Slurry distributor, system and method for using same

{
  "publication_number": "US10239230B2",
  "country": "US",
  "kind": "B2",
  "title": "Slurry distributor, system and method for using same",
  "abstract": "A slurry distribution system can include a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit can include a first feed inlet and a second feed inlet disposed in spaced relationship thereto. The distribution conduit can extend generally along a longitudinal axis and include an entry portion and a distribution outlet in fluid communication therewith. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The slurry distribution system can be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry.",
  "claims": [
    "1. A method of distributing an aqueous calcined gypsum slurry upon a web of cover sheet material moving along a machine direction, the method comprising: discharging an aqueous calcined gypsum slurry from a mixer; splitting the aqueous calcined gypsum slurry from the mixer into a first flow of aqueous calcined gypsum slurry and a second flow of aqueous calcined gypsum slurry; passing the first flow of aqueous calcined gypsum slurry through a first feed inlet of a slurry distributor; passing the second flow of aqueous calcined gypsum slurry through a second feed inlet of the slurry distributor, the second feed inlet in spaced relationship to the first feed inlet; combining the first and second flows of aqueous calcined gypsum slurry in the slurry distributor; and discharging the combined first and second flows of aqueous calcined gypsum slurry from the slurry distributor upon the moving web.",
    "2. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the combined first and second flows of aqueous calcined gypsum slurry are discharging at an average discharge velocity, and the web of cover sheet material is moving along the machine direction at a web velocity, wherein the ratio of the average discharge velocity to the web velocity is about 2 or less.",
    "3. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the combined first and second flows of aqueous calcined gypsum slurry discharge from the slurry distributor through a distribution outlet, the web has a width extending along a cross-machine direction substantially perpendicular to the machine direction, and the distribution outlet includes an outlet opening with a width extending along the cross-machine direction and sized such that the ratio of the width of the cover sheet to the width of the outlet opening of the distribution outlet is within a range from about 1 to about 6.",
    "4. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, further comprising: mixing and agitating water and calcined gypsum in a water-to-calcined gypsum ratio from about 0.4 to about 1.2 to form the first and second flows of aqueous calcined gypsum slurry.",
    "5. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the combined first and second flows of aqueous calcined gypsum slurry discharge from the slurry distributor through a distribution outlet and form a spread pattern upon the moving web, the method further comprising: adjusting at least one of the size and shape of the distribution outlet to change the spread pattern.",
    "6. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the first and second flows of aqueous calcined gypsum slurry combine in the slurry distributor such that the combined first and second flows of aqueous calcined gypsum slurry move in a distribution direction generally along the machine direction.",
    "7. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the first flow of aqueous calcined gypsum slurry passes through the first feed inlet in a first feed direction, and the second flow of aqueous calcined gypsum slurry passes through the second feed inlet in a second feed direction, the method further comprising: redirecting in the slurry distributor the first flow of slurry moving in the first feed flow direction through a change in direction angle in a range up to about 135° to an outlet flow direction; redirecting in the slurry distributor the second flow of slurry moving in the second feed flow direction through a change in direction angle in a range up to about 135° to the outlet flow direction; wherein the combined first and second flows of aqueous calcined gypsum slurry discharge from the slurry distributor moving generally in the outlet flow direction.",
    "8. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 7, wherein the outlet flow direction is substantially parallel to the machine direction.",
    "9. The method of distributing an aqueous calcined gypsum slurry upon a moving web of claim 1, wherein the aqueous calcined gypsum slurry from the mixer is split such that the first and second flows of aqueous calcined gypsum slurry are substantially balanced."
  ],
  "description_excerpt": "The present disclosure relates to continuous board (e.g., wallboard) manufacturing processes and, more particularly, to an apparatus, system and method for the distribution of an aqueous calcined gypsum slurry.\n\nIt is well-known to produce gypsum board by uniformly dispersing calcined gypsum (commonly referred to as “stucco”) in water to form an aqueous calcined gypsum slurry. The aqueous calcined gypsum slurry is typically produced in a continuous manner by inserting stucco and water and other additives into a mixer which contains means for agitating the contents to form a uniform gypsum slurry. The slurry is continuously directed toward and through a discharge outlet of the mixer and into a discharge conduit connected to the discharge outlet of the mixer. An aqueous foam can be combined with the aqueous calcined gypsum slurry in the mixer and/or in the discharge conduit. The stream of slurry passes through the discharge conduit from which it is continuously deposited onto a moving web of cover sheet material supported by a forming table. The slurry is allowed to spread over the advancing web. A second web of cover sheet material is applied to cover the slurry and form a sandwich structure of a continuous wallboard preform, which is subjected to forming, such as at a conventional forming station, to obtain a desired thickness. The calcined gypsum reacts with the water in the wallboard preform and sets as the wallboard preform moves down a manufacturing line.",
  "cpc": [
    "B28B 19/0092",
    "B05C 5/02",
    "B05C 5/0225",
    "B05C 5/0245",
    "B05C 5/0254",
    "B05C 5/0262",
    "B28B 19/00",
    "B28C 7/04",
    "Y10T 137/0318",
    "Y10T 137/87571"
  ],
  "ipc": [
    "B05C 5/02",
    "B28B 19/00"
  ],
  "assignees": [
    "United States Gypsum Co"
  ],
  "inventors": [
    "Alfred Li",
    "Chris C. Lee",
    "Cesar Chan",
    "Ronald E. Schenck",
    "Weixin David SONG",
    "Curtis B. LORING",
    "James R. Wittbold",
    "William J. RAGO",
    "Christopher Robert Nelson"
  ],
  "filing_date": "2017-04-10",
  "publication_date": "2019-03-26",
  "grant_date": "2019-03-26",
  "priority_date": "2010-12-30",
  "application_number": "US-201715483585-A",
  "family_id": "45532037",
  "cited_by_count": 5,
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