RU2677720C2 - Binding slurry distributor with profiling mechanism, system, and method for using same - Google Patents

Abstract

FIELD: technological processes.SUBSTANCE: group of inventions relates to continuous processes for manufacturing boards (for example, wall boards) and, in particular, to a device, system and method for the distribution of a binding slurry. Binding slurry distributor comprises a distribution conduit and profiling mechanism. Distribution conduit generally extends along the longitudinal axis and comprises an entry portion and distribution outlet in fluid communication with the entry portion. Said distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. Distribution outlet comprises an outlet having a width, measured along the transverse axis, and a height, measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis. Profiling mechanism comprises a profiling member which is in contact with the distribution conduit and is arranged to move in a predetermined range so that the profiling member is in the range of positions, in which the profiling member is in an increased compressive engagement with a portion of the distribution conduit near the distribution outlet for changing the shape and / or size of the outlet. Profiling member is configured for rotation around a hinge axis, describing the arc in such a way that the profiling member has a compressive effect which varies along the transverse axis on a portion of the distribution conduit, so that the height of the outlet varies along the transverse axis.EFFECT: technical result is high uniformity of the suspension.23 cl, 83 dwg

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims the benefit of the non-provisional patent application 13 / 659,516, filed October 24, 2012, named "Suspension Dispenser, System and Method for Their Use", and the partially continued patent application 13 / 844,550, filed March 15, 2013, named "Dispenser suspensions with a profiling mechanism, system and method of their use. "

[0002] All of the above applications by reference are fully incorporated into this application.

FIELD OF TECHNOLOGY

[0003] The present invention relates to continuous processes for the manufacture of boards (eg, wall boards) and, in particular, to a device, system and method for distributing an aqueous gypsum slurry.

BACKGROUND

[0004] It is known to manufacture a gypsum board by uniformly dispersing calcined gypsum (commonly referred to as "plaster") in water to form an aqueous calcined gypsum slurry. An aqueous calcined gypsum slurry is usually prepared in a continuous manner by introducing gypsum, water and other additives into a mixer, which contains means for mixing the contents to form a uniform gypsum slurry. The suspension is continuously directed to the outlet of the mixer and through it to the outlet pipe connected to the outlet of the mixer. Aqueous foam may be combined with an aqueous calcined gypsum slurry in a mixer and / or in an exhaust line. The flow of slurry passes through the exhaust pipe, from which it is continuously released onto the advancing web of coating material supported by the molding table. Allow the suspension to spread over an advancing web. A second web of coating material is used to coat the slurry and form a multilayer structure of the continuous blank for the wall plate, which is subjected to forming, such as in a conventional pressure treatment station, to obtain the required thickness. Calcined gypsum reacts with water in the billet of the wall building plate and sets during the advancement of the billet of the wall plate along the production line. The billet is cut into parts at the site of the production line in which the billet is sufficiently hardened, rotated 180 °, dried (for example, in a drying oven) to remove excess water and processed until the final product wall plate with the required dimensions is obtained.

[0005] Known devices and methods for solving some of these problems associated with the manufacture of gypsum wall plates are described in the same copyright holder of US patents No. 5,683,635; 5,643,510; 6,494,609; 6,874,930; 7,007,914 and 7,296,919, which are incorporated into this application by reference.

[0006] The weight proportion of water relative to the stucco in the mixture formulated to form a given amount of the finished product is known in the art as the “water-gypsum ratio” (WSR). A decrease in the specified water-gypsum ratio without changing the composition, respectively, leads to an increase in the viscosity of the solution and thus to a decrease in the ability of the suspension to spread on the molding table. Reducing the use of water (i.e., reducing the water-gypsum ratio) during the manufacturing process of the gypsum board can provide many advantages, including the possibility of reducing energy consumption in the process. However, the uniform distribution of high viscosity gypsum slurries on the molding table remains a big problem.

[0007] Furthermore, in some situations in which the suspension is a multiphase medium containing air, separation of the air-liquid suspension may be carried out in a conduit for discharging the suspension from the mixer. With a decrease in the water-gypsum ratio, the air volume increases to maintain the same bulk mass that was in the dry state. The volume of the air phase separated from the liquid phase of the suspension is increased, as a result of which there is a tendency to an increase in mass or a change in density.

[0008] It should be noted that the present description of the prior art is intended to assist the reader and should not be construed as an indication that any of the identified problems are independently recognized in the prior art. Although the described principles in some aspects and embodiments can alleviate the problems inherent in other systems, it should be noted that the scope of protection of the present invention is determined by the points of the attached formula, and not the ability of any described distinguishing features to solve any specific problem noted in this application.

SUMMARY OF THE INVENTION

[0009] In one aspect, the present invention is directed to embodiments of a suspension distribution system for use in preparing a gypsum product. According to one embodiment, the slurry distributor may comprise a supply pipe and a distribution pipe in fluid communication with the supply pipe. The supply pipe may comprise a first inlet supply opening in fluid communication with the distribution pipe and a second inlet supply opening located at a distance from the first inlet supply opening and in fluid communication with the distribution pipe. The distribution pipe as a whole can extend along the longitudinal axis and comprise an inlet and an outlet distribution opening in fluid communication with the inlet. The inlet is in fluid communication with the first and second inlet feed openings of the supply pipe. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis.

[0010] According to other embodiments, the slurry distributor comprises a supply pipe and a distribution pipe. The feed pipe comprises a first inlet with a first inlet feed and a second inlet with a second inlet feed located at a distance from the first inlet feed. The distribution pipe as a whole extends along the longitudinal axis and contains an inlet and an outlet distribution opening in fluid communication with the inlet. The inlet is in fluid communication with the first and second inlet feed openings of the supply pipe. The outlet distribution hole extends a predetermined distance along the transverse axis. The transverse axis is essentially perpendicular to the longitudinal axis. Each of the first and second inlet feed openings has an opening with a cross-sectional area. The inlet of the distribution pipe has an opening with a cross-sectional area that is larger than the sum of the cross-sectional areas of the openings of the first and second inlet feed openings.

[0011] According to other embodiments, the slurry distributor comprises a supply pipe, a distribution pipe, and at least one support segment. The feed pipe comprises a first inlet to a first inlet feed and a second inlet with a second inlet feed located at a distance from the first inlet feed. The distribution pipe as a whole extends along the longitudinal axis and contains an inlet and an outlet distribution opening in fluid communication with the inlet. The inlet is in fluid communication with the first and second inlet feed openings of the supply pipe. Each support segment is movable in a travel range so that the support segment is in a position range in which the support segment is in increasing compressive interaction with a portion of at least one of the supply pipe and the distribution pipe.

[0012] In another aspect of the present invention, the slurry dispenser may be in fluid communication with a gypsum slurry mixer configured to mix water and calcined gypsum to form an aqueous calcined gypsum suspension. In one embodiment, a gypsum slurry mixing and dispensing assembly is provided that includes a gypsum slurry mixer configured to mix water and calcined gypsum to form an aqueous calcined gypsum suspension. The slurry distributor is in fluid communication with the gypsum slurry mixer and is configured to receive a first stream and a second stream of aqueous calcined gypsum slurry from a gypsum slurry mixer and distribute the first and second streams of aqueous calcined gypsum slurry to a moving bed.

[0013] The slurry dispenser comprises a first inlet feed opening configured to receive a first stream of aqueous calcined gypsum slurry from a gypsum slurry mixer, a second inlet feed opening configured to receive a second stream of aqueous calcined gypsum slurry from a gypsum slurry mixer, and an outlet distribution port in fluid communication with the first and second inlet feed openings and configured so that the first and second sweat and the aqueous calcined gypsum slurry discharged from the slurry outlet of the distributor to a distributor orifice.

[0014] According to another embodiment, the slurry distributor comprises a supply pipe and a distribution pipe. The supply pipe comprises an inlet with an inlet feed opening and an outlet feed hole in fluid communication with the inlet feed hole. The inlet runs along the axis of the first feed stream. The supply pipe contains a profiled pipe containing a bulb-shaped part in fluid communication with the outlet of the input part. The supply pipe contains a transition part in fluid communication with the bulb-shaped part. The transition part extends along the axis of the second feed stream, which is not parallel to the axis of the first feed stream.

[0015] The distribution pipe generally extends along the longitudinal axis and includes an inlet and an outlet distribution port in fluid communication with the inlet part. The inlet is in fluid communication with the inlet of the supply pipe. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis.

[0016] The bulb-shaped portion has an expansion region with a flow cross-sectional area that is larger than the flow cross-sectional area in an adjacent region upstream of the expansion region with respect to the direction of flow of the slurry flowing from the inlet feed opening to the distribution outlet port of the distribution pipe. The profiled pipeline has a convex inner surface located opposite the outlet supply opening of the inlet.

[0017] According to yet another embodiment, the slurry distributor comprises a bifurcated feed pipe and a distribution pipe. The bifurcated supply pipe comprises first and second supply parts, each of which contains an inlet part with an inlet supply opening and an outlet supply opening in fluid communication with the inlet supply opening, a profiled conduit comprising a bulb-shaped part in fluid communication with the inlet supply opening parts, and a transition part in fluid communication with the bulb-shaped part. The input part generally runs along the vertical axis. The transitional part runs along the longitudinal axis, which is perpendicular to the vertical axis.

[0018] The distribution pipe extends generally along the longitudinal axis and includes an inlet and an outlet distribution port in fluid communication with the inlet part. The inlet is in fluid communication with the first and second inlet feed openings of the supply pipe. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis.

[0019] Each of the first and second bulb-shaped parts has an expansion region with a flow cross-sectional area that is larger than the flow cross-sectional area in an adjacent region upstream of the expansion region with respect to the direction of flow of the suspension flowing from the respective first and second inlet feed openings direction to the outlet distribution hole of the distribution pipe. Each of the first and second profiled pipelines has a convex inner surface located opposite the respective first and second outlet feed openings of the first and second inlet parts.

[0020] According to another embodiment, the slurry dispenser comprises a distribution pipe and a slurry wiping mechanism. The distribution pipe generally runs along the longitudinal axis, the outlet distribution port is in fluid communication with the inlet portion, and the lower surface extends between the inlet part and the outlet distribution port. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis. The suspension wiping mechanism comprises a movable cleaning blade that is in contact with the bottom surface of the distribution pipe. The cleaning blade is arranged to reciprocate along the cleaning path between the first position and the second position. The cleaning path passes next to the outlet distribution hole.

[0021] According to another embodiment, the slurry distributor comprises a distribution pipe and a profiling mechanism. The distribution pipe as a whole extends along the longitudinal axis and contains an inlet and an outlet distribution opening in fluid communication with the inlet. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis. The outlet distribution hole comprises an outlet having a width measured along the transverse axis and a height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis.

[0022] The profiling mechanism comprises a profiling element in contact with a distribution conduit. The profiling element is movable in a moving range so that the profiling element is in a range of positions in which the profiling element is in an increased compressive interaction with a part of the distribution pipe next to the outlet distribution hole to change the shape and / or size of the outlet.

[0023] In another aspect of the present invention, a slurry dispenser may be used in a mixing and dispensing binder suspension assembly. For example, a slurry dispenser may be used to distribute an aqueous calcined gypsum slurry onto a moving web. According to other embodiments, the mixing and distribution unit of the gypsum slurry comprises a mixer and a suspension distributor in fluid communication with the mixer. The mixer is capable of mixing aqueous and calcined gypsum to form an aqueous calcined gypsum slurry. The slurry spreader comprises a supply pipe and a distribution pipe.

[0024] The supply pipe comprises a first inlet with a first inlet feed and a second inlet with a second inlet feed located at a distance from the first inlet feed. The first inlet feed port is configured to receive a first stream of aqueous calcined gypsum slurry from the gypsum slurry mixer. The second inlet feed port is configured to receive a second stream of aqueous calcined gypsum slurry from the gypsum slurry mixer.

[0025] The distribution pipe generally extends along the longitudinal axis and includes an inlet and an outlet distribution port in fluid communication with the inlet part. The inlet is in fluid communication with the first and second inlet feed openings of the supply pipe. The outlet distribution hole extends a predetermined distance along the transverse axis. The transverse axis is essentially perpendicular to the longitudinal axis. The outlet distribution port is in fluid communication with the first and second inlet feed ports and is configured such that the first and second streams of aqueous calcined gypsum slurry exit the suspension distributor through the outlet distribution port.

[0026] Each of the first and second inlet feed openings has an opening with a cross-sectional area. The inlet of the distribution pipe has an opening with a cross-sectional area that is larger than the sum of the cross-sectional areas of the openings of the first and second inlet supply openings.

[0027] The mixing and distributing binder suspension assembly comprises a mixer configured to mix water and binder to form an aqueous binder suspension, and a suspension distributor in fluid communication with the mixer. The suspension dispenser may be any of various suspension dispensers according to the present invention.

[0028] In yet another aspect of the present invention, a suspension distribution system can be used in a method for preparing a cementitious product. For example, a slurry dispenser may be used to distribute an aqueous calcined gypsum slurry onto a moving web.

[0029] According to some embodiments, a method for dispensing an aqueous calcined gypsum slurry onto a moving bed can be performed using a slurry dispenser made in accordance with the principles of the present invention. The first stream of aqueous calcined gypsum slurry and the second stream of aqueous calcined gypsum slurry respectively pass through a first inlet feed opening and a second inlet feed opening of the suspension distributor. 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 from the outlet of the dispenser of the slurry dispenser onto a moving web.

[0030] According to other embodiments, a method for preparing a gypsum product can be implemented by using a slurry dispenser according to the present invention. The first stream of aqueous calcined gypsum slurry passes with a first average feed rate through the first inlet feed opening of the slurry distributor. The second stream of aqueous calcined gypsum slurry passes at a second average feed rate through the second inlet feed opening of the slurry distributor. The second inlet feed opening is located at a distance from the first inlet feed hole. The first and second streams of aqueous calcined gypsum slurry are combined in a slurry distributor. The combined first and second streams of aqueous calcined gypsum slurry are discharged at an average discharge speed from the outlet distribution port of the slurry distributor onto a web of coating material advancing along the machine direction. The average discharge speed is less than the first average feed rate and the second average feed rate.

[0031] According to another embodiment, a method for preparing a cementitious product can be implemented by using a suspension dispenser according to the present invention. A stream of aqueous binder slurry is discharged from the mixer. The aqueous binder slurry stream flows at an average feed rate through the inlet feed opening of the slurry distributor along the axis of the first feed stream. The flow of the aqueous binder suspension passes into the bulbous portion of the suspension distributor. The bulbous portion has an expansion region with a flow cross-sectional area that is larger than the flow cross-sectional area in an adjacent region upstream of the expansion region with respect to the direction of flow of the slurry flowing from the intake inlet. The bulbous portion is configured to reduce the average flow rate of the aqueous binder suspension moving from the inlet feed opening through the bulbous portion. The profiled pipeline has a convex inner surface located opposite the axis of the first feed stream so that the aqueous binder suspension moves in a radial flow in a plane substantially perpendicular to the axis of the first feed stream, and the flow of the aqueous binder suspension passes into the transition portion along the axis of the second feed flow, which is not parallel to the axis of the first feed stream. An aqueous binder slurry flows into the distribution pipe. The distribution pipe comprises an outlet distribution opening extending a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

[0032] According to another embodiment, a method for preparing a binder product comprises discharging an aqueous binder suspension from a mixer. The flow of the aqueous binder slurry passes through the inlet of the distribution pipe of the slurry distributor. The aqueous binder slurry is discharged from the outlet of the dispenser of the slurry distributor onto a web of coating material advancing along the machine direction. The cleaning blade reciprocates along the cleaning path along the lower surface of the distribution pipe between the first position and the second position to remove an aqueous binder suspension from it. The cleaning path passes next to the outlet distribution hole.

[0033] According to another embodiment, a method for preparing a binder product comprises discharging an aqueous binder suspension from a mixer. An aqueous binder suspension flows through the inlet of the distribution pipe of the suspension distributor. The aqueous binder of the slurry flows from the outlet of the outlet of the dispenser of the slurry distributor onto a web of coating material advancing along the machine direction. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis. The outlet has a width measured along the transverse axis and a height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis. A portion of the distribution pipe adjacent to the outlet distribution hole is subjected to compressive action to change the shape and / or size of the outlet.

[0034] The present application also describes embodiments of a mold for use in a method for manufacturing a slurry dispenser according to the present invention. The present application also describes embodiments of suspension dispenser holders according to the present invention.

[0035] Additional and alternative aspects and features of the described principles will be apparent from the following detailed description and accompanying drawings. It should be borne in mind that the system for the distribution of the suspension described in this application can be performed and used in other and different embodiments and can be modified in various respects. Accordingly, it should be understood that in the above general description and the following detailed description, examples are provided that are for explanation only and do not limit the scope of the attached claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] A patent or application file contains at least one color drawing. Copies of this patent or publication of a patent application with a color drawing (s) may be provided by the Office upon request and after payment of the required fee.

[0037] FIG. 1 is a perspective view of an embodiment of a suspension dispenser in accordance with the principles of the present invention.

[0038] FIG. 2 shows a perspective view of the suspension distributor shown in FIG. 1, and a perspective view of an embodiment of a suspension distributor holder constructed in accordance with the principles of the present invention.

[0039] FIG. 3 shows a front view of the suspension dispenser shown in FIG. 1 and the suspension distributor holder shown in FIG. 2.

[0040] FIG. 4 is a perspective view of an embodiment of a slurry dispenser constructed in accordance with the principles of the present invention, which forms an internal geometry similar to that of the slurry dispenser shown in FIG. 1, but which is made of rigid material and has a detachable structure.

[0041] FIG. 5 shows another perspective view of the suspension dispenser shown in FIG. 4, but with a profiling system removed for clarity.

[0042] FIG. 6 is a perspective view of another embodiment of a slurry spreader constructed in accordance with the principles of the present invention, which comprises a first inlet feed opening and a second inlet feed opening located at a feed angle of about 60 ° with respect to the longitudinal axis or machine direction of the slurry distributor.

[0043] FIG. 7 shows a top view of the top of the slurry dispenser shown in FIG. 6.

[0044] FIG. 8 is a rear view of the suspension dispenser shown in FIG. 6.

[0045] FIG. 9 shows a top view of the upper part of the first part of the suspension distributor shown in FIG. 6, which has a detachable design.

[0046] FIG. 10 is a perspective front view of a portion of the slurry dispenser shown in FIG. 9.

[0047] FIG. 11 is an exploded view of the slurry dispenser shown in FIG. 6, and a support system for a slurry dispenser constructed in accordance with the principles of the present invention.

[0048] FIG. 12 is a perspective view of the suspension distributor and the support system shown in FIG. eleven.

[0049] FIG. 13 is an exploded view of the slurry dispenser shown in FIG. 6, and another embodiment of a support system constructed in accordance with the principles of the present invention.

[0050] FIG. 14 is a perspective view of the slurry dispenser and support system shown in FIG. 13.

[0051] FIG. 15 is a perspective view of an embodiment of a slurry dispenser constructed in accordance with the principles of the present invention, which forms an internal geometry similar to that of the slurry dispenser shown in FIG. 6, but which is made of flexible material and has a composite structure.

[0052] FIG. 16 is a plan view of the top of the slurry dispenser shown in FIG. fifteen.

[0053] FIG. 17 is an enlarged perspective view of the internal geometry defined by the suspension distributor shown in FIG. 15, showing successive flow cross-sections of a portion of its supply pipe.

[0054] FIG. 18 is an enlarged perspective view of the internal geometry of the suspension distributor shown in FIG. 15, showing other consecutive flow cross-sections of the supply pipe.

[0055] In FIG. 19 is an enlarged perspective view of the internal geometry of the suspension distributor shown in FIG. 15, showing yet another sequence of cross-sections of the flow of the supply pipe, which is aligned with half of the inlet towards the distribution pipe of the suspension distributor shown in FIG. fifteen.

[0056] FIG. 20 is a perspective view of the suspension dispenser shown in FIG. 15, and another embodiment of a support system constructed in accordance with the principles of the present invention.

[0057] FIG. 21 is a perspective view similar to that shown in FIG. 20, but with a support frame removed to illustrate the display of the retaining plates placed in various places on the slurry dispenser shown in FIG. fifteen.

[0058] FIG. 22 shows a perspective front view of another embodiment of a suspension dispenser and another embodiment of a support system configured in accordance with the principles of the present invention.

[0059] FIG. 23 shows a perspective rear view of the suspension distributor and the support system shown in FIG. 22.

[0060] FIG. 24 is a plan view of the slurry dispenser and support system shown in FIG. 22.

[0061] FIG. 25 is a side view of the suspension distributor and the support system shown in FIG. 22.

[0062] FIG. 26 is a front view of the suspension dispenser and the support system shown in FIG. 22.

[0063] FIG. 27 is a rear view of the suspension distributor and the support system shown in FIG. 22.

[0064] FIG. 28 is an enlarged detailed view of a distal portion of a suspension distributor illustrating an embodiment of a suspension wiping mechanism according to the present invention.

[0065] FIG. 29 is a perspective view of a profiling mechanism according to the present invention used in the slurry dispenser shown in FIG. 22.

[0066] FIG. 30 is a front view of the profiling mechanism shown in FIG. 29.

[0067] FIG. 30A is a view shown in FIG. 30, showing the profiling element of the profiling mechanism in a compressed position.

[0068] FIG. 30B is a view shown in FIG. 30, showing the profiling element of the profiling mechanism in a rotated position.

[0069] FIG. 30C is an enlarged detail exploded view of a profiling element showing a connection method between a movement control rod and a profiling segment.

[0070] FIG. 31 is a side view of the profiling mechanism shown in FIG. 29.

[0071] FIG. 32 is a plan view of the profiling mechanism shown in FIG. 29.

[0072] FIG. 33 is a bottom view of the profiling mechanism shown in FIG. 29.

[0073] FIG. 34 is a plan view of the slurry dispenser and support system shown in FIG. 22, with the support frame removed for illustrative purposes.

[0074] FIG. 35 is an enlarged detailed side view of the bulb-shaped portion of the suspension dispenser shown in FIG. 22.

[0075] FIG. 36 is a perspective view of a pair of rigid support inserts arranged on a lower support member of the support system shown in FIG. 22.

[0076] In FIG. 37 is a side view of the rigid support insert shown in FIG. 36.

[0077] FIG. 38 is a front view of the rigid support insert shown in FIG. 36.

[0078] FIG. 39 is a rear view of the rigid support insert shown in FIG. 36.

[0079] FIG. 40 is a front view of the suspension dispenser shown in FIG. 22.

[0080] FIG. 41 is a rear view of the suspension dispenser shown in FIG. 22.

[0081] FIG. 42 is a bottom perspective view of the slurry dispenser shown in FIG. 22.

[0082] FIG. 43 is a bottom view of the suspension dispenser shown in FIG. 22.

[0083] FIG. 44 is a plan view of half of the slurry dispenser shown in FIG. 22.

[0084] FIG. 45 is a sectional view taken along line 45-45 of FIG. 44.

[0085] FIG. 46 is a sectional view taken along line 46-46 of FIG. 44.

[0086] FIG. 47 is a sectional view taken along line 47-47 of FIG. 44.

[0087] FIG. 48 is a sectional view taken along line 48-48 of FIG. 44.

[0088] FIG. 49 is a sectional view taken along line 49-49 of FIG. 44.

[0089] FIG. 50 is a sectional view taken along line 50-50 of FIG. 44.

[0090] FIG. 51 is a sectional view taken along line 51-51 of FIG. 44.

[0091] FIG. 52 is a sectional view taken along line 52-52 of FIG. 44.

[0092] FIG. 53 is a sectional view taken along line 53-53 of FIG. 44.

[0093] FIG. 54 is a perspective view of an embodiment of a composite mold for manufacturing the slurry dispenser shown in FIG. 1 made according to the present invention.

[0094] FIG. 55 is a plan view of the mold shown in FIG. 54.

[0095] FIG. 56 is an exploded view of an embodiment of a composite mold for manufacturing the slurry dispenser shown in FIG. 15, made according to the present invention.

[0096] FIG. 57 is a perspective view of another embodiment of a mold for manufacturing a portion of a releasable slurry distributor according to the present invention.

[0097] FIG. 58 is a plan view of the mold shown in FIG. 57.

[0098] FIG. 59 is a schematic diagram of one embodiment of a gypsum slurry mixing and dispensing assembly comprising a slurry dispenser according to the present invention.

[0099] FIG. 60 is a diagram of another embodiment of a gypsum slurry mixing and dispensing assembly comprising a slurry dispenser according to the present invention.

[00100] FIG. 61 is a diagram of an embodiment of a loading portion of a production line for manufacturing a gypsum wallboard in accordance with the principles of the present invention.

