JP2016503354A - Slurry distributor, system and method of use thereof - Google Patents

Abstract

The slurry distributor may include a distribution conduit and a copying mechanism. The distribution conduit includes an entry portion and a distribution outlet that extends generally along the longitudinal axis and is in fluid communication with the entry portion. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially orthogonal to the longitudinal axis. The dispensing outlet includes an outlet opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal and transverse axes. The profiling mechanism is in contact with the distribution conduit and the profiling member within a range of increased compression engagement with a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening. And a copying member that is movable over the range of travel. [Selection] Figure 22

Description

CROSS REFERENCE TO RELATED APPLICATIONS This patent application is a non-provisional patent application No. 13 / 659,516 entitled “Slurry Distributor, System and Method of Use thereof,” filed Oct. 24, 2012, and March 2013. We claim the benefit of the continuation-in-part patent application 13 / 844,550 entitled "Slurry Dispenser with Copying Mechanism, System and Method of Use", filed on 15th.

  The entirety of all the aforementioned related applications are incorporated herein by this reference.

  The present disclosure relates to a continuous board (eg, wallboard) manufacturing process, and more particularly to an instrument, system and method for dispensing aqueous calcined gypsum slurry.

  It is well known to produce gypsum board by uniformly dispersing calcined gypsum (commonly referred to as “stucco”) in water to form an aqueous calcined gypsum slurry. 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 agitating the contents to form a uniform gypsum slurry. The slurry is continuously directed through the mixer outlet and into the outlet conduit connected to the mixer outlet. Aqueous foam may be combined with the aqueous calcined gypsum slurry in the mixer and / or in the discharge conduit. The slurry stream is continuously deposited on the moving web of cover sheet material that passes through the discharge conduit and is supported by the forming table therefrom. The slurry is allowed to spread on the advancing web. A web of second cover sheet material is applied to cover the slurry to form a continuous wallboard preform sandwich structure, which is subjected to formation in a conventional forming station or the like to a desired thickness. Get The calcined gypsum hardens by reacting with the water in the wallboard preform as it moves down the production line. The wallboard preform is cut into segments along the line where the wallboard preform is fully cured, and the segments are turned over and dried (eg, in a furnace) to expel excess water. Processed to provide the final wallboard product of the desired dimensions.

  Prior apparatus and methods for addressing some operational problems associated with the manufacture of gypsum wallboard are disclosed in US Pat. Nos. 5,683,635 and 5,643, assigned to the assignee of the present invention. , 510, 6,494,609, 6,874,930, 7,007,914 and 7,296,919, which are incorporated herein by reference. It is.

  The weight ratio of water to stucco that is blended together to form a given amount of finished product is often referred to in the art as the “water stucco ratio” (WSR). A reduction in WSR without recombination will increase the slurry viscosity accordingly, thereby reducing the ability of the slurry to spread on the forming table. Reducing water usage in the gypsum board manufacturing process (ie, reducing WSR) can provide many benefits, including the opportunity to reduce energy demand in the process. However, spreading the increasingly viscous gypsum slurry evenly on the forming table leaves a major challenge.

  Furthermore, in some situations where the slurry is a multiphase slurry containing gas, gas-liquid slurry separation can develop in the slurry discharge conduit from the mixer. As WSR decreases, the gas volume increases to maintain the same dry density. The degree of gas phase separated from the liquid slurry phase increases, thereby resulting in a greater mass trend or density change.

  This background description is made to assist the reader by the inventor and understands that any of the problems presented are not considered as signs of understanding in the art per se. I want to be. While the described principles may alleviate inherent problems in other systems in some aspects and embodiments, the scope of innovation protected is that defined by the appended claims, It should be understood that it is not defined by the ability of any disclosed functions to solve any particular problems described herein.

  In one aspect, the present disclosure is directed to an embodiment of a slurry distribution system for use in preparing a gypsum product. In one embodiment, the 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 disposed in isolated relationship with the first supply inlet and in fluid communication with the distribution conduit. The distribution conduit may extend generally along the longitudinal axis and include an inlet and a distribution outlet in fluid communication therewith. The entry portion is in fluid communication with the first and second supply inlets of the supply conduit. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially orthogonal to the longitudinal axis.

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

  In other embodiments, the slurry distributor includes a supply conduit, a distribution conduit and at least one support segment. The supply conduit includes a first entry segment that includes a first supply inlet and a second entry segment that includes a second supply inlet disposed in an isolated relationship with the first supply inlet. The distribution conduit includes an entry portion and a distribution outlet that extends generally along the longitudinal axis and is in fluid communication with the entry portion. The entry portion is in fluid communication with the first and second supply inlets of the supply conduit. Each support segment is movable over a range of travel such that the support segment is over a range where the support segment increases compression engagement with at least one portion of the supply and distribution conduits.

  In another aspect of the present disclosure, the slurry distributor may be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. In one embodiment, the present disclosure describes a gypsum slurry mixing and dispensing assembly that includes a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. The slurry distributor is in fluid communication with the gypsum slurry mixer and receives the first and second streams of aqueous calcined gypsum slurry from the gypsum slurry mixer, and first and second aqueous calcined gypsum slurry on the advancing web. Adapted to distribute two streams.

  The slurry distributor is adapted to receive a first aqueous calcined gypsum slurry stream from the gypsum slurry mixer, a first feed inlet adapted to receive a first aqueous calcined gypsum slurry stream from the gypsum slurry mixer. The second feed inlet, and both the first and second feed inlets, and the first and second streams of aqueous calcined gypsum slurry are discharged from the slurry distributor through the dispense outlet. Includes an adapted dispensing outlet.

  In another embodiment, the slurry distributor includes a supply conduit and a distribution conduit. The supply conduit includes an entry segment with a supply inlet and a supply entry outlet in fluid communication with the supply inlet. The entry segment extends along the first supply flow axis. The supply conduit includes a shaped duct having a spherical portion in fluid communication with the supply entry outlet of the entry segment. The supply conduit includes a transition segment in fluid communication with the bulb. The transition segment extends along a second supply flow axis that is non-parallel with the first supply flow axis.

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

  The bulb has a spreading area with a flow cross-sectional area that is greater than the flow cross-sectional area of the adjacent area upstream from the area of the spreading with respect to the flow direction from the supply inlet towards the distribution outlet distribution conduit. The molded duct has a convex inner surface that is in a relationship facing the supply entry and exit of the entry segment.

  In yet another embodiment, the slurry distributor includes a branched supply conduit and a distribution conduit. The branched supply conduit is formed with an inlet segment having a supply inlet and first and second supply sections each having a supply entry outlet in fluid communication with the supply inlet, and a spherical section in fluid communication with the supply entry outlet of the entry segment. The duct includes a transition segment in fluid communication with the bulb. The entry segment extends generally along the vertical axis. The transition segment extends along a longitudinal axis that is orthogonal to the vertical axis.

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

  The first and second bulbs each have a flow break larger than the flow cross-sectional area of the adjacent zone upstream from the zone extending with respect to the flow direction from the respective first and second feed inlets towards the distribution outlet distribution conduit. It has a spreading area with an area. The first and second shaped ducts each have a convex inner surface in a relationship facing the first and second supply entry outlets of the first and second entry segments, respectively.

  In another embodiment, the slurry distributor includes a distribution conduit and a slurry wiping mechanism. The distribution conduit extends along a generally longitudinal axis, a distribution outlet in fluid communication with the entry section, and a bottom surface extending between the entry section and the distribution outlet. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially orthogonal to the longitudinal axis. The slurry wiping mechanism includes a movable wiper blade that is in contact with the bottom surface of the distribution conduit. The wiper blade can reciprocate on a clearing path between the first location and the second location. The clearing path is disposed adjacent to the distribution outlet.

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

  The copying mechanism includes a copying member in contact with the distribution conduit. The profiling member is on a range that the profiling member travels within a range where the profiling member increases compression engagement with a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening. Is movable.

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

  The supply conduit includes a first entry segment that includes a first supply inlet and a second entry segment that includes a second supply inlet disposed in an isolated relationship with the first supply inlet. The first feed inlet is adapted to receive a first stream of aqueous calcined gypsum slurry from a gypsum slurry mixer. The second feed inlet is adapted to receive a second stream of aqueous calcined gypsum slurry from the gypsum slurry mixer.

  The distribution conduit includes an entry portion and a distribution outlet that extends generally along the longitudinal axis and is in fluid communication with the entry portion. The entry portion is in fluid communication with the first and second supply inlets of the supply conduit. The dispensing outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The distribution outlet is in fluid communication with both the first and second supply inlets and is adapted such that the first and second streams of aqueous calcined gypsum slurry are discharged from the slurry distributor through the distribution outlet.

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

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

  In yet another aspect of the present disclosure, the slurry dispensing system may be used in a method of preparing a cementitious product. For example, a slurry distributor may be used to dispense an aqueous calcined gypsum slurry onto the advancing web.

  In some embodiments, a method of dispensing an aqueous calcined gypsum slurry on a moving web may be performed using a slurry distributor assembled according to the principles of the present disclosure. A first stream of aqueous calcined gypsum slurry and a second stream of aqueous calcined gypsum slurry are sent through a first feed inlet and a second feed inlet of the slurry distributor, respectively. The first and second streams of aqueous calcined gypsum slurry are combined in a slurry distributor. The first and second streams of aqueous calcined gypsum slurry are discharged onto a web moving from the dispensing outlet of the slurry distributor.

  In other embodiments, the method of preparing a gypsum product may be performed using a slurry distributor assembled according to the principles of the present disclosure. The first flow of aqueous calcined gypsum slurry passes through the first feed inlet of the slurry distributor at an average first feed rate. The second stream of aqueous calcined gypsum slurry passes through the second feed inlet of the slurry distributor with an average second feed rate. The second supply inlet is in an isolated relationship with the first supply inlet. The first and second streams of aqueous calcined gypsum slurry are combined in a slurry distributor. The first and second streams of combined aqueous calcined gypsum slurry are discharged onto a web of cover sheet material moving longitudinally from the distribution outlet of the slurry distributor at an average discharge rate. The average discharge rate is lower than the average first supply rate and the average second supply rate.

  In another embodiment, the method of preparing a cementitious product may be performed using a slurry distributor assembled according to the principles of the present disclosure. The aqueous cementitious slurry stream is discharged from the mixer. The flow of aqueous cementitious slurry passes through the feed inlet of the slurry distributor along the first feed flow axis at an average feed rate. The aqueous cementitious slurry stream is routed into the spherical portion of the slurry distributor. The bulb has a spreading area with a flow cross-sectional area that is greater than the flow cross-sectional area of the adjacent area upstream from the area of the spreading with respect to the flow direction from the feed inlet. The bulb is configured to reduce the average velocity of the aqueous cementitious slurry stream moving from the feed inlet through the bulb. The shaped duct has a convex inner surface that is in a relationship facing the first supply flow axis so that the flow of the aqueous cementitious slurry enters a radial flow in a plane substantially perpendicular to the first supply flow axis. The aqueous cementitious slurry stream is routed into a transition segment that extends along a second feed flow axis that is non-parallel to the first feed flow axis. A stream of aqueous cementitious slurry is sent into the distribution conduit. The distribution conduit includes a distribution outlet extending a predetermined distance along the transverse axis substantially perpendicular to the longitudinal axis.

  In another embodiment, a method of preparing a cementitious product includes draining a stream of aqueous cementitious slurry from a mixer. A stream of aqueous cementitious slurry is routed through the inlet of the distribution conduit of the slurry distributor. A flow of aqueous cementitious slurry is discharged from a dispensing outlet of the slurry distributor onto a web of cover sheet material moving along the machine direction. The wiper blade reciprocates over the clearing path along the bottom surface of the distribution conduit between the first and second locations to remove the aqueous cementitious slurry therefrom. The clearing path is disposed adjacent to the distribution outlet.

  In yet another embodiment, a method of preparing a cementitious product includes draining a stream of aqueous cementitious slurry from a mixer. A stream of aqueous cementitious slurry is routed through the inlet of the distribution conduit of the slurry distributor. The aqueous cementitious slurry stream is discharged onto a web of cover sheet material that travels longitudinally from the outlet opening of the distribution outlet of the slurry distributor. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially orthogonal to the longitudinal axis. The outlet opening has a width along the transverse axis and a height along a vertical axis that is orthogonal to the longitudinal and transverse axes. A portion of the distribution conduit adjacent to the distribution outlet is compressed and engaged to change the shape and / or size of the outlet opening.

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

  Further aspects and functions of the disclosed principles will be understood from the following detailed description and accompanying drawings. As will be appreciated, the slurry dispensing systems disclosed herein are capable of being implemented and used in other and different embodiments and are capable of being modified in various aspects. Accordingly, it is to be understood that both the foregoing summary and the following detailed description are exemplary and explanatory only and do not limit the scope of the appended claims.

The patent and application documents contain drawings prepared in at least one color. Copies of this patent or patent application publication with color drawing (s) will be provided by the Office upon request and payment of the necessary fee.
1 is a perspective view of an embodiment of a slurry distributor assembled in accordance with the principles of the present disclosure. FIG. FIG. 2 is a perspective view of the slurry distributor of FIG. 1 and a perspective view of an embodiment of a slurry distributor support assembled according to the principles of the present disclosure. FIG. 3 is a front view of the slurry distributor of FIG. 1 and the slurry distributor support of FIG. 2. FIG. 2 is a perspective view of an embodiment of a slurry distributor similar to the slurry distributor of FIG. 1 but constructed according to the principles of the present disclosure that is constructed from a hard material and defines an internal shape having a two-piece structure. FIG. 5 is another perspective view of the slurry distributor of FIG. 4 with the profiling system removed for illustrative purposes. Another slurry distributor assembled in accordance with the principles of the present disclosure, including a first supply inlet and a second supply inlet disposed at a supply angle of about 60 degrees relative to the longitudinal axis or longitudinal direction of the slurry distributor FIG. 3 is an isometric view of the embodiment. FIG. 7 is a top plan view of the slurry distributor of FIG. 6. FIG. 7 is a rear view of the slurry distributor of FIG. 6. FIG. 7 is a top plan view of a first piece of the slurry distributor of FIG. 6 having a two-piece structure. FIG. 10 is a front perspective view of the slurry distributor piece of FIG. 9. FIG. 7 is an exploded view of a support system for the slurry distributor of FIG. 6 and a slurry distributor assembled according to the principles of the present disclosure. FIG. 12 is a perspective view of the slurry distributor and support system of FIG. 11. FIG. 7 is an exploded view of another embodiment of the slurry distributor of FIG. 6 and a support system assembled in accordance with the principles of the present disclosure. FIG. 14 is a perspective view of the slurry distributor and support system of FIG. 13. FIG. 7 is a perspective view of an embodiment of a slurry distributor similar to the slurry distributor of FIG. 6, but assembled from a flexible material and assembled according to the principles of the present disclosure defining an internal shape having a unitary structure. FIG. 16 is a top plan view of the slurry distributor of FIG. 15. FIG. 16 is an enlarged perspective view of the internal shape defined by the slurry distributor of FIG. 15 illustrating the advancing flow cross-section of a portion of the supply conduit. FIG. 16 is an enlarged perspective view of the internal shape of the slurry distributor of FIG. 15 illustrating another progressive flow cross-sectional area of the supply conduit. 15 is an enlarged, internal shape of the slurry distributor of FIG. 15 illustrating yet another progressive flow cross-sectional area of the supply conduit that is in line with half of the entry into the distribution conduit of the slurry distributor of FIG. It is a perspective view. FIG. 16 is a perspective view of another embodiment of the slurry distributor of FIG. 15 and a support system assembled in accordance with the principles of the present disclosure. FIG. 21 is a perspective view of something similar to FIG. 20, but with the support frame removed for illustrative purposes showing a plurality of retaining plates in a distributed relationship with the slurry distributor of FIG. FIG. 6 is a front perspective view of another embodiment of a slurry distributor and another embodiment of a support system assembled in accordance with the principles of the present disclosure. FIG. 23 is a rear perspective view of the slurry distributor and support system of FIG. FIG. 23 is a top plan view of the slurry distributor and support system of FIG. FIG. 23 is a side view of the slurry distributor and support system of FIG. FIG. 23 is a front view of the slurry distributor and support system of FIG. FIG. 23 is a rear view of the slurry distributor and support system of FIG. FIG. 3 is an enlarged detail view of a distal portion of a slurry distributor illustrating an embodiment of a slurry wiping mechanism assembled in accordance with the principles of the present disclosure. FIG. 23 is a perspective view of a copying mechanism assembled in accordance with the principles of the present disclosure and used in the slurry distributor of FIG. FIG. 30 is a front view of the copying mechanism of FIG. 29. It is a figure of the thing similar to FIG. 30 which illustrates the copying member of the copying mechanism in the compressed position. It is a figure of the thing similar to FIG. 30 which illustrates the copying member of the copying mechanism in the turning position. FIG. 3 is an enlarged detailed exploded view of a profiling member illustrating a coupling technique between a translation rod and a profiling segment; FIG. 30 is a side view of the copying mechanism of FIG. 29. FIG. 30 is a top plan view of the copying mechanism of FIG. 29. FIG. 30 is a bottom view of the copying mechanism of FIG. 29. FIG. 23 is a top plan view of the slurry distributor and support system of FIG. 22 with the support frame removed for illustrative purposes. FIG. 23 is an enlarged detail view from the side of the spherical portion of the slurry distributor of FIG. FIG. 23 is a perspective view of a pair of rigid support inserts on a bottom support member of the support system of FIG. FIG. 37 is a side view of the rigid support insert of FIG. 36. FIG. 37 is a front view of the rigid support insert of FIG. 36. FIG. 37 is a rear view of the rigid support insert of FIG. 36. FIG. 23 is a front view of the slurry distributor of FIG. 22. FIG. 23 is a rear view of the slurry distributor of FIG. 22. FIG. 23 is a bottom perspective view of the slurry distributor of FIG. 22. FIG. 23 is a bottom plan view of the slurry distributor of FIG. 22. FIG. 23 is a top plan view of a half portion of the slurry distributor of FIG. 22. FIG. 45 is a cross-sectional view taken along line 45-45 in FIG. 44. FIG. 45 is a cross-sectional view taken along line 46-46 in FIG. 44. FIG. 45 is a cross-sectional view taken along line 47-47 in FIG. 44. FIG. 45 is a cross-sectional view taken along line 48-48 in FIG. 44. FIG. 45 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. 45 is a cross-sectional view taken along line 51-51 in FIG. 44. FIG. 45 is a cross-sectional view taken along line 52-52 in FIG. 44. FIG. 45 is a cross-sectional view taken along line 53-53 in FIG. 44. 2 is a perspective view of a multi-piece mold embodiment for making a slurry distributor similar to FIG. 1 assembled according to the principles of the present disclosure; FIG. FIG. 55 is a top plan view of the mold of FIG. 54. FIG. 16 is an exploded view of a multi-piece mold embodiment for making a slurry distributor similar to FIG. 15 assembled according to the principles of the present disclosure. FIG. 6 is a perspective view of another embodiment of a mold for making a piece of a two-piece slurry distributor assembled according to the principles of the present disclosure. FIG. 58 is a top plan view of the mold of FIG. 57. 1 is a schematic plan view of an embodiment of a gypsum slurry mixing and dispensing assembly including a slurry distributor according to the principles of the present disclosure. FIG. FIG. 6 is a schematic plan view of another embodiment of a gypsum slurry mixing and dispensing assembly including a slurry distributor according to the principles of the present disclosure. 1 is a schematic elevation view of a wet end embodiment of a gypsum wallboard production line in accordance with the principles of the present disclosure. FIG. 1 is a perspective view of an embodiment of a flow splitter assembled according to the principles of the present disclosure suitable for use in a gypsum slurry mixing and dispensing assembly including a slurry distributor. FIG. FIG. 63 is a side view, in cross section, of the flow splitter of FIG. 62. FIG. 63 is a side view of the flow splitter of FIG. 62 with an embodiment of a squeezer attached thereto assembled according to the principles of the present disclosure. FIG. 16 is a top plan view of a half portion of a slurry distributor similar to the slurry distributor of FIG. FIG. 66 is a plot of the data from Table I of Example 1 showing dimensionless distance versus dimensionless area and dimensionless hydraulic radius from the feed inlet for the half portion of the slurry distributor of FIG. From Tables II and III of Examples 2 and 3 showing dimensionless distance versus dimensionless velocity from the feed inlet of the modeled slurry stream moving through half of the slurry distributor of FIG. 65, respectively. Is a plot of the data. From Tables II and III of Examples 2 and 3 showing dimensionless distance from the feed inlet versus dimensionless shear rate in the modeled slurry traveling through the slurry distributor half of FIG. 65, respectively. It is a plot of the data. Data from Tables II and III of Examples 2 and 3 showing dimensionless distance versus dimensionless viscosity from the feed inlet of the modeled slurry moving through the slurry distributor half of FIG. 65, respectively. Is a plot of From Tables II and III of Examples 2 and 3, showing dimensionless distance from the feed inlet versus dimensionless shear stress in the modeled slurry traveling through the half of the slurry distributor of FIG. 65, respectively. It is a plot of the data. From Tables II and III of Examples 2 and 3, showing dimensionless distance versus dimensionless Reynolds number from the feed inlet of the modeled slurry moving through half of the slurry distributor of FIG. 65, respectively. It is a plot of the data. FIG. 23 is a top plan view of a slurry distributor similar to the slurry distributor of FIG. FIG. 73 is a top perspective view of computational fluid dynamics (CFD) model output for a half portion of the slurry distributor of FIG. 72. FIG. 74 is an illustration of an object similar to FIG. 73 illustrating various regions discussed in Examples 4-6. FIG. 75 is a diagram of a region A shown in FIG. 74. FIG. 6 is a top plan view of a region A illustrating a radial position used for performing CFD analysis. FIG. 74 is a plot of the data from Table IV of Example 4 showing the radial position versus dimensionless average velocity in region A moving through region A of the half of the slurry distributor of FIG. FIG. 73 is an enlarged detail taken from FIG. 72 illustrating a region B of a slurry distributor in which the flow of slurry traveling there has a vortex motion. FIG. 74 is a plot of data from Table VI of Example 6 showing dimensionless distance versus dimensionless velocity from the feed inlet of a modeled slurry stream moving through half of the slurry distributor of FIG. 73. . FIG. 74 is a plot of the data from Table VI of Example 6 showing dimensionless distance from the feed inlet versus dimensionless shear rate for a modeled slurry traveling through half of the slurry distributor of FIG. 73. FIG. 74 is a plot of the data from Table VI of Example 6 showing dimensionless distance versus dimensionless viscosity from a model slurry feed inlet moving through half of the slurry distributor of FIG. FIG. 74 is a plot of the data from Table VI of Example 6 showing dimensionless distance versus dimensionless Reynolds number from a model slurry feed inlet moving through half of the slurry distributor of FIG. From Table VII of Example 7 showing dimensionless distance versus divergence angle along the width of the outlet opening from the mid-transverse midpoint of the modeled slurry discharged from half of the slurry distributor of FIG. Is a plot of the data.

