momentum of the slurry (mass flow rate * average velocity) for both cases would be ~ 2, 618,000 and 1,891,000 lb · ft / min ² for each conventional boot and slurry dispenser. Dividing the respective calculated momentum by the widths of the conventional boot outlet and the slurry outlet of the slurry dispenser, the momentum per unit width of the slurry discharged from the convention boots is 402,736 (lb · ft / min ² ) / (width across the boot width) The slurry discharged from the slurry dispenser constructed according to the principles of the disclosure has a momentum per unit width of 78,776 (lb · ft / min ² ) / (slurry dispenser width across inches). In this case, the slurry discharged from the slurry dispenser has approximately 20% of the momentum per unit width as compared to conventional boots.

A slurry distributor constructed in accordance with the principles of the present disclosure may have a relatively low WSR or a more conventional WSR, e.g., from about 0.4 to about 1.2, for example below 0.75 in some embodiments, A desired diffusion pattern can be achieved during use of the aqueous fired gypsum slurry over a wide range of water-to-stoichiometric ratios, including a water to gypsum ratio of between about 0.8. Embodiments of the slurry dispenser constructed in accordance with the principles of the present disclosure include first and second streams of aqueous fired gypsum slurry as the first and second streams advance from the first and second feed inlets through the slurry distributor toward the dispensing outlet, And may include an internal flow shape adapted to produce controlled shear effects in the second flows. Application of a controlled shear in a slurry dispenser can selectively reduce the viscosity of the slurry as a result of receiving such shear. Under the effects of controlled shear in a slurry dispenser, a slurry with a lower water-to-stoichiometric ratio can be dispensed from a slurry dispenser having a diffusional pattern in the cross-machine direction comparable to slurries with conventional WSR.

The internal flow geometry of the slurry dispenser may be adapted to further accommodate slurries of various water-to-stoichiometric ratios to provide an increased flow adjacent the boundary wall regions of the interior shape of the slurry dispenser. By including flow features in the slurry dispenser adapted to increase the degree of flow around the boundary wall layers, the tendency of the slurry to recycle in the slurry dispenser and / or to stop the flow and solidify therein is reduced. Thus, the accumulation of solidification slurry in the slurry dispenser can be reduced as a result.

A slurry dispenser constructed in accordance with the principles of the present disclosure may have a combination of slurries discharged from the dispensing outlet to selectively control the diffusion angle and the diffusion width of the slurry in the cross machine direction as the substrate moves down the production line towards the forming station. And a profile system mounted adjacent to the dispensing outlet to alter cross machine velocity components of the dispensed flows. The profile system can help achieve the desired diffusion pattern while the slurry discharged from the distribution outlet is less susceptible to slurry viscosity and WSR. The profile system may be used to change the fluid flow field of the slurry discharged from the distribution outlet of the slurry dispenser from the distribution outlet of the slurry distributor so that the slurry guides the slurry flow to have a more uniform velocity in the cross machine direction. Using a profile system may help the gypsum slurry mixing and dispensing assembly constructed in accordance with the principles of the present disclosure to be used in gypsum wall manufacturing equipment to manufacture wallboards of different types and volumes.

Thus, in one embodiment, the slurry dispenser includes a distribution conduit extending generally along its longitudinal axis and includes a dispensing outlet in fluid communication with the entry portion and the entry portion. The dispensing outlet extends a predetermined distance along the abscissa. The horizontal axis is substantially perpendicular to the vertical axis. The dispensing outlet includes an exit 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. The profiling mechanism including the profiling member is in contact with the distribution conduit. The profiling member is moved over the course of the progress so that the profiling member is in the range over a portion of the distribution conduit adjacent to the dispensing outlet and the positions that increase the compression tightness to vary the shape and / It is possible.

In another embodiment, the outlet opening of the dispensing outlet has a width to height ratio of about 4 or more.

In another embodiment, the outlet opening of the dispensing outlet has a width along the abscissa. The profiling member has a width that extends a predetermined second distance along the abscissa. The width of the exit opening is greater than the width of the profiling member. The profiling member is positioned such that a pair of lateral portions of the dispensing outlet are in an offset relationship to the profiling member.

In another embodiment, the profiling member of the slurry dispenser is movable along a vertical axis.

In another embodiment, the profiling member of the slurry distributor member has at least two degrees of freedom.

In another embodiment, the profiling member of the slurry dispenser is rotatable along at least one axis and rotatable relative to at least one pivot axis.

In another embodiment, the profiling member of the slurry dispenser is rotatable about a pivot axis that is translatable along a vertical axis and substantially parallel to the longitudinal axis. The profiling element is rotatable about the pivot axis over the arc length so that the profiling element is in the range of positions where it is variable compressibly coupled with a portion of the distribution conduit across the abscissa so that the height of the exit opening varies along the abscissa Do.

In another embodiment, the profiling member of the slurry dispenser includes a support assembly having a stationary support member and a pivot support member. The pivot support member is rotatable about the pivot axis over the arc length relative to the fixed support member. The pivot support member supports the profiling member.

In another embodiment, the profiling element of the slurry dispenser has an arc length such that the profiling element is in the range of positions where the profiling element is variable compressibly fastened to a portion of the distribution conduit over the abscissa so that the height of the exit opening is varied along the transverse axis. Lt; RTI ID = 0.0 > pivot < / RTI >

In another embodiment, the profiling member of the slurry dispenser includes a support assembly, a clamping segment extending generally longitudinally and transversely, and a translation adjustment rod extending vertically from the clamping segment as a whole. The translation adjustment rod of the profiling member is movably secured to the support assembly such that the profiling member is movable over a range of vertical positions.

In another embodiment, the support assembly includes a clamping mechanism adapted to selectively fasten the translation adjustment rod to secure the profiling member to a selected one of a range of vertical positions.