[00101] In FIG. 62 is a perspective view of an embodiment of a flow divider made in accordance with the principles of the present invention, suitable for use in a gypsum slurry mixing and dispensing assembly comprising a slurry dispenser.

[00102] In FIG. 63 is a cross-sectional side view of the flow divider shown in FIG. 62.

[00103] In FIG. 64 is a side view of the flow divider shown in FIG. 62, with a compression device attached thereto according to the present invention.

[00104] In FIG. 65 is a plan view of half of a suspension distributor similar to the suspension distributor shown in FIG. fifteen.

[00105] In FIG. 66 is a graph based on the data from Table I of Example 1 showing the dimensionless area and dimensionless hydraulic radius of half of the slurry dispenser shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00106] In FIG. 67 is a graph based on the data from Tables II and III of Examples 2 and 3, respectively, showing the dimensionless flow rate of a simulated suspension moving through half of the suspension distributor shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00107] In FIG. 68 is a graph based on the data from Tables II and III of Examples 2 and 3, respectively, showing the dimensionless shear rate in a simulated suspension moving through half of the suspension distributor shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00108] In FIG. 69 is a graph based on the data from Tables II and III of Examples 2 and 3, respectively, showing the dimensionless viscosity of the simulated suspension moving through half of the suspension distributor shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00109] FIG. 70 is a graph based on the data from Tables II and III of Examples 2 and 3, respectively, showing the dimensionless shear stress in a simulated suspension moving through half of the suspension distributor shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00110] In FIG. 71 is a graph based on the data from Tables II and III of Examples 2 and 3, respectively, showing the dimensionless Reynolds number of a simulated suspension moving through half of the suspension distributor shown in FIG. 65, depending on the dimensionless distance from the inlet feed opening.

[00111] In FIG. 72 is a plan view of a suspension distributor similar to the suspension distributor shown in FIG. 22.

[00112] In FIG. 73 is a perspective top view of an output stream simulated by a hydrodynamic simulation (CFD) method for half of the slurry dispenser shown in FIG. 72.

[00113] In FIG. 74 is a view similar to that shown in FIG. 73, showing the various areas described in Examples 4-6.

[00114] In FIG. 75 is a view of area A indicated in FIG. 74.

[00115] In FIG. 76 is a top view of region A showing radial locations used for analysis by a hydrodynamic simulation method.

[00116] In FIG. 77 is a graph based on the data from Table IV of Example 4, showing the dimensionless average speed of half of the slurry distributor shown in FIG. 73, depending on the radial location in the specified area A.

[00117] In FIG. 78 is an enlarged detail view taken from FIG. 72, showing a region B of a suspension distributor in which the flow of the suspension moving through it has a vortex.

[00118] In FIG. 79 is a graph based on the data from Table VI of Example 6 showing the dimensionless flow rate of a simulated suspension moving through half of the suspension distributor shown in FIG. 73, depending on the dimensionless distance from the inlet feed.

[00119] In FIG. 80 is a graph based on the data from Table VI of Example 6, showing the dimensionless shear rate in a simulated suspension moving through half of the suspension distributor shown in FIG. 73, depending on the dimensionless distance from the inlet feed.

[00120] In FIG. 81 is a graph based on the data from Table VI of Example 6 showing the dimensionless viscosity of a simulated suspension moving through half of the suspension distributor shown in FIG. 73, depending on the dimensionless distance from the inlet feed.

[00121] In FIG. 82 is a graph based on the data from Table VI of Example 6 showing the dimensionless Reynolds number of a simulated suspension moving through half of the suspension distributor shown in FIG. 73, depending on the dimensionless distance from the inlet feed.

[00122] In FIG. 83 is a graph based on the data from Table VII of Example 7 showing the propagation angle of a simulated suspension discharged from half of the suspension distributor shown in FIG. 73, depending on the dimensionless distance along the width of the outlet from the central transverse midline.

DETAILED DESCRIPTION OF EXAMPLE IMPLEMENTATION OPTIONS

[00123] The present invention provides various embodiments of a slurry distribution system that can be used to make products, including cement products, such as, for example, a gypsum wallboard. Embodiments of a slurry dispenser created in accordance with the principles of the present invention can be used in the manufacturing process to efficiently distribute a multiphase slurry, such as a slurry containing air and liquid phases, such as those contained in an aqueous foamed gypsum slurry.

[00124] Embodiments of a distribution system made in accordance with the present invention can be used to dispense a slurry (eg, an aqueous calcined gypsum slurry) over a moving web (eg, paper or film) moving on a conveyor during a continuous plate manufacturing process (eg wall plate). In one aspect, a slurry distribution system according to the present invention can be used in the conventional drywall manufacturing process as a discharge pipe or part thereof connected to a mixer configured to mix calcined gypsum and water to form an aqueous calcined gypsum slurry.

[00125] Embodiments of a distribution system for distributing a slurry according to the present invention are directed to performing expanded distribution (along a direction perpendicular to the machine) of a uniform gypsum slurry. The distribution system for distributing the slurry according to the present invention is made suitable for use with a gypsum slurry having a range of gypsum-water ratios, including gypsum-water ratios traditionally used to make gypsum wallboard, as well as for suspensions having a relatively low gypsum-water ratio and thus a relatively higher viscosity. In addition, the gypsum slurry distribution system of the present invention can be used to facilitate control of phase separation in an air-liquid slurry such as a foamed aqueous gypsum slurry, including a foamed gypsum slurry having a very high foam volume. The spread of the aqueous calcined gypsum slurry over the advancing web can be controlled by directing and distributing the slurry using the distribution system shown and described herein.

[00126] The kneading and dispersing cementitious slurry assembly of the present invention can be used to form any type of cement product, such as, for example, a slab. In some embodiments, a cement slab may be formed, such as, for example, gypsum dry plaster, Portland cement slab or acoustic panel.

[00127] The cementitious slurry may be any known cementitious slurry, for example any cementitious slurry commonly used for the manufacture of gypsum wallboard, acoustic panels, including, for example, acoustic panels described in US Patent Application Publication No. 2004/0231916, or Portland cement board. Also, the binder suspension may additionally contain any additives used for the manufacture of slabs from binder products. Such additives can be structural additives, including mineral wool, continuous or chopped glass fibers (also called fiberglass), perlite, clay, vermiculite, calcium carbonate, polyester and paper fiber, as well as chemical additives such as foaming agents, fillers, accelerators, sugar, reinforcing agents such as phosphates, phosphonates, borates and the like, inhibitors, binders (e.g. starch and latex), dyes, fungicides, biocides, a hydrophobic reagent such as a silicone-based material (n example, silane, siloxane, or silicone-based matrix resin), etc. Examples of the use of some of these and other additives are described, for example, in US patent No. 6,342,284; 6,632,550; 6,800,131; 5,643,510; 5,714,001; 6,774,146; and US Patent Publication Nos. 2004/0231916; 2002/0045074; 2005/0019618; 2006/0035112; and 2007/0022913.

[00128] Non-limiting examples of binders include Portland cement, magnesia cement, slag cement, fly ash, aluminum-calcium cement, water-soluble calcium sulfate anhydrite, calcium sulfate anhydrate, calcium sulfate β-hemihydrate, natural, synthetic or chemically modified calcium sulfate hemihydrate, calcium sulfate dihydrate (“gypsum”, “set gypsum” or “hydrated gypsum”) and mixtures thereof. In one aspect of the present invention, the binder optionally contains calcined gypsum, such as in the form of calcium sulfate alpha hemihydrate, calcium sulfate beta hemihydrate and / or calcium sulfate anhydrite. In some embodiments, the calcined gypsum may be fibrous and, in some embodiments, non-fibrous. Calcined gypsum may contain at least about 50% beta calcium sulfate hemihydrate. In other embodiments, the calcined gypsum may contain at least about 86% beta calcium sulfate hemihydrate. The weight ratio of water to calcined gypsum can be any suitable ratio, but one skilled in the art will appreciate that reduced ratios can be more effective since the minimum amount of excess water must be removed during manufacture to save energy in this way. In some embodiments, an astringent slurry can be prepared by combining water and calcined gypsum with a ratio in the range of ratios from about 1: 6 by weight, respectively, to about 1: 1, such as, for example, 2: 3, to make a board depending on products.

[00129] Embodiments of a method for preparing a knitting product, such as a gypsum product, according to the present invention may include distributing an aqueous calcined gypsum slurry onto a moving bed using a slurry dispenser made in accordance with the principles of the present invention. Various embodiments of a method for distributing an aqueous calcined gypsum slurry onto a moving web are described below.

[00130] In FIG. 1 to 3 show an embodiment of a suspension dispenser 120 according to the present invention, and FIG. 4 and 5 show another embodiment of a suspension dispenser 220 according to the present invention. The suspension dispenser 120 shown in FIG. 1-3 is made of an elastic flexible material, while the distributor 220 shown in FIG. 3 and 4, made of relatively rigid material. However, the internal flow geometry of both valves 120, 220 shown in FIG. 1-5 is the same, and when considering the distributor 120 shown in FIG. 1-3, reference is also made to FIG. 5.

[00131] As shown in FIG. 1, the slurry distributor 120 comprises a supply pipe 122, which has a first and second inlet supply holes 124, 125, and a distribution pipe 128, which has an outlet distribution hole 130 and is in fluid communication with the supply pipe 128. The profile system 132 (shown in FIG. .3) is configured to locally resize the outlet distribution hole 130 of the distribution pipe 128.

[00132] As shown in FIG. 1, the supply pipe 122 extends generally along a transverse axis or a direction 60 perpendicular to the machine direction, which is essentially perpendicular to the longitudinal axis or the machine direction 50. The first inlet feed opening 124 is located at a distance from the second inlet feed hole 125. The first inlet feed hole 124 and the second inlet feed opening 125 form corresponding openings 134, 135, which have substantially the same area. The openings 134, 135 of the first and second inlet feed openings 124, 125 shown in the drawing both have a circular cross-sectional shape, as shown in the drawings for this example. According to other embodiments, the cross section of the inlet feed openings 124, 125 may take other forms depending on the particular application and process conditions.

[00133] The first and second inlet feed openings 124, 125 are opposed to each other along an axis 60 perpendicular to the machine direction, such that the first and second inlet feed openings 124, 125 are substantially 90 ° to the machine axis 50. According to in other embodiments, the first and second inlet feed openings 124, 125 may be oriented in various ways with respect to the machine direction. For example, in some embodiments, the first and second inlet feed openings 124, 125 may be oriented at an angle between 0 ° and about 135 ° with respect to machine direction 50.

[00134] The supply pipe 122 comprises first and second inlet portions 136, 137 and a bifurcated connecting portion 139 located between the first and second inlet portions 136, 137. The first and second inlet portions 136, 137 are generally cylindrical and extend along the transverse axis 60 so that they are essentially parallel to the plane 57 formed by the longitudinal axis 50 and the transverse axis 60. The first and second inlet feed openings 124, 125 are located at the distal ends of the first and second inlet portions 136, 137, respectively, and communicate with them fluid.

[00135] According to other embodiments, the first and second inlet feed openings 124, 125, and the first and second inlet portions 136, 137 can be oriented in a different manner relative to the transverse axis 60, machine direction 50, and / or plane 57 defined by the longitudinal axis 50 and transverse axis 60. For example, in some embodiments, each of the first and second inlet feed openings 124, 125, and each of the first and second inlet portions 136, 137 may be located essentially in a plane 57 defined by a longitudinal axis 50 and along with a vertical axis 60, with a feed angle θ relative to the longitudinal axis or machine direction 50, said angle being in the range of up to about 135 ° relative to machine direction 50, according to other embodiments, in the range from about 30 ° to about 135 °, according to other embodiments in the range of from about 45 ° to about 135 °, according to other variants of implementation in the range of from about 40 ° to about 110 °.

[00136] The bifurcated connecting portion 139 is in fluid communication with the first and second inlet feed openings 124, 125 and the first and second inlet portions 136, 137. The bifurcated connecting portion 139 comprises first and second profiled conduits 141, 143. The first and second inlet feeds the holes 124, 125 of the supply pipe 22 are in fluid communication with the first and second profiled pipes 141, 143, respectively. The first and second profiled pipelines 141, 143 of the connecting part 139 are adapted to receive a first stream having a first supply direction 190, and a second stream having a second supply direction 191, an aqueous calcined gypsum slurry flowing from the first and second inlet feed holes 124, 125 respectively, and redirecting the first and second streams 190, 191 of the aqueous calcined gypsum slurry to the distribution pipe 128.

[00137] As shown in FIG. 5, the first and second profiled conduits 141, 143 of the connecting portion 139 form a first and second outlet supply openings 140, 145, respectively, in fluid communication with the first and second inlet supply openings 124, 125. Each outlet supply 140, 145 is in fluid communication distribution conduit 128. Each of the first and second outlet supply openings 140, 145 shown in the drawing forms an opening 142 having a generally rectangular inner portion 147 and a substantially circular side portion 149. ruglye side portions 149 arranged close to the side walls 151, 153 of the distribution manifold 128.

[00138] According to some embodiments, the openings 142 of the first and second outlet supply openings 140, 145 may have a cross-sectional area greater than the cross-sectional area of the openings 134, 135 of the first inlet supply opening 124 and the second inlet supply hole 125, respectively. For example, in some embodiments, the cross-sectional area of the openings 142 of the first and second outlet supply openings 140, 145 may exceed the cross-sectional area of the openings 134, 135 of the first inlet supply opening 124 and the second inlet supply hole 125, respectively, by a value ranging from 0% up to about 300%, according to other variants of implementation in the range from 0% to about 200%, and according to other variants of implementation from 0% to about 150%.

[00139] According to some embodiments, the openings 142 of the first and second outlet supply openings 140, 145 may have a hydraulic diameter (4 × cross-sectional area / perimeter) that is smaller than the hydraulic diameter of the openings 134, 135 of the first inlet supply opening 124 and the second inlet feed holes 125, respectively. For example, in some embodiments, the hydraulic diameter of the openings 142 of the first and second outlets 140, 145 may be about 80% or less of the hydraulic diameter of the openings 134, 135 of the first inlet 124 and the second inlet 125, respectively, according to other embodiments about 70% or less; and in other embodiments, about 50% or less.

[00140] As shown in FIG. 1, the connecting portion 139 essentially extends parallel to a plane 57 defined by the longitudinal axis 50 and the transverse axis 60. According to other embodiments, the connecting part 139 may be oriented in various ways with respect to the transverse axis 60, machine direction 50 and / or plane 57 formed by the longitudinal axis 50 and transverse axis 60.

[00141] The first inlet feed opening 124, the first inlet 136 and the first profiled pipe 141 are mirror images of the second inlet feed hole 125, the second inlet 137 and the second profiled pipe 143, respectively. Thus, it is understood that a description of one inlet feed opening can be applied to another inlet feed opening, a description of one inlet part can be applied to another inlet, and a description of one profiled pipe can also be applied to another profiled pipe in an appropriate manner.

[00142] The first profiled conduit 141 is in fluid communication with the first inlet supply port 124 and the first inlet portion 136. The first profiled conduit 141 is also in fluid communication with the distribution conduit 128 to facilitate fluid communication of the first inlet conduit 124 and the outlet distribution hole 130 so that the first suspension stream 190 flows into the first inlet feed hole 124, moves in the first inlet portion 136, along the first of the coated pipe 141 flows into the distribution pipe 128 and can be discharged from the slurry distributor 120 through the outlet distribution hole 130.

[00143] The first profiled conduit 141 has a front outer curved wall 157 and an opposite rear inner curved wall 158 defining a curved guide surface 165 configured to redirect the first slurry stream from the first supply direction 190, which is substantially parallel to the transverse direction or perpendicular machine direction 60, to the direction of the output stream 192, which is essentially parallel to the longitudinal axis or machine direction 50 and along perpendicular to the first feed direction 190. The first profiled conduit 141 is configured to receive a first slurry stream having a first feed direction 190 and redirect the slurry stream by changing the direction angle α, as shown in FIG. 9, so that the first slurry stream is redirected to the distribution conduit 128 and moves substantially in the direction 192 of the outlet stream.

[00144] In use, the first stream of calcined gypsum slurry flows through the first inlet feed 124 in the first feed direction 190, and the second stream of calcined gypsum slurry flows through the second inlet feed hole 125 in the second feed direction 191. In some embodiments, the first and the second feed directions 190, 191 may be symmetrical with respect to each other along the longitudinal axis 50. The first flow of suspension moving in the first feed is directed 190, is redirected to the slurry distributor 120 by changing a steering angle α in the range of up to about 135 ° to the direction 192 of the output stream. The second slurry stream moving in the second feed direction 191 is redirected to the slurry distributor 120 by changing the steering angle α, which is in the range of up to about 135 °, to the direction 192 of the output stream. The combined first and second streams 190, 191 of an aqueous calcined gypsum slurry are discharged from the slurry distributor 120 as a whole in the direction 192 of the outlet stream. The direction of the output stream 192 may essentially be parallel to the longitudinal axis or machine direction 50.

[00145] For example, in the embodiment shown in the drawing, the first slurry stream is redirected from the first feed direction 190, oriented along the 60 direction, perpendicular to the machine direction, by changing the guide angle α of about 90 °, with the flow turning around the vertical axis 55 to the direction 192 output stream oriented along machine direction 50. In some embodiments, the suspension stream may be redirected from the first feed direction 190 by changing a directional angle α that rotates the flow around the vertical axis 55 and is in the range of up to about 135 ° with respect to the direction 192 of the output stream, according to other embodiments in the range of from about 30 ° to about 135 °, according to other embodiments in the range of from about 45 ° to about 135 ° and according to other variants of implementation in the range from about 40 ° to about 110 °.

[00146] According to some embodiments, the shape of the rear curved guide surface 165 may be generally parabolic, which in the embodiment shown may be formed by a parabola described by the formula Ax ² + B. According to other embodiments, higher order curves may be used to form the rear curved guide surface 165, or according to yet another embodiment, the rear inner wall 158 may have a generally curved shape, which is composed of straight or linear parts, the ends of which are oriented in such a way that together they form a generally curved wall. In addition, the parameters used to form specific external wall form factors may depend on the specific operating parameters of the process in which the specified suspension distributor is used.

[00147] At least one pipeline from the supply pipe 122 and the distribution pipe 128 may include an expansion area having a cross-sectional area of the flow, which is larger than the cross-sectional area of the flow of the adjacent area located upstream of the expansion area in the direction from the supply pipe 122 to the distribution pipe 128. The first inlet 136 and / or the first profiled pipe 141 may have a cross section that varies along the direction of flow and to facilitate the spread of the first stream of suspension flowing through it. The shaped conduit 141 may have a cross-sectional area of the flow that increases in the first flow direction 195 from the first inlet feed port 124 to the distribution conduit 128 so that the first suspension flow slows down when it flows in the first shaped conduit 141. According to some embodiments, the first the shaped conduit 141 may have a maximum cross-sectional area of the flow at a given location along the first flow direction 195, which decreases from the maximum value in subsequent places along the first direction 195 of the stream.

[00148] According to some embodiments, the maximum cross-sectional area of the flow of the first profiled pipe 141 is about 200% of the area of the hole 134 of the first inlet feed hole 124 or less. According to other embodiments, the maximum cross-sectional area of the flow of the shaped conduit 141 is about 150% of the area of the opening 134 of the first inlet supply 124 or less. According to other embodiments, the maximum cross-sectional area of the flow of the shaped conduit 141 is approximately 125% of the area of the opening 134 of the first inlet supply 124 or less. According to other embodiments, the maximum cross-sectional area of the flow of the shaped conduit 141 is about 110% of the area of the opening 134 of the first inlet supply 124 or less. In some embodiments, the cross-sectional area of the stream is controlled so that the cross-sectional area of the stream does not change more than a predetermined value in a given section to facilitate the prevention of large changes in the flow regime.

[00149] According to some embodiments, the first inlet 136 and / or the first profiled conduit 141 may comprise one or more guide channels 167, 168 that are configured to facilitate the distribution of the first slurry stream toward the outer and / or inner walls 157, 158 of the supply pipe 122. The guide channels 167, 168 are configured to increase the flow of the suspension near the boundary wall layers of the distributor 120 of the suspension.

[00150] As shown in FIG. 1 and 5, the guide channels 167, 168 may be formed with a larger cross-sectional area than the cross-sectional area of the adjacent portion 171 of the supply pipe 122, which creates an obstacle that promotes the flow in the direction of the adjacent guide channel 167, 168, respectively, located in the wall area of the dispenser 120 of the suspension. In the embodiment shown in the drawing, the supply pipe 122 comprises an outer guide channel 167 located adjacent to the outer wall 157 and the side wall 151 of the distribution pipe 128, and an inner guide channel 168 located close to the inner wall 158 of the first profiled pipe 141. The cross-sectional area of the outer and the inner guide channels 167, 168 may exhibit a progressive decrease in the first flow direction 195. The outer guide channel 167 may extend substantially along the side wall 151 of the distribution pipe 128 to the outlet distribution hole 130. At this point in the cross section of the first profiled pipe 141 in the direction perpendicular to the first flow direction 195, the outer guide channel 167 has an increased cross-sectional area than inner guide channel 168, to facilitate deviation of the first suspension stream from its original displacement line in the first feed direction 190 to the outer wall 157.

[00151] The use of guide channels adjacent to the wall regions can facilitate flow control or flow direction of the suspension in areas known in the art as “dead ends”. By stimulating the flow of the slurry in the wall regions of the slurry distributor 120 by means of the guide channels, suspension of the slurry in the slurry distributor is eliminated, and the purity of the interior of the slurry distributor 120 can be improved. The growth rate of suspension sediments, which are torn off by pieces and can break through the advancing web from the coating material, can also be reduced.

[00152] According to other embodiments, the relative dimensions of the outer and inner guide channels 167, 168 can be changed to facilitate control of the suspension flow to improve flow stability and reduce phase separation of the air-liquid suspension. For example, in applications that use a relatively high viscosity slurry at a given cross-sectional location in the first profiled conduit 141 in a direction perpendicular to the first flow direction 195, the outer guide channel 167 may have a reduced cross-sectional area than the inner guide channel 168, for facilitating the convergence of the first stream of the suspension with the inner wall 158.

[00153] The inner curved walls 158 of the first and second profiled pipelines 141, 142 meet to define a sharp protrusion 175 adjacent to the inlet portion 152 of the distribution pipe 128. The sharp protrusion 175 effectively bisects the connecting portion 139. Each outlet supply opening 140, 145 is in fluid communication. with the inlet portion 152 of the distribution pipe 128.

[00154] According to other embodiments, the location of the sharp protrusion 175 along the longitudinal axis 50 may be changed. For example, the inner curved walls 158 of the first and second profiled conduits 141, 142 may be less bent according to other embodiments such that the sharp protrusion 175 is located further from the outlet distribution hole 130 along the longitudinal axis 50 than is shown in the drawing with the suspension distributor 120 . According to other embodiments, the sharp protrusion 175 may be located closer to the outlet distribution hole 130 along the longitudinal axis 50 than is shown in the drawing with the suspension distributor 120.

[00155] The distribution conduit 128 is substantially parallel to the plane 57 formed by the longitudinal axis 50 and the transverse axis 60, and is configured to give the combined first and second streams of aqueous calcined gypsum slurry from the first and second profiled conduits 141, 142 a generally flat structure to improve stability and uniformity. The outlet distribution hole 130 has a width extending a predetermined distance along the transverse axis 60 and a height extending along the vertical axis 55, which are mutually perpendicular to the longitudinal axis 50 and the transverse axis 60. The height of the outlet distribution hole 130 is less than its width. Distribution conduit 128 may be oriented relative to the advancing web of coating material on the forming table so that the dispensing conduit 128 is substantially parallel to the advancing web.

[00156] The distribution pipe 128 generally extends along the longitudinal axis 50 and includes an inlet portion 152 and an outlet distribution hole 130. The inlet portion 152 is in fluid communication with the first and second inlet ports 124, 125 of the feed line 122. As shown in FIG. 5, the inlet portion 152 is configured to receive the first and second streams of aqueous calcined gypsum slurry from the first and second inlet feed openings 124, 125 of the supply pipe 122. The inlet portion 152 of the distribution pipe 128 includes an inlet distribution hole 154 in fluid communication with the first and the second outlet supply openings 140, 145 of the supply line 122. The inlet distribution hole 154 shown in the drawing defines an opening 156 that substantially corresponds to an opening Iam 142 of the first and second outlet feed ports 140, 145. The first and second streams of aqueous calcined gypsum slurry are combined in a distribution line 128 so that the combined streams extend generally in the direction 192 of the output stream, which may substantially coincide with the line of movement of the web from coating material advancing along the molding table of a production line for manufacturing a wall plate.

