Abstract: A multi-piece mold for use in a method for making a slurry distributor includes a plurality of mold segments adapted to be removably secured together. The mold segments are configured such that, when the mold segments are assembled together, the assembled mold segments define a substantially continuous exterior surface adapted to be a negative image of an interior flow region of a slurry distributor molded thereupon. Each mold segment has a maximum cross-sectional area in a plane substantially transverse to a direction of movement of the mold segment along a removal path out of a respective opening of the molded slurry distributor. The maximum cross-sectional area of each mold segment is up to about 150% of the smallest area of the interior flow region of the molded slurry distributor through which the mold segment traverses when moving along the respective removal path.

Abstract: A flow splitter can include an inlet conduit and first and second outlet conduits separated by a junction portion. The inlet conduit can include an inlet end and a junction end. The inlet conduit is disposed along a main flow axis extending between the inlet end and the junction end. The inlet end defines an inlet opening. The junction end defines first and second junction openings. The first junction opening is disposed in spaced relationship to the second junction opening. The junction portion is disposed at the junction end of the inlet conduit between the first and second junction openings. The junction portion includes a substantially planar wall region that is substantially perpendicular to the main flow axis. The flow splitter can be placed in fluid communication with a cementitious slurry mixer and a slurry distributor with the flow splitter disposed therebetween.

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 foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first and second port inserts respectively define first and second foam passageways having first and second orifice sizes. The first and second orifice sizes are different. The first and second port inserts are adapted to removably mount to the foam injection body such that the respective foam passageway is in fluid communication with the slurry passageway via the port opening of the port passageway. One port insert can be replaced with another to readily vary the pressure of the foam passing through the particular port insert and injected into a cementitious slurry traveling through the slurry passageway.

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 slurry distributor can include a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit can include a first and second feed inlets disposed in spaced relationship to each other. 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. The first and second feed inlets each has an opening with a cross-sectional area. The entry portion of the distribution conduit has an opening with a cross-sectional area which is greater than the sum of the cross-sectional areas of the openings of the first and second feed inlets. The slurry distributor can be placed in fluid communication with a gypsum slurry mixer.

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

Abstract: A multi-leg discharge boot can include an inlet conduit and first and second outlet conduits separated by a junction portion. The inlet conduit includes an entry segment, a transition segment and a heel portion disposed therebetween. The inlet conduit can include an inlet end and a junction end. A junction portion is disposed at the junction end of the inlet conduit between first and second junction openings. The junction portion includes a substantially planar wall region that is substantially perpendicular to a main flow discharge axis.

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 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 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 foam injection system for use in the manufacture of cementitious products includes a foam injection body and first and second port inserts. The foam injection body defines a slurry passageway and a port passageway having a port opening in fluid communication with the slurry passageway. The first and second port inserts respectively define first and second foam passageways having first and second orifice sizes. The first and second orifice sizes are different. The first and second port inserts are adapted to removably mount to the foam injection body such that the respective foam passageway is in fluid communication with the slurry passageway via the port opening of the port passageway. One port insert can be replaced with another to readily vary the pressure of the foam passing through the particular port insert and injected into a cementitious slurry traveling through the slurry passageway.

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

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 gypsum slurry is described that includes water, a hydraulic component comprising at least 50% calcined gypsum by weight based on the dry weight of the hydraulic component, foam, a defoamer, a polycarboxylate dispersant having olefinic unsaturated mono-carboxylic acid moieties and (poly)oxyalkylene moieties, a first portion of a retarder and a second portion of a retarder. In some embodiments of the invention, the defoamer is combined with the dispersant prior to being added to the gypsum slurry. The defoamer and dispersant can be added as a physical mixture, wherein the defoamer is attached onto the dispersant polymer, or a combination thereof. In some embodiments, a gypsum building panel is made from the gypsum slurry.

Abstract: A gypsum slurry is described that includes water, a hydraulic component comprising at least 50% calcined gypsum by weight based on the dry weight of the hydraulic component, foam, a defoamer and a polycarboxylate dispersant. In some embodiments of the invention, the defoamer is combined with the dispersant prior to being added to the gypsum slurry. The defoamer and dispersant can be added as a physical mixture, wherein the defoamer is attached onto the dispersant polymer, or a combination thereof. In some embodiments, a gypsum building panel is made from the gypsum slurry.

Abstract: Methods and systems are provided for preparing a heat resistance accelerator (HRA) slurry. Also provided are methods and systems for introducing a HRA slurry to an aqueous dispersion of calcined gypsum in a discharge apparatus downstream of a stucco mixer in which the dispersion was prepared. These methods and systems are useful in the production of various gypsum products such as board including wallboard and ceiling tiles.

Abstract: Provided are methods and systems for introducing a wet gypsum accelerator or other high viscosity production additive to an aqueous dispersion of calcined gypsum in a discharge apparatus downstream of a stucco mixer in which the dispersion was prepared. These methods and systems are useful in the production of various gypsum products such as board including wallboard and ceiling tiles.

Abstract: A method for providing a smoothly mixed slurry to a web is provided which includes inserting calcined gypsum and water into a mixer (12), agitating the contents of the mixer (12) to form an aqueous dispersion of the calcined gypsum, and passing the agitated contents from an outlet (20) of the mixer (12) into a slurry dispensing apparatus (22) including a flexible, resilient conduit (24). Additionally, the method includes the step of creating a back-pressure on the mixture in the slurry dispensing apparatus by constricting the conduit (24). The constricting of the conduit (24) is effected by a constrictor valve (28) located on the conduit (24).