  The present disclosure provides various embodiments of slurry dispensing systems that can be used in the manufacture of products, including, for example, cementitious products such as gypsum wallboard. Embodiments of slurry distributors assembled in accordance with the principles of the present disclosure are intended to efficiently distribute multiphase slurries, such as those containing gas and liquid phases, such as found in aqueous foam gypsum slurries. It may be used in the manufacturing process.

  An embodiment of a dispensing system assembled in accordance with the principles of the present disclosure is a slurry (e.g., aqueous based) on an advancing web (e.g., paper or mat) that moves on a conveyor during a continuous board (e.g., wallboard) manufacturing process. May be used to dispense a calcined gypsum slurry). In one aspect, a slurry dispensing system assembled in accordance with the principles of the present disclosure is attached to a mixer adapted to agitate calcined gypsum and water to form an aqueous calcined gypsum slurry in a conventional gypsum drywall manufacturing process. May be used as, or as part of, a discharge conduit.

  Embodiments of a slurry dispensing system assembled in accordance with the principles of the present disclosure are aimed at achieving a wider distribution (along the width direction) of a uniform gypsum slurry. Embodiments of the slurry distribution system of the present disclosure include gypsum slurries having a range of WSRs, including those conventionally used to produce gypsum wallboard and those having a relatively lower and relatively higher viscosity. Suitable for use with. Furthermore, the gypsum slurry dispensing system of the present disclosure may be used to help control gas-liquid phase separation, such as in aqueous foam gypsum slurries, including foam gypsum slurries with very large foam volumes. The spreading of the aqueous calcined gypsum slurry on the advancing web can be controlled by routing and dispensing the slurry using a dispensing system as shown and described herein.

  A cementitious slurry mixing and dispensing assembly according to the principles of the present disclosure may be used to form any type of cementitious product, such as, for example, a board. In some embodiments, cementitious boards such as gypsum drywall, Portland cement boards or sound absorbing panels may be formed.

  The cementitious slurry produces any conventional cementitious slurry, such as a gypsum wallboard, for example a sound absorbing panel, including a sound absorbing panel described in US 2004/0231916, or a Portland cement board. It can be any cementitious slurry commonly used for this purpose. Accordingly, the cementitious slurry may optionally further comprise any additive commonly used to produce a cementitious board product. These additives include mineral wool, continuous or shredded glass fibers (also called fiberglass), structural additives including perlite, clay, vermiculite, calcium carbonate, polyester and paper fibers, As well as foaming agents, fillers, accelerators, sugars such as enhancers such as phosphates, phosphonates and borates, retarders, binders (eg starch and latex), colorants, fungicides, biocides And chemical additives such as hydrophobic agents such as agents, silicone-based materials (eg, silane, siloxane or silicone-resin matrix). Examples of the use of some of these and other additives are described, for example, in US Pat. Nos. 6,342,284, 6,632,550, 6,800,131, 5,643,510. Nos. 5,714,001 and 6,774,146, and U.S. Patent Application Publication Nos. 2004/0231916, 2002/0045074, 2005/0019618, 2006/0035112 and 2007 /. No. 0022913.

  Non-limiting examples of cementitious materials include Portland cement, sorrel cement, slag cement, fly ash cement, calcium alumina cement, water-soluble anhydrous calcium sulfate, calcium sulfate α-hemihydrate, calcium sulfate β-hemihydrate, natural, synthetic or chemically modified calcium sulfate hemihydrate, calcium sulfate dihydrate (“gypsum”, “hardened gypsum” or “hydrated gypsum”) and mixtures thereof . In one embodiment, the cementitious material desirably comprises calcined gypsum, such as calcium sulfate alpha hemihydrate, calcium sulfate beta hemihydrate and / or anhydrous calcium sulfate forms. In embodiments, calcined gypsum may be fibrous in some embodiments and non-fibrous in others. The calcined gypsum may comprise at least about 50% beta calcium sulfate hemihydrate. In other embodiments, calcined gypsum may comprise at least about 86% beta calcium sulfate hemihydrate. The weight ratio of water to calcined gypsum may be any suitable ratio, but as those skilled in the art will appreciate, less excess water needs to be expelled during manufacture, thereby saving energy. So lower ratios can be more efficient. In some embodiments, the cementitious slurry comprises water and calcined gypsum in a range of about 1: 6 to about 1: 1 ratio by weight, such as about 2: 3, respectively, for board production depending on the product. It can be prepared by mixing.

  An embodiment of a method for preparing a cementitious product according to the principles of the present disclosure, such as a gypsum product, includes dispensing an aqueous calcined gypsum slurry onto a forward web using a slurry distributor assembled according to the principles of the present disclosure. Can be included. Various embodiments of a method for dispensing an aqueous calcined gypsum slurry on a moving web are described herein.

  Referring now to the drawings, there is illustrated an embodiment of a slurry distributor 120 according to the principles of the present disclosure shown in FIGS. 1-3 and another embodiment of a slurry distributor 220 according to the principles of the present disclosure shown in FIGS. is there. 1-3 is assembled from an elastically flexible material, while the slurry distributor 220 shown in FIGS. 3 and 4 is made from a relatively rigid material. The However, the internal flow shapes of both slurry distributors 120, 220 in FIGS. 1-5 are the same, and FIG. 5 should also be referred to when considering the slurry distributor 120 of FIGS.

  Referring to FIG. 1, the slurry distributor 120 includes a supply conduit 122 having first and second supply inlets 124, 125 and a distribution conduit 128 that includes a distribution outlet 130 and is in fluid communication with the supply conduit 128. A scanning system 132 (see FIG. 3) adapted to locally change the size of the distribution outlet 130 of the distribution conduit 128 may also be provided.

  Referring to FIG. 1, the supply conduit 122 generally extends along a transverse axis or width direction 60 that is substantially perpendicular to the longitudinal axis or longitudinal direction 50. The first supply inlet 124 is in an isolated relationship with the second supply inlet 125. The first supply inlet 124 and the second supply inlet 125 define respective openings 134, 135 having substantially the same area. The illustrated openings 134, 135 of the first and second supply 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 application and existing process conditions.

  The first and second supply inlets 124, 125 are cross-machine-axis (cross-axis) such that the first and second supply inlets 124, 125 are arranged at an angle of 90 ° with respect to the machine axis 50. machine axes) 60 are opposed to each other. In other embodiments, the first and second supply inlets 124, 125 may be oriented with respect to the longitudinal direction in different ways. For example, in some embodiments, the first and second supply inlets 124, 125 may be at an angle of 0 ° to about 135 ° with respect to the longitudinal direction 50.

  Supply conduit 122 includes first and second entry segments 136, 137 and a branched coupler segment 139 disposed between first and second entry segments 136, 137. The first and second entry segments 136, 137 are generally cylindrical and have a transverse axis such that they are substantially parallel to a plane 57 defined by the longitudinal axis 50 and the transverse axis 60. 60 extends along. The first and second supply inlets 124, 125 are disposed at and in fluid communication with the distal ends of the first and second entry segments 136, 137, respectively.

  In other embodiments, the first and second supply inlets 124, 125 and the first and second entry segments 136, 137 may include the transverse axis 60, the longitudinal direction 50, and / or the longitudinal axis 50 and the transverse axis 60. May be oriented differently with respect to the plane 57 defined by. For example, in some embodiments, the first and second supply inlets 124, 125 and the first and second entry segments 136, 137 are planes 57 defined by a longitudinal axis 50 and a transverse axis 60, respectively. At a supply angle θ relative to the longitudinal axis or longitudinal direction 50, which is an angle in the range up to about 135 ° relative to the longitudinal direction 50, and in other embodiments In the range of about 30 ° to about 135 °, and in still other embodiments in the range of about 45 ° to about 135 °, and in still other embodiments in the range of about 40 ° to about 110 °. It is.

  The bifurcated connector segment 139 is in fluid communication with the first and second supply inlets 124, 125 and the first and second entry segments 136, 137. The branched connector segment 139 includes first and second molded ducts 141, 143. First and second supply inlets 124, 125 of supply conduit 22 are in fluid communication with first and second shaped ducts 141, 143, respectively. The first and second shaping ducts 141, 143 of the connector segment 139 respectively have a first flow in the first supply direction 190 of the aqueous calcined gypsum slurry from the first and second supply inlets 124, 125 and It is adapted to receive the second stream in the second feed direction 191 and direct the first and second streams 190, 191 of the aqueous calcined gypsum slurry into the distribution conduit 128.

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

  In an embodiment, the openings 142 of the first and second supply outlets 140, 145 have a cross-sectional area that is greater than the cross-sectional area of the openings 134, 135 of the first supply inlet 124 and the second supply inlet 125, respectively. It may be. For example, in some embodiments, the cross-sectional area of the opening 142 of the first and second supply outlets 140, 145 is the cross-sectional area of the openings 134, 135 of the first supply inlet 124 and the second supply inlet 125, respectively. It may range from greater than to about 300%, in other embodiments may range from greater than to about 200%, and in yet other embodiments may range from greater than to about 150% greater. It's okay.

  In an embodiment, the opening 142 of the first and second supply outlets 140, 145 has a hydraulic diameter (less than the hydraulic diameter of the openings 134, 135 of the first supply inlet 124 and the second supply inlet 125, respectively. 4 × cross-sectional area / periphery). For example, in some embodiments, the hydraulic diameter of the opening 142 of the first and second supply outlets 140, 145 is the hydraulic diameter of the openings 134, 135 of the first supply inlet 124 and the second supply inlet 125, respectively. It may be about 80% or less of the diameter, in other embodiments about 70% or less, and in still other embodiments about 50% or less.

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

  The first supply inlet 124, the first entry segment 136 and the first shaping duct 141 are mirror images of the second supply inlet 125, the second entry segment 137 and the second shaping duct 143, respectively. Thus, in a corresponding manner, the description of one supply inlet is applicable to the other supply inlet, the description of one entry segment is applicable to the other entry segment, and one molded duct Will be understood to be applicable to the other shaped duct.

  The first shaping duct 141 is fluidly connected to the first supply inlet 124 and the first entry segment 136. The first shaping duct 141 is distributed as the first stream 190 of slurry enters the first supply inlet 124 and travels through the first entry segment 136, the first shaping duct 141 and the distribution conduit 128. Also fluidly connected to the distribution conduit 128 so that it can be discharged from the slurry distributor 120 through the outlet 130, thereby helping to fluidly connect the first supply inlet 124 and the distribution outlet 130. .

  The first forming duct 141 is substantially parallel to the longitudinal axis or longitudinal direction 50 and substantially from the first feed flow direction 190, which is substantially parallel to the transverse direction or the width direction 60. A front outer curved wall 157 defining a curved guide surface 165 adapted to change the direction of the flow of the first slurry in the outlet flow direction 192 and orthogonal to the one feed flow direction 190 and the opposite back surface It has an inner curved wall 158. The first shaping duct 141 is configured to move the first slurry in the first feed flow direction 190 such that the first slurry flow is carried in a distribution conduit 128 that moves substantially in the outlet flow direction 192. It is adapted to receive the flow and change the direction of the slurry flow by changing the direction angle α as shown in FIG.

  In use, the first aqueous calcined gypsum slurry stream passes through the first feed inlet 124 in the first feed direction 190, and the second aqueous calcined gypsum slurry stream passes through the second feed inlet 125. 2 in the supply direction 191. The first and second supply directions 190, 191 may be symmetric with respect to each other along the longitudinal axis 50 in some embodiments. The first slurry stream traveling in the first feed flow direction 190 is redirected in the slurry distributor 120 to the outlet flow direction 192 by changing the directional angle α in the range of up to about 135 °. The second slurry stream moving in the second feed flow direction 191 is redirected in the slurry distributor 120 to the outlet flow direction 192 by changing the directional angle α in the range of up to about 135 °. The combined first and second streams 190, 191 of aqueous calcined gypsum slurry travel generally in the outlet flow direction 192 and are discharged from the slurry distributor 120. The outlet flow direction 192 may be substantially parallel to the longitudinal axis or the longitudinal direction 50.

  For example, in the illustrated embodiment, the first slurry flow is from the first feed flow direction 190 along the width direction 60 to the longitudinal direction 50 by a change of about 90 degrees in the direction angle α around the vertical axis 55. Direction to the exit flow direction 192 along In some embodiments, the slurry flow ranges up to about 135 °, and in other embodiments from about 30 ° to about 135 °, and in still other embodiments from about 45 ° to about 135 °. Direction from the first feed flow direction 190 to the outlet flow direction 192 by changing the directional angle α around the vertical axis 55 in the range of °, and in still other embodiments in the range of about 40 ° to about 110 °. You can change it.

In some embodiments, the shape of the back curved guide surface 165 may be generally parabolic, which may be defined by the parabola of the formula Ax ² + B in the illustrated embodiment. In another embodiment, higher order curves may be used to define the back curved guide surface 165, or alternatively, the back, inner walls 158 are directed toward their ends to form a generally curved wall. It may have a generally curved shape made up of straight or straight segments that collectively define. In addition, the parameters used to define the shape factor specific to the outer wall may depend on the operating parameters specific to the process in which the slurry distributor will be used.

  At least one of the supply conduit 122 and the distribution conduit 128 includes a region of spread having a flow cross-sectional area greater than the flow cross-sectional area of the adjacent region upstream from the region of expansion in the direction from the supply conduit 122 toward the distribution conduit 128. Good. The first entry segment 136 and / or the first shaping duct 141 has a cross section that assists in distributing the flow of the first slurry that varies along the direction of flow and travels therethrough. It's okay. The forming duct 141 has a flow cross-sectional area that increases in a first flow direction 195 from the first supply inlet 124 to the distribution conduit 128 such that the flow of the first slurry decelerates as it passes through the first forming duct 141. You may have. In some embodiments, the first shaped duct 141 has a maximum flow cross-sectional area at a predetermined point along the first flow direction 195 and at a further point along the first flow direction 195. It may be reduced from the maximum flow cross section.

  In some embodiments, the maximum flow cross-sectional area of the first shaping duct 141 is no greater than about 200% of the cross-sectional area of the opening 134 of the first supply inlet 124. In yet other embodiments, the maximum flow cross-sectional area of the forming duct 141 is no greater than about 150% of the cross-sectional area of the opening 134 of the first supply inlet 124. In still other embodiments, the maximum flow cross-sectional area of the forming duct 141 is no more than about 125% of the cross-sectional area of the opening 134 of the first supply inlet 124. In still other embodiments, the maximum flow cross-sectional area of the forming duct 141 is no more than about 110% of the cross-sectional area of the opening 134 of the first supply inlet 124. In some embodiments, the flow cross-sectional area is controlled such that the flow area does not change more than a predetermined amount for a given length to help prevent large changes in flow conditions. .

  In some embodiments, the first entry segment 136 and / or the first shaping duct 141 distributes the first slurry flow toward the outer and / or inner walls 157, 158 of the supply conduit 122. One or more guide channels 167, 168 adapted to assist may be included. Guide channels 167, 168 are adapted to increase the flow of slurry around the boundary wall layer of slurry distributor 120.

  With reference to FIGS. 1 and 5, guide channels 167, 168 are adjacent portions 171 of supply conduit 122 that define a stenosis that advances flow to adjacent guide channels 167, 168, respectively, located in the wall region of slurry distributor 120. It may be configured to have a larger cross-sectional area. In the illustrated embodiment, the supply conduit 122 includes an outer guide channel 167 adjacent to the outer wall 157 and side wall 151 of the distribution conduit 128 and an inner guide channel 168 adjacent to the inner wall 158 of the first molded duct 141. The cross-sectional area of the outer and inner guide channels 167, 168 may be progressively smaller in the first flow direction 195. The outer guide channel 167 may extend substantially along the side wall 151 of the distribution conduit 128 to the distribution outlet 130. At a given cross-sectional position through the first shaping duct 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 has a larger cross-sectional area than the inner guide channel 168 and has a first slurry. Of the flow from the initial line of movement in the first feed direction 190 towards the outer wall 157.

  Providing guide channels adjacent to the wall regions can be an area where low slurry flow “dead spots” are seen in conventional systems, which can help direct or guide the slurry flow to those regions. . By assisting the slurry flow in the wall region of the slurry distributor 120 by providing the guide flow path, the slurry can be prevented from accumulating inside the slurry distributor, and the cleanliness inside the slurry distributor 120 can be improved. . The frequency at which the slurry build-up collapses into the mass that can tear the moving web of cover sheet material can also be reduced.

  In other embodiments, the relative sizes of the outer and inner guide channels 167, 168 can help regulate the slurry flow to improve flow stability and reduce the occurrence of gas-liquid slurry phase separation. You may change it. For example, in applications using a relatively more viscous slurry, the outer guide channel 167 may be in the inner wall 158 at a given cross-sectional position through the first molded duct 141 in a direction perpendicular to the first flow direction 195. It may have a smaller cross-sectional area than the inner guide channel 168 to expedite the flow of the first slurry toward it.

  The inner curved walls 158 of the first and second shaped ducts 141, 142 intersect to define a vertex 175 adjacent to the entry portion 152 of the distribution conduit 128. The vertex 175 substantially branches the connector segment 139. Each supply outlet 140, 145 is in fluid communication with the entry 152 of the distribution conduit 128.

