Abstract:
A cementitious slurry mixing and dispensing system includes a slurry mixer that agitates and forms aqueous cementitious slurry, a discharge conduit in communication with the mixer and forming an interior surface defining a slurry flow path to convey the slurry therethrough to an outlet, a distribution mat disposed proximally to the outlet, a vibrating plate supporting the distribution mat, an overhead bracing system from which the vibrating plate is suspended, and a plurality of support members coupled between the overhead bracing system and the vibrating plate. The vibrating plate is adapted to impart vibrational forces on the distribution mat to promote movement of the aqueous slurry. Each support member includes a rod, a hollow coupling member, and at least one resilient bushing assembly adapted to dampen the vibrational forces exerted by the vibrating plate, thereby isolating the rod and the overhead bracing system from the vibrational forces.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure generally relates to production of wallboard and, more particularly, to devices for managing vibrations in a production machine. 
       BACKGROUND 
       [0002]    In many types of cementitious articles, set gypsum (calcium sulfate dehydrate) is often a major constituent. For example, set gypsum is a major component of end products created by use of traditional plasters (e.g., plaster surfaced internal building walls), and also in faced gypsum board employed in drywall construction of interior walls and ceilings of buildings. Typically, such gypsum-containing cementitious products are made by preparing a mixture of calcined gypsum (calcium sulphate alpha or bet hemihydrate and/or calcium sulfate anhydrite), water, and other components, as desired, to form cementitious slurry. 
         [0003]    Typically, a cementitious article such as wallboard or gypsum board is manufactured by uniformly dispersing calcined gypsum in water to form an aqueous calcined gypsum slurry. This slurry is typically produced in a continuous manner by inserting the calcined gypsum, water, and other additives into a mixer which contains any number of apparatuses for agitating the contents to form a uniform gypsum slurry. The slurry is directed toward and through a discharge outlet of the mixer and into a discharge conduit. A stream of slurry passes through the discharge conduit and out of a distribution mat supported by a forming table. As the slurry passes through the distribution mat and onto a conveyor belt, it is evenly distributed therethrough. The slurry then travels on the conveyor belt for further processing and/or to be formed as a final wallboard product. In some known systems, the system can include components that impart vibrational forces on the distribution mat to ensure the slurry does not get stuck or clogged. Depending on the construct of the system, however, repeated application of vibratory forces can damage the mechanical components and connections. 
       SUMMARY 
       [0004]    In accordance with one or more aspects, systems and approaches for mounting components in a slurry distribution system may address the need for a strong and effective device. These components can provide isolation control for extended periods of time before failure, thereby allowing the system to operate in an efficient manner. Components in the system can be easily swappable, thus requiring little downtime in the event of material failures. Further, components can be constructed and arranged in a way that, in the event of component failure, still provides support for all system components, thus reducing or eliminating the occurrence of damage to sensitive components. 
         [0005]    In accordance with a first exemplary aspect, a cementitious slurry mixing and dispensing system may include a slurry mixer adapted to agitate a cementitious material and water to form aqueous cementitious slurry, a discharge conduit in fluid communication with the slurry mixer, the discharge conduit forming an interior wall surface defining a slurry flow path which conveys aqueous cementitious slurry therethrough to an outlet, a distribution mat disposed proximally to the outlet of the discharge conduit, a vibrating plate supporting the distribution mat, the vibrating plate adapted to impart vibrational forces on the distribution mat to promote movement of the aqueous cementitious slurry therethrough, an overhead bracing system from which the vibrating plate is suspended, and a plurality of support members coupled between the overhead bracing system and the vibrating plate. In many forms, the discharge conduit is constructed from a resilient material. The distribution mat is adapted to evenly distribute the aqueous cementitious slurry onto a moving conveyor belt. 
         [0006]    In these forms, each of the support members includes a rod, a hollow coupling member, and at least one resilient bushing assembly. An upper end portion of the rod is fixed to the overhead bracing system and a lower end portion of the hollow coupling member is coupled to the vibrating plate. The resilient bushing assembly is mounted between the lower end of the rod and the upper portion of the hollow coupling member. The resilient bushing assembly is adapted to dampen the vibrational forces exerted by the vibrating plate, thereby isolating the rod and the overhead bracing system from the vibrational forces. 
