Apparatus and methods for producing gypsum wallboard

Patent metadata

Field	Value
Publication number	US-9745222-B2
Application number	US-201514807111-A
Country	US
Kind code	B2
Filing date	Jul 23, 2015
Priority date	Jul 23, 2015
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

An apparatus for production of a gypsum product is provided which comprises a conveyer comprising a conveyer belt and means for rotating the conveyer belt; means for forming a gypsum product; and at least one laser scanner positioned over the conveyer belt at the location where the scanner scans at least one edge of the gypsum product which is at least partially set; and the laser scanner is in communication with a processor. Methods for forming a gypsum product with the apparatus are provided as well.

First claim

What is claimed is:

1. A method for producing a gypsum product, the method comprising:
feeding a first sheet of paper on a conveyer belt;
depositing gypsum slurry on the first sheet of paper;
covering the gypsum slurry with a second sheet of paper;
forming a gypsum panel;
allowing the gypsum panel to set at least partially while the gypsum panel is moving on the conveyer belt; and
scanning with a laser scanner at least one edge of the gypsum panel as it is moving on the conveyer belt and passes the location at which the laser scanner is located; wherein the laser scanner transmits scans to a processor, and the processor is equipped with a software which calculates an edge angle of the gypsum product and a deviation in the value of the edge angle calculated from a pre-specified value for the edge angle; and wherein if the calculated deviation is larger than a pre-specified value, the gypsum slurry is reformulated to even its distribution between the first sheet of paper and the second sheet of paper.

2. The method of claim 1 , wherein the laser scanner is a three-dimensional laser scanner.

3. The method of claim 1 , wherein the laser scanner transmits scans to a processor wirelessly.

4. The method of claim 1 , wherein the laser scanner transmits scans to a processor and the processor is equipped with a software which calculates an edge angle of the gypsum product and a deviation in the value of the edge angle from a pre-specified value for the edge angle and wherein the pre-specified value is 90°.

5. The method of claim 1 , wherein the laser scanner transmits scans to a processor, and the processor is equipped with a software which calculates an edge angle of the gypsum product and a deviation in the value of the edge angle from a pre-specified value for the edge angle, and wherein the software generates a signal when the deviation is larger than the pre-specified value.

6. The method of claim 1 , wherein the laser scanner transmits data about the left and the right edges of the gypsum panel.

7. The method of claim 1 , wherein the laser scanner transmits scans of at least one edge and the width of the gypsum panel to a processor.

Assignees

• United States Gypsum Co

Inventors

• Eversole Leslie
• Dellangelo Scott
• Lash Jason

Classifications

• B28B5/027 Primary

  the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed (feeding B28B13/02) · CPC title

• C04B11/00 Primary

  Calcium sulfate cements · CPC title

• G01B11/26

  for measuring angles or tapers; for testing the alignment of axes · CPC title

• B32B37/142

  Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket · CPC title

• G01B11/046

  for measuring width · CPC title