[00157] The outlet distribution port 130 is in fluid communication with the inlet portion 152 and thus with the first and second inlet supply openings 124, 125 and the first and second outlet supply openings 140, 145 of the supply pipe 122. The outlet distribution 130 is in communication fluid with the first and second profiled pipelines 141, 143 and configured to release the combined first and second flow of the suspension along the direction 192 of the output stream to the canvas of the coating material, promoting Esja along the machine direction 50.

[00158] Shown in FIG. 1, the outlet distribution hole 130 forms a generally rectangular hole 181 with semicircular narrow ends 183, 185. The semicircular ends 183, 185 of the hole 181 of the outlet distribution hole 130 may be the terminating end of the outer guide channels 167 located adjacent to the side walls 151, 153 of the distribution pipe 128 .

[00159] The opening 181 of the outlet distribution hole 130 has an area that is larger than the sum of the areas of the openings 134, 135 of the first and second inlet supply openings 124, 125, and less than the sum of the areas of the openings 142 of the first and second outlet supply holes 140, 145 ( i.e., inlet distribution holes 156 156). Accordingly, the area of the opening 156 of the inlet portion 152 of the distribution pipe 128 is larger than the area of the opening 181 of the outlet distribution hole 130.

[00160] For example, in some embodiments, the cross-sectional area of the outlet 181 of the outlet distribution hole 130 may range from more than about 400% more than the sum of the cross-sectional areas of the holes 134, 135 of the first and second inlet feed holes 124, 125 , according to other variants of implementation in the range from more than to about 200% more, and according to other variants of implementation in the range from more than to about 150% more. According to other embodiments, the ratio of the sum of the areas of the openings 134, 135 of the first and second inlet supply openings 124, 125 to the area of the opening 181 of the outlet distribution hole 130 can be changed based on one or more factors, including the speed of the production line, the viscosity of the slurry distributed by the distributor 120 the width of the plate manufactured using the distributor 120, and the like. In some embodiments, the area of the opening 156 of the inlet portion 152 of the distribution pipe 128 may be in the range of from more than about 200% larger than the cross-sectional area of the opening 181 of the outlet of the distribution hole 130, according to other embodiments, in the range of from more than about 150% more, and according to other variants of implementation in the range from more than to about 125% more.

[00161] The outlet distribution hole 130 extends substantially along the transverse axis 60. The opening 181 of the outlet distribution hole 130 has a width W _{1 of} about 24 inches (60.96 cm) along the transverse axis 60 and a height of H _{1 of} about 1 inch (2.54 cm) ) along the vertical axis 55 (as shown in Fig. 3). In other embodiments, the size and shape of the outlet 181 of the outlet distribution hole 130 may be changed.

[00162] The outlet distribution hole 130 is positioned intermediate along the transverse axis 60 between the first inlet feed hole 124 and the second inlet feed hole 125 so that the first inlet feed hole 124 and the second inlet feed hole 125 are substantially equally spaced D ₁ , D ₂ from the transverse central median line 187 of the exhaust distribution port 130 (as shown in FIG. 3). The outlet distribution hole 130 may be made of flexible elastic material so that its shape can be changed along the transverse axis 60, for example, by means of a profiling system 32.

[00163] It is contemplated that the width W ₁ and / or the height H _{1 of the} outlet 181 of the outlet distribution hole 130 according to other embodiments may be changed for different operating conditions. In general, according to various embodiments, the overall dimensions of the slurry dispensers described in this application can be increased or decreased depending on the type of product being manufactured (for example, the thickness and / or width of the manufactured product), the speed of the production line used, and the speed of applying the slurry through the dispenser viscosity of the suspension, and the like. For example, the width W _{1 of the} outlet distribution hole 130, measured along the transverse axis 60, for use in the manufacturing process of the wall plate, which is traditionally supplied with a nominal width of not more than 54 inches (137.16 cm), according to some variants of implementation may be in the range from about 8 inches (20.32 cm) to about 54 inches (137.16 cm); and according to other embodiments, in the range of about 18 inches (45.72 cm) to about 30 inches (76.2 cm). In other embodiments, the ratio of the width W ₁ measured along the transverse axis 60 of the outlet distribution hole 130 to the maximum nominal width of a panel manufactured in a manufacturing system using a slurry distributor made in accordance with the principles of the present invention may range from about 1/7 to about 1, according to other options for implementation from about 1/3 to about 1, according to other options for implementation from about 1/3 to about 2/3 and according to other options realization in the range from about 2.1 to about 1.

[00164] the Height of the outlet distribution hole according to some variants of implementation may be in the range from about 3/16 inch (4.76 mm) to about 2 inches (50.8 mm) and according to other variants of implementation between about 3/16 inch (4 , 76 mm) and approximately 1 inch (25.4 mm). In some embodiments using a rectangular outlet distribution hole, the ratio of the rectangular width to the rectangular height of the outlet may be about 4 or more, according to other embodiments, about 8 or more, according to some embodiments, from about 4 to about 288, according to others embodiments from about 9 to about 288; according to other embodiments from about 18 to about 288; and according to other embodiments from rno 18 to about 160.

[00165] The distribution conduit 128 comprises a converging portion 182 in fluid communication with the inlet portion 152. The height of the converging portion 182 is less than the height in the region of the maximum cross-sectional area of the flow of the first and second profiled conduits 141, 143, and less than the height of the opening 181 of the outlet distribution hole 130. In some embodiments, the height of the converging portion 182 may be approximately half the height of the hole 181 of the outlet distribution hole 130.

[00166] The converging portion 182 and the height of the outlet distribution hole 130 may be interconnected to facilitate controlling the average speed of the combined first and second streams of aqueous calcined gypsum slurry distributed from the distribution pipe 128. The height and / or width of the outlet distribution hole 130 may be changed to adjust the average speed of the combined first and second flows of the suspension discharged from the distributor 120 of the suspension.

[00167] According to some embodiments, the outlet flow direction 192 is substantially parallel to the plane 57 defined by the machine direction 50 and perpendicular to the machine direction 60 of the system transporting the advancing web of coating material. According to other embodiments, the first and second feed directions 190, 191 and the exit direction 192 are substantially parallel to a plane 57 formed by machine direction 50 and perpendicular to machine direction 60 of the system transporting the advancing web of coating material. In some embodiments, the slurry dispenser may be configured and positioned relative to the molding table in such a way that the slurry stream is redirected in the slurry distributor 120 from the first and second feed directions 190, 191 to the output stream direction 192 without substantially redirecting the stream by turning around the machine perpendicular 60 .

[00168] According to some embodiments, the slurry distributor may be configured and positioned relative to the molding table such that the first and second slurry streams are redirected in the slurry distributor from the first and second feed directions 190, 191 to the output stream direction 192, by redirecting the first and second slurry flows by rotation around approximately 60 machine direction perpendicular to an angle of approximately 45 ° or less. Such a rotation can be achieved according to some embodiments by adjusting the slurry distributor so that the first and second inlet feed openings 124, 125 and the first and second feed directions 190, 191 of the first and second slurry flows are located at an angle ω of vertical displacement between the vertical axis 55 and a plane 57 formed by the machine axis 50 and perpendicular to the machine direction by the axis 60. According to some embodiments, the first and second inlet feed openings 124, 125 and the first and second The other feed directions 190, 191 of the first and second suspension flows can be arranged at a vertical angle ω in the range from zero to about 60 ° so that the suspension flow is redirected around machine axis 50 and runs along the vertical axis 55 in the suspension distributor 120 from the first and the second feed directions 190, 191 to the direction 192 of the output stream. In some embodiments, at least one of the respective inlet 136, 137 and profiled conduit 141, 143 may be configured to facilitate redirection of the slurry around machine axis 50 along vertical axis 55. In some embodiments, the first and second slurry streams may be redirected from the first and second feeding directions 190, 191 by changing the angle α of the direction around an axis essentially perpendicular to the angle ω of vertical displacement, and / or at least one of the other this rotation in the range from about 45 ° to about 150 ° to the direction 192 of the output stream so that the direction 192 of the output stream is generally aligned with the machine direction 50.

[00169] In use, the first and second streams of aqueous calcined gypsum slurry pass through the first and second inlet feed ports 124, 125 in the converging first and second feed directions 190, 191. The first and second profiled conduits 141, 143 redirect the first and second streams of suspension from the first feed direction 190 and the second feed direction 191 such that the first and second flow of the suspension are mixed at an angle α of the direction from both directions, essentially parallel to the transverse axis 60, to both directions eniyam substantially parallel to the machine direction 50. The distribution manifold 128 may be positioned so that it extends along a longitudinal axis 50 which substantially coincides with the machine direction 50 along which the web material moves from the coating according to the method of manufacturing gypsum board. The first and second streams of aqueous calcined gypsum slurry are combined in a slurry distributor 120 such that the combined first and second streams of aqueous calcined gypsum slurry pass through an outlet distribution port 130 in the direction of the 192 outlet stream as a whole along the longitudinal axis 50 and in the machine direction.

[00170] As shown in FIG. 2, the slurry dispenser holder 100 can be used to support the slurry dispenser 120, which in the embodiment shown is made of an elastic material, such as, for example, PCB or urethane. The slurry distributor holder 100 may be made of a suitable rigid material to facilitate maintaining the elastic slurry distributor 120. The slurry dispenser holder 100 may be detachable. The two parts 101, 103 can be hinged relative to each other around the hinge axis 105 located in the rear side of the holder, to provide free access to the inner part 107 of the holder 100. The inner part 107 of the holder 100 can be formed so that essentially corresponds to the external contours of the suspension distributor 120 to limit the movement of the suspension distributor 120 relative to the holder 100 and / or to facilitate the formation of the internal geometry of the suspension distributor 120 uu, wherein the slurry will flow.

[00171] As shown in FIG. 3, according to some embodiments, the suspension distributor holder 100 may be made of a suitable elastic elastic material that has a supporting function and may be deformed in response to the profiling system 132 attached to the holder 100. The profiling system 132 may be attached to the holder closely to the outlet distribution hole 130 of the suspension distributor 120. A profiling system 132 thus installed can cause a local change in the size and / or shape of the outlet distribution hole 130 of the distribution pipe 128, as well as a change in size and / or shape in close accordance with the holder 100, which in turn affects the size and / or the shape of the outlet distribution hole 130.

[00172] As shown in FIG. 3, the profiling system 132 may be configured to selectively change the size and / or shape of the outlet 181 of the outlet distribution hole 130. According to some embodiments, the profiling system may be used to selectively control the height H _{1 of the} outlet 181 of the outlet distribution hole 130.

[00173] The profiling system 132 shown in the drawing comprises a plate 90, a plurality of mounting bolts 92 securing the plate to a distribution pipe 128, and a series of adjusting bolts 94, 95 connected to it by a thread. Mounting bolts 92 are used to fasten the plate 90 to the holder 100 close to the outlet distribution hole 130 of the slurry distributor 120. The plate 90 extends essentially along the transverse axis 60. In the embodiment shown in the drawing, the plate 90 is in the form of a section of a steel corner profile. In other embodiments, plate 90 may have various shapes and may contain various materials. In other embodiments, the profiling system may include other components configured to selectively change the size and / or shape of the outlet 181 of the outlet distribution hole 130.

[00174] The profiling system 132 shown in the figure is configured to locally change along the transverse axis 60 the size and / or shape of the outlet 181 of the outlet distribution hole 130. The adjustment bolts 94, 95 are evenly spaced apart from each other along the transverse axis 60 on top of the outlet distribution holes 130. The adjusting bolts 94, 95 are independently adjustable to locally change the size and / or shape of the outlet distribution hole 130.

[00175] The profiling system 132 can be used to locally change the outlet distribution hole 130 to alter the structure of the combined first and second streams of aqueous calcined gypsum slurry distributed from the slurry distributor 120. For example, a mid-line adjustment bolt 95 may be screwed down to contract the transverse central median line 187 of the outlet distribution hole 130 to increase the deviation of the edge stream further from the longitudinal axis 50 to facilitate the spread of the slurry in the 60 direction perpendicular to the machine direction and improve flow uniformity slurry in a direction 60 perpendicular to the machine direction.

[00176] A profiling system 132 can be used to resize the outlet distribution hole 130 along the transverse axis 60 and maintain the new shape of the outlet distribution hole 130. The plate 90 may be made of a material that has adequate strength so that the plate 90 can withstand the action the force exerted by the adjusting bolts 94, 95 in response to the adjustment made by the adjusting bolts 94, 95 while giving the outlet distribution hole 130 new oh form. The profiling system 132 can be used to facilitate smoothing out changes in the suspension flow profile (for example, as a result of different specific gravities of the suspension and / or different inlet feed rates) released from the outlet distribution hole 130 such that the outlet relief of the suspension released from the distribution pipe 128, more uniform.

[00177] According to other embodiments, the number of adjusting bolts may be different so that the distance between adjacent adjusting bolts varies. According to other embodiments, if the width W _{1 of the} outlet distribution hole 130 is different, the number of adjusting bolts can also be different to achieve the required distance between adjacent bolts. In other embodiments, the separation distance between adjacent bolts may be varied along the transverse axis 60, for example, to provide improved locally variable flow control at the lateral edges 183, 185 of the outlet distribution hole 130.

[00178] The suspension dispenser, made in accordance with the principles of the present invention, may contain any suitable material. In some embodiments, the slurry dispenser may comprise any suitable substantially rigid material, which may comprise a suitable material allowing the size and shape of the outlet to be changed, for example, by using a profiling system. For example, an appropriate rigid plastic, such as ultra-high molecular weight plastic (UHMWPE), or metal, can be used. In other embodiments, a slurry dispenser made in accordance with the principles of the present invention may be made of an elastic material, such as a suitable elastic plastic, including, for example, polyvinyl chloride (PCV) or urethane. In some embodiments, a slurry dispenser made in accordance with the principles of the present invention may comprise a single inlet feed opening, an inlet, and a profiled conduit that is in fluid communication with the distribution conduit.

[00179] A gypsum slurry dispenser made in accordance with the principles of the present invention can be used to facilitate the expanded transverse direction of the machine to spread aqueous calcined gypsum slurry to facilitate the spread of a high viscosity gypsum slurry with a low water-gypsum ratio over a sheet of coating material moving over the molding table. A gypsum slurry distribution system can also be used to facilitate blocking the phase separation of the air-liquid slurry.

[00180] According to another aspect of the present invention, the gypsum suspension mixing and dispensing assembly may comprise a suspension dispenser made in accordance with the principles of the present invention. The slurry dispenser may be in fluid communication with a gypsum slurry mixer configured to mix water and calcined gypsum to form an aqueous calcined gypsum suspension. According to one embodiment, the slurry dispenser is configured to receive a first stream and a second stream of aqueous calcined gypsum slurry from a gypsum slurry mixer and to distribute the first and second streams of aqueous calcined gypsum slurry over a moving web.

[00181] The slurry dispenser may comprise a portion of the discharge conduit or act as the discharge conduit of a conventional gypsum slurry mixer (eg, paddle mixer) known in the art. The slurry dispenser can be used with components that are used in a traditional discharge line. For example, a slurry dispenser may be used with components that are used in a traditional discharge line in the form of a known discharge hopper discharge device or a device described in US Pat. Nos. 6,494,609; 6,874,930; 7,007,914 and 7,296,919.

[00182] The slurry dispenser, made in accordance with the principles of the present invention, should preferably be considered as an improvement to the existing wallboard manufacturing system. The slurry dispenser may preferably be used to replace a conventional single-wire or multi-wire dispenser used in known discharge lines. This gypsum slurry dispenser may be modified for a known slurry piping device, such as, for example, described in US Pat. Nos. 6,874,930 or 7,007,914, as a replacement for a remote distribution chute or dispenser. However, according to some embodiments, the slurry distributor according to yet another embodiment of the present invention may be connected to at least one outlet or openings of the dispenser.

[00183] As shown in FIG. 4 and 5, the suspension dispenser 220 is similar to the suspension dispenser 120 shown in FIG. 1-3, except that it is made essentially of rigid material. The internal geometry 207 of the slurry distributor 220 shown in FIG. 4 and 5, is similar to the geometry of the slurry distributor 120 shown in FIG. 1-3, and similar reference numbers are used to indicate like elements. The internal geometry 207 of the slurry distributor 220 is configured to form a gypsum slurry stream moving therein, which is in the form of a laminar flow with minimal or substantially zero phase separation of the air-liquid suspension and substantially no swirls.

[00184] According to some embodiments, the slurry distributor 220 may comprise any suitable substantially rigid material, which may comprise a suitable material enabling the size and shape of the outlet 130 to be changed, for example, by using a profiling system. For example, an appropriate rigid plastic, such as ultra-high molecular weight plastic (UHMWPE), or metal, can be used.

[00185] As shown in FIG. 4, the slurry dispenser 220 has a detachable structure. The upper part 221 of the slurry distributor 220 comprises a recess 227 adapted to accommodate a profiling system 132. These two parts 221, 223 can be pivotally movable relative to each other around a hinge 205 located on their rear side to facilitate easy access to the inner part 207 of the slurry distributor 220. The mounting holes 229 are used to facilitate the connection of the upper part 221 with the lower part 223 complementary to it.

[00186] In FIG. 6-8 show another embodiment of a slurry distributor 320 made in accordance with the principles of the present invention. The slurry distributor 320 shown in FIG. 6-8 is similar to the slurry dispenser 220 shown in FIG. 4 and 5, except that the first and second inlet feed openings 324, 325 and the first and second inlet portions 336, 337 of the slurry distributor 320 shown in FIG. 6-8 are arranged at an angle Θ of the feed relative to the longitudinal axis or machine direction 50 of approximately 60 ° (as shown in FIG. 7).

[00187] The slurry distributor 320 has a detachable structure comprising an upper portion 321 and a lower portion 323 complementary to it. These two parts 321, 323 of the slurry distributor 320 can be connected together in any suitable manner, for example, by using connecting elements inserted in an appropriate amount mounting holes 329 made in each part 321, 323. The upper part 321 of the slurry distributor 320 comprise a recess 327 adapted to receive a profiling system 132. The slurry distributor 320, shown in FIG. 6-8, in other respects similar to the suspension dispenser 220 shown in FIG. 4 and 5.

[00188] In FIG. 9 and 10 show the lower portion 323 of the slurry distributor 320 shown in FIG. 6. The lower portion 323 defines a first portion 331 of the internal geometry 307 of the slurry distributor 320 shown in FIG. 6. The upper part 323 defines a symmetrical second part of the internal geometry 307 so that if the upper and lower parts 321, 323 are connected together, as shown in FIG. 6, they form the complete internal geometry 307 of the slurry distributor 320 shown in FIG. 6.

[00189] As shown in FIG. 9, the first and second profiled pipelines 341, 343 are configured to receive the first and second slurry streams flowing in the first and second feed directions 390, 3791, and redirect the slurry stream by changing the angle α in such a way that the first and second slurry streams flow into the distribution pipe 328 essentially in the direction of the output stream 392, which coincides with the machine direction or the longitudinal axis 50.

[00190] In FIG. 11 and 12 show another embodiment of a slurry distributor holder 300 for use with the slurry distributor 320 shown in FIG. 6. The suspension distributor holder 300 may comprise upper and lower plates 301, 302 made of suitably rigid material, such as, for example, metal. The holder plates 301, 302 may be attached to the distributor using any suitable means. In use, plates 301, 302 can facilitate maintaining the slurry distributor 320 in place above a flow line containing a conveyor assembly supporting and transporting a moving panel sheet. The holder plates 301, 302 may be attached to respective uprights placed on both sides of the conveyor assembly.

[00191] In FIG. 13 and 14 show yet another embodiment of a suspension distributor holder 310 for use with the suspension distributor 320 shown in FIG. 6, which also contains the upper and lower plates 311, 312. The cutouts 313, 314, 318 in the upper holder plate 311 reduce the weight of the holder 310 during manufacture and provide access to parts of the slurry distributor 320, such as, for example, parts for accommodating mounting fasteners elements. The slurry dispenser holder 310 shown in FIG. 13 and 14 may otherwise be similar to the suspension distributor holder 300 shown in FIG. 11 and 12.

[00192] In FIG. 15-19 show another embodiment of a suspension dispenser 420, which is similar to the suspension dispenser 320 shown in FIG. 6-8, except that it is made essentially of flexible material. The suspension dispenser 420 shown in FIG. 15-19 also includes first and second inlet feed openings 324, 325 and first and second inlet portions 336, 337, which are disposed at a feed angle θ relative to the longitudinal axis or machine direction 50 of approximately 60 ° (as shown in FIG. 7 ) The internal geometry 307 of the slurry distributor 420 shown in FIG. 15-19 are similar to the internal geometry of the slurry distributor 320 shown in FIG. 6-8, and similar reference numbers are used to indicate like elements.

[00193] In FIG. 17-19, the internal geometry of the second inlet portion 337 and the second profiled conduit 343 of the slurry distributor 420 shown in FIG. 15 and 16. The cross-sectional areas 411, 412, 413, 414 of the outer and inner guide channels 367, 368 may exhibit a progressive decrease in the second flow direction 397 to the outlet distribution hole 330. The outer guide channel 367 may extend substantially along the outer wall 357 of the second profiled pipe 343 and along the side wall 353 of the distribution pipe 328 to the outlet distribution hole 330. The inner guide channel 368 extends close to the inner wall 358 of the second profiled pipe 343 and terminates in a sharp protrusion 375 of a bisected connecting portion 339. The slurry distributor 420 shown in FIG. 15-19, in other respects similar to the slurry distributor 120 shown in FIG. 1 and the slurry distributor 320 shown in FIG. 6.

[00194] Shown in FIG. 20 and 21, an embodiment of a slurry dispenser 420 is made of a flexible material, such as, for example, polyvinyl chloride or urethane. A holder 400 may be used to facilitate the maintenance of the slurry dispenser 420. The slurry dispenser holder 400 may comprise a support element, which in the embodiment shown is in the form of a lower support tray 401 filled with a suitable support medium 402 that forms a bearing surface 404. Bearing surface 404 is configured to actually match at least a portion of the outer surface of at least one of the supply pipe 322 and predelitelnogo conduit 328 for restricting a relative movement between the distributor 420 and the suspension support tray 401. In some embodiments the bearing surface 404 may also help maintain the intrinsic geometry of the slurry distributor 420 through which the slurry will flow.

[00195] The slurry distributor holder 400 may also include a collapsible support assembly 405 located at a distance from the lower support tray 401. The collapsible support assembly 405 may be located above the slurry distributor 420 and configured to hold the slurry distributor 420 to help maintain the internal geometry 307 of the indicated slurry dispenser in the required configuration.

[00196] The collapsible support assembly 405 may comprise a support frame 407 and a plurality of support segments 415, 416, 417, 418, 419 that are movably supported by the support frame 407. The support frame 407 may be attached to at least one of the lower support tray 401, or a correspondingly arranged rack or posts, for holding the support frame 407 motionless with respect to the lower supporting tray 401.

[00197] According to some embodiments, the at least one support segment 415, 416, 417, 418, 419 are independently movable relative to another support segment 415, 416, 417, 418, 419. In the embodiment shown, each support segment 415, 416, 417, 418, 419 can be independently movable relative to the support frame 407 within a predetermined range of movement. In some embodiments, each support segment 415, 416, 417, 418, 419 is configured to move within a predetermined range of movement such that each support segment is in a range of positions in which a corresponding support segment 415, 416, 417, 418, 419 is in increased compressive interaction with a portion of at least one of the supply pipe 322 and the distribution pipe 328.

[00198] The position of each support segment 415, 416, 417, 418, 419 can be adjusted to bring the support segments 415, 416, 417, 418, 419 into compressive interaction with at least a portion of the dispenser 420. Each support segment 415, 416, 417, 418, 419 can be independently adjusted to bring each support segment 415, 416, 417, 418, 419 into an increased compressive interaction with at least a portion of the slurry distributor 420 for thereby locally compressing the inside of the distributor 420 or in reduced compressive interaction with at least a portion of the distributor 420 to thereby enable the inner part of the distributor 420 to expand outwardly, for example, in response to water pressure gypsum slurry flowing in said rail.

[00199] In the embodiment shown in the drawing, each of the supporting segments 415, 416, 417 is configured to move in a range of movement along the vertical axis 55. According to other embodiments, at least one of the supporting segments may be configured to move along another line action of force.

[00200] The collapsible support assembly 405 includes a clamping mechanism 408 associated with each supporting segment 415, 416, 417, 418, 419. Each clamping mechanism 408 may be configured to selectively hold the associated supporting segment 415, 416, 417, 418 associated with it. , 419 in a selected position relative to the support frame 407.