         [0007]    The resilient bushing assembly can include an outer bumper constructed of a resilient material and an inner core. The outer bumper defines an opening therethrough, and the inner core is disposed therein. The inner core constructed of a rigid material. In some examples, the inner core is adapted to maintain the distribution mat at the desired vertical orientation if the outer bumper experiences a material failure. The resilient bushing assembly can also include any number of components such as support washer disposed below the upper portion of the hollow coupling member to provide an additional form of support. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The above needs are at least partially met through provision of the slurry distribution system isolation mounting system described in the following detailed description, particularly when studied in conjunction with the drawings, wherein: 
           [0009]      FIG. 1  comprises a perspective view of an exemplary slurry distribution system using an isolation mounting support member in accordance with various embodiments of the invention; 
           [0010]      FIG. 2  comprises a front elevation view of an exemplary support member of the slurry distribution system of  FIG. 1  in accordance with various embodiments of the invention; 
           [0011]      FIG. 3  comprises a front elevation view of the exemplary support member of  FIG. 2  upon experiencing material failure of the resilient bushing assembly in accordance with various embodiments of the invention; and 
           [0012]      FIG. 4  comprises a perspective view of an exemplary resilient bushing assembly of the slurry distribution system of  FIGS. 1-3  in accordance with various embodiments of the invention. 
       
    
    
       [0013]    The figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein. 
       DETAILED DESCRIPTION 
       [0014]    Generally speaking, the present disclosure relates to a slurry distribution system (SDS)  100  for manufacturing wallboard (e.g., drywall) panels and, also an isolation mounting system  150  for the SDS  100 . As illustrated in  FIG. 1 , the SDS  100  includes a slurry mixer  102 , a discharge conduit  106 , a distribution mat, pouch, or bladder  110 , a vibrating plate  130 , an overhead bracing system  140 , and any number of isolation mounting systems or support members  150 . The system  100  can include any number of additional components and/or subsystems known to those having skill in the art and will not be described herein for the sake of brevity. Some examples of SDSs and SDS components that may be part of the SDS  100  of the present disclosure are disclosed in U.S. Publication No. 2012/0168527; U.S. Publication No. 2013/0098268; and U.S. Publication No. 2015/0231799, the contents of which are herein incorporated by reference in their entirety. 
         [0015]    The slurry mixer  102  can be any type of mixer (e.g., a pin mixer, a paddle mixer, an auger mixer, a vibratory mixer, a barrel mixer, etc.) adapted to agitate and combine a number of ingredients to form an aqueous cementitious slurry. Other examples of mixers are possible. The slurry mixer  102  includes an inlet  103  for receiving the ingredient or ingredients, an outlet  104  for transferring the ingredients therefrom, and a flow path extending between the inlet  103  and the outlet  104 . The mixer  102  can also include any number of mixing apparatuses therein such as a number of paddles and/or blades to assist in mixing any materials added thereto. In some examples, the mixer  102  may use any number of augers or rotating screws to incorporate and mix the materials. Other examples as well as combinations of these examples of mixing apparatuses are possible. The mixing apparatus contained in the slurry mixer  102  may be mounted in any number of configurations (such as, for example, horizontally or vertically) which are disposed in the flow path. 
         [0016]    The materials can be supplied to the slurry mixer  102  at the inlet  103  via one or more feeding tanks, inlets, hoppers, conveyors, or other devices as known in the art. Examples of materials can include a cementitious material, water, additives, and any number of additional ingredients. In some examples, the ingredients include any number of minerals, pigments, starches, thickeners, anti-bacterial, dyes, and other commonly known materials. The wet ingredients  104  can include water, latex, defoamers, dispersants, as well as any other commonly known materials. It is understood that in some examples, a subset of materials may be separately fed to the system  100  after the mixed composition exits the outlet  104 . For example, a defoamer may be added to the mixed composition after the ingredients have been mixed together to form the mixed composition. 
         [0017]    The discharge conduit  106  includes an inlet  107  in fluid communication with the outlet  104  of the mixer  102  and an outlet  108 . The discharge conduit  106  can be constructed of a material such as, for example, PVC or urethane. Other examples are possible. The discharge conduit  106  extends in a longitudinal direction and has a sidewall portion and an interior wall surface (not shown). The interior wall surface defines a slurry passage or flow path  109  which conveys the aqueous cementitious slurry therethrough. The discharge conduit  106  can be bifurcated or otherwise split into a number of distinct parallel tubes which may be separated or joined at any point along the flow path  109 . Any suitable approach for forming the discharge conduit  106  can be used. For example, a multi-piece mold can be used to make the conduit  106  from a flexible material. Other examples are possible. 