In another embodiment, the support assembly is adapted to rotatably support the profiling member such that the profiling member is rotatable relative to the pivot axis over a range of positions along the arc length.

In another embodiment, the support assembly includes a stationary support member and a pivot support member. The pivot support member is rotatable about the pivot axis over the arc length relative to the fixed support member. The pivot support member supports the profiling member.

In another embodiment, the support assembly includes a rotation adjustment rod extending between the stationary support member and the pivot support member. The rotation adjusting rod is movably fixed to the fixed supporting member such that moving the rotation adjusting rod relative to the fixing member pivots the pivot supporting member with respect to the pivot shaft with respect to the fixed supporting member.

In another embodiment, the support assembly includes a clamping mechanism adapted to selectively fasten the rotation adjusting rod to secure the profiling member to a selected one of a range of positions along the arc length.

In another embodiment, the cement slurry mixing and dispensing assembly includes a mixer adapted to agitate the water and cement material to form an aqueous cement slurry and a slurry dispenser in fluid communication with the mixer. The slurry dispenser generally includes a dispensing conduit extending along the longitudinal axis and including a dispensing outlet that is in fluid communication with the entry portion and the entry portion. The dispensing outlet extends a predetermined distance along the transverse axis. The horizontal axis is substantially perpendicular to the vertical axis. The dispensing outlet includes an exit 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. The slurry dispenser also includes a profiling mechanism including a profiling member in contact with the dispensing conduit, wherein the profiling member is configured to allow the profiling member to be in fluid communication with the dispensing conduit adjacent to the dispensing outlet, And to have a profiling member in a range spanning the positions that increase compression engagement.

In another embodiment, the cement slurry mixing and dispensing assembly further comprises a dispenser support member that supports the dispensing conduit. The profiling mechanism of the slurry dispenser includes a support assembly having a stationary support member and a pivot support member. The stationary support member is connected to the distributor support member. The pivot support member is rotatable about the pivot axis over the arc length relative to the fixed support member, and the pivot support member supports the profiling member.

In another embodiment, the cement slurry mixing and dispensing assembly comprises a delivery conduit disposed between and in fluid communication with the mixer and slurry dispenser, a flow modifying element associated with the delivery conduit and adapted to control the flow of the aqueous cement slurry from the mixer, And an aqueous bubble supply conduit in fluid communication with at least one of the mixer and the delivery conduit.

In another embodiment, the cement slurry mixing and dispensing comprises a feed conduit comprising a first incoming segment having a first feed inlet and a second incoming segment having a second feed inlet arranged in spaced relation to the first feed inlet Lt; / RTI > The inlet 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 the aqueous cement slurry from the mixer. The second feed inlet being adapted to receive a second flow of the aqueous cement slurry from the mixer, the distribution outlet being in fluid communication with both the first and second feed inlets, and the combined first and second streams of aqueous cement slurry, Is adapted to be discharged from the dispenser through the dispensing outlet.

In another embodiment, the gypsum slurry mixing and dispensing assembly is a delivery conduit disposed between and in fluid communication with the mixer and the slurry dispenser, the delivery conduit comprising a main delivery trunk and first and second delivery branches, A flow divider connecting the first and second transmission branches, further comprising a flow divider disposed between the main transmission trunk and the first transmission branch and between the main transmission trunk and the second transmission branch. The first delivery branch is in fluid communication with the first delivery inlet of the slurry dispenser and the second delivery branch is in fluid communication with the second delivery inlet of the slurry dispenser.

In another embodiment, a method of preparing a cement product comprises: (a) discharging a stream of an aqueous cement slurry from a mixer; (b) passing a stream of the aqueous cement slurry through the entry portion of the distribution conduit of the slurry dispenser; (c) discharging a stream of aqueous cement slurry from the outlet opening of the dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction, the dispensing outlet extending a predetermined distance along the transverse axis, Wherein the outlet opening has 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; And (d) compressing a portion of the distribution conduit adjacent the dispensing outlet to change the shape and / or size of the outlet opening.

In another embodiment, a method of making a cement product includes compressing a distribution conduit by a profiling mechanism such that the flow of the aqueous cement slurry is released from the exit opening at an increased diffusion angle relative to the machine direction.

In another embodiment, a method of making a cement product includes compressing the distribution conduit by a profiling mechanism having a profiling member in contact with the distribution conduit. The profiling member is moveable in a progressive manner such that the profiling member is a profiling member in a range over positions that increase the distribution conduit and compression tightening.

In another embodiment, a method of manufacturing a cement product further comprises moving the profiling member along a vertical axis to adjust the size and / or shape of the exit opening.

In another embodiment, a method of making a cement product includes moving a profiling member such that the profiling member translates along at least one axis and rotates about at least one axis to adjust the size and / or shape of the exit opening .

Examples

Referring to Figure 65, the shape and flow characteristics of one embodiment of a slurry dispenser constructed in accordance with the principles of the present disclosure have been evaluated in Examples 1-3. The upper plane of the half portion 1205 of the slurry dispenser is shown in Fig. The half portion 1205 of the slurry dispenser includes a half portion 1207 of the feed conduit 320 and a half portion 1209 of the distribution conduit 328. The half portion 1207 of the feed conduit 322 includes a second feed inlet 325 defining a second opening 335, a second entry segment 337, and a half portion 1211 of the branch connector segment 339, . The half portion 1209 of the distribution conduit 328 includes a half portion 1214 of the entry portion 352 of the distribution conduit 328 and a half portion 1217 of the distribution outlet 330.