[00201] In the embodiment shown, a rod 409 is attached to each support segment 415, 416, 417, 418, 419 and extends upward through a corresponding hole in the support frame 407. Each clamping mechanism 408 is attached to the support frame 407 and is associated with one of the rods 409 extending from the corresponding support segment 415, 416, 417, 418, 419. Each clamping mechanism 408 may be configured to selectively hold the related rod 409 in a fixed position relative to the support frame 407. those indicated in the drawing the clamping mechanisms 408 are known clamps with activation lever, which surround the corresponding shank 409 and allow stepless adjustment between clamping mechanism 408 and the associated rod 409.

[00202] One of ordinary skill in the art will appreciate that any suitable clamping mechanism 408 may be used. According to some embodiments, each shaft 409 can be moved by means of a suitable actuating mechanism (eg, hydraulic or electric) that is controlled by it electronic control device. The actuating mechanism can act as a clamping mechanism by clamping a supporting segment 415, 416, 417, 418, 419 related thereto in a fixed position relative to the support frame 407.

[00203] As shown in FIG. 21, each of the supporting segments 415, 416, 417, 418, 419 may include a contact surface 501, 502, 503, 504, 505, configured to actually match the surface with the desired geometric shape of at least one of the supply pipe 322 and distribution a pipeline 328 of a slurry distributor 420. In the embodiment shown, a distributor pipe support segment 415 is used, which comprises a contact surface 501 corresponding to the outer and inner shape of the distributor pipe portion 328, over which the support segment 415 is located. A pair of profile pipe support segments 416, 417 are also used, which respectively comprise the contact surface 502, 503 corresponding to the outer and inner shape of the part of the first and second profiled pipelines 3 41, 343, respectively, on top of which the segments 416, 417 supporting the profiled conduit are located. A pair of input support segments 418, 419 are also used, which respectively comprise a contact surface 504, 505 corresponding to the outer and inner shapes of the first and second inlet parts 336, 337, respectively on top of which are segments 418, 419 supporting the profiled pipeline. Contact surfaces 501, 502, 503, 504, 505 are made with the possibility of contact with the selected part of the suspension distributor 420 for relieving the maintenance of the part with which they come into contact with the distributor 420 in a position conducive to the formation of the internal geometry 307 of the suspension distributor 420.

[00204] In use, the collapsible support assembly 405 can be manipulated to independently introduce each support segment 415, 416, 417, 418, 419 into the necessary relationships with the suspension dispenser 420. Supporting segments 415, 416, 417, 418, 419 can help maintain the internal geometry 307 of the distributor 420 to promote the flow of the suspension through it and help ensure that the suspension actually fills the volume formed by the internal geometry 307 during use. The location of the specific contact surface of a given support segment 415, 416, 417, 418, 419 can be adjusted to locally change the internal geometry of the distributor 420. For example, a segment 415 supporting the dispenser conduit can be moved along the vertical axis 55 closer to the lower support tray 401 to reduce the height of the distribution pipe 328 in the area over which the supporting segment 415 is located.

[00205] According to other embodiments, the number of support segments may be different. In other embodiments, the size and / or shape of a given support segment may be different.

[00206] In FIG. 22-27, another embodiment of a slurry distributor 1420 according to the present invention is shown. Suspension dispenser 1420 is made essentially of a flexible material, such as, for example, polyvinyl chloride or urethane. The suspension dispenser 1420 shown in FIG. 22-27 also includes first and second inlet feed openings 1424, 1425 and first and second inlet portions 1436, 1437 that are located at a feed angle θ that is substantially parallel to the longitudinal axis or machine direction 50 (as shown in FIG. 24) .

[00207] The slurry distributor 1420 includes a bifurcated feed pipe 1422, a distribution pipe 1428, a slurry wiper mechanism 1417, and a profiling mechanism 1432. The slurry distributor holder 1400 can be used to support the slurry distributor 1420.

[00208] As shown in FIG. 22 and 23, the slurry distributor holder 1400 may comprise a support member, which in the embodiment shown is in the form of a lower support member 1401 defining a supporting surface 1402. The supporting surface 1402 may essentially be adapted to adapt to at least part of the outer side of at least one of the supply pipe 1422 and the distribution pipe 1428 to limit the relative movement between the distributor 1420 of the suspension and the lower erzhivayuschim element 1401. In some embodiments the bearing surface 1402 may also contribute to maintaining internal geometry slurry spreader 1420, through which the suspension that will flow. In some embodiments, an additional anchor structure may be used to attach the slurry distributor 1420 to the lower support member 1401.

[00209] The slurry distributor holder 1400 may also include an upper supporting element 1404 located at a distance from the lower supporting element 1401. The upper supporting element 1404 may be located above the slurry distributor 1420 and adapted to be positioned to support the slurry distributor 1420 to facilitate maintaining the necessary internal geometry 1407 of a suspension distributor 1420.

[00210] The upper support member 1404 may include a support frame 1407 and a plurality of support segments 1413, 1415, 1416 that are firmly supported by the support frame 1407. The support frame 1407 may be attached to at least one of the lower support member 1401 or one or more respectively struts for holding the support frame 1407 in a fixed position relative to the lower supporting tray 1401. Each of the supporting segments 1413, 1415, 1416 may have a contact surface made with the ability to adapt to the surface part of the desired geometric shape of at least one of the supply pipe 1422 and the distribution pipe 1428 of the distributor 1420 of the suspension. In some embodiments, the support frame 1407 may be configured to move the spatial arrangement between the supporting segments 1413, 1415, 1416 and the slurry distributor 1420. For example, in some embodiments, the support frame 1407 can move the support segments 1413, 1415, 1416 in a range of movement along the vertical axis 55.

[00211] As shown in FIG. 22, the slurry-wiping mechanism 1417 comprises a pair of actuating mechanisms 1510, 1511, operatively connected to a cleaning blade 1514 for selectively reciprocating movement of the cleaning blade 1514. The actuating mechanisms 1510, 1511 are attached to the lower supporting member 1401 near the far the end 1515 of the distribution pipe 1428. The cleaning blade 1514 extends across between the actuating mechanisms 1510, 1511.

[00212] As shown in FIG. 26, the outlet distribution hole 1430 comprises an outlet 1481 having a width W ₂ measured along the transverse axis 60. The cleaning blade 1514 extends a predetermined width W ₃ along the transverse axis 60. The width W _{2 of the} outlet 1481 is less than the width W _{3 of the} cleaning blades 1514 so that the cleaning blade 1514 is wider than the outlet 1481.

[00213] As shown in FIG. In 28 embodiments, each actuating mechanism 1510, 1511 comprises a double-acting pneumatic cylinder having a reciprocating piston 1520. The piston rod 1522 1522 is connected to a cleaning blade 1514. According to some embodiments, a pair of pneumatic air ducts can be connected to ejector port 1525 and retractor port 1526. The source of compressed gas 1530 can be controlled using a suitable control valve 1532, which controls an electronic control device 1534 for selectively reciprocating the cleaning blade 1514 along the longitudinal axis 50. According to various embodiments, the air duct can couple the ejector ports 1525 of both actuator-drive mechanisms 1510, 1511 together in parallel, and a separate air duct can connect the retractor ports 1526 of both executive drive mechanisms 1510, 1511 together in parallel. According to other embodiments, the actuating mechanisms may be in any way adapted to move the cleaning blade mutually, including, for example, manually manipulated devices.

[00214] The movable cleaning blade 1514 is in contact with the bottom surface 1540 of the distribution pipe 1428. The cleaning blade 1514 is reciprocated along the cleaning path between the first position and the second position (shown by dashed lines). A cleaning path is located adjacent to the distal end 1515 of the distribution pipe 1428, which includes an outlet distribution hole 1430. The cleaning blade reciprocates longitudinally along the cleaning path. In the embodiment shown in the drawing, the first position of the cleaning blade 1514 is longitudinally higher (in the direction of travel) of the outlet distribution hole 1430, and the second position is longitudinally lower (in the direction of movement) of the outlet distribution hole 1430.

[00215] The electronic control device 1534 is configured to selectively control the actuating mechanisms for reciprocating movement of the cleaning blade 1514. According to some embodiments, the electronic control device 1534 is configured to move the cleaning blade 1514 in the cleaning direction 1550 from a first position to a second position during the cycle of cleaning and moving the cleaning blade in the opposite opposite direction 1560 from the second position to the first position in reverse during the cycle. In some embodiments, the electronic control device 1534 is configured to move the cleaning blade 1514 in such a way that the duration of the cleaning cycle is substantially equal to the duration of the reverse cycle.

[00216] According to some embodiments, the electronic control device 1534 may be configured to reciprocate the cleaning blade 1514 between a first position and a second position in a cycle having a wipe period. The wiping period comprises a wiping time, which is the travel time during the cleaning cycle, a return time, which is the travel time during the return cycle, and a cumulative delay time, which is a predetermined period of time during which the wiper blade 1514 remains in the first position. In some embodiments, the wiping time is substantially equal to the return time. In some embodiments, the electronic control device 1534 is configured to change the cumulative delay time in a controlled manner.

[00217] As shown in FIG. 34, the lower supporting member 1401 supporting the lower surface of the distribution pipe 1428 has a perimeter 1565. The outlet distribution hole 1430 is offset longitudinally from the lower supporting element 1401 so that the distal portion 1515 of the outlet of the distribution pipe 1428 extends from the perimeter 1565 of the lower supporting element 1401. As shown in FIG. 28, the cleaning blade 1514 supports the distal portion of the outlet 1515 of the slurry distributor 1420 if it is in the first position.

[00218] As shown in FIG. 22, the profiling mechanism 1432 comprises a profiling element 1610 in contact with the distribution conduit 1428, and the holder assembly 1620 is configured to provide the profiling element 1610 with at least two degrees of freedom. According to some embodiments, the profiling element is movable along at least one axis and is capable of rotating around at least one hinge axis. According to various embodiments, the profiling element is movable along the vertical axis 55 and is able to rotate around the hinge axis 1630, which is essentially parallel to the longitudinal axis 50.

[00219] As shown in FIG. 26, 30 and 30A, the profiling element 1610 is movable in a moving range such that the profiling element 1610 is in a position range in which the profiling element 1610 is in an increasing compressive interaction with a portion of the distribution pipe 1428 adjacent to the outlet distribution hole 1430 to change the shape and / or size of the outlet 1430.

[00220] As shown in FIG. 26, the outlet 1481 of the outlet distribution hole 1430 has a width W ₂ along the transverse axis 60. The contacting profiling segment of the profiling element 1410 has a width W ₄ extending a predetermined distance along the transverse axis. In various embodiments, the width W _{2 of the} outlet 1481 is greater than the width W _{4 of the} profiling element 1410. According to other embodiments, the width W _{2 of the} outlet 1481 is less than or equal to the width W _{4 of the} profiling element 1410. The profiling element 1410 is positioned so that a pair of side portions 1631, 1632 of the outlet distribution hole 1430 are laterally offset relative to the profiling element 1410 so that the profiling element does not interact with the side portions 1631, 1632. According to some embodiments, the side portions 1631, 1632 may have a combined width of approximately one quarter of the width W _{2 of the} outlet 1481.

[00221] As shown in FIG. 23, the holder assembly 1620 comprises a pair of fixed legs 1642, 1643, a transverse fixed support element 1645, and a transverse hinged support element 1647 that is articulated to the transverse stationary support element 1645 using any suitable hinge. The fixed struts 1642, 1643 can be attached to the lower supporting element 1401. The transverse stationary supporting element 1645 can extend in the transverse direction between the fixed posts 1642, 1643.

[00222] As shown in FIG. 29, 30, 30B and 31, the hinge support member 1647 is rotatable around the hinge axis 1630 along an arc 1652 relative to the fixed support member 1645. According to some embodiments, the length of the arc 1652 tilts the hinge end 1653 of the hinge support member 1647 upward relative to the transverse axis 60 and down relative to the transverse axis 60. The hinge support element 1647 supports the profiling element 1610.

[00223] According to some embodiments, the profiling element 1610 is movable along the vertical axis 55 and is able to rotate around the hinge axis 1630, which is essentially parallel to the longitudinal axis 50. The profiling element 1610 is rotatable around the hinge axis 1630 along an arc 1652 in this way that the profiling element 1610 is in the range of positions in which the profiling element is in a variable compressive interaction with part of the distribution pipe 1428 along the transverse axis 60 so that the height H _{2 of the} outlet 1481 varies along the transverse axis 60.

[00224] As shown in FIG. 29 and 33, the profiling member 1610 comprises an interacting segment 1660 generally extending in the longitudinal and transverse directions, and a movement-controlling rod 1662 extending generally vertically from the interacting segment 1660. The moving-controlling stem 1662 of the profiling element 1610 is movably mounted to the articulated support element 1647 of the node 1620 of the holder so that the profiling element 1610 can move along the vertical axis 55 in the range of vertical positions. A pair of guide rods 1663, 1665 are connected to the interacting segment 1660 and pass through the respective bushings 1667, 1668 attached to the hinge support element 1647. The guide rods 1663, 1665 are movable relative to the bushings 1667, 1668 along the vertical axis 55.

[00225] The holder assembly 1620 may include a clamping device configured to selectively engage with the displacement control rod 1662 to secure the profiling member 1610 at a selected position in a range of vertical positions. In the embodiment shown in the drawing, the threaded connection between the displacement control rod 1662 and the articulated support member 1647 acts as a clamping device. Locknut 1664 is designed to lock a threaded rod that controls the movement of the rod 1662 in place. An elastic nut 1666 is located adjacent to the distal end 1657 of the control rod 1662 to maintain sufficient clearance for the cap screw 1669 (shown in FIG. 30C) attached to the distal end rotatably. As shown in FIG. 30C, a blind hole 1658 is made in the profiling member 1610 to accommodate the cap screw 1669 to allow rotation of the cap screw around the axis of the control rod 1662.

[00226] As shown in FIG. 30B and 31, the holder assembly 1620 may be configured to rotationally support the profiling member 1610 such that the profiling member 1610 can rotate around the hinge axis 1630 in a range of positions along the length of the arc 1652. The holder assembly 1620 includes a rotating adjustment rod 1670 extending between the stationary a supporting member 1645 and a hinged supporting member 1647 through a support bracket 1672 connected to a fixed supporting member 1645 (also shown in FIG. 31). The rotary adjusting rod 1670 is movably mounted to the fixed support element 1645 by threaded connection to the support bracket 1672 so that moving the rotary adjusting rod 1670 relative to the stationary support element 1645 by rotating its T-shaped handle rotates the hinge support element 1647 around the hinge axis 1630 with respect to the fixed support member 1645. The support bracket 1672 may be configured so that it can It can provide some bending during the tilt operation. Bushings 1673, 1674 can be used to increase reliability.

[00227] The holder assembly 1620 may comprise a clamping device adapted to selectively engage the rotary adjusting rod 1670 to secure the profiling member 1610 in a selected position from a range of positions along the arc 1652. In the embodiment shown, a lock nut 1677 can be used to secure the provided threaded rod 1670 relative to the cylindrical nut 1679.

[00228] As shown in FIG. 34 and 40, the bifurcated feed pipe 1422 of the slurry distributor 1420 comprises first and second feed parts 1701, 1702. Each of the first and second feed parts 1701, 1702 comprises a respective inlet 1436, 1437 having an inlet feed opening 1424, 1425 and an outlet feed hole 1710, 1711, in fluid communication with the inlet feed opening 1424, 1425, profiled conduit 1441, 1443, having a bulbous portion 1720, 1721 (as also shown in FIG. 41), in fluid communication with the delivery feed opening 1710, 1711, respectively input guide part 1436, and a transition portion 1730, 1731, in fluid communication with a respective bulbous portion 1720, 1721.

[00229] As shown in FIG. 34, the first and second inlet feed openings 1424, 1425 and the first and second inlet portions 1436, 1437 can be arranged with a corresponding feed angle θ, measured as the degree of rotation about the vertical axis 55 in the range up to about 135 ° relative to the longitudinal axis 50. Shown in in the drawing, the first and second inlet feed openings 1424, 1425 and the first and second inlet portions 1436, 1437 are arranged with a corresponding feed angle θ substantially aligned with the longitudinal axis 50.

[00230] The first feed part 1701 is substantially identical to the second feed part 1702. Thus, it should be understood that the description of one feed part is equally applicable to the other feed part. According to other embodiments, only a single feeding part can be used, or according to still other embodiments, more than two feeding parts can be used.

[00231] As shown in FIG. 35, the inlet 1436 is generally cylindrical and extends along the axis 1735 of the first feed stream. The axis 1735 of the first feed stream shown in the drawing of the input part 1436 generally runs along the vertical axis 55.

[00232] According to other embodiments, the axis 1735 of the first feed stream may have a different orientation with respect to a plane 57 formed by a longitudinal axis 50 and a transverse axis 60. For example, according to other embodiments, the axis 1735 of the first feed stream may be located with a feed angle α measured as the degree of rotation with respect to the transverse axis 60, which is not perpendicular to the plane 57 formed by the longitudinal axis 50 and the transverse axis 60. According to various embodiments, the inclination angle σ measured from Aulnay axis 50 in a direction opposite the machine direction 92 up to a vertical axis 55, as shown in FIG. 35 may range from about 0 ° to about 135 °, according to other embodiments, from about 15 ° to about 120 °, according to yet other embodiments, from about 30 ° to about 105 °, according to other embodiments, from about 45 ° to about 105 °, and in other embodiments, from about 75 ° to about 105 °. According to other embodiments, the axis 1735 of the first feed stream may be located at an angle of the feed roller, measured as the degree of rotation relative to the longitudinal axis 50, which is not perpendicular to the plane 57 formed by the longitudinal axis 50 and the transverse axis 60.

[00233] As shown in FIG. 34, the profiled conduit 1441 comprises a pair of side walls 1740, 1741 and a bulb-shaped portion 1720. The profiled conduit 1441 is in fluid communication with the outlet supply opening 1711 of the inlet portion 1436. As shown in FIG. 35, the bulbous portion 1720 is configured to reduce the average flow rate of the suspension moving from the inlet portion 1436 through the bulbous portion 1720 to the transition portion 1730. According to some embodiments, the bulbous portion 1720 is configured to reduce the average flow rate of the suspension moving from the inlet portion 1436 through a bulbous portion 1720 to a transition portion 1730, at least 20%.

[00234] As shown in FIG. 45-47, the bulb-shaped portion 1720 has an expansion region 1750 with a cross-sectional area of the flow that is larger than the cross-sectional area of the flow of the adjacent area upstream of the expansion area relative to the direction 1752 of the flow from the inlet supply opening 1424 to the outlet distribution hole 1430 of the distribution pipe 1428 According to some embodiments, the bulb-shaped portion 1720 has a region 1752 with a cross-sectional area in a plane perpendicular to the axis 1735 of the first stream, which th larger than the area of the exhaust supply opening in 1711.

[00235] The profiled conduit 1441 has a convex inner surface 1758 towards the outlet supply opening 1711 of the inlet portion 1436. The bulbous portion 1720 as a whole has a radial guide channel 1460 located adjacent to said convex inner surface. The guide channel 1460 is configured to bias the radial flow into a plane substantially perpendicular to the axis 1735 of the first feed stream. As shown in FIG. 45, the convex inner surface 1758 is configured to form a central narrowing 1762 of the flow path, which also helps to increase the average speed of the suspension in the radial guide channel 1760.

[00236] The profiled conduit 1441 may be configured such that a stream of slurry moving in an area adjacent to the convex inner surface 1758 and adjacent to at least one of the side walls 1740, 1741 toward the outlet distribution hole 1430 has a vortex with the parameter (S _m) spins of about 0 to about 10, according to other embodiments up to about 3, and according to other embodiments from about 0.5 to about 5. according to some embodiments of the slurry stream, the roaming in the area next to the convex inner surface 1758 and adjacent to at least one of the sidewalls 1740, 1741 to a final distribution aperture 1430 has an angle (S _m) swirls about 0 ° to about 84 ° and according to other embodiments from about 10 ° to about 80 °.

[00237] As shown in FIG. 34 and 35, the transition portion 1730 is in fluid communication with the bulb-shaped portion 1720. The transition portion 1730 shown in the drawing extends along the longitudinal axis 50. The transition portion 1730 is configured so that its width, measured along the transverse axis 60, increases in the direction of flow of the suspension flowing from the bulb-shaped portion 1720 to the outlet 1430. The transition portion 1730 extends along the axis 1770 of the second feed stream, which is not parallel to the axis 1735 of the first feed stream.

[00238] According to some embodiments, the axis 1735 of the first feed stream is substantially perpendicular to the longitudinal axis 50. According to some embodiments, the axis 1735 of the first feed stream is substantially parallel to the vertical axis 55, which is perpendicular to the longitudinal axis 50 and the transverse axis 60. According to some embodiments, the axis 1770 of the second feed stream is located at a corresponding feed angle θ in the range of up to about 135 ° with respect to the longitudinal axis 50.

[00239] According to some embodiments, the supply pipe 1422 comprises a bifurcated connecting segment 1439 having first and second guide surfaces 1780, 1781. According to some embodiments, the first and second guide surfaces 1780, 1781, respectively, may be configured to redirect the first and second suspension streams. flowing into the supply pipe through the first and second inlets 1424, 1425, by changing the steering angle in the range up to about 135 ° relative to the direction output stream.

[00240] As shown in FIG. 41-43, each of the profiled pipelines 1441, 1443 has a concave outer surface 1790, 1791, essentially complementary to its convex inner surface 1758 and located under it. Each concave outer surface 1790, 1791 forms a recess 1794, 1795, respectively.

[00241] As shown in FIG. 27, 35 and 36, the supporting insert 1801, 1802 is located within each recess 1794, 1795 of the suspension distributor 1420. Supporting inserts 1801, 1802 are located under the corresponding convex inner surfaces of profiled pipelines 1441, 1443. Supporting inserts 1801, 1802 can be made of any suitable material that facilitates maintaining the slurry distributor and maintaining the desired shape located above the insert of the convex inner surface. In the embodiment shown, the supporting inserts 1801, 1802 are substantially the same. According to other embodiments, various supporting inserts may be used, or according to other further embodiments, the inserts are not used.

[00242] As shown in FIG. 37-39, the rigid support insert 1801 has a supporting surface 1810 substantially corresponding to the shape of the convex inner surface of the shaped conduit. In some embodiments, the shaped conduit of the slurry distributor may be made of a sufficiently flexible material such that the convex inner surface is in the form of a supporting surface 1810 of the supporting insert 1801. In such cases, the concave outer surface of the shaped conduit may be omitted.

[00243] The support insert 1801 includes a feed end 1820 and a dispensing end 1822. The support insert 1801 extends along a central axis 1825 of the holder. The support insert 1801 is substantially axisymmetric about the axis 1825 of the holder. The support insert 1801 is asymmetric about the central axis 1830, perpendicular to the axis 1825 of the holder.

[00244] As shown in FIG. 34, the distribution pipe 1428 extends generally along the longitudinal axis 50 and includes an inlet 1452 and an outlet distribution 1430 in fluid communication with the inlet 1452. The inlet 1452 is in fluid communication with the first and second inlet feed openings 1424, 1425 pipeline 1422. The width of the distribution pipe 1428 increases from the inlet 1452 to the outlet distribution hole 1430. However, according to other embodiments, the width of the distribution pipe 1428 is nshaetsya or remains unchanged from the input part 1452 to the outlet 1430 distribution aperture.

[00245] The inlet 1452 comprises an inlet 1453 having an inlet width W _{5 of the} distributor measured along the transverse axis 60 and an inlet height H ₄ measured along the vertical axis 55, the inlet width W _{5 of the} distributor being less than the width W _{2 of the} outlet 1481 of the outlet distribution port 1430. According to other embodiments, the inlet width W _{5 of the} distributor is greater than or equal to the width W _{2 of the} outlet port 1481 of the outlet distribution port 1430. In some embodiments, the ratio of the width of the outlet 1481 to its height is about 4 or more.

[00246] According to some embodiments, the at least one pipeline from the supply pipe 1422 and the distribution pipe 1428 comprises a flow stabilizing region configured to reduce the average feed rate of the slurry flowing into the inlet supply openings 1424, 1425 and moving into the outlet distribution hole 1430 such so that the flow of slurry flows out of the outlet distribution port at an average discharge rate of at least twenty percent bigger than the average feeding speed.

[00247] In FIG. 44-53 progressively show the internal geometry 1407 of the half portion 1504 of the slurry distributor 1420 shown in FIG. 22. The slurry distributor 1420 shown in FIG. 22 is, in other respects, similar to the suspension dispenser 120 shown in FIG. 1 and the slurry dispenser 420 shown in FIG. twenty.

[00248] Any suitable method may be used to manufacture a suspension dispenser made in accordance with the principles of the present invention. For example, in embodiments where the slurry dispenser is made of a flexible material, such as polyvinyl chloride or urethane, a composite mold may be used. In some embodiments, the areas of the mold parts are about 150% or less of the area of the slurry molded through which the part of the mold can be removed during removal, in other embodiments, about 125% or less, in other embodiments, about 115 % or less, and in other embodiments, about 110% or less.

