MX2015005052A

MX2015005052A - Slurry distributor with a profiling mechanism, system, and method for using same.

Info

Publication number: MX2015005052A
Application number: MX2015005052A
Authority: MX
Inventors: James Wittbold; William Rago
Original assignee: United States Gypsum Co
Priority date: 2012-10-24
Filing date: 2013-10-21
Publication date: 2015-07-17
Also published as: EP2911846A1; JP6343617B2; RU2015119351A; CA2888273A1; BR112015009117A2; AU2013334952B2; UA118093C2; KR20150074054A; JP2016503354A; TWI622475B; NZ707757A; ZA201503244B; PE20151111A1; TW201429660A; CL2015001025A1; WO2014066211A1; CN103770213B; CN204076480U; AR093139A1; AU2013334952A1

Abstract

A slurry distributor can include a distribution conduit and a profiling mechanism. The distribution conduit extends generally along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The distribution outlet includes an outlet opening having a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis. The profiling mechanism includes a profiling member in contacting relationship with the distribution conduit and movable over a range of travel such that the profiling member is in a range of positions over which it is in increasing compressive engagement with a portion of the distribution conduit adjacent the distribution outlet to vary the shape and/or size of the outlet opening.

Description

TIMING DISTRIBUTOR WITH A PROFILING MECHANISM, SYSTEM, AND METHOD OF USE OF THE SAME BACKGROUND OF THE INVENTION The present disclosure relates to manufacturing processes of continuous panels (eg, gypsum board) and, more particularly, to an apparatus, system and method for the distribution of an aqueous slurry of calcined gypsum.

It is well known to produce gypsum panels by uniformly dispersing calcined gypsum (commonly referred to as "stucco") in water to form an aqueous slurry of calcined gypsum. The aqueous calcined gypsum slurry is typically produced in a continuous manner by inserting stucco and water and other additives into a mixer containing means for stirring the contents to form a uniform gypsum slurry. The slurry is directed continuously to and through a discharge outlet of the mixer and into a discharge conduit connected to the discharge outlet of the mixer. An aqueous foam may be combined with the aqueous calcined gypsum slurry in the mixer and / or in the discharge conduit. The slurry stream passes through the discharge conduit from which it is continuously deposited in a mobile mesh of roof sheet material supported by a forming table. The grout is allowed to extend into the advancing mesh. A second mesh cover sheet material 256285 it is applied to cover the slurry and form an interleaved structure of a continuous gypsum panel preform, which is subjected to forming, such as in a conventional forming station, to obtain a desired thickness. The calcined gypsum reacts with the water in the gypsum board preform and hardens when the gypsum board preform moves down to a manufacturing line. The gypsum board preform is cut into segments at a point along the line where the gypsum board preform has hardened sufficiently, the segments are flipped, dried (eg, in an oven) to remove the excess water, and processed to provide the final gypsum panel product of desired dimensions.

Prior devices and methods for addressing some of the operational problems associated with the production of prior gypsum panels are described 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 that is combined to form a given amount of finished product is often referred to in the art as the "water-stucco ratio" (WSR). A reduction in the WSR without a corresponding formulation change will increase the viscosity of the slurry, which reduces the capacity of the slurry for spread out on the training table. Reducing water use (ie, decreasing the WSR) in the drywall manufacturing process can provide many benefits, including the opportunity to reduce the energy demand in the process. However, the extension of increasingly viscous gypsum slurries evenly over the training table remains a great challenge.

In addition, in some situations where the slurry is a multi-phase slurry, including air, the separation of the air-liquid slurry can develop in the slurry discharge duct of the mixer. As the WSR decreases, the volume of air increases to maintain the same dry density. The phase phase of air separated from the liquid slurry phase increases, which results in the larger mass propensity or variation in density.

It will be appreciated that this background description has been created by the inventors to assist the reader, and should not be taken as an indication that some of the problems noted were appreciated in the art. While the principles described may, in some aspects and modalities, alleviate the problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the appended claims and not by the ability of any described feature to solve any specific problem. indicated in I presented.

BRIEF DESCRIPTION OF THE INVENTION In one aspect, the present disclosure relates to embodiments of a grout distribution system for use in the preparation of a gypsum product. In one embodiment, a slurry distributor may include a supply conduit and a distribution conduit in fluid communication therewith. The supply conduit may include a first supply inlet in fluid communication with the distribution conduit and a second supply inlet arranged in spaced relationship with the first supply inlet and in fluid communication with the distribution conduit. The distribution conduit may generally extend along a longitudinal axis and include an inlet portion and a distribution outlet in fluid communication therewith. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis.

In other embodiments, a slurry distributor includes a supply conduit and a distribution conduit. The feed conduit includes a first input segment with a first feed input and a second inlet segment with a second feed inlet positioned in spaced relationship with the first feed inlet. The distribution conduit extends generally along a longitudinal axis and includes an inlet portion and a distribution outlet in fluid communication with the inlet portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. Each of the first and second feed inlets has an opening with a cross-sectional area. The entrance portion of the distribution conduit has an opening with a cross-sectional area that is greater than the sum of the cross-sectional areas of the openings of the first and second supply inlets.

In other embodiments, a slurry distributor includes a supply conduit, a distribution conduit, and at least one support segment. The feed conduit includes a first inlet segment with a first feed inlet and a second inlet segment with a second feed inlet positioned in spaced relationship with the first feed inlet. He The distribution conduit extends generally along a longitudinal axis and includes an inlet portion and a distribution outlet in fluid communication with the inlet portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. Each support segment is movable in a range of travel so that the support segment is in a range of positions over which the support segment is in increased compressive engagement with a portion of at least one of the supply conduit and the conduit of distribution.

In another aspect of the present disclosure, a slurry distributor can be placed in fluid communication with a gypsum slurry mixer adapted to agitate the water and calcined gypsum to form an aqueous slurry of calcined gypsum. In one embodiment, the description describes a gypsum slurry mixing and distribution assembly that includes a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous slurry of calcined gypsum. A slurry distributor is in fluid communication with the gypsum slurry mixer and is adapted to receive a first flow and a second flow of aqueous slurry from calcined gypsum from the gypsum slurry mixer and distribute the first and second slurry flows. of plaster calcined in a mesh that advances.

The slurry distributor includes a first feed inlet adapted to receive the first flow of calcined gypsum slurry from the gypsum slurry mixer, a second feed inlet adapted to receive the second flow of calcined gypsum slurry from the mixer of gypsum slurry, and a distribution outlet in fluid communication with the first and second feed inlets and adapted so that the first and second flows of calcined gypsum slurry are discharged from the slurry distributor through the distribution outlet .

In another embodiment, a slurry distributor includes a supply conduit and a distribution conduit. The feed conduit includes an input segment with a power input and a power input output in fluid communication with the power input. The input segment extends along a first axis of feed flow. The feed conduit includes a shaped conduit having a bulb portion in fluid communication with the input input outlet of the input segment. The feed conduit includes a transition segment in fluid communication with the bulb portion. The transition segment extends along a second feed flow axis, which is in non-parallel relationship with the first axis of feed flow.

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

The bulb portion has an expansion area with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area with respect to a flow direction of the supply inlet towards the distribution outlet distribution duct. The shaped duct has a convex inner surface in confronting relation with the input inlet of the input segment.

In yet another embodiment, a slurry distributor includes a bifurcated feed line and a distribution line. The bifurcated feed conduit includes a first and a second feed portion, each having an input segment with a feed inlet and a feed input inlet. fluid communication with the feed inlet, a shaped duct having a bulb portion in fluid communication with the input input outlet of the input segment, and a transition segment in fluid communication with the bulb portion. The entry segment generally extends along a vertical axis. The transition segment extends along a longitudinal axis, which is perpendicular to the vertical axis.

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

Each of the first and second bulb portions has an expansion area with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area with respect to a direction of flow. flow of the first and second respective feed inputs to the distribution outlet distribution conduit.

Each of the first and second shaped ducts has a convex inner surface in confronting relation with the first and second respective feed input outputs of the first and second input segments.

In another embodiment, a slurry distributor includes a distribution conduit and a slurry cleaning mechanism. The distribution conduit extends generally along a longitudinal axis, a distribution outlet in fluid communication with the inlet portion, and a lower surface extending between the inlet portion and the distribution outlet. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The grout cleaning mechanism includes a movable wiper blade in contact relation with the lower surface of the distribution duct. The cleaning sheet is reciprocally movable on a cleaning path between a first position and a second position. The cleaning path is placed adjacent to the distribution outlet.

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

The profiling mechanism includes a profiling member in contact relation with the distribution conduit. The profiling member is movable in a range of travel so that the profiling member is in a range of positions over which the profiling member is in enhanced compressive engagement with a portion of the distribution conduit adjacent to the distribution outlet for vary the shape and / or size of the exit opening.

In another aspect of the present disclosure, the slurry distributor can be used in a cement slurry mixing and distribution assembly. For example, a slurry distributor can be used to distribute an aqueous slurry of calcined gypsum in an advancing mesh. In other embodiments, a gypsum slurry mixing and distribution assembly includes a mixer and a slurry distributor in fluid communication with the mixer. The mixer is adapted to stir water and calcined gypsum to form an aqueous slurry of calcined gypsum. The grout distributor includes a supply duct and a distribution duct: The feed conduit includes a first inlet segment with a first feed inlet and a second inlet segment with a second feed inlet positioned in spaced relationship with the first feed inlet. The first feed inlet is adapted to receive a first flow of aqueous slurry of calcined gypsum from the gypsum slurry mixer. The second feed inlet is adapted to receive a second flow of calcined aqueous gypsum slurry from the gypsum slurry mixer.

The distribution conduit extends generally along a longitudinal axis and includes an inlet portion and a distribution outlet in fluid communication with the inlet portion. The inlet portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The distribution output is in fluid communication with both the first and the second power input and is adapted so that the first and second Aqueous grout fluxes from calcined gypsum are discharged from the slurry distributor through the distribution outlet.

Each of the first and second feed inlets has an opening with a cross-sectional area. The entrance portion of the distribution conduit has an opening with a cross-sectional area that is greater than the sum of the cross-sectional areas of the openings of the first and second supply inlets.

A cement slurry mixing and distribution assembly including a mixer adapted to agitate the water and a cementitious material to form an aqueous cement slurry and a slurry distributor in fluid communication with the mixer. The slurry distributor can be any of the various embodiments of a slurry distributor following the principles of the present disclosure.

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

In some embodiments, a method for distributing an aqueous slurry of calcined gypsum in a mobile mesh is can be made using a slurry distributor constructed in accordance with the principles of the present disclosure. A first flow of aqueous calcined gypsum slurry and a second flow of aqueous calcined gypsum slurry are passed respectively through a first feed inlet and a second feed inlet of the slurry distributor. The first and second aqueous slurry streams of calcined gypsum are combined in the slurry distributor. The first and second aqueous slurry fluxes of calcined gypsum are discharged from a distribution outlet of the slurry distributor in the mobile mesh.

In other embodiments, a method for preparing a gypsum product can be performed using a slurry distributor constructed in accordance with the principles of the present disclosure. A first flow of aqueous slurry of calcined gypsum is passed to a first average feed rate through a first feed inlet of a slurry distributor. A second flow of aqueous slurry of calcined gypsum is passed to a second average feed rate through a second feed inlet of the slurry distributor. The second power inlet is in spaced relationship with the first power inlet. The first and second aqueous slurry streams of calcined gypsum are combined in the grout distributor. The first and second combined streams of aqueous calcined gypsum slurry are discharged at an average discharge velocity from a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction . The average discharge speed is lower than the first average feed speed and the second average feed speed.

In another embodiment, a method for preparing a cementitious product can be performed using a slurry distributor constructed in accordance with the principles of the present disclosure. A flow of aqueous cement slurry is discharged from a mixer. A flow of aqueous cement slurry is passed at an average feed rate through a feed inlet of a slurry distributor along a first feed flow axis. The flow of aqueous cement slurry is passed into a bulb portion of the slurry distributor. The bulb portion has an expansion area with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area with respect to a flow direction of the supply inlet . The bulb portion is configured to reduce the average speed of the cement grout flow that moves from the feed inlet through the bulb portion. The shaped conduit has a convex inner surface in confronting relationship with the first feed flow axis so that the flow of aqueous cement slurry moves in the radial flow in a plane substantially perpendicular to the first supply flow axis. The aqueous cement slurry flow is passed in a transition segment extending along a second feed flow axis, which is in non-parallel relationship with the first feed flow axis. The flow of aqueous cement slurry is passed in a distribution conduit. The distribution conduit includes a distribution outlet extending a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis.

In another embodiment, a method for preparing a cementitious product includes the discharge of an aqueous cement slurry stream from a mixer. The flow of aqueous cement slurry is passed through an inlet portion of a distribution conduit of a slurry distributor. The flow of aqueous cement slurry is discharged from a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction. A cleaning sheet reciprocates on a cleaning path along a lower surface of the distribution conduit between a first position and a second position to clean the aqueous cementitious slurry thereof. The cleaning path is placed adjacent to the distribution outlet.

In yet another embodiment, a method for preparing a cementitious product includes the discharge of an aqueous cement slurry stream from a mixer. The flow of aqueous cement slurry is passed through an inlet portion of a distribution conduit of a slurry distributor. The aqueous cement slurry stream is discharged from an outlet opening of a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The outlet opening has a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis. A portion of the distribution conduit adjacent to the dispensing outlet is compressively coupled to vary the shape and / or size of the outlet opening.

The embodiments of a mold for use in a method for producing a slurry distributor in accordance with the principles of the present disclosure are also described in the present. The embodiments of a grout distributor in accordance with the principles of the present disclosure are also described herein.

The additional and alternative aspects and features of the principles described will be appreciated from the following detailed description and the accompanying figures. As will be appreciated, the slurry distribution systems described herein are capable of being made and used in other and different embodiments, and are capable of being modified in several aspects. Accordingly, it is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and do not limit the scope in accordance with the appended claims.

BRIEF DESCRIPTION OF THE FIGURES The patent file or application contains at least one figure executed in color. Copies of this patent or patent application publication with the color figure (s) will be provided by the Office upon request and payment of the necessary fee.

FIG. 1 is a perspective view of a form of a slurry distributor constructed in accordance with the principles of the present disclosure.

FIG. 2 is a perspective view of the slurry distributor of FIG. 1 and a view in perspective of a form of a grout distributor support constructed in accordance with the principles of the present disclosure.

FIG. 3 is a front elevation view of the slurry distributor of FIG. 1 and the grout distributor support of FIG.2.

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

FIG. 5 is another perspective view of the slurry distributor of FIG. 4 but with a shaping system removed for illustrative purposes.

FIG. 6 is an isometric view of another embodiment of a slurry distributor constructed in accordance with the principles of the present disclosure, which includes a first feed inlet and a second feed inlet positioned at approximately a sixty degree feed angle. with respect to a longitudinal axis or machine direction of the slurry distributor.

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

FIG. 8 is a rear elevational view of the slurry distributor of FIG. 6.

FIG. 9 is a top plan view of a first piece of the slurry distributor of FIG. 6, which has a two-piece construction.

FIG. 10 is a front perspective view of the slurry distributor part of FIG. 9.

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

FIG. 12 is a perspective view of the slurry distributor and the support system of FIG. eleven.

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

FIG. 14 is a perspective view of the slurry distributor and the support system of FIG. 13 FIG. 15 is a perspective view of a slurry distributor embodiment constructed in accordance with the principles of the present disclosure that defines an interior geometry that is similar to the slurry distributor of FIG. 6, but that is constructed of a flexible material and has an integral construction.

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

FIG. 17 is an enlarged perspective view of the interior geometry defined by the slurry distributor of FIG. 15, illustrating areas of progressive cross-sectional flow of a portion of the feed conduit thereof.

FIG. 18 is an enlarged perspective view of the interior geometry of the slurry distributor of FIG. 15, which illustrates another flow area of progressive cross-section of the feed conduit.

FIG.19 is an enlarged perspective view of the interior geometry of the slurry distributor of FIG. 15, which illustrates another flow area of progressive cross-section of the feed conduit that is aligned with a half of an inlet portion to a distribution conduit of the slurry distributor of FIG.15.

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

FIG.21 is a perspective view as in FIG. 20, but with a support frame removed for purposes illustrative for showing a plurality of retaining plates in distributed relationship with the slurry distributor of FIG.15.

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

FIG. 23 is a rear perspective view of the slurry distributor and the support system of FIG. 22 FIG. 24 is a top plan view of the slurry distributor and support system of FIG. 22 FIG. 25 is a side elevational view of the slurry distributor and the support system of FIG. 22 FIG. 26 is a front elevational view of the slurry distributor and the support system of FIG. 22 FIG. 27 is a rear elevational view of the slurry distributor and the support system of FIG. 22 FIG. 28 is an enlarged detail view of a distal portion of the grout dispenser, illustrating one embodiment of a grout cleaning mechanism constructed in accordance with the principles of the present description.

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

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

FIG. 30B is a view as in FIG. 30, illustrating a profiling member of the profiling mechanism in a compressed position.

FIG. 30C is a view as in FIG. 30, illustrating the profiling member of the profiling mechanism in a pivoted position.

FIG. 30D is an exploded view in enlarged detail of the profiling member, illustrating a connection technique between a translation bar and a profile segment.

FIG. 31 is a side elevational view of the profiling mechanism of FIG.29.

FIG. 32 is a top plan view of the profiling mechanism of FIG.29.

FIG.33 is a lower elevation view of the profiling mechanism of FIG.29.

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

FIG.35 is an enlarged detail view taken from the side of a bulb portion of the slurry distributor of FIG.22.

FIG. 36 is a perspective view of a pair of rigid support inserts resting on a lower support member of the support system of FIG. 22.

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

FIG. 38 is a front elevation view of the rigid support insert of FIG.36.

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

FIG. 40 is a front elevation view of the slurry distributor of FIG.22.

FIG. 41 is a rear elevational view of the slurry distributor of FIG.22.

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

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

FIG.44 is a top plan view of a middle portion of the slurry distributor of FIG.22.

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

FIG. 46 is a cross-sectional view taken along line 46-46 in FIG.44.

FIG. 47 is a cross-sectional view taken along line 47-47 in FIG. 44.

FIG. 48 is a cross-sectional view taken along line 48-48 in FIG. 44.

FIG. 49 is a cross-sectional view taken along line 49-49 in FIG. 44 FIG. 50 is a cross-sectional view taken along line 50-50 in FIG. 44.

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

FIG. 52 is a cross-sectional view taken along line 52-52 in FIG. 44.

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

FIG. 54 is a perspective view of one embodiment of a multi-part mold for producing a slurry distributor as in FIG. 1 constructed in accordance with the principles of the present description.

FIG. 55 is a top plan view of the mold of FIG. 54.

FIG.56 is an exploded view of one embodiment of a multi-part mold to produce a slurry distributor as in FIG.15 constructed in accordance with principles of the present description.

FIG. 57 is a perspective view of another embodiment of a mold for producing a part of a two-part slurry distributor constructed in accordance with the principles of the present disclosure.

FIG. 58 is a top plan view of the mold of FIG.57.

FIG.59 is a schematic plan diagram of one embodiment of a gypsum slurry mixing and distribution assembly that includes a slurry distributor in accordance with the principles of the present disclosure.

FIG. 60 is a schematic plan diagram of another embodiment of a gypsum slurry mixing and distribution assembly that includes a slurry distributor in accordance with the principles of the present disclosure.

FIG. 61 is a schematic elevation diagram of a wet end embodiment of a gypsum board manufacturing line in accordance with the principles of the present disclosure.

FIG. 62 is a perspective view of a flow divider embodiment constructed in accordance with the principles of the present disclosure suitable for use in a gypsum slurry mixing and distribution assembly that includes a slurry distributor.

FIG. 63 is a side elevation view, in section, of the flow divider of FIG.62.

FIG. 64 is a side elevational view of the flow separator of FIG. 62 with an embodiment of a compression apparatus constructed in accordance with the principles of the present description mounted thereon.

FIG. 65 is a top plan view of a middle portion of a slurry distributor similar to the slurry distributor of FIG.15.

FIG. 6 is a graph of the data in Table I of Example 1 showing the dimensionless distance of the feed input versus the dimensionless area and the dimensionless hydraulic radius of the middle portion of the slurry distributor of FIG. 65.

FIG. 67 is a graph of the data in Tables II and III of Examples 2 and 3, respectively, showing the dimensionless distance of the feed input against the dimensionless speed of a patterned grout flow moving through the portion mean of the grout distributor of FIG.65.

FIG. 68 is a graph of the data of Tables II and III of Examples 2 and 3, respectively, showing the dimensionless distance of the feed input versus the non-dimensional shear rate in the patterned slurry that moves through the portion mean of the grout distributor of FIG.65.