  The location of the apex 175 along the longitudinal axis 50 may be different in other embodiments. For example, the inner curved walls 158 of the first and second molded ducts 141, 142 are more distant from the distribution outlet 130 at the apex 175 along the longitudinal axis 50 than shown in the illustrated slurry distributor 120. In other embodiments, the curvature may be small. In other embodiments, the apex 175 may be closer to the dispensing outlet 130 along the longitudinal axis 50 than shown in the illustrated slurry distributor 120.

  The distribution conduit 128 provides a stable and uniform flow of the first and second aqueous calcined gypsum slurry that is substantially parallel to and combined with the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. It may be adapted to urge the first and second shaping ducts 141, 142 generally into a two-dimensional flow pattern for improvement. The distribution outlet 130 has a width that extends a predetermined distance along the transverse axis 60 and a height that extends along the vertical axis 55 that is orthogonal to the longitudinal axis 50 and the transverse axis 60. The height of the distribution outlet 130 is small compared to its width. The distribution conduit 128 may be oriented with respect to the moving web of cover sheets on the forming table such that the distribution conduit 128 is substantially parallel to the moving web.

  The distribution conduit 128 extends generally along the longitudinal axis 50 and includes an entry portion 152 and a distribution outlet 130. The entry portion 152 is in fluid communication with the first and second supply inlets 124, 125 of the supply conduit 122. Referring to FIG. 5, the entry portion 152 is adapted to receive both the first and second aqueous calcined gypsum slurry flows from the first and second supply inlets 124, 125 of the supply conduit 122. The inlet 152 of the distribution conduit 128 includes a distribution inlet 154 that is 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 that substantially corresponds to the opening 142 of the first and second supply outlets 140, 145. The flow of the first and second aqueous calcined gypsum slurries is generally in line with the web movement line of the cover sheet material where the combined flow moves substantially over the forming table in the wallboard production line. Combine in the distribution conduit 128 to move in the outlet flow direction 192 that may be.

  The distribution outlet 130 is in fluid communication with the inlet 152 and thus the first and second supply inlets 124, 125 of the supply conduit 122 and the first and second supply outlets 140, 145. The distribution outlet 130 advances the first and second flows of slurry in fluid communication and combination with the first and second shaping ducts 141, 143 along the outlet flow direction 192 and from there along the longitudinal direction 50. Adapted to discharge onto a web of cover sheet material.

  Referring to FIG. 1, the illustrated dispensing outlet 130 generally defines a rectangular opening 181 with semicircular narrow ends 183, 185. The semicircular ends 183, 185 of the opening 181 of the distribution outlet 130 may be the end of the outer guide channel 167 disposed adjacent to the side walls 151, 153 of the distribution conduit 128.

  The opening 181 of the distribution outlet 130 is larger than the sum of the areas of the openings 134, 135 of the first and second supply inlets 124, 125 and the total area of the openings 142 of the first and second supply outlets 140, 145 ( That is, it has a smaller area than the opening 156) of the distribution inlet 154. Accordingly, the cross-sectional area of the opening 156 of the entry 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 ranges from greater than the sum of the cross-sectional areas of the openings 134, 135 of the first and second supply inlets 124, 125 to about 400% greater; In other embodiments, it may range from greater to about 200% greater, and in other embodiments greater than about 150% greater. In an embodiment, the ratio of the sum of the cross-sectional areas of the openings 134, 135 of the first and second supply inlets 124, 125 to the cross-sectional area of the opening 181 of the distribution outlet 130 is distributed by the speed of the production line, the distributor 120. May vary based on one or more factors including the viscosity of the slurry to be produced, the width of the board product produced by the distributor 120, and the like. In some embodiments, the cross-sectional area of the opening 156 of the entry portion 152 of the distribution conduit 128 ranges from greater than about 200% greater than the cross-sectional area of the opening 181 of the distribution outlet 130, and in other embodiments is greater than about The range may be 150% greater, and in still other embodiments greater to about 125% greater.

The distribution outlet 130 extends substantially along the transverse axis 60. The opening 181 of the dispensing outlet 130 has a width W ₁ of about 24 inches along the transverse axis 60 and a height H ₁ of about 1 inch along the vertical axis 55 (see also FIG. 3). In other embodiments, the size and shape of the opening 181 of the dispensing outlet 130 may be varied.

The distribution outlet 130 has a transverse axis 60 such that the first supply inlet 124 and the second supply inlet 125 are located at substantially the same distances D ₁ , D ₂ from the transverse central midpoint 187 of the distribution outlet 130. Along the middle between the first supply inlet 124 and the second supply inlet 125. (See also FIG. 3). The dispensing outlet 130 may be made from an elastically flexible material such 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 W ₁ and / or height H ₁ of the opening 181 of the dispensing outlet 130 may vary in other embodiments for different operating conditions. Overall, the overall dimensions of various embodiments of the slurry distributor as disclosed herein are the type of product being manufactured (eg, the thickness and / or width of the manufactured product), It may be scaled up or down depending on the speed of the production line used, the rate of slurry deposition through the distributor, the viscosity of the slurry, and the like. For example, the width W ₁ of the dispensing outlet 130 along the transverse axis 60, conventionally provided with a nominal width of 54 inches or less, for use in a wallboard manufacturing process, in some embodiments is about It may be in the range of 8 to about 54 inches, and in other embodiments in the range of about 8 inches to about 30 inches. In other embodiments, the ratio of the width W ₁ of the distribution outlet 130 along the transverse axis 60 to the maximum nominal width of a panel produced on a manufacturing system using a slurry distributor assembled according to the principles of the present disclosure is In the range from about 1/7 to about 1, in other embodiments from about 1/3 to about 1, in still other embodiments from about 1/3 to about 2/3, and so on. In this embodiment, it may range from about 1/2 to about 1.

  The height of the dispensing outlet may be in the range of about 3/16 inch to about 2 inches in some embodiments, and between about 3/16 inch to about 1 inch in other embodiments. In some embodiments, including rectangular dispensing outlets, the ratio of the rectangular width to the rectangular height of the outlet opening is about 4 or more, in other embodiments about 8 or more, and in some embodiments from about 4 It may be about 288, in other embodiments from about 9 to about 288, in other embodiments from about 18 to about 288, and in still other embodiments from about 18 to about 160.

  Distribution conduit 128 includes a converging portion 182 in fluid communication with entry portion 152. The height of the converging portion 182 is lower than the height at the maximum flow cross-sectional area of the first and second forming ducts 141 and 143 and lower than the height of the opening 181 of the distribution outlet 130. In some embodiments, the height of the converging portion 182 may be about half of the height of the opening 181 of the dispensing outlet 130.

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

  In some embodiments, the exit flow direction 192 is substantially parallel to a plane 57 defined by a longitudinal direction 50 and a transverse width direction 60 of a system that conveys an advancing web of cover sheet material. In other embodiments, the first and second feed directions 190, 191 and the outlet flow direction 192 are all defined by the longitudinal direction 50 and the transverse width direction 60 of the system carrying the advancing web of cover sheet material. It is substantially parallel to the plane 57. In some embodiments, the slurry distributor includes first and second feeds within the slurry distributor 120 without subjecting the slurry flow to substantial flow diversion by rotating around the width direction 60. It may be adapted and arranged with respect to the forming table such that it can be redirected from directions 190, 191 to outlet flow direction 192.

  In some embodiments, the slurry distributor is configured such that the first and second streams of slurry rotate by rotating about an angle of about 45 degrees or less around the width direction 60. May be adapted and arranged with respect to the forming table so as to be diverted from the first and second feed directions 190, 191 to the outlet flow direction 192 in the slurry distributor. Such rotation may cause the first and second feed inlets 124, 125 and the first and second feed directions 190, 191 of the first and second streams of slurry in some embodiments to move the vertical shaft 55 and machine. It can be achieved by applying the slurry distributor to be arranged at a vertical offset angle ω with respect to the plane 57 formed by the axis 50 and the cross machine axis 60. In an embodiment, the first and second feed inlets 124, 125 and the first and second feed directions 190, 191 of the first and second flows of slurry are such that the slurry flow is directed around the machine axis 50. And a vertical offset angle in the range of 0 to about 60 degrees to move in the slurry distributor 120 along the vertical axis 55 from the first and second feed directions 190, 191 to the outlet flow direction 192. It may be arranged at ω. In an embodiment, at least one of the respective entry segments 136, 137 and forming ducts 141, 143 may be adapted to facilitate turning of the slurry around the machine axis 50 and along the vertical axis 55. . In embodiments, the first and second flows of slurry may be about 45 degrees to about about 45 degrees of directional angle α about an axis that is substantially perpendicular to the vertical offset angle ω and / or one or more other rotational axes. Changes in the range of 150 degrees may be redirected from the first and second feed directions 190, 191 to the outlet flow direction 192 such that the outlet flow direction 192 is generally aligned with the longitudinal direction 50.

  In use, the first and second aqueous calcined gypsum slurry flows through the first and second feed inlets 124, 125 in the converging first and second feed directions 190, 191. The first and second shaping ducts 141, 143 go from a state where both the first and second flow of slurry are substantially parallel to the transverse axis 60 to a state where both are substantially parallel to the longitudinal direction 50. The first and second streams of slurry are redirected from the first supply direction 190 and the second supply direction 191 so that they can move with varying directional angles α. The distribution conduit 128 may be positioned to extend along a longitudinal axis 50 that substantially coincides with the longitudinal direction 50 in which the web of cover sheet material travels in the method of making the gypsum board. The flow of the first and second aqueous calcined gypsum slurries is such that the combined first and second aqueous calcined gypsum slurry flows through the distribution outlet 130 generally along the longitudinal axis 50 in the outlet flow direction 192 and They are combined in the slurry distributor 120 so as to pass through in the longitudinal direction.

  Referring to FIG. 2, a slurry distributor support 100 may be provided to help support the slurry distributor 120, which in the illustrated embodiment is a flexible material such as PVC or urethane, for example. Made from material. The slurry distributor support 100 can be made from a rigid material suitable to assist in supporting the flexible slurry distributor 120. The slurry distributor support 100 may include a two-piece structure. The two pieces 101, 103 may be pivotable relative to each other about the hinge 105 at the rear end thereof to allow easy access to the interior 107 of the support 100. The interior 107 of the support 100 is intended to help limit the amount of movement that the slurry distributor 120 can undergo with respect to the support 100 and / or the interior of the slurry distributor 120 through which the slurry will flow. To help define the shape, the interior 107 may be configured to substantially coincide with the exterior of the slurry distributor 120.

  Referring to FIG. 3, in some embodiments, the slurry distributor support 100 provides a suitable elastically flexible support that is deformable in response to a scanning system 132 that provides support and is attached to the support 100. It may be made from a flexible material. The copying system 132 may be attached to the support 100 adjacent to the distribution outlet 130 of the slurry distributor 120. The scanning system 132 so installed may serve to change the size and / or shape of the distribution outlet 130 of the distribution conduit 128 by also changing the size and / or shape of the closely matched support 100. This in turn affects the size and / or shape of the dispensing outlet 130.

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

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

  The illustrated tracing system 132 is adapted to locally change the size and / or shape of the opening 181 of the dispensing outlet 130 along the transverse axis 60. The adjusting bolts 94, 95 are in a regular, isolated relationship with each other along the transverse axis 60 on the dispensing outlet 130. The adjustment bolts 94, 95 can be adjusted independently to locally change the size and / or shape of the dispensing outlet 130.

  The copying system 132 may be used to locally change the dispensing outlet 130 to change the flow pattern of the combined first and second aqueous calcined gypsum slurry dispensed from the slurry distributor 120. . For example, the centerline adjustment bolt 95 squeezes the transverse center midpoint 187 of the distribution outlet 130 to increase the edge flow angle away from the longitudinal axis 50 to promote spreading in the width direction 60 and in the width direction 60. It may be tightened to improve slurry flow uniformity.

  The profiling system 132 may be used to change the size of the dispensing outlet 130 along the transverse axis 60 to maintain the dispensing outlet 130 in the new shape. The plate 90 is suitably strong material so that the plate 90 can resist the reaction force exerted by the adjusting bolts 94, 95 in response to adjustments made by the adjusting bolts 94, 95 that force the dispensing outlet 130 into a new shape. You may create from. The profiling system 132 provides a flow profiling of the slurry discharged from the distribution outlet 130 (eg, as a result of different slurry densities and / or different supply inlet velocities) such that the slurry outflow pattern from the distribution conduit 128 is more uniform. May be used to help keep the change in the constant.

In other embodiments, the number of adjustment bolts may be changed such that the spacing between adjacent adjustment bolts changes. Such as when the width W ₁ of the dispensing outlet 130 are different, in other embodiments, the number of adjusting bolts may be varied in order to achieve the desired adjacent bolt spacing. In yet other embodiments, the spacing between adjacent bolts varies along the transverse axis 60 to provide greater locally varying control, for example at the side edges 183, 185 of the dispensing outlet 130. It's okay.

  A slurry distributor assembled in accordance with the principles of the present disclosure may comprise any suitable material. In some embodiments, the slurry distributor comprises any suitable substantially rigid material that may include, for example, a suitable material that may allow the size and shape of the outlet to be modified using a profiling system. May contain. For example, a suitably hard plastic such as ultra high molecular weight (UHMW) plastic, or metal may be used. In other embodiments, a slurry distributor assembled in accordance with the principles of the present disclosure is made from a flexible material, such as a suitable flexible plastic material, including, for example, polyvinyl chloride (PVC) or urethane. You can do it. In some embodiments, a slurry distributor assembled in accordance with the principles of the present disclosure may include a single supply inlet, an entry segment, and a molded duct in fluid communication with the distribution conduit.

  A gypsum slurry distributor constructed in accordance with the principles of the present disclosure is a high viscosity / low WSR gypsum slurry on a web of cover sheet material that travels over a forming table to help provide a wide distribution of aqueous calcined gypsum slurry. May be used to facilitate the spread of. A gypsum slurry distribution system may also be used to help control gas-slurry phase separation.

  In accordance with another aspect of the present disclosure, the gypsum slurry mixing and dispensing assembly may include a slurry distributor assembled according to the principles of the present disclosure. The slurry distributor may be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry. In one embodiment, the slurry distributor receives a first stream and a second stream of aqueous calcined gypsum slurry from a gypsum slurry mixer on a web that advances the flow of first and second aqueous calcined gypsum slurry. Adapted to dispense.

  The slurry distributor may include a portion of the discharge conduit of a conventional gypsum slurry mixer (eg, a pin mixer) as known in the art, or may function as such. The slurry distributor may be used with conventional discharge conduit components. For example, a slurry distributor may be a gate-canister-boot facility as known in the art or US Pat. Nos. 6,494,609, 6,874,930, 7, It may be used with the components of the discharge conduit facility described in 007,914 and 7,296,919.

  A slurry distributor assembled in accordance with the principles of the present disclosure may be advantageously configured as a retrofit component in existing wallboard manufacturing systems. The slurry distributor can be used to replace a conventional single or multi-branch boot, preferably used in a conventional discharge conduit. The gypsum slurry distributor is an existing slurry discharge conduit facility such as that shown in US Pat. No. 6,874,930 or 7,007,914, for example, as a replacement for a distal dispensing outlet or boot. It may be incorporated as a refurbished part. However, in some embodiments, the slurry distributor may instead be attached to one or more boot outlets.

  Referring 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 from a substantially rigid material. The internal shape 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 like reference numerals are used to indicate like structure. The internal shape 207 of the slurry distributor 207 is that of laminar flow that undergoes reduced gas-liquid slurry phase separation or substantially undergoes no gas-liquid slurry phase separation and substantially does not go through a vortex channel. Adapted to define a flow path for the gypsum slurry traveling therethrough.

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

  Referring to FIG. 4, the slurry distributor 220 has a two-piece structure. The upper piece 221 of the slurry distributor 220 includes a recess 227 adapted to receive the copying system 132 therein. The two pieces 221, 223 may be pivotable relative to each other around the hinge 205 at the rear end to allow easy access to the interior 207 of the slurry distributor 220. A mounting hole 229 is provided to facilitate the connection of the upper piece 221 and its mating lower piece 223.

  6-8, another embodiment of a slurry distributor 320 assembled in accordance with the principles of the present disclosure assembled from a hard material is shown. The slurry distributor 320 of FIGS. 6-8 has the first and second supply inlets 324, 325 and the first and second entry segments 336, 337 of the slurry distributor 320 of FIGS. Similar to the slurry distributor 220 of FIGS. 4 and 5 except that it is arranged at a feed angle θ of about 60 ° relative to the longitudinal direction 50 (see FIG. 7).

  The slurry distributor 320 has a two-piece structure including an upper piece 321 and a lower piece 323 with which the upper piece 321 is fitted. The two pieces 321, 323 of the slurry distributor 320 are joined together using any suitable technique, such as by using fasteners through the corresponding number of mounting holes 329 provided in each piece 321, 323. It may be fixed to. The upper piece 321 of the slurry distributor 320 includes a recess 327 adapted to receive the copying system 132 therein. The slurry distributor 320 of FIGS. 6-8 is similar to the slurry distributor 220 of FIGS. 4 and 5 in other respects.

  Referring to FIGS. 9 and 10, the lower piece 323 of the slurry distributor 320 of FIG. 6 is shown. The lower piece 323 defines a first portion 331 of the internal shape 307 of the slurry distributor 320 of FIG. The upper piece 323 has an internal shape such that when the upper and lower pieces 321, 323 are mated, as shown in FIG. 6, they define the complete internal shape 307 of the slurry distributor 320 of FIG. 307 symmetric second portions are defined.

  Referring to FIG. 9, the first and second shaping ducts 341, 343 move the first and second flow of slurry in a substantially outlet flow direction 392 aligned with the longitudinal or longitudinal axis 50. Receiving the first and second streams of slurry traveling in the first and second feed flow directions 390, 391 to be conveyed into the distribution conduit 328 and changing the slurry flow direction by changing the direction angle α To be adapted.

  11 and 12 depict another embodiment of a slurry distributor support 300 for use with the slurry distributor 320 of FIG. The slurry distributor support 300 may include top and bottom support plates 301, 302 assembled from a suitably rigid material, such as, for example, metal. Support plates 301, 302 may be secured to the distributor by any suitable means. In use, the support plates 301, 302 may help support the slurry distributor 320 at a location on the machine line that includes the conveyor assembly that supports and conveys the moving cover sheet. Support plates 301, 302 may be attached to suitable struts placed on either side of the conveyor assembly.

  FIGS. 13 and 14 depict yet another embodiment of a slurry distributor support 310 for use with the slurry distributor 320 of FIG. 6 that also includes top and bottom support plates 311, 312. The notches 313, 314, 318 in the upper support plate 311 make the support 310 lighter than without it, for example, to those portions of the slurry distributor 320, such as those portions that accommodate mounting fasteners. Can provide access. The slurry distributor support 310 of FIGS. 13 and 14 can be otherwise similar to the slurry distributor support 300 of FIGS. 11 and 12.

  15-19 illustrate another embodiment of a slurry distributor 420 that is similar to the slurry distributor 320 of FIGS. 6-8 except that it is assembled from a substantially flexible material. The slurry distributor 420 of FIGS. 15-19 also includes first and second feed inlets 324, 325 and a first and second feed angle θ disposed about 60 ° relative to the longitudinal axis or longitudinal direction 50. Ingress segments 336, 337 are included (see FIG. 7). The internal shape 307 of the slurry distributor 420 of FIGS. 15-19 is similar to that of the slurry distributor 320 of FIGS. 6-8, and like reference numerals are used to indicate like structures.

  17-19 progressively depict the internal shape of the second entry segment 337 and the second shaped duct 343 of the slurry distributor 420 of FIGS. The cross-sectional areas 411, 412, 413, 414 of the outer and inner guide channels 367, 368 may be progressively smaller in the second supply direction 397 toward the distribution outlet 330. The outer guide channel 367 may extend to the distribution outlet 330 substantially along the outer wall 357 of the second shaping duct 343 and along the side wall 353 of the distribution conduit 328. The inner guide channel 368 terminates at the apex 375 of the connector segment 339 adjacent and bisected to the inner wall 358 of the second molded duct 343. The slurry distributor 420 of FIGS. 15-19 is otherwise similar to the slurry distributor 120 of FIG. 1 and the slurry distributor 320 of FIG.