         [0018]    The distribution mat  110  is disposed proximal to the outlet  108  of the discharge conduit  106 . The distribution mat  110  can be a bladder or pouch having an open end  111  allowing the slurry to exit therethrough in a manner described herein. The distribution mat  110  receives the aqueous cementitious slurry from the discharge conduit  106  and evenly distributes the slurry onto the moving conveyor belt  112 . 
         [0019]    A grate or upper plate  114  can be adjustably disposed above the distribution mat  110 . The grate  114  acts to prevent the distribution mat  110  from expanding in a vertical direction, and thus maintains the distributed slurry at a uniform thickness as it exits the outlet  111 . The grate  114  can include webbing or openings  116  having any desired shape, size, and orientation and allows the distribution mat  110  to be slightly deformed to reduce the possibility of the slurry becoming stuck or clogged upon exiting the distribution mat  110 . 
         [0020]    The vibrating plate  130  can be constructed of any suitable material such as, for example, steel, aluminum, plastic, or other metals. The vibrating plate is operably coupled to support the distribution mat  110  and can include any number of motors  132  such as vibrators, agitators, or other devices capable of imparting a vibratory force on the distribution mat  110  to assist with maintaining a continuous flow of slurry therethrough. The vibrating plate  130  can include any number of coupling portions disposed along an outer perimeter thereof. 
         [0021]    The overhead bracing system  140  can include any type of support system, and is adapted to support the distribution mat  110 , the grate  114 , the vibrating plate  130 , and any other desired components. The overhead bracing system  140  can be constructed from high-strength materials such as steel, titanium, aluminum, and the like. Other examples are possible. In the example illustrated in  FIG. 1 , the overhead bracing system  140  includes a central cross-member  142  and a number of lateral arms  143  extending therefrom. Each arm  143  includes a vertical support  144  depending downwardly therefrom and having a receiving end  145  that receives the support member  150 . The central cross-member  142  is coupled to a vertical post  146  which can then be fixed to the ground of the environment, for example, for a solid foundation. In other examples, the overhead bracing system  140  can be mounted using any number of additional components and/or techniques known to those skilled in the art. 
         [0022]    As shown in  FIG. 2 , each support member  150  can include a rod  152  having an upper end  153  and a lower end  154 , a hollow coupling member  156  having an upper portion  157  and a lower portion  158 , and a resilient bushing assembly  170 . The rod  152  can be constructed of any suitable material such as steel or aluminum. In some examples, all or a portion of the rod  152  can be threaded and thus can be threadably inserted into the receiving end  145  of the vertical support  144 . Any length of the rod  152  can be inserted into the receiving end  145  of the vertical support  144 , thus the overall length of the support member  150  is variable as desired. It is understood that the upper end  153  of the rod  152  can be coupled to the vertical support  144  using type of known connector. In one example, the overall length of the support member  150  can be adjusted between approximately 3 inches and 30 inches. Other lengths are possible. 
         [0023]    The hollow coupling member  156  can be constructed of any suitable material such as, for example, steel or other metals. As illustrated in  FIG. 2 , the hollow coupling member  156  can be generally rectangular when viewed from a front elevation view. In alternative embodiments, the cross section of the hollow coupling member  156  may have a shape other than rectangular. For example, the hollow coupling member  156  can have a circular, parabolic, ovaloid, triangular, trapezoidal, or any other shape. The top and bottom portions  157 ,  158  of the hollow coupling member  156  have a central hole or opening  157   a ,  158   a , respectively. The opening  157   a  in the top portion  157 . The opening  158   a  in the bottom portion  158  is dimensioned appropriately to accept a fastener  166 , as will be discussed below. In some embodiments, the corners  159  of the hollow coupling member  156  may be curved, chamfered, or otherwise angled to reduce the occurrence of material failure at these locations. 
         [0024]    As shown in  FIG. 4 , the resilient bushing assembly  170  can be constructed from one or more portions. The resilient bushing assembly  170  in the depicted version includes a first portion  170   a  and a second portion  170   b . Here, the first portion  170   a  is positioned above the second portion  170   b  relative to the orientation of  FIG. 4 . In other examples, the portions  170   a ,  170   b  of the resilient bushing assembly  170  may be separate and not coupled to each other, or the bushings may be entirely separate components, or the bushing assembly may be a one-piece integral component. 