FIG. 69 is a graph of the data in Tables II and III of Examples 2 and 3, respectively, showing the dimensionless distance of the feed input versus the dimensionless viscosity of the patterned slurry moving through the middle portion of the feed. grout distributor of FIG.65.

FIG. 70 is a graph of the data of Tables II and III of Examples 2 and 3, respectively, showing the dimensionless distance of the feed input against the dimensionless shear stress in the patterned slurry moving through the middle portion of the grout distributor of FIG.65.

FIG. 71 is a graph of the data in Tables II and III of Examples 2 and 3, respectively, showing the dimensionless distance of the feed input versus the dimensionless Rcynolds number of the patterned slurry moving through the portion mean of the grout distributor of FIG.65.

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

FIG. 73 is a top perspective view of an output of the computational fluid dynamics model (CFD) for a middle portion of the slurry distributor of FIG. 72.

FIG. 74 is a view as in FIG. 73, which illustrates various regions discussed in Examples 4-6.

FIG. 75 is a view of region A indicated in FIG. 74.

FIG. 76 is a top plan view of region A illustrating the radial locations used to perform the CFD analysis.

FIG. 77 is a graph of the data of Table IV of Example 4 showing the radial location in region A versus the dimensionless average velocity moving through region A of the middle portion of the slurry distributor of the FIG.73.

FIG. 78 is an enlarged detail view taken from FIG. 72, which illustrates a region B of the slurry distributor in which a flow of slurry moving therethrough has a swirling motion.

FIG.79 is a graph of the data in Table VI of Example 6 showing the dimensionless distance of the feed input versus the dimensionless speed of a patterned grout flow moving through the middle portion of the slurry distributor of FIG. 73.

FIG. 80 is a graph of the data of Table VI of Example 6 showing the dimensionless distance of the feed input versus the non-dimensional shear rate in the patterned slurry moving through the middle portion of the slurry distributor of FIG. 73.

FIG.81 is a graph of the data of Table VI of Example 6 showing the dimensionless distance of the feed inlet against the dimensionless viscosity of the patterned slurry moving through the middle portion of the slurry distributor of the slurry. FIG.73.

FIG.82 is a graph of the data in the Table VI of Example 6 showing the dimensionless distance of the feed inlet against the dimensionless Rcynolds number of the patterned slurry moving through the middle portion of the slurry distributor of FIG. 73.

FIG. 83 is a graph of the data in the Table VII of Example 7 showing the dimensionless distance along the width of the exit opening of a transverse center midpoint against the extension angle of the patterned slurry discharging from the middle portion of the slurry distributor of FIG. 73 DETAILED DESCRIPTION OF THE INVENTION The present disclosure provides various embodiments of a grout distribution system that can be used in the manufacture of products, including cementitious products such as gypsum panels, for example. The embodiments of a slurry distributor constructed in accordance with the principles of the present disclosure can be used in a manufacturing process to distribute effectively a multi-phase slurry, such as one containing air and liquid phases, such as those found in an aqueous slurry of foamed gypsum, for example.

The embodiments of a distribution system constructed in accordance with the principles of the present disclosure can be used to distribute a slurry (eg, an aqueous slurry of calcined gypsum) into an advancing mesh (eg, paper or mat) that It moves on a conveyor belt during a continuous panel manufacturing process (eg, drywall). In one aspect, a grout distribution system constructed in accordance with the principles of the present disclosure can be used in a conventional drywall manufacturing process as, or portion of, a discharge duct attached to a mixer adapted to agitate calcined gypsum. and water to form an aqueous slurry of calcined gypsum.

The embodiments of a slurry distribution system constructed in accordance with the principles of the present disclosure are aimed at achieving a wider distribution (along the direction through the machine) of a uniform gypsum slurry. The embodiments of a grout distribution system of the present disclosure are suitable for use with a grout of gypsum having a WSR range, including WSR conventionally used for manufacturing gypsum panels and those which are relatively minor and have a relatively higher viscosity. In addition, a gypsum slurry distribution system of the present disclosure can be used to help control the separation of air-liquid phases, such as, in the aqueous slurry gypsum slurry, including foamed gypsum slurry having a bulk volume. of very high foam. The extent of the aqueous calcined gypsum slurry in the advancing mesh can be controlled by slurring and distributing the slurry using a distribution system as shown and described herein.

A cement grout mixing and distribution assembly in accordance with the principles of the present disclosure can be used to form any type of cementitious product, such as a panel, for example. In some embodiments, a cementitious panel may be formed, such as a drywall, a Portland cement panel or an acoustic panel, for example.

The cementitious slurry can be any conventional cementitious slurry, for example, any cementitious slurry commonly used to produce gypsum panels, acoustical panels including, for example, acoustic panels described in United States Patent Application Publication No. 2004/0231916 , or cement panel Portland As such, the cementitious slurry can optionally further comprise any additive commonly used to produce cementitious panel products. Such additives include structural additives including mineral wool, continuous or cut glass fibers (also referred to as glass fiber), perlite, clay, vermiculite, calcium carbonate, polyester and paper fiber, as well as chemical additives such as foaming agents, fillers , accelerators, sugar, enhancing agents such as phosphates, phosphonates, borates and the like, retardants, binders (eg, starch and latex), colorants, fungicides, biocides, hydrophobic agent, such as a silicone-based material (e.g. a silane, siloxane or silicone-resin matrix), and the like. Examples of the use of some of these and 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 United States Patent Application Publication No.2004 / 0231916; 2002/0045074; 2005/0019618; 2006/0035112; and 2007/0022913.

Non-limiting examples of cementitious materials include Portland cement, sorrel cement, slag cement, fly ash cement, calcium alumina cement, water soluble anhydrite calcium sulfate, calcium sulfate a-hemihydrate, b-sulfate hemihydrate of calcium, natural calcium sulfate hemihydrate, synthetic or chemically modified, calcium sulfate dihydrate ("gypsum", "set gypsum," or "hydrated gypsum"), and mixtures thereof. In one aspect, the cementitious material desirably comprises calcined gypsum, such as in the form of calcium sulfate alpha hemihydrate, beta calcium sulfate hemihydrate and / or anhydrite calcium sulfate. In modalities, calcined gypsum may be fibrous in some modalities and non-fibrous in others. The calcined gypsum may include at least about 50% calcium beta sulfate hemihydrate. In other embodiments, the calcined gypsum may include at least about 86% calcium beta sulfate hemihydrate. The weight ratio of water to calcined gypsum can be any suitable ratio, although, as one of ordinary skill in the art will appreciate, lower ratios can be more efficient because less excess water must be expelled during manufacturing, thus conserving energy . In some embodiments, the cementitious slurry can be prepared by combining water and calcined gypsum in a range from about a 1: 6 weight ratio, respectively, to about a 1: 1 ratio, such as about 2: 3, for panel production depending on the products.

The embodiments of a method for preparing a cementitious product, such as a gypsum product, in accordance with the principles of the present disclosure may include the distribution of an aqueous slurry of calcined gypsum in a advancing mesh using a slurry distributor constructed in accordance with the principles of the present disclosure. The various embodiments of a method for distributing an aqueous slurry of calcined gypsum in a mobile mesh are described herein.

Turning now to the Figures, FIGS. 1-3 show a modality of a slurry distributor 120 according to the principles of the present description, and in FIGS. 4 and 5, another embodiment of a dispenser is shown. grout 220 according to the principles of the present disclosure. The grout distributor 120 shown in FIGS. 1-3 is constructed of an elastically flexible material, while the slurry distributor 220 shown in FIGS. 3 and 4 is made of a relatively rigid material. However, the internal flow geometry of both slurry distributors 120, 220 in FIGS. 1-5 is the same, and reference should also be made to FIG.5 when considering the slurry distributor 120 of FIGS.1-3.

With reference to FIG. 1, the slurry distributor 120 includes a feed duct 122, having first and second feed inlets 124, 125, and a distribution duct 128, which includes a distribution outlet 130 and is in fluid communication with the feed conduit 128. A profiling system 132 (see FIG.3) adapted to locally vary the size of the distribution outlet 130 of the distribution conduit 128 can also be provided.

With reference to FIG. 1, the feed conduit 122 extends generally along a transverse axis to the direction through the machine 60, which is substantially perpendicular to a longitudinal axis or machine direction 50. The first feed inlet 124 is in spaced relation with the second feed inlet 125. The first feed inlet 124 and the second feed inlet 125 define respective openings 134, 135 which have substantially the same area. The illustrated openings 134, 135 of the first and second feed inlets 124, 125 both 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 intended applications and current process conditions.

The first and second feed inlets 124, 125 are in opposite relation to each other along the axis through the machine 60 so that the first and second feed inlets 124, 125 are placed substantially at an angle of 90 ° with with respect to the axis of the machine 50. In other embodiments, the first and second feed inputs 124, 125 can be oriented differently with respect to the machine direction. For example, in some embodiments, the first and second feed inlets 124, 125 may be at an angle between 0 ° and about 135 ° with respect to the machine direction 50.

The feed conduit 122 includes first and second input segments 136, 137 and a bifurcated connector segment 139 positioned between the first and second input segments 136, 137. The first and second input segments 136, 137 are generally cylindrical and are they extend along the transverse axis 60 so that they are substantially parallel to a plane 57 defined by the longitudinal axis 50 and the transverse axis 60. The first and second feed inlets 124, 125 are placed at the distal ends of the first and second ones. second input segments 136, 137, respectively, and are in fluid communication with these.

In other embodiments, the first and second feed inputs 124, 125 and the first and second input segments 136, 137 can be oriented differently with respect to the transverse axis 60, the machine direction 50, and / or the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. For example, in some embodiments, the first and second feed inlets 124, 125 and the first and second inlet segments 136, 137 may each be placed substantially in the plane 57 defined by the longitudinal axis 50 and the transverse axis 60 at a feed angle Q with respect to the longitudinal axis or direction of the machine 50, which is an angle in a range of up to about 135 ° with respect to the machine direction 50, and in other embodiments in a range from about 30 ° to about 135 ° , and in still other embodiments in a range from about 45 ° to about 135 °, and in still other embodiments in a range from about 40 ° to about 110 °.

The bifurcated connector segment 139 is in fluid communication with the first and second feed inputs 124, 125 and the first and second input segments 136, 137. The bifurcated connector segment 139 includes first and second shaped ducts 141, 143. The first and second feed inlets 124, 125 of the feed duct 22 are in fluid communication with the first and second shaped ducts 141, 143, respectively. The first and second shaped conduits 141, 143 of the connector segment 139 are adapted to receive a first flow in a first feed direction 190 and a second flow in a second flow direction 191 of the calcined aqueous gypsum slurry of the first and second feed inlets 124, 125, respectively, and for directing the first and second flows 190, 191 of the aqueous calcined gypsum slurry in the distribution conduit 128.

As shown in FIG. 5, the first and second shaped ducts 141, 143 of the connector segment 139 define first and second supply outlets 140, 145, respectively, in fluid communication with the first and second feed inlets 124, 125 Each feed outlet 140, 145 is in fluid communication with the distribution conduit 128. Each of the first and second illustrated feed exits 140, 145 defines an opening 142 with a generally rectangular inner portion 147 and a substantially circular side portion. 149. The circular side portions 145 are positioned adjacent the side walls 151, 153 of the distribution conduit 128.

In embodiments, the openings 142 of the first and second feed exits 140, 145 may have a cross-sectional area that is greater than the cross-sectional area of the openings 134, 135 of the first feed inlet 124 and the second inlet. 125 feed, respectively. For example, in some embodiments, the cross-sectional area of the openings 142 of the first and second feed exits 140, 145 may be in a range from greater than up to about 300% greater than the cross-sectional area of the openings 134, 135 of the first feed inlet 124 and the second feed inlet 125, respectively, in a range from greater than up to about 200% greater than in other modalities, and in a range from greater than up to approximately 150% higher in still other modalities.

In embodiments, the openings 142 of the first and second feed outlets 140, 145 can have a hydraulic diameter (4 x cross section area / perimeter) that is smaller than the hydraulic diameter of the openings 134, 135 of the first inlet of the first inlet. feed 124 and second feed input 125, respectively. For example, in some embodiments, the hydraulic diameter of the openings 142 of the first and second feed outlets 140, 145 may be from about 80% or less than the hydraulic diameter of the openings 134, 135 of the first feed inlet 124. and the second power input 125, respectively, approximately 70% or less in other modes, and approximately 50% or less in still other modes Referring again to FIG.1, the connector segment 139 is substantially parallel to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. In other embodiments, the connector segment 139 can be oriented from a different manner with respect to the transverse axis 60, the machine direction 50, and / or the plane 57 defined by the longitudinal axis 50 and the transverse axis 60.

The first feed inlet 124, the first inlet segment 136, and the first shaped duct 141 are a mirror image of the second feed inlet 125, the second inlet segment 137, and the second shaped duct 143, respectively. Accordingly, it will be understood that the description of one power inlet is applicable to the other power inlet, the description of one inlet segment is applicable to the other inlet segment, and the description of one shaped duct is applicable to the other shaped duct , as well as in a corresponding way.

The first shaped duct 141 is fluidly connected to the first feed inlet 124 and the first inlet segment 136. The first shaped duct 141 is also fluidly connected to the distribution duct 128 to thereby assist in connecting fluidly the first feed inlet 124 and the distribution outlet 130 so that the first flow 190 of the slurry can enter the first feed inlet 124; traveling through the first entry segment 136, the first shaped duct 141, and the distribution duct 128; and be discharged from the grout distributor 120 to through the distribution outlet 130.

The first shaped conduit 141 has a front outer curved wall 157 and an opposite rear inner curved wall 158 defining a curved guide surface 165 adapted to redirect the first slurry flow of the first feed flow direction 190, which is substantially parallel to the transverse direction or direction through the machine 60, to an output flow direction 192, which is substantially parallel to the longitudinal axis or direction of the machine 50 and substantially perpendicular to the first feed flow direction 190. The first Conduit duct 141 is adapted to receive the first slurry flow moving in the first feed flow direction 190 and redirect the slurry flow direction by a change in the steering angle a, as shown in FIG.9 , so that the first flow of slurry is transported in the distribution conduit 128 which moves substantially in the direction output flow 192.

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

For example, in the illustrated embodiment, the first slurry flow is redirected from the first feed flow direction 190 along the direction through the machine 60 through a change in the steering angle OI from about ninety. degrees around the vertical axis 55 to the output flow direction 192 along the machine direction 50. In some embodiments, the slurry flow can be redirected from a first feed flow direction 190 through a change in the steering angle about vertical axis 55 which is in a range up to about 135 ° to the outflow direction 192, and in other embodiments in a range from about 30 ° to about 135 °, and in still other embodiments in a range from about 45 ° to about 135 °, and in still other embodiments in a range from about 40 ° to 110 °.

In some embodiments, the shape of the rear curved guide surface 165 may be generally parabolic, which in the embodiment illustrated may be defined by a parabola of the form Ax2 + B. In alternative embodiments, higher order curves can be used to define the rear curved guide surface 165 or, alternatively, the rear inner wall 158 can have a generally curved shape that is composed of straight or linear segments that have been oriented in their ends to collectively define a generally curved wall. In addition, the parameters used to define the factors of specific shape of the outer wall may depend on specific operating parameters of the process in which the slurry distributor is used.

At least one of the feed conduit 122 and the distribution conduit 128 may include an area of expansion having a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area in a direction from the supply conduit 122 to the distribution conduit 128. The first segment inlet 136 and / or the first shaped duct 141 can have a cross section that varies along the flow direction to help distribute the first flow of slurry that moves through it. The shaped duct 141 can have a cross-sectional flow area that increases in a first flow direction 195 of the first feed inlet 124 to the distribution duct 128 so that the first slurry flow decelerates as it passes to Through the first shaped duct 141. In some embodiments, the first shaped duct 141 can have a maximum cross-sectional flow area at a predetermined point along the first flow direction 195 and decreases the maximum cross-sectional flow area at additional points along the first flow direction 195.

In some embodiments, the maximum cross-sectional flow area of the first shaped duct 141 is approximately 200% of the cross-sectional area of the opening 134 of the first feed inlet 124 or less. In still other modalities, the maximum flow area The cross-sectional area of the shaped duct 141 is approximately 150% of the cross-sectional area of the opening 134 of the first feed inlet 124 or less. In still other embodiments, the maximum cross-sectional flow area of the shaped duct 141 is approximately 125% of the cross-sectional area of the opening 134 of the first feed inlet 124 or less. In still other embodiments, the maximum cross-sectional flow area of the shaped duct 141 is approximately 110% of the cross-sectional area of the opening 134 of the first feed inlet 124 or less. In some embodiments, the cross sectional flow area is controlled so that the flow area does not vary more than a predetermined amount over a given length to help prevent large variations in the flow rate.

In some embodiments, the first inlet segment 136 and / or the first shaped duct 141 may include one or more guide channels 167, 168 that are adapted to assist in distributing the first flow of slurry to the exterior and / or interior walls 157 , 158 of the feed conduit 122. The guide channels 167, 168 are adapted to increase the flow of slurry around the boundary wall layers of the slurry distributor 120.

With reference to FIGS. 1 and 5, the channels of guide 167, 168 can be configured to have a larger cross-sectional area than an adjacent portion 171 of the feed conduit 122 defining a restriction that promotes flow to the adjacent guide channel 167, 168 positioned respectively in the wall region of the distributor of slurry 120. In the illustrated embodiment, the feed conduit 122 includes the outer guide channel 167 adjacent the outer wall 157 and the side wall 151 of the distribution conduit 128 and the inner guide channel 168 adjacent the interior wall 158. of the first shaped conduit 141. The cross-sectional areas of the outer and inner guide channels 167, 168 may progressively become mobile menors in the first flow direction 195. The outer guide channel 167 may extend substantially along from the side wall 151 of the distribution conduit 128 to the distribution outlet 130. In a cross-sectional location When given through the first shaped conduit 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 has a larger cross-sectional area than the interior guide channel 168 to help deflect the first flow of slurry. from its initial line of movement in the first feed direction 190 to the outer wall 157.

The proportion of guide channels adjacent to the Wall regions can help direct or guide the flow of slurry in regions, which can be areas in conventional systems where low-flow grout "dead spots" are found. By stimulating the flow of slurry in the wall regions of the slurry distributor 120 through the provision of guide channels, the accumulation of slurry inside the slurry distributor is degenerated and the cleaning of the interior of the slurry distributor 120 is it can be better. It is also possible to decrease the frequency of breakage of accumulation of slurry into pieces that can tear the mobile mesh of cover sheet material.

In other embodiments, the relative sizes of the outer and inner guide channels 167, 168 can be varied to help adjust the flow of slurry to improve flow stability and reduce the occurrence of phase separation of air-liquid slurry. . For example, in applications using a slurry that is relatively more viscous, at a given cross-sectional location through the first shaped conduit 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 may have a smaller cross-sectional area than the inner guide channel 168 to help push the first flow of slurry towards the inner wall 158.

The interior curved walls 158 of the first and second shaped ducts 141, 142 are to define a peak 175 adjacent an inlet portion 152 of the distribution duct 128. The peak 175 effectively bifurns the connector segment 139. Each feed outlet 140, 145 is in fluid communication with the inlet portion 152 of the distribution conduit 128.

The location of the peak of 175 along the longitudinal axis 50 may vary in other embodiments. For example, the inner curved walls 158 of the first and second shaped conduits 141, 142 may be less curved in other embodiments so that the peak 175 is further away from the distribution outlet 130 along the longitudinal axis 50 than as shown. shows in the illustrated grout distributor 120. In other embodiments, the peak 175 may be closer to the distribution outlet 130 along the longitudinal axis 50 than as shown in the illustrated grout 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 push the first and second combined streams of calcined aqueous slurry from the first and second shaped conduits 141, 142 in a flow pattern generally two-dimensional to improve stability and uniformity. The distribution outlet 130 has a width that extends a distance predetermined along the transverse axis 60 and a height extending along a vertical axis 55, which is mutually perpendicular to the longitudinal axis 50 and the transverse axis 60. The height of the distribution outlet 130 is small in relation to its width. The distribution conduit 128 can be oriented relative to a moving cover sheet mesh on a forming table so that the distribution conduit 128 is substantially parallel to the moving mesh.

