DK2707185T3 - Plasterboard fabrication plant and method for making a plasterboard. - Google Patents

Description

[0001 ] The invention concerns a gypsum board manufacturing facility according to claim 1.

[0002] Furthermore, the invention concerns a method for manufacturing a gypsum board according to claim 10 [0003] Gypsum board manufacturing facilities with circulating conveyor belts are known in the prior art. A principal function of the conveyor belts is to allow a moist gypsum layer placed on them to bind, so that the gypsum layer can be further processed by dividing it into gypsum boards. Such gypsum boards can then be mounted at a construction site, for example, on a wall or ceiling. Furthermore, it is known how to produce gypsum boards by means of such a gypsum board manufacturing facility which have a bevel at their four edges to enable an easy spackling and covering of the joints when several gypsum boards are laid alongside each other. In this regard, refer to EP 1 499 482 B1.

[0004] In EP 1 499 482 B1, forming strips are placed underneath or arranged at the bottom side of the gypsum layer being processed, so that when pressure is applied to the gypsum layer they are forced into it and form corresponding recesses in the gypsum layer.

[0005] After the stiffening of the gypsum layer which accompanies the binding process, these recesses remain intact in the gypsum layer. In particular, it is a drawback that the forming webs have to be arranged on the gypsum layer and removed from it once again for each forming process.

[0006] Another solution is shown in DE 20 2004 008 232 U1. In this prior art, a forming device is provided underneath a conveyor belt, which comprises a belt with a forming lath. If the forming lath runs between two sheets at the same time as the gypsum layer, an impression is produced in the gypsum layer. For this, it is necessary to synchronize the running speed of the forming lath or the forming lath belt arranged underneath the conveyor belt with the speed of the conveyor belt, or else irregular recesses will result from a relative movement between forming lath and conveyor belt. The necessary synchronization makes the overall facility prone to malfunction and increases the production expense.

[0007] US 2001/044016 discloses a gypsum board manufacturing facility according to the preamble of claim 1.

[0008] On the other hand, one problem which the present invention proposes to solve is to propose a gypsum board manufacturing facility as well as a method for manufacturing a gypsum board in which the production expense for the gypsum board being formed is reduced and in particular a reliable and well reproducible quality of the gypsum board can be achieved.

[0009] This problem is solved by a gypsum board manufacturing facility according to claim 1 and a method for manufacturing a gypsum board according to claim 10.

[001 0] In particular, the problem is solved by a gypsum board manufacturing facility, comprising at least one rotating conveyor belt device for receiving a gypsum layer and forming and hardening the gypsum layer of the gypsum layer, wherein the conveyor belt device has a carrying belt for supporting the gypsum layer comprising an external side onto which the gypsum layer is applied in operation, and an internal side, at least one plurality of forming webs is provided, wherein the forming webs are mounted at the external side relative to the carrying belt transversely, i.e., perpendicular, to a running direction of the conveyor belt device at a regular interval from each other and constitute a part of the external side of the conveyor belt device so that the forming webs co-rotate with the conveyor belt device.

[0011 ] In what follows, the external side of the conveyor belt device shall always mean that side which actually comes into contact with the gypsum layer during operation. The term “external side” is to be understood in that the particular elements “at the external side” (such as the forming web) is arranged in relation to another element (such as the carrying belt) on the side which faces the carried gypsum layer during the operation of the gypsum board manufacturing facility.

[0012] The external side must be fashioned so that it withstands the gypsum layer (for example, its moisture content).

[0013] A key notion of the invention is therefore that the at least one forming web or the forming webs form a part of the external side of the conveyor belt device and come into direct contact with the gypsum layer during operation. The forming webs are thus an integral part of the conveyor belt device, so that no synchronization is needed. This simplifies the production of the gypsum board and improves the reproducibility of the gypsum boards being manufactured.

