Patent ID: 7172403
Filing Date: 2007-02-06
Classification: B28B,B29C,C04B

Abstract:
1. An apparatus for producing a gypsum wallboard core, the apparatus comprising: (a) a mixer; (b) an extrusion die comprising a die inlet in fluid communication with the mixer, an adjustable top plate, an adjustable bottom plate, and two adjustable side plates defining a substantially rectangular die exit, and a manifold disposed between the die inlet and the die exit, wherein the top, bottom and side plates can be adjusted to a variety of widths and thicknesses, so that the die exit is dimensioned to have a ratio of width to thickness of about 48:1 to about 216:1, and so that a slurry passing through the extrusion die is extruded at a substantially similar thickness and width to that of the finished gypsum wallboard core; (c) at least one secondary inlet having a base connected at one of the lateral edges of the extrusion die, a top and an elongated tube between the top and the base, wherein the base, the top and the elongated tube form a conduit into the extrusion die to allow for the introduction of at least one gypsum slurry additive, which is an emulsion or fluid, directly to the extrusion die, so that the gypsum slurry additive can be added to a gypsum slurry passing through the extrusion die; (d) a substantially flat, movable surface disposed adjacent to the die exit; and (e) a dryer.