The distribution conduit 128 extends generally along the longitudinal axis 50 and includes the inlet portion 152 and the distribution outlet 130. The inlet portion 152 is in fluid communication with the first and second feed inlets 124, 125 of the feed conduit 122. With reference to FIG. 5, the inlet portion 152 is adapted to receive the first and second flows of aqueous calcined gypsum slurry from the first and second feed inlets 124, 125 of the feed conduit 122. The inlet portion 152 of the distribution conduit 128 includes a distribution inlet 154 in fluid communication with the first and second supply outlets 140, 145 of the supply conduit 122. The illustrated distribution inlet 154 defines an opening 156 corresponding substantially to the openings 142 of the first and second exits of feed 140, 145. The first and second flows of calcined gypsum slurry are combined in distribution conduit 128 so that the combined flows generally move in the outflow direction 192 which can be substantially aligned with the flow line. movement of a mesh roof sheet material that moves on a training table in a gypsum board manufacturing line.

The distribution outlet 130 is in fluid communication with the inlet portion 152 and therefore the first and second supply inlets 124, 125 and the first and second supply outlets 140, 145 of the supply conduit 122. The distribution outlet 130 is in fluid communication with the first and second shaped ducts 141, 143 and is adapted to discharge the first and second combined slurry streams thereof along the outflow direction 192 into a cover sheet material mesh that advances along the direction of the machine 50.

With reference to FIG. 1, the illustrated dispensing outlet 130 defines a generally rectangular aperture 181 with narrow semi-circular ends 183, 185. The semi-circular ends 183, 185 of the aperture 181 of the dispensing outlet 130 may be the terminating end of the apertures. exterior guide channels 167 placed adjacent to the side walls 151, 153 of the distribution conduit 128.

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

For example, in some embodiments, the cross-sectional area of the opening 181 of the distribution outlet 130 may be in a range from greater than up to approximately 400% greater than the sum of the cross-sectional areas of the openings 134., 135 of the first and second feed inputs 124, 125, in a range from greater than up to approximately 200% higher than in other embodiments, and in a range from greater than up to approximately 150% higher in still other embodiments. In other embodiments, the ratio of the sum of the cross-sectional areas of the openings 134, 135 of the first and second feed inlets 124, 125 to the sectional area cross section of the opening 181 of the distribution outlet 130 can be varied based on one or more factors, including the speed of the manufacturing line, the viscosity of the slurry that is distributed by the distributor 120, the width of the panel product that was made with the distributor 120, etc. In some embodiments, the cross-sectional area of the opening 156 of the inlet portion 152 of the distribution conduit 128 may be in a range from greater than up to about 200% greater than the cross-sectional area of the outlet opening 181 of distribution 130, in a range from greater than approximately 150% greater than in other embodiments, and in a range from greater than approximately 125% greater in yet other embodiments.

The distribution outlet 130 extends substantially along the transverse axis 60. The opening 181 of the distribution outlet 130 has a width Wi from approximately 60.96 cm (twenty-four inches) along the transverse axis 60 and a height of Hi from approximately (2.54 cm) one inch along the vertical axis 55 (see FIG.3, too). In other embodiments, the size and shape of the opening 181 of the distribution outlet 130 can be varied.

The distribution outlet 130 is positioned intermediate along the transverse axis 60 between the first power inlet 124 and second power inlet 125 so that the first feed inlet 124 and the second feed inlet 125 are placed substantially at the same distance Di, D2 from a transverse center midpoint 187 of the distribution outlet 130 (See FIG.3, too). The distribution outlet 130 can be made of an elastically flexible material so that its shape is adapted to be variable along the transverse axis 60, such as by the profiling system 32, for example.

It is contemplated that the width Wi and / or the height Hi of the opening 181 of the distribution outlet 130 may be varied in other embodiments for different operating conditions. In general, the general dimensions of the various embodiments of the slurry dispensers as described herein can be scaled up or down depending on the type of product being manufactured (for example, the thickness and / or width of the manufactured product). ), the speed of the manufacturing line that is used, the speed of deposition of the slurry through the distributor, the viscosity of the slurry, and the like. For example, the width Wi, along the transverse axis 60, of the distribution outlet 130 for use in a gypsum panel manufacturing process, which is conventionally provided in nominal widths no greater than 137.16 cm (fifty-four inches), can be within a range of from about 20.32 cm to about 137.16 cm (eight to about fifty-four inches) in some embodiments, and in other embodiments within a range from about 45.72 to about 76.2 cm ( eighteen to about thirty inches). In other embodiments, the ratio of the width Wi, along the transverse axis 60, of the distribution outlet 130 to the maximum nominal panel width that occurs in the manufacturing system using the grout distributor constructed in accordance with The principles of the present disclosure may range from about 1/7 to about 1, in a range from about 1/3 to about 1 in other embodiments, in a range from about 1/3 to about 2/3 in others. modes, and in a range from about 1/2 to about 1 in still other modalities.

The height of the dispensing outlet may be within a range from about 0.47 cm (3/16 inch) to about 5.08 cm (two inches) in some embodiments, and in other embodiments between about 0.47 cm (3/16 inch) ) and approximately 2.54 cm (one inch). In some modalities that includes a rectangular distribution outlet, the ratio of the width rectangular at the rectangular height of the exit opening may be approximately 4 or more, in other embodiments approximately 8 or more, in some embodiments from approximately 4 to approximately 288, in other embodiments from approximately 9 to approximately 288, in other embodiments from approximately 18 to about 288, and still in other embodiments from about 18 to about 160.

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

The converging portion 182 and the height of the distribution outlet 130 can cooperate together to help control the average velocity of the first and second combined flows of aqueous calcined gypsum that is distributed from the distribution conduit 128. The height and / or width of the distribution output 130 can be varied to adjust the average speed of the first and second flows combined grout that is discharged from the grout distributor 120.

In some embodiments, the outflow direction 192 is substantially parallel to the plane 57 defined by the machine direction 50 and the transverse direction through the machine 60 of the system carrying the advancing mesh of the cover sheet material. In other embodiments, the first and second feed directions 190, 191 and the outflow direction 192 are all substantially parallel to the plane 57 defined by the machine direction 50 and the transverse direction through the machine 60 of the system that transports the advancing mesh of cover sheet material. In some embodiments, the slurry distributor can be adapted and positioned with respect to the forming table so that the slurry flow is redirected in the slurry distributor 120 of the first and second feed directions 190, 191 to the direction of output flow 192 without undergoing substantial flow redirection by rotating around the address through the machine 60.

In some embodiments, the slurry distributor can be adapted and arranged with respect to the forming table so that the first and second slurry streams are redirected in the slurry distributor of the first and second feed directions 190, 191 to the outflow direction 192 by redirecting the first and second slurry flows by rotating around the direction through the machine 60 at an angle from about forty-five degrees or less. Such rotation can be performed in some embodiments by adapting the slurry distributor so that the first and second feed inlets 124, 125 and first and second feed directions 190, 191 of the first and second slurry flows are placed at an angle vertical offset w with respect to the vertical axis 55 and the plane 57 formed by the axis of the machine 50 and the axis through the machine 60. In embodiments, the first and second feed inputs 124, 125 and the first and second directions of feed 190, 191 of the first and second slurry flows can be placed at a vertical offset angle w within a range of zero to about sixty degrees so that the slurry flow is redirected around the axis of the machine 50 and moves along the vertical axis 55 in the grout distributor 120 of the first and second feed directions 190, 191 to the output flow direction 192. In fashion At least one of the respective inlet segments 136, 137 and the shaped ducts 141, 143 can be adapted to facilitate redirection of the slurry around the axis of the machine 50 and along the vertical axis 55. In embodiments, the first and second Slurry flows can be redirected from the first and second feed directions 190, 191 through a change in the steering angle to about an axis substantially perpendicular to the vertical offset angle w and / or one or more other axes of rotation within an interval from about forty-five degrees to about one hundred fifty degrees with respect to the outlet flow direction 192 so that the outlet flow direction 192 is generally aligned with the machine direction 50.

In use, the first and second flows of calcined gypsum slurry pass through the first and second feed inlets 124, 125 in the first and second converging feed directions 190, 191. The first and second shaped ducts 141, 143 the first and second slurry streams of the first feed direction 190 and the second feed direction 191 are redirected so that the first and second slurry streams move on a change in the steering angle a of both which is substantially parallel to the transverse axis 60 so that both substantially parallel to the machine direction 50. The distribution conduit 128 can be positioned so that it extends along the longitudinal axis 50 which substantially coincides with the direction of the machine 50 along of which a mesh of Cover sheet material moves in a method that produces a drywall. The first and second aqueous slurry fluxes of calcined gypsum are combined in the slurry distributor 120 so that the first and second combined streams of calcined gypsum slurry pass through the distribution outlet 130 in the outflow direction 192 generally along the longitudinal axis 50 and in the direction of the machine direction.

With reference to FIG. 2, a slurry distributor support 100 can be provided to assist in supporting the slurry distributor 120, which in the illustrated embodiment is made of a flexible material, such as PVC or urethane, for example. The slurry distributor support 100 can be made of a suitable rigid material to assist in supporting the flexible slurry distributor 120. The slurry distributor support 100 can include a two-piece construction. The two parts 101, 103 can be pivotally movable relative to each other around a hinge 105 at the rear end thereof to allow easy access to an interior 107 of the support 100. The interior 107 of the support 100 can be configured so that the interior 107 substantially fits the exterior of the grout distributor 120 to help limit the amount of movement of the slurry distributor 120 which may suffer with respect to support 100 and / or to help define the interior geometry of slurry distributor 120 through which a slurry will flow.

With reference to FIG. 3, in some embodiments, the slurry distributor support 100 can be made from a suitable resilient flexible material that provides support and is capable of being deformed in response to the shaping system 132 mounted on the support 100. Shaping system 132 can be mounted to support 100 adjacent distribution outlet 130 of slurry distributor 120. Shaping system 132 thus installed can act to vary the size and / or shape of distribution outlet 130 of the supply duct 130. distribution 128 also varying the size and / or shape of the closely shaped support 100, which in turn, influences the size and / or shape of the distribution outlet 130.

With reference to FIG. 3, the profiling system 132 can be adapted to selectively change the size and / or shape of the opening 181 of the distribution outlet 130. In some embodiments, the profiling system can be used to adjust selectively the height Hi of the opening 181 of the distribution outlet 130.

The illustrated profiling system 132 includes a plate 90, a plurality of mounting screws 92 that they secure the plate to the distribution conduit 128, and a series of adjustment screws 94, 95 threadably secured thereto. The mounting screws 92 are used to secure the plate 90 to the support 100 adjacent to the distribution outlet 130 of the slurry distributor 120. The plate 90 extends substantially along the transverse axis 60. In the illustrated embodiment, the plate 90 It is in the shape of an angular iron length. In other embodiments, the plate 90 may have different shapes and may comprise different materials. In still other embodiments, the profiling system may include other components adapted to selectively change the size and / or shape of the opening 181 of the distribution outlet 130.

The illustrated profiling system 132 is adapted to vary locally along the transverse axis 60 the size and / or shape of the opening 181 of the distribution outlet 130. The adjusting screws 94, 95 are in regular spaced relation to each other. along the transverse axis 60 on the distribution outlet 130. The adjustment screws 94, 95 are independently adjustable to vary locally the size and / or shape of the distribution outlet 130.

The profiling system 132 can be used to locally vary the distribution outlet 30 to alter the flow pattern of the first and second combined flows of calcined gypsum slurry which is distributed from the slurry distributor 120. For example, the mid-line adjusting screw 95 can be tightened to contract the transverse center mid-point 187 of the distribution outlet 130 to increase the flow angle of edge away from the longitudinal axis 50 to facilitate extension in the direction through the machine 60 and to improve the flow uniformity of the slurry in the direction through the machine 60.

The profiling system 132 may be used to vary the size of the distribution outlet 130 along the transverse axis 60 and maintain the distribution outlet 130 in the new shape. The plate 90 can be made of a material that is suitably strong, so that the plate 90 can withstand the opposing forces exerted by the adjusting screws 94, 95 in response to the adjustments made by the adjusting screws 94, 95 urging the distribution output 130 in a new way. The profiling system 132 can be used to help equalize variations in the grout flow profile (e.g., as a result of different grout densities and / or different feed inlet rates) that is discharged from the outlet distribution 130 so that the outlet pattern of the grout of the distribution duct 128 is more uniform.

In other embodiments, the number of adjustment screws may be varied so that the spacing between the adjacent adjustment screws changes. In other embodiments, such as when the width Wi of the distribution outlet 130 is different, the number of adjustment screws may also be varied to achieve a desired adjacent screw spacing. In still other embodiments, the spacing between the adjacent screws may vary along the transverse axis 60, for example to provide greater locally variable control at the lateral edges 183, 185 of the distribution outlet 130.

A slurry distributor constructed in accordance with the principles of the present disclosure can comprise any suitable material. In some embodiments, a slurry distributor may comprise any suitable substantially rigid material which may include a suitable material that may allow the size and shape of the outlet to be modified using a profile system, for example. For example, a suitably rigid plastic, such as ultra high molecular weight (UHMW) plastic, or metal can be used. In other embodiments, a slurry distributor constructed in accordance with the principles of the present disclosure can be made of a flexible material, such as a suitable flexible plastic material, including polyvinyl chloride (PVC) or urethane, for example. In some embodiments, a slurry distributor constructed in accordance with the principles of the present disclosure may include a single feed inlet, inlet segment, and shaped duct that is in fluid communication with a distribution duct.

A gypsum slurry distributor constructed in accordance with the principles of the present disclosure can be used to help provide wide distribution through the calcined gypsum slurry machine to facilitate the spreading of high viscous / low gypsum slurries. WSR in a mesh cover sheet material that moves on a training table. The gypsum slurry distribution system can be used to help control the separation of air-slurry phases, as well.

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

The slurry distributor may comprise a portion of, or act as a discharge conduit for a conventional gypsum slurry mixer (e.g., a needle mixer) as is known in the art. The grout distributor can be used with components of a conventional discharge duct. For example, the slurry distributor may be used with components of a gate-container-hopper arrangement as is known in the art or of the discharge chute arrangements that are described in U.S. Patent Nos. 6,494,609; 6,874,930; 7,007,914; and 7,296,919.

A slurry distributor constructed in accordance with the principles of the present disclosure can advantageously be configured as a modification in an existing gypsum panel manufacturing system. The slurry dispenser can preferably be used to replace a conventional single or multiple branching hopper used in conventional discharge ducts. This gypsum slurry distributor can be modified to an existing slurry discharge duct arrangement, such as that shown in U.S. Patent No. 6,874,930 or 7,007,914, for example, as a replacement for the spout or distal distribution hopper. However, in some embodiments, the slurry distributor, alternatively, may be attached to one or more outlets of the hopper.

With reference to FIGS.4 and 5, the slurry distributor 220 is similar to the slurry distributor 120 of FIGS. 1-3, except that it is constructed of a substantially rigid material. The interior geometry 207 of the slurry distributor 220 of FIGS. 4 and 5 is similar to that of the slurry distributor 120 of FIGS. 1-3, and similar reference numbers are used to indicate the similar structure. The interior geometry 207 of the slurry distributor 207 is adapted to define a flow path of the gypsum slurry traveling through it which is in the manner of a laminar flow, which is subjected to reduced or substantially no phase separation of air-liquid slurry and substantially without undergoing a vortex flow path.

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

With reference to FIG. 4, the distributor of Grout 220 has a two-piece construction. An upper part 221 of the grout distributor 220 includes a recess 227 adapted to receive a profiling system 132 therein. The two parts 221, 223 can be pivotally movable relative to each other around a hinge 205 at the rear end thereof to allow easy access to an interior 207 of the grout distributor 220. The mounting holes 229 are provided for facilitating the connection of the upper part 221 and its lower coupling part 223.

With reference to FIGS. 6-8, another embodiment of a grout distributor 320 constructed in accordance with the principles of the present disclosure is shown which is constructed of a rigid material. The grout distributor 320 of FIGS. 6-8 is similar to the grout distributor 220 of FIGS. 4 and 5, except that the first and second feed inlets 324, 325 and the first and second inlet segments 336, 337 of the slurry distributor 320 of FIGS. 6-8 are positioned at a feed angle Q with respect to the longitudinal axis or machine direction 50 from about 60 ° (see FIG. 7).

The grout distributor 320 has a two-piece construction that includes an upper piece 321 and its lower coupling piece 323. The two pieces 321, 323 of the grout distributor 320 can be secured between yes using any suitable technique, such as using fasteners through a corresponding number of mounting holes 329 provided in each piece 321, 323, for example. The upper part 321 of the grout distributor 320 includes a recess 327 adapted to receive a profiling system 132 therein. The grout distributor 320 of FIGS. 6-8 is similar in other aspects to the slurry distributor 220 of FIGS. 4 and 5.

With reference to FIGS.9 and 10, the lower piece 323 of the grout distributor 320 of FIG. 6. The lower part 323 defines a first portion 331 of the interior geometry 307 of the grout distributor 320 of FIG. 6. The upper piece 323 defines a second symmetrical portion of the inner geometry 307 so that when the upper and lower pieces 321, 323 are coupled together, as shown in FIG. 6, they define the complete interior geometry 307 of the distributor of grout 320 of FIG.6.

With reference to FIG. 9, the first and second shaped conduits 341, 343 are adapted to receive the first and second slurry flows that move in the first and second feed flow directions 390, 391 and redirect the flow direction of slurry by a change in the steering angle a such that the first and second slurry flows are transported in the distribution conduit 328 that moves substantially in the outflow direction 392, which is aligned with the machine direction or longitudinal axis 50.

FIGS.11 and 12 represent another embodiment of a grout distributor support 300 for use with the grout distributor 320 of FIG. 6. The grout distributor support 300 may include a top and bottom support plate 301, 302 constructed of a suitably rigid material, such as metal, for example. The support plates 301, 302 can be secured to the dispenser by any suitable means. In use, the support plates 301, 302 can help support the grout distributor 320 in place on a machine line that includes a conveyor assembly that supports and transports a movable cover sheet. The support plates 301, 302 can be mounted on appropriate posts positioned on either side of the conveyor assembly.

FIGS. 13 and 14 still represent another embodiment of a slurry distributor support 310 for use with the slurry distributor 320 of FIG. 6, which also includes upper and lower support plates 311, 312. The cutouts 313, 314, 318 on the upper support plate 311 can make the support 310 lighter than it would otherwise be and provide access to portions of the support. grout distributor 320, such as the portions that They house mounting fasteners, for example. The grout distributor support 310 of FIGS. 13 and 14 may be similar in other respects to the grout distributor support 300 of FIGS. 11 and 12.

FIGS. 15-19 illustrate another embodiment of a slurry distributor 420, which is similar to the slurry distributor 320 of FIGS. 6-8, except that it is constructed of a substantially flexible material. The grout distributor 420 of FIGS. 15-19 also includes first and second feed inlets 324, 325 and first and second inlet segments 336, 337 that are positioned at a feed angle Q with respect to the longitudinal axis or machine direction 50 from about 60 ° (see FIG.7). The interior geometry 307 of the grout distributor 420 of FIGS. 15-19 is similar to that of the grout distributor 320 of FIGS.6-8, and similar reference numbers are used to indicate similar structure.

FIGS. 17-19 progressively depict the inner geometry of the second inlet segment 337 and the second shaped duct 343 of the slurry distributor 420 of FIGS.15 and 16. The cross-sectional areas 411, 412, 413, 414 of the guide channels external and internal 367, 368 may become progressively smaller moving in a second flow direction 397 towards the distribution outlet 330. The guide channel outer 367 may extend substantially along the outer wall 357 of the second shaped duct 343 and along the side wall 353 of the distribution duct 328 to the distribution outlet 330. The inner guide channel 368 is adjacent to the wall 358 of the second shaped duct 343 and ends at the peak 375 of the bisected connector segment 339. The slurry distributor 420 of FIGS.15-19 is similar in other respects to the slurry distributor 120 of FIG.1 and the distributor of grout 320 of FIG.6.

With reference to FIGS. 20 and 21, the illustrated embodiment of the slurry distributor 420 is made of a flexible material, such as PVC or urethane, for example. A grout distributor support 400 may be provided to assist in supporting the grout distributor 420. The grout distributor support 400 may include a support member, which in the illustrated embodiment is in the form of a lower support tray 401 filled with a suitable support means 402 defining a support surface 404. The support surface 404 is configured to substantially conform to at least a portion of an exterior of at least one of the supply conduit 322 and the distribution conduit 328 for help limit the amount of relative movement between the grout distributor 420 and the support tray 401. In some embodiments, the support surface 404 may also help maintain the interior geometry of the slurry distributor 420 through which a slurry will flow.

The grout distributor bracket 400 may also include a movable support assembly 405 placed in spaced relationship with the lower support tray 401. The movable support assembly 405 may be placed above the grout distributor 420 and adapted to be placed in relation of support with the grout distributor 420 to help maintain the interior geometry 307 of the grout distributor in a desired configuration.