[0014] Preferably, the forming webs are detachably secured to the conveyor belt device. One can therefore easily control the configuration of the gypsum boards being manufactured. For example, in the most simple instance, removal of the forming webs can produce a gypsum board having no recess or bevelling in the corresponding edge region. Especially when several forming webs are being used, the spacing of the recesses resulting from the forming webs can be varied especially easily by removal of individual forming webs. Of course, it is possible to secure the forming webs each time at the desired spacing on the conveyor belt device in order to be able to produce gypsum boards of a predetermined length.

It is conceivable to provide a detachable fastening at any desired length position of the conveyor belt device; alternatively, it is also possible to provide discrete fastening positions so that the establishing or maintaining of equal spacings is simplified. In this way, the same gypsum board manufacturing facility can be used for several gypsum boards, in particular, gypsum board lengths. Preferably, the forming webs are realized with a flexible material, such as plastic.

[0015] In a preferred embodiment, the gypsum board manufacturing facility comprises at least one conveying means downstream from the conveyor belt device, wherein the forming webs are preferably arranged exclusively on the conveyor belt device and also optionally on the conveying means or on certain of its partial conveying means. For adequate binding of the applied gypsum layer it is often necessary to transport it over a comparatively long stretch (such as 80 m to 450 m). But after a given distance, the gypsum layer solidifies thanks to the binding so that the recess introduced by the forming webs remains intact. Therefore, the conveyor belt device can have for example at least 20%, preferably at least 40% and/or at most 60%, preferably at most 50% of the overall length of the conveyor belt device and conveying means. The conveying means is preferably arranged behind the conveyor belt device in the running direction. In operation, the gypsum layer can pass over from the conveyor belt device to the conveying means. The conveying means itself can be divided in turn into several partial conveying means. The conveying means or individual partial conveying means can be configured as a conveyor belt or as a roller conveyor.

[0016] For the overall layout consist of conveyor belt device and conveying means, the following in no way definitive sample embodiments result: 1. conveyor belt (forming and hardening), 2nd conveyor belt, 3rd conveyor belt, ... and so on, then roller conveyor 2. conveyor belt (forming and hardening), 2nd conveyor belt, then roller conveyor 3. conveyor belt (forming and hardening), then roller conveyor at once.

[0017] Preferably, the conveyor belt device and/or downstream partial conveying means or the downstream conveying means is of a length of at least 10 m, further preferred at least 15 m, even further preferred 30 m and/or at most 90 m, further preferred at most 30 m, even further preferred at most 15 m. It has been found that an adequate solidification by binding or drying of the gypsum layer is assured with the indicated lengths.

[0018] In alternative embodiments, the forming web can be of a triangular or trapezoidal or rectangular cross-section. Especially preferred is a trapezoidal cross-section, which results in gypsum boards - when the gypsum layer is divided appropriately - which have bevels at their edges and which can be especially easily spackled or plastered.

[0019] According to the invention, the conveyor belt device has a rotating board forming belt which co-rotates on the carrying belt with the conveyor belt device and has forming webs arranged spaced from each other.

[0020] The board forming belt can additionally have two lateral longitudinal forming webs, each of which are associated with the distal ends of the forming webs, in particular permanently or even integrally, so that the gypsum board strand receives both a bevel at its longitudinal edges (parallel to the edges of the carrying belt) and at a predetermined interval in the cross-direction due to the forming webs.

[0021] In an especially preferred embodiment the board forming belt is fashioned as a grid or ladder, that is, the two parallel running longitudinal forming webs are joined at predetermined distance by the forming webs, so that rectangular openings remain in the board forming belt and the gypsum board strand lies in these regions directly on the carrying belt. But it is also conceivable to close these openings with a thin film or carrying belt layer, or to fashion the board forming belt integrally as a continuous belt with the longitudinal forming webs fashioned as elevations and with the forming webs running at right angles to the latter.