The other half of the slurry dispenser, which is the mirror image of the half portion 1205 of Figure 65, has a lateral center midpoint 387 of the dispensing outlet 330 to form a slurry dispenser substantially similar to the slurry dispenser 420 of Figure 15, It should be understood that it can be connected and aligned integrally with the half portion 1205 of FIG. Thus, the shape and flow characteristics described below are equally applicable to the mirror image half of the slurry dispenser.

Referring to FIG. 72, the shape and flow characteristics of another embodiment of a slurry dispenser 2020 constructed in accordance with the principles of the present disclosure have been evaluated in Examples 4-6. The slurry dispenser 2020 shown in FIG. 72 is substantially the same as the slurry dispenser 1420 of FIG. The flow characteristics of the slurry dispenser 2020 of FIG. 72 using a profiling mechanism constructed in accordance with the principles of the present disclosure were evaluated in Example 7. The profiling mechanism evaluated in Example 7 is substantially the same as the profiling mechanism 1432 of FIG.

Example 1

65, the specific shape of the half portion 1205 of the slurry dispenser is defined by the first position L ₁ at the second feed inlet 325 and the half portion 1207 of the dispensing outlet 330. In this example, It was evaluated in the 16th position (L _{16) 16} different locations (L _{1 -16)} in between. Each location (L _{1 -16} ) represents a section slice of the half portion 1205 as indicated by the corresponding line. A flow line 1212 along the geometric center of each section slice was used to determine the distance between adjacent locations (L _{1 -16} ). The eleventh position L ₁₁ is located at a half of the entry portion 352 of the distribution conduit 328 corresponding to the opening 342 of the second feed outlet 345 of the half portion 1207 of the feed conduit 320 1214). Thus, the first to tenth positions L _{1 -10} are taken from the half portion 1207 of the feed conduit 320 and the eleventh to sixteenth positions are taken from the half portion 1209 of the distribution conduit 328 It is taken.

For each position (L _{1 - 16} ), the following geometric values were determined: the distance along the flow line 1212 between the second feed inlet 325 and the specific position (L _{1 - 16} ); The cross-sectional area of the opening at position L _{1 -16} ; The perimeter of position (L _{1 -16} ); And the hydraulic diameter of the position (L _{1 -16} ). The hydraulic diameter was calculated using the following equation:

D _hyd = 4 x A / P (Equation 1)

Where D _hyd is the hydraulic diameter,

A is the cross-sectional area of the specific position (L _{1 -16} )

P is the perimeter of the specific position (L _{1 -16} ).

Using inlet conditions, the dimensionless values for each location (L _{1 - 16} ) can be determined to account for the internal flow shape, as shown in Table 1. Curve fitting equations are used to illustrate the dimensionless shape of the half portion 1205 of the slurry dispenser in FIG. 66, which represents the dimensionless distance versus dimensionless area and hydraulic diameter from the inlet.

Analysis of the dimensionless values for each of the positions L _{1 -16} shows that the cross-sectional flow area extends from the first position L ₁ at the second feed inlet 325 to the entry portion 352 (also referred to as the second feed outlet To the eleventh position (L ₁₁ ) in the half portion 1214 of the opening (342) of the opening (345). In an exemplary embodiment, the cross-sectional flow area at the half portion 1214 of the entry portion 352 is approximately one-third greater than the cross-sectional flow area at the second feed inlet 325. Between the first position L ₁ and the eleventh position L ₁₁ , the cross sectional flow area of the second entry segment 337 and the second forming duct 339 varies from position to position L _1-11 . In this area, at least two adjacent positions L ₆ and L ₇ are located at a position L ₇ , which is located further from the second feed inlet 325, than a position L ₇ , which is closer to the second feed inlet 325 ₆ ). ≪ / RTI >

Between the first position L ₁ and the eleventh position L ₁₁ the half portion 1217 of the dispensing outlet 330 from the second inlet 335 in the half portion 1207 of the feed conduit 322 (For example, L < ₄ > _-6 ) having a cross sectional flow area larger than the cross sectional flow area of the adjacent area (for example, L ₃ ) The second entry segment 337 and the second forming duct 341 have a cross section that varies along the direction of the flow 1212 to help distribute the second flow of slurry moving therethrough.

The cross sectional area is the same as the cross sectional area at the eleventh position L ₁₁ in the half portion 1214 of the entry portion 352 of the distribution conduit 328, To the position (L ₁₆ ). The cross sectional flow area of the half portion 1214 of the entry portion 352 is approximately 95% of that of the half portion 1217 of the distribution outlet 330. In an exemplary embodiment,

The cross sectional flow region at the first position L ₁ at the second feed inlet 325 is located at the 16th position L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 Sectional flow area. The cross sectional flow area at the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately one fourth greater than the cross sectional flow area at the second feed inlet 325. In an exemplary embodiment,

The hydraulic diameter decreases from the first position L ₁ in the second feed inlet 325 to the eleventh position L ₁₁ in the half portion 1214 of the entry portion 352 of the distribution conduit 328. In an exemplary embodiment, the hydraulic diameter at the half portion 1214 of the entry portion 352 of the distribution conduit 328 is approximately one-half of the hydraulic diameter at the second feed inlet 325.

The hydraulic diameter is the same as the diameter at the eleventh position L ₁₁ in the half portion 1214 of the entry port 352 of the distribution conduit 328, 16 position (L ₁₆ ). The hydraulic diameter of the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately 95% of that of the half portion 1214 of the entry portion 352 of the distribution conduit 328. In an exemplary embodiment,

The hydraulic diameter at the first position L ₁ at the second inlet 325 is equal to the hydraulic diameter at the 16th position L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 . In an exemplary embodiment, the hydraulic diameter in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 is less than about half of that of the second feed inlet 325.