[00249] In FIG. 54 and 55 show an embodiment of a composite mold 550 suitable for use in the manufacture of the slurry distributor 120 shown in FIG. 1, from a flexible material such as polyvinyl chloride or urethane. The composite mold 550 shown in the drawing contains five segments 551, 552, 553, 554, 555. The segments 551, 552, 553, 554, 555 of the composite mold 550 may be made of any suitable material, such as, for example, aluminum.

[00250] In the embodiment shown in the drawing, the casting segment of the distributor pipe is configured to form an internal flow geometry of the distributor pipe 128. The first and second profiled segments 552, 553 of the pipe mold are configured to form internal flow geometry in the first and second profiled pipelines 141, 143. The first and second inlet segments of the mold 554, 555 form the internal flow geometry of the first inlet portion 136 and the first inlet feed openings 124 and a second inlet 137 and a second inlet feed opening 125, respectively. In other embodiments, the composite mold may comprise a different number of mold segments, and / or the mold segments may have various shapes and / or sizes.

[00251] As shown in FIG. 54, connecting bolts 571, 572, 573 can be inserted through two or more mold segments to engage and align segments 551, 552, 553, 554, 555 so that a substantially continuous outer surface 580 of the composite mold 550 is formed. In some embodiments, the distal portions 575 of the connecting bolts 571, 572, 573 have an external thread that is capable of threadedly engaging with one of the segments 551, 552, 553, 554, 555 to connect at least two segments 551, 552, 553, 554, 555. Outdoor the surface 580 of the composite mold 550 is configured to form the internal geometry of the slurry molded in the form of a slurry 120 so that the gaps in the joints are minimal. Connecting bolts 571, 572, 573 can be removed to remove the composite mold 550 during removal of the mold 550 from the inside of the molded in the form of a distributor 120 of the suspension.

[00252] The assembled composite mold 550 is immersed in a solution of a flexible material such as polyvinyl chloride or urethane, so that the mold 550 is completely immersed in the solution. Then the mold 550 can be removed from the material solution. A certain amount of solution may adhere to the outer surface 580 of the composite mold 550, resulting in the formation of a molded slurry distributor 120 after the solution has solidified. In some embodiments, the composite mold 550 may be used in any suitable submersible process to make a molded part.

[00253] In the manufacture of the mold 550 from a plurality of individual aluminum parts, for example, from five parts, as in the embodiment shown, which are designed to fit together to form the desired internal flow geometry, segments 551, 552, 553, 554 , 555 molds can be disengaged from each other and removed from the mortar after it begins to set, but so far it remains warm. At sufficiently high temperatures, the flexible material is flexible enough to remove aluminum casting mold segments 551, 552, 553, 554, 555 having an enlarged design area through small design regions of the molded slurry distributor 120 without breaking it. According to some embodiments, the largest area of the mold part is up to about 150% of the smallest cavity area of the slurry molded in the form of a slurry through which a particular part of the mold is removed in the transverse direction during the removal process, according to other embodiments, up to about 125%, according to others embodiments up to about 115%; and according to other embodiments up to about 110%.

[00254] In FIG. 56 shows an embodiment of a composite mold 650 suitable for use in the manufacture of the slurry distributor 320 shown in FIG. 6, from a flexible material such as polyvinyl chloride or urethane. The composite mold 650 shown in the drawing comprises five segments 651, 652, 653, 654, 655. The segments 651, 652, 653, 654, 655 of the composite mold 550 may be made of any suitable material, such as, for example, aluminum. In FIG. 56, segments 651, 652, 653, 654, 655 are shown in disengaged position.

[00255] Connecting bolts can be used to connect the segments 651, 652, 653, 654, 655 of the mold together in a releasable manner to assemble the mold 650 so that these segments form a substantially continuous outer surface of the composite mold 650. The outer surface of the composite the mold 650 forms the internal flow geometry in the slurry distributor 220 shown in FIG. 6. The mold 650 may be similar in design to the mold 550 shown in FIG. 54 and 55, in that each part of the mold 650 shown in FIG. 56, is designed so that its area is within the predetermined smallest area of the slurry molded in the form of a slurry distributor 220, through which it is necessary to move the indicated part of the mold when it is removed (for example, according to some embodiments, up to about 150% of the smallest area of the cast cavity in the form of a slurry distributor, through which a specific part of the mold is moved during the extraction process, according to other embodiments, up to about 125%, according to others options for sales up to about 115% and according to other options for sales up to about 110%).

[00256] In FIG. 57 and 58 show an embodiment of the mold 750 for use in the manufacture of one of the parts 221, 223 of the slurry distributor 220 shown in FIG. 4. As shown in FIG. 57, mounting hole-determining elements 752 may be used to form mounting holes in a portion of the split valve 220 shown in FIG. 4, to facilitate its connection with another part.

[00257] As shown in FIG. 57 and 58, the mold 750 comprises a surface 754 extending from the bottom surface 756 of the mold 750. The boundary wall 756 extends along a vertical axis and gives depth to said mold. The mold surface 754 is located within the boundary wall 756. The boundary wall 756 is configured to fill the volume of the cavity 758 bounded by the specified boundary wall with molten mold material so that the mold surface 754 is immersed therein. The surface 754 of the mold is configured to reverse display the internal geometry of the flow formed by a specific part of the cast split distributor.

[00258] In use, the cavity 758 of the mold 750 can be filled with molten material such that the surface of the mold is immersed and the cavity 758 is filled with molten material. Then, the molten material is cooled and removed from the mold 750. To form the counterpart of the distributor 220 shown in FIG. 4, another mold may be used.

[00259] As shown in FIG. 59, an embodiment of a gypsum slurry mixing and dispensing assembly 810 comprises a gypsum slurry mixer 912 in fluid communication with a slurry spreader 820 similar to the slurry spreader 320 shown in FIG. 6. The gypsum slurry mixer 812 is configured to mix water and calcined gypsum to form an aqueous calcined gypsum suspension. Water and calcined gypsum can be fed into the mixer 812 through one or more inlets, as is known in the art. With this slurry dispenser, any suitable mixer (e.g., paddle mixer) can be used.

[00260] The slurry dispenser 820 is in fluid communication with the gypsum slurry mixer 812. The slurry distributor 820 comprises a first inlet feed opening 824 configured to receive a first stream of aqueous calcined gypsum slurry from a gypsum slurry mixer 812 moving in a first feed direction 890, a second inlet feed opening 825 configured to receive a second stream of aqueous calcined gypsum slurry from a mixer 812 of a gypsum slurry moving in a second feed direction 891, and an outlet distribution hole 830 in fluid communication with Foods with first and second inlet feed holes 824, 825 and arranged such that the first and second flows of aqueous calcined gypsum slurry discharged from the distributor 820 through slurry outlet dispensing bore 830 substantially along the machine direction 50.

[00261] The slurry dispenser 820 comprises a supply pipe 822 in fluid communication with the distribution pipe 828. The supply pipe contains a first inlet feed hole 824 and a second inlet feed hole 825 located at a distance from the first inlet feed hole 824, which both form an angle θ a feed of approximately 60 ° with respect to machine direction 50. The feed pipe 822 includes a structure configured to receive the first and second slurry streams, flowing in the first and second feeding directions 890, 891, and redirecting the suspension flow by changing the angle α (as shown in Fig. 9) so that the first and second suspension flows are redirected to the distribution pipe 828 and move essentially in the direction 892 of the output flow, which essentially coincides with the machine direction 50. Each of the first and second inlet feed openings 824, 825 has a certain area, and the inlet portion 852 of the distribution pipe 828 is an opening yuschee certain area which is greater than the sum of the areas of the first and second inlet feed apertures 824, 825.

[00262] The distribution pipe 828 generally extends along a longitudinal axis or machine direction 50, which is substantially oriented perpendicular to the transverse axis 60. The distribution pipe 828 includes an inlet portion 852 and an outlet distribution hole 830. The inlet portion 852 is in fluid communication with the first and second inlet feed openings 824, 825 of feed pipe 822 so that the inlet portion 852 is configured to receive first and second streams of aqueous calcined gypsum slurry from them sion. The outlet distribution hole 830 is in fluid communication with the inlet portion 852. The outlet distribution hole 830 of the distribution pipe 828 extends a predetermined distance along the transverse axis 60 to facilitate the discharge of the combined first and second streams of aqueous calcined gypsum slurry in a direction perpendicular to the machine or along the transverse axis 60 The slurry spreader 820 may be otherwise similar in other respects to the slurry spreader 320 shown in FIG. 6.

[00263] The supply line 814 is located between the gypsum slurry mixer 812 and the slurry dispenser 820 and is in fluid communication with them. The supply line 814 comprises a main supply line 815, a first supply branch 817 in fluid communication with the first inlet supply opening 824 of the slurry distributor 820, and a second supply branch 818 in fluid communication with the second inlet supply port 825 of the slurry distributor 820. The main supply line 815 is in fluid communication with the first and second supply branches 817, 818. In other embodiments, the first and second supply branches 817, 818 can independently communicate in fluid with a gypsum slurry mixer 812.

[00264] The supply line 814 may be made of any suitable material and may take various forms. In some embodiments, the supply pipe 814 may comprise a flexible pipe.

[00265] The water foam supply line 821 may be in fluid communication with at least one of the gypsum slurry mixer 812 and the supply line 814. Water foam from the foam source may be added to the composite materials through the foam supply line 821 at any suitable location. downstream of mixer 812 and / or directly in mixer 812 to form a foamed gypsum slurry for feeding slurry into dispenser 220. In the embodiment shown in the drawing, the foam supply line 821 is located downstream of the gypsum slurry mixer 812. In the embodiment shown, the supply line 821 for water foam comprises a collector-type device for supplying foam to the injection circuit or unit in fluid communication with the supply line 814, as described, for example, in US Pat. No. 6,874,930.

[00266] In other embodiments, one or more foam supply lines may be used provided that they are in fluid communication with a mixer 812. In other embodiments, the supply line or foam can be in fluid communication with only one gypsum slurry mixer. Those skilled in the art will appreciate that the means for introducing water foam into the gypsum slurry in the mixing and dispensing gypsum slurry assembly 810, including the relative location of these funds in the assembly, can be different and / or optimized to provide a uniform dispersion of the water foam in the gypsum slurry to make the slab, which is suitable for its purpose.

[00267] Any suitable foaming agent may be used. Preferably, the water foam is made in a continuous manner, according to which the flow of the mixture of the foaming agent and water is directed to the foam generator, and the flow of the resulting water foam is released from the foam generator, directed to the calcined gypsum slurry and mixed with it. Some examples of suitable blowing agents are described, for example, in US Pat. Nos. 5,683,635 and 5,643,510.

[00268] After setting and drying the foamed gypsum slurry, the foam scattered in the slurry forms voids in it that reduce the overall density of the wall plate. The amount of foam and / or the amount of air in the foam can be different to control the density of the dry plate so that the resulting product of the wall plate is in the desired weight range.

[00269] At least one flow-changing element 823 may be in fluid communication with a supply line 814 and may be configured to control the first and second streams of aqueous calcined gypsum slurry from the gypsum slurry mixer 812. The flow-changing element or elements 823 can be used to control the performance of the first and second streams of an aqueous calcined gypsum slurry. As shown in FIG. In a 59 embodiment, the flow-changing element or elements 823 are connected to a main supply line 815. Examples of suitable flow-changing elements include volume limiters, pressure reducers, butterfly valves, containers, and the like, as described, for example, in US Pat. Nos. 6,494,609; 6,874,930; 7,007,914 and / or 7,296,919.

[00270] The main supply line 815 may be connected to the first and second supply branches 817, 818 via a suitable Y-shaped flow splitter 819. A spacer 819 is located between the main supply pipe 815 and the first supply pipe 817 and between the main supply pipe 815 and the second supply pipe 818. In some embodiments, the flow splitter 819 may be configured to facilitate separation of the first and second gypsum slurry streams in this way that said streams are essentially the same. In other embodiments, additional components may be added to facilitate regulation of the first and second suspension streams.

[00271] In use, the aqueous calcined gypsum slurry is discharged from the mixer 812. The aqueous calcined gypsum slurry discharged from the mixer 812 is separated in a flow separator 819 into a first aqueous calcined gypsum slurry stream and a second aqueous calcined gypsum slurry stream. The aqueous calcined gypsum slurry discharged from the mixer 812 can be separated so that the first and second streams of the aqueous calcined gypsum slurry are substantially balanced.

[00272] In FIG. 60 shows another embodiment of a gypsum slurry mixing and dispensing assembly 910. The gypsum slurry mixing and dispensing assembly 910 comprises a gypsum slurry mixer 912 in fluid communication with the slurry dispenser 920. The gypsum slurry mixer 912 is configured to mix water and calcined gypsum to form an aqueous calcined gypsum suspension. The design of the suspension dispenser 920 may be similar to the design of the suspension dispenser 320 shown in FIG. 6.

[00273] A supply line 914 is located between the gypsum slurry mixer 912 and the slurry dispenser 920 and is in fluid communication with them. The supply pipe 914 comprises a main supply pipe 915, a first supply branch 917 in fluid communication with the first inlet supply opening 924 of the suspension distributor 920, and a second supply branch 918 in fluid communication with the second inlet supply opening 924 of the suspension distributor 920.

[00274] The main supply line 915 is located between the gypsum slurry mixer 912 and the first and second supply branches 917, 918 and is in fluid communication with them. The water foam supply line 921 may be in fluid communication with at least one of the gypsum slurry mixer 912 and the supply line 914. In the embodiment shown, the water foam supply line 921 is connected to the main supply line 915 of the supply line 914.

[00275] A first feed branch 917 is located between the gypsum slurry mixer 912 and the first inlet feed opening 924 of the slurry distributor 920 and is in fluid communication with them. At least one first flow modifying element 923 is in fluid communication with the first supply branch 917 and is configured to control a first aqueous calcined gypsum slurry from the gypsum slurry mixer 912.

[00276] A second feed branch 918 is located between the gypsum slurry mixer 912 and the second inlet feed opening 925 of the slurry distributor 920 and is in fluid communication with them. At least one second flow modifying element 927 is in fluid communication with a second supply branch 918 and is configured to control a second aqueous calcined gypsum slurry stream from the gypsum slurry mixer 912.

[00277] The first and second flow modifying elements 923, 927 can be manipulated to control the performance of the first and second streams of an aqueous calcined gypsum slurry. The first and second flow-changing elements 923, 927 may be independently operable. According to some embodiments, the first and second flow-changing elements 923, 927 can be activated to supply the first and second suspension flows, the speed of which varies between relatively reduced and relatively increased average speeds in an opposing manner so that at a given moment the first suspension stream has an average a speed that is higher than the average speed of the second suspension stream, and at another point in time, the first suspension stream has an average speed that is lower than the average speed awns second stream suspension.

[00278] One skilled in the art will recognize that one or both of the coating material webs can be pretreated using a very thin layer of gypsum slurry having an increased density (compared to the gypsum slurry contained in the core) known in the art as a primer. which, if necessary, is applied over the canvas and / or at least one compacted stream of gypsum slurry along the edges of the canvas for the manufacture of hard edges. In addition, the mixer 912 comprises a first auxiliary conduit 929 that is configured to receive a stream of dense aqueous calcined gypsum slurry that is relatively denser than the first and second streams of aqueous calcined gypsum slurry fed into the slurry dispenser (i.e., " Solid Primer / Hard Edge "). The first auxiliary conduit 929 can hold a primed / solid edge stream on top of an advancing coating material web upstream of the primer roller 931, which is configured to apply a primer layer to the advancing web of coating material and forming hard edges in the peripheral region of the advancing web due to the width of the roller 931, which is less than the width of the advancing web, as is known in the prior art. Hard edges can be formed from the same dense suspension, which forms a thin dense layer, by directing a portion of the dense suspension around the ends of the roller used to apply the dense layer to the web.

[00279] The mixer 912 may also include a second auxiliary conduit 933 configured to receive a stream of dense aqueous calcined gypsum slurry that is relatively denser (ie, a “reverse primer stream”) compared to the first and second aqueous calcined streams gypsum slurry delivered to the slurry dispenser. The second auxiliary pipeline 933 can accommodate the reverse primer flow on the second advancing coating material web upstream (in the direction of the second web moving) of the primer roller 937, which is configured to apply a primer layer to the second advancing web of coating material, as known in the art (and also shown in FIG. 61).

[00280] According to other embodiments, individual auxiliary pipelines may be connected to a mixer to deliver at least one separate edge stream to an advancing web of coating material. Other suitable equipment (such as auxiliary mixers) can be used in auxiliary pipelines to facilitate the manufacture of a denser suspension therein, for example, by mechanical destruction of the foam in the suspension and / or chemical destruction of the foam through the use of a suitable defoaming agent.

[00281] According to other embodiments, each of the first and second supply branches may comprise a foam supply pipe, which is respectively configured to independently introduce water foam into the first and second streams of calcined gypsum slurry delivered to the slurry dispenser. In other embodiments, multiple mixers may be used to supply independent slurry streams to the first and second inlet feed openings of the slurry dispenser in accordance with the principles of the present invention. It should be noted that other implementations are also possible.

[00282] The gypsum slurry mixing and dispensing assembly 910 shown in FIG. 60 may be made to otherwise similarly mix and dispense the gypsum suspension assembly 810 shown in FIG. 59. It is further contemplated that other slurry dispensers made in accordance with the principles of the present invention may be used in accordance with other embodiments of the gypsum slurry mixing and dispensing assembly described herein.

[00283] In FIG. 61 shows an exemplary embodiment of a boot portion 1011 of a gypsum wallboard production line. The feed portion 1011 comprises a gypsum slurry mixing and dispensing assembly 1010, which comprises a gypsum slurry mixer 1012 in fluid communication with the slurry spreader 1020, similar in design and function to the slurry spreader 320 shown in FIG. 6, a hard edge / face primer roller 1031 located upstream of the slurry dispenser 1020 and supported above the molding table 1038 so that the first advancing coating material web 1039 is disposed between them, the reverse primer roller 1037 located above the supporting member 1041 is so that a second advancing coating material web 1043 is disposed between them, and a pressure treatment station 1045 configured to form a preform with a desired thickness. Primer rollers 1031, 1037, molding table 1038, support element 1041 and pressure treatment station 1045 may contain known equipment suitable for this purpose, as is known in the art. The boot portion 1011 may be equipped with other conventional equipment known in the art.

[00284] In another aspect of the present invention, a suspension dispenser made in accordance with the principles of the present invention can be used in various manufacturing processes. For example, in one embodiment, a suspension distribution system may be used in a method of preparing a gypsum product. The slurry dispenser may be used to distribute the aqueous calcined gypsum slurry to the first advancing web 1039.

[00285] Water and calcined gypsum can be mixed in a mixer 1012 to form first and second streams 1047, 1048 of an aqueous calcined gypsum slurry. In some embodiments, continuous addition of water and calcined gypsum to the mixer can be performed with a ratio of water to calcined gypsum in the range of from about 0.5 to about 1.3, and in other embodiments, about 0.75 or less.

[00286] The products of the gypsum board are typically formed face-down, so that the advancing sheet 1039 functions as the face of the board after it is mounted. A front primer / hard edge stream 1049 (a layer of a denser aqueous calcined gypsum slurry relative to at least one of the first and second aqueous gypsum gypsum slurry streams) can be applied to the first advancing canvas 1039 upstream of the hard edge / face primer roller 1031 relative to machine direction 1092 for applying a primer layer to the first web 1039 and forming hard edges of the slab.

[00287] The first stream 1047 and the second stream 1048 of an aqueous calcined gypsum slurry respectively pass through a first inlet feed port 1024 and a second inlet feed port 1025 of the slurry distributor 1020. The first and second streams 1047, 1048 of an aqueous calcined gypsum slurry are combined in a slurry distributor 1020. The first and second streams of aqueous calcined gypsum slurry 1047, 1048 pass along a flow path through a slurry distributor 1020 in the form of a laminar flow with minimal or substantially zero phase separation of the air-liquid suspension and essentially no swirls.

[00288] The first advancing web 1039 is advanced along the longitudinal axis 50. The first calcined gypsum slurry stream 1047 passes through the first inlet 1024, and the second calcined gypsum slurry stream 1048 passes through the second inlet 1025. The distribution conduit 1028 is thus positioned that it extends along the longitudinal axis 50, which substantially coincides with the machine direction 1092, along which the first web 1039 of coating material is advanced. Preferably, the center center line of the outlet distribution hole 1030 (taken along the transverse axis / perpendicular to the machine direction 60) substantially coincides with the center center line of the first advancing coating material 1039. The first and second streams of aqueous calcined gypsum slurry 1047, 1048 are combined in a slurry distributor 1020 such that the combined first and second streams of aqueous calcined gypsum slurry 1051 pass through an outlet distribution hole 1030 in a distribution direction 1093 as a whole along machine direction 1092.

[00289] According to some embodiments, the distribution conduit 1028 is positioned so that it substantially extends parallel to a plane defined by a longitudinal axis 50 and a transverse axis 60 of a first web 1039 advancing along the forming table. In other embodiments, the inlet of the distribution pipe may be vertically lower or higher than the outlet distribution hole 1030 with respect to the first web 1039.

[00290] The combined first and second calcined gypsum slurry streams 1051 are discharged from the slurry distributor 1020 onto the first advancing web 1039. The front primer / hard-edged stream 1049 can be discharged from the mixer 1012 at a point upstream of the direction of travel of the first advancing web 1039 in a machine direction 1092, in which the first and second streams 1047, 1048 of an aqueous calcined gypsum slurry are discharged from the slurry distributor 1020 onto a first advancing web 1039. Combine The first and second streams of 1047, 1048 aqueous calcined gypsum slurry can be discharged from the slurry distributor with a reduced pulse per unit width along the machine direction perpendicular to the conventional design of the dispenser to facilitate the prevention of the “wash-out” of the 1049 face primer / hard edge applied onto the first advancing web 1039 (i.e. in a situation in which part of the laid primer layer is displaced from its position on the advancing canvas 1039 in response to the effect of the suspension applied to it).

[00291] The first and second streams of aqueous calcined gypsum slurry 1047, 1048, respectively, flowing through the first and second inlet feed holes 1024, 1025 of the slurry distributor 1020, can be selectively controlled by at least one flow-changing element 1023. For example, according to some embodiments the first and second streams of 1047, 1048 aqueous calcined gypsum slurry are selectively controlled such that the average speed of the first stream of 1047 aqueous calcined gypsum slurry flows flowing through the first inlet 1024, and the average speed of the second stream 1048 of an aqueous calcined gypsum slurry flowing through the second inlet 1025 are the same.

[00292] In some embodiments, the first calcined gypsum slurry aqueous stream 1047 flows at an average first feed rate through the first inlet feed port 1024 of the slurry distributor 1020. A second stream 1048 of an aqueous calcined gypsum slurry flows at an average second feed rate through a second inlet feed port 1025 of the slurry distributor 1020. The second inlet feed hole 1025 is located at a distance from the first inlet feed hole 1024. The first and second streams of water calcined gypsum slurry 1051 are combined in a slurry distributor 1020. The combined first and second streams of aqueous calcined gypsum slurry 1051 are discharged at an average outlet speed from the outlet distribution hole 1030 of the slurry distributor 1020 onto a web 1039 of coating material advancing in the machine direction 1092. The average outlet speed is less than the average first feed rate and the average second speed filing.

[00293] In some embodiments, the average discharge rate is less than about 90% of the average first feed rate and the average second feed rate. In some embodiments, the average output rate is less than about 80% of the average first feed rate and the average second feed rate.

[00294] The combined first and second aqueous calcined gypsum slurry streams 1051 are discharged from the slurry distributor 1020 through the outlet distribution port 1020. The outlet distribution port 1020 has a width extending along the transverse axis 60 and a size at which the ratio of the width of the first advancing web 1039 of material coating to the width of the outlet distribution hole 1030 is in the range between inclusive approximately 1: 1 and approximately 6: 1. In some embodiments, the ratio of the average velocity of the combined first and second streams of aqueous calcined gypsum slurry 1051 discharged from the slurry distributor 1020 to the speed of a moving bed 1039 of coating material advancing in machine direction 1092 may be about 2: 1 or less according to some embodiments and from about 1: 1 to about 2: 1 according to other embodiments.

[00295] The combined first and second calcined gypsum slurry streams 1051 discharged from the slurry dispenser 1020 form a propagation pattern on the advancing web 1039. At least one of the size and shape of the outlet dispensing opening 1030 can be adjusted, which in turn can The distribution topography is changed.