[0022] In an alternative embodiment, the board forming belt laterally has two toothed belts which in each case are detachably, permanently or integrally associated with the distal ends of the forming webs. Toothed belts constitute an especially simple and expedient option for monitoring the synchronized running of the two side edges of the board strand. For example, the synchronized running can be achieved in a purely mechanical way, such as by providing drive rollers which are outfitted with projections and engage in the correspondingly formed interstices of the toothed belt. Alternatively, however, it is also conceivable to detect the recesses of the toothed belt by a sensor and provide an electronic regulation which ensures the synchronized running of the two circulating toothed belts spaced apart from each other.

[0023] Instead of a toothed belt, a perforated belt for example can also be used. When the board strand is configured with toothed belts or perforated strip, although the toothed belts or perforated strip have no influence on the shaping of the gypsum board strand, i.e., the longitudinal edges of the gypsum board strand either have no flattening or the flattening is achieved in another way, such as by parallel revolving longitudinal forming webs, one possible configuration might be for the toothed belts or perforated strips to be permanently joined to them or to have integrally moulded-on longitudinal forming webs, so that a bevelling can be accomplished at the same time in the longitudinal edges of the gypsum board strand.

[0024] One or more smoothing device can be provided for smoothing the gypsum layer at its side facing away from the forming webs. In this way, (slight) deformations on the side opposite the forming webs, such as might be caused by the indentation of the forming web, can be smoothed out once more, which improves the quality of the gypsum boards.

[0025] The forming webs can have a height of 0.2 mm to 2.8 mm, in particular 1.8 mm to 2.5 mm and/or a maximum width of 80 mm to 200 mm, in particular 120 mm to 160 mm. In this way, gypsum boards can be manufactured which are especially easy to work with or plaster.

[0026] The above-mentioned problem is also solved by a method for manufacturing a gypsum board, wherein the method involves providing a gypsum board manufacturing facility of the above-described kind and applying a gypsum layer of a predefined viscosity onto the external side of the conveyor belt device such that the forming webs, due to the intrinsic weight of the gypsum layer, press themselves into the same. As for the benefits, refer to the already described gypsum board manufacturing facility.

[0027] Further embodiments will appear from the subsidiary claims.

[0028] The invention will also be described below in regard to further features and benefits with the aid of sample embodiments, which are explained more closely with the aid of the figures.

[0029] There are shown here:

Fig. 1, a first embodiment of a gypsum board manufacturing facility in a schematic side view;

Fig. 2, a second embodiment of the gypsum board manufacturing facility in a schematic side view;

Fig. 3, the second embodiment in a schematic top view;

Fig. 4, a third embodiment of the gypsum board manufacturing facility in a schematic side view;

Fig. 5, the third embodiment in a schematic top view;

Fig. 6, a fourth embodiment of the gypsum board manufacturing facility in a schematic side view;

Fig. 7, the fourth embodiment in a schematic top view; and Fig. 8, a first embodiment of a forming web in a side view.

[0030] In the following description, the same reference numbers are used for the same and equivalent parts.

[0031 ] Fig. 1 shows in a schematic side view a gypsum board manufacturing facility for the production of a gypsum board, specifically a gypsum board panel. One sees a conveyor belt device 10 with a carrying belt 11. On the external side on the carrying belt 11 there are arranged forming webs 12 (two of which can be seen as an example), specifically, above applicator devices 13. The carrying belt 11 is deflected about a first and a second deflecting unit 14, 15.

[0032] The forming webs 12 are triangular in cross-section and form corresponding recesses 17 in a gypsum layer 16.

[0033] For the placement of the gypsum layer on the conveyor belt device 10, at first a first cardboard strip 18 is brought up. Moist gypsum mass 19 is applied on it. In turn, a second cardboard strip 20 is applied to the gypsum mass 19.

[0034] The moist gypsum layer consisting of first and second cardboard strips 18, 20 and the gypsum mass 19 drops by its own weight over the forming webs 12, so that the corresponding recesses 17 are produced by penetration into the gypsum layer 16. In the further travel, the gypsum layer 16 or gypsum strand hardens as a result of binding, so that the recesses 17 remain intact. The gypsum layer is lying here on one external side 50 of the conveyor belt device. An internal side is designated by the reference 60.