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

  The slurry distributor support 400 may also include a movable support assembly 405 disposed in an isolated relationship with the bottom support tray 401. A movable support assembly 405 is positioned over the slurry distributor 420 and is placed in a supporting relationship with the slurry distributor 420 to help maintain the slurry distributor internal shape 307 in the desired configuration. May be adapted.

  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 is attached to at least one of the bottom support tray 401 or a suitably positioned post or posts to hold the support frame 407 in a fixed relationship with respect to the bottom support tray 401. Good.

  In an embodiment, at least one support segment 415, 416, 417, 418, 419 is movable independently of another support segment 415, 416, 417, 418, 419. In the illustrated embodiment, each support segment 415, 416, 417, 418, 419 may be independently movable with respect to the support frame 407 over a predetermined range of travel. In an embodiment, each support segment 415, 416, 417, 418, 419 has a respective support segment 415, 416, 417, 418, 419 with at least one portion of supply conduit 322 and distribution conduit 328. It is possible to move over the range of movement so that each support segment is in the range of locations where the compression engagement is increased.

  The location of each support segment 415, 416, 417, 418, 419 may be adjusted to place the support segments 415, 416, 417, 418, 419 in compression engagement with at least a portion of the slurry distributor 420. . Each support segment 415, 416, 417, 418, 419 independently independently further compresses and engages at least a portion of the slurry distributor 420, thereby locally compressing the interior of the slurry distributor 420, or slurry. The compression engagement with at least a portion of the distributor 420 is reduced, thereby allowing the interior of the slurry distributor 420 to expand outwardly, eg, in response to an aqueous gypsum slurry flowing therethrough. Either may be adjusted to place the respective support segment 415, 416, 417, 418, 419.

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

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

  In the illustrated embodiment, the rod 409 is attached to each support segment 415, 416, 417, 418, 419 and extends upward through a corresponding opening in the support frame 407. Each clamp mechanism 408 is associated with one of the rods 409 attached to the support frame 407 and protruding from the respective support segment 415, 416, 417, 418, 419. Each clamping mechanism 408 may be adapted to selectively hold the associated rod 409 in a fixed relationship to the support frame 407. The illustrated clamping mechanism 408 is a conventional lever-actuated clamp that surrounds each rod 409 and allows infinitely variable adjustment between the clamping mechanism 408 and the associated rod 409.

  As will be appreciated by those skilled in the art, any suitable clamping mechanism 408 may be used in other embodiments. In some embodiments, each associated rod 409 can be moved by a suitable actuator (eg, either hydraulic or electric) controlled by a controller. The actuator may function as a clamping mechanism by holding the associated support segments 415, 416, 417, 418, 419 in a fixed location relative to the support frame 407.

  Referring to FIG. 21, support segments 415, 416, 417, 418, 419 each substantially coincide with at least one desired geometric surface of supply conduit 322 and distribution conduit 328 of slurry distributor 420. Contact surfaces 501, 502, 503, 504, 505 may be included. In the illustrated embodiment, a distributor conduit support segment 415 is provided that includes a contact surface 501 that conforms to the external and internal shape of a portion of the distributor conduit 328 on which the distributor conduit support segment 415 is disposed. . A pair of molded ducts each including contact surfaces 502, 503 that conform to the external and internal shapes of a portion of the first and second molded ducts 341, 343, respectively, on which molded duct support segments 416, 417 are disposed Support segments 416, 417 are provided. A pair of entry supports each including contact surfaces 504, 505 that conform to the exterior and interior shapes of a portion of the first and second entry segments 336, 337, respectively, on which molded duct support segments 418, 419 are disposed. Segments 418, 419 are provided. The contact surfaces 501, 502, 503, 504, 505 are adapted to be placed in contact relationship with selected portions of the slurry distributor 420, so that the contact portion of the slurry distributor 420 becomes the internal shape of the slurry distributor 420. Help maintain 307 where it helps to define.

  In use, the movable support assembly 405 may operate to place each support segment 415, 416, 417, 418, 419 independently in the desired relationship with the slurry distributor 420. Support segments 415, 416, 417, 418, 419 facilitate the flow of slurry therethrough to help ensure that the volume defined by internal shape 307 is substantially filled with slurry in use. It may help to maintain the internal shape 307 of the slurry distributor 420. The position of the particular contact surface of a given support segment 415, 416, 417, 418, 419 may be adjusted to locally modify the internal shape of the slurry distributor 420. For example, the distributor conduit support segment 415 moves closer to the bottom support tray 401 along the vertical axis 55 to reduce the height of the distribution conduit 328 in the area over which the distributor conduit support segment 415 is located. May be.

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

  22-27 illustrate another embodiment of a slurry distributor 1420 assembled according to the principles of the present disclosure. The slurry distributor 1420 is made from a substantially flexible material such as, for example, PVC or urethane. The slurry distributor 1420 of FIGS. 22-27 also includes first and second supply inlets 1424, 1425 and first and second supply angles θ that are substantially parallel to the longitudinal axis or the longitudinal direction 50. Includes ingress segments 1436, 1437 (see FIG. 24).

  The slurry distributor 1420 includes a branched supply conduit 1422, a distribution conduit 1428, a slurry wiping mechanism 1417 and a copying mechanism 1432. A slurry distributor support 1400 may be provided to help support the slurry distributor 1420.

  With reference to FIGS. 22 and 23, the slurry distributor support 1400 may include a support member that is in the form of a bottom support member 1401 that defines a support surface 1402 in the illustrated embodiment. The support surface 1402 is substantially disposed on at least a portion of at least one exterior of the supply conduit 1422 and the distribution conduit 1428 to help limit the amount of relative movement between the slurry distributor 1420 and the bottom support member 1401. May be configured to coincide with each other. In some embodiments, the support surface 1402 may also help maintain the internal shape of the slurry distributor 1420 through which the slurry will flow. In embodiments, additional anchoring structures may be provided to help secure the slurry distributor 1420 to the bottom support member 1401.

  The slurry distributor support 1400 may also include a top support member 1404 disposed in an isolated relationship with the bottom support member 1401. The upper support member 1404 is positioned over the slurry distributor 1420 and adapted to be placed in a supporting relationship with the slurry distributor 1420 to help maintain the internal shape 1407 of the slurry distributor 1420 in the desired configuration. May have been.

  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 is attached to at least one of the bottom support member 1401 or one or more appropriately positioned struts to hold the support frame 1407 in a fixed relationship with respect to the bottom support tray 1401. Good. Each of the support segments 1413, 1415, 1416 has a contact surface configured to substantially conform to at least one desired geometric surface of the supply conduit 1422 and the distribution conduit 1428 of the slurry distributor 1420. You can do it. In an embodiment, the support frame 1407 may be adapted to movably adjust the spatial relationship between the support segments 1413, 1415, 1416 and the slurry distributor 1420. For example, in some embodiments, the support frame 1407 may move the support segments 1413, 1415, 1416 over a range that travels on the vertical axis 55.

  Referring to FIG. 22, the slurry wiping mechanism 1417 includes a pair of actuators 1510 and 1511 operably aligned with the wiper blade 1514 for selectively reciprocating the wiper blade 1514. Actuators 1510, 1511 are attached to bottom support member 1401 adjacent to distal end 1515 of distribution conduit 1428. The wiper blade 1514 extends laterally between the actuators 1510 and 1511.

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

  Referring to FIG. 28, in the illustrated embodiment, each actuator 1510, 1511 comprises a double-acting pneumatic cylinder having a reciprocating piston 1520. The rod 1522 of the piston 1520 is connected to the wiper blade 1514. In the embodiment, the pair of pneumatic air pipes may be connected to the drive port 1525 and the storage port 1526, respectively. Pressurized gas source 1530 may be controlled using a suitable control valve assembly 1532 that is controlled by controller 1534 to selectively reciprocate wiper blade 1514 along longitudinal axis 50. In an embodiment, the air line may connect both drive ports 1525 of actuators 1510, 1511 together in parallel, and a separate air line may connect both storage ports 1526 of actuators 1510, 1511 together in parallel. Good. In other embodiments, the actuator may be anything capable of reciprocating the wiper blade, including, for example, a manual device.

  The movable wiper blade 1514 is in contact with the bottom surface 1540 of the distribution conduit 1428. The wiper blade 1514 can reciprocate along a clearing path between the first location and the second location (shown in phantom). The clearing path is disposed adjacent to the distal end 1515 of the distribution conduit 1428 that includes the distribution outlet 1430. The wiper blade reciprocates in the longitudinal direction along the clearing path. In the illustrated embodiment, the first location of wiper blade 1514 is longitudinally upstream of dispensing outlet 1430 and the second location is longitudinally downstream of dispensing outlet 1430.

  The controller 1534 is adapted to selectively control the actuator to reciprocate the wiper blade 1514. In an embodiment, the controller 1534 moves the wiper blade 1514 on the wiping stroke from the first location to the second location in the clearing direction 1550 and moves the wiper blade on the return stroke from the second location to the first location. Adapted to move the return direction 1560 opposite. In an embodiment, the controller 1534 is adapted to move the wiper blade 1514 such that the time to move on the wiping stroke is substantially the same as the time to move on the return stroke.

  In an embodiment, the controller 1534 may be adapted to reciprocate the wiper blade 1514 between a first location and a second location in a cycle having a sweep period. The sweep period includes a wiping portion that includes time to move on the wiping stroke, a return portion that includes time to move on the return stroke, and an accumulation delay portion that includes a predetermined period for which the wiper blade 1514 remains in the first location. It is. In an embodiment, the wiping portion is substantially the same as the return portion. In an embodiment, the controller 1534 is adapted to adjustably change the accumulation delay portion.

  Referring to FIG. 34, the bottom support member 1401 supporting the bottom surface of the distribution conduit 1428 includes an outer periphery 1565. Distribution outlet 1430 steps longitudinally from bottom support member 1401 such that distal outlet portion 1515 of distribution conduit 1428 extends from outer periphery 1565 of bottom support member 1401. Referring back to FIG. 28, the wiper blade 1514 supports the distal outlet portion 1515 of the slurry distributor 1420 when the wiper blade is in the first location.

  Referring to FIG. 22, the profiling mechanism 1432 includes a profiling member 1610 that is in contact 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 an embodiment, the profiling member is translatable along at least one axis and is rotatable about at least one pivot axis. In an embodiment, the profiling member is movable along a vertical axis 55 and rotatable about a pivot axis 1630 that is substantially parallel to the longitudinal axis 50.

  Referring to FIGS. 26, 30 and 30A, the profiling member 1610 may be configured such that the profiling member 1610 is adjacent to the dispensing outlet 1430 so that the profiling member 1610 changes the shape and / or size of the outlet opening 1430. It is possible to move over a range to advance so as to be in the range of places where compression engagement with a part is increased.

Referring to FIG. 26, the outlet opening 1481 of the dispensing outlet 1430 has a width W ₂ along the transverse axis 60. Contact copying segments of the scanning member 1410 has a width W ₄ extending a predetermined distance along the transverse axis. In the embodiment, the width W ₂ of the outlet opening 1481 is larger than the width W ₄ of the copying member 1410. In another embodiment, the width W ₂ of the outlet opening 1481 is less than or equal to the width W ₄ of the copying member 1410. The copying member 1410 is placed so that the pair of side surface parts 1631 and 1632 of the distribution outlet 1430 are stepped laterally with respect to the copying member 1410 so that the copying member does not engage with the side surface parts 1631 and 1632. It is burned. In some embodiments, the side portions 1631, 1632 may have a combined width that is approximately one quarter of the width W ₂ of the outlet opening 1481.

  Referring to FIG. 23, the support assembly 1620 includes a pair of fixed struts 1642, 1643, a laterally fixed support member 1645, and a laterally fixed support member 1645 using any suitable pivotal connection. Includes a lateral pivot support member 1647 pivotally coupled to the body. The fixed struts 1642 and 1643 may be attached to the bottom support member 1401. The laterally fixed support member may extend laterally between the fixed struts 1642 and 1643.

  Referring to FIGS. 29, 30, 30 </ b> B and 31, pivot support member 1647 is rotatable about pivot axis 1630 on arc length 1652 with respect to fixed support member 1645. In an embodiment, the arc length 1652 allows the pivot end 1653 of the pivot support member 1647 to be tilted both about the transverse axis 60 and downward about the transverse axis 60. The pivot support member 1647 supports the copying member 1610.

In an embodiment, the profiling member 1610 is translatable along the vertical axis 55 and rotatable about a pivot axis 1630 that is substantially parallel to the longitudinal axis 50. Copying member 1610, the location member copying thereon is high H ₂ of the outlet opening 1481 with a portion variable compression engagement distribution conduit 1428 across the transverse axis 60 to vary along the transverse axis 60 It can be rotated about the pivot axis 1630 on the arc length 1652 so that the profile member 1610 is in range.

  Referring to FIGS. 29 and 33, the profiling member 1610 includes an engagement segment 1660 that extends generally longitudinally and laterally and a translation adjustment rod 1662 that extends generally perpendicularly from the engagement segment 1660. The translation adjustment rod 1662 of the profiling member 1610 is movably fixed to the pivot support member 1647 of the support assembly 1620 so that the profiling member 1610 can move along the vertical axis 55 over a range of vertical positions. A pair of translation guide rods 1663, 1665 extend through respective ridges 1667, 1668 that are coupled to the engagement segment 1660 and attached to the pivot support member 1647. Guide rods 1663, 1665 are movable with respect to the collars 1667, 1668 along the vertical axis 55.

  The support assembly 1620 may include a clamping mechanism adapted to selectively engage the translation adjustment rod 1662 to secure the profiling member 1610 in one of a range of selected vertical positions. In the illustrated embodiment, the threaded connection between the translation adjustment rod 1662 and the pivot support member 1647 functions as a clamping mechanism. A lock nut 1664 is provided to secure the threaded translation adjustment rod 1662 in place. The resilient nut 1666 maintains sufficient spacing to allow rotation of a cap screw 1669 (see FIG. 30C) disposed near the distal end 1657 of the translation adjustment rod 1662 and attached to the distal end. . Referring to FIG. 30C, a blind hole 1658 is defined in the profiling member 1610 to accommodate the cap screw 1669 and allow the cap screw to rotate about the axis of the translation adjustment rod 1662.

  Referring to FIGS. 30B and 31, support assembly 1620 can rotatably support copying member 1610 such that copying member 1610 can rotate about pivot axis 1630 over a range of locations along arc length 1652. May be adapted. The support assembly 1620 includes a rotation adjustment rod 1670 that extends between a fixed support member 1645 and a pivot support member 1647 via a support bracket 1672 coupled to a fixed support member 1645 (see also FIG. 31). ). The rotation adjustment rod 1670 moves the rotation adjustment rod 1670 relative to the fixed support member 1645 by rotating its T-handle to pivot the pivot support member 1647 relative to the fixed support member 1645. It is movably fixed to a support member 1645 that is fixed by screw connection with a support bracket 1672 so as to pivot around the shaft 1630. The support bracket 1672 may be configured to allow some bending during tilting operations. Axial bands 1673, 1674 may be provided for further reliability.

  Support assembly 1620 includes a clamping mechanism adapted to selectively engage rotating adjustment rod 1670 to secure profiling member 1610 in one of a range of selected positions along arc length 1652. May be. In the illustrated embodiment, a thin nut 1677 may be provided to lock the threaded rod 1670 to the barrel nut 1679.

  Referring to FIGS. 34 and 40, the branched supply conduit 1422 of the slurry distributor 1420 includes first and second supplies 1701, 1702. Each of the first and second supply portions 1701, 1702 has a respective inlet segment 1436, 1437 with a supply inlet 1424, 1425 and a supply inlet outlet 1710, 1711 in fluid communication with the supply inlet 1424, 1425, respectively. Formed ducts 1441, 1443 (see also FIG. 41) having spherical portions 1720, 1721 in fluid communication with the supply entry and exit outlets 1710, 1711 of segment 1436, and transition segments 1730, 1731 in fluid communication with the respective spherical portions 1720, 1721. Have.

  Referring to FIG. 34, the first and second supply inlets 1424, 1425 and the first and second entry segments 1436, 1437 are relative to the vertical axis 55 in the range of up to about 135 ° relative to the longitudinal axis 50. It may be arranged at each supply angle θ, measured as the angle of rotation. The illustrated first and second supply inlets 1424, 1425 and first and second entry segments 1436, 1437 are disposed at respective supply angles θ that are substantially in line with the longitudinal axis 50.

  The first supply unit 1701 is substantially the same as the second supply unit 1702. Thus, it should be understood that the description of one supply is equally applicable to the other supply. In other embodiments there may be only a single supply or in yet further embodiments there may be more than one supply.

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

  In other embodiments, the first feed flow axis 1735 may have a different orientation relative to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. For example, in other embodiments, the first feed flow axis 1735 is measured as the angle of rotation relative to the transverse axis 60 that is not orthogonal to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. It may be arranged at an inclination angle σ. In the embodiment, as shown in FIG. 35, the inclination angle σ measured upward from the longitudinal axis 50 to the vertical axis 55 in the direction opposite to the longitudinal direction 92 is about 0 to about 135 degrees, in other embodiments From about 15 to about 120 degrees, in still other embodiments from about 30 to about 105 degrees, in yet other embodiments from about 45 to about 105 degrees, and in other embodiments from about 75 to about 105 degrees. It can be anywhere in the range. In other embodiments, the first feed flow axis 1735 is measured as the angle of rotation relative to the longitudinal axis 50 that is not orthogonal to the plane 57 defined by the longitudinal axis 50 and the transverse axis 60. May be arranged.

  Referring to FIG. 34, the molded duct 1441 includes a pair of side wall side walls 1740, 1741 and a spherical portion 1720. The molded duct 1441 is in fluid communication with the supply entry outlet 1711 of the entry segment 1436. Referring to FIG. 35, the bulb 1720 is configured to reduce the average velocity of the slurry flow moving from the entry segment 1436 through the bulb 1720 to the transition segment 1730. In an embodiment, the bulb 1720 is configured to reduce the average velocity of the slurry flow moving from the entry segment 1436 through the bulb 1720 to the transition segment 1730 by at least 20 percent.

  Referring to FIGS. 45-47, the bulb 1720 has a flow cross-sectional area greater than the flow cross-sectional area of the adjacent area upstream from the area of expansion relative to the flow direction 1752 from the supply inlet 1424 toward the distribution outlet 1430 of the distribution conduit 1428. And has an area 1750 of spreading. In an embodiment, the spherical portion 1720 has a region 1752 having a cross-sectional area in a plane perpendicular to the first flow axis 1735 that is larger than the cross-sectional area of the supply entry / exit 1711.

  The molded duct 1441 has a convex inner surface 1758 that faces the supply entry / exit 1711 of the entry segment 1436. The spherical portion 1720 has a radial guide channel 1460 disposed generally adjacent to the convex inner surface. Guide channel 1460 is configured to promote radial flow in a plane substantially perpendicular to first supply flow axis 1735. Referring to FIG. 45, the convex inner surface 1758 is configured to define a central constriction 1762 in the flow path that also helps to increase the average velocity of the slurry in the radial guide flow path 1760.

The forming duct 1441 has a slurry flow from about 0 to about 10 moving toward the distribution outlet 1430 through a region adjacent to the convex inner surface 1758 and adjacent to at least one of the side sidewalls 1740, 1741, other embodiments. May be configured to have a vortex motion (S _m ) of up to about 3 and in still other embodiments from about 0.5 to about 5. In an embodiment, the slurry flow moving toward the distribution outlet 1430 through a region adjacent to the convex inner surface 1758 and adjacent to at least one of the side sidewalls 1740, 1741 is about 0 ° to about 84 °, and other Embodiments have a swivel angle (S _m ) of about 10 ° to about 80 °.

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

  In an embodiment, the first supply flow axis 1735 is substantially perpendicular to the longitudinal axis 50. In an embodiment, the first feed flow axis 1735 is substantially parallel to the vertical axis 55, which is orthogonal to the longitudinal axis 50 and the transverse axis 60. In an embodiment, the second supply flow axis 1770 is arranged at a respective supply angle θ in a range up to about 135 ° with respect to the longitudinal axis 50.