         [0025]    The first portion  170   a  can include an outer bumper  172   a  constructed of any number of resilient materials such as, for example, rubbers, polymers, cork, foam, or any other suitable material having dampening capabilities. The outer bumper  172   a  defines a through bore  171   a  extending between a top surface  176   a  and a bottom surface  177   a  thereof. An inner core  174   a  constructed of a rigid material (such as, for example, steel or other metals) is disposed in the bore  171   a . This inner core  174   a  itself defines a central bore  175   a  that extends coaxially with the through bore  171   a  of the outer bumper  172   a  and has a cylindrical shape through which the rod  152  can pass. In some examples, the resilient bushing assembly  170  may not include an inner core  174 , and the rod  152  passes directly through the bore  171   a  in the bumper  172   a . As shown in  FIG. 4 , the first portion  170   a  of the bushing assembly  170  of the present version may also include an inner portion  178  consisting of a first segment  178   a  and a neck or shoulder portion  178   b  extending beneath the outer bumper  172   a . In some versions, the inner portion  178  can be part of the outer bumper  172   a , the inner core  174   a , or both. 
         [0026]    The second portion  170   b  of the resilient bushing assembly  170  can also include an outer bumper  172   b  which defines a through bore  171   b  extending between a top surface  176   b  and a bottom surface  177   b  thereof. In some versions, an inner core  174   b  constructed of a rigid material can be disposed in the bore  171   b , but this is not necessary. This inner core  174   b  defines a central bore  175   b  having a cylindrical shape. When assembled into the larger system, as will be described, the first portion  170   a  and the second portion  170   b  can be coupled together by inserting the first segment  178   a  of the inner portion  178  of the first portion  170   a  of the bushing assembly  170  into the central bore  175   b  of the second portion  170   b  of the bushing assembly  170 . In some versions, the first segment  178   a  of the inner portion  178  is friction fit or otherwise secured into the central bore  175   b.    
         [0027]    In one example, the resilient bushing assembly  170  may be a McMaster-Carr Versa-Mount Vibration-Damping Mount having part number 6309K34. This bushing  170  has a compression capacity of 130 pounds and a total deflection of 0.07″ at this maximum compression capacity, a shear force capacity of 50 lbs. with a maximum deflection of 0.02″ at this force, an overall height of approximately 1.94″, an outer diameter of 1.88″, an inner diameter of 0.53″, an inner portion  178  outer diameter of 1.30″, an inner portion  175  length of 0.56″, and an outer bumper  172   a ,  172   b  length of 0.78 inches. 
         [0028]    To couple the support member  150  to the system  100 , the upper end  153  of the rod  152  is coupled to the receiving end  145  of the vertical support  144  in a manner as previously described. The first segment  178   a  of the inner portion  178  of the first portion  170   a  of the bushing assembly  170  is inserted into the central hole  157   a  formed through the top portion  157  of the hollow coupling member  156 , and the second portion  170   b  of the bushing assembly  170   b  is friction fit (or otherwise coupled) onto the first segment  178   a  of the inner portion  178  as described above. That is, the neck or shoulder portion  178   b  of the inner portion  178  may act as a stop for the second portion  170   b , and may be have an axial dimension equal to the thickness of the top portion  157  of the coupling member  156 . Accordingly, the first portion  170   a  of the resilient bushing assembly  170  may rest against the upper surface of the top portion  157 . Any number of washers  165 , seals, O-rings, or grommets may be disposed between the fasteners  160 ,  162 , the upper portion  157  of the hollow coupling member  156 , and the resilient bushing assembly  170 . 
         [0029]    In this manner, the bushing assembly  170  is effectively coupled to the hollow coupling member  156 . Then, the lower end  154  of the rod  152  is inserted through the central bore  175   a  of the first portion  170   a  of the resilient bushing assembly  170 , which too extends through the central hole  157   a  in the top portion  157  of the hollow coupling member  156 , and then through the central bore  175   b  of the second portion  170   b  of the resilient bushing assembly  170 . So configured, the rod  152  is slidably disposed in the bushing assembly  170 , which is coupled to the hollow coupling member  156 , such that the bushing assembly  170  and hollow coupling member  156  can move relative to the rod  152  and vice versa. A first fastener  160  secures the first portion  170   a  of the resilient bushing assembly  170  to the top portion  157  of the hollow coupling member  156 . In the example illustrated in  FIGS. 2 and 3 , the first fastener  160  is a nut which threadably engages the rod  152 . Other examples of suitable fasteners are possible. A second fastener  162  can be used to couple the second portion  170   b  of the resilient bushing assembly  170  to a lower surface of the top portion  157  of the hollow coupling member  156 . As seen in  FIG. 2 , the first and second fasteners  160 ,  162  limit axial displacement of the rod  152  relative to the bushing assembly  170  and hollow coupling member  156 . 