The movable support assembly 405 may include a support frame 407 and a plurality of support segments 415, 416, 417, 418, 419 that are movably supported by the support frame 407. The support frame 407 may be mounted in at least one of the lower support tray 401 or a post or poles suitably arranged to retain the support frame 407 in fixed relation to the lower support tray 401.

In embodiments, at least one support segment 415, 416, 417, 418, 419 is independently movable relative to another support segment 415, 416, 417, 418, 419. In the illustrated embodiment, each support segment 415, 416 , 417, 418, 419 can be independently movable relative to the support frame 407 in a range of travel predetermined. In modalities, each support segment 415, 416, 417, 418, 419 is movable in a range of travel so that each support segment is in a range of positions over which the respective support segment 415, 416, 417, 418, 419 is in compressive engagement enhanced with a portion of at least one of the supply conduit 322 and the distribution conduit 328.

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 compressive engagement with at least a portion of the slurry distributor 420. Each support segment 415, 416, 417, 418, 419 it can be independently adjusted to position each support segment 415, 416, 417, 418, 419, either in additional compressive engagement with at least a portion of the slurry distributor 420, locally compressing the interior of the slurry distributor 420, or in coupling compressive reduced with at least a portion of the slurry distributor 420, thereby allowing the interior of the slurry distributor 420 to expand outwardly, such as in response to the aqueous gypsum slurry flowing therethrough.

In the illustrated embodiment, each of the support segments 415, 416, 417 is movable in a range of travel along the vertical axis 55. In others At least one of the support segments can be mobile along a different line of action.

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

In the illustrated embodiment, a bar 409 is mounted on each support segment 415, 416, 417, 418, 419 and extends upward through a corresponding opening in the support frame 407. Each fastening mechanism 408 is mounted on the support frame 407 and associated with one of the bars 409 protruding from a respective support segment 415, 416, 417, 418, 419. Each fastening mechanism 408 can be adapted to selectively retain the associated bar 409 in fixed relation with the support frame 407. The illustrated fastening mechanisms 408 are conventional lever-operated clamps surrounding the respective bar 409 and permit infinitely variable adjustment between the clamping mechanism 408 and the associated bar 409.

As an expert in the art will appreciate, any suitable fixing mechanism 408 can be used in other embodiments. In some embodiments, each associated bar 409 it can be moved through a suitable actuator (either hydraulic or electric, for example) that is controlled through a controller. The actuator can function as a clamping mechanism by retaining the associated support segment 415, 416, 4 7, 418, 419 in a fixed position with respect to the support frame 407.

With reference to FIG. 21, the support segments 415, 416, 417, 418, 419 may each include a contact surface 501, 502, 503, 504, 505 which is configured to substantially conform to a portion of the surface of the desired geometric shape of at least one of the supply conduit 322 and the distribution conduit 328 of the slurry distributor 420. In the illustrated embodiment, a distributor conduit support segment 415 is provided which includes a contact surface 501 that conforms to the outer shape and inside a portion of the distributor conduit 328 on which the distributor conduit support segment 415 is positioned. A pair of shaped conduit support segments 416, 417 are provided, which respectively include a contact surface 502 , 503 which conforms to the outer and inner shape of a portion of the first and second shaped conduits 341, 343, respectively, on which the supporting segments are placed. e of shaped duct 416, 417. A pair of segments of input holder 418, 419 which include, respectively, a contact surface 504, 505 that conforms to the outer and inner shape of a portion of the first and second input segments 336, 337, respectively, on which are placed the Conduit conduit support segments 418, 419. The contact surfaces 501, 502, 503, 504, 505 are adapted to be placed in contact relation with a selected portion of the slurry distributor 420 to help maintain the contact portion of the slurry distributor 420 in position to help define the interior geometry 307 of the slurry distributor. 420 In use, the movable support assembly 405 can be operated to position each support segment 415, 416, 417, 418, 419 independently in a desired ratio with the slurry distributor 420. The support segments 415, 416, 417, 418, 419 can help maintain the interior geometry 307 of the slurry distributor 420 to promote the slurry flow to through these and to help ensure that the volume defined by the interior geometry 307 is substantially filled with the slurry during use. The location of the particular contact surface of a given support segment 415, 416, 417, 418, 419 can be adjusted to locally modify the interior geometry of the slurry distributor 420. For example, the distributor conduit support segment 415 You can move it along the vertical axis 55 closer to the lower support tray 401 to decrease the height of the distribution conduit 328 in an area on which the distributor conduit support segment 415 is.

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.

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

The slurry distributor 1420 includes a bifurcated feed line 1422, a distribution pipe 1428, a grout cleaning mechanism 1417, and a profiling mechanism 1432. A grout distributor support 1400 can be provided to help support the distributor of grout 1420.

With reference to FIGS.22 and 23, the support of Slurry distributor 1400 may include a support element, which in the illustrated embodiment is in the form of a lower support member 1401 defining a support surface 1402. Support surface 1402 may be configured to substantially conform to at least one portion of an exterior of at least one of the supply duct 1422 and the distribution duct 1428 to help limit the amount of relative movement between the slurry distributor 1420 and the lower support member 1401. In some embodiments, the supporting surface 1402 can also help maintain the interior geometry of the slurry distributor 1420 through which a slurry will flow. In embodiments, the additional anchoring structure can be provided to help secure the slurry distributor 1420 to the lower support member 1401.

The grout distributor support 1400 may also include an upper support member 1404 positioned in spaced relation with the lower support member 1401. The upper support member 1404 may be placed on top of the grout distributor 1420 and adapted to be placed in relation of support with the grout distributor 1420 to help maintain the interior geometry 1407 of the grout distributor 1420 in a desired configuration.

The upper support member 1404 may include a support frame 1407 and a plurality of support segments 1413, 1415, 1416 that are fixedly supported by the support frame 1407. The support frame 1407 may be mounted on at least one of the element bottom support 1401 or one or more posts suitably arranged to retain the support frame 1407 in fixed relation to the lower support tray 1401. The support segments 1413, 1415, 1416 may each have a contact surface that is configured to adapt substantially a portion of the surface of the desired geometric shape of at least one of the supply duct 1422 and the distribution duct 1428 of the slurry distributor 1420. In embodiments, the support frame 1407 can be adapted to moveably adjust the spatial relationship between the support segments 1413, 1415, 1416 and the grout distributor 1420. For example, in some embodiments, the frame The support segment 1407 can move the support segments 1413, 1415, 1416 in a range of travel on the vertical axis 55.

With reference to FIG. 22, the grout cleaning mechanism 1417 includes a pair of actuators 1510, 1511 operatively arranged with a wiper blade 1514 to selectively reciprocate the wiper blade 1514. The actuators 1510, 1511 are mounted on the lower support member 1401 adjacent to a wiper blade 1514. distal end 1515 of the distribution duct 1428. The cleaning sheet 1514 extends transversely between the actuators 1510, 1511.

With reference to FIG. 26, the distribution outlet 1430 includes an outlet opening 1481 having a width W2, along the transverse axis 60. The cleaning sheet 1514 extends a predetermined width distance W3 along the transverse axis 60. The width W2 of the outlet opening 1481 is smaller than the width W3 of the cleaning sheet 1514 so that the cleaning sheet 1514 is wider than the exit opening 1481.

With reference to FIG. 28, in the illustrated embodiments, each actuator 1510, 1511 comprises a double-acting pneumatic cylinder having a reciprocally mobile piston 1520. A rod 1522 of the piston 1520 is connected to the cleaning blade 1514. In embodiments, a pair of air lines pneumatic can be respectively connected to a pulse port 1525 and a retraction port 1526. A source of pressurized gas 1530 can be controlled using a suitable control valve assembly 1532 controlled by a controller 1534 to selectively reciprocally move the cleaning sheet 1514 to along the longitudinal axis 50. In embodiments, an air line may link the pulse ports 1525 of both actuators 1510, 1511 together in parallel, and a separate air line may join the retraction ports 1526 of both actuators 1510, 1511 together parallel. In other embodiments, the actuators may be anything capable of reciprocally moving the wiper blade, including, for example, hand operated devices.

The mobile wiper blade 1514 is in contact relation with a lower surface 1540 of the distribution duct 1428. The wiper blade 1514 is reciprocally movable on a cleaning path between a first position and a second position (shown in broken lines). The cleaning path is positioned adjacent the distal end 1515 of the delivery conduit 1428 including the dispensing outlet 1430. The cleaning sheet reciprocates longitudinally along the cleaning path. In the illustrated embodiment, the first position of the cleaning sheet 1514 is longitudinally upstream of the distribution outlet 1430, and the second position is longitudinally downstream of the distribution outlet 1430.

The controller 1534 is adapted to selectively control the actuators to reciprocally move the cleaning sheet 1514. In embodiments, the controller 1534 is adapted to move the cleaning sheet 1514 in a cleaning direction 1550 from the first position to the second position in a stroke of cleaning and to move the cleaning sheet in an opposite return direction 1560 from the second position to the first position in a return stroke. In embodiments, the controller 1534 is adapted to move the cleaning sheet 1514 so that the time to move in the cleaning stroke is substantially the same as the time to move in the return stroke.

In embodiments, the controller 1534 can be adapted to move the cleaning sheet 1514 reciprocally between the first position and the second position in a cycle having a cleaning period. The cleaning period includes a cleaning portion comprising the time to move in the cleaning stroke, comprising a return portion comprising the time to move in the return stroke, and an accumulation delay portion comprising a period of predetermined time in which the cleaning sheet 1514 remains in the first position. In embodiments, the cleaning portion is substantially the same as the return portion. In embodiments, the controller 534 is adapted to vary the accumulation delay portion in an adjustable manner.

With reference to FIG. 34, the lower support member 1401 supporting the lower surface of the distribution conduit 1428 includes a perimeter 1565. The distribution outlet 1430 is longitudinally displaced from the lower support member 1401 so that the outlet portion distal 1515 of distribution conduit 1428 extends from perimeter 1565 of lower support member 1401. Referring again to FIG. 28, the cleaning sheet 1514 supports the distal exit portion 1515 of the slurry distributor 1420 when the cleaning sheet is in the first position.

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

With reference to FIGS. 26, 30A and 30B, the profiling member 1610 is movable in a range of travel such that the profiling member 1610 is in a range of positions over which the profiling member 1610 is in compressive engagement enhanced with a portion of the conduit of distribution 1428 adjacent to distribution outlet 1430 to vary the shape and / or size of outlet opening 1430.

With reference to FIG. 26, the outlet opening 1481 of the distribution outlet 1430 has a width W2 along the transverse axis 60. The contact profiling segment of the profiling member 1410 has a width W4 extending a predetermined distance along the transverse axis. In embodiments, the width W2 of the outlet opening 1481 is larger than the width W4 of the profiling member 1410. In other embodiments, the width W2 of the exit opening 1481 is less than or equal to the width W4 of the delivery member. profiled 1410. Profiling member 1410 is positioned so that a pair of side portions 1631, 1632 of distribution outlet 1430 is in laterally offset relation to profiling member 1410 so that the profiling member does not engage lateral portions 1631 , 1632. In some embodiments, the side portions 1631, 1632 may have a combined width from about a quarter of the width W2 the exit opening 1481.

With reference to FIG. 23, the support assembly 1620 includes a pair of fixed posts 1642, 1643, a fixed transverse support member 1645, and a transverse pivoting support member 1647 that is pivotally connected to the fixed support member. cross section 1645 using any suitable pivoting connection. Fixed posts 1642, 1643 can be mounted on the lower support element 1401. The transverse fixed support element 1645 can be extended transversely between the fixed posts 1642, 1643.

With reference to FIGS. 29, 30A, 30B, and 31, the pivoting support member 1647 can rotate about the pivot axis 1630 over an arc length 1652 with respect to the fixed support member 1645. In embodiments, the length of arc 1652 allows the inclination of a pivot end 1653 of pivoting support member 1647, both upwardly above transverse axis 60 and downwardly below transverse axis 60. Pivoting support member 1647 supports profiled member 1610.

In embodiments, the profiling member 1610 is movable along the vertical axis 55 and can rotate about the pivot axis 1630 which is substantially parallel to the longitudinal axis 50. The profiling member 1610 can rotate about the pivot axis 1630 on the arc length 1652 so that the profiling member 1610 is in a range of positions over which the profiling member is in variable compressive engagement with the portion of the distribution conduit 1428 through the transverse axis 60 so that the height ¾ of the outlet opening 1481 varies along the transverse axis 60.

With reference to FIGS. 29 and 33, the profiling member 1610 includes a coupling segment 1660 extending generally longitudinally and transversely and a translation adjustment bar 1662 extending generally vertically from the coupling segment 1660. The translation adjustment bar 1662 of the profiling member 1610 is movably secured to the pivoting support member 1647 of the support assembly 1620 so that the profiling member 1610 is movable along the vertical axis 55 in a range of vertical positions. A pair of translation guide bars 1663, 1665 is connected to the coupling segment 1660 and extends through a respective collar 1667, 1668 mounted on the pivoting support member 1647. The guide bars 1663, 1665 are movable relative to to collars 1667, 1668 along vertical axis 55.

The support assembly 1620 may include a clamping mechanism adapted to selectively couple the translation adjustment bar 1662 to secure the profiled member 1610 in one of the range of selected vertical positions. In the illustrated embodiment, a threaded connection between the translation adjustment bar 1662 and the pivoting support member 1647 functions as a clamping mechanism. A locking nut 1664 is provided to secure the threaded translation adjustment rod 1662 in place. An elastic nut 1666 is positioned near a distal end 1657 of the translation adjustment bar 1662 to maintain sufficient space for a 1669 head screw (see FIG.30D) attached to the distal end to be allowed to rotate. With reference to FIG. 30D, a blind hole 1658 is defined in the profiling member of 1610 to adapt the head screw 1669 to allow the head screw to rotate about the axis of the translation adjustment bar 1662.

With reference to FIGS.30C and 31, the support assembly 1620 can be adapted to rotatably support the profiling member 1610 so that the profiling member 1610 is rotatable about the pivot axis 1630 in a range of positions a along the arc length 1652. The support assembly 1620 includes a rotation adjustment bar 1670 extending between the fixed support member 1645 and the pivoting support member 1647 by means of a support bracket 1672 connected to the element of fixed support 1645 (see FIG.31 as well). The rotation adjustment bar 1670 is movably secured to the fixed support member 645 through a threaded connection with the support bracket 1672 so that the movement of the rotation adjustment rod 1670 with respect to the fixed support element 1645, by rotating its T-handle, pivots the pivoting support member 1647 about the pivot shaft 1630 with respect to the fixed support member 1645. The support bracket 1672 can be configured so that some flexing can be allowed during a tilting operation. The shaft collars 1673, 1674 can be provided for greater reliability.

The support assembly 1620 may include a clamping mechanism adapted to selectively couple the rotation adjustment bar 1670 to secure the profiling member 1610 in one of the range of selected positions along the arc length 1652. In the illustrated embodiment , a locknut 1677 can be provided to lock the threaded bar 670 to the cylindrical nut 1679.

With reference to FIGS.34 and 40, the bifurcated feed conduit 1422 of the slurry distributor 1420 includes a first and second feed portion 1701, 1702. Each of the first and second feed portions 1701, 1702 has a segment of respective input 1436, 1437 with a power inlet 1424, 1425 and a power inlet outlet 1710, 1711 in fluid communication with the power inlet 1424, 1425, a shaped duct 1441, 1443 has a bulb portion 1720, 1721 ( see FIG. 41 as well) in fluid communication with the power input output 1710, 1711 of the respective input segment 1436, and a transition segment 1730, 1731 in fluid communication with the respective bulb portion 1720, 1721.

With reference to FIG. 34, the first and second power inlets 1424, 1425 and the first and second inlet segments 1436, 1437 can be placed at a respective feed angle Q, measured as the degree of rotation with respect to the vertical axis 55, in a range of up to about 135 ° with with respect to the longitudinal axis 50. The first and second illustrated feed inlets 1424, 1425 and the first and second inlet segments 1436, 1437 are positioned at a respective feed angle Q substantially aligned with the longitudinal axis 50.

The first feed portion 1701 is substantially identical to the second feed portion 1702. It should be understood, therefore, that the description of one feed portion is equally applicable to the other feed portion, as well. In other embodiments there may be a single feeding portion or in still further embodiments there may be more than two feeding portions.

With reference to FIG.35, the input segment 1436 is generally cylindrical and extends along a first supply flow axis 1735. The first supply flow axis 1735 of the illustrated input segment 1436 generally extends to along the vertical axis 55.

In other embodiments, the first feed flow axis 1735 may have a different orientation with respect to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. For example, in other embodiments, the The first supply flow axis 1735 can be placed at a feeding passage angle a, measured as the degree of rotation with respect to the transverse axis 60, which is not perpendicular to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60 In embodiments, the pitch angle s, measured from the longitudinal axis 50 in a direction opposite to the machine direction 92 upwardly from the vertical axis 55 as shown in FIG. 35, can be anywhere in a range from about zero to about one hundred thirty-five degrees, from about fifteen to about one hundred twenty degrees in other embodiments, from about thirty to about one hundred and five degrees in yet other embodiments, from about forty-five to about one hundred and five degrees in still others modalities, and from approximately seventy-five to approximately one hundred and five degrees in other modalities. In other embodiments, the first feed flow axis 1735 can be positioned at a feed roller angle, measured as the degree of rotation with respect to the longitudinal axis 50, which is not perpendicular to the plane 57 defined by the longitudinal axis 50 and The transversal axis 60.

With reference to FIG. 34, the shaped duct 1441 includes a pair of side walls 1740, 1741 and the bulb portion 1720. The shaped duct 1441 is in fluent communication with the power input output 1711 of the input segment 1436. With reference to FIG. 35, the bulb portion 1720 is configured to reduce the average speed of a slurry flow that moves from the input segment 1436 through the bulb portion 1720 to the transition segment 1730. In embodiments, the bulb portion 1720 is configured to reduce the average speed of a slurry flow that moves from the input segment 1436 through the bulb portion 1720 to the transition segment 1730 by at least twenty percent.

With reference to FIGS. 45-47, the bulb portion 1720 has an expansion area 1750 with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area with respect to a direction of flow 1752 of the feed inlet 1424 towards the distribution outlet 1430 of the distribution conduit 1428. In embodiments, the bulb portion 1720 has a region 1752 with a cross-sectional area in a plane perpendicular to the first flow axis 1735 that is greater than the cross-sectional area of the power input output 1711.

The shaped duct 1441 has a convex inner surface 1758 in relation to the outlet inlet inlet 1711 of inlet segment 1436. Bulb portion 1720 has a generally radial guide channel 1460 positioned adjacent to the convex inner surface. The guide channel 1460 is configured to promote radial flow in a plane substantially perpendicular to the first supply flow axis 1735. With reference to FIG. 45, the convex inner surface 1758 is configured to define a central restriction 1762 in the flow path which also helps to increase the average speed of the slurry in the radial guide channel 1760.

The shaped duct 1441 can be configured such that a slurry flow moving through a region adjacent the convex inner surface 1758 and adjacent to at least one of the side walls 1740, 741 towards the distribution outlet 1430 has a swirl movement (Sm) from about zero to about 10, up to about 3, in other embodiments, and from about 0.5 to about 5 in still other embodiments. In embodiments, the flow of slurry moving through the region adjacent the convex inner surface 1758 and adjacent to at least one of the side walls 1740, 1741 toward the distribution outlet 1430 has a swirl angle (Sm) from about 0 to about 84 ° and from about 10 ° to about 80 ° in other embodiments.

With reference to FIGS. 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, it increases in the flow direction of the bulb portion 1720 to the discharge outlet 1430. The transition segment 730 extends along a second supply flow axis 1770, which is in non-parallel relationship with the first feed flow axis 1735.

In embodiments, the first supply flow axis 1735 is substantially perpendicular to the longitudinal axis 50. In embodiments, the first supply 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 positioned at a respective feed angle Q in a range of up to about 135 ° with respect to the longitudinal axis 50.

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

With reference to FIGS.41-43, each of the shaped conduits 1441, 1443 has a concave outer surface 1790, 1791 substantially complementary to the shape of the convex inner surface 1758 thereof and in underlying relation thereto. Each concave outer surface 1790, 1791 defines a recess 1794, 1795.

With reference to FIGS.27, 35, and 36, a support insert 1801, 1802 is placed within each recess 1794, 1795 of the slurry distributor 1420. The support inserts 1801, 1802 are placed in underlying relation to the respective convex inner surfaces of the shaped ducts 1441, 1443. The support inserts 1801, 1802 can be made of any suitable material that will help support the slurry distributor and maintain a desired shape of the overlying inner convex surface. In the illustrated embodiment, the support inserts 1801, 1802 are substantially the same. In other embodiments, different support inserts may be used or in still further embodiments the inserts are not used.