[00296] Thus, the slurry is fed into both inlet feed openings 1024, 1025 of the supply pipe 1022 and then discharged through the adjustable distribution outlet 1030. The converging portion 1082 may provide a slight increase in the flow rate of the suspension to reduce undesired output effects and thus further improve flow stability on the free surface. Changes in adjacent flows and / or any local changes can be reduced by performing transverse profile (CD) control at the outlet 1030 using said profiling system. This distribution system can facilitate obstruction of the separation of air and liquid in the slurry, resulting in a more uniform and consistent material delivered to molding table 1038.

[00297] The reverse primer stream 1053 (a layer of a denser aqueous calcined gypsum slurry relative to at least one of the first and second streams of calcined gypsum slurry 1047, 1048) can be applied to the second advancing canvas 1043. The reverse primer stream 1053 can be released from the mixer 1012 at a location higher upstream of the direction of travel of the second advancing web 1043 of the reverse primer roller 1037.

[00298] According to other embodiments, the average speeds of the first and second streams 1047, 1048 of the aqueous calcined gypsum slurry are varied. In some embodiments, the suspension speeds in the inlet feed holes 1024, 1025 of the feed pipe 1022 may periodically fluctuate between relatively high and low average speeds (i.e., at one point in time, a higher speed is observed in one inlet than in the other inlet, and then vice versa at a predetermined point in time) to reduce the probability of deposits in the geometry itself.

[00299] According to some embodiments, the first calcined gypsum slurry stream 1047 flowing through the first inlet 1024 has a shear rate that is lower than the shear rate of the combined first and second streams 1051 discharged from the outlet distribution hole 1030, and a second stream 1048 an aqueous calcined gypsum slurry flowing through a second inlet feed 1025 has a shear rate that is lower than the shear rate of the combined first and second streams 1051, in discharged from the outlet distribution hole 1030. According to some embodiments, the shear rate of the combined first and second streams 1051 discharged from the outlet distribution hole 1030 may exceed by more than about 150% the shear rate of the first stream 1047 of an aqueous calcined gypsum slurry flowing through the first inlet 1024, and / or the second stream 1048 of an aqueous calcined gypsum slurry flowing through the second inlet 10 25, according to other embodiments, more than about 175%, and according to other embodiments, about two times or more. Of course, the viscosity of the aqueous calcined gypsum slurry of the first and second streams 1047, 1048 and the combined first and second streams 1051 can be inversely proportional to the shear rate present at this location, so that with an increase in the shear rate the viscosity decreases.

[00300] According to some embodiments, the first stream 1047 of an aqueous calcined gypsum slurry flowing through the first inlet 1024 has a shear stress that is lower than the shear stress of the combined first and second streams 1051 discharged from the outlet distribution hole 1030, and a second stream 1048 an aqueous calcined gypsum slurry flowing through a second inlet 1025 has a shear stress that is lower than the shear stress of the combined first second streams 1051 discharged from the outlet distribution hole 1030. In some embodiments, the shear stress of the combined first and second streams 1051 discharged from the outlet distribution hole 1030 may be greater than about 110% of the shear stress of the first stream 1047 of an aqueous calcined gypsum slurry flowing through a first inlet feed opening 1024, and / or a second stream 1048 of an aqueous calcined gypsum slurry flowing through a second inlet feed opening term in 1025.

[00301] In some embodiments, the first stream 1047 of an aqueous calcined gypsum slurry flowing through the first inlet 1024 has a Reynolds number that is higher than the Reynolds number of the combined first and second streams 1051 discharged from the outlet distribution hole 1030, and a second stream 1048 an aqueous calcined gypsum slurry flowing through a second inlet 1025 has a Reynolds number that is higher than the Reynolds number of the combined first and second streams 1051 discharged from the outlet distribution hole 1030. In some embodiments, the Reynolds number of the combined first and second streams 1051 discharged from the outlet distribution hole 1030 may be less than about 90% of the Reynolds number of the first stream 1047 of an aqueous calcined gypsum slurry flowing through the first an inlet feed 1024, and / or a second stream 1048 of an aqueous calcined gypsum slurry flowing through a second inlet feed 1025, according to other antam realization of less than about 80%, and according to other embodiments of less than about 70%.

[00302] In FIG. 62 and 63 show an embodiment of a Y-shaped flow divider 1100 according to the present invention suitable for use in a gypsum suspension mixing and dispensing assembly made in accordance with the principles of the present invention. The flow divider 1100 may be in fluid communication with the gypsum slurry mixer and slurry dispenser such that the flow divider 1100 receives a single stream of calcined gypsum slurry from the mixer and discharges two separate streams of calcined gypsum slurry towards the first and second inlet feed ports of the distributor suspensions. One or more flow-changing elements may be located between the mixer and the flow divider 1100 and / or between one or both of the supply branches extending between the divider 1100 and the associated slurry distributor.

[00303] The flow divider 1100 essentially has a circular inlet 1102 located in a main branch 1103 adapted to receive a single slurry stream, and a pair of substantially circular outlet openings 1104, 1106 located respectively in the first and second output branches 1105, 1107 which enable two slurry streams to be discharged from the divider 1100. The cross-sectional areas of the inlet openings 1102 and the outlet openings 1104, 1106 can be changed depending on the desired flow rate. According to embodiments in which the cross-sectional areas of the openings of the outlet openings 1104, 1106 are substantially equal to the cross-sectional areas of the opening of the inlet 1102, the flow rate of the slurry discharged from each outlet 1104, 1106 can be reduced to approximately 50% of the single flow rate slurry fed into the inlet 1102, and the volumetric flow rates through the inlet 1102 and both outlet openings 1104, 1106 are essentially the same.

[00304] According to some embodiments, the diameter of the outlet openings 1104, 1106 can be made smaller than the diameter of the inlet 1102 to maintain a relatively high flow rate throughout the divider 1100. According to embodiments, in which the cross-sectional area of the outlet openings 1104, 1106 is smaller than the cross-sectional area of the inlet 1102, the flow rate can be maintained in the outlet 1104, 1106, or at least reduced to a minimum than if the outlet 1104, 1106 and inlet 1102 had substantially equal cross-sectional areas. For example, in some embodiments, the flow divider 1100 has an inlet 1102 that has an inner diameter of ID _{1 of} approximately 3 inches (7.62 cm), and each outlet 1104, 1106 has an inner diameter of ID _{2 of} approximately 2.5 inches (6, 35 cm) (according to other embodiments, other diameters of the inlet and outlet may be used). According to an embodiment with these dimensions, at a conveyor speed of 350 ft / min (106.7 m / min), a decrease in the diameter of the outlet openings 1104, 1106 reduces the flow rate in each outlet to about 28% of the speed of a single suspension flow in the inlet 1102 .

[00305] The flow divider 1100 comprises a central profiled portion 1114 and a connecting portion 1120 between the first and second output branches 1105, 1107. The central profiled portion 1114 forms a restriction 1108 in the central inner region of the flow divider 1100 upstream of the connecting portion 1120, which facilitates displacement flow to the outer edges 1110, 1112 of the divider to reduce the buildup of deposits of the suspension in the connecting part 1120. The shape of the central profiled part 1114 leads to a displacement of the guide channels 1111, 1113 near e to the outer edges 1110, 1112 of the divider 1100. The narrowing 1108 in the central shaped portion 1114 has a reduced height H ₂ than the height H _{3 of the} guide channels 1111, 1113. The guide channels 1111, 1113 have a cross-sectional area that is larger than the cross-sectional area of the central constriction 1108. As a result, the flowing suspension encounters less hydraulic resistance in the guide channels 1111, 1113 than in the central restriction 1108, and the flow is directed to the outer edges of the connecting part 1120 of the divider.

[00306] The connecting part 1120 forms openings for the first and second output branches 1105, 1107. The connecting part 1120 consists of a flat wall surface 1123 that is substantially perpendicular to the direction 1125 of the input stream.

[00307] In FIG. 64 shows an automatic device 1150 according to some embodiments for compressing the divider 1100 at adjustable and regular time intervals to prevent the deposition of solid particles in the divider 1100. According to some embodiments, the compression device 1150 may comprise a pair of plates 1152, 1154 located on opposite sides 1142, 1143 the central profiled portion 1114. The plates 1152, 1154 are arranged to move relative to each other by means of a suitable actuating mechanism zma 1160. The actuator-drive mechanism 1160 can be controlled automatically or selectively to simultaneously move the plates 1152, 1154 relative to each other to apply compressive force to the divider 1100 in the region of the central profiled part 1114 and the connecting part 1120.

[00308] When compressed by the compressing device 1150 of the flow divider, the compressive action exerts a compressive force on the divider 1100, which results in its reciprocal bending inward. This compressive force can prevent the deposition of solid particles in the divider 1100, which can disrupt a substantially equally branched flow for the suspension to propagate through the outlet openings 1104, 1106. According to some embodiments, the compressive device 1150 is configured to automatically deliver a pulse using a programmable controller in a working environment. position connected to actuating mechanisms. The duration of the application of compressive force by the compressing device 1150 and / or the interval between pulses can be adjusted. In addition, the stroke length of the plates 1152, 1154 moving relative to each other in the compressive direction can also be adjusted.

[00309] A method for preparing an astringent product according to one embodiment can be implemented using a suspension dispenser made in accordance with the principles of the present invention. A stream of aqueous binder suspension is discharged from the mixer. The aqueous binder slurry flows at an average feed rate through the inlet feed opening of the slurry distributor along the axis of the first feed stream. The aqueous binder slurry is allowed to flow into the bulb-shaped portion of the slurry spreader. Said bulb-shaped portion has an expansion region in which the cross-sectional area of the stream is larger than the cross-sectional area of the stream in an adjacent region upstream of the expansion region with respect to the direction of flow of the suspension flowing from the inlet feed port. The bulbous portion is configured to reduce the average flow rate of the aqueous binder suspension moving from the inlet feed opening through the bulbous portion. The profiled pipe has a convex inner surface relative to the axis of the first feed stream, made in such a way that the aqueous binder slurry moves in a radial stream in a plane substantially perpendicular to the axis of the first feed stream. The aqueous binder slurry flows into the transition portion extending along the axis of the second feed stream, which is not parallel to the axis of the first feed stream.

[00310] An aqueous binder slurry flows into a distribution pipe. The distribution pipe comprises an outlet distribution opening extending a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis.

[00311] According to some embodiments, the flow of the slurry moving in the region of the convex inner surface and near at least one of the side walls towards the outlet distribution hole has a vortex with a swirl parameter (S _m ) of from about 0 to about 10 and according to to other embodiments, from about 0.5 to about 5. According to some embodiments, a stream of slurry moving in the region of a convex inner surface and near at least one of the side walls in the direction enii dispensing opening to the outlet has an angle (S _m) swirls about 0 ° to about 84 °.

[00312] In some embodiments, the aqueous binder slurry flows in a flow stabilizing region configured to reduce the average feed rate of the aqueous binder slurry entering the inlet feed opening and moving to the outlet distribution hole. An aqueous binder slurry flows out of the outlet distribution port with an average discharge speed that is at least 20% less than the average feed rate.

[00313] According to another embodiment, a method for preparing a binder product comprises discharging an aqueous binder suspension from a mixer. An aqueous binder suspension flows through the inlet of the distribution pipe of the suspension distributor. An aqueous binder suspension flows from the outlet distribution hole of the suspension distributor onto a web made of coating material advancing along the machine direction. The cleaning blade reciprocates along the cleaning path along the bottom surface of the distribution pipe between the first position and the second position to remove the aqueous binder slurry from it. The cleaning path passes next to the outlet distribution hole.

[00314] According to some embodiments, the distribution pipe generally extends along the longitudinal axis between the inlet and the outlet distribution hole. The cleaning blade reciprocates in the longitudinal direction along the cleaning path.

[00315] According to some embodiments, the cleaning blade moves in the cleaning direction from the first position to the second position during the cleaning cycle, and the cleaning blade moves in the opposite, return direction from the second position to the first position during the reverse cycle. The cleaning blade reciprocates in such a way that the cleaning cycle time is substantially equal to the time of the reverse cycle.

[00316] According to some embodiments, the cleaning blade moves in the cleaning direction from the first position to the second position during the cleaning cycle, and the cleaning blade moves in the opposite, return direction from the second position to the first position during the reverse cycle. The cleaning blade reciprocates between the first position and the second position in a cycle having a wiping period. The wiping period comprises a wiping time including a cleaning cycle execution time, a return time including a reverse cycle execution time, and a cumulative delay time including a predetermined period of time during which the cleaning blade remains in the first position. In some embodiments, the wiping time is substantially equal to the return time. In some embodiments, the cumulative delay time can be adjusted.

[00317] According to another embodiment, a method for preparing a binder product comprises discharging an aqueous binder suspension from a mixer. An aqueous binder suspension flows through the inlet of the distribution pipe of the suspension distributor. An aqueous binder suspension flows from the outlet of the outlet distribution hole of the suspension distributor onto a web made of coating material advancing along the machine direction. The outlet distribution hole extends a predetermined distance along the transverse axis, which is substantially perpendicular to the longitudinal axis. The outlet has a width measured along the transverse axis and a height measured along a vertical axis mutually perpendicular to the longitudinal axis and the transverse axis. A portion of the distribution pipe adjacent to the outlet distribution hole is subjected to compressive action to change the shape and / or size of the outlet. In some embodiments, the distribution conduit is subjected to a compressive action using a profiling mechanism such that an aqueous binder slurry flows out of the outlet with an increased propagation angle relative to the machine direction.

[00318] According to some embodiments, the distribution conduit is subjected to compressive action using a profiling mechanism comprising a profiling element in contact with the distribution conduit. The profiling element is arranged to move in the range of movement so that the profiling element is in the range of positions in which the profiling element is in a state of increased compressive interaction with the distribution pipe. In various embodiments, the method includes moving the profiling element along a vertical axis to adjust the size and / or shape of the outlet. According to various embodiments, the method includes moving the profiling element so that the profiling element moves along at least one axis and / or rotates around at least one axis to adjust the size and / or shape of the outlet.

[00319] The present application describes embodiments of a slurry distributor mixing and distributing a gypsum slurry assembly and methods for using them, which can provide many improved process features useful in the manufacture of a gypsum wallboard in commercial production. A slurry dispenser, made in accordance with the principles of the present invention, can facilitate the propagation of an aqueous calcined gypsum slurry onto an advancing web made of coating material as it moves past the mixer in the loading portion of the production line to the pressure processing station.

[00320] A gypsum slurry mixing and dispensing assembly, made in accordance with the principles of the present invention, can separate a stream of calcined gypsum slurry from a mixer into two separate streams of calcined gypsum slurry, which can be recombined downstream in a slurry dispenser made in in accordance with the principles of the present invention, to provide the necessary relief distribution. The design of the dual inlet configuration and the outlet dispensing opening can provide extended propagation of a more viscous suspension in the perpendicular machine direction over an advancing web made of coating material. The slurry spreader can be configured such that two separate streams of aqueous calcined gypsum slurry enter the slurry spreader along inlet feed directions containing a component perpendicular to the machine direction, redirected to the slurry spreader so that said two slurry streams flow substantially in the machine direction and recombine in the distributor in some way to improve transverse uniformity of the combined flows of water calcined gypsum slurry flowing out of the exhaust camshaft holes slurry distributor for reducing the mass flow change for a long time or along a transverse axis perpendicular to the machine direction. Representation of the first and second streams of aqueous calcined gypsum slurry in the first and second feed directions, which contain a component perpendicular to the machine direction, can facilitate the release of recombined streams of the suspension from the suspension distributor with reduced momentum and / or energy.

[00321] An internal flow cavity in the slurry distributor may be formed such that each of the two slurry streams passes through the slurry distributor in the form of a laminar flow. An internal flow cavity in the suspension distributor may be formed such that each of the two suspension flows passes through the suspension distributor with minimal or substantially zero phase separation of the air-liquid suspension. An internal flow cavity in the slurry dispenser may be formed such that each of the two slurry streams passes through the slurry dispenser substantially without swirls.

[00322] A gypsum slurry mixing and dispensing assembly made in accordance with the principles of the present invention can shape the flow geometry upstream of the outlet of the dispenser of the slurry distributor to reduce the speed of the slurry in one or more steps. For example, to reduce the speed of the slurry introduced into the slurry distributor, a flow divider may be inserted between the mixer and the slurry distributor. As another example, the flow geometry in the mixing and distribution unit of the gypsum suspension may contain expansion areas upstream and in the suspension distributor to slow down the suspension so that it becomes controllable when it is discharged from the outlet of the suspension distributor.

[00323] The geometry of the outlet distribution hole may also facilitate control of the speed and momentum of the suspension as it is discharged from the suspension distributor onto an advancing web of coating material. The flow geometry in the slurry dispenser can be adapted so that the slurry discharged from the outlet dispenser retains a substantially flat stream structure with a relatively reduced height compared to the outlet port expanded in the machine direction perpendicular to improve stability and uniformity.

[00324] The relatively wide outlet creates an impulse per unit width of the suspension discharged from the outlet dispenser, which is lower than the impulse per unit width of the suspension discharged from a conventional dispenser under similar operating conditions. A reduced pulse per unit of width may prevent the primer of the dense layer applied to the canvas from the coating material upstream of the place where the suspension is discharged from the suspension distributor onto the canvas.

[00325] In the case in which the outlet width of the known dispenser used is 6 inches (15.24 cm) and the thickness is 2 inches (5.08 cm), the average velocity in the outlet for a large volume product is 761 ft / min (232.105 m / min). According to embodiments in which a slurry spreader, made in accordance with the principles of the present invention, comprises an outlet dispensing opening having an opening of 24 inches (60.96 cm) wide and 0.75 inches (1.905 cm) thick, the average speed is 550 ft / min (167.75 m / min). The mass flow rate is the same for both devices and is 3,437 lb / min (1,560.398 kg / min). The suspension impulse (mass flow rate times the average velocity) for both cases would be approximately 2,618,000 lb-ft / min ² and 1,891,000 lb-ft / min ² (361284 kg⋅m / min ² and 260958 kg⋅m / min ² ) for a known dispenser and slurry dispenser according to the present invention, respectively. By dividing the corresponding calculated impulse by the width of the outlet of the known dispenser and the width of the outlet of the slurry dispenser according to the present invention, a pulse per unit width of slurry discharged from the known dispenser of 402736 (lb ft / min ² ) / (inch transverse) can be obtained width switchgear) (23706 (kg m / m ² / cm of transverse width of the slurry distributor)), and the pulse width per unit slurry discharged from the camshaft, suspension divider constructed in accordance with principles of the present invention is 78,776 (funt⋅fut / m ²⁾ / (inch width transverse slurry distributor) (4280.807 (kg m / m ² / cm of transverse width of the slurry distributor)). In this case, the impulse per unit width for the slurry discharged from the suspension distributor according to the present invention is approximately 20% of the impulse per unit width for the compared prior art dispenser.

[00326] A slurry spreader, made in accordance with the principles of the present invention, allows to achieve the desired distribution profile when using an aqueous calcined gypsum slurry in a wide range of water to gypsum ratios, including a relatively low water-gypsum ratio or a more traditional water-gypsum ratio, such as the ratio of water to calcined gypsum is from about 0.4 to about 1.2, for example, below 0.75 according to some embodiments, and between about 0.4 and approximately 0.8 according to other options for implementation. Embodiments of a slurry dispenser made in accordance with the principles of the present invention may comprise an internal flow geometry configured to generate controlled shear effects acting on the first and second streams of aqueous calcined gypsum slurry as the first and second streams pass from the first and second inlet feed openings in a slurry distributor to an outlet distribution port. The use of controlled shear in a slurry dispenser can help selectively reduce the viscosity of the slurry as a result of such shear. Under the influence of controlled shear in the distributor, a suspension having a low water-gypsum ratio can be distributed from the suspension distributor with a propagation relief in the perpendicular machine direction, comparable to suspensions having a traditional water-gypsum ratio.

[00327] The internal flow geometry in the slurry distributor can be adapted to further accommodate the slurry with various gypsum-water ratios to provide an increase in flow close to the boundary wall regions of the internal geometry of the slurry distributor. By using the geometry of the flow in the slurry distributor, configured to increase the degree of flow around the boundary wall layers, the tendency of the slurry to recycle in the slurry distributor and / or to stop the flow and deposition is reduced. Accordingly, as a result, the accumulation of the precipitate of the suspension in the suspension distributor can be reduced.

[00328] A slurry dispenser made in accordance with the principles of the present invention may comprise a profiling system mounted close to the outlet distribution hole to change the velocity component of the combined suspension flows discharged from their outlet distribution hole perpendicular to the machine to selectively control the propagation angle and width spreading the suspension in the perpendicular machine direction on a substrate advancing along the production Tween line to the station for pressure processing. A profiling system can facilitate the achievement of the desired propagation profile of a slurry discharged from the outlet distribution hole, which exhibits a reduced sensitivity to the viscosity and gypsum-water ratio of the solution. A profiling system can be used to change the dynamics of the flow of the slurry discharged from the outlet of the slurry dispenser to direct the flow of the slurry so that the slurry has a more uniform velocity in the perpendicular machine direction. The use of a profiling system can also facilitate the use of a mixing and distribution unit for gypsum slurry made in accordance with the principles of the present invention in the manufacture of gypsum wall plates of various types and volumes.

[00329] Thus, according to one embodiment, the slurry distributor comprises a distribution conduit generally extending along a longitudinal axis and comprising an inlet and an outlet distribution port in fluid communication with the inlet portion. The outlet distribution hole extends a predetermined distance along the transverse axis. The transverse axis is essentially perpendicular to the longitudinal axis. The outlet distribution hole comprises an outlet having a width measured along the transverse axis and a height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis. The profiling mechanism comprises a profiling element that is in contact with the distribution pipe. The profiling element is movable in a moving range so that the profiling element is in a range of positions in which the profiling element is in an increased compressive interaction with a part of the distribution pipe next to the outlet distribution hole to change the shape and / or size of the outlet.

[00330] According to another embodiment, the outlet of the outlet distribution hole has a width to height ratio of about 4 or more.

[00331] According to another embodiment, the outlet of the outlet distribution hole has a width measured along a transverse axis. The profiling element has a width extending a predetermined second distance along the transverse axis. The width of the outlet is larger than the width of the profiling element. The profiling element is positioned so that a pair of side portions of the outlet distribution hole is offset from the profiling element.

[00332] According to another embodiment, the profiling element of the suspension distributor is movable along a vertical axis.

[00333] According to another embodiment, the profiling element of the suspension distribution element has at least two degrees of freedom.

[00334] According to another embodiment, the profiling element of the suspension distributor is arranged to move along at least one axis and can rotate around at least one hinge axis.

[00335] According to another embodiment, the profiling element of the slurry distributor is movable along a vertical axis and can rotate around a hinge axis that is substantially parallel to the longitudinal axis. The profiling element can rotate around the hinge axis along the length of the arc so that the profiling element is in a range of positions in which the profiling element is in a variable compressive interaction with a part of the distribution pipe along the transverse axis so that the height of the outlet changes along the transverse axis.

[00336] According to another embodiment, the profiling element of the suspension distributor comprises a holder assembly having a fixed support element and a hinged support element. The articulated support element is configured to rotate around the articulated axis along the length of the arc relative to the stationary support element. The articulated support element supports the profiling element.

[00337] According to another embodiment, the profiling element of the suspension distributor is rotatable around the hinge axis along the length of the arc so that the profiling element is in the range of positions in which the profiling element is in a variable compressive interaction with a portion of the distribution pipe along the transverse axis in this way that the height of the outlet changes along the transverse axis.

[00338] According to another embodiment, the slurry profiling element comprises a holder assembly, an interacting segment, generally extending in the longitudinal direction and in the transverse direction, and controlling the movement of the rod, generally extending vertically from the interacting segment. The movement control rod of the profiling element is movably attached to the holder assembly in such a way that the profiling element can move in a range of vertical positions.

[00339] According to another embodiment, the holder assembly comprises a clamping device adapted to selectively engage with the displacement control rod to fix the profiling element in a selected range of vertical positions.

[00340] According to another embodiment, the holder assembly is rotatably supported for the profiling element so that the profiling element can rotate around the hinge axis in a range of positions along the length of the arc.

[00341] According to another embodiment, the holder assembly comprises a fixed support member and an articulated support member. The articulated support element is configured to rotate around the articulated axis along the length of the arc relative to the stationary support element. The articulated support element supports the profiling element.

[00342] According to another embodiment, the holder assembly comprises a rotating adjustment rod extending between the fixed support member and the hinged support member. The rotary adjusting rod is movably attached to the fixed support element in such a way that moving the rotary adjustment rod relative to the fixed element causes articulated movement of the articulated support element about the articulated axis relative to the stationary support element.