Example 2

In this example, the half portion 1205 of the slurry dispenser of Figure 65 was used to model the flow of gypsum slurry through it under different flow conditions. For all flow conditions, the density (rho) of the aqueous gypsum slurry was set at 1,000 kg / m < ³ >. The aqueous gypsum slurry is a shear thinning material that allows its viscosity to decrease as the 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:

(방정식 2)

(Equation 2)

here,

K is a constant,

는 전단 속도이고,

Is the shear rate,

n is a constant such as 0.133 in this case.

), 멱법칙 모델(방정식 2)을 사용하여 산출된 점도, 전단 응력, 및 레이놀즈 수(Re).In the first flow condition, the gypsum slurry enters the second feed inlet 325 with a viscosity K factor of 50 in the power law model at 2.5 m / s. Computational fluid dynamics techniques with finite volume methods were used to determine flow characteristics in a distributor. At each location (L _{1 -16} ), the following flow characteristics were determined: area weighted average velocity (U), area weighted average shear velocity (

), The viscosity, shear stress, and Reynolds number (Re) calculated using the power law model (equation 2).

The shear stress was calculated using the following equation:

(방정식 3)Shear stress = μ ×

(Equation 3)

here

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

는 전단 속도이다.

Is the shear rate.

The Reynolds number was calculated using the following equation:

Re = =? X U x D _hyd /? (Equation 4)

here

rho is the density of the gypsum slurry,

U is the area weighted average speed,

D _hyd is the hydraulic diameter,

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

In the second flow condition case, the feed rate of the gypsum slurry to the second feed inlet 325 was increased to 3.55 m / s. All other conditions were the same as in the first flow condition of this example. Dimensional values for the mentioned flow characteristics at each position (L _1-16 ) for both the first flow condition with an inlet velocity of 2.5 m / s and the second flow condition with an inlet velocity of 3.55 m / s are modeled . Using the inlet conditions, the dimensionless values of the flow characteristics for each position (L _{1 -16} ) were determined, as shown in Table II.

For both of the flow conditions in which K is set to be equal to 50, the average velocity is greater than the average velocity at the first position L ₁ at the second feed inlet 325, at the half portion 1217 of the distribution outlet 330 of the distribution conduit 328, To the sixteenth position (L ₁₆ ) in FIG. In the illustrated embodiment, the average speed was reduced by about 1/5, as shown in Fig.

For both of the flow conditions the shear rate is at the 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325 L ₁₆ ). In the illustrated embodiment, the shear rate is increased from the first position L ₁ at the second feed inlet 325 to the half portion 1217 of the distribution outlet 330 of the distribution conduit 328, ) To the 16th position (L ₁₆ ) in the second row.

For both flow conditions the calculated viscosity is at the 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325, (L ₁₆₎ was reduced to. In the illustrated embodiment, the calculated viscosity is calculated from the first position (L ₁ ) at the second feed inlet 325 to the half portion of the distribution outlet 330 of the distribution conduit 328 1217) to the sixteenth position (L ₁₆ ).

70, the shear stress is greater than the shear stress at the second feed inlet 325 at the first position (L ₁ ) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 16 position (L ₁₆ ). In the illustrated embodiment, the shear stress is reduced by approximately 10% in the first portion (L ₁ ) at the second feed inlet 325 in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 16 position (L ₁₆ ).

For the flow conditions both, the Reynolds number in Figure 71 is first in the half portion 1217 of the second feed inlet 325, a first location (L ₁₎ the distribution conduit (328) distribution outlet 330 in the in 16 position (L ₁₆ ). In the illustrated embodiment, the Reynolds number is at the 16th position L (L ₁ ) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ at the second feed inlet 325 ₁₆ ) by about 1/3. For both flow conditions, the Reynolds number at the 16th position (L ₁₆ ) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 is in the lamina region.

Example 3

In this example, the half portion 1205 of the slurry dispenser of FIG. 65 is a flow of gypsum slurry under flow conditions similar to those of Example 2, except that the value for coefficient K in the power law model (equation 2) To model it through it. The flow conditions were similar to those of Example 2 in other respects.

), 멱법칙 모델(방정식 2)을 사용하여 산출된 점도, 전단 응력(방정식 3), 및 레이놀즈 수(Re)(방정식 4). 입구 조건들 하에, 각각의 위치(L_{1 -16})에 대한 흐름 특성들의 무차원 값들은 표 III에 나타낸 바와 같이, 결정되었다.The flow characteristics were also evaluated for both the feed rate of the gypsum slurry to the second feed inlet 325 at 2.50 m / s and of 3.55 m / s. At each location (L _{1 -16} ), the following flow characteristics were determined: area weighted average velocity (U), area weighted average shear velocity (

(Equation 3), and Reynolds number (Re) (Equation 4) calculated using the power law model (equation 2). Under the inlet conditions, the dimensionless values of the flow characteristics for each location (L _{1 -16} ) were determined, as shown in Table III.

For both of the flow conditions in which K is set equal to 100, the average velocity is greater than the average velocity at the first location L ₁ in the second feed inlet 325, in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328, To the sixteenth position (L ₁₆ ) in FIG. In the illustrated embodiment, the average speed was reduced by about 1/5. The results for the average speed were substantially the same as those of Example 2 and Figure 67 on a dimensionless basis.

For both of the flow conditions the shear rate is at the 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325 L ₁₆ ). In the illustrated embodiment, the shear rate is greater than or equal to the 16th position L (L) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ at the second feed inlet 325 ₁₆ ). The results for shear rate were substantially the same as those of Example 2 and Figure 68 on a dimensionless basis.

For both flow conditions the calculated viscosity is at the 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325, (L ₁₆₎ was reduced to. In the illustrated embodiment, the calculated viscosity is at the 16th position (L ₁ ) in the half position 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325 L ₁₆ ). The results for the calculated viscosity were substantially the same as those of Example 2 and Figure 69 on a dimensionless basis.

