Abstract: An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.

Abstract: A structural cementitious panel, produced by a multi-layer process including providing a moving web; b. one of depositing a first layer of loose fibers upon the web and c. depositing a layer of settable slurry upon the web; d. depositing a second layer of loose fibers upon the slurry; e. embedding said second layer of fibers into the slurry; and f. repeating steps c. through e. until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. Also provided are an apparatus suitable for producing structural cementitious panels according to the present process, and a structural cementitious panel having multiple layers, each layer created by depositing a layer of settable slurry upon a moving web, depositing fibers upon the slurry and embedding the fibers into the slurry such that each layer is integrally formed with the adjacent layers.

Abstract: The present invention is an apparatus and process for cooling and de-steaming hot calcined stucco used in the production of gypsum boards or bagged plaster. The apparatus is a fluid bed stucco cooler and comprises a cooler housing having a plenum having a stucco inlet and stucco outlet. The stucco cooler includes a rotating disk in the plenum. The rotating disk includes nozzle for spraying fluid, and is attached to a rotable shaft extending from the side of the cooler also includes a fluidization pad and agitator to help to mix the air and the stucco powder to insure fluidization, prevent channeling, and prevent the stucco powder from building up on the various components. The air also forces steam from the hot calcined stucco out through an air outlet located at the top of the stucco cooler, thereby de-steaming the stucco. The stucco flows through the plenum and passes over the cooling coils, thereby cooling the stucco as it reaches the stucco outlet.

Abstract: A process is disclosed for making dead burn calcium sulfate anhydrite. The process includes a slurry calcination step to produce calcium sulfate anhydrite followed by removing free water from the anhydrite while avoiding substantial rehydration. Also disclosed are dead burn calcium sulfate anhydrite particles with high aspect ratios, e.g. fibers having an average aspect ratio of at least 4:1, or very fine particle size, e.g., at or below 2 micrometers average, combined with very low water content, e.g., less than 0.5, preferably less than 0.3, wt. % water. These particles are typically useful as fillers.

Abstract: An embedment device includes a first integrally formed elongate shaft rotatably secured to the support frame and having a first plurality of axially spaced disks axially fixed to the first shaft, a second integrally formed elongate shaft rotatably secured to the support frame and having a second plurality of axially spaced disks axially fixed to the second shaft, the first shaft being disposed relative to the second shaft to be horizontally aligned and so that the disks intermesh with each other, and wherein, when viewed from the side, peripheries of the first and second pluralities of disks overlap each other.

Abstract: A structural cementitious panel, produced by a multi-layer process including providing a moving web; b. one of depositing a first layer of loose fibers upon the web and c. depositing a layer of settable slurry upon the web; d. depositing a second layer of loose fibers upon the slurry; e. embedding said second layer of fibers into the slurry; and f. repeating steps c. through e. until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. Also provided are an apparatus suitable for producing structural cementitious panels according to the present process, and a structural cementitious panel having multiple layers, each layer created by depositing a layer of settable slurry upon a moving web, depositing fibers upon the slurry and embedding the fibers into the slurry such that each layer is integrally formed with the adjacent layers.

Abstract: A multi-layer process for producing structural cementitious panels, includes, a. providing a moving web; b. one of depositing a first layer of loose fibers upon the web and c. depositing a layer of settable slurry upon the web; d. depositing a second layer of loose fibers upon the slurry; e. embedding said second layer of fibers into the slurry; and f. repeating steps c. through e. until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. Also provided are a structural panel produced by the present process, an apparatus suitable for producing structural cementitious panels according to the present process, and a structural cementitious panel having multiple layers, each layer created by depositing a layer of settable slurry upon a moving web, depositing fibers upon the slurry and embedding the fibers into the slurry such that each layer is integrally formed with the adjacent layers.

Abstract: An agitation mechanism for a gypsum processing apparatus which includes a housing having a bottom wall and at least one side wall. The housing can be constructed and arranged to receive and process gypsum-based products. An agitator frame having a similarly shaped cross-section to the cross-section of the housing is provided and positioned adjacent the bottom wall of the housing. The agitator frame is pivotally connected internally to the housing for reciprocating movement between first and second positions. The agitation mechanism is operable for preventing fluid channeling to ensure good fluidization of the gypsum products from collecting adjacent the bottom wall of the housing.

Abstract: An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.

