Baffled donut apparatus for use in system and method for forming gypsum board

A system for introducing a slurry mixture for making gypsum board, the system comprising:

• a mixer constructed and arranged to mix slurry to a first flow rate and direct the mixed slurry to an exit gate;
• a foam injector constructed and arranged to inject foam into the mixed slurry in the exit gate to form a slurry mixture;
• a canister constructed and arranged to induce a swirl to the slurry mixture;
• and
• a funnel body constructed and arranged to induce turbulence into the slurry mixture, the funnel body being connected to the canister,
• wherein the funnel body extends in a longitudinal direction and has a top portion, a bottom portion, an inner wall, an outer wall, an inlet at a top portion thereof for receiving the slurry mixture from the canister, an outlet provided between the top portion and the bottom portion for outputting the slurry mixture, the inner wall comprising a first wall portion that slopes from the inlet opening towards the outlet opening and a second wall portion that extends from the outlet opening and towards the bottom portion, and a plurality of baffles projecting from the first wall portion of the inner wall towards a center of the funnel body, the plurality of baffles being spaced around the first wall portion of the inner wall, each baffle comprising a first side, a second side and a length extending between the inlet opening and the outlet opening, the first side of each baffle being provided adjacent the inlet opening and the second side of each baffle being provided adjacent the outlet opening, and
• wherein the plurality of baffles are configured to induce turbulence into the slurry mixture poured into the inlet from the canister as the slurry mixture moves towards the outlet before exiting the outlet for depositing onto paper to form the gypsum board.

A method for mixing a slurry mixture for making gypsum board, comprising:

• mixing a slurry at a first flow rate;
• directing the mixed slurry to an exit gate;
• injecting foam into the mixed slurry in the exit gate to form a slurry mixture;
• inducing a swirl to the slurry mixture;
• induce turbulence into the slurry mixture;
• and
• depositing the slurry mixture via an outlet of a funnel body onto paper to form the gypsum board,
• wherein the method is implemented with a system including a mixer constructed and arranged to mix the slurry to the first flow rate and direct the mixed slurry to the exit gate, a foam injector constructed and arranged to inject the foam into the mixed slurry in the exit gate to form the slurry mixture, a canister constructed and arranged to induce the swirl to the slurry mixture;
• and a funnel body constructed and arranged to further induce the turbulence into the slurry mixture, the funnel body extending in a longitudinal direction and having a top portion, a bottom portion, an inner wall, an outer wall, an inlet for receiving the slurry mixture from the canister, the outlet provided between the top portion and the bottom portion, the inner wall comprising a first wall portion that slopes from the inlet opening towards the outlet opening and a second wall portion that extends from the outlet opening and towards the bottom portion, and a plurality of baffles projecting from the first wall portion of the inner wall towards a center of the funnel body, the plurality of baffles being spaced around the first wall portion of the inner wall and configured to induce turbulence into the slurry mixture poured into the inlet from the canister as the slurry mixture moves towards the outlet, each baffle comprising a first side, a second side and a length extending between the inlet opening and the outlet opening, the first side of each baffle being provided adjacent the inlet opening and the second side of each baffle being provided adjacent the outlet opening.