[00343] According to another embodiment, the holder assembly comprises a clamping device adapted to selectively engage with a rotating adjusting rod to fix the profiling element in a selected range of positions along the length of the arc.

[00344] According to another embodiment, the mixing and distributing binder suspension assembly comprises: a mixer configured to mix water and binder material to form an aqueous binder suspension, and a suspension distributor in fluid communication with the mixer. The slurry distributor comprises a distribution pipe generally extending along a longitudinal axis and comprising an inlet and an outlet distribution port in fluid communication with the inlet. The outlet distribution hole extends a predetermined distance along the transverse axis. The transverse axis is essentially perpendicular to the longitudinal axis. The outlet distribution hole comprises an outlet having a width measured along the transverse axis and a height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis. The slurry distributor also includes a profiling mechanism comprising a profiling element in contact with the distribution pipe and configured to move in a range of movement such that the profiling element is in a range of positions in which the profiling element is in an increased compressive interaction with a portion of the distribution pipe adjacent with an outlet distribution hole for changing the shape and / or size of the outlet.

[00345] According to another embodiment, the mixing and distributing cementitious slurry assembly further comprises a distributor support member that supports the distribution pipe. The profiling mechanism of the suspension distributor comprises a holder assembly comprising a fixed support member and a hinge support member. The fixed support element is connected to the support element of the distributor. The articulated support element is rotatable around the articulated axis along the length of the arc relative to the stationary support element and supports the profiling element.

[00346] According to another embodiment, the mixing and distributing binder suspension unit further comprises: a supply pipe located between the mixer and the slurry distributor and in fluid communication with them; a flow-changing element coupled to a supply pipe and configured to control the flow of an aqueous binder slurry flowing from the mixer; and a feed line for water foam in fluid communication with at least one of the mixer and the feed line.

[00347] According to another embodiment, the binder mixing and dispensing assembly comprises a slurry distributor comprising a supply pipe having a first inlet with a first inlet feed opening and a second inlet with a second inlet feed hole located at a distance from the first inlet feed hole. The inlet of the distribution pipe is in fluid communication with the first and second inlet feed openings of the supply pipe. The first inlet feed port is configured to receive a first stream of aqueous binder slurry from the mixer. The second inlet feed opening is configured to receive a second stream of aqueous binder suspension from the mixer, and the outlet distribution port is in fluid communication with the first and second inlet feed holes and is configured such that the combined first and second streams of the aqueous binder suspension are discharged from the suspension distributor through outlet distribution hole.

[00348] According to another embodiment, the gypsum slurry mixing and distributing unit further comprises a supply line located between the mixer and the slurry distributor and fluidly communicating with them, the supply line comprising a main supply line and a first and second supply branch, as well as a divider flow connecting the main supply main pipe with the first and second supply branches, while the flow divider is located between the main a supply main pipe and a first supply branch and between a main supply main pipe and a second supply branch. The first supply branch is in fluid communication with the first inlet supply opening of the suspension distributor, and the second supply branch is in fluid communication with the second inlet supply opening of the suspension distributor.

[00349] According to another embodiment, the method for preparing the binder product comprises the steps of: (a) discharging the aqueous binder suspension from the mixer, (b) allowing the aqueous binder suspension to flow through the inlet of the distribution pipe of the suspension dispenser, (c) discharging the aqueous binder suspension from the outlet of the outlet of the distribution hole of the slurry distributor onto a web of coating material advancing along the machine direction, and the outlet of the distribution the hole extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis, wherein the outlet has a width measured along the transverse axis and a height measured along a vertical axis that is mutually perpendicular to the longitudinal axis and the transverse axis, and (d) compressive action part of the distribution pipe next to the outlet distribution hole to change the shape and / or size of the outlet.

[00350] According to another embodiment, the method for preparing the binder product comprises the step of compressing the distribution pipe by means of a profiling mechanism so that the flow of the aqueous binder suspension is discharged from the outlet with an increased propagation angle with respect to the machine direction.

[00351] According to another embodiment, a method for preparing a cementitious product comprises the step of compressing the distribution pipe by means of a profiling mechanism comprising a profiling element in contact with the distribution pipe. The profiling element is movable in the range of movement so that the profiling element is in the range of positions in which the profiling element is in an increased compressive interaction with the distribution pipe.

[00352] According to another embodiment, the method of preparing the binder product further comprises moving the profiling element along a vertical axis to adjust the size and / or shape of the outlet.

[00353] According to another embodiment, the method of preparing the binder product further comprises moving the profiling element such that the profiling element moves along at least one axis and / or rotates at least one axis to adjust the size and / or shape of the outlet.

EXAMPLES

[00354] In FIG. 65 shows Examples 1-3 in which the geometry and rheological properties of a slurry distributor constructed in accordance with the principles of the present invention were evaluated. In FIG. 65 is a plan view of half of the suspension dispenser portion 1205. Half of slurry distributor half 1205 comprises half 1207 of supply pipe 320 and half 1209 of distribution pipe 328. Half 1207 of supply pipe 322 includes a second inlet supply 325, defining a second hole 335, a second inlet part 337, and a half part 1211 of the split connecting segment 339 The half portion 1209 of the distribution pipe 328 comprises a half portion 1214 of the inlet portion 352 of the distribution pipe 328 and a half portion 1217 of the exhaust pipe distribution holes 330.

[00355] Of course, the other half of the slurry dispenser, which is a mirror image of the half of 1205 shown in FIG. 65 can be integrated and aligned with the half portion 1205 shown in FIG. 65, relative to the transverse central median line 387 of the outlet distribution port 330 to form a slurry dispenser that is substantially similar to the slurry dispenser 420 shown in FIG. 15. Accordingly, the geometry and rheological properties described below are also equally applicable to the mirrored half of the slurry dispenser.

[00356] In FIG. 72 shows another embodiment of a suspension dispenser 2020 made in accordance with the principles of the present invention, the geometry and rheological characteristics of which are evaluated in Examples 4-6. The slurry dispenser 2020 shown in FIG. 72 are essentially the same as the suspension dispenser 1420 shown in FIG. 34. The rheological characteristics of the distributor 2020 shown in FIG. 72, in which a profiling mechanism made in accordance with the principles of the present invention is used, is evaluated in Example 7. The profiling mechanism evaluated in Example 7 is essentially the same as the profiling mechanism 1432 shown in FIG. 22.

EXAMPLE 1

[00357] In this Example and in the related FIG. 65, the particular geometry of the half portion 1205 of the slurry distributor was evaluated at sixteen different locations L _1-16 between the first location L ₁ in the second intake port 325 and the sixteenth location L ₁₆ in the half portion 1207 of the outlet distribution port 330. Each location L _1-16 represents a transverse a section of half of the suspension distributor part 1205, as indicated by the corresponding line. To determine the distance between adjacent places L _1-16 , a flow line 1212 was used that runs along the geometric center of each cross section. The eleventh place L ₁₁ corresponds to the half part 1214 of the inlet portion 352 of the distribution pipe 328, which corresponds to the hole 342 of the second outlet supply hole 345 of the half part 1207 of the supply pipe 320. Accordingly, from the first to tenth places L _1-10 were defined in the half part 1207 of the supply pipe 320, and from the eleventh to sixteenth places were assigned in half of the 1209 distribution pipe 328.

[00358] For each location L _1-16 , the following geometric values were determined: the distance along the current line 1212 between the second inlet feed port 325 and the specific location L _1-16 ; the area of the hole in place L _1-16 ; seat perimeter L _1-16 and hydraulic seat diameter L _1-16 . The hydraulic diameter was calculated using the following formula:

D _hyd = 4 × A / P (Equation 1),

Where:

D _hyd - hydraulic diameter,

A is the area of a particular place L _1-16 and

P - the perimeter of a particular place L _1-16 .

To describe the internal geometry of the flow, dimensionless values can be determined for each location L _1-16 using the input conditions as shown in Table 1. To describe the dimensionless geometry of the half portion 1205 of the slurry dispenser shown in FIG. 66, equations of selected curves were used that show the dimensionless distance from the inlet depending on the dimensionless area and hydraulic diameter.

[00359] Analysis of dimensionless values for each location L _1-16 shows that the cross-sectional area of the flow increases from the first location L ₁ in the second inlet feed port 325 to the eleventh place L ₁₁ in the half portion 1214 of the inlet portion 352 (also in the hole 342 of the second outlet feed port 345). In this embodiment, the cross-sectional area of the flow in half half 1214 of the inlet 352 is approximately 1/3 larger than the cross-sectional area of the flow in the second inlet 325. Between the first location L ₁ and the eleventh location L _11, the cross-sectional area of the flow of the second inlet 337 and the second profiled pipeline 339 changes in the direction from place to place L _1-11 . In this area, at least two adjacent places L ₆ , L _{7 are} designed so that the place L ₇ located further from the second inlet feed 325 has a flow cross section that is smaller than the adjacent place L ₆ located closer to the second inlet feed port 325.

[00360] Between the first location L ₁ and the eleventh location L ₁₁ in the half portion 1207 of the supply pipe 322 there is an expansion area (eg, L _4-6 ) having a flow cross-sectional area that is larger than the flow cross-sectional area in the adjacent area (for example, L ₃₎ upstream of the expansion region in the direction of flow from the second inlet 335 to the outlet half part 1217 the dispensing bore 330. The second inlet part 337 and a second shaped conduit 341 having a cross section that varies along the direction otok 1212 to facilitate the distribution of the second slurry stream flowing therethrough.

[00361] The cross-sectional area decreases, starting from the eleventh place L ₁₁ located in the half portion 1214 of the inlet portion 352 of the distribution pipe 328, and to the sixteenth place L ₁₆ located in the half portion 1217 of the outlet distribution hole 330 of the distribution pipe 328. In the example according to In this embodiment, the cross-sectional area of the half section 1214 of the inlet 352 is approximately 95% of the cross-sectional area of the half section 1217 of the exhaust distribution port 330.

[00362] The flow cross-sectional area at the first location L ₁ located in the second inlet feed port 325 is smaller than the flow cross-sectional area at the sixteenth position L ₁₆ located at half of the 1217 outlet of the distribution port 330 of the distribution pipe 328. In the example according to this embodiment the implementation of the cross-sectional area of the flow in half of the 1217 exhaust distribution hole 330 of the distribution pipe 328 is approximately 1/4 larger than the cross-sectional area of the flow in the second inlet feed port 325.

[00363] The hydraulic diameter decreases from the first place L ₁ located in the second inlet 325, and the eleventh place L ₁₁ located in half of the inlet portion 1214 of the distribution pipe 352 328. In the example according to this embodiment, the hydraulic diameter in the half portion 1214 of the inlet portion 352 of the distribution pipe 328 is about 1/2 of the hydraulic diameter in the second inlet feed port 325.

[00364] The hydraulic diameter decreases from the eleventh location L ₁₁ located in the half portion 1214 of the inlet portion 352 of the distribution pipe 328 to the sixteenth location L ₁₆ located in the half portion 1217 of the outlet distribution hole 330 of the distribution pipe 328. In the example according to this In an embodiment, the hydraulic diameter of the half portion 1217 of the exhaust distribution port 330 of the distribution pipe 328 is approximately 95% of the hydraulic diameter of the half part 1214 of the inlet part 352 of the distribution pipe 328.

[00365] The hydraulic diameter in the first place L ₁ located in the second inlet 325 is larger than the hydraulic diameter in the sixteenth place L ₁₆ located in the half part 1217 of the outlet distribution hole 330 of the distribution pipe 328. In the example according to this embodiment, the hydraulic diameter in the half portion 1217 of the exhaust distribution port 330 of the distribution pipe 328 is less than about half the hydraulic diameter of the second inlet feed port 325.

TABLE I - GEOMETRY A place Dimensionless values Inlet distance Area Perimeter Hydraulic diameter L1 0.00 1.00 1.00 1.00 L2 0,07 1.00 1.00 1.00 L3 0.14 0.91 0.98 0.93 L4 0.20 1.01 1,07 0.94 L5 0.27 1.18 1.24 0.95 L6 0.34 1.25 1.45 0.87 L7 0.41 1.16 1.68 0.69 L8 0.47 1.13 1.93 0.59 L9 0.54 1.23 2.20 0.56 L10 0.61 1.35 2.47 0.55 L11 0.68 1.33 2.73 0.49 L12 0.75 1.28 2.70 0.47 L13 0.81 1.27 2.68 0.48 L14 0.88 1.26 2.67 0.47 L15 0.95 1.26 2.67 0.47 L16 1.00 1.26 2.67 0.47

EXAMPLE 2

[00366] In this Example, the half portion 1205 of the slurry dispenser shown in FIG. 65 was used to simulate the flow of gypsum slurry flowing through it under various flow conditions. For all flow conditions, the density (ρ) of the aqueous gypsum slurry was set to 1000 kg / m ³ . An aqueous gypsum slurry is a shear thinning material, so that when shear is applied to it, its viscosity decreases. The viscosity (μ) in Pa⋅s of gypsum slurry was calculated using a fluid model obeying a power law, which can be described by the following equation:

^n-1 (Уравнение 2),μ = K⋅

^n-1 (Equation 2),

Where:

K is a constant

- скорость сдвига, и

is the shear rate, and

n is a constant, in this case equal to 0.133.

); вязкость, вычисленная с использованием модели степенного закона (Уравнение 2); сдвиговое напряжение и число Рейнольдса (Re).[00367] In the first flow state, the gypsum slurry has a viscosity coefficient K = 50 in the power law model and flows into the second inlet feed port 325 at a speed of 2.5 m / s. To determine the rheological characteristics of the distributor, a computational method of hydrodynamics using the finite volume method was used. At each location L _1-16 , the following rheological characteristics were determined: area-weighted average speed (U); area-weighted average shear rate (

); viscosity calculated using a power law model (Equation 2); shear stress and Reynolds number (Re).

[00368] Shear stress was calculated using the following equation:

(Уравнение 3),Shear stress = μ ×

(Equation 3)

Where:

μ is the viscosity calculated using the power law model (Equation 2), and

- скорость сдвига.

- shear rate.

[00369] 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 - calculated using the power law model (Equation 2).

[00370] In the second flow condition, the gypsum slurry feed rate to the second inlet feed port 325 was increased to 3.55 m / s. All other conditions remained the same as in the first state of the flow in this Example. Dimensional values were modeled for the indicated rheological characteristics at each location L _1-16 for the first flow condition at which the inlet velocity is 2.5 m / s and for the second flow state at which the inlet velocity is 3.55 m / from. The dimensionless rheological values for each L _1-16 site were determined using input conditions, as shown in Table II.

[00371] For both flow conditions at which K was set to 50, the average speed decreased from the first place L ₁ in the second inlet port 325 to the sixteenth place L ₁₆ in the half part 1217 of the outlet distribution hole 330 of the distribution pipe 328. In shown in In an embodiment, the average speed decreased to about 1/5, as shown in FIG. 67.

[00372] For both flow conditions, the shear rate increased from the first location L ₁ in the second inlet 325 and the sixteenth place L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment shown, the shear rate was approximately doubled in the area from the first place L ₁ in the second inlet feed port 325 to the sixteenth place L ₁₆ in the half part 1217 of the outlet distribution hole 330 of the distribution pipe 328, as shown in FIG. 68.

[00373] For both flow conditions, the design viscosity decreased from the first location L ₁ in the second inlet 325 and to the sixteenth place L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment shown, the design viscosity decreased from the first place L ₁ in the second inlet supply bore 325 to the sixteenth location L ₁₆ at half the exhaust camshaft 1217 apertures 330 of the distribution manifold 328 by about half as dormancy Zano FIG. 69.

[00374] For both flow conditions, as shown in FIG. 70, the shear stress increased from the first location L ₁ in the second inlet 325 and the sixteenth place L ₁₆ in the half portion 1217 of the outlet distribution pipe 330 of the distribution pipe 328. In the embodiment shown, the shear stress increased by about 10% from the first place L ₁ in the second inlet feed port 325 to a sixteenth place L ₁₆ in the half portion 1217 of the exhaust distribution port 330 of the distribution pipe 328.

[00375] For both flow conditions, the Reynolds number, as shown in FIG. 71 decreased from a first location L ₁ in the second inlet 325 and a sixteenth place L ₁₆ in the half 1217 of the exhaust distribution port 330 of the distribution pipe 328. In the embodiment shown, the Reynolds number decreased from the first place L ₁ in the second inlet feed 325 to the sixteenth place of L ₁₆ in half 1217 of the exhaust distribution hole 330 of the distribution pipe 328 by about 1/3. For both flow conditions, the Reynolds number in sixteenth place L ₁₆ in half 1217 of the exhaust distribution port 330 of the distribution pipe 328 is in the laminar region.

TABLE II - DIMENSIONAL RHEOLOGICAL PROPERTIES (K = 50) A place Inlet speed = 2.50 m / s Inlet speed = 3.55 m / s Speed Shear rate Design viscosity Shear stress Reynolds number Speed Shear rate Design viscosity Shear stress Reynolds number L1 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 L2 1.00 1.18 0.87 1,02 1.15 1.00 1.20 0.85 1,03 1.17 L3 1.10 1.36 0.77 1,04 1.33 1.10 1.40 0.75 1.05 1.36 L4 1.00 1.30 0.80 1,04 1.18 0.99 1.32 0.79 1,04 1.19 L5 0.86 1.19 0.86 1,02 0.96 0.86 1.22 0.84 1,03 0.98 L6 0.83 1.23 0.83 1,03 0.86 0.83 1.28 0.81 1,03 0.89 L7 0.90 1.65 0.65 1,07 0.96 0.90 1.73 0.62 1,08 0.99 L8 0.90 1.73 0.62 1,08 0.85 0.90 1.80 0.60 1,08 0.88 L9 0.82 1,67 0.64 1,07 0.72 0.82 1.74 0.62 1,08 0.74 L10 0.77 1,63 0.65 1,07 0.64 0.77 1.73 0.62 1,08 0.68 L11 0.76 1.83 0.59 1,08 0.62 0.76 1.93 0.57 1.09 0.65 L12 0.78 1.84 0.59 1,08 0.63 0.78 1.92 0.57 1.09 0.65 L13 0.78 1.88 0.58 1.09 0.64 0.78 1.93 0.57 1.09 0.65 L14 0.78 1.88 0.58 1.09 0.64 0.78 1.95 0.56 1.09 0.66 L15 0.78 1.85 0.59 1.09 0.63 0.78 1.92 0.57 1.09 0.65 L16 0.79 1.89 0.58 1.09 0.65 0.79 1.98 0.55 1.09 0.67

EXAMPLE 3

[00376] In this Example, half of the slurry dispenser portion 1205 shown in FIG. 65, to simulate the flow of gypsum slurry flowing through it, at flow conditions similar to the flow conditions indicated in Example 2, except that the coefficient K in the power law model (Equation 2) was set to 100. In other respects, the state the flow were similar to the flow conditions in Example 2.

); вязкость, вычисленная с использованием модели степенного закона (Уравнение 2); сдвиговое напряжение (Уравнение 3) и число Рейнольдса (Re) (Уравнение 4). Безразмерные значения реологических характеристик для каждого места L_1-16 были определены с использованием входных условий, как показано в Таблице III.[00377] In addition, rheological characteristics were also evaluated for the gypsum slurry feed rates into the second inlet 325 at 2.50 m / s and 3.55 m / s. At each location L _1-16 , the following rheological characteristics were determined: area-weighted average speed (U); area-weighted average shear rate (

); viscosity calculated using a power law model (Equation 2); shear stress (Equation 3) and Reynolds number (Re) (Equation 4). The dimensionless rheological values for each L _1-16 site were determined using input conditions, as shown in Table III.

[00378] For both flow conditions, for which the coefficient K was set to 100, the average speed decreased from the first position L ₁ in the second inlet port 325 to the sixteenth place L ₁₆ in the half part 1217 of the outlet distribution hole 330 of the distribution pipe 328. In the shown in the drawing, the implementation of the average speed was reduced by about 1/5. The results for the average speed on a dimensionless basis were essentially the same as in Example 2 and in FIG. 67.

[00379] For both flow conditions, the shear rate increased from the first location L ₁ in the second inlet 325 and the sixteenth place L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment shown, the shear rate was approximately doubled from the first places L ₁ in the second inlet supply bore 325 to place the sixteenth L ₁₆ at half the exhaust camshaft 1217 apertures 330 of the distribution manifold 328. The results for scab shift on the basis of the dimensionless were substantially the same as that in Example 2 and FIG. 68.

[00380] For both flow conditions, the design viscosity decreased from a first location L ₁ in a second inlet 325 and a sixteenth place L ₁₆ in a half portion 1217 of a distribution outlet 330 of a distribution pipe 328. In the embodiment shown, the design viscosity decreased from a first place L ₁ in the second inlet feed port 325 to the sixteenth place L ₁₆ in the half portion 1217 of the outlet distribution port 330 of the distribution pipe 328 is approximately halfway. The results for the calculated viscosity on a dimensionless basis were essentially the same as in Example 2 and in FIG. 69.

[00381] For both flow conditions, the shear stress increased from the first location L ₁ in the second inlet 325 and the sixteenth place L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment shown, the shear stress increased by about 10 % from the first place L ₁ in the second inlet feed port 325 to the sixteenth place L ₁₆ in the half part 1217 of the outlet distribution hole 330 of the distribution pipe 328. Cut the alloys for shear stress on a dimensionless basis were essentially the same as in Example 2 and in FIG. 70.

[00382] For both flow conditions, the Reynolds number decreased from the first place L ₁ in the second inlet 325 and the sixteenth place L ₁₆ in the half portion 1217 of the distribution outlet 330 of the distribution pipe 328. In the embodiment shown, the Reynolds number decreased from the first place L ₁ in the second inlet feed port 325 to the sixteenth place L ₁₆ in the half portion 1217 of the outlet distribution port 330 of the distribution pipe 328 by about 1/3. For both flow conditions, the Reynolds number in sixteenth place L ₁₆ in half 1217 of the outlet distribution port 330 of the distribution pipe 328 is in the laminar region. The results for the Reynolds number on a dimensionless basis were essentially the same as in Example 2 and in FIG. 71.

[00383] In FIG. 67-71 are graphs of rheological characteristics calculated for different flow conditions in Examples 2 and 3. To describe the changes in the rheological characteristics depending on the distance between the inlet feed hole and half of the outlet distribution hole, the equations of selected curves were used. Accordingly, Examples 2 and 3 show that the rheological characteristics are constant and independent of changes in inlet velocity and / or viscosity.

TABLE III - DIMENSIONAL RHEOLOGICAL CHARACTERISTICS (K = 100) A place Inlet speed = 2.50 m / s Inlet speed = 3.55 m / s Speed Shear rate Design viscosity Shear stress Reynolds number Speed Shear rate Design viscosity Shear stress Reynolds number L1 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 L2 1.00 1.16 0.88 1,02 1.13 1.00 1.21 0.85 1,03 1.18 L3 1.10 1.35 0.77 1,04 1.32 1.10 1.39 0.75 1,04 1.35 L4 1.00 1.28 0.80 1,03 1.17 1.00 1.35 0.77 1,04 1.22 L5 0.87 1.15 0.88 1,02 0.94 0.86 1.23 0.84 1,03 0.99 L6 0.83 1.18 0.87 1,02 0.83 0.83 1.27 0.81 1,03 0.88 L7 0.90 1,60 0.66 1.06 0.93 0.90 1.70 0.63 1,07 0.98 L8 0.90 1.70 0.63 1,07 0.84 0.90 1.77 0.61 1,08 0.87 L9 0.82 1,61 0.66 1,07 0.69 0.82 1.71 0.63 1,07 0.73 L10 0.77 1,57 0.68 1.06 0.62 0.77 1,67 0.64 1,07 0.66 L11 0.76 1.76 0.61 1,08 0.60 0.76 1.88 0.58 1.09 0.64 L12 0.78 1.79 0.60 1,08 0.61 0.78 1.90 0.57 1.09 0.64 L13 0.78 1.81 0.60 1,08 0.62 0.78 1.93 0.57 1.09 0.65 L14 0.78 1.84 0.59 1,08 0.63 0.78 1.94 0.56 1.09 0.66 L15 0.78 1.80 0.60 1,08 0.62 0.78 1.90 0.57 1.09 0.64 L16 0.79 1.87 0.58 1.09 0.64 0.79 1.96 0.56 1.09 0.67

EXAMPLE 4

[00384] In this Example, the slurry distributor 2020 shown in FIG. 72. As shown in FIG. 72, each of the first and second inlet parts 2036, 2037 of the suspension distributor 2020 has a diameter D. The suspension distributor 2020 has a length measured along the longitudinal axis of about 12 × D. The slurry distributor 2020 is axisymmetric about a central longitudinal axis 50, generally extending in machine direction 2192. The slurry distributor 2020 can be divided into two half parts 2004, 2005, which are essentially axisymmetric about a central longitudinal axis.