Abstract: A process is disclosed for making dead burn calcium sulfate anhydrite. The process includes a slurry calcination step to produce calcium sulfate anhydrite followed by removing free water from the anhydrite while avoiding substantial rehydration. Also disclosed are dead burn calcium sulfate anhydrite particles with high aspect ratios, e.g. fibers having an average aspect ratio of at least 4:1, or very fine particle size, e.g., at or below 2 micrometers average, combined with very low water content, e.g., less than 0.5, preferably less than 0.3, wt. % water. These particles are typically useful as fillers.

Abstract: An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.

Abstract: An embedment device for use in a structural panel production line wherein a slurry is transported on a moving carrier relative to a support frame, and chopped fibers are deposited upon the slurry, includes a first elongate shaft secured to the support frame and having a first plurality of axially spaced disks, a second elongate shaft secured to the support frame and having a second plurality of axially spaced disks, the first shaft being disposed relative to the second shaft so that the disks intermesh with each other. The intermeshing relationship enhances embedment of the fibers into the slurry and also prevents clogging of the device by prematurely set slurry particles.

Abstract: An apparatus for calcining gypsum including a housing having a bottom wall, open top, and a plurality of side walls extending therebetween. A fixture is located adjacent the open top for receiving gypsum from a source and transferring the gypsum into the housing. At least one burner is connected to the housing and operable for combusting an air-fuel mixture to heat the gypsum. At least one serpentine burner conduit extends from the burner through the housing and terminates through a support floor of the apparatus. The exhaust flow is then directed through a fluidization pad and into the gypsum to further heat the gypsum product. An agitation mechanism is operable to mix the gypsum adjacent the fluidization pad to prevent pockets of gypsum from coagulating and preventing fluidization of the gypsum.

Abstract: An agitation mechanism for a gypsum processing apparatus which includes a housing having a bottom wall, and at least one side wall. The housing can be constructed and arranged to receive and process gypsum-based products. An agitator frame having a similarly shaped cross-section to the cross-section of the housing is provided and positioned adjacent the bottom wall of the housing. The agitator frame is pivotally connected internally to the housing for reciprocating movement between first and second positions. The agitation mechanism is operable for preventing fluid channeling to ensure good fluidization of the gypsum products from collecting adjacent the bottom wall of the housing.

Abstract: A feed apparatus for use in depositing a slurry upon a moving web having a direction of travel includes a main metering roll, a companion roll disposed in closely spaced relation to the metering roll to form a nip therebetween. The nip is constructed and arranged to retain a supply of the slurry, and the rolls are driven so that slurry retained in the nip progresses over an upper outer peripheral surface of the metering roll to be deposited upon the web. Also preferably included is a thickness control roll disposed in operational relationship to the metering roll for controlling thickness of a layer of slurry drawn from the nip over the outer metering roll surface. Preferably, the metering roll, the companion roll and the thickness control roll are driven in the same direction.

Abstract: An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.

Abstract: A slurry spray machine for spraying a settable slurry includes a main passageway configured for receiving a supply of pressurized slurry and having a supply end and an outlet end opposite the supply end. A first compressed gas inlet is disposed intermediate the supply and outlet ends and in fluid communication with the passageway for introducing a first supply of pressurized gas into the slurry, and a second pressurized gas inlet is disposed closer to the outlet end than the first inlet and in fluid communication with the passageway for introducing a second supply of pressurized gas into the slurry. A pressurized supply of adjuvant is provided in fluid communication with the second pressurized gas inlet for providing a blended gas to the second gas inlet. At least one valve is provided for controlling the flow of slurry through the passageway and the flow of the first and second gases into the passageway.

Abstract: The disclosed invention consists of a means for conveying a gypsum or gypsum/cellulose fiber board to a rotary cylinder brush station where pMDI resin is delivered onto the rotary cylinder brush just as the board passes under the brush. A resin distribution system is used to coat the rotary cylinder brush applicator with pMDI. Optionally, a second rotary cylinder brush station is included, if desired, to smooth out and spread the pMDI resin over the surface of the gypsum board substrate to achieve complete coverage.

Abstract: The present invention is an apparatus and process for cooling and de-steaming hot calcined stucco used in the production of gypsum boards or bagged plaster. The apparatus is a fluid bed stucco cooler and comprises a cooler housing having a plenum with two chambers, a first chamber having a stucco inlet and a second chamber having a stucco outlet. The stucco cooler includes cooling coils that are located within the plenum and a fluidization pad positioned through the fluidization pad help to mix the air and the stucco powder to insure fluidization, prevent channeling, and prevent the stucco powder from building up on the cooling coils. The air also forces steam from the hot calcined stucco out through an air outlet located at the top of the stucco cooler, thereby de-steaming the stucco. The stucco flows through the plenum and passes over the cooling coils, thereby cooling the stucco as it reaches the stucco outlet.