Method of forming gypsum board, method of analyzing gypsum core, and gypsum core analysis tool

Abstract

The present disclosure generally relates to methods of analyzing and manufacturing gypsum boards (100), e.g., suitable for use as building surface products. The present disclosure more particularly relates to a method of forming a gypsum board (100). The method includes forming a porous slurry layer (144) on a receiving surface (102) using a plurality of operating parameters; and solidifying the porous slurry layer (144) to form a gypsum core (104) of the gypsum board (100). The plate is then cut (e.g., cut by a router 128) to form a cut surface (108) extending through the gypsum core (104), and an image of an area of the cut surface (108) is captured by a camera (152). The image is analyzed to identify bubbles that intersect the cut surface (108). A bubble contact measure in the gypsum core (104) is then calculated from the identified bubbles in the image. Based on the bubble contact measure, an operating parameter for forming the porous slurry layer (144) is modified.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of priority of European Patent Application No. 22306490.8, filed on October 5, 2022, which is hereby incorporated by reference in its entirety. Background of the Invention 1. Field of the Technology

[0003] The present disclosure generally relates to methods of analyzing and manufacturing, for example, gypsum boards suitable for use as building surface products. The present disclosure more particularly relates to a method of forming a gypsum board and a method of analyzing a gypsum core. 2. Background Art

[0005] The properties of gypsum make it very suitable for use in building surface products such as gypsum boards. Gypsum is an abundant material and is generally inexpensive. In addition, through successive steps of dehydration and rehydration, gypsum can be cast, molded, or otherwise formed into useful shapes. For example, many interior walls are formed using gypsum boards that include a solidified gypsum core sandwiched between facing sheets.

[0006] To reduce the weight of a gypsum board, the gypsum core within the board typically includes a distribution of air bubbles. The air bubbles displace a certain proportion of the solid material of the board, making the board lighter and easier to handle. Although the air bubbles may limit certain performance characteristics of the gypsum board, such as the mechanical strength of the board, it is possible to control the addition of air bubbles in the gypsum core such that the advantage of weight reduction outweighs any undesirable consequences that the air bubbles may have on the performance characteristics of the gypsum board. For example, controlling both the size of the air bubbles and the total density of the gypsum board affects the performance characteristics of the board.

[0007] However, the inventors have determined that these properties of the air bubbles are not the determining factors in the performance of gypsum boards, and that other properties of the air bubbles within the gypsum core may affect performance. Summary of the Invention

[0008] In one aspect, the present disclosure provides a method of forming a gypsum board, the method comprising:

[0009] forming a porous slurry layer on a receiving surface using a plurality of operating parameters, wherein forming the porous slurry layer comprises:

[0010] combining plaster and water in a mixer,

[0011] adding foam to the plaster material and water,

[0012] agitating the plaster, water, and foam in the mixer to form a slurry, and

[0013]

[0014] ​Distribute the slurry on a receiving surface;

[0015] Solidify the porous slurry layer to form a gypsum core of a gypsum board;

[0016] Form a cut surface extending through the gypsum core;

[0017] Capture an image of an area of the cut surface;

[0018] Analyze the image to identify bubbles with a diameter of at least 50 μm that intersect the cut surface;

[0019] Determine a set of contacting bubbles from the identified bubbles, where each contacting bubble in the set of contacting bubbles contacts at least one other bubble;

[0020] Based on the set of contacting bubbles, determine a bubble contact measure in the gypsum core based on the identified bubbles in the image; and

[0021] Optionally, based on the bubble contact measure, modify a first operating parameter among a plurality of operating parameters for forming the porous slurry layer on the receiving surface.

[0022] In another aspect, the present disclosure provides a computer-implemented method for analyzing a gypsum core, the method comprising:

[0023] Receive an image of an area of a cut surface of the gypsum core;

[0024] Identify bubbles with a diameter of at least 50 μm in a portion of the image;

[0025] Identify a set of contacting bubbles, where each contacting bubble in the set of contacting bubbles contacts at least one other bubble; and

[0026] Based on the set of bubbles, determine a bubble contact measure in the gypsum core.

[0027] In another aspect, the present disclosure provides a non-transitory computer-readable medium having program instructions stored thereon, the program instructions, when executed by a processor, cause a set of operations to be performed to execute the method for analyzing a gypsum core according to the present disclosure.

[0028] In another aspect, the present disclosure provides a computing device, the computing device comprising:

[0029] A processor; and

[0030] A non-transitory computer-readable medium according to the present disclosure.

[0031] In another aspect, the present disclosure provides a gypsum core analysis tool, the gypsum core analysis tool comprising:

[0032] A camera configured to capture an image of an area of a cut surface of a gypsum core; and

[0033] A computing device according to the present disclosure.

[0034] Other aspects of the present disclosure will be apparent in light of the disclosure herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The drawings are included to provide a further understanding of the methods and apparatuses of the present disclosure and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and the dimensions of various elements may be distorted for clarity. The drawings illustrate one or more embodiments of the present disclosure and, together with the description, serve to explain the principles and operations of the present disclosure.

[0036] Figure 1 is a schematic view of a mixer used in a process according to an embodiment of the present disclosure;

[0037] Figure 2 is a schematic view of a system for forming a gypsum board according to an embodiment of the present disclosure;

[0038] Figure 3 is a schematic view of a method for forming a cut edge in a gypsum board according to an embodiment of the present disclosure;

[0039] Figure 4 is a schematic view of a gypsum board characterization tool according to an embodiment of the present disclosure;

[0040] Figures 5 to 7 is a schematic view of an image analysis according to an embodiment of the present disclosure;

[0041] Figure 8 is a schematic view of an image analysis according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0042] As described above, the inventors have determined that bubble size and gypsum density are not the only characteristics related to bubbles that can affect the performance parameters of gypsum boards.

[0043] Accordingly, one aspect of the present disclosure is a method of forming a gypsum board. The method includes forming a porous slurry layer on a receiving surface using a plurality of operating parameters. Forming the porous slurry layer includes: combining plaster and water in a mixer, adding foam to the plaster and water, agitating the plaster material, water, and foam in the mixer to form a slurry, and distributing the slurry on the receiving surface. The porous slurry layer is then solidified to form the gypsum core of the gypsum board. A cut edge is then formed that extends across the gypsum core. An image of an area of the cut surface is then captured. The image is analyzed to identify bubbles in the gypsum core that intersect the cut surface and have a diameter of at least 50 μm. A set of contacting bubbles is determined from the identified bubbles, where each contacting bubble in the set of contacting bubbles contacts at least one other bubble. Based on the set of contacting bubbles, a bubble contact measure in the gypsum core is then determined based on the identified bubbles in the image. Based on the bubble contact measure, a first operating parameter among the plurality of operating parameters used to form the porous slurry layer on the receiving surface is modified.