For both of the flow conditions the shear stress is applied at a first position L ₁ in the second feed inlet 325 to a 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 L ₁₆ ). In the illustrated embodiment, the shear stress is reduced by approximately 10% in the first portion (L ₁ ) at the second feed inlet 325 in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 16 position (L ₁₆ ). The results for the shear stresses were substantially the same as those of Example 2 and Figure 70 on a dimensionless basis.

For both flow conditions the Reynolds number is at the 16th position in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ in the second feed inlet 325 L ₁₆ ). In the illustrated embodiment, the Reynolds number is at the 16th position L (L ₁ ) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 at the first position L ₁ at the second feed inlet 325 ₁₆ ) by about 1/3. For both flow conditions, the Reynolds number at the 16th position (L ₁₆ ) in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 is in the lamina region. The results for the Reynolds number were essentially the same as those of Example 2 and Figure 71 on a dimensionless basis.

Figs. 67-71 are graphs of flow characteristics calculated for different flow conditions of Examples 2 and 3. Fig. Curve fitting equations were used to account for changes in flow characteristics over the distance between the feed inlet and the half portion of the distribution outlet. Thus, Examples 2 and 3 show that the flow characteristics are consistent across changes in inlet velocity and / or viscosity.

Example 4

In this example, the slurry dispenser 2020 of FIG. 72 was used to model the flow of gypsum slurry in one of the bulb portions 2120 of the feed conduit 2022. Referring to FIG. 72, each of the first and second incoming segments 2036 and 2037 of the slurry distributor 2020 has a diameter D. Slurry distributor 2020 has a length along the longitudinal axis of approximately 12 x D. The slurry dispenser 2020 is symmetrical about a central longitudinal axis 50 that extends generally in the machine direction 2192. Slurry dispenser 2020 can be split into two half portions 2004, 2005 that are substantially symmetric about the central longitudinal axis.

Referring to Figure 73, the half portion 2004 of the slurry dispenser of Figure 72 is used to model the flow of gypsum slurry through flow conditions similar to those of Example 2, except that different non-dimensional representations of velocity are used Respectively. The inlet diameter D (x * = x / D) was chosen to be the length scaled to dimension the position vector x (x * = x / D) and the average inlet velocity U was chosen as the velocity vector u / U) at a rate that is scaled. The flow conditions were similar to those of Example 2 in other respects.

With reference to Figures 73-76, computational fluid dynamics (CFD) techniques with a finite volume method were used to determine flow characteristics in the half portion of the distributor. In particular, average velocities at different vertical positions from region A were calculated. An area extending from the center of the entry segment approximately 0.75 D in area A was analyzed. Twelve radially-spaced vertical slices were analyzed to calculate different average slurry velocities radially around the bulb portion. The twelve locations were substantially radially spaced such that each adjacent radial location was approximately 30 degrees apart. 75 and 76, radial position 1 corresponds to the direction in opposed relationship to the machine direction 2192 and radial position 7 corresponds to the machine direction 2192. The radial positions 4 and 10 are substantially aligned with the transverse axis 60.

The CFD technique was used with two different inlet velocity conditions, u ₁ = U and u ₂ = _1.5 U. The results of CFD analysis are found in Table IV. The magnitude of the velocity is expressed as a dimensionless absolute value (| u | * = | u | / U). The data is also shown in Fig. It should be understood that the other half portion 2005 of the slurry dispenser 2020 exhibits similar flow characteristics.

For both flow conditions, the average velocity at each radial position 1-12 was less than the inlet velocity, but greater than zero. Average speeds ranged from approximately half of the inlet velocity to approximately 7/8 (u * ~ 0.48-0.83 of the inlet velocity). The contoured convex dimple surface in the bulb portion helped to direct the flow in all directions radially outward from the incoming segment.

The slurry velocity was also decelerated relative to the inlet velocity. The average velocity of all 12 radial positions for a given flow condition was substantially similar (~ 0.65 or 65% of the inlet velocity).

Also, for each flow condition, the highest average velocities occurred at radial positions 3-5 and 9-11. A higher average velocity along the transverse axis or along the cross machine direction 60 helps to provide more edge flow to the lateral sides.

Thus, this example illustrates that bulb portion 2120 helps to slow down the slurry and change the orientation of the slurry from a downward vertical direction to a radially outer horizontal plane. Further, the bulb portion 2120 is configured to switch the flow of slurry to the lateral outer and inner sidewalls of the forming duct of the half portion 2004 of the slurry dispenser 2020 to promote slurry movement in the cross machine direction 60 Help.

Example 5

In this example, the slurry dispenser 2020 of FIG. 72 was used to model the flow of gypsum slurry in one of the forming ducts 2041 of the feed conduit 2022. Referring to Figure 78, the half portion 2004 of the slurry dispenser 2020 of Figure 72 shows the flow of the gypsum slurry under flow conditions similar to those of the Examples, except that the non-dimensional representation of the velocity is similar to that of Example 4 It was used to model through. In particular, the swirling motion of the slurry in the lateral and outer walls of the forming ducts was analyzed.

73, 74, and 78, a computational fluid dynamics (CFD) technique with a finite volume method was used to determine flow characteristics in the half portion 2004 of the distributor 2020. [ In particular, the swirling motion of the slurry near the lateral and outer sidewalls of the forming duct 2041 was analyzed. Referring to FIG. 73, the slurry moves in a swirling manner as it enters the forming duct 2041. The slurry stream lines were further trimmed as the slurry moved along the machine direction 2192 to the dispensing outlet 2030. The swirl motion of the slurry was analyzed in the region of the forming duct 2041 at a vertical position of approximately 1-3 / 4 D (1.72D) in the regions B1 and B2, as shown in Figures 74 and 78 .

