Abstract:
A feed apparatus for use in depositing a slurry (46) upon a moving web (26) having a direction of travel includes a main metering roll (50), a companion roll (52) disposed in closely spaced relation to the metering roll (50) to form a nip (54) therebetween. The nip (54) is constructed and arranged to retain a supply of the slurry (46), and the rolls (50, 52) are driven so that slurry (46) retained in the nip (54) progresses over an upper outer peripheral surface (70) of the metering roll (50) to be deposited upon the web (26). Also preferably included is a thickness control roll (68) disposed in operational relationship to the metering roll (50) for controlling thickness of a layer of slurry (46) drawn from the nip (54) over the outer metering roll surface. Preferably, the metering roll (50), the companion roll (52) and the thickness control roll (68) are driven in the same direction.
Abstract:
Disclosed is a foam modifier, e.g., useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C6-C16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.
Abstract:
Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.