[00385] As shown in FIG. 73, half 2004 of the slurry dispenser shown in FIG. 72, was used to simulate the flow of gypsum slurry flowing through it, with flow parameters similar to those that were present in Example 2, except for the use of various dimensionless velocity expressions. The input diameter D (x * = x / D) was chosen as the length scale for the dimensionless position vector x (x * = x / D), and the average input velocity (U) was used as the velocity scale for the dimensionless vector u (u * = u / U) of speed. In other respects, the flow parameters were similar to the flow parameters in Example 2.

[00386] As shown in FIG. 73-76, to determine the rheological characteristics in the half of the distributor, the method of hydrodynamic modeling (CFD) with the finite volume method was used. In particular, the average velocities were calculated in different vertical places of region A. An area was analyzed that covered a distance of about 0.75D from the center of the inlet in region A. To calculate twelve different average velocities of the suspension flowing radially around the bulb-shaped part, twelve were analyzed radially spaced vertical sections. These twelve places were essentially radially spaced so that each adjacent radial place was approximately 30 ° away from the adjacent one. As shown in FIG. 75 and 76, radial location 1 corresponds to a direction opposite to machine direction 2192, and radial location 7 corresponds to direction coinciding with machine direction 2192. Radial locations 4 and 10 correspond to directions substantially coinciding with transverse axis 60.

[00387] The hydrodynamic simulation method was used with two different input velocity conditions, u ₁ = U and u ₂ = 1.5U. The results of the analysis by the method of hydrodynamic modeling are shown in Table IV. The velocity value is expressed in the form of a dimensionless absolute value (| u | * = | u | / U). This data is also graphically represented in FIG. 77. Of course, the other half of the 2005 slurry distributor 2020 should have similar rheological characteristics.

[00388] For both flow conditions, the average velocity in each radial location 1-12 was less than the input velocity, but greater than 0. The average velocity was in the range from about 1/2 to about 7/8 of the input velocity (u * ~ from 0.48 to 0.83 input speed). The profiled convex surface of the cavity in the bulb-shaped part facilitated the redirection of the flow of the suspension flowing from the inlet part radially outward in all directions.

[00389] The suspension speed also decreased relative to the input speed. The average speed in all twelve radial locations for a given flow condition was essentially the same (~ 0.65 or 65% of the input speed).

[00390] In addition, in each flow state, the highest average velocities were observed at radial locations 3-5 and 9-11. A higher average speed along the transverse axis or along the perpendicular to the machine direction 60 contributes to an increase in the marginal flow at the side walls.

[00391] Accordingly, this Example shows that the bulb-shaped portion 2120 helps to slow down the flow of the suspension and change the direction of flow of the suspension from the downward vertical direction to the radial direction outward in the horizontal plane. In addition, the bulb-shaped portion 2120 allows you to deflect the flow of the suspension to the outer and inner side walls of the profiled pipe of the half portion 2004 of the suspension distributor 2020 to facilitate the movement of the suspension in the perpendicular machine direction 60.

TABLE IV - Dimensionless Radial Distribution Speed Input speed U ₁ = U U ₂ = 1,5U A place u * = u / U ₁ u * = u / U ₂ R1 0.48 0.50 R2 0.56 0.60 R3 0.68 0.74 R4 0.76 0.72 R5 0.75 0.72 R6 0.60 0.49 R7 0.59 0.57 R8 0.58 0.58 R9 0.79 0.82 R10 0.79 0.83 R11 0.72 0.75 R12 0.53 0.61 Average speed u * 0.65 0.66

EXAMPLE 5

[00392] In this Example, to simulate the flow of gypsum slurry in one of the profiled conduits 2041 of the supply conduit 2022, the slurry distributor 2020 shown in FIG. 72. As shown in FIG. 78, half 2004 of the distributor 2020 shown in FIG. 72, was used to simulate the flow of a gypsum slurry flowing through it, with flow parameters similar to the flow parameters in Example 2, except for using a dimensionless velocity expression, like Example 4. In particular, the vorticity of the suspension at the side inner and outer walls of the shaped pipeline was analyzed .

[00393] As shown in FIG. 73, 74 and 78, to determine the rheological characteristics in half of the 2004 distributor 2020, a computational fluid dynamics method (hydrodynamic simulation method) with a finite volume method was used. In particular, the vorticity of the slurry near the inner and outer side walls of the shaped conduit 2041 was analyzed. As shown in FIG. 73, the suspension, after flowing into the profiled conduit 2041, is moved in a swirling flow. By moving the slurry along machine direction 2192 to the outlet distribution hole 2030, the slurry flow lines become more streamlined. The vorticity of the slurry was analyzed in the region of the profiled pipe 2041 in a longitudinal location of approximately 1 D to 3/4 D (1.72 D) in regions B1 and B2, as shown in FIG. 74 and 78.

[00394] The vorticity of a suspension is a function of its tangential velocity and its velocity in the axial (or machine) direction. As shown in FIG. 78, the degree of vorticity of the swirling flow is usually characterized by a swirl parameter (S) calculated as the ratio of the angular and linear momentum flows using the following formula:

(Уравнение 5),

(Equation 5),

those.

S = Moment of the tangential velocity component / Moment of the axial velocity component = ∫ wur dr / ∫ uur dr, where w is the tangential velocity, u is the axial velocity, and r represents the radial location.

[00395] If you use the average values of the tangential velocity and axial velocity in Equation 5, it will take the following form:

(Уравнение 6),

(Equation 6),

those. S ~ average tangential velocity / average axial velocity = w _ave / u _ave .

For this example, the characteristic vorticity with a twist parameter (S _m ) can be expressed using the following formula:

(Уравнение 7),

(Equation 7),

those. S _m ~ maximum tangential velocity / average axial velocity.

In this example, the calculated vorticity was used to calculate the vortex angle using the following formula:

(Уравнение 8),

(Equation 8)

those. swirl angle ~ tg ^-1 (S _m ).

[00396] The hydrodynamic simulation method was used with two different dimensionless input conditions u ₁ = U and u ₂ = 1,5U. The results of the analysis by hydrodynamic modeling are shown in Table V. Of course, the other half of the suspension distributor should have similar rheological characteristics. As a result of this analysis, it turned out that according to various embodiments, the slurry distributor can be made to achieve a vorticity with a swirl parameter S _m in the range from about 0 to about 10 and a swirl angle in the range from about 0 ° to about 84 °.

[00397] For both flow conditions, the maximum tangential velocity at the edges was at least about half the inlet velocity in the edge region of the inlet portion of the profiled pipeline. The swirl near the side walls is expected to help keep the internal geometry of the slurry distributor clean during use. As shown in FIG. 73, the vortex of the slurry decreases along the machine axis 50 in the flow direction to the outlet distribution hole 2030.

TABLE V - VORTEX Input speed U ₁ = U U ₂ = 1,5 U u * = u / U ₁ u * = u / U ₂ Location MD = 1.72 D B1 B2 B1 B2 Maximum tangential speed 0.50 0.75 0.55 0.74 Average axial speed 0.71 0.63 0.67 0.65 Bottom line Upper bound Vortex, sm 0.71 1.19 0.82 1.14 0 10 Swirl Angle (°) 35 fifty 39 49 0 84

EXAMPLE 6

[00398] In this example, the suspension distributor 2020 shown in FIG. 72 was used to simulate the flow of gypsum slurry through feed line 2022 and distribution pipe 2028. As shown in FIG. 73 and 74, half 2004 of the distributor 2020 shown in FIG. 72, was used to simulate the flow of a gypsum slurry flowing through it, with flow parameters similar to those in Example 2, except for using a dimensionless velocity expression like Example 4.

), вязкость, вычисленная с использованием степенного уравнения течения (Уравнение 2), и число Рейнольдса (Rе) (Уравнение 4). Также был вычислен гидравлический диаметр (Уравнение 1) в отмеченных последовательных безразмерных местах вдоль продольной оси 50. Безразмерные значения реологических характеристик для каждого места были определены с использованием входных параметров потока, как показано в Таблице VI.[00399] For all flow conditions, the density (ρ) of the aqueous gypsum slurry was set to 1000 kg / m ³ and the viscosity coefficient K was set to 50. Again, the rheological characteristics were estimated as for the dimensionless feed rate of the gypsum slurry to the inlet feed hole 2024 in the regions B and 1.5B. The following rheological characteristics were determined in each consecutive dimensionless place downstream of the inlet portion of the profiled pipeline 2041 along machine direction 2192 as a function of inlet diameter D: area-weighted average velocity (U), area-weighted average shear rate (

), the viscosity calculated using the power equation of the flow (Equation 2), and the Reynolds number (Re) (Equation 4). The hydraulic diameter (Equation 1) was also calculated at the marked consecutive dimensionless locations along the longitudinal axis 50. The dimensionless rheological characteristics for each location were determined using the input flow parameters, as shown in Table VI.

[00400] FIG. 79-82 show graphs of rheological characteristics calculated for various flow parameters in Example 6. To describe the changes in rheological characteristics depending on the distance between the inlet feed opening and half of the 2004 outlet distribution hole 2030, suitable curve equations were used. Accordingly, the examples show that the rheological characteristics are constant and independent of changes in input speed.

[00401] For both flow parameters, the average velocity decreased from the first place (approximately 3D) in the supply pipe to the last place (approximately 12D) in half 2117 of the outlet distribution hole 2030 of the distribution pipe 2028. The average speed was substantially progressively reduced as the suspension moved along the machine 2192. In the embodiment shown in the drawing, the average speed decreased to about 1/3 of the input speed, as shown in FIG. 79.

[00402] For both flow parameters, the shear rate increased from first place (approximately 3D) in the supply pipe 2022 to the last place (approximately 12D) in half 2117 of the distribution outlet 2030 of the distribution pipe 2028. The shear rate varied from place to place. In the embodiment shown in the drawing, the shear rate increased in half of the exhaust manifold 2130 of the distribution manifold 2028 relative to the inlet, as shown in FIG. 80.

[00403] For both flow parameters, the design viscosity decreased from first place (approximately 3D) in the supply pipe to the last place (approximately 12D) in half 2117 of the distribution outlet 2030 of the distribution pipe 2028. The design viscosity varied from place to place. In the embodiment shown in the drawing, the design viscosity decreased in half of the exhaust manifold 2130 of the distribution manifold 2028 relative to the inlet, as shown in FIG. 81.

[00404] For both flow parameters, the Reynolds number, as shown in FIG. 82, decreased from the first place (approximately 3D) in the supply pipe to the last place (approximately 12D) in the half portion 2117 of the distribution distribution outlet 2030 of the distribution pipe 2028. In the embodiment shown, the Reynolds number decreased in the half part 2117 of the distribution distribution of the distribution outlet 2030 pipeline 2028 relative to the inlet to approximately 1/2. For both flow parameters, the Reynolds number in half of the 2117 exhaust distribution hole 2030 of the distribution pipe 2028 is in the laminar region.

[00405] Accordingly, it has been found that the far half of the slurry distributor (between about 6D and about 12D) is configured to create a flow stabilization region in which the average slurry speed and the Reynolds number are generally stable and decrease relative to the inlet supply conditions. As shown in FIG. 73, the suspension as a whole flows in a vortex-free mode along machine direction 2192 through said flow stabilization regions.

TABLE VI - DIMENSIONAL RHEOLOGICAL CHARACTERISTICS (K = 50) Geometry Input Speed = U ₁ Input Speed = U ₂ MD distance Hydraulic diameter Speed Shear rate Design viscosity Reynolds number Speed Shear rate Design viscosity Reynolds number 3.11 0.35 0.74 1,08 0.93 0.55 0.75 1.09 0.93 0.56 4.31 0.31 0.74 1.19 0.86 0.53 0.75 1.21 0.85 0.54 5.51 0.31 0.71 1.17 0.87 0.50 0.72 1.18 0.86 0.50 6.71 0.31 0.68 1,11 0.91 0.46 0.69 1.12 0.91 0.46 7.91 0.32 0.66 1.05 0.95 0.44 0.66 1.06 0.95 0.44 8.92 0.31 0.66 1,07 0.94 0.43 0.66 1,07 0.94 0.43 9.93 0.31 0.66 1.09 0.93 0.43 0.66 1.09 0.93 0.43 10.94 0.30 0.66 1,11 0.91 0.43 0.66 1,11 0.91 0.43 11.95 0.30 0.66 1.13 0.89 0.43 0.66 1.14 0.89 0.43

EXAMPLE 7

[00406] In this example, the slurry distributor 2020 shown in FIG. 72 was used to simulate the flow of gypsum slurry in the outlet distribution hole 2030 of the distribution pipe 2028. In this example, the half portion 2004 of the suspension distributor shown in FIG. 73 was used to simulate the flow of gypsum slurry flowing through it, with flow parameters similar to those in Example 2, except for using the dimensionless expression of the outlet width 2081. The dimensionless width (w / W) was measured across half of the 2119 part of the outlet distribution port 2019 holes 2030 (and the middle line in the region of the transverse central median line 2187 is zero, as shown in Fig. 72). In other respects, the flow parameters are similar to those in Example 2.

[00407] To determine the rheological characteristics in half of the 2004 distributor 2020, a hydrodynamic modeling method with a finite volume method was used. In particular, the angle of propagation of the slurry discharged from the outlet 2081 was analyzed at various locations along the width of the half portion 2119 of the outlet 2081 of the outlet distribution hole 2030. The propagation angle was determined from the following formula:

Propagation angle = tg ^-1 (V _x / V _z ), (Equation 9)

where V _x is the average speed in the perpendicular to the machine direction and V _z is the average speed in the machine direction.

[00408] The propagation angle was calculated for two different conditions: when the profiling mechanism does not compress the outlet 2081 ("without profiling"), and when the profiling mechanism compresses the outlet 2081 ("with profiling"). In the simulated suspension distributor 2020, the outlet 2081 has a height of approximately 3/4 inch (19.05 mm) over its entire width of approximately 10 inches (254 mm) for each half of 2004, 2005, and thus the full width of the outlet Bore 2081 is 20 inches (508 mm). The simulated profiling mechanism comprises a profiling element that is approximately 15 inches (381 mm) wide and aligned with the transverse center median line so that the side of the outlet distribution hole is offset from the profiling element and thus cannot be compressed. Under the “profiled” simulation condition, the profiling mechanism compresses the outlet to about 1/8 inch (3.2 mm) so that the outlet is about 5/8 inch (15.9 mm) in the area under the profiling element. The propagation angle was determined for both conditions, as shown in Table VII.

[00409] Under both conditions, the propagation angle increases as the space moves further outward from the transverse central median line 2187 (width = 0). The propagation angle is maximum at the lateral edge of the outlet 2081.

[00410] The propagation angle can be increased using a profiling mechanism to compress the outlet 2030 and thus reduce the height of the outlet 2081. Under the simulated condition, the maximum propagation angle at the lateral edge (width = 0.466) increases by more than 25% of the maximum angle under the condition "without profiling." Under the “with profiling” condition, the average propagation angle increases by more than 50% relative to the average angle under the “without profiling” condition.

TABLE VII - ANGLE OF SPREAD OF SUSPENSION BY MEANS OF PROFILING MECHANISM The width of the outlet at the location of the angle (relative to the midline) Propagation Angle (°) No profiling With profiling 0.017 0.108 0,093 0,052 0.232 0.435 0,086 0.440 0.739 0.121 0.561 1,032 0.155 0.634 1,374 0.190 0.981 1,800 0.224 1,279 2,402 0.259 1,458 3,079 0.293 1,848 3,612 0.328 2,173 3,941 0.362 2,298 4,027 0.397 2,488 3,972 0.431 2,857 4,020 0.466 3,208 4,064 Average value 1,469 2,471

[00411] All references, including publications, patent applications and patents cited in this application, are hereby incorporated by reference to the same extent that each reference has been individually and specifically assigned to be incorporated by reference and has been fully incorporated into the present application.

[00412] Used in this application, the terms "some" and "specified", as well as similar indicators in the context of the description of the present invention (especially in the context of the appended claims) should be interpreted as covering the singular and plural, unless expressly indicated otherwise in this application or obviously not contrary to the context. The terms “comprising,” “having,” “including,” and “consisting of” should be interpreted as open terms (i.e. meaning “comprising, inter alia,”) unless expressly stated otherwise. Indication of ranges of values in this application serves only as a way of briefly referring individually to each individual value falling within the specified range, unless explicitly indicated otherwise, and each individual value is included in the specification as if it were individually described in this application. All methods described in this application can be carried out in any suitable order, unless explicitly stated otherwise or clearly does not contradict the context. The use of any and all examples, or an approximate expression (for example, "such as") in this application is intended only for ease of description of the present invention and is not a limitation of the scope of protection of the present invention, unless expressly indicated otherwise. No expression in the description should be construed as an indication of an undeclared element, essential for the practical implementation of the present invention.

[00413] Preferred embodiments of the present invention described herein comprise the best mode of implementation of the present invention known to the inventors. Changes to the preferred embodiments described above may be apparent to those skilled in the art after reviewing the above description. Specialists can use such changes as appropriate without departing from the idea and scope of protection of the present invention. Accordingly, the scope of protection of the present invention covers all modifications and equivalents of the subject matter described in the appended claims in accordance with the relevant legislation. In addition, any combination of the above elements in all their possible changes falls within the scope of protection of the present invention, unless expressly indicated otherwise in this application or clearly does not contradict its context.

Claims (40)

1. A binder suspension dispenser comprising: a distribution conduit generally extending along a longitudinal axis and comprising an inlet and an outlet distribution port in fluid communication with the inlet portion, wherein said outlet distribution port extends a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis; moreover, the outlet distribution hole contains an outlet having a width measured along the transverse axis, and a height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and the transverse axis; a profiling mechanism comprising a profiling element in contact with the distribution pipe and configured to move in a predetermined range such that the profiling element is in a range of positions in which the profiling element is in increased compressive interaction with a portion of the distribution pipe adjacent to the outlet distribution hole to change the shape and / or size of the outlet, wherein the profiling element is made to rotate around the hinge axis, describing the arc in such a way that the profiling element has a compressive action that changes along the transverse axis on the part of the distribution pipe, so that the height of the outlet changes along the transverse axis. 2. The binder suspension dispenser of claim 1, wherein the ratio of the width to the height of the outlet of the outlet of the outlet is about 4 or more. 3. The binder suspension distributor according to claim 1 or 2, wherein the profiling element has a width extending a predetermined second distance along the transverse axis, wherein the width of the outlet is larger than the width of the profiling element, and the profiling element is positioned so that a pair of side parts of the outlet distribution hole is offset relative to the profiling element. 4. The distributor of binder suspension according to claim 1 or 2, in which the profiling element is made with the possibility of movement along the vertical axis. 5. The binder suspension dispenser according to claim 1 or 2, wherein the profiling element has at least two degrees of freedom. 6. The dispenser of the binder suspension according to claim 5, in which the profiling element is arranged to move along at least one axis. 7. The binder suspension distributor according to claim 1 or 2, wherein the profiling mechanism comprises a holder assembly comprising a fixed support element and a hinged support element, wherein the hinged support element is rotatable around the hinge axis, describing an arc relative to the fixed support element, wherein The articulated support element supports the profiling element. 8. The binder suspension distributor according to claim 1 or 2, in which the profiling mechanism comprises a holder assembly, and the profiling element comprises an interacting segment, generally extending in the longitudinal direction and in the transverse direction, and controlling the movement of the rod, generally extending vertically from the interacting segment moreover, the rod regulating the movement of the profiling element is attached with the possibility of movement to the node of the holder so that the profiling element can move in a given range of verti local provisions. 9. The binder suspension distributor according to claim 8, wherein the holder assembly comprises a clamping device configured to selectively interact with a rod controlling the movement to fix the profiling element in a predetermined range of vertical positions. 10. The binder suspension distributor according to claim 8, wherein the holder assembly is configured to support and rotate the profiling element so that the profiling element can rotate around the hinge axis, describing the arc in a given range of positions. 11. The binder suspension distributor according to claim 10, wherein the holder assembly comprises a fixed supporting element and a hinged supporting element, wherein the hinged supporting element is rotatable around the hinge axis, describing an arc relative to the stationary supporting element, while the hinged supporting element supports the profiling element . 12. The binder suspension distributor according to claim 11, wherein the holder assembly comprises a rotating adjustment rod extending between the stationary supporting element and the hinged supporting element, the rotating adjustment rod being movably attached to the stationary supporting element such that the rotating adjustment rod is moved relative to fixed support element causes articulated movement of the articulated support element around the hinge axis relative completely motionless support element. 13. The binder suspension distributor according to claim 12, wherein the holder assembly comprises a clamping device configured to selectively engage with a rotating adjustment rod to fix the profiling element in a predetermined range of arc positions. 14. Mixing and distributing astringent suspension node containing: a mixer configured to mix water and a binder to form an aqueous binder suspension; a binder suspension dispenser made according to any one of paragraphs. 1-13 and in fluid communication with the mixer. 15. The mixing and distributing binder suspension of the node according to claim 14, further comprising: a distributor support member that supports the distribution pipe; moreover, the profiling mechanism of the suspension distributor comprises a holder assembly comprising a fixed supporting element and a hinged supporting element, the fixed supporting element being connected to the supporting element of the distributor, the hinged supporting element being rotatable around the hinge axis, describing the arc relative to the fixed supporting element, and supporting profiling element. 16. The mixing and distributing binder suspension of the site according to claim 14 or 15, further comprising: a supply pipe located between the mixer and the binder suspension distributor and in fluid communication with them; a flow-changing element coupled to a supply pipe and configured to control the flow of an aqueous binder slurry flowing from the mixer; a supply line for water foam in fluid communication with the mixer and / or the feed line. 17. The mixing and distributing binder suspension assembly according to claim 14 or 15, wherein the binder suspension distributor comprises a supply pipe having a first inlet part with a first inlet feed opening and a second inlet part with a second inlet feed hole located at a distance from the first inlet feed holes, and the inlet of the distribution pipe is in fluid communication with the first and second inlet feed openings of the supply pipe, while the first inlet feed opening It is configured to receive a first stream of aqueous binder slurry from the mixer, a second inlet feed port is configured to receive a second stream of aqueous binder slurry from the mixer, and the outlet distribution port is in fluid communication with the first and second inlet feed openings and is configured so that the combined first and second streams of the aqueous binder slurry are discharged from the binder slurry distributor through the outlet distribution hole. 18. The mixing and distributing binder suspension of the node according to claim 17, further comprising: a supply pipe located between the mixer and the binder slurry distributor and in fluid communication with them, the feed pipe comprising a main supply main pipe and a first and second supply branch; a flow divider connecting the main supply main pipe with the first and second supply branches, wherein the flow divider is located between the main supply main pipe and the first supply branch and between the main supply main pipe and the second supply branch; moreover, the first supply branch is in fluid communication with the first inlet supply opening of the binder suspension distributor, and the second supply branch is in fluid communication with the second inlet supply opening of the binder suspension distributor. 19. A method of preparing an astringent product, comprising the steps according to which: an aqueous binder suspension is discharged from the mixer, ensure the flow of the aqueous binder suspension through the inlet of the distribution pipe of the binder suspension distributor, made according to any one of paragraphs. 1-13 and the distribution pipe which is oriented along the longitudinal axis; the aqueous binder suspension is discharged from the outlet of the outlet distribution hole of the binder suspension distributor onto a web of coating material advancing along the machine direction, the outlet distribution hole extending a predetermined distance along a transverse axis that is substantially perpendicular to the longitudinal axis, the outlet opening having a width of measured along the transverse axis, and height measured along the vertical axis, which is mutually perpendicular to the longitudinal axis and pop river axis, and subject to compression the portion of the distribution pipe next to the outlet distribution hole using the profiling element of the profiling mechanism of the binder suspension distributor in contact with the distribution pipe to change the shape and / or size of the outlet. 20. The method according to p. 19, according to which the distribution pipe is subjected to compressive action by means of a profiling mechanism so that the flow of the aqueous binder suspension is discharged from the outlet with an increased propagation angle relative to the machine direction. 21. The method according to p. 19 or 20, according to which the distribution pipe is subjected to compressive action by means of a profiling mechanism, the profiling element of which is configured to move in a predetermined range so that the profiling element is in the range of positions in which the profiling element is in an enlarged compressing interaction with the distribution pipeline. 22. The method according to p. 19 or 20, according to which the profiling element is additionally moved along the vertical axis to adjust the size and / or shape of the outlet. 23. The method according to p. 19 or 20, according to which the profiling element is additionally moved so that the profiling element moves along at least one axis and / or rotates at least around one axis to adjust the size and / or shape of the outlet.

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