With reference to FIGS. 37-39, the insert of Rigid support 1801 includes a support surface 1810 that substantially conforms to the shape of the convex inner surface of the shaped conduit. In embodiments, the shaped duct of the slurry distributor can be made of a sufficiently flexible material so 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 shaped duct it can be omitted.

The support insert 1801 includes a feed end 1820 and a dispensing end 1822. The support insert 1801 extends along a central support shaft 1825. The support insert 1801 is substantially symmetrical about the support shaft 825 The support insert 1801 is asymmetric around a central axis 1830 perpendicular to the support axis 1825.

With reference to FIG. 34, the distribution conduit 1428 extends generally along the longitudinal axis 50 and includes an input portion 1452 and a distribution health 1430 in fluid communication with the input portion 1452. The input portion 1452 is in fluid communication with the first and second feed inlets 1424, 1425 of the supply duct 1422. The width of the distribution duct 1428 increases from the inlet portion 1452 to the distribution outlet 1430. In other embodiments, however, the width of the distribution conduit 1428 decreases or is constant from the input portion 1452 to the distribution outlet 1430.

The inlet portion 1452 includes an inlet opening 1453 having a distribution inlet width W5, along the transverse axis 60, and an inlet height H4, along the vertical axis 55, wherein the width of the distribution port 5 is smaller than the width W2 of the outlet opening 1481 of the distribution outlet 1430. In other embodiments the distribution input width W5 is greater than or equal to the width W2 of the outlet opening 1481 of the distribution outlet 1430. In embodiments, the width to height ratio of the outlet opening 1481 is approximately four or more.

In embodiments, at least one of the supply conduit 1422 and the distribution conduit 1428 includes a flow stabilization region adapted to reduce an average feed rate of a slurry flow entering the feed inlets 1424, 1425 and which is moves to the distribution outlet 1430 so that the slurry flow is discharged from the distribution outlet at an average discharge rate that is at least twenty percent less than the average supply speed.

FIGS. 44-53 progressively depict the inner geometry 1407 of an average portion 1504 of the grout distributor 1420 of FIG. 22. The slurry distributor 1420 of FIG.22 is similar in other respects to the slurry distributor 120 of FIG.1 and the slurry distributor 420 of FIG.20.

Any suitable technique can be used to produce a slurry distributor constructed in accordance with the principles of the present disclosure. For example, in embodiments where the slurry distributor is made of a flexible material, such as PVC or urethane, a multi-piece mold can be used. In some embodiments, the mold part areas are approximately 150% or less than the area of the molded slurry distributor through which the mold part is being removed during removal, approximately 125% or less, in other embodiments, approximately 115% or less in still other modalities, and approximately 110% or less in still other modalities.

With reference to FIGS.54 and 55, one embodiment of a multi-piece mold 550 suitable for use in the production of the slurry distributor 120 of FIG. 1 of a flexible material, such as PVC or urethane. The illustrated multi-piece mold 550 includes five mold segments 551, 552, 553, 554, 555. The mold segments 551, 552, 553, 554, 555 of the multi-piece mold 550 can be made of any suitable material, such like aluminum, for example.

In the illustrated embodiment, the distributor duct mold segment 551 is configured to define the interior flow geometry of the distributor duct 128. The first and second shaped duct mold segments 552, 553 are configured to define the interior flow geometry of the first and second shaped conduits 141, 143. The first and second input mold segments 554, 555 define the interior flow geometry of the first input segment 136 and the first feed input 124 and the second input segment 137 and the second power input 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.

With reference to FIG. 54, the connecting screws 571, 572, 573 can be inserted through two or more mold segments to interlock and align the mold segments 551, 552, 553, 554, 555 so that a substantially continuous outer surface is defined 580 of the multi-piece mold 550. In some embodiments, a distal portion 575 of the connecting screws 571, 572, 573 includes an outer thread that is configured to threadably engage one of the mold segments 551, 552, 553, 554, 555 to interconnect at least two of the mold segments 551, 552, 553, 554, 555. The outer surface 580 of the mold Multi-piece 550 is configured to define the interior geometry of the molded slurry distributor 120 so that intermittency in the joints is reduced. The connecting screws 571, 572, 573 can be removed to disassemble the multi-piece mold 550 during the removal of the mold 550 from inside the molded grout distributor 120.

The assembled multi-piece mold 550 is immersed in a solution of flexible material, such as PVC or urethane, so that the mold 550 is completely immersed in the solution. The mold 550 can then be removed from the submerged material. A quantity of the solution can adhere to the outer surface 580 of the multi-piece mold 550 which will constitute the molded grout distributor 120 once the solution changes to a solid form. In embodiments, the multi-piece mold 550 can be used in any suitable immersion process to form the molded part.

By producing the mold 550 from multiple separate aluminum pieces - in the illustrated embodiment, five pieces - which have been designed to fit together to provide the desired interior flow geometry, the mold segments 551, 552, 553, 554, 555 they can be uncoupled from one another and removed from the solution once they have started to set but while they are still hot. At temperatures sufficiently high, the flexible material is quite flexible to remove large calculated areas of aluminum mold parts 551, 552, 553, 554, 555 through the smaller calculated areas of the molded grout distributor 120 without breaking it. In some embodiments, the largest mold part area is up to about 150% of the smaller area of the molded slurry distributor cavity through which the particular mold piece traverses transversely during the removal process, up to about 125% in other modalities, up to approximately 115% in other modalities, and up to approximately 110% in still other modalities.

With reference to FIG. 56, a modality of a multi-piece mold 650 suitable for use in the production of the slurry distributor 320 of FIG. 6 of a flexible material, such as PVC or urethane. The illustrated multi-piece mold 650 includes five mold segments 651, 652, 653, 654, 655. The mold segments 651, 652, 653, 654, 655 of the multi-piece mold 550 can be made of any suitable material, such like aluminum, for example. The mold segments 651, 652, 653, 654, 655 are shown in a disassembled condition in FIG. 56 The connecting screws can be used to removably connect the mold segments 651, 652, 653, 654, 655 together to assemble the mold 650 so as to define a substantially continuous outer surface of the multi-piece mold 650. The outer surface of the multi-piece mold 650 defines the internal flow geometry of the slurry distributor 220 of the FIG.6. The mold 650 may be similar in construction to the mold 550 of FIGS. 54 and 55 because each piece of the mold 650 of FIG.56 is constructed so that its area is within a predetermined amount of the smaller area of the molded slurry distributor 220 through which the mold part must traverse when it is being removed (e.g., up to about 150% of the smaller area of the cavity area of the molded slurry distributor through which the particular mold piece traverses transversely during the removal process in some embodiments, up to about 125% in other embodiments, up to about 115% in still other embodiments, and up to approximately 110% in still other modalities).

With reference to FIGS.57 and 58, one embodiment of a mold 750 is shown for use in the production of one of the pieces 221, 223 of the two-part slurry distributor 220 of FIG. With reference to FIG.57, the elements defining the mounting holes 752 can be included to define the mounting holes in the part of the two-piece slurry distributor 220 of FIG. which are made to facilitate their connection with the other piece.

With reference to FIGS.57 and 58, the mold 750 includes a mold surface 754 projecting from a bottom surface 756 of the mold 750. A boundary wall 756 extends along the vertical axis and defines the depth of the mold . The mold surface 754 is positioned within the boundary wall 756. The boundary wall 756 is configured to allow the volume of a cavity 758 defined within the boundary wall to be filled with molten molding material, so that the mold surface 754 is submerged. The mold surface 754 is configured to be a negative image of the interior flow geometry defined by the particular part of the two-part distributor that is molded.

In use, the cavity 758 of the mold 750 can be filled with a molten material, so that the mold surface is immersed and the cavity 758 is filled with the molten material. The molten material can be allowed to cool and removed from the mold 750. Another mold can be used to form the coupling part of the grout distributor 220 of FIG.

With reference to FIG. 59, one embodiment of a gypsum slurry mixing and distribution assembly 810 includes a gypsum slurry mixer 912 in fluid communication with a slurry distributor 820 similar to grout distributor 320 shown in FIG. 6. The gypsum grout mixer 812 is adapted to agitate the water and calcined gypsum to form an aqueous slurry of calcined gypsum. Both the water and the calcined gypsum can be supplied to the mixer 812 through one or more inlets as is known in the art. Any suitable mixer (for example, a needle mixer) can be used with the grout dispenser.

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

The slurry distributor 820 includes a supply conduit 822 in fluid communication with a distribution conduit 828. The supply conduit includes the first supply inlet 824 and the second supply inlet 825 arranged in spaced relationship with the first supply inlet 824 , which are both placed at a feed angle Q from approximately 60 ° with respect to the machine direction 50. The feed conduit 822 includes a structure therein adapted to receive the first and second slurry flows moving in the first and second feed flow direction 890, 891 and redirect the flow direction of the slurry by a change in the steering angle a (see FIG 9) so that the first and second slurry flows are transported in the conduit of distribution 828 that moves substantially in the direction of outflow 892, which is substantially aligned with the direction of the machine 50. The first and second feed inlets 824, 825 each have an opening with a cross-sectional area, and the inlet portion 852 of the distribution conduit 828 has an opening with a cross-sectional area that is greater than the sum of the cross-sectional areas of the openings of the first and second feed inlets 824, 825.

The distribution conduit 828 extends generally along the longitudinal axis or direction of the machine 50, which is substantially perpendicular to a transverse axis 60. The distribution conduit 828 includes an input portion 852 and the distribution outlet 830. The input portion 852 is in communication fluid with the first and second feed inlets 824, 825 of the feed conduit 822 so that the inlet portion 852 is adapted to receive both the first and second flows of aqueous gypsum gypsum slurry therefrom. The distribution outlet 830 is in fluid communication with the inlet portion 852. The distribution outlet 830 of the distribution conduit 828 extends a predetermined distance along the transverse axis 60 to facilitate the discharge of the first and second combined flows of aqueous slurry of calcined gypsum in the direction through the machine or along the transverse axis 60. The slurry distributor 820 may be similar in other respects to the slurry distributor 320 of FIG.6.

A supply conduit 814 is placed between and in fluid communication with the gypsum slurry mixer 812 and the slurry distributor 820. The supply conduit 814 includes a main supply trunk 815, a first supply ram 817 in fluid communication with The first power input 824 of the distributor of slurry 820, and a second supply branch 818 in fluid communication with the second supply inlet 825 of the slurry distributor 820. The main supply trunk 815 is in fluid communication with the first and second supply branches 817, 818. In other embodiments, the first and second supply branches 817, 818 may be in independent fluid communication with the gypsum grout mixer 812.

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

An aqueous foam supply conduit 821 may be in fluid communication with at least one of the gypsum slurry mixer 812 and the supply conduit 814. An aqueous foam from a source may be added to the constituent materials through the supply conduit. suppg foam 821 at any suitable location downstream of the mixer 812 and / or in the mixer 812 itself to form a foamed gypsum slurry that is provided to the slurry distributor 220. In the embodiment illustrated, the foam supply conduit 821 is placed downstream of the gypsum slurry mixer 812. In the illustrated embodiment, the aqueous foam supply conduit 821 has a distributor type arrangement for providing foam to an injection ring or block associated with the supply conduit 814 as described in U.S. Patent No. 6,874,930, for example.

In other embodiments, one or more foam supply conduits that are in fluid communication with the mixer 812 may be provided. In still other embodiments, the aqueous foam supply conduits may be in fluid communication with the gypsum grout mixer alone. . As will be appreciated by those skilled in the art, the means for introducing aqueous foam into the gypsum slurry in the gypsum slurry mixing and distribution assembly 810, including its relative location in the assembly, can be varied and / or optimized for provide a uniform dispersion of aqueous foam in the gypsum slurry to produce panels that are fit for their intended purpose.

Any suitable foaming agent can be used. Preferably, the aqueous foam is produced in a continuous manner in which a stream of the foaming agent and water mixture is directed to a foam generator, and a stream of the resulting aqueous foam exits the generator and is directed and mixed with the calcined gypsum grout. Some examples of suitable foaming agents are described in U.S. Patent Nos. 5,683,635 and 5,643,510, for example.

When the foamed gypsum slurry hardens and dries, the foam dispersed in the slurry produces air voids in it that act to reduce the overall density of the gypsum board. The amount of foam and / or amount of air in the foam can be varied to adjust the density of the dry panel so that the resulting gypsum panel product is within a desired weight range.

One or more flow modifier elements 823 may be associated with the supply conduit 814 and adapted to control the first and second flows of calcined gypsum slurry from the gypsum slurry mixer 812. The flow modifier elements 823 may be used. for controlling an operation characteristic of the first and second aqueous slurry flows of calcined gypsum. In the illustrated embodiment of FIG.59, the flow modifier elements 823 are associated with the main supply trunk 815. Examples of suitable flow modifier elements include volume restrictors, pressure reducers, constricting valves, containers, etc. , including those described in U.S. Patent Nos. 6,494,609; 6,874,930; 7,007,914; and 7,296,919, for example.

The main supply trunk 815 can be attached to the first and second supply branches 817, 818 through a suitable Y-shaped flow divider 819.

The flow divider 819 is positioned between the main supply trunk 815 and the first supply branch 817 and between the main supply trunk 815 and the second supply branch 818. In some embodiments, the flow divider 819 can be adapted to help divide the first and second flows of gypsum slurry so that they are substantially equal. In other embodiments, additional components may be added to help regulate the first and second slurry flows.

In use, an aqueous slurry of calcined gypsum is discharged from the mixer 812. The calcined aqueous gypsum slurry from the mixer 812 is divided into the flow splitter 819 in the first aqueous slurry flow of calcined gypsum and the second slurry flow. Aqueous calcined gypsum. The aqueous calcined gypsum slurry of the mixer 812 can be divided so that the first and second aqueous slurry streams of calcined gypsum are substantially balanced.

With reference to FIG. 60, another embodiment of a gypsum slurry mixing and distribution assembly 910 is shown. The gypsum slurry mixing and distribution assembly 910 includes a gypsum slurry mixer 912 in fluid communication with a gypsum slurry distributor 920. The gypsum grout mixer 912 is adapted to stir the water and calcined gypsum to form a grout Aqueous calcined gypsum. The grout distributor 920 may be similar in construction and function to the grout distributor 320 of FIG. 6.

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

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

The first supply branch 917 is placed between and in fluid communication with the gypsum grout mixer 912 and the first feed entrance 924 of the grout distributor 920. At least one first element Flow modifier 923 is associated with the first supply branch 917 and is adapted to control the first flow of aqueous calcined gypsum slurry from the gypsum slurry mixer 912.

The second supply branch 918 is placed between and in fluid communication with the gypsum grout mixer 912 and the second feed inlet 925 of the grout distributor 920. At least a second flow modifier element 927 is associated with the second branch of 918 supply and is adapted to control the second flow of calcined gypsum slurry from the gypsum grout mixer 912.

The first and second flow modifier elements 923, 927 can be operated to control an operation characteristic of the first and second aqueous slurry flows of calcined gypsum. The first and second flow modifier elements 923, 927 can be independently operable. In some embodiments, the first and second flow modifier elements 923, 927 may be operated to supply first and second flows of slurries that alternate between a relatively slower and relatively faster average speed in opposite manner so that at a given time the first slurry has an average speed that is faster than the second slurry flow and at another point in time, the First grout has an average speed that is slower than that of the second grout flow.

As one skilled in the art will appreciate, one or both of the cover sheet material meshes can be pre-treated with a relatively thin, relatively denser layer of gypsum slurry (relative to the gypsum slurry comprising the core). , often referred to as a finishing coating in the art, and / or hard edges, if desired. For this, the mixer 912 includes a first auxiliary conduit 929 which is adapted to deposit a dense aqueous slurry stream of calcined gypsum which is relatively denser than the first and second aqueous slurry fluxes of calcined gypsum supplied to the slurry distributor (is say, a "front finish / hard edge coating stream"). The first auxiliary conduit 929 can deposit the front finish / hard edge coating stream in a moving mesh of cover sheet material upstream of a finishing coating roll 931 which is adapted to apply a finish coating layer to the mobile mesh of cover sheet material and to define the hard edges at the periphery of the moving mesh by virtue of the width of the roll 931 that is smaller than the width of the moving mesh as is known in the art. Hard edges can be formed from the same dense grout that forms the layer Thin dense by directing the portions of the dense grout around the ends of the roller used to apply the dense layer to the mesh.

The mixer 912 may also include a second auxiliary conduit 933 adapted to deposit a dense aqueous slurry stream of calcined gypsum which is relatively denser than the first and second aqueous slurry streams of calcined gypsum supplied to the slurry distributor (i.e. "Rear finish coating stream"). The second auxiliary conduit 933 can deposit the subsequent finishing coating stream on a second moving mesh of upstream cover sheet material (in the direction of movement of the second mesh) of a finishing coating roll 937 which is adapted for applying a topcoat layer to the second movable screen of cover sheet material as is known in the art (see FIG. 61 as well).

In other embodiments, the separate auxiliary conduits may be connected to the mixer to supply one or more separate edge streams to the moving mesh of the cover sheet material. Other suitable equipment (such as auxiliary mixers) can be provided in the auxiliary ducts to help make the grout in this more dense, such as by mechanically breaking the foam in the grouting and / or chemically breaking the foam by the use of a suitable defoaming agent.

In still other embodiments, the first and second supply ramifications may each include a foam supply conduit therein, which is respectively adapted to independently introduce aqueous foam into the first and second aqueous slurry streams of calcined gypsum supplied to the distributor. grout. In still other embodiments, a plurality of mixers can be provided to provide independent slurry streams to the first and second feed inlets of a slurry distributor constructed in accordance with the principles of the present disclosure. It will be appreciated that other modalities are possible.

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

With reference to FIG. 61, an exemplary embodiment of a wet end 1011 of a gypsum panel manufacturing line is shown. The wet end 1011 includes a gypsum slurry mixing and distribution assembly 1010 having a gypsum slurry mixer 1012 in fluid communication with a slurry distributor 1020 similar in construction and function to the slurry distributor 320 of FIG. 6, a front facing / hard edge coating roll 1031 positioned upstream of the slurry distributor 1020 and supported on a forming table 1038 so that a first moving mesh 1039 of cover sheet material is placed between these, a roller of rear finish coating 1037 placed on a support member 1041 so that a second movable mesh 1043 of cover sheet material is placed therebetween, and a forming station 1045 adapted to form the preform into a desired thickness. The finishing coating rolls 1031, 1037, the forming board, the supporting element 1041, and the forming station 1045 may all comprise conventional equipment suitable for its intended purposes, as is known in the art. Wet end 1011 may be equipped with other conventional equipment as is known in the art.

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

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

The drywall products are typically formed "upside down" so that the advancing mesh 1039 serves as the "face" cover sheet of the finished panel. A front finish / hard edge coating stream 1049 (a denser aqueous gypsum layer of calcined gypsum with respect to at least one of the first and second aqueous slurry streams of calcined gypsum) can be applied to the first 1039 mobile mesh upstream of the front finish / hard edge coating roll 1031, with respect to the machine direction 1092, to apply a finish coating layer to the first 1039 mesh and define the hard edges of the panel.

The first flow 1047 and the second flow 1048 of aqueous slurry of calcined gypsum are passed respectively to through the first feed inlet 1024 and the second feed inlet 1025 of the slurry distributor 1020. The first and second flows 1047, 1048 of calcined gypsum slurry are combined in the slurry distributor 1020. The first and second flows 1047 , 1048 of calcined aqueous gypsum slurry which move along a flow path through the slurry distributor 1020 in the form of a laminar flow, are subjected to minimal or substantially no phase separation of air-liquid slurry and substantially do not undergo a vortex flow path.

The first movable mesh 1039 moves along the longitudinal axis 50. The first flow 1047 of aqueous slurry of calcined gypsum passes through the first feed inlet 1024, and the second flow 1048 of the aqueous slurry of calcined gypsum passes through of the second feed inlet 1025. The distribution duct 1028 is positioned so that it extends along the longitudinal axis 50 which substantially coincides with the machine direction 1092 along which the first 1039 mesh of material cover sheet moves. Preferably, the central mid-point of the distribution outlet 1030 (taken along the direction of the transverse axis / through the machine 60) substantially coincides with the central mid-point of the first movable cover sheet 1039. The first and second 1047, 1048 fluxes of calcined gypsum aqueous slurry are combined in the slurry distributor 1020 so that the first and second combined flows 1051 of calcined gypsum slurry pass through the distribution outlet 1030 in a distribution direction 1093 generally along the direction of the machine 1092.