  In an embodiment, the supply conduit 1422 includes a bifurcated coupler segment 1439 that includes first and second guide surfaces 1780, 1781. In an embodiment, the first and second guide surfaces 1781 each provide a first of the slurry entering the supply conduit through the first and second inlets 1424, 1425 with a change in directional angle in the range of up to about 135 °, respectively. And may be adapted to redirect the second flow in the direction of the outlet flow.

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

  With reference to FIGS. 27, 35 and 36, support inserts 1801, 1802 are disposed within respective recesses 1794, 1795 of slurry distributor 1420. The support inserts 1801, 1802 are arranged in a relationship lying under the respective convex inner surface of the molding ducts 1441, 1443. The support inserts 1801, 1802 may be made from any suitable material that will support the slurry distributor and will maintain the desired shape for the overlying in-convex surface. In the illustrated embodiment, the support inserts 1801, 1802 are substantially the same. In other embodiments, a different support insert may be used, or in yet a further embodiment no insert is used.

  Referring to FIGS. 37-39, the rigid support insert 1801 includes a support surface 1810 that substantially matches the shape of the convex inner surface of the molded duct. In an embodiment, the molded duct of the slurry distributor may be made from a sufficiently flexible material such that the convex inner surface is defined by the support surface 1810 of the support insert 1801. In such a case, the concave outer surface of the molded duct may be omitted.

  Support insert 1801 includes a supply end 1820 and a dispensing end 1822. Support insert 1801 extends along a central support axis 1825. Support insert 1801 is substantially symmetric about support axis 1825. The support insert 1801 is asymmetric with respect to a central axis 1830 that is orthogonal to the support axis 1825.

  Referring to FIG. 34, the distribution conduit 1428 includes an entry portion 1452 that extends generally along the longitudinal axis 50 and in fluid communication with the entry portion 1452. Inlet 1452 is in fluid communication with first and second supply inlets 1424, 1425 of supply conduit 1422. The width of distribution conduit 1428 increases from entry 1452 toward distribution outlet 1430. However, in other embodiments, the width of the distribution conduit 1428 decreases or is constant from the entry 1452 toward the distribution outlet 1430.

Entry portion 1452 has a width _{W 2} smaller than the outlet opening 1481 of the distribution entry width _{W 5} is distributed outlet 1430, along the transverse axis 60, along the distribution entry width _{W 5} and the vertical axis 55, enters the height H ₄ includes an entry opening 1453 having _four . In other embodiments, the dispensing entry width W ₅ is greater than or equal to the width W ₂ of the outlet opening 1481 of the dispensing outlet 1430. In an embodiment, the width to height ratio of the outlet opening 1481 is about 4 or greater.

  In an embodiment, at least one of the supply conduit 1422 and the distribution conduit 1428 enters and distributes the supply inlets 1424, 1425 such that the slurry flow exits the distribution outlet at an average discharge rate that is at least 20 percent lower than the average supply rate. A flow stabilization region is included that is adapted to reduce the average feed rate of the slurry stream moving to the outlet 1430.

  44-53 progressively depict the internal shape 1407 of the half portion 1504 of the slurry distributor 1420 of FIG. 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.

  Any suitable technique may be used to make a slurry distributor assembled according to the principles of the present disclosure. For example, in embodiments where the slurry distributor is made from a flexible material, such as PVC or urethane, a multi-piece mold may be used. In some embodiments, the mold piece area is no more than about 150% of the area of the molded slurry distributor that the mold piece is pulled through upon removal, in other embodiments no more than about 125%, and other In this embodiment, it is about 115% or less, and in yet another embodiment, about 110% or less.

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

  In the illustrated embodiment, the distributor conduit type segment 551 is configured to define the internal flow shape of the distributor conduit 128. The first and second shaped duct mold segments 552, 553 are configured to define the internal flow shape of the first and second shaped ducts 141, 143. The first and second entry type segments 554, 555 are respectively the internal flow shape of the first entry segment 136 and the first supply inlet 124 and the internal flow shape of the second entry segment 137 and the second supply inlet. 125 is defined. 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.

  54, the connecting bolts 571, 572, 573 interlock the mold segments 551, 552, 553, 554, 555 such that a substantially continuous outer surface 580 of the multi-piece mold 550 is defined. May be inserted through more than one mold segment for alignment. In some embodiments, the distal portion 575 of the connecting bolts 571, 572, 573 is threaded into one of the mold segments 551, 552, 553, 554, 555 to form the mold segments 551, 552, 553, 554, A male thread configured to interconnect at least two of 555 to each other. The outer surface 580 of the multi-piece mold 550 is configured to define an internal shape of the slurry distributor 120 that is shaped to reduce vigorous flow at the joint. The connecting bolts 571, 572, 573 may be removed to disassemble the multi-piece mold 550 upon removal of the mold 550 from the interior of the molded slurry distributor 120.

  The assembled multi-piece mold 550 is immersed in a solution of a flexible material such as PVC or urethane so that the mold 550 is completely submerged in the solution. The mold 550 may then be removed from the soaked material. An amount of the solution may adhere to the outer surface 580 of the multi-piece mold 550 that will constitute the molded slurry distributor 120 when the solution changes to a solid form. In embodiments, the multi-piece mold 550 may be used in any suitable dipping process to form a molded piece.

  By creating the mold 550 from a plurality of separate aluminum pieces that are made to combine to provide the desired internal flow shape (5 pieces in the illustrated embodiment), the mold segments 551, 552, 553. 554, 555 may be released from each other and may be removed from the solution once curing has started but is still warm. At a sufficiently high temperature, the flexible material tears the larger calculated area of the aluminum mold piece 551, 552, 553, 554, 555 through the smaller calculated area of the molded slurry distributor 120. Be flexible enough to pull without. In some embodiments, the largest mold piece area is up to about 150% of the smallest area of the molded slurry distributor cavity area through which a particular mold piece traverses laterally during the removal process, etc. Up to about 125% in yet other embodiments, up to about 115% in yet other embodiments, and up to about 110% in yet other embodiments.

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

  The connecting bolt is used to assemble the mold 650 by removably connecting the mold segments 651, 652, 653, 654, 655 together such that a substantially continuous outer surface of the multi-piece mold 650 is defined. It's okay. The outer surface of the multi-piece mold 650 defines the inner flow shape of the slurry distributor 220 of FIG. The mold 650 is such that each piece of the mold 650 of FIG. 56 is within a predetermined amount of the minimum area of the molded slurry distributor 220 that area must travel through when the mold piece is removed. (E.g., up to about 150% of the smallest area of the molded slurry distributor cavity area through which a particular mold piece traverses laterally during the removal process in some embodiments). Up to about 125% in other embodiments, up to about 115% in yet other embodiments, and up to about 110% in yet other embodiments), configured similar to mold 550 of FIGS. It's okay.

  57 and 58, an embodiment of a mold 750 for use in making one of the pieces 221, 223 of the 2-piece slurry distributor 220 of FIG. 4 is shown. Referring to FIG. 57, a mounting hole defining element 752 is included to define mounting holes in the piece of the 2-piece slurry distributor 220 of FIG. 4 created to facilitate connection with other pieces. It's okay.

  With reference to FIGS. 57 and 58, the mold 750 includes a mold surface 754 that protrudes from the bottom surface 756 of the mold 750. The boundary wall 756 extends along the vertical axis and defines the depth of the mold. The mold surface 754 is disposed within the boundary wall 756. The boundary wall 756 is configured to allow the volume of the cavity 758 defined in the boundary wall to be filled with molten mold material such that the mold surface 754 is immersed. The mold surface 754 is configured to be a reversal of the internal flow shape defined by the particular piece of the 2-piece distributor being molded.

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

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

  The slurry distributor 820 is in fluid communication with the gypsum slurry mixer 812. The slurry distributor 820 has a first supply inlet 824 adapted to receive a first flow of aqueous calcined gypsum slurry from a gypsum slurry mixer 812 moving in a first supply direction 890, a second supply direction 891. In fluid communication with a second feed inlet 825 adapted to receive a second stream of aqueous calcined gypsum slurry from the gypsum slurry mixer 812 moving to the first and second feed inlets 824, 825. And a distribution outlet 830 adapted to discharge the first and second aqueous calcined gypsum slurry streams from the slurry distributor 820 through the distribution outlet 830 substantially along the longitudinal direction 50.

  The slurry distributor 820 includes a supply conduit 822 that is in fluid communication with the distribution conduit 828. The supply conduits are arranged in an isolated relationship with the first supply inlet 824 and the first supply inlet 824, both arranged at a supply angle θ of about 60 ° relative to the longitudinal direction 50. 825. The supply conduit 822 is provided with first and second supply streams such that the first and second streams of slurry are conveyed to a distribution conduit 828 that moves substantially in an exit flow direction 892 that is substantially aligned with the longitudinal direction 50. Included therein are structures adapted to receive the first and second streams of slurry moving in directions 890, 891 and to change the slurry flow direction by changing the direction angle α (see FIG. 9). Each of the first and second supply inlets 824, 825 has an opening having a cross-sectional area, and the entry 852 of the distribution conduit 828 is the sum of the cross-sectional areas of the openings of the first and second supply inlets 824, 825. It has an opening with a larger cross-sectional area.

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

  A delivery conduit 814 is disposed between the gypsum slurry mixer 812 and the slurry distributor 820 and is in fluid communication. Delivery conduit 814 is in fluid communication with main delivery main stream 815, first delivery branch 817 in fluid communication with first supply inlet 824 of slurry distributor 820, and second supply inlet 825 of slurry distributor 820. 2 outgoing branches 818 are included. The main delivery mainstream 815 is in fluid communication with both the first and second delivery branches 817, 818. In other embodiments, the first and second delivery branches 817, 818 may be in fluid communication independently of the gypsum slurry mixer 812.

  The delivery conduit 814 may be made from any suitable material and may have a different shape. In some embodiments, the delivery conduit 814 may comprise a flexible conduit.

  The aqueous foam replenishment conduit 821 may be in fluid communication with at least one of the gypsum slurry mixer 812 and the delivery conduit 814. Aqueous foam from the source is configured through a foam refill conduit 821 at any suitable location downstream of mixer 812 and / or within mixer 812 itself to form a foam gypsum slurry provided to slurry distributor 220. It may be added to the material. In the illustrated embodiment, the foam refill conduit 821 is disposed downstream of the gypsum slurry mixer 812. In the illustrated embodiment, the aqueous foam refill conduit 821 is a manifold for refilling an infusion ring or block associated with a delivery conduit 814 as described, for example, in US Pat. No. 6,874,930. Has mold facilities.

  In other embodiments, one or more foam refill conduits in fluid communication with the mixer 812 may be provided. In still other embodiments, the aqueous foam replenishment conduit (s) may be in fluid communication only with the gypsum slurry mixer. As will be appreciated by those skilled in the art, means for introducing aqueous foam into the gypsum slurry in the gypsum slurry mixing and dispensing assembly 810, including its relative position in the assembly, can be achieved with aqueous foam in the gypsum slurry. May be modified and / or optimized to provide a uniform dispersion of the board to provide a board suitable for its intended purpose.

  Any suitable blowing agent may be used. Preferably, the aqueous foam is a continuous mixture in which the flow of the foaming agent and water mixture is directed to the foam generator and the resulting aqueous foam stream leaves the generator and is directed to the calcined gypsum slurry. Generated by a traditional technique. Some examples of suitable blowing agents are described, for example, in US Pat. Nos. 5,683,635 and 5,643,510.

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

  One or more flow modification elements 823 may be associated with the delivery conduit 814 and may be adapted to control the flow of the first and second aqueous calcined gypsum slurry from the gypsum slurry mixer 812. The flow modifying element (s) 823 may be used to control the operational characteristics of the first and second aqueous calcined gypsum slurry flows. In the illustrated embodiment of FIG. 59, the flow modification element (s) 823 may be associated with the main delivery mainstream 815. Examples of suitable flow modifying elements are described, for example, in US Pat. Nos. 6,494,609, 6,874,930, 7,007,914, and 7,296,919. Examples include volume restrictors including objects, pressure reducers, compressor valves, canisters, and the like.

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

  In use, the aqueous calcined gypsum slurry is discharged from the mixer 812. The aqueous calcined gypsum slurry from mixer 812 is split at flow splitter 819 into a first aqueous calcined gypsum slurry stream and a second aqueous calcined gypsum slurry stream. The aqueous calcined gypsum slurry from the mixer 812 may be divided so that the flow of the first and second aqueous calcined gypsum slurry is substantially balanced.

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

  A delivery conduit 914 is disposed between the gypsum slurry mixer 912 and the slurry distributor 920 and is in fluid communication. The delivery conduit 914 is in fluid communication with the main delivery mainstream 915, the first delivery branch 917 in fluid communication with the first supply inlet 924 of the slurry distributor 920, and the second supply inlet 925 of the slurry distributor 920. 2 outgoing branches 918 are included.

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

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

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

  The first and second flow modification elements 923, 927 may be operated to control the operational characteristics of the first and second aqueous calcined gypsum slurry flows. The first and second flow modification elements 923, 927 can be operated independently. In some embodiments, the first and second flow modifying elements 923, 927 may have an average velocity that the first slurry has an earlier than the average velocity of the second flow of slurry at a given time and is separate. The first and second of the slurries varying between a relatively slower and a relatively faster average speed in the opposite manner so that the first slurry has an average speed that is slower than the average speed of the second flow of slurry at It may be activated to deliver the second stream.

  As one skilled in the art will appreciate, one or both of the webs of coversheet material is applied to a very thin gypsum slurry (core core), often referred to in the art as a skim coat and / or hard edge, as appropriate. It may be pretreated with a relatively denser layer (as compared to the gypsum slurry with which it is provided). To that end, the mixer 912 is adapted to deposit a dense aqueous calcined gypsum slurry stream that is relatively denser than the first and second aqueous calcined gypsum slurry streams delivered to the slurry distributor. A first auxiliary conduit 929 is included (ie, “surface skim coat / hard edge flow”). The first auxiliary conduit 929 is applied around the moving web by virtue of the width of the roller 931 smaller than the width of the moving web, applying a skim coat layer to the moving web of cover sheet material as is well known in the art. A surface skim coat / hard edge stream may be deposited on the moving web of cover sheet material upstream of the skim coat roller 931 adapted to define a hard edge. The hard edge may be formed from a slurry of the same density that forms a thin dense layer by directing a portion of the dense slurry around the end of the roller used to apply the dense layer to the web. .

  The mixer 912 is adapted to deposit a dense aqueous calcined gypsum slurry stream that is relatively denser than the first and second aqueous calcined gypsum slurry streams delivered to the slurry distributor. The secondary auxiliary conduit 933 may also be included (ie, “back skim coat flow”). The second auxiliary conduit 933 includes a second skim coat roller 937 adapted to apply the back skim coat stream to the moving web of second cover sheet material as is well known in the art (second An upstream second cover sheet material (in the direction of web movement) may be deposited on the moving web (see also FIG. 61).

  In other embodiments, a separate auxiliary conduit may be coupled to the mixer to deliver one or more separate edge streams to the moving web of cover sheet material. Other suitable equipment (such as an auxiliary mixer) can further break the slurry therein, for example, by mechanically breaking the foam in the slurry and / or by chemically breaking the foam by using a suitable antifoam agent. It may be provided in the auxiliary conduit to help achieve high density.

  In still other embodiments, the first and second delivery branches independently introduce aqueous foam into the first and second aqueous calcined gypsum slurry streams respectively delivered to the slurry distributor. Each may include a adapted foam refill conduit. In yet other embodiments, multiple mixers may be provided to provide independent slurry streams to the first and second feed inlets of a slurry distributor assembled according to the principles of the present disclosure. It should be understood that other embodiments are possible.

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

  Referring to FIG. 61, an exemplary embodiment of a wet end 1011 of a gypsum wallboard production line is shown. The wet end 1011 has a gypsum slurry mixing and dispensing assembly 1010 having a gypsum slurry mixer 1012 similar in structure and function to the slurry distributor 320 of FIG. A hard edge / surface skim coat roller 1031 disposed upstream of the slurry distributor 1020 and supported on a forming table 1038 such that a first moving web 1039 is disposed, a second of the cover sheet material therebetween. A back skim coat roller 1037 disposed on the support element 1041 such that the moving web 1043 is disposed, and a forming station 1045 adapted to shape the preform to a desired thickness. Skim coat rollers 1031, 1037, forming table 1038, support element 1041, and forming station 1045 may all be equipped with conventional equipment suitable for their intended purpose, as is well known in the art. . The wet end 1011 may comprise other conventional equipment as is well known in the art.

  In another aspect of the present disclosure, a slurry distributor assembled according to the principles of the present disclosure may be used in various manufacturing processes. For example, in one embodiment, the slurry dispensing system may be used in a method of preparing a gypsum product. A slurry distributor may be used to distribute the aqueous calcined gypsum slurry onto the first advancing web 1039.

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

  The gypsum board product is typically formed “front down” so that the advancing web 1039 functions as a “front” cover sheet for the finished board. The front skim coat / hard edge stream 1049 (a layer of aqueous calcined gypsum slurry having a higher density compared to at least one of the first and second aqueous calcined gypsum slurry streams) applies the skim coat layer to the first web 1039. However, to define the hard edge of the board, it may be applied to the first moving web 1039 upstream of the hard edge / surface skim coat roller 1031 relative to the machine direction 1092.

  A first stream 1047 and a second stream 1048 of aqueous calcined gypsum slurry are routed through a first feed inlet 1024 and a second feed inlet 1025 of the slurry distributor 1020, respectively. The first and second streams 1047, 1048 of aqueous calcined gypsum slurry are combined in a slurry distributor 1020. The first and second streams 1047, 1048 of the aqueous calcined gypsum slurry undergo laminar flow behavior with or without undergoing minimal gas-liquid slurry phase separation and substantially through the vortex channel. Move along the flow path through the slurry distributor 1020.

  The first moving web 1039 moves along the longitudinal axis 50. A first stream of aqueous calcined gypsum slurry 1047 passes through the first feed inlet 1024 and a second stream of aqueous calcined gypsum slurry 1048 passes through the second feed inlet 1025. The distribution conduit 1028 is positioned such that it extends along a longitudinal axis 50 that substantially coincides with the longitudinal direction 1092 along which the first web 1039 of cover sheet material moves. Preferably, the central midpoint of the dispensing outlet 1030 (taken along the transverse axis / width direction 60) substantially coincides with the central midpoint of the first moving cover sheet 1039. The first and second streams 1047, 1048 of the aqueous calcined gypsum slurry are distributed at the distribution outlet 1030 in the distribution direction 1093 along which the combined first and second streams 1051 of the aqueous calcined gypsum slurry are generally along the longitudinal direction 1092. Are combined in a slurry distributor 1020.

  In some embodiments, the distribution conduit 1028 is positioned to be substantially parallel to a plane defined by the longitudinal axis 50 and the transverse axis 60 of the first web 1039 moving along the forming table. . In other embodiments, the inlet of the distribution conduit may be positioned lower or higher perpendicular to the first web 1039 than the distribution outlet 1030.

  The combined first and second streams 1051 of aqueous calcined gypsum slurry are discharged from the slurry distributor 1020 onto the first moving web 1039. The front skim coat / hard edge stream 1049 is the first in the longitudinal direction 1092 where the first and second streams 1047, 1048 of the aqueous calcined gypsum slurry are discharged from the slurry distributor 1020 onto the first moving web 1039. It may be deposited from the mixer 1012 at a point upstream with respect to the direction of movement of the moving web 1039. The first and second streams 1047, 1048 of the combined aqueous calcined gypsum slurry are “washed out” (ie, the deposited skim coat) of the front skim coat / hard edge stream 1049 deposited on the first moving web 1039. Reduced compared to conventional boot designs to help prevent part of the layer from being displaced from its place on the web 339 moving in response to the impact of the slurry deposited thereon It may be discharged from the slurry distributor with a momentum per unit width along the width direction.