The swirl motion of the slurry is a function of its tangential velocity and its axial (or machine direction) velocity. Referring to Figure 78, the degree of swirl that swells the flow is typically characterized by the swirl number S as pluses of angular and linear momentum using the following equations:

w = 접선 속도 및 u = 축방향 속도를 가짐(방정식 5)

w = tangential velocity and u = axial velocity (Equation 5)

r represents the radial position.

If the mean values of the tangential velocity and the axial velocity are used in equation 5, then it is:

(방정식 6)

(Equation 6)

For this example, the unique swirl motion S _m is expressed using the following equation:

(방정식 7)

(Equation 7)

In this example, the calculated swirl motion was used to calculate the swirl angle using the following equation:

Swirl angle ~ tan ^-1 (S _m ) (Equation 8).

The CFD technique was used with two different dimensionless inlet velocity conditions, u ₁ = U and u ₂ = _1.5 U. The results of the CFD analysis are found in Table V. It should be understood that the other half portions of the slurry dispenser exhibit similar flow characteristics. Through this analysis, it can be seen that in embodiments the slurry dispenser can be configured to produce a swirl motion (S _m ) in the range of about 0 to about 10 in the slurry dispenser and a swirl angle from about 0 degrees to about 84 degrees Found.

For both flow conditions, the maximum tangential velocity at the edges was at least about half of the inlet velocity in the edge region of the entrance of the forming duct. The swirl motion near the lateral sides is expected to help maintain the cleanliness of the internal shape of the slurry dispenser in use. As shown in FIG. 73, the swirl motion of the slurry is reduced to the distribution outlet 2030 in the direction of flow along the machine axis 50.

Example 6

In this example, slurry dispenser 2020 of Figure 72 was used to model the flow of gypsum slurry through feed conduit 2022 and distribution conduit 2028. [ 73 and 74, the half portion 2004 of the slurry dispenser 2020 of FIG. 72 is similar to that of Example 2 except under the flow conditions similar to those of Example 2, except that a non- It was used to model the flow of gypsum slurry through it.

), 멱법칙 모델(방정식 2)을 사용하여 산출된 점도, 및 레이놀즈 수(Re)(방정식 4). 수력 직경(방정식 1)은 또한 종축(50)을 따라 언급된 연속적 무차원 위치에서 산출되었다. 입구 흐름 조건들을 사용하면, 각각의 위치에 대한 흐름 특성들의 무차원 값들은 표 VI에 도시된 바와 같이, 결정되었다.For all flow conditions, the density (rho) of the aqueous gypsum slurry was set at 1,000 kg / m < ³ > and the viscosity K factor was set at 50. The flow characteristics were also evaluated for both the non-dimensional feed rate of the gypsum slurry to the feed inlet 2024 of B and 1.5B. The following flow characteristics were determined at each successive non-dimensional position downstream from the incoming portion of the forming duct 2041 along the machine direction 2192, expressed as a function of the inlet diameter D: region weighted average velocity U, Area weighted average shear rate (

), The viscosity calculated using the power law model (equation 2), and the Reynolds number (Re) (equation 4). The hydraulic diameter (Equation 1) was also calculated at a continuous non-dimensional position along the longitudinal axis 50. Using inlet flow conditions, the dimensionless values of flow characteristics for each location were determined, as shown in Table VI.

79-82 are graphs of flow characteristics calculated for different flow conditions of Example 6; Curve fitting equations were used to account for changes in flow characteristics over the distance between the feed inlet and the half portion 2004 of the distribution outlet 2030. [ Thus, the examples show that the flow characteristics are consistent over changes in the inlet velocity.

For both flow conditions, the average velocity was reduced from the first position (approximately 3D) in the delivery conduit to the last position (approximately 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. The average velocity was substantially continuously reduced as the slurry moved along the machine direction 2192. In the illustrated embodiment, the average speed was reduced by about 1/3 from the inlet speed, as shown in FIG.

For both of the flow conditions, the shear rate is increased from the first position (approximately 3D) in the feed conduit 2022 to the last position (approximately 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 Respectively. Shear rate was changed from position to position. In the illustrated embodiment, the shear rate was increased in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 relative to the inlet, as shown in FIG.

For both flow conditions, the calculated viscosity was reduced from the first position (approximately 3D) in the delivery conduit to the last position (approximately 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 . The calculated viscosity was changed from position to position. In the illustrated embodiment, the calculated viscosity was reduced in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 as compared to the inlet, as shown in FIG.

82, the Reynolds number in Figure 82 is the final position (approximately 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 in the first position (approximately 3D) in the delivery conduit, Respectively. In the illustrated embodiment, the Reynolds number has been reduced by approximately one-half in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 relative to the inlet. For both flow conditions, the Reynolds number in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 is in the lamina region.

Thus, it has been found that the distal half of the slurry dispenser (between approximately 6D and approximately 12D) is configured to provide a flow stabilization zone in which the mean and Reynolds numbers of the slurry are generally stable and reduced relative to feed inlet conditions. As shown in FIG. 73, the slurry travels in a stream line manner through this flow stabilization zone as a whole along the machine direction 2192.

Example 7

In this example, the slurry dispenser 2020 of FIG. 72 was used to model the flow of gypsum slurry at the dispensing outlet 2030 of the distribution conduit 2028. In this example, the half portion 2004 of the slurry dispenser of Fig. 73 has a flow of gypsum slurry through it under flow conditions similar to those of Example 2, except that a dimensionless representation of the width of the outlet opening 2081 is used. It was used for modeling. The dimensionless width (w / W) traverses the half portion 2119 of the outlet opening 2081 of the dispensing outlet 2030 (the centerline at the transverse midpoint 2187 is zero and equivalence). The flow conditions are similar to those of Example 2 in other respects.