In some embodiments, the distribution conduit 1028 is positioned so as to be substantially parallel to the plane defined by the longitudinal axis 50 and the transverse axis 60 of the first mesh 1039 moving along the forming table. In other embodiments, the inlet portion of the distribution conduit can be positioned vertically smaller or larger than the distribution outlet 1030 relative to the first mesh 1039.

The first and second combined streams 1051 of calcined aqueous slurry are discharged from the slurry distributor 1020 in the first moving net 1039. The front finish / hard edge finishing stream 1049 can be deposited from the mixer 1012 at an upstream point. , with respect to the direction of movement of the first mobile mesh 1039 in the machine direction 1092, where the first and second flows 1047, 1048 of calcined aqueous slurry are discharged from the slurry distributor 1020 in the first mobile mesh 1039. The first and second combined slurry flows 1047, 1048.

Aqueous calcined gypsum can be discharged from the slurry distributor with a reduced moment per unit width along the direction through the machine in relation to a conventional hopper design to help prevent the "washing" of the stream from front finish / hard edge coating 1049 deposited on the first movable mesh 1039 (i.e., the situation where a portion of the deposited finish coating layer is displaced from its position on the moving mesh 339 in response to the impact of the grout that is deposited in this).

The first and second flows 1047, 1048 of calcined aqueous slurry passed respectively through the first and second feed inlets 1024, 1025 of the slurry distributor 1020 can be selectively controlled with at least one flow modifier element 1023. For example , in some embodiments, the first and second flows 1047, 1048 of calcined gypsum aqueous slurry are selectively controlled so that the average velocity of the first flow 1047 of calcined aqueous slurry gypsum passing through the first feed inlet 1024 and the average velocity of the second flow 1048 of calcined aqueous slurry gypsum passing through the second feed inlet 1025 are substantially the same.

In embodiments, the first slurry flow 1047 Aqueous calcined gypsum is passed to a first average feed rate through the first feed inlet 1024 of the slurry distributor 1020. The second flow 1048 of calcined aqueous slurry is passed at a second average feed rate through the medium. the second feed inlet 1025 of the slurry distributor 1020. The second feed inlet 1025 is in spaced relationship with the first feed inlet 1024. The first and second flows 1051 of calcined gypsum slurry are combined in the slurry distributor 1020 The first and second combined streams 1051 of calcined aqueous slurry are discharged at an average discharge velocity from a distribution outlet 1030 of the slurry distributor 1020 into the 1039 mesh of roof sheet material moving along the length of the sheet. an address of the machine 1092. The average discharge speed is lower than the first feed speed average and the second average feed rate.

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

The first and second combined flows 1051 of calcined aqueous slurry are discharged from the slurry distributor 1020 through the distribution outlet 1030. The opening of the distribution outlet 1030 has a width extending along the transverse axis 60. and is dimensioned such that the ratio of the width of the first movable mesh 1039 of cover sheet material to the width of the opening of the distribution outlet 1030 is within a range including and between approximately 1: 1 and approximately 6: 1. In some embodiments, the ratio of the average velocity of the first and second combined flows 1051 of aqueous slurry of calcined gypsum discharged from the slurry distributor 1020 to the speed of the mobile mesh 1039 of shroud sheet material moving to along the direction of the machine 1092 may be about 2: 1 or less in some embodiments, and from about 1: 1 to about 2: 1, in other embodiments.

The first and second combined streams 1051 of calcined aqueous slurry that are discharged from the slurry distributor 1020 form an extension pattern in the mobile mesh 1039. At least one of the size and shape of the distribution outlet 1030 can be adjusted, which In turn you can change the extension pattern.

Therefore, the slurry is fed into both feed inlets 1024, 1025 of the feed duct 1022 and then exits through the distribution outlet 1030 with an adjustable opening. A converging portion 1082 can provide a slight increase in the speed of the slurry to reduce unwanted outflow effects and thus further improve the flow stability on the free surface. The side-by-side flow variation and / or any of the local variations can be reduced by performing profiling control through the machine (CD) at the discharge outlet 1030 using the profiling system. This distribution system can help prevent the separation of air-liquid slurry in the resulting slurry into a more uniform and consistent material supplied to the training table 1038.

A further finishing coating stream 1053 (a denser aqueous gypsum layer of calcined gypsum with respect to at least one of the first and second fluxes 1047, 1048 of calcined gypsum aqueous slurry) can be applied to the second movable 1043 mesh The rear finish coating stream 1053 can be deposited from the mixer 1012 at an upstream point, with respect to the direction of movement of the second movable mesh 1043, of the rear finish coating roller 1037.

In other modalities, the average speed of the first and second flows 1047, 1048 of calcined gypsum aqueous slurry is varied. In some embodiments, the slurry rates at the feed inputs 1024, 1025 of the feed conduit 1022 may periodically range between relatively greater and smaller average speeds (at one point in time one input has a higher speed than the other input, and then at a predetermined point of time and vice versa) to help reduce the possibility of accumulation within the geometry itself.

In embodiments, the first flow 1047 of calcined aqueous gypsum slurry passing through the first feed inlet 1024 has a shear rate that is less than the shear rate of the first and second combined streams 1051 that are discharged from the distribution outlet 1030, and the second flow 1048 of calcined aqueous slurry gypsum passing through the second feed inlet 1025 has a shear rate that is lower than the shear rate of the first and second combined flows 1051 that is discharges from the distribution outlet 1030. In embodiments, the shear rate of the first and second combined flows 1051 discharged from the distribution outlet 1030 may be greater than about 150% of the shear rate of the first slurry flow 1047. Aqueous calcined gypsum that passes through the first feeding inlet 1024 and / or the second flow 1048 of calcined aqueous slurry gypsum passing through the second feeding inlet 1025, greater than about 175% in still other modes, and about twice or more in still other embodiments . It should be understood that the viscosity of the first and second flows 1047, 1048 of calcined aqueous slurry gypsum and the first and second combined flows 1051 can be inversely proportional to the shear rate present at a given location so that as the velocity of shear rises, the viscosity decreases.

In embodiments, the first flow 047 of aqueous calcined gypsum slurry passing through the first feed inlet 1024 has a shear stress that is less than the shear stress of the first and second combined flows 1051 that are discharged from the outlet distribution 1030, and the second flow 1048 of calcined aqueous slurry gypsum passing through the second feed inlet 1025 has a shear stress that is less than the shear stress of the first and second combined flows 1051 that are discharged from the outlet 1030. In embodiments, the shear stress of the first and second combined flows 1051 that are discharged from the distribution outlet 1030 may be greater than about 110%. of the shearing rate of the first flow 1047 of calcined aqueous slurry gypsum passing through the first feed inlet 1024 and / or the second flow 1048 of calcined aqueous slurry gypsum passing through the second feed inlet 1025 .

In embodiments, the first flow 047 of aqueous slurry of calcined gypsum passing through the first feed inlet 1024 has a number of Rcynolds which is greater than the Reynolds number of the first and second combined streams 1051 which are discharged from the distribution outlet 1030, and the second flow 1048 of calcined aqueous slurry gypsum passing through the second feed inlet 1025 has a Reynolds number that is greater than the Reynolds number of the first and second combined flows 1051 that is discharges from the distribution outlet 1030. In embodiments, the Reynolds number of the first and second combined flows 1051 discharged from the distribution outlet 1030 may be less than about 90% of the Reynolds number of the first aqueous slurry flow 1047. of calcined gypsum passing through the first feed inlet 1024 and / or the second flow 1048 of aqueous slurry of calcined gypsum passing through s of the second power source 1025, less than about 80% in still other embodiments, and less than about 70% in still other embodiments.

With reference to FIGS.62 and 63, a form of a Y-shaped flow divider 1100 suitable for use in a gypsum slurry mixing and distribution assembly constructed in accordance with the principles of the present disclosure is shown. The flow divider 1100 can be placed in fluid communication with a gypsum slurry mixer and a slurry distributor so that the flow splitter 1100 receives a single stream of calcined aqueous slurry from the mixer and discharges two separate streams of slurry. aqueous slurry of calcined gypsum from this to the first and second feed inlets of the slurry distributor. One or more flow modifier elements may be placed between the mixer and the flow divider 1100 and / or between one or both of the supply branches leading between the divider 1100 and the associated slurry distributor.

The flow divider 1100 has a substantially circular inlet 1102 positioned in a main branch 1103 adapted to receive a single slurry flow and a pair of substantially circular outlets 1104, 1106 positioned respectively in the first and second outlet branches 1105, 1107 that allow that two slurry streams are discharged from the divider 1100. The cross-sectional areas of the inlet openings 1102 and the outlets 1104, 1106 may vary depending on the desired flow rate. In modalities where the areas of cross section of the outlet openings 1104, 1106 are each substantially equal to the cross sectional area of the opening of the inlet 1102, the flow rate of the slurry discharged from each outlet 1104, 1106 can be reduced to approximately 50 % of the single flow rate of slurry entering inlet 1102 where the volumetric flow rate through inlet 1102 and both outlets 1104, 1106 is substantially the same.

In some embodiments, the diameter of the outlets 1104, 1106 can be made smaller than the diameter of the inlet 1102 to maintain a relatively high flow rate throughout the divider 1100. In embodiments where the cross-sectional areas of the openings of the outputs 1104, 1106 are each smaller than the cross-sectional area of the opening of the inlet 1102, the flow rate can be maintained at the outlets 1104, 1106 or at least reduced to a lesser extent than if the outlets 1104, 1106 and input 1102 all have substantially equal cross-sectional areas. For example, in some embodiments, the flow divider 1100 having the inlet 1102 has an inside diameter (IDi) of about 7.62 cm (3 inches), and each outlet 1104, 1106 has an ID2 of about 6.35 cm (2.5 inches) (although other input and output diameters can be used in other modes). In a modality with these dimensions to a line speed of 106.68 meters per minute (350 feet per minute), the smaller diameter of outlets 1104, 1106 causes the flow rate at each flow outlet to be reduced by approximately 28% of the flow rate of the single flow of grout at the entrance 1102.

The flow divider 1100 may include a central contoured portion 1114 and a junction 1120 between the first and second output branches 1105, 1107. The central contoured portion 1114 creates a restriction 1108 in the central interior region of the flow divider 1100 upstream of the joint 1120 which helps to promote flow to the outer edges 1110, 1112 of the splitter to reduce the occurrence of grout accumulation in the joint 120. The shape of the central contoured portion 1114 results in lili guide channels, 1113 adjacent to the outer edges 1110, 1112 of the flow divider 1100. The restriction 1108 in the central contoured portion 1114 has a height ¾ less than the height ¾ of the guide channels lili, 1113. The guide channels lili, 1113 have an area of cross section that is greater than the cross-sectional area of the central restriction 1108. As a result, the flowing slurry finds less flow resistance through the lili guide channels, 1113 through the central constraint 1108, and the flow is directed towards the outer edges of the divider junction 1120.

The joint 1120 establishes the openings for the first and second outlet branches 1105, 1107. The joint 1120 is composed of a flat wall surface 1123 that is substantially perpendicular to an inlet flow direction 1125.

With reference to FIG. 64, in some embodiments, an automatic device 1150 for compressing the divider 1100 at adjustable and regular time intervals can be provided to prevent the accumulation of solids within the divider 1100. In some embodiments, the compression apparatus 1150 may include a pair of plates 1152, 1154 positioned on opposite sides 1142, 1143 of the central contoured portion 1114. The plates 1152, 1154 are movable relative to each other by a suitable actuator 1160. The actuator 1160 can be operated automatically or selectively to move the plates 1152, 1154 together with respect to each other to apply a compression force on the divider 1100 in the central contoured portion 1114 and the joint 1120.

When the compression apparatus 1150 compresses the flow divider, the compression action applies compression force to the flow divider 1100, which flexes inwardly in response. This compression force can help prevent the accumulation of solids inside the divider 1100 that can substantially interrupt the flow equally divided for the distribution of slurry through the outlets 1104, 1106. In some embodiments, the compression apparatus 1150 is designed to pulse automatically by the use of a programmable controller operatively arranged with the actuators. The duration of the application of the compression force by the compression apparatus 1150 and / or the interval between moments can be adjusted. In addition, the stroke length that plates 1152, 1154 run relative to each other in a compression direction can be adjusted.

In one embodiment, a method for preparing a cementitious product can be performed using a slurry distributor constructed in rdance with the principles of the present disclosure. A flow of aqueous cement slurry is discharged from a mixer. A flow of aqueous cement slurry is passed at an average feed rate through a feed inlet of a slurry distributor along a first feed flow axis. The flow of aqueous cement slurry is passed into a bulb portion of the slurry distributor. The bulb portion has an expansion area with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream of the expansion area with respect to a flow direction of the supply inlet . The bulb portion is configured to reduce the average velocity of the aqueous cement slurry flow moving from the feed inlet through the bulb portion. The shaped conduit has a convex inner surface in confronting relationship with the first feed flow axis so that the flow of aqueous cement slurry moves in the radial flow in a plane substantially perpendicular to the first supply flow axis. The aqueous cement slurry flow is passed in a transition segment extending along a second feed flow axis, which is in non-parallel relationship with the first feed flow axis.

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

In embodiments, the flow of slurry that moves through a region adjacent the convex inner surface and adjacent to at least one of the side walls toward the dispensing outlet has a vortex motion (Sm) from about zero to about 10. , and from about 0.5 to about 5 in other modalities. In modalities, the grout flow that moves through the region adjacent to the inner surface convex and adjacent to at least one of the side walls towards the distribution outlet has a swirl angle (Sm) from about 0o to about 84 °.

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

In another embodiment, a method for preparing a cementitious product includes discharging a flow of aqueous cement slurry from a mixer. The flow of aqueous cement slurry is passed through an inlet portion of a distribution conduit of a slurry distributor. The flow of aqueous cement slurry is discharged from a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction. A cleaning sheet reciprocates on a cleaning path along a lower surface of the distribution conduit between a first position and a second position to clean the aqueous cementitious slurry therefrom. The cleaning path It is placed adjacent to the distribution outlet.

In embodiments, the distribution conduit extends generally along a longitudinal axis between the input portion and the distribution outlet. The cleaning sheet reciprocates longitudinally along the cleaning path.

In embodiments, the wiper blade moves in a cleaning direction from the first position to the second position on a cleaning stroke, and the wiper blade moves in an opposite return direction from the second position to the first position on a stroke return. The wiper blade moves reciprocally so that the time to move about the cleaning stroke is substantially the same as the time to move over the return stroke.

In embodiments, the wiper blade moves in a cleaning direction from the first position to the second position on a cleaning stroke, and the wiper blade moves in an opposite return direction from the second position to the first position on a stroke return. The cleaning sheet reciprocates between the first position and the second position in a cycle that has a cleaning period. The cleaning period includes a cleaning portion comprising the time to move through the cleaning stroke, a return portion that it comprises the time to move about the return stroke, and a portion of accumulation delay comprising a predetermined period of time in which the cleaning sheet remains in the first position. In embodiments, the cleaning portion is substantially the same as the return portion. In embodiments, the accumulation delay portion is adjustable.

In yet another embodiment, a method for preparing a cementitious product includes discharging an aqueous cement slurry stream from a mixer. The flow of aqueous cement slurry is passed through an inlet portion of a distribution conduit of a slurry distributor. The aqueous cement slurry stream is discharged from an outlet opening of a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The outlet opening has a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis. A portion of the distribution conduit adjacent to the distribution outlet is compressively engaged to vary the shape and / or size of the opening departure. In embodiments, the distribution conduit is compressively engaged by a profiling mechanism so that the flow of aqueous cement slurry is discharged from the outlet opening at an increased extension angle with respect to the machine direction.

In embodiments, the distribution conduit is compressively engaged by a profiling mechanism having a profiling member in contact relation with the distribution conduit. The profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in compressive engagement increased with the distribution conduit. In embodiments the method includes moving the profiling member along the 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 is translated along at least one axis and / or rotates about at least one axis to adjust the size and / or shape of the aperture. departure.

The embodiments of a slurry distributor, a cement slurry mixing and distribution assembly, and methods of using the same are provided herein, which can provide many improved process characteristics useful in the manufacture of products. cementitious, such as drywall in a commercial environment. A slurry distributor constructed in accordance with the principles of the present disclosure can facilitate the spreading of the calcined aqueous gypsum slurry in a moving mesh of roofing sheet material as it progresses past a mixer at the wet end of the slurry. manufacturing line to a training station.

A gypsum slurry mixing and distribution assembly constructed in accordance with the principles of the present disclosure can divide an aqueous slurry stream of calcined gypsum from a mixer into two separate flows of calcined gypsum slurry that can be recombined downstream in a slurry distributor constructed in accordance with the principles of the present disclosure to provide a desired extension pattern. The design of the dual input configuration and the distribution outlet can allow a wider extension of more viscous slurry in the direction through the machine in the mobile mesh of cover sheet material. The slurry distributor can be adapted so that the two separate flows of calcined gypsum slurry that enter a slurry distributor along feed inlet directions that include a steering component through the machine are re-circulated. -directed inside the grout distributor of so that the two slurry streams are movable substantially in one machine direction, and recombine in the distributor in a manner to improve the uniformity of transverse direction of the combined fluxes of calcined gypsum slurry that are discharged from the outlet of the slurry. distribution of the slurry distributor to help reduce the variation of mass flow over time along the transverse axis or direction through the machine. The introduction of the first and second aqueous slurry fluxes of calcined gypsum in first and second feed directions including a directional component through the machine can help the re-mixed slurry flows to be discharged from the slurry distributor with a moment and / or reduced energy.

The interior flow cavity of the slurry distributor can be configured such that each of the two slurry streams moves through the slurry distributor in a laminar flow. The interior flow cavity of the slurry distributor can be configured such that each of the two slurry streams moves through the slurry distributor with minimal or substantially no phase separation of air-liquid slurry. The interior flow cavity of the slurry distributor can be configured so that each of the two slurry flows moves through the slurry distributor substantially without undergoing a vortex flow path.

A gypsum slurry mixing and distribution assembly constructed in accordance with the principles of the present disclosure may include flow geometry upstream of the distribution outlet of the slurry distributor to reduce the speed of the slurry in one or multiple stages. For example, a flow divider may be provided between the mixer and the slurry distributor to reduce the speed of the slurry entering the slurry distributor. As another example, the flow geometry in the gypsum slurry mixing and distribution assembly can include expansion areas upstream and inside the slurry distributor to encourage slurry so it is manageable when discharging from the distribution outlet of the slurry. grout distributor.

The geometry of the distribution outlet can also help to control the rate of discharge and the timing of the slurry as it is discharged from the slurry distributor into the mobile mesh of roof sheet material. The flow geometry of the slurry distributor can be adapted such that the slurry discharged from the distribution outlet is substantially maintained in a two-dimensional flow pattern with a relatively small height compared to the output wider in the direction through the machine to help improve stability and uniformity.

The relatively broad discharge outlet produces a moment per unit width of the slurry that is discharged from the distribution outlet that is less than the moment per unit width of a slurry discharged from a conventional hopper under similar operating conditions. The reduced unit moment of width can help prevent the washing of a dense layer finish coating applied to the cover sheet material mesh upstream of the location where the slurry is discharged from the slurry distributor in the mesh.

In the situation where a conventional hopper current outlet is used is 15.24 cm (6 inches) wide and 5.08 cm (2 inches) thick, the average speed of the output for a high volume product can be approximately 231.95 m / min (761 ft / min). In embodiments where the slurry distributor constructed in accordance with the principles of the present disclosure includes a dispensing outlet having an opening that is 60.96 cm (24 inches) wide and 1.90 cm (0.75 inches) thick, the average speed it can be approximately 167.6 cm (550 ft / min). The mass flow rate is the same for both devices at 1560 kg / min (3,437 lb / min). The moment of the grout (flow rate of mass * average speed) for both cases would be -100.53 and 72.61 kg.m / s2 (-2,618,000 and 1,891,000 lb.ft / min2) for the conventional hopper and slurry distributor, respectively. Dividing the respective time calculated by the widths of the output and the output hopper conventional distributor slurry, the moment per unit width of the slurry is discharged from the hopper convention is 15.46 kg.m / s2 (402.736 (Ib ft / min 2)) / (inches across the width of the hopper), and the moment per unit width of the slurry discharged from the slurry distributor constructed according to the principles of the present disclosure is 3.02 kg.m / s2 (78,776 kg.m / s2 (Ib.ft / min2)) / (inch across the width of the slurry distributor). In this case, the slurry that is discharged from the slurry distributor is approximately 20% of the moment per unit width compared to the conventional hopper.