  The first and second streams 1047, 1048 of the aqueous calcined gypsum slurry that are routed through the first and second feed inlets 1024, 1025, respectively, of the slurry distributor 1020 are selectively at least one flow modifying element 1023. May be controlled. For example, in some embodiments, the first and second streams of aqueous calcined gypsum slurry 1047, 1048 are equal to the average velocity of the first stream 1047 of aqueous calcined gypsum slurry passing through the first feed inlet 1024 and the second. The average rate of the second stream 1048 of the aqueous calcined gypsum slurry passing through the feed inlet 1025 is selectively controlled to be substantially the same.

  In an embodiment, the first stream 1047 of aqueous calcined gypsum slurry is sent at an average first feed rate through the first feed inlet 1024 of the slurry distributor 1020. A second stream 1048 of aqueous calcined gypsum slurry is sent at an average second feed rate through a second feed inlet 1025 of the slurry distributor 1020. The second supply inlet 1025 is in an isolated relationship with the first supply inlet 1024. The first and second streams 1051 of aqueous calcined gypsum slurry are combined in a slurry distributor 1020. The combined first and second streams 1051 of the aqueous calcined gypsum slurry are discharged at an average discharge rate from a distribution outlet 1030 of the slurry distributor 1020 onto a web 1039 of cover sheet material moving along the longitudinal direction 1092. . The average discharge rate is lower than the average first supply rate and the average second supply rate.

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

  The combined first and second streams 1051 of the aqueous calcined gypsum slurry are discharged from the slurry distributor 1020 through the distribution outlet 1030. The opening of the dispensing outlet 1030 extends along the transverse axis 60 and the ratio of the width of the first moving web 1039 of cover sheet material to the width of the opening of the dispensing outlet 1030 is about 1: 1 and about 6: 1. Including a width within a range between them. In some embodiments, the combined first and second streams 1051 of the aqueous calcined gypsum slurry exiting the slurry distributor 1020 relative to the speed of the moving web 1039 of the cover sheet material moving along the longitudinal direction 1092. The ratio of average speeds may be about 2: 1 or less in some embodiments and about 1: 1 to about 2: 1 in other embodiments.

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

  Thus, slurry is fed to both feed inlets 1024, 1025 of feed conduit 1022 and then exits through distribution outlet 1030 with adjustable gaps. The converging portion 1082 may provide a slight increase in slurry speed to reduce unwanted exit effects and thereby further improve flow stability at the free surface. Alternate left and right flow fluctuations and / or any local fluctuations may be reduced by performing cross-machine (CD) scanning control at the discharge outlet 1030 using a scanning system. This distribution system may help prevent gas-liquid slurry separation in the slurry and provide a more uniform and consistent material that is delivered to the forming table 1038.

  A back skim coat stream 1053 (a layer of aqueous calcined gypsum slurry that is denser compared to at least one of the first and second streams 1047, 1048 of the aqueous calcined gypsum slurry) is applied to the second moving web 1043. It's okay. The back skim coat stream 1053 may be deposited from the mixer 1012 at a point upstream of the back skim coat roller 1037 with respect to the direction of movement of the second moving web 1043.

  In other embodiments, the average speed of the first and second streams 1047, 1048 of the aqueous calcined gypsum slurry varies. In some embodiments, the slurry speed at the supply inlets 1024, 1025 of the supply conduit 1022 is such that the relatively fast average speed and the slow average speed to help reduce the possibility of accumulation inside the shape itself. May cycle back and forth between (one inlet has a faster speed than the other at one point and then vice versa at a given point in time).

  In an embodiment, the first stream 1047 of aqueous calcined gypsum slurry passing through the first feed inlet 1024 has a shear rate that is lower than the shear rate of the combined first and second streams 1051 exiting the distribution outlet 1030. And the second stream 1048 of aqueous calcined gypsum slurry passing through the second supply inlet 1025 has a shear rate that is lower than the shear rate of the combined first and second streams 1051 exiting the distribution outlet 1030. In an embodiment, the shear rate of the combined first and second streams 1051 exiting the distribution outlet 1030 is such that the first stream 1047 and / or the second stream of aqueous calcined gypsum slurry passing through the first feed inlet 1024. It may be greater than about 150% of the shear rate of the second stream 1048 of the aqueous calcined gypsum slurry passing through the feed inlet 1025, and in yet other embodiments may be greater than about 175%, and in still other embodiments. It may be about twice or more. The viscosity of the first and second streams 1047, 1048 of the aqueous calcined gypsum slurry and the combined first and second streams 1051 are in a given position such that the viscosity decreases as the shear rate increases. It should be understood that it may be inversely proportional to the shear rate to be applied.

  In an embodiment, the first stream 1047 of aqueous calcined gypsum slurry passing through the first supply inlet 1024 has a shear stress that is lower than the shear stress of the combined first and second streams 1051 exiting the distribution outlet 1030. And the second stream 1048 of aqueous calcined gypsum slurry passing through the second feed inlet 1025 has a shear stress that is lower than the shear stress of the combined first and second streams 1051 exiting the distribution outlet 1030. In an embodiment, the shear stress of the combined first and second streams 1051 exiting from the distribution outlet 1030 is such that the first stream 1047 and / or the second stream of aqueous calcined gypsum slurry passing through the first supply inlet 1024. It may be greater than about 110% of the shear rate of the second stream 1048 of aqueous calcined gypsum slurry passing through the feed inlet 1025.

  In an embodiment, the first stream 1047 of aqueous calcined gypsum slurry passing through the first feed inlet 1024 has a Reynolds number that is higher than the Reynolds number of the combined first and second streams 1051 exiting the distribution outlet 1030. And the second stream 1048 of the aqueous calcined gypsum slurry passing through the second feed inlet 1025 has a Reynolds number that is higher than the Reynolds number of the combined first and second streams 1051 exiting the distribution outlet 1030. In an embodiment, the combined Reynolds number of the first and second streams 1051 exiting the distribution outlet 1030 is such that the first stream 1047 and / or the second stream of aqueous calcined gypsum slurry passing through the first feed inlet 1024. May be less than about 90% of the Reynolds number of the second stream 1048 of the aqueous calcined gypsum slurry passing through the feed inlet 1025, and in other embodiments may be less than about 80%, and still other implementations. In form, it may be less than about 70%.

  62 and 63, an embodiment of a Y-shaped flow splitter 1100 suitable for use in a gypsum slurry mixing and dispensing assembly assembled according to the principles of the present disclosure is shown. The flow splitter 1100 receives a single aqueous calcined gypsum slurry stream from the mixer and from there two separated aqueous calcined gypsum slurry streams from the first and second feed inlets of the slurry distributor. May be placed in fluid communication with the gypsum slurry mixer and slurry distributor for discharge to One or more flow modifying elements may be disposed between one or both delivery branches that connect between the mixer and the flow splitter 1100 and / or between the splitter 1100 and the associated slurry distributor.

  The flow splitter 1100 is disposed within a substantially circular inlet 1102 disposed within a main branch 1103 adapted to receive a single slurry flow and first and second outlet branches 1105, 1107, respectively. And a pair of substantially circular outlets 1104, 1106 that allow two streams of slurry to exit the splitter 1100. The cross-sectional areas of the inlet 1102 and outlet 1104, 1106 openings may vary depending on the desired flow rate. In embodiments where the cross-sectional area of the openings of the outlets 1104, 1106 is substantially equal to the cross-sectional area of the openings of the inlets 1102, the flow rate of the slurry discharged from the respective outlets 1104, 1106 is It may be reduced to about 50% of the flow rate of a single slurry entering the inlet 1102, where the volumetric flow rate through both is substantially the same.

In some embodiments, the diameter of the outlets 1104, 1106 may be made smaller than the diameter of the inlet 1102 to maintain a relatively high flow rate throughout the splitter 1100. In embodiments where the cross-sectional area of the opening of the outlets 1104, 1106 is less than the cross-sectional area of the opening of the inlet 1102, respectively, the flow rate is maintained at the outlets 1104, 1106, or at least all of the outlets 1104, 1106 and the inlet 1102 are substantially. May be reduced to a lower extent than when it has a cross-sectional area equal to. For example, in some embodiments, the flow splitter 1100 has an inlet 1102 having an inner diameter (ID ₁ ) of about 3 inches and a respective outlet 1104, 1106 having an ID _{2 of} about 2.5 inches (however, In other embodiments, other inlet and outlet diameters may be used). In one embodiment having these dimensions at a line speed of 350 fpm, the smaller diameter of the outlets 1104, 1106 reduces the flow rate at each outlet by approximately 28% of the flow rate of a single slurry flow at the inlet 1102.

The flow splitter 1100 may include a central relief 1114 and a junction 1120 between the first and second outlet branches 1105, 1107. Central relief 1114 helps to promote flow to the outer edges 1110, 1112 of the splitter within the central interior region of the flow splitter 1100 upstream of the junction 1120 to reduce the occurrence of slurry accumulation at the junction 1120. 1108 is created. The shape of the central relief 1114 provides guide channels 1111, 1113 that are adjacent to the outer edges 1110, 1112 of the flow splitter 1100. The narrowing 1108 in the central undulation 1114 has a height H ₂ that is smaller than the height H ₃ of the guide channels 1111, 1113. The guide channels 1111 and 1113 have a cross-sectional area larger than that of the central narrowing 1108. As a result, the flowing slurry encounters a flow resistance through the guide channels 1111, 1113 that is less than the flow resistance through the central constriction 1108, and the flow is directed to the outer edge of the splitter junction 1120.

  The junction 1120 establishes openings to the first and second outlet branches 1105, 1107. The joint 1120 is configured by a planar wall surface 1123 that is substantially orthogonal to the inlet flow direction 1125.

  Referring to FIG. 64, in some embodiments, an automatic device 1150 for squeezing the splitter 1100 at adjustable and regular time intervals is provided to prevent solids from accumulating inside the splitter 1100. You can do it. In some embodiments, the press 1150 may include a pair of plates 1152, 1154 disposed on opposite sides 1142, 1143 of the central relief 1114. The plates 1152, 1154 are movable relative to each other by suitable actuators 1160. The actuator 1160 may be manipulated to move the plates 1152, 1154 together relative to each other, either automatically or selectively to apply a compressive force to the splitter 1100 at the central undulation 1114 and joint 1120.

  When the squeezer 1150 squeezes the flow splitter, the squeezing action applies a compressive force to the flow splitter 1100 that bends inward in response. This compressive force can help prevent solid buildup inside the splitter 1100 that can impede a substantially equally divided flow to the slurry distribution through the outlets 1104, 1106. In some embodiments, the squeezer 1150 is configured to automatically pulse through the use of a programmable controller operably aligned with the actuator. The duration of application of compressive force by the squeezer 1150 and / or the time interval between pulses may be adjustable. Furthermore, the stroke length that the plates 1152, 1154 travel relative to each other in the compression direction may be adjustable.

  In one embodiment, the method of preparing a cementitious product may be performed using a slurry distributor assembled according to the principles of the present disclosure. The aqueous cementitious slurry stream is discharged from the mixer. A stream of aqueous cementitious slurry is sent at an average feed rate through the feed inlet of the slurry distributor along the first feed flow axis. The aqueous cementitious slurry stream is sent to the spherical portion of the slurry distributor. The bulb has a spreading area with a flow cross-sectional area that is greater than the flow cross-sectional area of the adjacent area upstream from the area of the spreading with respect to the flow direction from the feed inlet. The bulb is configured to reduce the average velocity of the aqueous cementitious slurry stream moving from the feed inlet through the bulb. The shaped duct has a convex inner surface that is in a relationship facing the first supply flow axis so that the flow of the aqueous cementitious slurry enters a radial flow in a plane substantially perpendicular to the first supply flow axis. The aqueous cementitious slurry stream is routed into a transition segment extending along a second feed flow axis that is non-parallel to the first feed flow axis.

  A stream of aqueous cementitious slurry is sent to the distribution conduit. The distribution conduit includes a distribution outlet extending a predetermined distance along the transverse axis substantially perpendicular to the longitudinal axis.

In embodiments, the flow of slurry moving toward the distribution outlet through the region adjacent to the convex inner surface and adjacent to at least one of the side sidewalls is about 0 to about 10, and in other embodiments about 0.00. 5 to about 5 vortex motion (S _m ). In embodiments, the slurry flow moving toward the distribution outlet through a region adjacent to the convex inner surface and adjacent to at least one of the side sidewalls has a swirl angle (S _m ) of about 0 ° to about 84 °. .

  In an embodiment, the aqueous cementitious slurry stream is routed through a flow stabilization zone adapted to reduce the average feed rate of the aqueous cementitious slurry stream entering the feed inlet and moving to the distribution outlet. The aqueous cementitious slurry stream exits the dispensing outlet at an average discharge rate that is at least 20 percent lower than the average feed rate.

  In another embodiment, a method of preparing a cementitious product includes draining a stream of aqueous cementitious slurry from a mixer. A stream of aqueous cementitious slurry is routed through the inlet of the distribution conduit of the slurry distributor. A flow of aqueous cementitious slurry is discharged from a dispensing outlet of the slurry distributor onto a web of cover sheet material moving along the machine direction. The wiper blade reciprocates over the clearing path along the bottom surface of the distribution conduit between the first and second locations to remove the aqueous cementitious slurry therefrom. The clearing path is disposed adjacent to the distribution outlet.

  In an embodiment, the distribution conduit extends between the entry and the distribution outlet generally along the longitudinal axis. The wiper blade reciprocates in the longitudinal direction along the clearing path.

  In an embodiment, the wiper blade moves in a clearing direction on the wiping stroke from the first location to the second location, and the wiper blade opposes on the return stroke from the second location to the first location. Move in the return direction. The wiper blade reciprocates so that the time to move on the wiping stroke is substantially the same as the time to move on the return stroke.

  In an embodiment, the wiper blade moves in a clearing direction on the wiping stroke from the first location to the second location, and the wiper blade opposes on the return stroke from the second location to the first location. Move in the return direction. The wiper blade reciprocates between the first location and the second location in a cycle having a sweep period. The sweep period includes a wiping portion that includes time to move on the wiping stroke, a return portion that includes time to move on the return stroke, and an accumulation delay portion that includes a predetermined period during which the wiper blade remains in the first location. . In an embodiment, the wiping portion is substantially the same as the return portion. In an embodiment, the accumulation delay portion is adjustable.

  In yet another embodiment, a method of preparing a cementitious product includes draining a stream of aqueous cementitious slurry from a mixer. A stream of aqueous cementitious slurry is routed through the inlet of the distribution conduit of the slurry distributor. The aqueous cementitious slurry stream is discharged onto a web of cover sheet material that travels longitudinally from the outlet opening of the distribution outlet of the slurry distributor. The dispensing outlet extends a predetermined distance along a transverse axis that is substantially orthogonal to the longitudinal axis. The outlet opening has a width along the transverse axis and a height along a vertical axis that is orthogonal to the longitudinal and transverse axes. A portion of the distribution conduit adjacent to the distribution outlet is compressed and engaged to change the shape and / or size of the outlet opening. In an embodiment, the distribution conduit is compressed and engaged by a profiling mechanism such that the flow of aqueous cementitious slurry is discharged from an outlet opening having an increased divergence angle with respect to the longitudinal direction.

  In an embodiment, the distribution conduit is compressed and engaged by a profiling mechanism having a profiling member in contact with the distribution conduit. The profiling member is movable in a range over which the profiling member is in a range of locations where the profiling member increases compression engagement with the distribution conduit. In an embodiment, the method includes moving the profiling member along a vertical axis to adjust the size and / or shape of the outlet opening. In an embodiment, the method includes the copying member such that the copying member translates and / or rotates about at least one axis to adjust the size and / or shape of the outlet opening. A moving step is included.

  Embodiments of slurry distributors, cementitious slurry mixing and dispensing assemblies, and methods of use thereof that can provide many enhanced process properties useful in the manufacture of cementitious products, such as gypsum wallboard in commercial environments, are described herein. Provided in the description. A slurry distributor constructed in accordance with the principles of the present disclosure facilitates spreading of the aqueous calcined gypsum slurry as the moving web of cover sheet material advances past the mixer at the wet end of the production line toward the forming station You can do it.

  A gypsum slurry mixing and dispensing assembly assembled in accordance with the principles of the present disclosure may divide the aqueous calcined gypsum slurry stream from the mixer into two separate aqueous calcined gypsum slurry streams, which are in accordance with the principles of the present disclosure. It may be recombined downstream in the assembled slurry distributor to provide the desired spreading pattern. The dual inlet configuration and distribution outlet design allows for a wider spread in the width direction of the higher viscosity slurry onto the moving web of cover sheet material. The slurry distributor is such that two separate aqueous calcined gypsum slurry streams enter the slurry distributor along a feed inlet direction that includes a widthwise component and the two slurry streams move substantially longitudinally. Recombined in the distributor in a manner that improves the width uniformity of the flow of the combined aqueous calcined gypsum slurry that is redirected inside the slurry distributor and discharged from the distribution outlet of the slurry distributor. It may be adapted to help reduce mass flow fluctuations over time along the direction axis or width direction. Introducing the first and second aqueous calcined gypsum slurry flows in the first and second feed directions including the widthwise component causes the combined slurry streams to have reduced momentum and / or energy. Can help drain from the dispenser.

  The internal flow cavity of the slurry distributor may be configured such that each of the two slurry streams moves through the slurry distributor in a laminar flow. The internal flow cavity of the slurry distributor is configured such that each of the two slurry streams moves through the slurry distributor with or without minimal gas-liquid slurry phase separation. Good. The internal flow cavity of the slurry distributor may be configured such that each of the two slurry streams moves through the slurry distributor without substantially passing through the vortex channel.

  A gypsum slurry mixing and dispensing assembly assembled in accordance with the principles of the present disclosure may include a flow shape upstream of the dispensing outlet of the slurry distributor to reduce the slurry velocity in one or more steps. For example, a flow splitter may be provided between the mixer and the slurry distributor to reduce the slurry speed entering the slurry distributor. As another example, the flow shape in the gypsum slurry mixing and dispensing assembly may include areas of expansion upstream and inside the slurry distributor to slow down the slurry, so that the slurry is distributed at the distribution outlet of the slurry distributor. Easy to handle when the slurry is discharged from.

  The shape of the dispensing outlet may also help control the slurry discharge rate and momentum as it is discharged from the slurry distributor onto the moving web of cover sheet material. The flow shape of the slurry distributor is substantially two-dimensional with the slurry exiting the distribution outlet having a relatively small height compared to the wider outlet in the width direction to help improve stability and uniformity. May be adapted to be maintained in a current flow pattern.

  The relatively wide discharge outlet provides a momentum per unit width of slurry discharged from the dispensing outlet that is less than the momentum per unit width of slurry discharged from a conventional boot under similar operating conditions. The reduced momentum per unit width may help prevent the skim coat of the dense layer applied to the web of coversheet material upstream from where the slurry is discharged from the slurry distributor onto the web.

In situations where a conventional boot outlet that is 6 inches wide and 2 inches thick is used, the average outlet speed for high volume products may be about 761 ft / min. In embodiments where a slurry distributor assembled in accordance with the principles of the present disclosure includes a distribution outlet having an opening that is 24 inches wide and 0.75 inches thick, the average speed may be about 550 ft / min. The mass flow rate is the same 3,437 lb / min for both devices. For both cases, the momentum of the slurry (mass flow rate ^* average speed) would be ˜2,618,000 and 1,891,000 lb · ft / min ² for the conventional boot and slurry distributor, respectively. Dividing the calculated momentum by the width of the conventional boot outlet and the slurry distributor outlet, the momentum per unit width of the slurry discharged from the conventional boot is 402,736 (lb · ft / min ² ). / (Inches across the boot width), and the momentum per unit width of the slurry discharged from the slurry distributor constructed according to the principles of the present disclosure is 78,776 (lb · ft / min ² ) / ( Inch from end to end of the slurry distributor width. In this case, the slurry discharged from the slurry distributor has a momentum per unit width of about 20% compared to a conventional boot.