         [0030]    As seen in  FIG. 3 , the lower portion  158  of the hollow coupling member  156  is coupled to a portion of the vibrating plate  130 . A plate fastener  166  which, in some embodiments, may be inserted through an opening of the vibrating plate  130  and through the hole  158   a  of the lower portion  158 . A fastener  164  may then be used to secure the lower portion  158  to the vibrating plate  130 . Any number of washers  167 , seals, O-rings, or grommets  169  may be disposed between the fasteners  164 ,  166 , the lower portion  158 , and the vibrating plate  130 . Any number of additional fasteners  164  or configurations may be used to provide a secure coupling between the vibrating plate  130  and the hollow coupling member  156  such as, for example, via a number of clamping devices. In alternative versions, the hollow coupling member  156  may be secured or affixed to the vibrating plate  130  via any number of approaches such as welding, riveting, and the like. Other examples are possible. Additionally, support washers  165 ,  167  may be disposed in various positions along the rod  162 . So configured, the hollow coupling member  156  is coupled to and supports the vibrating plate  130  in a suspended vertical position. 
         [0031]    When the aqueous cementitious slurry is being mixed and pumped along the flow path  109 , the motor  132  is engaged to vibrate the vibrating plate  130 . As a result, the distribution mat  110 , which is supported by the vibrating plate  130 , also receives the vibrations. Accordingly, the aqueous cementitious slurry experiences this vibrational force while flowing through the distribution mat  110  towards the opening  111 , and as a result, clogging of the distribution mat  110  is minimized due to the constant movement exerted by the vibrating plate  130 . 
         [0032]    When the vibrating plate  130  vibrates, the vibrational forces are transmitted through the hollow coupling member  156  and are dampened and absorbed by the outer bumper  172   a ,  172   b  of the resilient bushing assembly  170 . Accordingly, the vibrational forces are not transmitted along the rod  152  to the overhead bracing system  140 , thereby isolating the rod  152 , the vertical bracing system  140 , and any other components from experiencing vibrations. 
         [0033]    Upon operating the system  100  for extended periods of time, the vibrational forces imparted on the resilient bushing assembly  170  may eventually cause some amount of material failure, breaking, or compression of the outer bumper  172   a ,  172   b . In the event that the outer bumper  172   a ,  172   b  does fail (as illustrated in  FIG. 3 ), the inner core  174   a ,  174   b  (as illustrated in 
         [0034]      FIG. 4 ) remains intact and thus will continue to support the hollow coupling member  156  and the vibrating plate  130 . The support washer  165  may assist in providing continued support of the hollow coupling member  156  upon failure of the resilient bushing assembly  170  in order to maintain the vertical positioning of the vibrating plate  130 . Accordingly, even if the outer bumper  172   a ,  172   b  fails, the version of the support member  150  disclosed herein will continue to suspend the vibrating plate  130  at its original vertical position, and thus will minimize any damage associated with the vibrating plate  130  and/or the distribution mat  110  falling onto the conveyor belt  112  or otherwise moving abruptly. 
         [0035]    So configured, each support member  150  is adapted to withstand a force (e.g., a vibrational force, a weight of the vibration plate  130 , or any combination of the two) between approximately 5 lbs and approximately 500 lbs. By using multiple support members  150  coupled to the overhead bracing system  140 , the cumulative amount of force capable of being supported is proportional to the number of support members  150  in use. 
         [0036]    It is understood that while the support member  150  thus far disclosed will continue to support the vibrating plate  130  upon failure or compression of the outer bumper  172   a ,  172   b , the vibrational forces will not be isolated from the overhead bracing system  140 . Accordingly, replacement of the resilient bushing assembly  170  will be desired. The damaged resilient bushing assembly  170  can be easily replaced by uncoupling the support member  150  from the vertical hollow coupling member  156 . 
         [0037]    Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.