The CFD technique with the finite volume method was used to determine the flow characteristics in the half portion 2004 of the distributor 2020. In particular, the angle of diffusion of the slurry discharged from the outlet opening 2081 at various locations across the width of the half portion 2119 of the outlet opening 2081 of the distribution outlet 2030 was analyzed. The angle of diffusion was determined using the following equation:

Angle of diffusion = tan ^-1 (V _x / V _z ), (Equation 9)

Where V _x is the average velocity in the cross machine direction

V _z is the average speed in the machine direction.

The angle of diffusion was calculated for two different conditions: the profiling mechanism did not compress the exit opening 2081 ("no profiler") and that the profiling mechanism did not compress the exit opening 2081 "Profiler"). In the modeled slurry dispenser 2020, the outlet opening 2081 has an overall width of approximately 10 inches for each half portion 2004, 2005, for a total of 20 inches for the entire width of the outlet opening 2081 Lt; / RTI > of about 1 inch across. The profiled profiling mechanism has a profile member that is approximately 15 inches wide and aligned with the transverse center midpoint so that the lateral portion of the dispensing outlet is in offset relationship with the profiling member and not compressed. In the modeled "profiler" condition, the profiling mechanism compresses the exit opening by approximately 1/8 of an inch so that the exit opening is approximately 5/8 of an inch in the area below the profiling member. The angles of diffusion for both conditions were determined, as shown in Table VII.

Under both conditions, the angle of diffusion increases as the position moves further outward from the transverse center midpoint 2187 (width = 0). The angle of diffusion is greatest at the lateral edge of the exit opening 2081.

The angle of diffusion is increased by using a profiling mechanism to compress the discharge outlet 2030, thereby reducing the height of the exit opening 2081. In the modeled "profiler" condition, the maximum angle of diffusion at the lateral edge (width = 0.466) was increased by more than 25 percent compared to the "no profiler" condition. In the "profiler" condition, the average angle of diffusion was increased by more than 50 percent compared to the "no profiler" condition.

All references, including publications, patent applications, and patents, which are incorporated herein by reference, are hereby incorporated by reference to the same extent as if each individual reference was specifically and individually indicated to be incorporated by reference, ≪ / RTI >

The use of the terms "a " and" an ", and the " the "and similar directives in the context of describing the invention (especially in the context of the following claims) If not explicitly contradicted, it should be construed to include both the singular and the plural. The terms "comprising," "including," "including," and "containing", unless otherwise indicated, include adjustable terms (ie, The meaning of which is not to be interpreted). The enumeration of ranges of values herein is only intended to serve as a simple way of individually addressing each separate value within its range unless otherwise specified herein, Are hereby incorporated by reference as if individually recited. All methods described herein may be performed in any suitable order unless otherwise explicitly contradicted by context or where expressly provided herein. The use of any and all examples, or exemplary instances (e.g., "such as") provided herein is merely intended to better illuminate the invention and, unless otherwise claimed, fall within the scope of the present invention No restrictions are raised. Any language in this specification is to be construed as representative of any non-claimed element as essential to the practice of the invention.

Preferred embodiments of the present invention, including the best modes known to the inventors for carrying out the invention, are described herein. Variations of such preferred embodiments may be apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to make appropriate use of such changes and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, the 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-recited elements in all possible variations is encompassed by the present invention unless otherwise specified herein or clearly contradicted by context.

Claims (25)