  A slurry distributor assembled in accordance with the principles of the present disclosure may have a relatively low or more conventional WSR, such as from about 0.4 to about 1.2, such as less than 0.75 in some embodiments, And in other embodiments, the desired spreading pattern can be achieved using a wide range of water stucco ratio aqueous calcined gypsum slurries, including a water to calcined gypsum ratio of about 0.4 to about 0.8. Embodiments of slurry distributors assembled in accordance with the principles of the present disclosure include first and second streams as the first and second streams advance from the first and second supply inlets through the slurry distributor toward the distribution outlet. It may include an inner flow shape adapted to produce a controlled shear effect on the flow of the second aqueous calcined gypsum slurry. The application of controlled shear in the slurry distributor can selectively reduce the viscosity of the slurry as a result of undergoing such shear. Under the effect of controlled shear in the slurry distributor, a slurry with a lower water stucco ratio can be dispensed from the slurry distributor with a spreading pattern in the width direction equivalent to a slurry with conventional WSR. .

  The internal flow shape of the slurry distributor may be further adapted to apply to various water stucco ratio slurries to provide increased flow adjacent to the boundary wall region of the internal shape of the slurry distributor. By including flow shape characteristics in a slurry distributor adapted to increase the degree of flow around the boundary wall layer, the tendency of the slurry to recirculate through the slurry distributor and / or the stop flow and curing therein is reduced. Decrease. Thus, the accumulation of cured slurry in the slurry distributor can be reduced as a result.

  A slurry distributor constructed in accordance with the principles of the present disclosure is a slurry in the width direction on a base that changes the width velocity component of the combined flow of slurry discharged from the distribution outlet and down the production line toward the forming station. A profiling system mounted adjacent to the dispensing outlet may be included to selectively control the spread angle and spread width. The profiling system can help the slurry discharged from the dispensing outlet achieve the desired spreading pattern while being less sensitive to slurry viscosity and WSR. The profiling system may be used to change the flow dynamics of the slurry 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 width direction. Using a profiling system may also help gypsum slurry mixing and dispensing assemblies assembled according to the principles of the present disclosure to be used in gypsum wallboard manufacturing environments to produce different types and volumes of wallboard.

  Thus, in an embodiment, the slurry distributor comprises a distribution conduit that includes a distribution outlet that extends generally along the longitudinal axis and is in fluid communication with the input section. The dispensing outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The dispensing outlet includes an outlet opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal and transverse axes. The copying mechanism including the copying member is in contact with the distribution conduit. The profiling member has a range of travel such that the profiling member is within a range where the profiling member increases compression engagement with a portion of the dispensing conduit adjacent to the dispensing outlet to change the shape and / or size of the outlet opening. It can move on.

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

  In another embodiment, the outlet opening of the dispensing outlet has a width along the transverse axis. The copying member has a width that extends a predetermined second distance along the transverse axis. The width of the outlet opening is larger than the width of the copying member. The copying member is positioned such that the pair of side surface portions of the distribution outlet are in a stepped relationship with the copying member.

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

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

  In another embodiment, the replica member of the slurry distributor is translatable along at least one axis and rotatable about at least one pivot axis.

  In another embodiment, the profiling member of the slurry distributor is translatable along a vertical axis and rotatable about a pivot axis that is substantially parallel to the longitudinal axis. The profiling member is in a range where the profiling member is in variable compression engagement with the end-to-end portion of the distribution conduit transverse axis so that the height of the outlet opening varies along the transverse axis. Thus, it is possible to rotate around the turning axis on the arc length.

  In another embodiment, the replica member of the slurry distributor includes a support assembly having a fixed support member and a pivot support member. The pivot support member is rotatable about the pivot axis over the arc length with respect to the fixed support member. The pivot support member supports the copying member.

  In another embodiment, the profile member of the slurry distributor may have a variable compression engagement with the end-to-end portion of the distribution conduit transverse axis such that the height of the outlet opening varies along the transverse axis. It is possible to rotate around the pivot axis on the arc length so that the copying member is in the range of the joining place.

  In another embodiment, the tracing member of the slurry distributor includes a support assembly, an engagement segment that extends generally longitudinally and laterally, and a translational adjustment rod that extends generally perpendicularly from the engagement segment. The scanning member's translational adjustment rod is movably secured to the support assembly such that the scanning member is movable over a range of vertical positions.

  In another embodiment, the support assembly includes a clamping mechanism adapted to selectively engage the translation adjustment rod to secure the profiling member in one of the selected vertical position ranges.

  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 locations along the arc length.

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

  In another embodiment, the support assembly includes a rotational adjustment rod that extends between a fixed support member and a pivot support member. The rotation adjustment rod can be moved to a fixed support member so that moving the rotation adjustment rod relative to the fixed member causes the pivot support member to pivot about the pivot axis relative to the fixed support member Fixed to.

  In another embodiment, the support assembly includes a clamping mechanism adapted to selectively engage the rotational adjustment rod to secure the profiling member in one of a range of selected locations along the arc length. Including.

  In another embodiment, the cementitious slurry mixing and dispensing assembly comprises a mixer adapted to agitate water and cementitious material to form an aqueous cementitious slurry and a slurry distributor in fluid communication with the mixer. The slurry distributor includes a distribution conduit that extends generally along the longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion. The dispensing outlet extends a predetermined distance along the transverse axis. The transverse axis is substantially perpendicular to the longitudinal axis. The dispensing outlet includes an outlet opening having a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal and transverse axes. A slurry distributor is a profiling member in contact with a distribution conduit, wherein the profiling member is in compression engagement with a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening. Also included is a copying mechanism that includes a copying member that is movable over the range of travel such that the copying member is within the range of the increased location.

  In another embodiment, the cementitious slurry mixing and dispensing assembly further comprises a distributor support member that supports the distribution conduit. The tracing mechanism of the slurry distributor includes a support assembly having a fixed support member and a pivot support member. The fixed support member is connected to the distributor support member. The pivot support member is rotatable about the pivot axis on the arc length with respect to the fixed support member in a state where the pivot support member supports the copying member.

  In another embodiment, the cementitious slurry mixing and dispensing assembly is disposed between the mixer and the slurry distributor and is in fluid communication with a delivery conduit, associated with the delivery conduit, to flow the aqueous cementitious slurry from the mixer. It further comprises a flow modifying element adapted to control and an aqueous foam replenishment conduit in fluid communication with at least one of the mixer and the delivery conduit.

  In another embodiment, the cementitious slurry mixing and dispensing includes a first entry segment with a first supply inlet and a second supply inlet disposed in an isolated relationship with the first supply inlet. A slurry distributor comprising a supply conduit comprising two entry segments. The inlet of the distribution conduit is in fluid communication with the first and second supply inlets of the supply conduit. The first feed inlet is adapted to receive a first stream of aqueous cementitious slurry from the mixer. The second feed inlet is adapted to receive a second stream of aqueous cementitious slurry from the mixer, and the dispensing outlet is an aqueous in fluid communication and combination with both the first and second feed inlets. The first and second streams of cementitious slurry are adapted to exit the slurry distributor through the distribution outlet.

  In another embodiment, the gypsum slurry mixing and dispensing assembly is a delivery conduit disposed between and in fluid communication between the mixer and the slurry distributor, the main delivery main stream, and the first and second delivery branches. A main splitter and a first delivery branch, between the main delivery main part and the first delivery branch and between the main delivery main part and the second delivery branch. And a delivery conduit including a flow splitter disposed between the branches. The first delivery branch is in fluid communication with the first supply inlet of the slurry distributor, and the second delivery branch is in fluid communication with the second supply inlet of the slurry distributor.

  In another embodiment, a method of preparing a cementitious product comprises: (a) discharging a stream of aqueous cementitious slurry from a mixer; and (b) passing through an inlet of a distribution conduit of a slurry distributor. Sending a flow of slurry; and (c) discharging a flow of aqueous cementitious slurry onto a web of coversheet material moving longitudinally from an outlet opening of a distribution outlet of the slurry distributor, the flow comprising: The outlet extends a predetermined distance along the transverse axis, the transverse axis is substantially perpendicular to the longitudinal axis, the outlet opening is along the transverse axis, the width, and the longitudinal and transverse axes with respect to each other. A step having a height along an orthogonal vertical axis, and (d) a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening The compressing and a step of engaging.

  In another embodiment, the method of preparing a cementitious product is compressed and engaged by a profiling mechanism such that the flow of aqueous cementitious slurry is discharged from the outlet opening at an increased divergence angle with respect to the machine direction. Includes distribution conduit.

  In another embodiment, a method of preparing a cementitious product includes a dispensing conduit that is compressed and engaged by a profiling mechanism having a profiling member in contact with the dispensing conduit. The profiling member is movable over a range of travel such that the profiling member is in a range where the profiling member increases compression engagement with the distribution conduit.

  In another embodiment, the method of preparing a cementitious product further includes moving the profiling member along a vertical axis to adjust the size and / or shape of the outlet opening.

  In another embodiment, a method of preparing a cementitious product includes the copying member translating along at least one axis and / or about at least one axis to adjust the size and / or shape of the outlet opening. The method further includes the step of moving the copying member to rotate.

  With reference to FIG. 65, the shape and flow characteristics of an embodiment of a slurry distributor assembled according to the principles of the present disclosure were evaluated in Examples 1-3. A top plan view of the half portion 1205 of the slurry distributor is shown in FIG. The slurry distributor half 1205 includes a supply conduit 320 half 1207 and a distribution conduit 328 half 1209. The half portion 1207 of the supply conduit 322 includes a second supply inlet 325 defining a second opening 335, a second entry segment 337, and a half portion 1211 of the branched coupler segment 339. Half portion 1209 of distribution conduit 328 includes half portion 1214 of entry 352 of distribution conduit 328 and half portion 1217 of distribution outlet 330.

  Another half portion of the slurry distributor, which is a mirror image of half portion 1205 of FIG. 65, is substantially coupled and aligned with half portion 1205 of FIG. It should be understood that a slurry distributor similar to the slurry distributor 420 of FIG. 15 may be formed. Accordingly, the shape and flow characteristics described below are equally applicable to the half of the mirror image of the slurry distributor as well.

  Referring to FIG. 72, the shape and flow characteristics of another embodiment of a slurry distributor 2020 assembled according to the principles of the present disclosure were evaluated in Examples 4-6. The slurry distributor 2020 shown in FIG. 72 is substantially the same as the slurry distributor 1420 of FIG. The flow characteristics of the slurry distributor 2020 of FIG. 72 using a scanning mechanism assembled according to the principles of the present disclosure were evaluated in Example 7. The copying mechanism evaluated in the seventh embodiment is substantially equivalent to the copying mechanism 1432 in FIG.

Example 1
With reference to FIG. 65 in this example, the specific shape of the slurry distributor half 1205 is defined as the first position L ₁ at the second feed inlet 325 and the sixteenth position L at the half 1207 of the distribution outlet 330. It was assessed in 16 different positions _{L 1 to 16} between _16. Each location L _1-16 represents a cross-sectional slice of the slurry distributor half 1205 as indicated by the corresponding line. Streamline 1212 along the geometric center of each cross-sectional slice was used to determine the distance between adjacent positions _L1-16 . The eleventh position L ₁₁ corresponds to the half portion 1214 of the entry 352 of the distribution conduit 328 corresponding to the opening 342 of the second supply outlet 345 of the half portion 1207 of the supply conduit 320. Accordingly, the first to tenth positions L _1-10 are taken at half portion 1207 of supply conduit 320 and the eleventh to sixteenth positions are taken at half portion 1209 of distribution conduit 328.

For each position L _1-16 , the following geometric quantities: distance along the streamline 1212 between the second supply inlet 325 and the specific position L _1-16 , breakage of the opening at position L _1-16 area was measured outer peripheral position _{L 1 to 16,} and the hydraulic diameter of the position _{L 1 to 16.} The hydraulic diameter was calculated using the following formula:
D _hyd = 4 × A / P (Equation 1)
( _Where D _hyd is the hydraulic diameter,
A is the area of the specific positions L 1 to ₁₆ , and P is the outer periphery of the specific positions L 1 to ₁₆ ).
Using the inlet conditions, dimensionless values for each location L _1-16 can be determined to represent the internal flow shape, as shown in Table 1. A curve fitting equation is used to represent the dimensionless shape of the slurry distributor half portion 1205 in FIG. 66, which indicates dimensionless distance from the inlet versus dimensionless area and hydraulic diameter.

Analysis of the dimensionless values for each of the positions L _1-16 is from the first position L ₁ at the second supply inlet 325 to the half portion 1214 of the entry 352 (also the opening 342 of the second supply outlet 345). sectional area flows into the position L ₁₁ of the 11 in indicating that an increase. In the exemplary embodiment, the flow cross-sectional area at half portion 1214 of entry 352 is approximately one third greater than the flow cross-sectional area at second supply inlet 325. Between a position _{L 11} of the first position _{L 1} and the 11, the flow cross-sectional area of the second ingress segment 337 and the second forming duct 339 varies depending on the position _{L 1 to 11.} In this region, the at least two adjacent positions L ₆ , L ₇ are less than the adjacent position L ₆ where the position L ₇ located further from the second supply inlet 325 is closer to the second supply inlet 325. Configured to have an area.

Between the first position L ₁ and the eleventh position L ₁₁ , an adjoining upstream of the area of expansion in the direction from the second inlet 335 to the half part 1217 of the distribution outlet 330 in the half part 1207 of the supply conduit 322. There are areas of spread (eg, L _4-6 ) that have a flow cross-sectional area greater than that of the area (eg, L ₃ ). The second entry segment 337 and the second shaping duct 341 help distribute the second slurry stream that has a cross-section that varies along the direction of the flow 1212 and travels therethrough.

Cross-sectional area decreases from the position _{L 11} of the 11 in the halves 1214 of the entrance portion 352 of the distribution conduit 328 to the 16th position _{L 16} of halves 1217 of the distribution outlet 330 of the distribution conduit 328. In the exemplary embodiment, the flow cross-sectional area of half portion 1214 of entry 352 is approximately 95% of the flow cross-sectional area of half portion 1217 of distribution outlet 330.

The flow cross-sectional area at the first position L ₁ at the second supply inlet 325 is smaller than the flow cross-sectional area at the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the exemplary embodiment, the flow cross-sectional area at half portion 1217 of distribution outlet 330 of distribution conduit 328 is approximately ¼ greater than the flow cross-sectional area at second supply inlet 325.

The hydraulic diameter decreases from a first position L ₁ at the second supply inlet 325 to an eleventh position L _{11 at} the half portion 1214 of the entry 352 of the distribution conduit 328. In the exemplary embodiment, the hydraulic diameter at half portion 1214 of entry 352 of distribution conduit 328 is about ½ of the hydraulic diameter at second supply inlet 325.

The hydraulic diameter decreases from the eleventh L ₁₁ in the half portion 1214 of the entry 352 of the distribution conduit 328 to the sixteenth position L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the exemplary embodiment, the hydraulic diameter of half portion 1217 of distribution outlet 330 of distribution conduit 328 is about 95% of half portion 1214 of entry portion 352 of distribution conduit 328.

The hydraulic diameter at the first position L ₁ at the second inlet 325 is greater than the hydraulic diameter at the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the exemplary embodiment, the hydraulic diameter at half portion 1217 of distribution outlet 330 of distribution conduit 328 is less than about half of the hydraulic diameter of second supply inlet 325.

Example 2
In this example, the slurry distributor half 1205 of FIG. 65 was used to model the flow of gypsum slurry through it under different flow conditions. For all flow conditions, the density (ρ) of the aqueous gypsum slurry was set to 1,000 kg / m ³ . Aqueous gypsum slurry is a shear thinning material so that its viscosity can be reduced when a shear force is applied. Viscosity of gypsum slurry (μ) Pa. s was calculated using a Power Law Fluid Model with the following equation:
(Where
K is a constant,
Is the shear rate, and n is in this case a constant equal to 0.133).

In the first flow condition, the gypsum slurry enters the second feed inlet 325 at 2.5 m / s with a viscosity K coefficient of 50 in the power law model. The flow characteristics in the distributor were determined by using computational fluid dynamics technology with finite volume method. At each position L _1-16 , the following flow characteristics were determined: area weighted average velocity (U), area weighted average shear rate.
Viscosity, shear stress, and Reynolds number (Re) calculated using a power law model (Equation 2).

Shear stress was calculated using the following equation:
(Where
μ is the viscosity calculated using the power law model (Equation 2), and
Is the shear rate).

The Reynolds number was calculated using the following equation:
Re == ρ × U × D _hyd / μ (Equation 4)
(Where
ρ is the density of the gypsum slurry,
U is the area weighted average speed,
D _hyd is the hydraulic diameter, and μ is the viscosity calculated using the power law model (Equation 2)).

In the case of the second flow condition, the feed rate of the gypsum slurry into the second feed inlet 325 increased to 3.55 m / s. All other conditions were the same as in the first flow condition of this example. Dimensional values for the aforementioned flow characteristics at the respective positions L _1-16 for both the first flow condition with an inlet velocity of 2.5 m / s and the second flow condition with an inlet velocity of 3.55 m / s. Was modeled. The inlet conditions were used to determine the dimensionless values of the flow characteristics for each position L _1-16 as shown in Table II.

For both flow conditions where K is set equal to 50, the average speed is from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. It decreased to. In the illustrated embodiment, the average speed was reduced by about 1/5 as shown in FIG.

For both flow conditions, the shear rate increased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear rate is from a first position L ₁ at the second supply inlet 325 to a sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 as shown in FIG. Doubled.

For both flow conditions, the calculated viscosity decreased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the calculated viscosity is from the first position L ₁ at the second supply inlet 325 to the sixteenth position L at the half portion 1217 of the distribution outlet 330 of the distribution conduit 328 as illustrated in FIG. _It decreased by about half to ₁₆ .

For both flow conditions in FIG. 70, the shear stress increased from a _first position L ₁ at the second supply inlet 325 to a _sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear stress increased by about 10% from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328.

For both flow conditions, the Reynolds number in FIG. 71 decreased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the Reynolds number decreases by approximately 1/3 from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. did. For both flow conditions, the Reynolds number in the 16 position _{L 16} of halves 1217 of the distribution outlet 330 of the distribution conduit 328 is in the laminar flow region.

Example 3
In this example, the half portion 1205 of the slurry distributor of FIG. 65 is under flow conditions similar to those of Example 2 except that the value of the coefficient K in the power law model (Equation 2) is set to 100. It was used to model the flow of gypsum slurry through it. The flow conditions were the same as in Example 2 in other respects.

Again, the flow characteristics were evaluated for both 2.50 m / s and 3.55 m / s feed rates of the gypsum slurry into the second feed inlet 325. At each position L _1-16 , the following flow characteristics: area weighted average velocity (U), area weighted average shear rate
The viscosity, shear stress (Equation 3), and Reynolds number (Re) (Equation 4) calculated using a power law model (Equation 2) were determined. The inlet conditions were used to determine the dimensionless values of the flow characteristics for each position L _1-16 as shown in Table III.

For both flow conditions where K is set equal to 100, the average speed is from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. It decreased to. In the illustrated embodiment, the average speed was reduced by about 1/5. The results for average speed were substantially the same as in Example 2 and FIG. 67 on a dimensionless basis.

For both flow conditions, the shear rate increased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear rate is approximately doubled from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. . The results for shear rate were substantially the same as in Example 2 and FIG. 68 on a dimensionless basis.

For both flow conditions, the calculated viscosity decreased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the calculated viscosity has decreased approximately half from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. The results for the calculated viscosity were substantially the same as in Example 2 and FIG. 69 on a dimensionless basis.

For both flow conditions, the shear stress increased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the shear stress increased by about 10% from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. The results for shear stress were substantially the same as in Example 2 and FIG. 70 on a dimensionless basis.

For both flow conditions, the Reynolds number decreased from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. In the illustrated embodiment, the Reynolds number decreases by approximately 1/3 from the first position L ₁ at the second supply inlet 325 to the sixteenth position L _{16 at} the half portion 1217 of the distribution outlet 330 of the distribution conduit 328. did. For both flow conditions, the Reynolds number in the 16 position _{L 16} of halves 1217 of the distribution outlet 330 of the distribution conduit 328 is in the laminar flow region. The results for the Reynolds number were substantially the same as those in Example 2 and FIG. 71 on a dimensionless basis.

67-71 are graphs of flow characteristics calculated for the different flow conditions of Examples 2 and 3. FIG. A curve fitting equation was used to express the change in flow characteristics over the distance between the feed inlet and the half of the distribution outlet. Thus, Examples 2 and 3 show that the flow characteristics are consistent across variations in inlet velocity and / or viscosity.