A slurry distributor constructed in accordance with the principles of the present disclosure can achieve a desired pattern of extension while using an aqueous slurry of calcined gypsum over a wide range of water-stucco ratios, including a relatively low WSR or a higher WSR. conventional, such as, a ratio of water to calcined gypsum from about 0.4 to about 1.2, for example, below 0.75 in some embodiments, and between approximately 0.4 and approximately 0.8 in other modalities. Modalities of a distributor slurry constructed according to the principles of the present disclosure may include the geometry of internal flow adapted to generate shear effects controlled in the first and second flows of aqueous slurry of calcined gypsum when the first and second flows advancing from the first and second feed inlets through the slurry distributor to the distribution outlet. The controlled shear application in the slurry distributor can selectively reduce the viscosity of the slurry as a result of being subjected to such shear. Under the influence of shear controlled distributor slurry, the slurry having a ratio of water-stucco bottom can be distributed distributor slurry with a pattern of extension in the direction through the comparable machine with slurries having a Conventional WSR.

The internal flow geometry of the slurry distributor can be adapted to additionally accommodate slurries of various water-stucco ratios to provide increased flow adjacent to the boundary wall regions of the interior geometry of the slurry distributor. By including flow geometry features in the adapted slurry distributor to increase the degree of flow around the boundary wall layers, the tendency of the grout to re-circulate in the grout distributor and / or to stop flowing and hardening in it is reduced. Accordingly, the accumulation of hardened slurry in the slurry distributor can be reduced as a result.

A slurry distributor constructed in accordance with the principles of the present disclosure may include a profile system mounted adjacent to the distribution outlet to alter a velocity cnent through the machine of the combined slurry flows that are discharged from the outlet. of distribution for selectively controlling the extension angle and width of extension of the slurry in the direction through the machine on the substrate moving in the manufacturing line towards the forming station. The profile system can help the grout discharged from the distribution outlet achieve a desired extension pattern while being less sensitive to the viscosity of the grout and WSR. The profiling system can be used to change the flow dynamics of the slurry that is discharged from the distribution outlet of the slurry distributor to guide the slurry flow so that the slurry has a more uniform velocity in the direction through the slurry. machine. Using the profile system can also help make a montage of mixing and Gypsum slurry distribution constructed in accordance with the principles of the present disclosure is used in a gypsum board manufacturing environment to produce gypsum panels of different types and volumes.

Therefore, in one embodiment, a slurry distributor cises a distribution conduit that extends generally along a longitudinal axis and includes an inlet portion and a distribution outlet in fluid communication with the inlet portion. The distribution outlet extends a predetermined distance along a transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The distribution outlet includes an outlet opening having a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis. A profiling mechanism including a profiling member is in contact relation with the distribution conduit. The profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in cessed engagement enhanced with a portion of the distribution conduit adjacent to the distribution outlet for vary the shape and / or size of the exit opening.

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

In another embodiment, the outlet opening of the distribution outlet has a width along the transverse axis. The profiling member has a width extending a second predetermined distance along the transverse axis. The width of the exit opening is greater than the width of the profiling member. The profiling member is positioned so that a pair of side portions of the dispensing outlet are in displaced relationship with the profiling member.

In another embodiment, the profiling member of the grout distributor is movable along the vertical axis.

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

In another embodiment, the profiling member of the grout distributor is movable along at least one axis and rotatable about at least one pivot axis.

In another embodiment, the profiling member of the slurry distributor is movable along the vertical axis and rotatable about a pivot axis that is substantially parallel to the longitudinal axis. The profiling member is rotatable about the pivot axis on a arc length so that the profiling member is in a range of positions over which the profiling member is in variable compressive engagement with the portion of the distribution conduit through the transverse axis so that the height of the exit opening varies along the transverse axis.

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

In another embodiment, the profiling member of the slurry distributor is rotatable about a pivot axis over an arc length so that the profiling member is in a range of positions over which the profiling member is in variable compressive engagement. with the portion of the distribution conduit through the transverse axis so that the height of the outlet opening varies along the transverse axis.

In another embodiment, the profiling member of the slurry distributor includes a support assembly, a coupling segment that extends generally longitudinally and transversely, and an adjustment bar translation that extends generally vertically from the coupling segment. The translation adjustment bar of the profiling member is movably secured to the support assembly so 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 couple the translation adjustment bar to secure the profiling member in one of the range of selected vertical positions.

In another embodiment, 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.

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

In another embodiment, the support assembly includes a rotation adjustment bar that extends between the fixed support member and the pivoting support member. The The rotation adjustment bar is movably secured to the fixed support member so that the movement of the rotation adjustment bar with respect to the fixed member pivots the pivoting support member about the pivot axis with respect to the fixed support member .

In another embodiment, the support assembly includes a clamping mechanism adapted to selectively couple the rotation adjustment bar to secure the profiling member in one of the range of selected positions along the arc length.

In another embodiment, a cement grout mixing and distribution assembly comprises: a mixer adapted to agitate water and a cementitious material to form an aqueous cement slurry and a slurry distributor in fluid communication with the mixer. The slurry distributor includes a distribution conduit that extends generally along a longitudinal axis and includes an inlet portion and a distribution outlet in fluid communication with the inlet portion. The distribution outlet extends a predetermined distance along a transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The distribution outlet includes an outlet opening having a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the axis longitudinal and the transverse axis. The slurry distributor also includes a profiling mechanism that includes a profiling member in contact relation with the distribution conduit, the profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in compressive engagement enhanced with a portion of the distribution conduit adjacent to the distribution outlet to vary the shape and / or size of the outlet opening.

In another embodiment, the cement grout mixing and distribution assembly further comprises a distributor support member that supports the distribution conduit. The profiling mechanism of the grout dispenser includes a support assembly having a fixed support member and a pivoting support member. The fixed support member is connected to the distributor support member. The pivoting support member is rotatable about a pivot axis over an arc length with respect to the fixed support member, the pivoting support member supports the profiling member.

In another embodiment, the cement grout mixing and distribution assembly further comprises a supply conduit positioned between and in fluid communication with the mixer and the slurry distributor, a flow modifier element associated with the supply conduit and adapted to control a flow of the aqueous cement slurry of the mixer, and an aqueous foam supply conduit in fluid communication with at least one of the mixer and the supply conduit.

In another embodiment, the cement slurry mixing and distribution assembly comprises a slurry distributor including a supply conduit including a first inlet segment with a first feed inlet and a second inlet segment with a second feed in place in spaced relationship with the first power input. The inlet portion of the distribution conduit is in fluid communication with the first and second feed inlets of the supply conduit. The first feed inlet is adapted to receive a first flow of aqueous cement slurry from the mixer. The second feed inlet is adapted to receive a second flow of aqueous cement slurry from the mixer, and the distribution outlet is in fluid communication with the first and second feed inlets and is adapted so that the first and second combined streams of Aqueous cementitious slurry is discharged from the slurry distributor through the distribution outlet.

In another modality, the assembly of mixed and gypsum slurry distribution further comprises a supply conduit positioned between and in fluid communication with the mixer and the slurry distributor, the supply conduit includes a main supply trunk and first and second supply branches and a flow divider joining the main supply trunk and the first and second supply branches, the flow splitter is positioned between the main supply trunk and the first supply branch and between the main supply trunk and the second supply branch. The first supply branch is in fluid communication with the first supply inlet of the slurry distributor, and the second supply branch is in fluid communication with the second supply inlet of the slurry distributor.

In another embodiment, a method for preparing a cementitious product comprises: (a) discharging an aqueous cement slurry stream from a mixer; (b) passing the flow of aqueous cement slurry through an inlet portion of a distribution conduit of a slurry distributor; (c) discharging the aqueous cementitious slurry flow from an outlet opening of a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction, the distribution outlet it extends a distance predetermined along a transverse axis, the transverse axis is substantially perpendicular to the longitudinal axis, the exit opening has a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis; and (d) compressively coupling a portion of the distribution conduit adjacent to the distribution outlet to vary the shape and / or size of the exit opening.

In another embodiment, the method for preparing a cementitious product comprises the distribution conduit which is coupled in a compressive manner by a profiling mechanism so that the flow of aqueous cement slurry is discharged from the outlet opening at an expanded expansion angle with relation to the direction of the machine.

In another embodiment, the method for preparing a cementitious product comprises the distribution conduit which is compressively engaged by a profiling mechanism having a profiling member in contact relation with the distribution conduit. The profiling member is movable over a range of travel such that the profiling member is in a range of positions over which the profiling member is in compressed engagement with the distribution conduit.

In another modality, the method to prepare a The cementitious product further comprises moving the profiling member along the vertical axis to adjust the size and / or shape of the exit opening.

In another embodiment, the method for preparing a cementitious product further comprises moving the profiling member such that the profiling member moves along at least one axis and / or rotates around at least one axis to adjust the size and / or the shape of the exit opening.

EXAMPLES With reference to FIG. 65, the geometry and flow characteristics of a slurry distributor embodiment constructed in accordance with the principles of the present disclosure were evaluated in Examples 1-3. A top plan view of an average portion 1205 of a slurry distributor is shown in FIG. 65. The middle portion 1205 of the slurry distributor includes a middle portion 1207 of a supply duct 320 and a middle portion 1209 of a distribution duct 328. The middle portion 1207 of the supply duct 322 includes a second supply inlet 325 that defines a second opening 335, a second input segment 337, and a middle portion 1211 of a bifurcated connector segment 339. The middle portion 1209 of the distribution conduit 328 includes a middle portion 1214 of an input portion 352 of the distribution conduit 328 and a middle portion 1217 of a distribution outlet 330.

It should be understood that another middle portion of a slurry distributor, which is a mirror image of the middle portion 1205 of FIG. 65, can be integrally joined and aligned with the middle portion 1205 of FIG. 65 at a midpoint. transverse central 387 of dispensing outlet 330 to form a slurry distributor that is substantially similar to slurry distributor 420 of FIG. 15. Accordingly, the geometry and flow characteristics described below are equally applicable to the middle portion of the mirror image of the slurry distributor as well.

With reference to FIG. 72, the geometry and flow characteristics of another embodiment of a slurry distributor 2020 constructed in accordance with the principles of the present disclosure were evaluated in Examples 4-6. The grout distributor 2020 shown in FIG. 72 is substantially the same as the slurry distributor 1420 of FIG. 34. The flow characteristics of the slurry distributor 2020 of FIG.72 using a 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.22.

EXAMPLE 1 In this example and with reference to FIG.65, the particular geometry of the middle portion 1205 of the slurry distributor was evaluated at sixteen different Li-i6 locations between a first Li location at the second power input 325 and a sixteenth Li6 location in an average portion 1207 of the distribution outlet 330. Each location LI6 represents a cross-sectional part of the middle portion 1205 of the slurry distributor as indicated by the corresponding line. A flow line 1212 along the geometric center of each cross section was used to determine the distance between adjacent locations Li-i6. The eleventh location Ln corresponds to the middle portion 1214 of the inlet portion 352 of the distribution conduit 328 which corresponds to an opening 342 of a second supply outlet 345 of the middle portion 1207 of the supply conduit 320. Accordingly, the first up to tenth Li-io locations are taken in the middle portion 1207 of the feed conduit 320, and the eleventh to sixteenth locations are taken in the middle portion 1209 of the distribution conduit 328.

For each location LI-I6, the following geometric values were determined: the distance along the flow line 1212 between the second feed inlet 325 and the particular location LI-I6; the cross-sectional area of the opening at location Li-i6; the perimeter of the Li-i6 location; and the hydraulic diameter of location LI-6. The hydraulic diameter was calculated using the following formula: Dhyd = 4 x A / P (Ec.1) where Dhyd is the hydraulic diameter, A is the area of the particular location Li-i6, and P is the perimeter of the particular location Li-16. Using the input conditions, the dimensionless values for each Li-is location can be determined to describe the interior flow geometry, as shown in Table 1. The curve fitting equations were used to describe the dimensionless geometry of the portion 1205 of the slurry distributor in FIG.66, showing the dimensionless distance of the inlet against the dimensionless area and the hydraulic diameter.

The analysis of the dimensionless values for each Li-ie location shows that the cross-sectional flow area increases from the first location Li in the second feed inlet 325 to the eleventh location Ln in the middle portion 1214 of the input portion 352 (also the opening 342 of the second feed outlet 345). In the exemplary mode, the section flow area The cross section in the middle portion 1214 of the inlet portion 352 is approximately 1/3 greater than the cross sectional flow area in the second feed inlet 325. Between the first location Li and the eleventh location Ln, the flow area of cross section of the second input segment 337 and the second shaped conduit 339 varies from location to location Li-n. In this region, at least two adjacent locations Le, ln are configured such that the location ln located further away from the second feed entrance 325 has a cross-sectional flow area that is smaller than the adjacent location 1 & which is closer to the second power input 325.

Between the first location Li and the eleventh location Ln, in the middle portion 1207 of the feed conduit 322 there is an expansion area (eg, L4-6) that has a cross-sectional flow area that is greater than an area of cross-sectional flow of an adjacent area (eg, L3) upstream of the expansion area in a direction of the second inlet 335 towards the middle portion 1217 of the distribution outlet 330. The second inlet segment 337 and the second conduit formed 341 have a cross section that varies along flow direction 1212 to help distribute the second flow of grout moving to through this.

The cross-sectional area decreases from the eleventh location Ln in the middle portion 1214 of the entrance portion 352 of the distribution conduit 328 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In In the exemplary embodiment, the cross-sectional flow area of the middle portion 1214 of an inlet portion 352 is approximately 95% of that of the middle portion 1217 of the distribution outlet 330.

The cross sectional flow area at the first location Li at the second feed inlet 325 is smaller than the cross sectional flow area at the sixteenth location Li6 at the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 In the exemplary embodiment, the cross-sectional flow area in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately 1/4 greater than the cross-sectional flow area in the second supply inlet 325 .

The hydraulic diameter decreases from the first location Li in the second feed inlet 325 to the eleventh location Ln in the middle portion 1214 of the inlet portion 352 of the distribution conduit 328. In the exemplary embodiment, the hydraulic diameter in the middle portion 1214 of the inlet portion 352 of the distribution conduit 328 is approximately 1/2 of the hydraulic diameter in the second supply inlet 325.

The hydraulic diameter decreases from the eleventh location Ln in the middle portion 1214 of an inlet portion 352 of the distribution conduit 328 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the embodiment exemplary, the hydraulic diameter of the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 is approximately 95% of that of the middle portion 1214 of the inlet portion 352 of the distribution conduit 328.

The hydraulic diameter at the first location Li at the second inlet 325 is greater than the hydraulic diameter at the sixteenth location LI6 at the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the exemplary embodiment, the hydraulic diameter at the middle portion 217 of the distribution outlet 330 of the distribution conduit 328 is less than about half that of the second supply inlet 325.

EXAMPLE 2 In this example, the middle portion 1205 of the slurry distributor of FIG.65 was used to model the flow of gypsum slurry through this under different flow conditions. For all flow conditions, the density (p) of the aqueous gypsum slurry was set at 1,000 kg / m3. The aqueous gypsum slurry is a shear thinning material so that when this shear is applied, its viscosity may decrease. The viscosity (m) Pa.s of the gypsum slurry was calculated using the Lcy Fluid Model of Power that has the following equation: m = K ^ -1 (Ec.2) where, K is a constant, is the shear rate, and n is a constant equal to 0.133 in this case.

In the first flow condition, the gypsum slurry has a viscosity factor K of 50 in the Power Law model and enters the second feed inlet 325 at 2.5 m / s. A computational fluid dynamics technique with a finite volume method was used to determine the flow characteristics in the distributor. At each location LI-I6, the following flow characteristics were determined: average weighted area velocity (U), average weighted area shear velocity (y), viscosity calculated using the Power Law Model (Eq. 2), Shear stress, and Number of Rcynolds (Re).

The shear stress was calculated using the following equation: Shear force = m x f (Ec.3) where m is the viscosity calculated using the Power Law Model (Ec.2), and is the shear rate.

The Reynolds number was calculated using the following equation: Re = = p x U x Dhyd / m (Ec.4) where p is the density of gypsum slurry, U is the average weighted area velocity, Dhyd is the hydraulic diameter, and m is the viscosity calculated using the Power Law Model (Ec.2).

In a second case of flow condition, the feed rate of the gypsum slurry in the second feed inlet 325 was increased to 3.55 m / s. All other conditions were the same as in the first flow condition in this example. The dimensional values of the flow characteristics mentioned in each Li-i6 location were modeled for both the first flow condition where the entrance speed is 2.5 m / s and the second Flow condition where the entry speed is 3.55 m / s. Using the input conditions, the dimensionless values of the flow characteristics were determined for each location Li-i6, as shown in Table II.

For both flow conditions, where K is set equal to 50, the average speed was reduced from the first Li location in the second power input 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the average velocity was reduced by approximately 1/5, as shown in FIG. 67 For both flow conditions, the increased shear rate from the first location Li at the second feed inlet 325 to the sixteenth location Li6 at the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear rate approximately doubles from the first location Li in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution pipe 328, as shown in FIG. 68.

For both flow conditions, the calculated viscosity was reduced from the first Li location in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the embodiment illustrated, the calculated viscosity was reduced from the first location Li in the second feed inlet 325 to the Sixteenth location Lys in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 by approximately half, as illustrated in FIG. 69.

For both flow conditions in FIG. 70, the shear stress increased from the first location Li at the second feed inlet 325 to the sixteenth Lie location at the middle portion 1217 of the distribution outlet 330 of the distribution pipe 328. In In the illustrated embodiment, the shear stress increased by approximately 10% from the first location Li in the second feed inlet 325 to the sixteenth location LI6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328.

For both flow conditions, the number of Rcynolds in FIG. 71 was reduced from the first location Li in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the embodiment illustrated, the number of Reynolds was reduced from the first Li location on the second power inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 by approximately 1/3. For both flow conditions, the number of Rcynolds at the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 is in the laminar region.

Yes Yes EXAMPLE 3 In this example, the middle portion 1205 of the slurry distributor of FIG.65 was used to model the flow of gypsum slurry through it under flow conditions similar to those of Example 2, except that the value of the K coefficient in the Lcy Model of Power (Ec.2) was set to 100. The flow conditions were similar to those of Example 2 in other aspects.

Again, the flow characteristics were evaluated for a feed rate of the gypsum slurry in the second feed inlet 325 of 2.50 m / s and 3.55 m / s. At each Li-i6 location, the following flow characteristics were determined: average weighted area velocity (U), average weighted area shear rate (†), viscosity calculated using the Power Law Model (Eq. 2), shear stress (Eq. 3), and Reynolds number (Re) (Eq.4). Using the input conditions, the dimensionless values of the flow characteristics were determined for each location Li-i6, as shown in Table III.

For both flow conditions where K was set equal to 100, the average velocity was reduced from the first location Li in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated mode, the average speed was reduced by approximately 1/5. The results of the average velocity, on a dimensionless basis, were substantially the same as those of Example 2 and FIG.67.

For both flow conditions, the shear rate increased from the first location Li in the second feed inlet 325 to the sixteenth Lie location in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear rate approximately doubled from the first location Li at the second feed inlet 325 to the sixteenth location Li6 at the middle portion 1217 of the distribution outlet 330 of the distribution pipe 328. The results of the shear rate, on a dimensionless base, were substantially the same as those of Example 2 and FIG.68.

For both flow conditions, the calculated viscosity was reduced from the first location Li at the second feed inlet 325 to the sixteenth location Li6 at the middle portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the illustrated embodiment, the calculated viscosity was reduced from the first location Li in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 by about half. The results of the calculated viscosity, on a dimensionless basis, were substantially the same as those of Example 2 and FIG.69.

For both flow conditions, the shear stress increased from the first location Li at the second feed inlet 325 to the sixteenth location Li6 at the middle portion 127 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the Shear stress increased by approximately 10% from the first Li location in the second feed inlet 325 to the sixteenth location LI6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328. The results of the shear stress, on a dimensionless basis, were substantially the same as those of Example 2 and FIG.70.

For both flow conditions, the number of Rcynolds was reduced from the first location Li in the second feed inlet 325 to the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment illustrated, the Reynolds number was reduced from the first Li location in the second power input 325 to the sixteenth location L6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 for about 1/3. For both flow conditions, the number of Rcynolds at the sixteenth location Li6 in the middle portion 1217 of the distribution outlet 330 of the distribution conduit 328 is in the laminar region. The results of the Reynolds number, on a dimensionless basis, were substantially the same as those of Example 2 and FIG. 71.

FIGS.67-71 are graphs of the flow characteristics calculated for the different flow conditions of Examples 2 and 3. The curve fitting equations were used to describe the change in flow characteristics over the distance between the input of power to the middle portion of the distribution outlet. Accordingly, Examples 2 and 3 show that the flow characteristics are consistent over the variations in the velocity and / or input viscosity.