[0044] Figures 1 to 8 An embodiment of such a method is shown. Figure 1 A mixer 110 for forming a slurry 120 is shown, which slurry is subsequently dispersed on a forming table and dried to form a gypsum board, as explained in more detail below. The mixer 110 receives plaster 122 through a conduit 112 or another feed source, and receives water 123 through a separate conduit 113. Various additives can also be added to the slurry, which additives are either added with the plaster material, with the water, or independently to the mixer. The mixer 110 rotates at a fixed or adjustable speed to combine the plaster material 122 and water 123 into a slurry that can be spread to form the shape of a gypsum board. In some embodiments, the mixer 110 includes an agitator 115 having one or more blades or paddles for agitating the slurry. Additionally, in some embodiments, the entire container 111 of the mixer 110 rotates. Thus, rotation of the mixer can refer to the agitator within the mixer or the container itself.

[0045] As used herein, the term "plaster" refers to a calcium sulfate material that is predominantly (i.e., at least 50 wt%, desirably at least 75 wt%) calcium sulfate hemihydrate, but typical real-world samples also include anhydrous calcium sulfate, calcium sulfate dihydrate (referred to as "gypsum"), and various impurities. Plaster is typically produced by calcining a gypsum raw material to convert the calcium sulfate dihydrate to the hemihydrate; thus, it is also referred to in the art as "calcined gypsum" or "calcined plaster".

[0046] In some embodiments, the stucco added to the mixer is ready to be used as plaster of Paris by grinding and calcining at a relatively low temperature (such as about 120 °C to 170 °C) and at about atmospheric pressure. The stucco is combined with water to form a slurry, and then the slurry is spread into a desired shape. The slurry is then solidified by recrystallization to form a board.

[0047] In addition to the stucco 122 and water 123, foam 124 is also added to the mixer 110 through the nozzle 114. The inclusion of the foam 124 adds air bubbles to the slurry, and at least some of the air bubbles remain in the finished gypsum board. The air bubbles generated by the foam reduce the density of the finished gypsum board, thereby providing a lighter product that is easier to transport and handle during installation, and reducing the total weight of the finished structure. On the other hand, the size and distribution of the air bubbles also affect the performance characteristics of the core of the produced gypsum board, and thus the amount of foam selected may require a balance between competing characteristics and performance.

[0048] As will be understood by those of ordinary skill in the art, the foam is provided as an aqueous surfactant that has been aerated (or otherwise has bubbles formed therein). A variety of surfactants are known in the art for providing such foam. The surfactant is typically one or more of an alkyl sulfate (e.g., lauryl sulfate) and an alkyl ether sulfate (e.g., ethoxylated lauryl alcohol sulfate), see, for example, U54156615, U55085929, U55116671, US5643510, US6706128, US7033431, US7220373.

[0049] In some embodiments, the foam is generated using a foam generator upstream of the nozzle 114. For example, the surfactant that generates the foam is diluted with water and then mixed with compressed air in the foam generator. The resulting foam is then injected into the mixer through the nozzle 114. In some embodiments, the foam generator is a static foam generator, for example, including a tube filled with a permeable porous medium (such as sintered glass or ceramic packing beads with controlled pore spaces). The foam is then generated by injecting a blend of the foaming agent, water, and air into the tube. In some embodiments, the structure of the generated foam can be controlled by adjusting the back pressure applied to the tube.

[0050] In other embodiments, the foam generator is a dynamic foam generator, for example, including an internal rotating mechanism (for thoroughly mixing water, air, and the foaming agent to generate foam). In some cases, the rotating blades can be equipped with a mixing chamber that allows the nucleation of foam bubbles.

[0051] In some embodiments, additives are added to the slurry during the manufacturing process. Such additives can include retarders, accelerators, fiber materials, and starches. These additives can be added at various stages during the mixing process, such as through separate inlets, or can be added to the water, stucco, or foam before they are added to the mixer.

[0052] Although Figure 1 the mixer 110 shown in includes a single chamber for receiving all of the water, stucco, and foam added to the slurry, in other embodiments, the mixer includes multiple chambers that can receive different amounts of slurry components and are capable of processing the slurry in different ways. For example, in some embodiments, the mixer includes various chambers that provide the slurry at different densities. Additionally, although Figure 1 the mixer is shown receiving each of the various components from a single source, in other embodiments, the mixer is configured to receive at least one of the components from multiple sources, for example, through different conduits.

[0053] Figure 2 A system for producing gypsum board is schematically depicted in accordance with an example embodiment. System 130 includes a first supply roll 132 of a sheet of material that forms a lower facing sheet 102 of the finished gypsum board. The facing sheet 102 can be formed of a fiber mat, paper, or film. In some embodiments, the facing sheet is configured to be impregnated with a gypsum slurry, while in other embodiments, the slurry is applied to the upper (or inner) surface of the facing sheet.

[0054] The lower facing sheet 102 is unwound from the first supply roll 132 and is pulled through a number of forming stations 134 of the system 130. In some embodiments, after being removed from the supply roll, the lower facing sheet is creased or otherwise processed to include a suitable geometry at the edges of the facing sheet, thereby forming the sides of the gypsum board.

[0055] As the lower facing sheet 102 is pulled through the forming stations 134, a first dense slurry layer 142 is deposited onto the upper surface of the lower facing sheet 102. The first slurry outlet 116 of the mixer 110 distributes the dense slurry onto the upper surface of the lower facing sheet 102, and a pair of roll coaters 133 spreads and applies the dense slurry to form the first dense slurry layer 142. In some embodiments, in the case where the lower facing sheet is porous, the roll coaters 133 can also press the slurry into the openings within the facing sheet in order to penetrate the facing sheet and cover both its inner and outer surfaces.

[0056] The lower facing sheet 102 advances through the forming table 134 to the second slurry outlet 117, where the aerated slurry 120 from the mixer 110 is applied to the first dense slurry layer 142 on the lower facing sheet 102. The aerated slurry 120 has a lower density than the first dense slurry layer 142 and includes a greater proportion of air bubbles. The vibrator 135 located between adjacent forming tables 134 helps to evenly distribute the aerated slurry 120 over the first dense slurry layer 142 to form a porous slurry layer 144 on the lower facing sheet 102. Upon solidification, the porous slurry layer 144 becomes the gypsum core 104 of the finished gypsum board 100 as shown in Figure 3 Figure

[0057] Meanwhile, the upper facing sheet 106 is unwound from the second supply roller 136 and guided by the roller 131 onto a separate forming table 137. Another portion of the dense slurry is deposited on the upper facing sheet 106 through the third slurry outlet 118 at the separate forming table 137. Then, an additional roller coater 133 spreads and applies the dense slurry to form a second dense slurry layer 146 on the upper facing sheet 106. The upper facing sheet 106 is flipped with another guide roller 131 so that the second dense slurry layer 146 faces the lower facing sheet 102 and the porous slurry layer 144 deposited on the lower facing sheet.

[0058] Then the coated upper facing sheet 106 is guided to the upper surface of the porous slurry layer 144 and fixed to the porous slurry layer at the forming station. The forming station includes a forming plate 138 with an associated hinge 139. The forming station helps to press the layers together to produce a smooth gypsum board with a uniform thickness.

[0059] Various operating parameters affect the properties of the gypsum core formed from the porous slurry layer. For example, the weight percentage of each component of the slurry affects the properties of the gypsum core. For example, the volume of air bubbles within the solidified gypsum core can be determined in part based on the amount of foam added to the slurry.

[0060] Similarly, the specific composition and parameters of each component of the slurry also affect the properties of the gypsum core. For example, for the foam, the density of the foam, the range of bubble sizes of the foam, the median bubble size of the foam, the amount of surfactant, and the composition of the surfactant can all affect the properties of the air bubbles in the gypsum core.

[0061] Similarly, the composition of the plaster and the mineral content of the water can both affect the properties of the gypsum core. In addition, any additives contained in the slurry can also affect the air bubbles in the gypsum core. For example, the amount and composition of any fluidizing agent, retarder, or setting regulator can affect the retention, movement, and coalescence of the air bubbles in the gypsum core.

[0062] The mechanical operating parameters for preparing the slurry may also affect the properties of the gypsum core. For example, if foam is injected into the mixer, the foam injection pressure, the number of nozzles used to inject the foam, and the shape of the nozzles used to inject the foam may all affect the bubbles in the slurry, which may also affect the bubbles in the solidified gypsum core. Similarly, the way the slurry is mixed (such as the rotational speed of the mixer, the shape of any agitators used in the mixer, and the dynamics of the agitators) may affect the coalescence and collapse of the bubbles in the slurry.

[0063] In addition, the parameters for distributing the slurry onto the forming table or other receiving surface may also affect the bubbles in the gypsum core. For example, the dynamics of the slurry when it impacts the receiving surface may affect the number, size, and shape of the bubbles that collapse or are forced out of the slurry. Similarly, when the receiving surface vibrates while the slurry is being distributed on it, the speed or amplitude of the vibration may affect the retention of the bubbles in the slurry.

[0064] Once the shapes of the slurry layer and the facing sheet are determined, the gypsum is allowed to solidify to form the gypsum board 100. Figure 3 A section 105 of the gypsum board 100 is shown, which has been cut to form a cut edge 108 that extends across the gypsum core 104 of the gypsum board 100. In the illustrated embodiment, the gypsum board 100 has been removed from the production line and taken to a cutting tool in the form of a router table that includes a router 128. In other embodiments, the cutting tool may include a CNC machine, a saw, a water jet, a laser, a wire, a blade, or other cutting tools. Additionally, in other embodiments, the cut edge may be formed as part of the gypsum board manufacturing process, for example, along the edge of the gypsum board. In such embodiments, the cut edge may be formed without removing the gypsum board from the production line. Such cut edges may be formed where the gypsum is still wet, such as before the dryer, or may be formed after the dryer.

[0065] Figure 3 The cut edge 108 is shown extending across the thickness of the section 105 of the gypsum board 100 such that the cut edge 108 is perpendicular to the plane of the gypsum core 104. In other embodiments, the cut edge may have a different configuration. For example, in some embodiments, the cut edge is formed by removing a layer at the front or back of the gypsum board rather than by cutting through the gypsum board, such that the cut edge is parallel to the gypsum core.

[0066] Then the cut edge 108 of the gypsum board 100 is analyzed according to the method of analyzing the gypsum core according to the embodiments of the present disclosure. As explained in more detail below, embodiments of such methods are shown in Figures 4 to 6 and use a gypsum core analysis tool 150, as Figure 4As shown. As further explained below, the gypsum core analysis tool 150 analyzes an image of the cut edge 108 to identify bubbles in the gypsum core and the distribution of the bubbles in the gypsum core. The gypsum core analysis tool 150 also identifies bubbles that are in contact within the core and calculates a bubble contact metric for the gypsum core.

[0067] The inventors have determined that the amount of bubble contact within a gypsum core can affect various operating parameters of the gypsum core, such as mechanical properties, fire rating, and acoustic properties. For example, bubbles in contact within the gypsum core can contribute to the cracking of the gypsum core because the cracking can propagate through the bubbles in contact. Bubbles in contact with each other may have a similar effect on preventing the spread of fire and acoustic properties.

[0068] As used herein, the term "bubble" refers to an open space within the gypsum core that has a recognizable boundary to distinguish the area or volume of the bubble from the gypsum material and adjacent bubbles. Thus, the open space within the gypsum core can be formed by a single bubble or can be formed by two or more bubbles in contact. Bubbles in contact with each other may have begun to coalesce but are still recognizable as separate elements based on the shape of the open space within the gypsum. Thus, there may be many bubbles within the gypsum core, some of which are in contact with each other.

[0069] Bubbles in contact are defined herein as adjacent bubbles where an opening is formed between the bubbles due to their close proximity. As a result, there is no wall separating the bubbles in contact, and there is no measurable distance between the bubbles. Once two bubbles are in contact, the distance from the center point C1 of the first bubble to the center point C2 of the second bubble is less than or equal to the sum of the radius R1 of the first bubble and the radius R2 of the second bubble. As the contact between adjacent bubbles increases, the distance from the center point C1 of the first bubble to the center point C2 of the second bubble drops below the sum of the two radii R1 and R2.

[0070] As will be understood by one of ordinary skill in the art, the bubbles formed in a gypsum core can have a variety of different shapes. For example, the bubbles can have an aspect ratio other than 1. As will be understood by one of ordinary skill in the art, various methods can be used to determine the radius or diameter of a bubble having a non-circular shape. For example, in some embodiments, an area calculation algorithm can be used to determine the area of a bubble having a complex shape, and then the effective radius (and diameter) of the bubble can be calculated based on the calculated bubble area. Then, the radius or diameter can be used to analyze a group of bubbles.

[0071] In some embodiments, the voids identified as bubbles in the gypsum core are voids having an aspect ratio of no more than 5. Additionally, in some embodiments, the voids identified as bubbles have an aspect ratio of no more than 3.

[0072] In certain embodiments, one or more operating parameters used to form a porous slurry layer on a receiving surface are modified based on a measure of bubble contact in a gypsum core so as to affect the measure of bubble contact in a subsequent gypsum board. For example, in some embodiments, after modifying one or more of the parameters based on the measure of bubble contact, a second gypsum board is manufactured having a different measure of bubble contact.

[0073] In certain embodiments of a method of forming a gypsum board, the modified operating parameter is the weight percentage of a component of the slurry. For example, in some embodiments, the modified operating parameter is the weight percentage of water added to the slurry. In other embodiments, the modified operating parameter is the weight percentage of stucco added to the slurry. Additionally, in some embodiments, the modified operating parameter is the weight percentage of foam added to the slurry.

[0074] In certain embodiments of a method of forming a gypsum board, the modified operating parameter is a property of the foam. For example, in some embodiments, the modified operating parameter is the density of the foam. Similarly, in some embodiments, the modified operating parameter is the range of bubble sizes within the foam, or the median bubble size of the foam. Additionally, in some embodiments, the modified operating parameter is the type of foaming agent in the foam, or the weight percentage of the foaming agent in the foam. In some embodiments, the modified operating parameter is the type of surfactant in the foam, or the weight percentage of the surfactant in the foam.

[0075] In certain embodiments of a method of forming a gypsum board, the modified operating parameter is the target density of the porous slurry layer formed on the receiving surface.

[0076] In certain embodiments of a method of forming a gypsum board, the modified operating parameter is a mechanical operating parameter for preparing the slurry. For example, in some embodiments, the modified operating parameter is the injection pressure of the foam when it is added to the mixer. In other embodiments, the modified operating parameter is the shape of one or more nozzles used to inject the foam into the mixer. In some embodiments, the modified operating parameter is the location within the board manufacturing system where the foam is added. Additionally, in some embodiments, the modified operating parameter is the rotational speed of the mixer, such as the rotational speed of a stirrer in the mixer or the mixer chamber itself.

[0077] In certain embodiments of a method of forming a gypsum board, the modified operating parameter relates to one or more additives provided in the slurry. For example, in some embodiments, the modified operating parameter is the weight percentage of an additive added to the slurry, the additive being, for example, an accelerator, a retarder, a dispersant, a water repellent, a plasticizer, a fluidizing agent, a setting regulator, a fire retardant additive, a biocide, or a pH regulator.

[0078] Those of ordinary skill in the art are familiar with such additives and their uses in the manufacture of gypsum boards. Examples of accelerators include compounds containing calcium sulfate dihydrate and sugar, potassium sulfate, organic phosphonic acid compounds, and phosphate-containing compounds. Examples of retarders include citric acid and polyamides. Examples of dispersants include polycarboxylate dispersants (e.g., including polycarboxylic ether dispersants), polyphosphate dispersants, lignosulfonate dispersants, naphthalenesulfonate dispersants (such as β-naphthalenesulfonate), naphthalenesulfonate formaldehyde condensates, and naphthalenesulfate formaldehyde condensates. Examples of water repellents include waxes, siloxanes, and silicone-based materials. Examples of fluidizing agents include polycarboxylated ethers and basic derivatives of naphthalenesulfonate formaldehyde condensates. Examples of setting regulators include potassium sulfate and boric acid. Examples of fire-resistant additives include glass fibers and vermiculite. Examples of biocides include isothiazolinones, 2-((hydroxymethyl)amino)ethanol, and tributyltin benzoate. Examples of pH regulators include various acids and bases.

[0079] In certain embodiments of the method of forming a gypsum board, the modified operating parameters are related to the distribution of the slurry on the receiving surface. For example, in some embodiments, the modified operating parameter is the shape or size of the outlet of the slurry. In other embodiments, the modified operating parameter is the height of the outlet of the slurry above the receiving surface. Additionally, in some embodiments, the modified operating parameter is the vibration speed of the receiving surface.

[0080] In certain embodiments of the method of forming a gypsum board, the method is performed during the ongoing manufacture of the gypsum board. For example, as described above, in some embodiments, an imaged cut edge can be formed without removing the gypsum board from the production line. Thus, the production line can continue to produce gypsum boards without interruption while forming the cut edge, capturing an image, and analyzing the image to determine the modified operating parameters, which can then be used to form another gypsum board.

[0081] In other embodiments, a cut edge can be formed in a gypsum board that has been removed from the production line, but the production line continues to produce gypsum boards. For example, in some embodiments, forming the cut edge and capturing an image of the cut edge can be performed in the same facility. Additionally, in some embodiments, forming the cut edge, capturing an image of the cut edge, analyzing the image, and modifying the first operating parameter can be performed on the same day.

[0082] In another aspect, the present disclosure provides a method for analyzing a gypsum core. The method includes receiving an image of a region of a cut surface of the gypsum core and identifying air bubbles in a portion of the image. The method further includes determining a set of contacting air bubbles in the image, each contacting air bubble in the set of contacting air bubbles contacting at least one other air bubble. Additionally, based on the set of contacting air bubbles, a measure of air bubble contact in the gypsum core is determined.

[0083] Various methods can be used to identify air bubbles within a gypsum core. For an isolated air bubble, the boundary of the air bubble is formed by the gypsum material that completely surrounds the air bubble. For contacting air bubbles, a portion of the boundary can be formed by the gypsum material, and the boundary where the air bubbles contact can be determined using an algorithm. For example, in some embodiments, a watershed algorithm can be used to segment air bubbles that contact each other and define the boundary where the air bubbles contact each other. Such watershed algorithms are well known and are described, for example, in “Determining watersheds in digital pictures via flooding simulations” by Pierre Soille and Luc M. Vincent, SPIE Proceedings 1360, Visual Communications and Image Processing'90: Fifth in a Series (September 1, 1990); and “Watersheds in digital spaces: an efficient algorithm based on immersion simulations” by L. Vincent and P. Soille, IEEE Transactions on Pattern Analysis and Machine Intelligence, Vol. 13, No. 6, pp. 583 - 598, June 1991, each of which is hereby incorporated by reference in its entirety.

[0084] In some embodiments, the air bubbles identified by the gypsum core analysis tool have a width (e.g., diameter) of at least 50 μm. Thus, in some embodiments, the air bubbles are primarily those that result from incorporating foam or other air entrainments into the slurry, while small voids formed by water evaporation or other phenomena are excluded.

[0085] In certain embodiments of a method for analyzing a gypsum core, the analysis includes identifying at least 500 air bubbles in the gypsum core, e.g., at least 1000 air bubbles, e.g., at least 2000 air bubbles, e.g., at least 5000 air bubbles. The identified air bubbles may be provided in a single image or may be provided in a plurality of images of the gypsum core.

[0086] In Figures 4 to 8 such methods are shown. Figure 4 The use of a gypsum core analysis tool 150 is schematically shown, which analyzes the gypsum core 104 along the cut edge 108 of a gypsum board 100. The gypsum core analysis tool 150 includes a camera 152, a light source 154, and a frame 155 configured to hold the camera 152 in an orientation to view a section 105 of the gypsum board 100, where the cut edge 108 faces the camera 152. The frame 155 includes a rail 156 and a base 157 for securing the camera to the first rail 156. The rail 156 allows adjustment of the position of the camera 152 relative to the section 105 of the gypsum board 100. The frame 155 also includes a pair of clamps 158 configured to hold the section 105 of the gypsum board 100 in place. In other embodiments, the gypsum core analysis tool is not configured to hold any part of the gypsum board, but is configured to position the camera at a location where visual access to the gypsum board is possible, e.g., along a production line.

[0087] Figure 4 Also included is a schematic of a computing device 160 included in the gypsum core analysis tool 150, the computing device including a non-transitory computer-readable medium having program instructions stored thereon for performing the methods of the present disclosure. The computing device 160 includes a processor 162, a memory 164, and a network interface 166.

[0088] The processor 162 of the computing device 160 includes computer processing elements, such as a central processing unit (CPU), an integrated circuit that performs processor operations, a digital signal processor (DSP), or a network processor. In some embodiments, the processor includes register memory that temporarily stores the instructions and corresponding data being executed, and cache memory that temporarily stores the executed instructions. The memory 164 is computer-usable memory, such as random access memory (RAM), read-only memory (ROM), or non-volatile memory (such as flash memory, solid state drive, or hard disk drive). In certain embodiments, the memory 164 stores program instructions that can be executed by the processor 162 to perform the methods and operations of the present disclosure. The network interface 166 provides digital communication between the computing device 160 and other computing systems or devices. In some embodiments, the network interface operates via a physical wired connection (such as an Ethernet connection). In other embodiments, the network interface communicates via a wireless connection (e.g., IEEE 802.11 (Wifi) or Bluetooth). Other communication conventions are possible.

[0089] Although the computing device 160 of the gypsum core analysis tool 150 is disposed within the tool housing, in other embodiments, the computing device is separate from the housing. For example, in some embodiments, the computing device is part of a smart phone, tablet computer, or laptop computer. Additionally, although the computing device 160 is a client device, i.e., a device actively operated by a user, in other embodiments, the computing device is a server device, such as a device that provides computing services to client devices. Further, in embodiments of the present disclosure, other types of computing platforms are possible.

[0090] Figure 4 The gypsum core analysis tool 150 is shown when capturing an image of the area of the cut edge 108 of the gypsum board 100. During operation, the light source 154 is activated by the computing device 160 to illuminate the area of the cut edge 108. When the area of the cut edge 108 is illuminated by the light source 154, the camera 152 captures an image of the area of the cut edge 108. In some embodiments, the area of the cut edge is defined as the portion of the surface that is within the field of view of the camera and surrounds the optical axis of the camera. In other embodiments, the area corresponds to a portion of the field of view of the camera. Still in other embodiments, the area extends beyond the field of view of the camera.

[0091] As will be understood by one of ordinary skill in the art, the camera can include any of a variety of different image sensors, such as a charge-coupled device (CCD) or a complementary metal oxide semiconductor (CMOS) sensor. In other embodiments, the image can be captured by another tool. For example, in some embodiments, a tool can be used to capture a three-dimensional image of the gypsum core, such as an X-ray tomography device.

[0092] In some embodiments, the light source includes one or more lighting elements of any of a variety of different lighting elements. For example, in certain embodiments, the light source includes a light-emitting diode (LED). The LED can be part of an LED element that includes multiple LEDs. Additionally, as used herein, the term LED includes conventional LEDs, organic light-emitting diodes (OLEDs), and quantum dot LEDs. In other embodiments, the light source can be in the form of a lamp, such as an incandescent lamp, a fluorescent lamp, or a halogen lamp. Additionally, in other embodiments, the light source can be in the form of another lighting element, such as a laser.

[0093] Additionally, in some embodiments, the light source is an annular lamp that surrounds the optical axis of the camera. In some embodiments, the annular lamp is formed by a plurality of individual lighting elements (such as LEDs) that surround the optical axis. In other embodiments, the annular lamp is formed by a single annular-shaped light source that surrounds the optical axis.

[0094] The image captured by the camera 152 is received by the computing device 160, which analyzes the image to determine the characteristics of the bubbles in the gypsum core 104 of the drywall 100. In some embodiments, the lighting and the camera are configured to provide the computing device with an image in which portions of the gypsum material at the surface representing the cut edge of the image and portions of the bubbles intersecting the surface of the cut edge of the image have been identified. For example, white represents the gypsum material and black represents the bubbles. In other embodiments, the computing device initially analyzes the image to identify the portions of the image corresponding to the gypsum material at the surface of the cut edge and the portions of the image corresponding to the bubbles intersecting the surface of the cut edge. For example, in some embodiments, the computing device uses standard image processing to convert the image to a monochromatic image, such as black and white. In such a case, the areas that reflect a large amount of light can be identified as corresponding to the gypsum material at the surface of the cut edge, while the areas that reflect less light or no light can be identified as corresponding to the bubbles intersecting the surface of the cut edge. In other embodiments, the computing device uses an image processing algorithm to identify certain portions of the image that reflect light but are not at the surface of the cut edge. For example, in some embodiments, the computing device identifies reflections from the inner surface of the bubbles but does not include such reflections as part of the surface of the cut edge.

[0095] In some embodiments, the frame 155 further includes a pair of clamps 158 configured to hold a section 105 of the drywall 100 in place, the pair of clamps being capable of moving along the track 157 to allow other portions of the cut edge 108 to be positioned beneath the camera 152. Such movement can allow a series of images of the cut edge to be produced. The computing device 160 can then integrate two or more of the captured images to provide a more robust assessment of the bubble distribution along the cut edge. In some embodiments, this movement along the track is done manually, e.g., by an operator moving the clamps 158 and the section 105 to a second position. In other embodiments, this movement along the track is done automatically, such as by a motor and gears or a linear operator that can move the sample a predetermined distance to take the next image. In some embodiments, the automated movement and distance are calculated and articulated according to instructions provided by the computing device 160. In some embodiments, the range of movement that the clamps 158 and the section 105 can travel is a fixed distance to ensure that the images captured by the camera 152 cover at least a portion of the cut edge 108. In some embodiments, the track along which the clamps 158 and the section 105 travel has predetermined stop points to allow images of different sections 105 taken by the camera 152 to be taken at consistent relative positions. For example, if the first section 105 of a cut edge 108 that is 5 inches in length is to be imaged, the predetermined stop points can be at 1 inch, 2 inches, 3 inches, and 4 inches from the first edge, and at each stop point, an image can be taken. Then, when the second section 105 is to be measured, the second section will also stop at the same predetermined stop points as the first section to take those images. Thus, images from multiple samples can be compared or analyzed manually or computationally with each other.

[0096] Figure 5 An image after such image processing is shown, where the portion of the gypsum material at the surface of the image representing the cut edge is depicted as white, and the portion of the image representing the bubbles is depicted as black. In some embodiments, Figure 5 can be used to determine the percentage of the area occupied by bubbles in the gypsum core or the ratio of the area occupied by bubbles to the area occupied by the gypsum material.

[0097] Figure 6 and Figure 7 shows possible steps for determining other average bubble parameters within the gypsum core. Figure 6 Shows Figure 5 an image of where all of the partial bubbles around the perimeter of the image have been removed. Then, the remaining complete bubbles can be used to calculate the range and average diameter of the bubble diameters.

[0098] Figure 7Embodiments of techniques for determining the average wall thickness within a gypsum core are shown. As used herein, the term wall thickness refers to the minimum thickness of the material between two adjacent air bubbles. The wall thickness referred to herein may be an estimated value rather than an exact quantity. Figure 7 Include wall thickness lines between each air bubble and adjacent surrounding air bubbles. The wall thickness lines extend from the respective centers of adjacent pairs of air bubbles. Thus, the length of each wall thickness line represents the distance between the respective centers (center points C1 and C2) of the adjacent pair of air bubbles. Using the wall thickness lines, the value of the wall thickness can be calculated by subtracting the radius (R1, R2, etc.) of each air bubble from the length of the wall thickness line. Because some of the air bubbles around the outer perimeter of the image have been removed, Figure 7 Some of the wall thickness measurements around the outer perimeter of Figure 7 are artificially inflated because the wall thickness lines extend between air bubbles that are not truly adjacent within the gypsum core or the original image. Thus, in some embodiments, when determining the average wall thickness of the gypsum core, wall thickness measurements near the outer perimeter of the image are excluded.

[0099] In other embodiments, the wall thickness is measured more directly by identifying and measuring the thickness of the gypsum material between adjacent air bubbles rather than using the radius of each air bubble. For example, a computing device can measure the thickness of the gypsum material along the wall thickness line between adjacent air bubbles, or can identify the minimum wall thickness between air bubbles independent of the wall thickness line. Such techniques can account for variations in air bubble shape, but may also require time and computing power to determine.

[0100] Once the air bubbles are identified, the air bubbles in contact within the image can be determined. For example, each pair of adjacent air bubbles separated by a zero wall thickness in the image can be identified as contacting air bubbles. Then, each air bubble that contacts at least one other air bubble can be assigned to a group of contacting air bubbles. For example, Figure 8 The top of Figure 7 shows an initial image of an area of a gypsum core that includes multiple air bubbles. After identifying the air bubbles within the image, the air bubbles that contact each other are identified. Then, each air bubble that contacts at least one other air bubble is assigned to a group of contacting air bubbles, as shown at the bottom of Figure 8 Figure 7 .

[0101] Based on this group of contacting air bubbles in the image, a measure of air bubble contact within the gypsum core is then determined. As described above, using the measure of air bubble contact within the gypsum core, operating parameters can then be modified to affect the characteristics of the manufactured gypsum board. Thus, after modifying the identified operating parameters, subsequent gypsum boards can be produced with different measures of air bubble contact and also with different performance characteristics.

[0102] In certain embodiments of the method of analyzing a gypsum core as further described herein, the measure of air bubble contact is the ratio of the geometric area of the group of contacting air bubbles to the geometric area of all the identified air bubbles. For example, as shown in Figure 8As shown, the bubble contact measure can be the ratio of the area shown as black in the bottom image (i.e., the area covered by the contacting bubbles) to the area shown as black in the top image (i.e., the area covered by all bubbles). Similarly, in some embodiments, the bubble contact measure is the ratio of the volume of the set of contacting bubbles to the volume of the identified bubbles.

[0103] In other embodiments, the bubble contact measure is the ratio of the geometric area of the set of contacting bubbles to the geometric area of a portion of the image. For example, as Figure 8 shown, the bubble contact measure can be the percentage shown as black in the bottom image. Likewise, in some embodiments, the bubble contact measure is the ratio of the volume of the set of contacting bubbles to the volume of the analyzed portion of the image.

[0104] In addition, in other embodiments, the bubble contact measure is the ratio of the number of bubbles in the set of contacting bubbles to the number of bubbles identified in a portion of the image. For example, in some embodiments, the bubble contact measure is the ratio of the number of bubbles contacting other bubbles to the total number of bubbles in the image.

[0105] In certain embodiments of the method of analyzing a gypsum core as further described herein, the method includes determining a proposed operating parameter modification based on the bubble contact measure.

[0106] In certain embodiments of the method of analyzing a gypsum core as further described herein, the method includes sending the bubble contact measure from a computing device to a display. For example, the gypsum core analysis tool 150 includes a display 168 that communicates data with the computing device 160. The computing device 160 is operable to send certain information to the display 168 for outputting the information to a user. For example, after analyzing the image cut surface 108, in some embodiments, the computing device 160 sends the bubble contact measure to the display 168 for presentation to the user. In some embodiments, the image itself and other quantities calculated by the computing device can also be presented on the display.

[0107] In some embodiments, the display is physically coupled to other components of the gypsum core analysis tool. For example, in some embodiments, the display is disposed on a frame that supports a camera. In other embodiments, the display is physically separated from other components of the gypsum core analysis tool. For example, in some embodiments, the display is part of a laptop computer, a smart phone, or a tablet computer.

[0108] In other embodiments, the bubble contact metric is not sent to the display. For example, in some embodiments, the computing device uses the bubble contact metric to determine one or more other values (such as a proposed operating parameter modification), and sends such other values rather than the bubble contact metric itself to the display for presentation to the user.

[0109] Additionally, in some embodiments, the computing device uses the bubble contact metric to determine an appropriate operating parameter modification and automatically modifies the operating parameters within the production line of the gypsum board. For example, in response to the bubble contact metric determined by the computing device, the computing device can automatically send a signal to a component of the production line to modify the operating parameters, such as to reduce the amount of foam added to the slurry.

[0110] In certain embodiments of the method of the gypsum core analysis method as further described herein, the method further includes receiving information from a user. For example, in some embodiments, the method includes receiving a threshold of gypsum board characteristics from the user and determining a proposed operating parameter modification based on the threshold received from the user. As an example, in some embodiments, the gypsum core analysis tool requests information from the user related to a threshold of the density of the gypsum board. The computer can then use the received threshold density as a guide for determining a proposed operating parameter modification and exclude certain options based on the threshold.

[0111] In some embodiments, an input section (such as a keyboard, button, joystick, touch screen, or other input section understood by those of ordinary skill in the art) is used to input user information. In certain embodiments, the input section is coupled to other components of the gypsum core analysis tool. In other embodiments, the input section can be remote from the other components. For example, the input section can be part of a wireless controller, laptop computer, smart phone, or tablet computer.

[0112] In another aspect, the present disclosure provides a non-transitory computer-readable medium having program instructions stored thereon, the program instructions when executed by a processor causing a set of operations to be performed to execute the method of analyzing a gypsum core of the present disclosure. In another aspect, the present disclosure provides a computing device including a processor and a non-transitory computer-readable medium having program instructions stored thereon, the program instructions when executed by the processor causing a set of operations to be performed to execute the method of analyzing a gypsum core of the present disclosure.

[0113] In yet another aspect, the present disclosure provides a gypsum core analysis tool that includes a camera and a computing device. The camera is configured to capture an image of an area of a cut surface of a gypsum core. The computing device includes a processor and a non-transitory computer-readable medium having program instructions stored thereon that, when executed by the processor, cause a set of operations to be performed to carry out the method of analyzing a gypsum core of the present disclosure.

[0114] It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and apparatus described herein without departing from the scope of the present disclosure. Accordingly, the present disclosure is intended to cover these modifications and variations of the invention provided they fall within the scope of the appended claims and their equivalents.

[0115] Embodiments

[0116] Embodiment 1. A method of forming a gypsum board, the method comprising:

[0117] forming a porous slurry layer on a receiving surface using a plurality of operating parameters, wherein forming the porous slurry layer comprises:

[0118] combining plaster and water in a mixer,

[0119] adding foam to the plaster and water,

[0120] agitating the plaster, water, and foam in the mixer to form a slurry, and

[0121] distributing the slurry on the receiving surface;

[0122] solidifying the porous slurry layer to form a gypsum core of the gypsum board;

[0123] forming a cut surface extending across the gypsum core;

[0124] capturing an image of an area of the cut surface;

[0125] analyzing the image to identify bubbles intersecting the cut surface;

[0126] determining a bubble contact measure in the gypsum core based on the identified bubbles in the image; and

[0127] optionally, modifying a first operating parameter of the plurality of operating parameters used to form the porous slurry layer on the receiving surface based on the bubble contact measure.

[0128] Embodiment 2. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the weight percentage of water added to the slurry.

[0129] Embodiment 3. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the weight percentage of plaster added to the slurry.

[0130] Embodiment 4. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the weight percentage of foam added to the slurry.

[0131] Embodiment 5. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the density of the foam.

[0132] Embodiment 6. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter includes the median bubble size of the foam.

[0133] Embodiment 7. The method of forming a gypsum board according to Embodiment 1, wherein the foam contains a surfactant.

[0134] Embodiment 8. The method of forming a gypsum board according to Embodiment 7, wherein the first operating parameter is the weight percentage of surfactant in the foam.

[0135] Embodiment 9. The method of forming a gypsum board according to Embodiment 7, wherein the first operating parameter is the type of surfactant in the foam.

[0136] Embodiment 10. The method of forming a gypsum board according to Embodiment 1, wherein the foam is injected into the mixer under a foam injection pressure, and wherein the first operating parameter is the foam injection pressure.

[0137] Embodiment 11. The method of forming a gypsum board according to Embodiment 1, wherein the foam is injected into the mixer through a nozzle, and wherein the first operating parameter is the shape of the nozzle.

[0138] Embodiment 12. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the rotational speed of the mixer.

[0139] Embodiment 13. The method of forming a gypsum board according to Embodiment 1, wherein forming the porous slurry layer includes: adding a first additive to the slurry in the mixer.

[0140] Embodiment 14. The method of forming a gypsum board according to Embodiment 13, wherein the first operating parameter is the weight percentage of the first additive added to the slurry.

[0141] Embodiment 15. The method of forming a gypsum board according to Embodiment 13, wherein the first operating parameter is the composition of the first additive added to the slurry.

[0142] Embodiment 16. The method of forming a gypsum board according to any one of Embodiments 13 to 15, wherein the first additive is a retarder, a fluidizing agent or a setting regulator.

[0143] Embodiment 17. The method of forming a gypsum board according to Embodiment 1, wherein distributing the slurry on the receiving surface includes: vibrating the receiving surface.

[0144] Embodiment 18. The method of forming a gypsum board according to Embodiment 1, wherein the first operating parameter is the vibration speed of the receiving surface.

[0145] Embodiment 19. The method of forming a gypsum board according to any one of Embodiments 1 to 18, the method further includes: when capturing the image of the area of the cutting surface, illuminating the area of the cutting surface with a light source.

[0146] Embodiment 20. The method of forming a gypsum board according to Embodiment 19, wherein the light source is an annular lamp surrounding the area of the cutting surface.

[0147] Embodiment 21. The method of forming a gypsum board according to any one of Embodiments 1 to 20, wherein determining the bubble contact measure in the gypsum core includes:

[0148] identifying a group of bubbles, each bubble in the group of bubbles contacting at least one other bubble

[0149] contacting; and

[0150] based on the group of contacting bubbles, determining the bubble contact measure in the gypsum core.

[0151] Embodiment 22. The method of forming a gypsum board according to Embodiment 21, wherein the bubble contact measure is the ratio of the geometric area of the group of contacting bubbles to the geometric area of the identified bubbles.

[0152] Embodiment 23. The method of forming a gypsum board according to Embodiment 21, wherein the bubble contact measure is the ratio of the geometric area of the group of contacting bubbles to the geometric area of a part of the image.

[0153] Embodiment 24. The method of forming a gypsum board according to Embodiment 21, wherein the bubble contact measure is the ratio of the number of bubbles in the group of contacting bubbles to the number of identified bubbles in a part of the image.

[0154] Embodiment 25. The method of forming a gypsum board according to any one of Embodiments 21 to 24, wherein the identified bubbles do not include partial bubbles that intersect the edge of the part of the image.

[0155] Embodiment 26. The method of forming a gypsum board according to any one of Embodiments 1 to 25, the method further comprising: determining an average wall thickness between adjacent bubbles in the gypsum core.

[0156] Embodiment 27. The method of forming a gypsum board according to Embodiment 26, wherein determining the average wall thickness includes: excluding wall thickness measurement results between bubbles near the edge of the part of the image.

[0157] Embodiment 28. The method of forming a gypsum board according to Embodiment 21, the method further comprising: determining an operating parameter modification based on a threshold of gypsum board characteristics.

[0158] Embodiment 29. A method of analyzing a gypsum core, the method comprising:

[0159] Receiving an image of an area of a cut surface of the gypsum core;

[0160] Identifying bubbles in a part of the image;

[0161] Identifying a group of contacting bubbles, each contacting bubble in the group of contacting bubbles contacting at least

[0162] one other bubble; and

[0163] Determining a bubble contact measure in the gypsum core based on the group of bubbles.

[0164] Embodiment 30. The method of analyzing a gypsum core according to Embodiment 29, wherein the bubble contact measure is a ratio of a geometric area of the group of contacting bubbles to a geometric area of the identified bubbles.

[0165] Embodiment 31. The method of analyzing a gypsum core according to Embodiment 29, wherein the bubble contact measure is a ratio of a geometric area of the group of contacting bubbles to a geometric area of the part of the image.

[0166] Embodiment 32. The method of analyzing a gypsum core according to Embodiment 29, wherein the bubble contact measure is a ratio of the number of bubbles in the group of contacting bubbles to the number of identified bubbles in the part of the image.

[0167] Embodiment 33. The method for analyzing a gypsum core according to any one of Embodiments 29 to 32, wherein the identified bubbles do not include partial bubbles that intersect the edge of the part of the image.

[0168] Embodiment 34. The method for analyzing a gypsum core according to any one of Embodiments 29 to 33, the method further comprising: determining an average wall thickness between adjacent bubbles in the gypsum core.

[0169] Embodiment 35. The method for analyzing a gypsum core according to Embodiment 34, wherein determining the average wall thickness includes: excluding wall thickness measurement results between bubbles near the edge of the part of the image.

[0170] Embodiment 36. The method for analyzing a gypsum core according to any one of Embodiments 29 to 35, the method further comprising: sending the bubble contact measure to a display.

[0171] Embodiment 37. The method for analyzing a gypsum core according to any one of Embodiments 29 to 36, the method further comprising: determining a proposed modification of operating parameters based on the bubble contact measure.

[0172] Embodiment 38. The method for analyzing a gypsum core according to Embodiment 37, the method further comprising: sending the proposed modification of operating parameters to a display.

[0173] Embodiment 39. The method for analyzing a gypsum core according to Embodiment 37 or Embodiment 38, the method further comprising: receiving a threshold of gypsum board characteristics from a user; and determining the proposed modification of operating parameters based on the threshold received from the user.

[0174] Embodiment 40. A non-transitory computer-readable medium having program instructions stored thereon, the program instructions, when executed by a processor, cause a set of operations to be performed to execute the method according to any one of Embodiments 29 to 39.

[0175] Embodiment 41. A computing device, the computing device comprising:

[0176] a processor; and

[0177] the non-transitory computer-readable medium according to Embodiment 40.

[0178] Embodiment 42. A gypsum core analysis tool, the gypsum core analysis tool comprising:

[0179] a camera configured to capture an image of a region of a cut surface of a gypsum core;

[0180] and

[0181] The computing device according to embodiment 41.

[0182] Embodiment 43. The gypsum core analysis tool according to embodiment 42, the gypsum core analysis tool further comprising a light source configured to illuminate the area of the cut surface of the gypsum core.

[0183] Embodiment 44. The gypsum core analysis tool according to embodiment 42, wherein the light source is an annular lamp arranged around the optical axis of the camera.

[0184] Embodiment 45. The gypsum core analysis tool according to any one of embodiments 42 to 44, the gypsum core analysis tool further comprising a frame that holds the camera and is configured to hold a portion of a gypsum board, wherein the area of the cut surface is positioned within the field of view of the camera.

Claims

1. A method of forming a gypsum board, the method comprising: forming a porous slurry layer on a receiving surface using a plurality of operating parameters, wherein forming the porous slurry layer comprises: combining stucco and water in a mixer, adding foam to the stucco and water, agitating the stucco, water and foam in the mixer to form a slurry, and distributing the slurry on the receiving surface; solidifying the porous slurry layer to form a gypsum core of the gypsum board; forming a cut surface extending across the gypsum core; capturing an image of an area of the cut surface; analyzing the image to identify bubbles having a diameter of at least 50 μm that intersect the cut surface; determining a set of contacting bubbles from the identified bubbles, each contacting bubble in the set of contacting bubbles contacting at least one other bubble; determining a bubble contact measure in the gypsum core based on the set of contacting bubbles and the identified bubbles in the image; and modifying a first operating parameter among the plurality of operating parameters for forming the porous slurry layer on the receiving surface based on the bubble contact measure.

2. The method of forming a gypsum board according to claim 1, wherein the first operating parameter is a weight percentage of at least one of water, stucco or foam added to the slurry.

3. The method of forming a gypsum board according to claim 1, wherein the first operating parameter comprises the density of the foam, or the median bubble size of the foam.

4. The method of forming a gypsum board according to claim 1, wherein the first operating parameter is the type of surfactant in the foam, or the weight percentage of surfactant in the foam.

5. The method of forming a gypsum board according to claim 1, wherein the foam is injected into the mixer at a foam injection pressure, and wherein the first operating parameter is the foam injection pressure.

6. The method of forming a gypsum board according to claim 1, wherein the foam is injected into the mixer through a nozzle, and wherein the first operating parameter is the shape of the nozzle.

7. The method of forming a gypsum board according to claim 1, wherein the first operating parameter is the rotational speed of the mixer.

8. The method of forming a gypsum board according to claim 1, wherein the first operating parameter is the weight percentage or composition of a first additive added to the slurry.

9. A computer-implemented method of analyzing a gypsum core, the method comprising: receiving an image of an area of a cut surface of the gypsum core; identifying bubbles having a diameter of at least 50 μm in a portion of the image; identifying a set of contacting bubbles, each contacting bubble in the set of contacting bubbles contacting at least one other bubble; and determining a bubble contact measure in the gypsum core based on the set of bubbles.

10. The method of analyzing a gypsum core according to claim 9, wherein the bubble contact measure is the ratio of the geometric area of the set of contacting bubbles to the geometric area of the identified bubbles.

11. The method of analyzing a gypsum core according to claim 9, wherein the bubble contact metric is the ratio of the geometric area of the set of contacting bubbles to the geometric area of the portion of the image.

12. The method of analyzing a gypsum core according to claim 9, wherein the bubble contact metric is the ratio of the number of bubbles in the set of contacting bubbles to the number of bubbles identified in the portion of the image.

13. The method for analyzing a gypsum core according to any one of claims 9 to 12, the method further comprising: Determining a proposed operating parameter modification based on the bubble contact metric; and Optionally, sending the proposed operating parameter modification to a display.

14. A non-transitory computer-readable medium having program instructions stored thereon, the program instructions, when executed by a processor, causing a set of operations to be performed to execute the method according to any one of claims 9 to 13.

15. A computing device, the computing device comprising: a processor; and the non-transitory computer-readable medium according to claim 14.

16. A gypsum core analysis tool, the gypsum core analysis tool comprising: a camera configured to capture an image of a region of a cut surface of a gypsum core; and the computing device according to claim 15.

Images