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.

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.

Abstract: Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.

Abstract: A slurry distributor for use in a continuous manufacturing process includes an inlet opening and a shaped duct adapted to receive a flow of slurry provided at the inlet opening. The shaped duct has a parabolic guide surface adapted to redirect the flow of slurry. An outlet opening in fluid communication with the shaped duct is adapted to discharge the flow of slurry from the slurry distributor.

Abstract: Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. These waterproof gypsum panels have many uses, such as, tile backer board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, interior wall and ceiling, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, preferably silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: A slurry distributor can include a distribution conduit and a slurry wiping mechanism. The distribution conduit extends generally along a longitudinal axis and includes an entry portion, a distribution outlet in fluid communication with the entry portion, and a bottom surface extending between the entry portion and the distribution outlet. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The slurry wiping mechanism includes a movable wiper blade in contacting relationship with the bottom surface of the distribution conduit. The wiper blade is reciprocally movable between a first position and a second position over a clearing path, which is disposed adjacent the distribution outlet.

Abstract: A discharge gate is provided for a gypsum slurry mixer, and includes a lower member having an inlet opening configured for receiving the slurry, and an outlet opening configured for delivering the slurry to a dispensing device. An upper member is attached to the lower member, at least one of the upper and lower members having at least one opening for accommodating insertion of an injection port for introducing the foam to the slurry. A cavity is configured for mixing the foam and slurry, and is defined by inner surfaces of the lower member and the upper member.

Abstract: A cementitious slurry mixing and dispensing system includes a mixer, a discharge conduit, and a pulser assembly. The discharge conduit is in fluid communication with the mixer. The pulser assembly is adapted to periodically compress a portion of the discharge conduit. The pulser assembly can include a compression member adapted to contactingly engage the portion of the discharge conduit and a drive mechanism adapted to selectively move the compression member into compressing engagement with the discharge conduit such that the part of the interior wall surface underlying the compressed portion is flexed.

Abstract: A cementitious product with strengthened composite structure is provided. Energy-efficient methods for manufacturing such products are provided as well and include dewatering a partially-set cementitious product by applying vacuum, and also creating a concentration gradient across the product thickness. Systems for manufacturing such products are provided as well.

Abstract: Disclosed are methods relating to an extruded pregelatinized, partially hydrolyzed starch prepared by mixing at least water, non-pregelatinized starch, and acid to form a starch precursor. The acid can be a weak acid that substantially avoids chelating calcium ions or a strong acid in a small amount. In the method, pregelatinization and acid-modification of the starch precursor occurs in one step in an extruder. Also disclosed are methods of preparing board using the starch prepared according to the methods, as well as starches and boards prepared by various methods of the invention.

Abstract: A gypsum slurry is provided that includes calcium sulfate hemihydrate; water; a dispersant component comprising at least one of the following a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate; a foaming agent; and a polycondensation component with three polycondensation repeating units. Also provided is a method for making a gypsum slurry with a foaming agent in which the ratio between the dispersant component and the polycondensation component is adjusted to control for the size of foam bubbles in the gypsum slurry. Gypsum products made from the gypsum slurry are provided and methods for making the products are provided as well.

Abstract: Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.

Abstract: A gypsum slurry is provided that includes calcium sulfate hemihydrate; water; a dispersant component comprising at least one of the following a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate; a foaming agent; and a polycondensation component with three polycondensation repeating units. Also provided is a method for making a gypsum slurry with a foaming agent in which the ratio between the dispersant component and the polycondensation component is adjusted to control for the size of foam bubbles in the gypsum slurry. Gypsum products made from the gypsum slurry are provided and methods for making the products are provided as well.

Abstract: A panel is provided that includes stucco, water and a dispersant component having dispersing properties and comprising a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate. A polycondensation component is also included in the slurry that includes three repeating units. A method of making the gypsum panel includes combining stucco, water and a first dosage of a first dispersant to form a slurry, the first. A second dosage of a second dispersant is added to the slurry. Properties of the gypsum slurry are tested and it is formed into a product. The product sets and properties of the product are identified. The first dosage or the second dosage is changed based on the properties of the slurry or product.

Abstract: A slurry distributor includes a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit includes an entry segment with a feed inlet and a feed entry outlet in fluid communication therewith and extending along a first feed flow axis. The feed conduit includes a shaped duct having a bulb portion in fluid communication with the feed entry outlet. The feed conduit includes a transition segment in fluid communication with the bulb portion and extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The bulb portion has an area of expansion with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream from the area of expansion. The shaped duct has a convex interior surface in confronting relationship with the feed entry outlet of the entry segment.

Abstract: A method and apparatus for providing an evenly mixed additive enhanced gypsum slurry to a web. Calcined gypsum and water are inserted into a mixer through at least one inlet of the mixer. The contents are agitated to form a slurry. The slurry is passed from an outlet of the mixer into a conduit. An additive is introduced into the slurry along a length of the conduit to achieve a flow stream of a slurry/additive mixture. A cross section of the flow stream is expanded in the conduit while not changing direction of the flow stream and a direction of the flow stream is changed while not expanding the cross section of the flow stream and conduit, all prior to the flow steam exiting from an outlet of the conduit.

Abstract: A method and apparatus for providing an evenly mixed additive enhanced gypsum slurry to a web. Calcined gypsum and water are inserted into a mixer through at least one inlet of the mixer. The contents are agitated to form a slurry. The slurry is passed from an outlet of the mixer into a conduit. An additive is introduced into the slurry along a length of the conduit to achieve a flow stream of a slurry/additive mixture. A cross section of the flow stream is expanded in the conduit while not changing direction of the flow stream and a direction of the flow stream is changed while not expanding the cross section of the flow stream and conduit, all prior to the flow steam exiting from an outlet of the conduit.

Abstract: A slurry distributor for use in a continuous manufacturing process includes an inlet opening and a shaped duct adapted to receive a flow of slurry provided at the inlet opening. The shaped duct has a parabolic guide surface adapted to redirect the flow of slurry. An outlet opening in fluid communication with the shaped duct is adapted to discharge the flow of slurry from the slurry distributor.

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.