Transfer Plate Useful in the Manufacture of Panel and Board Products
The invention provides an apparatus for forming a panel comprising a mesh support and a transfer plate comprising at least one surface comprising a plurality of pores having an average pore diameter of about 1200 microns or less. The invention further provides a method comprising (i) forming an aqueous composition comprising a fiber material, (ii) depositing the composition onto a movable mesh support to form an entangled fiber material containing water; (iii) removing at least a portion of the water from the entangled fiber material, and (iv) transferring the entangled fiber material from the movable mesh support by passing it over a transfer plate, wherein the transfer plate comprises at least one surface comprising a plurality of pores having an average pore diameter of about 1200 microns or less.
1 . An apparatus for forming a panel comprising a movable mesh support and a transfer plate, wherein the transfer plate comprises at least one surface comprising a plurality of pores having an average pore diameter of about 1200 microns or less.
2 . The apparatus of claim 1 , wherein the pores of the transfer plate are in fluid communication with a source of pressurized air.
3 . The apparatus of claim 1 , wherein the pores of the transfer plate are in fluid communication with a source of water or steam.
4 . The apparatus of claim 2 , wherein air flows through the pores at an average pressure of about 0.05 psi to about 50 psi and an average air flow of about 0.1 cfm/ft 2 to about 200 cfm/ft 2 .
5 . The apparatus of claim 1 , wherein the surface of the transfer plate comprises about 1,500 holes per square inch or more.
6 . The apparatus of claim 1 , wherein the surface of the transfer plate comprises 2 or more compressed metal screens.
7 . The apparatus of claim 1 , wherein the surface of the transfer plate comprises stainless steel.
8 . The apparatus of claim 1 , wherein the surface of the transfer plate is coplanar with the support.
9 . The apparatus of claim 1 , wherein the transfer plate comprises two or more surfaces comprising a plurality of pores having an average pore diameter of about 1200 microns or less, wherein one porous surface is coplanar with the support, and a second porous surface is a leading edge surface.
10 . The apparatus of claim 1 , wherein the pores have an average pore diameter of about 200 microns or less.
11 . The apparatus of claim 1 , wherein the transfer plate extends across the width of the mesh support.
12 . The apparatus of claim 1 , wherein the apparatus comprises two or more transfer plates positioned side-by-side across the width of the mesh support.
13 . The apparatus of claim 12 , wherein each transfer plate has independent control of air flow rate and air pressure.
14 . The apparatus of claim 1 , further comprising a roller section, wherein the transfer plate is positioned between the mesh support and the roller section.
15 . A method for manufacturing a panel comprising:
(i) forming an aqueous composition comprising a fiber material,
(ii) depositing the composition onto a movable mesh support to form an entangled fiber material containing water;
(iii) removing at least a portion of the water from the entangled fiber material, and
(iv) transferring the entangled fiber material from the movable mesh support by passing it over a transfer plate,
wherein the transfer plate comprises at least one surface comprising a plurality of pores having an average pore diameter of about 1200 microns or less.
16 . The method of claim 15 , wherein the pores of the transfer plate are in fluid communication with a source of pressurized air.
17 . The method of claim 15 , wherein the surface of the transfer plate comprises 2 or more compressed metal screens.
18 . The method of claim 15 , wherein the surface of the transfer plate comprises stainless steel.
19 . The method of claim 15 , wherein the pores have an average pore size of about 200 microns or less.
20 . The method of claim 15 , wherein the aqueous composition further comprises a binder.
21 . The method of claim 15 , wherein the aqueous composition further comprises a lightweight inorganic aggregate.
22 . The method of claim 15 , wherein the transfer plate extends across the width of the mesh support.
23 . The method of claim 15 , wherein the surface of the transfer plate is coplanar with the mesh support.
24 . The method of claim 15 , wherein the surface of the transfer plate comprises about 1,500 holes per square inch or more.
25 . The method of claim 15 , wherein the entangled fiber material is transferred from the movable mesh support to a roller section.
26 . The method of claim 15 , wherein the panel is selected from the group consisting of an acoustical ceiling tile, an insulating panel, a sound absorbing wall panel, and a pipe and beam insulation panel.
27 . The method of claim 15 , wherein the fiber material is mineral fiber.
28 . A method for manufacturing a board product comprising:
(i) forming an aqueous composition comprising a cellulose fiber material and gypsum,
(ii) depositing the composition onto a movable mesh support;
(iii) heating the composition to convert gypsum to calcium sulfate hemihydrate;
(iv) removing at least a portion of the water from the composition, and
(v) transferring the composition from the movable mesh support by passing it over a transfer plate,
wherein the transfer plate comprises at least one surface comprising a plurality of pores having an average pore diameter of about 1200 microns or less.