Example 4
In this example, the slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry in one of the spherical portions 2120 of the supply conduit 2022. Referring to FIG. 72, the first and second entry segments 2036, 2037 of the slurry distributor 2020 each have a diameter D. The slurry distributor 2020 has a length of about 12 × D along the longitudinal axis. The slurry distributor 2020 is symmetrical about a central longitudinal axis 50 that extends generally in the longitudinal direction 2192. The slurry distributor 2020 may be separated into two halves 2004, 2005 that are substantially symmetrical about the central longitudinal axis.

Referring to FIG. 73, the slurry distributor half portion 2004 of FIG. 72 is allowed to flow a gypsum slurry stream therethrough under flow conditions similar to those of Example 2 except that a different dimensionless representation is used. Used for modeling. The inlet diameter D (x ^* = x / D) is selected as the length criterion for non-dimensionizing the position vector x (x ^* = x / D) and the average inlet velocity (U) Was used as a velocity reference to dedimensionalize the velocity vector u (u ^* = u / U). The flow conditions were the same as in Example 2 in other respects.

  Referring to FIGS. 73-76, the flow characteristics in the half of the distributor were determined using computational fluid dynamics (CFD) techniques with the finite volume method. Specifically, the average speed at different vertical positions from area A was calculated. An area extending about 0.75D from the center of the entry segment in area A was analyzed. Twelve radially spaced vertical slices were analyzed to calculate 12 different average slurry velocities around the radius of the bulb. The twelve positions were substantially radially spaced so that each adjacent radial position was approximately 30 ° apart. Referring to FIGS. 75 and 76, the radial position 1 coincides with the opposite direction of the vertical direction 2192, and the radial position 7 coincides with the vertical direction 2192. The radial positions 4 and 10 are substantially aligned with the transverse axis 60.

CFD technology was used with two different inlet velocity conditions, u ₁ = U and u ₂ = 1.5 U. 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 is also plotted in FIG. It should be understood that the other half portion 2005 of the slurry distributor 2020 will exhibit similar flow characteristics.

For both flow conditions, the average speed at each radial position 1-12 was lower than the inlet speed but greater than zero. The average speed ranged from about half the inlet speed to about 7/8 (u ^* to inlet speed 0.48 to 0.83). The undulating convex dimple surface in the bulb helped to divert the flow from the entry segment radially outward in all directions.

  The slurry speed was also reduced compared to the inlet speed. The average speed of all 12 radial locations for a given flow condition was substantially similar (˜0.65 or 65% of inlet speed).

  Furthermore, at each flow condition, the highest average velocity occurred at radial positions 3-5 and 9-11. Higher average velocities along the transverse axis or along the width direction 60 helped provide more edge flow to the side walls.

Thus, this example illustrates that the spherical portion 2120 helps to slow down the slurry and change the direction of the slurry from a downward vertical direction to a radially outward horizontal plane. In addition, the spherical portion 2120 assists in diverting the slurry flow to the inner side wall and the outer side wall of the forming duct of the half portion 2004 of the slurry distributor 2020 to facilitate the movement of the slurry in the width direction 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 forming ducts 2041 of the supply conduit 2022. Referring to FIG. 78, half portion 2004 of slurry distributor 2020 of FIG. 72 is under flow conditions similar to that of Example 2 except that it uses a non-dimensional representation of speed similar to that of Example 4. It was used to model the flow of gypsum slurry through it. Specifically, the vortex motion of the slurry on the inner side wall and the outer side wall of the forming duct was analyzed.

  Referring to FIGS. 73, 74 and 78, the flow properties in the half portion 2004 of the distributor 2020 were determined using computational fluid dynamics (CFD) techniques in conjunction with the finite volume method. Specifically, the vortex motion of the slurry near the inner side wall and the outer side wall of the forming duct 2041 was analyzed. Referring to FIG. 73, the slurry moves in a spiral behavior as it enters the forming duct 2041. As the slurry moves along the longitudinal direction 2192 to the distribution outlet 2030, the slurry streamlines become more ordered. The vortex motion of the slurry was analyzed in the region of the forming duct 2041 at a longitudinal position of about 1-3 / 4D (1.72D) in the areas B1 and B2 as shown in FIGS.

The vortex motion of the slurry is a function of its tangential velocity and its axial (or longitudinal) velocity. Referring to FIG. 78, the angle of swirl for a swirl flow is typically characterized by an angle using the following equation and a swirl number (S) as a variation of linear momentum:
And r represents the radial position).

When the average value of tangential velocity and axial flow velocity is used in Equation 5, the equation is as follows:
For this example, the characteristic vortex motion (S _m ) is expressed using the following equation:
In this example, the calculated vortex motion was used to calculate the turning angle using the following equation.

CFD technology was used with two different dimensionless inlet velocity conditions, u ₁ = U and u ₂ = 1.5 U. The results of the CFD analysis can be seen in Table V. It should be understood that the other half of the slurry distributor will exhibit similar flow characteristics. Throughout this analysis, in embodiments, the slurry distributor is configured to produce a vortex motion S _{m in} the range of about 0 to about 10 and a swirl angle in the range of about 0 degrees to about 84 degrees in the slurry distributor. I found it good.

For both flow conditions, the maximum tangential velocity at the edge was at least about half of the inlet velocity at the edge region of the entrance of the forming duct. Vortex motion near the side walls is expected to help maintain the cleanliness of the internal shape of the slurry distributor during use. As shown in FIG. 73, the vortex motion of the slurry decreases in the direction of flow along the machine axis 50 to the distribution outlet 2030.

Example 6
In this example, the slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry through the supply conduit 2022 and the distribution conduit 2028. Referring to FIGS. 73 and 74, the flow conditions similar to those of Example 2 except that the half portion 2004 of the slurry distributor 2020 of FIG. It was used to model the flow of gypsum slurry through it below.

For all flow conditions, the density (ρ) of the aqueous gypsum slurry was set to 1,000 kg / m ³ and the viscosity K coefficient was set to 50. Again, the flow characteristics were evaluated for both the dimensionless feed rate of the gypsum slurry into the B and 1.5B feed inlets 2024. The following flow characteristics expressed as a function of the inlet diameter D: area weighted average velocity (U), area weighted average shear rate
Viscosity calculated using the power law model (Equation 2) and Reynolds number (Re) (Equation 4) are determined at each successive dimensionless position downstream from the entrance of the forming duct 2041 along the longitudinal direction 2192. did. The hydraulic diameter (Equation 1) was also calculated at a dimensionless position continuous along the longitudinal axis 50 described. Using inlet flow conditions, dimensionless values of flow characteristics were determined for each position as shown in Table VI.

  79-82 are graphs of flow characteristics calculated for different flow conditions of Example 6. FIG. A curve fitting equation was used to express the change in flow characteristics over the distance between the feed inlet and the half portion 2004 of the dispensing outlet 2030. Thus, the examples show that the flow characteristics are consistent across variations in inlet velocity.

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

  For both flow conditions, the shear rate increased from a first position (about 3D) in the supply conduit 2022 to a final position (about 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. The shear rate was different depending on the position. In the illustrated embodiment, the shear rate increased at half portion 2117 of distribution outlet 2030 of distribution conduit 2028 compared to the inlet, as shown in FIG.

  For both flow conditions, the calculated viscosity decreased from a first position (about 3D) in the supply conduit to a final position (about 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. The calculated viscosity varied with position. In the illustrated embodiment, the calculated viscosity decreased at half portion 2117 of distribution outlet 2030 of distribution conduit 2028 as compared to the inlet, as shown in FIG.

  For both flow conditions, the Reynolds number in FIG. 82 decreased from the first position (about 3D) in the supply conduit to the final position (about 12D) in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028. In the illustrated embodiment, the Reynolds number was reduced by approximately ½ in the half portion 2117 of the distribution outlet 2030 of the distribution conduit 2028 compared to the inlet. For both flow conditions, the Reynolds number at half portion 2117 of distribution outlet 2030 of distribution conduit 2028 is in the laminar flow region.

Thus, the distal half of the slurry distributor (between about 6D and about 12D) provides a flow stabilization region where the average slurry velocity and Reynolds number are generally stable and reduced compared to the feed inlet conditions. It was found that it was configured as follows. As shown in FIG. 73, the slurry generally moves in a streamlined manner through this flow stabilization region along the longitudinal direction 2192.

Example 7
In this example, the slurry distributor 2020 of FIG. 72 was used to model the flow of gypsum slurry at the distribution outlet 2030 of the distribution conduit 2028. In this example, the half portion 2004 of the slurry distributor of FIG. 73 is used for gypsum slurry passing therethrough under flow conditions similar to those of Example 2 except that a dimensionless representation of the width of the outlet opening 2081 is used. Used to model the flow. The dimensionless width (w / W) is from end to end of the half portion 2119 of the outlet opening 2081 of the distribution outlet 2030 (with the centerline at the transverse central midpoint 2187 equal to 0 as shown in FIG. 72). is there. The flow conditions were the same as in Example 2 in other respects.

The flow characteristics in the half portion 2004 of the distributor 2020 were determined using CFD technology with a finite volume method. Specifically, the angle of spread of the slurry discharged from the outlet opening 2081 at various positions across the width of the half portion 2119 of the outlet opening 2081 of the distribution outlet 2030 was analyzed. The angle of spread was determined using the following formula:
Spreading angle = tan ⁻¹ (V _x / V _z ), (Equation 9)
(Where V _x is the average velocity in the width direction and V _z is the average velocity in the longitudinal direction).

  The angle of spread is calculated for two different conditions, one of which is that the profiling mechanism does not compress the exit opening 2081 (“no profiling”), and one is that the profiling mechanism compresses the exit opening 2081. ("Copier"). In the modeled slurry distributor 2020, the outlet opening 2081 extends from the end of its overall width of about 10 inches for each half 2004, 2005, for a total of 20 inches for the total width of the outlet openings 2081. It has a height of about 3/4 of an inch to the end. The modeled profiling mechanism has a profiling member that is about 15 inches wide and aligned with the transverse midpoint so that the side of the dispensing outlet is stepped with the profiling member and is uncompressed. . In the modeled “copying machine” condition, the profiling mechanism compresses the exit opening about 1/8 of an inch so that the exit opening is about 5/8 of an inch in the area under the copying member. As shown in Table VII, the spread angle was determined for both conditions.

  Under both conditions, the angle of spread increases as the position moves farther outward from the transverse midpoint 2187 (width = 0). The angle of spread is greatest at the side edge of the outlet opening 2081.

The spread angle was increased by compressing the discharge outlet 2030 using a profiling mechanism, thereby reducing the height of the outlet opening 2081. In the modeled “copier” condition, the maximum spread angle at the side edge (width = 0.466) increased by more than 25 percent compared to the “no copier” condition. In the “copier” condition, the average angle of spread increased by over 50 percent compared to the “no copy machine” condition.

  All references, including public relations, patent applications, and patents cited herein, are hereby incorporated by reference as if each reference was individually and specifically indicated. Incorporated herein by reference to the same extent as

  The use of “a” and “an” as well as “the” and similar directives in the context describing the present invention (especially in the context of the following claims) Unless otherwise indicated herein or unless clearly contradicted by context, it is intended to include both the singular and plural forms. Unless otherwise stated, the terms “comprising”, “having”, “including” and “containing” refer to the unlimited word (i.e., Meaning "not limited"). The recitation of value ranges herein is intended to serve as a simple way to individually reference each distinct range that is within the range, unless otherwise indicated herein. Separate values are incorporated herein as if they were individually enumerated herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples provided herein or exemplary words (eg, “such as”) are merely intended to better illustrate the invention and are No limitation is imposed on the scope of the present invention unless otherwise requested. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

  Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of these preferred embodiments will become apparent to those skilled in the art upon reading the foregoing description. The inventor expects those skilled in the art to adopt such variations as necessary and the inventor intends the invention to be practiced in ways other than those specifically described herein. Accordingly, this invention includes all modifications and equivalent methods of the subject matter as permitted by applicable law recited in the claims appended hereto. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims (25)

A distribution conduit that generally extends along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion, wherein the distribution outlet extends a predetermined distance along a transverse axis, the transverse direction The axis is substantially perpendicular to the longitudinal axis, and the dispensing outlet has a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal axis and the transverse axis. A distribution conduit comprising an outlet opening having
A copying mechanism including a copying member in contact with the distribution conduit, wherein the copying member is a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening. A slurry distributor comprising: a copying mechanism, wherein the copying member is movable over a range of travel so that the copying member is in a range of locations where compression engagement is increased.   The slurry distributor of claim 1, wherein the outlet opening of the distribution outlet has a width to height ratio of about 4 or greater.   The outlet opening of the dispensing outlet has a width along the transverse axis, the profiling member has a width extending a predetermined second distance along the transverse axis, and the outlet opening The width of the copying member is larger than the width of the copying member, and the copying member is positioned such that a pair of side surface portions of the distribution outlet are stepped with the copying member. The slurry distributor according to claim 1.   The slurry distributor according to any one of claims 1 to 3, wherein the copying member is movable along the vertical axis.   The slurry distributor according to claim 1, wherein the copying member has at least two degrees of freedom.   The slurry distributor according to any one of claims 1 to 5, wherein the copying member is translatable along at least one axis and rotatable about at least one pivot axis.   The profiling member is translatable along the vertical axis and rotatable about a pivot axis substantially parallel to the longitudinal axis, and the height of the outlet opening is along the transverse axis. The profiling member is on the arc length so that the profiling member is in a range where the profiling member is in variable compression engagement with the end-to-end portion of the transverse axis of the distribution conduit to vary The slurry distributor according to claim 5 or 6, wherein the slurry distributor is rotatable around a pivot axis.   The profiling mechanism includes a support assembly having a fixed support member and a pivot support member, the pivot support member rotating about the pivot axis over the arc length relative to the fixed support member The slurry distributor of claim 7, wherein the slurry support member is capable of supporting the profiling member.   The profiling member is within a range of locations where the profiling member is variably compression engaged with a portion of the distribution conduit across the transverse axis such that the height of the outlet opening varies along the transverse axis. The slurry distributor according to any one of claims 1 to 8, wherein the profiling member is rotatable about a pivot axis over an arc length such that   The profiling mechanism includes a support assembly, and the profiling member is an engagement segment extending generally longitudinally and laterally and a translational adjustment rod extending generally vertically from the engagement segment, 10. The slurry distributor of claim 1 including the translation adjustment rod of the profiling member movably secured to the support assembly such that the profiling member is movable over a range of vertical positions. .   11. The support assembly includes a clamping mechanism adapted to selectively engage the translation adjustment rod to secure the profiling member in one of the selected range of vertical positions. The slurry distributor according to claim 1.   12. The support assembly according to claim 10 or 11, wherein the support assembly is adapted to rotatably support the profiling member such that the profiling member is rotatable about a pivot axis over a range of locations along the arc length. The described slurry distributor.   The support assembly is a fixed support member and a pivot support member, the pivot support member being rotatable about the pivot axis over the arc length with respect to the fixed support member; 13. The slurry distributor according to any one of claims 10 to 12, wherein the pivot support member includes a pivot support member that supports the copying member.   The support assembly is a rotation adjustment rod extending between the fixed support member and the pivot support member, wherein moving the rotation adjustment rod relative to the fixed member is the pivot support member. The rotation adjustment rod includes a rotation adjustment rod that is movably fixed to the fixed support member so that the rotation adjustment rod rotates about the pivot axis with respect to the fixed support member. The slurry distributor according to any one of the preceding claims.   The support assembly includes a clamping mechanism adapted to selectively engage the rotational adjustment rod to secure the profiling member in one of the selected range of locations along the arc length. The slurry distributor according to any one of claims 10 to 14. A mixer adapted to agitate water and cementitious material to form an aqueous cementitious slurry;
A slurry distributor in fluid communication with the mixer;
A distribution conduit that generally extends along a longitudinal axis and includes an entry portion and a distribution outlet in fluid communication with the entry portion, wherein the distribution outlet extends a predetermined distance along a transverse axis, the transverse direction The axis is substantially perpendicular to the longitudinal axis, and the dispensing outlet has a width along the transverse axis and a height along a vertical axis perpendicular to the longitudinal axis and the transverse axis. A distribution conduit comprising an outlet opening having
A copying mechanism including a copying member in contact with the distribution conduit, wherein the copying member is a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening. Cementitious slurry mixing and dispensing assembly comprising: a profiling mechanism, wherein the profiling member is movable over a range of travel such that the profiling member is in a range of locations where compression engagement is increased . A distributor support member for supporting the distribution conduit,
The scanning mechanism of the slurry distributor is a support assembly having a fixed support member and a pivot support member, wherein the fixed support member is coupled to the distributor support member, and the pivot support member is A support assembly that is rotatable about a pivot axis over an arc length with respect to the fixed support member, the pivot support member supporting the profiling member;
The cementitious slurry mixing and dispensing assembly of claim 16, further comprising a distributor support member that supports the distribution conduit. A delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor;
A flow modifying element associated with the delivery conduit and adapted to control the flow of the aqueous cementitious slurry from the mixer;
The cementitious slurry mixing and dispensing assembly according to claim 16 or 17, further comprising an aqueous foam replenishment conduit in fluid communication with at least one of the mixer and the delivery conduit.   A supply conduit wherein the slurry distributor includes a first entry segment with a first supply inlet and a second entry segment with a second supply inlet disposed in an isolated relationship with the first supply inlet The inlet of the distribution conduit is in fluid communication with the first and second supply inlets of the supply conduit, and the first supply inlet is a first of the aqueous cementitious slurry from the mixer. The second feed inlet is adapted to receive a second stream of aqueous cementitious slurry from the mixer, and the dispensing outlet is the first and second. A first and second stream of aqueous cementitious slurry combined in fluid communication with both of the feed inlets of the first and second outlets are adapted to exit the slurry distributor through the distribution outlet. It includes a supply conduit, cementitious slurry mixing and dispensing assembly according to any one of claims 16 18. A delivery conduit disposed between and in fluid communication with the mixer and the slurry distributor, wherein the delivery conduit includes a main delivery mainstream and first and second delivery branches;
A flow splitter connecting the main delivery main stream and the first and second delivery branches, the flow splitter between the main delivery main stream and the first delivery branch and the main delivery main stream And a flow splitter disposed between the second delivery branch and the second delivery branch,
The first delivery branch is in fluid communication with the first supply inlet of the slurry distributor and the second delivery branch is in fluid communication with the second supply inlet of the slurry distributor;
20. A gypsum slurry mixing and dispensing assembly according to claim 19. Discharging the aqueous cementitious slurry stream from the mixer;
Sending the flow of the aqueous cementitious slurry through an entry portion of a distribution conduit of a slurry distributor;
Discharging the aqueous cementitious slurry stream onto a web of coversheet material moving longitudinally from an outlet opening of a distribution outlet of the slurry distributor, the distribution outlet being along a transverse axis; Extends a predetermined distance, the transverse axis is substantially perpendicular to the longitudinal axis, and the outlet opening is perpendicular to the transverse axis and to the width and the longitudinal axis and the transverse axis. A step having a height along the axis; and
Compressing and engaging a portion of the distribution conduit adjacent to the distribution outlet to change the shape and / or size of the outlet opening.   The distribution conduit of claim 21, wherein the distribution conduit is compressed and engaged by a profiling mechanism such that the flow of the aqueous cementitious slurry is discharged from the outlet opening at an increased divergence angle with respect to the longitudinal direction. A method for preparing cementitious products.   The distribution conduit is a profiling member in contact with the distribution conduit, wherein the profiling member is in a range of travel such that the profiling member is in a range where the profiling member increases compression engagement with the distribution conduit. 23. A method of preparing a cementitious product according to claim 21 or 22, wherein the cementitious product is compressed and engaged by a copying mechanism having the copying member that is movable. 24. A cementitious product according to any one of claims 21 to 23, further comprising the step of moving the profiling member along the vertical axis to adjust the size and / or shape of the outlet opening. Method. Moving the profiling member so that the profiling member translates and / or rotates about at least one axis to adjust the size and / or shape of the outlet opening; 25. A method for preparing a cementitious product according to any one of claims 21 to 24, further comprising: