EP1382424A1 - Method for manufacturing boards made of hydraulic binder with tapered edges, production line and apparatus for manufacturing such boards - Google Patents

Abstract

The manufacture of sheet materials such as plasterboard by passing a water-bound material (2) through a die (4) between two facing layers (1, 3) uses laths (6) delivered from a magazine and placed beneath the lower facing layer (1) to create lines of reduced thickness between adjacent sheets so that, when cut, they have tapered edges. The laths, having a thickness of 0.5 - 4 mm and a length equivalent at least to the width of the facing layer, are introduced before or during the plaster pouring phase, and the sheets are cut after widthdrawal of the lath once the plaster has set.

Description

The present invention relates to a method of manufacture of plates based on hydraulic binder such than plaster, these plates having thinned edges.

The invention also relates to a line of production of such plates and a device can be used to make these plates.

It has long been known to make edges longitudinal thinned on plasterboard. In indeed, U.S. Patent No. 1,754,429 and the U.S. Patent British No. 429,379 already proposed, respectively in 1922 and in 1934, techniques for manufacturing in continuous plasterboard with edges longitudinal thinned.

The existence of thinned edges makes possible a satisfactory assembly of two plasterboards adjacent. It fills the space left by the edges thinned by means of a joint coating, that we can then level with the surface of the plates, without creating any extra thickness. In addition, it reduces the risk of cracking between the plates.

The assembly thus produced of several plates constitutes a continuous surface with good flatness.

In 1937, U.S. Patent Nos. 2,238,017 and 2,246,987 attempted to resolve the problem of realization of thinned transverse edges.

The solution offered by the first of these patents consists of making a transverse groove in the sheet of lower paper by folding the latter before the pouring of the plaster composition and arrival on the conveyor belt. The transverse groove making protruding from the bottom sheet of paper, creates, once the sheet of paper on the carpet carrier, a hollow whose walls are at an angle. In then cutting the plate at the end of each part at an angle, we obtain two plates with transverse edges thinned.

Such a solution is difficult to implement because it requires the installation of special rollers for making the groove. In addition, the plate must be cut in two places, which further the disadvantage of producing a large amount of waste.

The solution proposed by the second American patent above (US 2,246,987) consists of fixing transversely on the conveyor belt of the production line in continuous plasterboard, side bars. This solution has the disadvantage of necessitating stopping the production line whenever we want modify the length of the plasterboard to be produced. These stops are long because it is necessary to separate the conveyor belt bars to move them, then fix again. Then it is necessary to hand over en route the entire plate production line plaster.

Such a solution is therefore difficult to implement works and causes high costs.

Despite the many years since the publication of these patents, no technique came provide a satisfactory solution to the problem of production on a continuous line, of plaster with thinned transverse edges.

This is surprising when you know the benefits brought by such plates and when we know that the use of plasterboard is constantly expanding in the whole world.

The object of the invention is therefore to propose a method allowing the manufacture of plasterboard having thinned transverse edges. This process achieves remedy the drawbacks of the techniques proposed in prior art.

1) on coule sur un matériau de parement une composition de liant hydraulique,

2) on fait passer le matériau revêtu obtenu dans une filière (4) de façon à obtenir une préforme,

3) on laisse la prise hydraulique de la composition de liant hydraulique s'effectuer, et

4) on coupe la préforme,
ce procédé se caractérisant en ce que

a) il comprend en outre les étapes suivantes :

• avant l'étape 2), on extrait d'un magasin à lattes, une latte dont la longueur est environ au moins égale à la largeur du matériau de parement et on introduit cette latte sous ledit matériau de parement;
• après l'étape 3), on retire ladite latte; et en ce que

b) la coupe de l'étape 4) est effectuée au niveau de l'amincissement créé par la latte.

More specifically, the invention relates to a method for manufacturing a plate based on hydraulic binder, with thinned edges, in which:

1) a hydraulic binder composition is poured onto a facing material,

2) the coated material obtained is passed through a die (4) so as to obtain a preform,

3) the hydraulic setting of the hydraulic binder composition is allowed to take place, and

4) the preform is cut,
this process being characterized in that

a) it also includes the following stages:

• before step 2), a slat whose length is approximately at least equal to the width of the facing material is extracted from a slat store and this slat is introduced under said facing material;
• after step 3), said slat is removed; and in that

b) the cutting of step 4) is carried out at the level of the thinning created by the slat.

The invention also relates to a line of production of hydraulic binder plates having edges thinned from a preform comprising at least minus one facing material covered with a composition of hydraulic binder, this production line comprising a sector, as well as, upstream of this means, for introducing, under the material of facing, a slat whose length is approximately at least equal to the width of the facing material.