EXAMPLE 4 In this example, the grout distributor 2020 of FIG. 72 was used to model the gypsum slurry flow in one of the bulb portions 2120 of the supply conduit 2022. With reference to FIG. 72, the first and second input segments 2036, 2037 of the slurry distributor 2020 have each one a diameter D. The slurry distributor 2020 has a length, along the longitudinal axis, of approximately 12 x D. The slurry distributor 2020 is symmetrical about a central longitudinal axis 50 which extends generally in the direction of the machine 2192. The slurry distributor 2020 can be separated into two half portions 2004, 2005 which are substantially symmetrical about the central longitudinal axis.

With reference to FIG. 73, the midportion 2004 of the slurry distributor of FIG. 72 was used to model the flow of gypsum slurry through this under flow conditions similar to those of Example 2, except using different dimensionless velocity expressions. An input diameter D (x * = x / D) was selected as the length scale to not dimension the position vector x (x * = x / D), and an average input velocity (U) was used as the speed scale to not dimensionalize the velocity vector u (u * = u / U).

The flow conditions were similar to those of Example 2 in other aspects.

With reference to FIGS.73-76, a computational fluid dynamics (CFD) technique with a finite volume method was used to determine the flow characteristics in the middle portion of the distributor. In particular, the average velocities at different vertical locations in area A were calculated. The area extending around 0.75D from a center of the input segment in area A was analyzed. Twelve radially spaced vertical portions were analyzed to calculate twelve different Average grout velocities radially around the bulb portion. The twelve locations were spaced substantially radially so that each adjacent radial location is spaced approximately 30 °. With reference to FIGS. 75 and 76, the radial location 1 corresponds to a direction in opposite relation to the machine direction 2192, and the radial location 7 corresponds to the machine direction 2192. The radial locations 4 and 10 substantially align with the transverse axis 60 The CFD technique was used with two different input speed conditions, ui = U and U2 = 1.5U. The results of the CFD analysis are found in Table IV. The magnitude of the velocity is expressed as a dimensionless absolute value (| u | * = | u | / U). The data was also plotted in FIG.77. It should be understood that the other 2005 mid portion of the 2020 slurry distributor would exhibit similar flow characteristics.

For both flow conditions, the average velocity at each radial location 1-12 was less than the input velocity, but was greater than zero. The average speed varied from about half to about 7/8 of the entry speed (u * -0.48 to 0.83 of the entry speed). The surface of the convex depression contoured in the bulb portion helped to redirect the flow of the input segment radially outward in all directions.

The speed of the grout also decreased with respect to the speed of entry. The average speed of all twelve radial locations for a given flow condition was substantially similar (-0.65 or 65% of the entry velocity).

Also, in each flow condition, the highest average speeds occurred at radial locations 3-5 and 9-11. The higher average speed along the transverse axis, or along the direction through the machine 60, helps to provide more edge flow to the sidewalls.

Accordingly, this Example illustrates that bulb portion 2120 helps to delay the slurry and change the direction of the grout from a vertical direction downward to a horizontal plane radially outward. In addition, the bulb portion 2120 helps to divert the flow of slurry to the outer and inner side walls of the shaped duct of the mid portion 2004 of the slurry distributor 2020 to stimulate the movement of the slurry in the direction through the machine 60. .

EXAMPLE 5 In this example, the slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry in one of the shaped conduits 2041 of the supply conduit 2022. With reference to FIG. The slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry through it under flow conditions similar to those of Example 2 except that using a dimensionless expression of speed similar to that of Example 4. In In particular, the swirl movement of the slurry in the inner and outer side walls of the shaped duct was analyzed.

With reference to FIGS. 73, 74, and 78, a computational fluid dynamics (CFD) technique with a finite volume method was used to determine the flow characteristics in the 2004 midportion of the 2020 distributor. In particular, the swirl movement of the grout near the inner and outer side walls of the shaped duct 2041. With Referring to FIG. 73, the slurry moves in a swirling manner when it enters the shaped duct 2041. As the slurry moves along the machine direction 2192 to the 2030 distribution outlet, the power lines of grout are more ordered. The swirl movement of the slurry was analyzed in a region of the shaped duct 2041 at a longitudinal location of approximately 1-3 / 4 D (1.72 D) in areas B1 and B2, as shown in FIGS. 74 and 78.

The swirling movement of the grout is a function of its tangential velocity and its axial speed (or machine direction). With reference to FIG. 78, the swirling degree of the swirling flow is generally characterized by the swirl number (S), such as angular and linear momentum fluxes using the following formula: Moment of the Tangential Speed Component S = Moment of the Axial Speed Component (Ec-5) | w u r dr with w = velocity tangencialy u = axial velocity | u u r dr and r represents the radial location.

If the average tangential velocity and axial velocity values are used in Equation 5, it becomes: Tangential Speed Average w, ve S - 5- = - (Ec.6) Average Axial Speed u For this example, the characteristic vortex motion (Sm) was expressed using the following formula: Maximum Tangential Speed - - (Ec.7) Average Axial Speed In this example, the calculated swirl movement was used to calculate the swirl angle using the following formula: Swirl Angle ~ tan-1 (Sm) (Eq. 8).

The CFD technique was used with two different adimensional velocity input conditions, ui = U and u2 = 1.5U. The results of the CFD analysis are found in Table V. It should be understood that the other middle portion of the slurry distributor would exhibit similar flow characteristics. Through this analysis it has been found that, in embodiments, the slurry distributor can be constructed to produce a swirl movement Sm in a range from about zero to about 10 in the slurry distributor and a swirl angle in a range from approximately zero degrees to approximately 84 °.

For both flow conditions, the maximum tangential velocity at the edges was at least about half the input velocity in an edge region of the inlet portion of the shaped conduit. It is expected that Swirling movement near the side walls helps maintain cleanliness of the interior geometry of the grout dispenser while in use. As shown in FIG. 73, the swirl movement of the slurry decreases along the axis of the machine 50 in the direction of flow to the distribution outlet 2030.

EXAMPLE 6 In this example, the grout distributor 2020 of FIG. 72 was used to model the gypsum slurry flow through the supply conduit 2022 and the distribution conduit 2028. With reference to FIGS. 73 and 74, the midportion 2004 of the slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry through it under flow conditions similar to those of Example 2 except using a dimensionless expression of velocity similar to that of Example 4.

For all flow conditions, the density (p) of the aqueous gypsum slurry was set at 1,000 kg / m3 and the viscosity factor K was set to 50. Again, the flow characteristics were evaluated for a speed of dimensionless feed of the gypsum slurry in feed inlet 2024 of B and 1.5B. The following flow characteristics were determined at each successive dimensionless location downstream of the shoulder portion of the shaped conduit 2041 along the machine direction 2192 expressed as a function of the inlet diameter D: average weighted area velocity (U) ), average weighted area shear velocity (), viscosity calculated using the Lcy Power Model (Eq. 2), and the Reynolds number (Re) (Eq.4). The hydraulic diameter (Eq. 1) was also calculated in the successive dimensionless locations observed along the longitudinal axis 50. Using the flow conditions For input, the dimensionless values of the flow characteristics for each location were determined, as shown in Table VI.

FIGS.79-82 are graphs of the flow characteristics calculated for the different flow conditions of Example 6. The curve fitting equations were used to describe the change in flow characteristics over the distance between the power input to the average portion 2004 of the distribution outlet 2030. Accordingly, the examples show that the flow characteristics are consistent over the variations in the input velocity.

For both flow conditions, the average velocity was reduced from the first location (approximately 3D) in the supply conduit to the last location (approximately 12D) in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. Average speed decreased substantially progressively as the slurry moved along the direction of the machine 2192. In the illustrated embodiment, the average speed was reduced by approximately 1/3 of the input speed, as shown in FIG. FIG. 79 For both flow conditions, the shear rate increased from the first location (approximately 3D) in the supply conduit 2022 to the last location (approximately 12D) in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. The shear rate varied from location to location. In the illustrated embodiment, the shear rate increased in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 with respect to the inlet, as shown in FIG.80.

For both flow conditions, the calculated viscosity was reduced from the first location (approximately 3D) in the supply conduit to the last location (approximately 12D) in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. Calculated viscosity varied from location to location. In the illustrated embodiment, the calculated viscosity decreased in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 with respect to the inlet, as shown in FIG.81.

For both flow conditions, the number of Rcynolds in FIG. 82 was reduced from the first location (approximately 3D) in the supply conduit to the last location (approximately 12D) in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. In the illustrated embodiment, the number of Rcynolds decreased in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 with respect to the inlet by approximately 1/2. For both flow conditions, the Reynolds number in the middle portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 is in the laminar region.

Accordingly, it has been found that the distal half of the slurry distributor (between about 6D and about 12D) was configured to provide a flow stabilization region in which the average slurry rate and the Reynolds number are generally stable and decreased with respect to feed intake conditions. As shown in FIG. 73, the grout generally moves in a laminar form along the machine direction 2192 through this flow stabilization region. 00 EXAMPLE 7 In this example, the grout distributor 2020 of FIG. 72 was used to model the gypsum slurry flow at the distribution outlet 2030 of the distribution conduit 2028. In this example, the 2004 midportion of the slurry distributor of FIG. 73 was used to model the flow of gypsum slurry. through this under flow conditions similar to those of Example 2 except that using a dimensionless expression of the width of the exit opening 2081. A dimensionless width (w / W) through the middle portion 2119 of the exit opening 2081 of the distribution output 2030 (with a center line at the transverse center midpoint 2187 that is equal to zero as shown in FIG. 72). The flow conditions were similar to those of Example 2 in other aspects.

A CFD technique with a finite volume method was used to determine the flow characteristics in the 2004 midportion of the 2020 distributor. In particular, the extension angle of the slurry discharged from the outlet opening 2081 was analyzed. several locations across the width of the middle portion 2119 of the outlet opening 2081 of the distribution outlet 2030. The extension angle was determined using the following formula: extension angle = tan-1 (Vx / Vz), (Eq. 9) where Vx is the average speed in the direction through the machine and Vz is the average speed in the machine direction.

The extension angle was calculated for two different conditions: one in which the profiling mechanism does not compress the outlet opening 2081 ("without profiler") and one in which the profiling mechanism compresses the outlet opening 2081 ("profiler") "). In the patterned grout distributor 2020, the outlet opening 2081 has a height of approximately 1.90 cm (3/4 inch) across its full width of approximately 25.4 cm (ten inches) for each half portion 2004, 2005, for a total of 50.8 cm (twenty inches) for the total width of the outlet opening 2081. The modeling shaping mechanism has a profile member that is approximately 38.1 cm (15 inches) wide and is aligned with the mid-center point transverse so that a lateral portion of the distribution outlet is in displacement relationship with the profiling member and is uncompressed. In the modeling "profiler" condition, the profiling mechanism compresses the exit opening by approximately 1/8 inch so that the exit opening is approximately 5/8 inch in the area below the profiling member. He Extension angle for both conditions was determined, as shown in Table VII.

Under both conditions, the extension angle increases as the location moves further away from the transverse center midpoint 2187 (width = 0). The extension angle is larger at the lateral edge of the outlet opening 2081.

The extension angle increased by using the profiling mechanism to compress the discharge outlet 2030, thereby reducing the height of the outlet opening 2081. In the modeling "profiler" condition, the maximum extension angle at the lateral edge ( width = 0.466) increased more than 25 percent with respect to the condition "without profiler". In the condition of "profiler", the average angle of extension increased by more than 50 percent with respect to the condition of "without profiler".

All references, including publications, patent applications and patents, cited herein are incorporated by reference to the same extent as if each reference were individual and specifically indicated to be incorporated as a reference and described in its entirety. totality in the present.

The use of the terms "a" and "one" and "the" and similar referents in the context of the description of the invention (especially in the context of the following claims) must be taken to cover both the singular and the plural , unless otherwise indicated herein or clearly contradicted by the context. The terms "comprising", "having", "including", and "containing" shall be construed as open terms (ie, meaning "including, but not limited to,") unless otherwise indicated. The citation of ranges of values herein is intended simply to serve as an abbreviated method to refer individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated in the description as if it were individually cited in the present. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by the context. The use of each and every example, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not raise a limitation on the scope of the invention unless the opposite is claimed. No language in the description should be construed as indicating any unclaimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of these preferred embodiments may become apparent to those of ordinary skill in the art upon reading the above description. The inventors expect the experts to employ such variations as appropriate, and the inventors claim that the invention can be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject cited in the claims appended thereto as permitted by the applicable law. On the other hand, any combination of the elements described above in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or is clearly contradicted by the context.

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property.

1. A grout distributor, characterized in that it comprises: a distribution conduit extending generally along a longitudinal axis and including an inlet portion and a distribution outlet in fluid communication with the inlet portion, the distribution outlet extends a predetermined distance along an axis transverse, the transverse axis is substantially perpendicular to the longitudinal axis, the distribution outlet includes an exit opening having a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis; a profiling mechanism including a profiling member in contact with the distribution conduit, the profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in compressive engagement increased with a portion of the distribution conduit adjacent to the outlet of distribution to vary the shape and / or size of the exit opening.

2. The slurry distributor according to claim 1, characterized in that the outlet opening of the dispensing outlet has a width to weight ratio of approximately 4 or more.

3. The slurry distributor according to claim 1 or claim 2, characterized in that the outlet opening of the distribution outlet has a width along the transverse axis, the profiling member has a width extending a second predetermined distance to along the transverse axis, the width of the exit opening is greater than the width of the profiling member, and the profiling member is positioned such that a pair of side portions of the distribution exit are in displaced relation with the member of profiling.

4. The slurry distributor according to any one of claim 1 to claim 3, characterized in that the profiling member is movable along the vertical axis.

5. The slurry distributor according to any one of claim 1 to claim 4, characterized in that the profiling member has at least two degrees of freedom.

6. The slurry distributor according to any one according to claim 1-5, characterized in that the profiling member is movable along at least one axis and rotatable about at least one pivot axis.

7. The slurry distributor according to claim 5-6, characterized in that the profiling member is translatable along the vertical axis and rotatable about a pivot axis that is substantially parallel to the longitudinal axis, the profiling member is rotatable about of the pivot axis on an arc length so that the profiling member is in a range of positions over which the profiling member is in variable compressive engagement with the portion of the distribution conduit through the transverse axis so that the The height of the outlet opening varies along the transverse axis.

8. The slurry distributor according to claim 7, characterized in that the profiling mechanism includes a support assembly having a fixed support member and a pivoting support member, the pivoting support member is rotatable about the pivot axis on the Arc length with respect to the fixed support member, the pivoting support member supports the profiling member.

9. The slurry distributor according to any one according to claim 1 to 8, characterized in that the profiling member is rotatable about a pivot axis over an arc length so that the profiling member is in a range of positions about wherein the profiling member is in variable compressive engagement with the portion of the distribution conduit through the transverse axis so that the height of the outlet opening varies along the transverse axis.

10. The slurry distributor according to claim 1 to claim 10, characterized in that the profiling mechanism includes a support assembly, and the profiling member includes a coupling segment that extends generally longitudinally and transversally and an adjustment rod of translation that extends generally vertically from the coupling segment, the translation adjustment bar of the profiling member is movably secured to the support assembly so that the profiling member is movable over a range of vertical positions.

11. The slurry distributor according to claim 10, characterized in that the support assembly includes a clamping mechanism adapted to selectively couple the translation adjustment bar. to secure the profiling member in one of the range of selected vertical positions.

12. The slurry distributor according to claim 10 or 11, characterized in that 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 arch length.

13. The slurry distributor according to claim 10-12, characterized in that the support assembly includes a fixed support member and a pivoting support member, the pivoting support member is rotatable about the pivot axis over the arc length with With respect to the fixed support member, the pivoting support member supports the profiling member.

14. The slurry distributor according to any one according to claim 10-13, characterized in that the support assembly includes a rotation adjustment bar extending between the fixed support member and the pivoting support member, the adjustment bar. The rotation member is movably secured to the fixed support member so that the movement of the rotation adjustment bar with respect to the fixed member pivots the pivoting support member about the pivot axis with respect to the fixed support member.

15. The slurry distributor according to any one of claim 10-14, characterized in that the support assembly includes a clamping mechanism adapted to selectively couple the rotation adjustment bar to secure the profiling member in one of the range of selected positions along the arc length.

16. A mixing and distribution assembly of cementitious slurry, characterized in that it comprises: a mixer adapted to agitate water and a cementitious material to form an aqueous cementitious slurry; A grout distributor in fluid communication with the mixer, the grout distributor includes: a distribution conduit extending generally along a longitudinal axis and including an inlet portion and a distribution outlet in fluid communication with the inlet portion, the distribution outlet extends a predetermined distance along an axis transverse, the transverse axis is substantially perpendicular to the longitudinal axis, the distribution outlet includes an exit opening having a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis, and a profiling mechanism that includes a member of profiled in contact relation with the distribution conduit, the profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in compressive engagement increased with a portion of the distribution conduit adjacent to the distribution outlet to vary the shape and / or size of the outlet opening.

17. The mixing and distribution assembly of cementitious slurry according to claim 16, characterized in that it also comprises: a distributor support member supporting the distribution conduit; wherein the profiling mechanism of the grout distributor includes a support assembly having a fixed support member and a pivoting support member, the fixed support member is connected to the distributor support member, the pivoting support member is rotatable about a pivot axis on an arc length with respect to the fixed support member, the pivoting support member supports the profiling member.

18. The mixing and distribution assembly of cementitious slurry according to claim 17, characterized in that it also comprises: a supply conduit placed between and in fluid communication with the mixer and the grout distributor; a flow modifier element associated with the supply conduit and adapted to control a flow of the aqueous cement slurry of the mixer; an aqueous foam supply conduit in fluid communication with at least one of the mixer and the supply conduit.

19. The cement slurry mixing and distribution assembly according to any one of claim 16-18, characterized in that the slurry distributor includes a supply duct including a first inlet segment with a first supply inlet and a second segment. Inlet with a second feed inlet positioned in spaced relationship with the first feed inlet, the inlet portion of the distribution duct is in fluid communication with the first and second feed inlets of the feed duct, the first feed inlet is adapted to receive a first flow of aqueous cement slurry from the mixer, the second feed inlet is adapted to receive a second flow of aqueous cement slurry from the mixer, and the distribution outlet is in fluid communication with the first and second inlets of the mixer. power and it adapts so that the first and second combined aqueous slurry flows are discharged from the slurry distributor through the distribution outlet.

20. The gypsum slurry mixing and distribution assembly according to claim 19, characterized in that it also comprises: a supply conduit positioned between and in fluid communication with the mixer and the slurry distributor, the supply conduit includes a main supply trunk and first and second supply branches; a flow divider joining the main supply trunk and the first and second supply branches, the flow divider is placed between the main supply trunk and the first supply branch and between the main supply trunk and the second branch of supply; wherein the first supply branch is in fluid communication with the first feed inlet of the slurry distributor, and the second supply branch is in fluid communication with the second supply inlet of the slurry distributor.

21. A method for preparing a cementitious product, characterized in that it comprises: discharge a flow of aqueous cementitious slurry from a mixer; passing the flow of aqueous cement slurry through an inlet portion of a distribution conduit of a slurry distributor; discharging the aqueous cementitious slurry stream from an outlet opening of a distribution outlet of the slurry distributor into a mesh of roof sheet material moving along a machine direction, the distribution outlet extending a predetermined distance along a transverse axis, the transverse axis is substantially perpendicular to the longitudinal axis, the exit opening has a width, along the transverse axis, and a height, along a vertical axis mutually perpendicular to the axis longitudinal and transverse axis; compressively coupling a portion of the distribution conduit adjacent to the distribution outlet to vary the shape and / or size of the outlet opening.

22. The method for preparing a cementitious product according to claim 21, characterized in that the distribution conduit is coupled in a compressive manner by a profiling mechanism so that the flow of aqueous cement slurry is discharged from the outlet opening at an angle of expansion increased in relation to the address of the machine.

23. The method for preparing a cementitious product according to claim 21 or 22, characterized in that it comprises the distribution conduit which is compressively coupled by a profiling mechanism having a profiling member in contact relation with the distribution conduit, the profiling member is movable over a range of travel so that the profiling member is in a range of positions over which the profiling member is in enhanced compressive engagement with the distribution conduit.

24. The method for preparing a cementitious product according to any one according to claim 21-23, characterized in that it further comprises: moving the profiling member along the vertical axis to adjust the size and / or shape of the exit opening.

25. The method for preparing a cementitious product according to any one according to claim 21-24, characterized in that it further comprises: moving the profiling member so that the profiling member moves along at least one axis and / or rotates around at least one axis to adjust the size and / or shape of the exit opening.