As a slurry dispenser,
A dispensing conduit extending generally along a longitudinal axis and including a dispensing outlet that is in fluid communication with the entry portion and the entry portion, the dispensing outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis, The dispensing outlet including an outlet opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal axis and the transverse axis;
A profiling mechanism comprising a profiling member in contact with the dispensing conduit, the profiling member being adapted to cause the profiling member to move to a dispensing conduit adjacent to the dispensing conduit to change the shape and / And said profiling mechanism being moveable over a range of travel such that there is said profiling member in a range over portions that increase compressive engagement. The slurry dispenser of claim 1, wherein the outlet opening of the dispensing outlet has a width-to-height ratio of about 4 or more. The apparatus of claim 1 or 2, wherein the outlet opening of the dispensing outlet has a width along the transverse axis and the profiling member has a width that extends a predetermined second distance along the transverse axis, The profiling member being positioned such that a pair of lateral portions of the dispensing outlet are in an offset relationship with the profiling member. The slurry dispenser of any one of claims 1 to 3, wherein the profiling member is movable along the vertical axis. The slurry dispenser of any one of claims 1 to 4, wherein the profiling member has at least two degrees of freedom. The slurry dispenser of any one of claims 1 to 5, wherein the profiling member is translatable along at least one axis and rotatable about at least one pivot axis. 7. The apparatus according to claim 5 or 6, wherein the profiling member is rotatable about a pivot axis translatable along the vertical axis and substantially parallel to the longitudinal axis, the profiling member having a height of the exit opening along the transverse axis Wherein the profiling member is rotatable with respect to the pivot axis over an arc length such that the profiling member is in the range of locations where the profile is variable compressibly coupled with a portion of the distribution conduit over the abscissa. 9. The apparatus of claim 7, wherein the profiling mechanism includes a support assembly having a fixed support member and a pivot support member, the pivot support member being rotatable about the pivot axis over the arc length relative to the fixed support member, Wherein the pivot support member supports the profiling member. 9. A method according to any one of claims 1 to 8, wherein the profiling element is located at a position where the profiling element is variable-compression-engaged with a portion of the distribution conduit over the transverse axis so that the height of the exit opening varies along the transverse axis Wherein the profiled member is rotatable about the pivot axis over an arc length so as to have the profiling member in a range spanning the entire length of the slurry distributor. 10. The method of any one of claims 1 to 9, wherein the profiling mechanism comprises a support assembly, the profiling member having a fastening segment extending generally longitudinally and transversely, and a translational rod extending vertically from the fastening segment as a whole. Wherein a translation adjustment rod of the profiling member is movably secured to the support assembly such that the profiling member is movable over a range of vertical positions. 11. The slurry dispenser of claim 10, wherein the support assembly comprises a clamp mechanism adapted to selectively fasten the translation adjustment rod to secure the profiling member to a selected one of a range of the vertical positions. 12. The slurry dispenser of claim 10 or 11, wherein the support assembly is adapted to rotatably support the profiling member such that the profiling member is rotatable about a pivot axis over a range of positions along an arc length. The pivoting support according to any one of claims 10 to 12, wherein the support assembly includes a fixed support member and a pivot support member, the pivot support member being rotatable about the pivot axis over the arc length relative to the fixed support member And the pivot support member supports the profiling member. The pivoting support apparatus according to any one of claims 10 to 13, wherein the support assembly includes a rotation adjustment rod extending between the fixed support member and the pivot support member, and the rotation adjustment rod is movably fixed to the fixed support member Wherein moving the rotation adjustment rod with respect to the stationary member pivots the pivot support member about the pivot axis with respect to the stationary support member. The support assembly of any one of claims 10 to 14, wherein the support assembly comprises a clamp mechanism adapted to selectively fasten the rotation adjustment rod to secure the profiling member to a selected one of a range of positions along the arc length Slurry dispenser. As a cement slurry mixing and dispensing assembly,
A mixer adapted to agitate the water and cement material to form an aqueous cement slurry;
And a slurry dispenser in fluid communication with the mixer,
A dispensing conduit extending generally along a longitudinal axis and including a dispensing outlet that is in fluid communication with the entry portion and the entry portion, the dispensing outlet extending a predetermined distance along a transverse axis, the transverse axis being substantially perpendicular to the longitudinal axis, The dispensing outlet comprising an outlet opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal axis and the transverse axis,
A profiling mechanism comprising a profiling member in contact with the dispensing conduit, the profiling member being adapted to cause the profiling member to move to a dispensing conduit adjacent to the dispensing conduit to change the shape and / And said profiling mechanism being moveable over an extent such that there is said profiling member in a range over portions that increase compression engagement. ≪ Desc / Clms Page number 13 > 18. The method of claim 16,
A dispenser support member for supporting the dispensing conduit;
Wherein the profiling mechanism of the slurry dispenser includes a support assembly having a stationary support member and a pivot support member, the stationary support member being connected to the distributor support member, the pivot support member having an arc length Wherein the pivot support member supports the profiling member. ≪ Desc / Clms Page number 20 > The method according to claim 16 or 17,
A delivery conduit disposed between and in fluid communication with said mixer and said slurry dispenser;
A flow modifying element associated with the delivery conduit and adapted to control the flow of the aqueous cement slurry from the mixer;
Further comprising an aqueous bubble supply conduit in fluid communication with at least one of the mixer and the delivery conduit. The slurry dispenser of any of claims 16 to 18, comprising a first incoming segment having a first feed inlet and a second incoming segment having a second feed inlet arranged in spaced relation to the first feed inlet Wherein the inlet portion of the distribution conduit is in fluid communication with the first and second feed inlets of the feed conduit and the first feed inlet is adapted to receive a first flow of the aqueous cement slurry from the mixer Wherein the second feed inlet is adapted to receive a second flow of the aqueous cement slurry from the mixer and the distribution outlet is in fluid communication with both the first and second feed inlets, Wherein the first and second flows are adapted to be discharged from the slurry dispenser through the dispensing outlet And dispensing assemblies. The method of claim 19,
A delivery conduit disposed between and in fluid communication with said mixer and said slurry distributor, said delivery conduit comprising a main delivery trunk and first and second delivery branches;
A flow divider connecting the main delivery trunk and the first and second transmission branches, the flow divider being disposed between the main delivery trunk and the first delivery branch and between the main delivery trunk and the second delivery branch, Further comprising:
Wherein the first transmission branch is in fluid communication with a first feed inlet of the slurry dispenser and the second transmission branch is in fluid communication with a second feed inlet of the slurry dispenser. A method of making a cement product,
Releasing a stream of aqueous cement slurry from the mixer;
Passing the stream of said aqueous cement slurry through an entry portion of a distribution conduit of a slurry dispenser;
Releasing a flow of the aqueous cement slurry from an outlet opening of a dispensing outlet of the slurry dispenser as the web of cover sheet material moves along the machine direction, the dispensing outlet extending a predetermined distance along a transverse axis, The transverse axis being substantially perpendicular to the longitudinal axis and the exit opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal axis and the transverse axis;
Compressing a portion of the distribution conduit adjacent the dispensing outlet to change the shape and / or size of the outlet opening. 23. The method of claim 21, wherein the distribution conduit is compressed by a profiling mechanism such that the flow of the aqueous cement slurry is discharged from the outlet opening at an increased diffusion angle relative to the machine direction. 22. A method according to claim 21 or claim 22, wherein said distribution conduit is compression-tightened by a profiling mechanism having a profiling member in contact with said distribution conduit, said profiling member being configured such that said profiling member Wherein the profiled member is movable over a range of travel over a range extending over positions that increase the length of the profile. The method of any one of claims 21 to 23,
Further comprising moving the profiling member along the vertical axis to adjust the size and / or shape of the exit opening. The method according to any one of claims 21 to 24,
Further comprising moving the profiling member such that the profiling member translates along at least one axis and rotates about the at least one axis to adjust the size and / or shape of the exit opening.

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