• un magasin à lattes;
• au moins une latte,
• des moyens pour extraire une latte, à la fois, du magasin à lattes ;
• des moyens pour recevoir la latte extraite ;
• des moyens pour déplacer la latte extraite dans une direction parallèle à sa longueur ;
• des moyens pour supporter la latte déplacée ; et
• des moyens pour mouvoir la latte déplacée dans une direction parallèle à sa largeur ;
  et se caractérisant en ce qu'il comprend en outre des moyens pour enduire de colle au moins une partie de la face supérieure de la latte.

Finally, the invention also provides a device for the introduction of slats under a facing material, with a view, in particular, to manufacturing plates based on hydraulic binder having thinned edges, this device comprising:

• a slatted shop;
• at least one slat,
• means for extracting one slat at a time from the slat store;
• means for receiving the extracted batten;
• means for moving the extracted slat in a direction parallel to its length;
• means for supporting the displaced batten; and
• means for moving the slat moved in a direction parallel to its width;
  and characterized in that it further comprises means for coating with glue at least a part of the upper face of the slat.

- la figure 1 représente schématiquement l'introduction de la latte sous le matériau de parement ;

- la figure 2 représente schématiquement le défilement de la préforme accompagnée par une latte ;

- la figure 3 représente schématiquement l'étape b) du procédé selon l'invention

- la figure 4 représente une plaque telle qu'obtenue par le procédé selon l'invention

- la figure 5 représente une plaque obtenue par le procédé selon un mode de réalisation préféré de l'invention

- la figure 6 représente schématiquement et en perspective, une partie de la ligne de production selon l'invention

- la figure 7 représente schématiquement et en vue de dessus, le dispositif selon l'invention ;

- la figure 8 représente schématiquement et en vue de côté, le dispositif selon l'invention ;

- la figure 9 représente schématiquement et en vue de côté une variante du dispositif selon l'invention ; et

- la figure 10 représente schématiquement et en coupe, un détail du dispositif de la figure 6, illustrant l'introduction d'une latte sous le matériau de parement.

Other characteristics and advantages of the invention will now be described in detail in the description which follows and which is given with reference to the figures, in which

- Figure 1 schematically shows the introduction of the slat under the facing material;

- Figure 2 schematically shows the scrolling of the preform accompanied by a slat;

- Figure 3 schematically shows step b) of the method according to the invention

- Figure 4 shows a plate as obtained by the method according to the invention

- Figure 5 shows a plate obtained by the method according to a preferred embodiment of the invention

- Figure 6 shows schematically and in perspective, part of the production line according to the invention

- Figure 7 shows schematically and in top view, the device according to the invention;

- Figure 8 shows schematically and in side view, the device according to the invention;

- Figure 9 shows schematically and in side view a variant of the device according to the invention; and

- Figure 10 shows schematically and in section, a detail of the device of Figure 6, illustrating the introduction of a slat under the facing material.

DETAILED DESCRIPTION OF THE INVENTION PROCESS ACCORDING TO THE INVENTION

By "transverse edges" is meant in the present exposed edges perpendicular to the direction of travel conveyor belt in a production line of hydraulic binder plates.

Referring to Figure 1, we see a line of production of plates produced by casting on a facing material 1 of a binder composition hydraulic 2 and generally covered by a second facing material 3. The passage of the assembly in the die comprising the forming plate 4 (in "forming plate") and plate 403 gives a preform 5.

The hydraulic binder composition includes preferably plaster.

The facing materials 1 and 3 can be made sheets of paper or cardboard, glass mats or any material known to those skilled in the art as being capable of serve as facing material.

Before passing the facing material coated with the composition of hydraulic binder in the die or in the equivalent device used in the line production (for example, a roll called in English "Master roll"), a slat 6 is inserted between the facing material 1 and plate 403. This plate 403 may have been obtained by cutting a piece of a plate 404 so as to create plate 403 and between this last and the rest of plate 404 a space for the introduction of the slat 6.

The introduction of the slat can be carried out in upstream, in or downstream of the pouring area.

The terms "upstream" and "downstream" refer to the meaning of scrolling of the preform 5.

It is done in such a way that the axis the length of the slat 6 is substantially perpendicular to the direction of movement of the belt carrier 7.

As can be seen in Figure 2, the slat 6 is then driven by the facing material 1 and the conveyor belt 7. The hydraulic outlet and the hardening of the plaster composition 2 takes place then throughout the movement of the preform 5, indicated by the arrows A.

The upper face 401 of the slat 6, that is to say that intended to come into contact with the material of facing 1 (see figure 1), can be at least partially coated with an adhesive allowing it to adhere to the facing material 1, especially when the introduction of the slat is carried out upstream of the pouring area.

According to a preferred embodiment of the invention, the slat 6 is removed before cutting the preform 5.

So after a while, which corresponds to a distance traveled by preform 5 on the mat transporter 7, which a person skilled in the art knows how to determine depending on the speed of movement of the belt carrier 7 and the setting time of the composition of plaster 2, the hardness of the preform 5 is sufficient to that the slat 6 can be removed without deforming the preform 5 and without the plaster composition 2 coming fill the space or thinning 8 (figure 3) left by removing the batten 6.

The removal of the slat 6 can be carried out according to any suitable way.

It can be done, quite simply, by the fall of the batten 6 due to its weight, this fall may have place, for example, in the space between two rollers of the conveyor belt system which, in general, is not continuous throughout the production line, but is formed by several mats driven by rollers between which there are free spaces.

The removal of the slat 6 can also be done, at the by means of a blade or a brush (not shown) scraping the underside of the facing material 1 to which the slat 6 adheres to a suitable place, for example example, in the space between two rollers mentioned in previous paragraph.

After removing the slat 6, the preform 5 continues to move, still driven by the carpet carrier 7 and curing the composition of plaster 2 continues.

As can be seen in Figure 3, when the thinning 8 arrives at the height of the cut generally consisting of two opposite knives 9 and 9bis, this device starts up and cuts the preform 5. This gives a 9ter plate, visible on Figure 4, the length of which is defined by the distance traveled by the conveyor belt between two operations cutting, that is to say, according to the invention, by the distance traveled by the conveyor belt between two consecutive thinning 8. This 9ter plate has therefore two thinned transverse edges 10.

Preferably, the cutting device is adjusted by so that the knives 9 and 9bis cut the preform 5 approximately in the middle of the thinning 8.

The size of each thinning 8 depends on the slat dimensions 6. The latter is generally a parallelepiped whose thickness is generally between 0.5 and 4 mm, preferably between 1.5 and 4 mm. Its width is generally between 5 and 20 cm and its length is approximately equal to the width of the material facing 1.

It may possibly be provided that the width of the batten 6 is less than that of the facing material 1, in particular, when longitudinal strips are used (called in English "tape").

The material of the slats 6 does not matter, from the as long as it allows these slats to resist the weight of the preform thickness 5 which is above each slat 6. It can therefore be a plastic material, wood, metal, cardboard, etc. presenting good wear resistance and stability over time.

According to a preferred embodiment of the invention, the process which has just been described complements of a known process for manufacturing plasterboard having two thinned longitudinal edges. This last generally provides for the installation of a band, usually plastic, usually called "Tape" on each longitudinal side of the carpet transporter 7. Such a process is described for example in European patent application No. 482,810.

This therefore makes it possible to obtain a binder-based plate. hydraulic 11 as illustrated in FIG. 5, having, in addition to its two thinned transverse edges 10, two edges longitudinal 25 thinned, making a total of four edges thinned.

It goes without saying that if the frequency of operations of cut is double that of the introduction of the slats 6, we obtain plates having three thinned edges (two longitudinal and a transverse).

The length of the plasterboard produced depends of course the speed of movement of the mat carrier and the frequency of cutting operations.

The frequency of cutting operations is generally directly related to the frequency of introduction of slats, because we generally seek to obtain plates having two thinned transverse edges.

Thus, the method according to the invention is very flexible, because to change the length of the plates manufactured, it just change the frequency of introduction slats.

We can also predict the presence of a straightener 4bis of classic type downstream from where is inserted lath 6 (see figure 2).

Binding plate manufacturing line hydraulic

In Figure 6 is shown part of a binder-based plate production line hydraulics implementing the method according to the invention.

We can therefore see a slat store 20 formed of a horizontal rectangular surface 21 from the corners from which rise vertically and parallel, four angular pieces 22, in the form of an angle iron and facing each other, so as to frame a stack of slats 23.

The dimensions of this slatted magazine 20 are such that it can store a high number of slats 23 (see also Figures 7 and 8).

The horizontal surface 21 of the slat magazine 20 is supported by feet 24.

At the level of the first batten 23, that is to say that located at the bottom of the stack, are arranged in parallel two cylinders 26, which are oriented so as to extract the first batten 23 from the stack by pushing and dragging it to an incline 27 consisting of a downwardly inclined surface 28 and a rim 29 at its lower part to retain the slat which has just been extracted and guide it later.

At the transverse side 30 of the inclined plane 27, that is to say the side opposite to the plate 403, a jack 31 is arranged parallel to the longitudinal axis of the plane inclined 27, so that the actuation of this cylinder 31 can give an impulse to the slat which comes to be extracted from the slat store 20. The slat as well propelled can then move by sliding parallel to the longitudinal axis of the inclined plane 27, whose rim 29 guides it, towards a second inclined plane 32 which extends the first inclined plane 27, on the side transverse opposite side 30.

According to one embodiment, means 402 are provided, for example between the first inclined plane 27 and the second inclined plane 32, to coat with adhesive at least partially the upper face 401 of the slats 23. These means 402 can be constituted, for example, by a brush 402 located above a slat 23, when this slat is on the first inclined plane 27. The displacement of the slat 23 of the first inclined plane 27 towards the second inclined plane 32 allows the brush 402 at least partially coat the upper face 401 of the batten 23 of an adhesive which then allows it to adhere to the facing material.

The second inclined plane 32 also consists an inclined surface 33 provided with a rim 34 at its lower part. It further comprises a stop 35 at its end opposite to the jack 31, this stop being generally consisting of a pneumatic shock absorber and being intended to put an end to the displacement of the batten propelled by the jack 31.

The rim 34 is provided with openings 36 opposite which are arranged two cylinders 37 oriented so as to propel the batten positioned on the second inclined plane 32 upwards of the inclined surface 33.

The first inclined plane 27 and the second plane tilted 32 are supported by feet, respectively, 38 and 39.

According to a variant visible in FIG. 9, a flat surface 40 is provided parallel to the surface 23, between the latter and the first inclined plane 27 to horizontally support a slat extracted from the slatted magazine 20 before its descent on the surface inclined 28 of the first inclined plane 27.

Thus, as can be seen in Figure 10, the height of feet 24, 38 and 39 is chosen so a slat positioned on the second inclined plane 32 is at a height lower than that of the preform 5.

• l'axe longitudinal du rebord 34 du deuxième plan incliné 32 est perpendiculaire à l'axe longitudinal de la plaque 403 (ou tapis transporteur 7) ;
• les moyens 32,33,34,35 pour supporter la latte déplacée se situent en face du début de la plaque 403; et
• la surface inclinée 33 du deuxième plan incliné 32 est adjacente à la plaque 403.

In general :

• the longitudinal axis of the rim 34 of the second inclined plane 32 is perpendicular to the longitudinal axis of the plate 403 (or conveyor belt 7);
• the means 32, 33, 34, 35 for supporting the displaced batten are located opposite the start of the plate 403; and
• the inclined surface 33 of the second inclined plane 32 is adjacent to the plate 403.

The length of the second inclined plane 32 is at least equal to that of lath 23, i.e. at least equal to, and preferably greater than, the width of the preform 5.

In this way, as can be understood by referring to FIG. 10, when the jacks 37 are actuated, the slat being in the second plane tilted 32 is pushed up from the surface inclined 33, that is to say towards the plate 403 and the facing material 1, and it gets stuck between these and driven by them.

Of course, we can provide that the slats are arranged otherwise than by stacking in the store at slats. They can for example be arranged side by side coast or according to any appropriate provision their allowing to be extracted individually from the store at slats.

The production line according to the invention comprises usually electronic means that control its function and allow, if necessary, to enslave between them the implementations of different operations.

These electronic means provide that after the introduction of a slat under the preform by actuation of the jacks 27, the jack 31 is actuated to introduce a new batten on the second plane inclined 32, then the cylinders 26 are actuated to introduce another slat on the first inclined plane 27, and so on. Electronic means can vary the frequency of these operations to reduce or increase the length of the plasterboard with edges thinnings produced.

Device according to the invention

The means 20 to 22, 24 to 39 and 402 which come to be described can be combined into a device according to the invention.

The main advantage of such a device is that it can be installed near a manufacturing line classic hydraulic binder-based plates with which he can then cooperate in order to implements the method according to the invention.

Claims (22)

Method for manufacturing a plate based on hydraulic binder (9ter, 11), with thinned edges (10), in which: 1) a hydraulic binder composition (2) is poured onto a facing material (1), 2) the coated material obtained is passed through a die (4.403) so as to obtain a preform (5), 3) the hydraulic setting of the hydraulic binder composition (2) is allowed to take place, and 4) the preform (5) is cut, this process being characterized in that a) it also includes the following stages: before step 2), a slat (6,23) whose length is approximately at least equal to the width of the facing material (1) is extracted from a store of slats (20) and this slat is introduced ( 6,23) under said facing material (1); after step 3), said slat (6,23) is removed; and in that b) the cutting of step 4) is carried out at the level of the thinning (8) created by the slat (6,23). The method of claim 1, wherein the introduction of the slat (6,23) is carried out upstream of the binder composition pouring area hydraulic (2). The method of claim 1, wherein the introduction of the batten (6,23) is carried out in or in downstream of the binder composition pouring area hydraulic (2) and before the passage of said material facing (1) coated in the die (4,403). Method according to claim 1 or the claim 2, further comprising a step coating at least part of the upper face (401) of the batten (6,23) by means of an adhesive. Method according to one of claims 1 to 4, characterized in that the cutting of step 4) takes place after the removal of the slat (6,23). Method according to one of claims 1 to 5, characterized in that the cutting of the plate based on hydraulic binder is carried out approximately in the middle of the thinning (8). Method according to one of claims 1 to 6, characterized in that said slat (6,23) has a thickness ranging from 0.5 to 4 mm, preferably from 1.5 to 4 mm. Method according to one of claims 1 to 7, characterized in that said slat (6,23) has a width between 5 and 20 cm. Method according to one of claims 1 to 8, characterized in that the conveyor belt (7) supports on each of its longitudinal sides, two lateral bands. Method according to one of claims 1 to 9, characterized in that it further comprises, between step 1) and step 2), a step of covering the hydraulic binder composition (2) by means of 'a second facing material (3). Method according to one of claims 1 to 10, characterized in that the hydraulic binder comprises plaster. Binder-based plate production line hydraulic (9ter, 11), having thinned edges (10), from a preform (5) comprising at least one material facing (1) covered with a binder composition hydraulic (2), this production line comprising a sector (4,403) as well as, upstream of this sector (4.403), means (20-22, 24-39) for introducing, under the facing material (1), a slat (6,23) whose length is approximately at least equal to the width of the facing material (1). Production line for hydraulic binder plates (9ter, 11) according to claim 12, characterized in that the means (20-22, 24-39) are located upstream of the casting area of the hydraulic binder composition (2 ). Production line for hydraulic binder plates (9ter, 11) according to claim 12, characterized in that the means (20-22, 24-39) are located in or downstream of the casting area of the hydraulic binder composition (2). Binder-based plate production line hydraulic (9ter, 11) according to claim 12 or the claim 13, further comprising means (402) to coat at least part of the face with glue upper (401) of the batten (23). Production line for hydraulic binder plates (9ter, 11) according to one of claims 12 to 15, comprising: a slatted store (20), at least one batten (23); means (26) for extracting one slat (23) at a time from the slat magazine (20); means (27,28,29) for receiving the extracted slat (23); means (31) for moving the extracted slat (23) in a direction parallel to its length; means (32,33,34,35) for supporting the displaced batten (23); and means (37) for sliding the slat (23) under the facing material (1). Production line for plates based on hydraulic binder (9ter, 11) according to claim 16, in which: the means (27, 28, 29) for receiving the extracted batten (23) comprise an inclined surface (28) provided at its lower part with a flange (29); the means (32, 33, 34, 35) for supporting the displaced batten (23) in an inclined position comprise an inclined surface (33) provided at its lower part with a flange (34) and on one side of a stop (35). A production line for sheets based on hydraulic binder (9ter, 11) according to claim 17, in which: the longitudinal axis of the flange (34) is perpendicular to the longitudinal axis of the conveyor belt (7); the means (32,33,34,35) for supporting the displaced batten (23) are located opposite the start of the plate (403); and the inclined surface (33) is adjacent to the plate (403). Line for producing hydraulic binder sheets (9ter, 11) according to one of Claims 12 to 18, characterized in that it further comprises means for covering the hydraulic binder composition (2) by means of 'a second facing material (3). Line for the production of sheets based on hydraulic binder (9ter, 11) according to one of claims 12 to 19, characterized in that the hydraulic binder comprises plaster. Device for the introduction of slats (6,23) on a facing material (1), comprising: a slat store (20); at least one batten (23), means (26) for extracting one slat (23) from both the slat magazine (20); means (27,28,29) for receiving the extracted slat (23); means (31) for moving the extracted slat (23) in a direction parallel to its length; means (32,33,34,35) for supporting the displaced batten; and means (37) for moving the slat (23) moved in a direction parallel to its width; characterized in that it further comprises means (402) for coating with adhesive at least part of the upper face (401) of a slat (23). Device according to claim 21, characterized in that : the means (27, 28, 29) for receiving the extracted batten (23) comprise an inclined surface (28) provided at its lower part with a flange (29); the means (32, 33, 34, 35) for supporting the displaced batten (23) in an inclined position comprise an inclined surface (33) provided at its lower part with a flange (34) and on one side of a stop (35).

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