[0035] In a separating step, not shown, the gypsum layer 16 can then be cut through in the region of the recesses 17, so that individual gypsum boards are formed, having a bevel in their edge region. Furthermore (likewise not shown), a device can be provided which forms a bevelling on the gypsum board strand on its longitudinal edge, i.e., on an edge parallel to the direction of running of the conveyor belt device 10, which is represented by an arrow 21. After the separating step, gypsum boards then result which have a bevel or recess on all four edges.

[0036] In the first embodiment according to Fig. 1, the forming webs 12 are placed directly with the aid of the applicator devices 13 on the carrying belt 11 and revolve during the production process with the carrying belt 11. The applicator devices 13 can be screws, for example.

[0037] Fig. 2 shows a second embodiment of the gypsum board manufacturing facility in a schematic side view. Fig. 3 shows a top view. In this embodiment, the forming webs 12 (of which only two are shown schematically as an example) are part of a board forming belt, which co-rotates in the production process on the external side in relation to the carrying belt 11. In the embodiment illustrated here, the board forming belt 22 has two longitudinal forming webs 28 at the sides, each of which is joined - permanently in the present embodiment - to the distal ends of the forming webs 12. In this embodiment, the gypsum board strand receives a predefined bevelling or recess or depression both on its longitudinal edges (parallel to the edges 25 of the carrying belt 11) and also in the cross-direction to this at predetermined intervals. The permanent fastening of the forming webs 12 in the present embodiment to the longitudinal forming webs 28 at the same time has the effect that both longitudinal forming webs are held in a defined relative position to each other during the rotation, i.e., one longitudinal forming web is prevented from rotating faster than the opposite one. Between the longitudinal forming webs 28 and the forming webs 12, rectangular recesses 29 are formed in the present embodiment. In the area of these recesses 29, the gypsum board strand lies directly on the carrying belt 11 arranged beneath the board forming belt. In an alternative embodiment, however, the recesses 29 can be filled in, i.e., the board forming belt is fashioned as a continuous belt, in which the longitudinal forming webs 28 as well as the forming webs 12 are fashioned as elevations.

[0038] The carrying belt 11 as per Fig. 2 is diverted around the already described deflecting units 14, 15. The board forming belt 22 here (for example) is led around four (in general, several) deflecting units 23, which make it possible for the carrying belt 11 to run inside the board forming belt 22. In the region in which the gypsum layer (in Fig. 2, the top side of the device) lies on the board forming belt 22, this preferably contacts the carrying belt 11.

[0039] Fig. 4 shows a third embodiment of the gypsum board manufacturing facility in a schematic side view. Fig. 5 shows this same embodiment in a top view. As can be seen in particular from Fig. 5, also in this embodiment there is provided a board forming belt 22, which rotates on top of the carrying belt 11. In a departure from the embodiment of Fig. 2 and Fig. 3, instead of the longitudinal forming webs 28 this has two toothed belts 24 revolving parallel to each other.

The toothed belts 24 are joined each time to the distal ends of the forming webs -detachably in the present embodiment. A fastening of the forming webs 12 to the toothed belt 24 can be done in any suitable manner, for example, by removable glue connection. With the toothed belts 24 it can be assured, either in mechanical fashion or by an electronic regulation, that both toothed belts 24 rotate with absolutely the same speed, so that the right-angled arrangement of the forming webs 12 to the toothed belts 24 or the longitudinal direction of travel of the carrying belt 11 is exactly maintained.

[0040] The toothed belts 24 here can run on the external side (on top) of longitudinal forming webs (not shown in the figures), making possible a bevelling of the gypsum layer on its longitudinal edges (parallel to the edges 25 of the carrying belt 11). In another embodiment, it is also conceivable to join or integrate longitudinal forming webs with the toothed belts 24.

[0041] In another embodiment, illustrated with the aid of Fig. 6 and 7, a board forming belt 22 is proposed in which perforated belts 27 are used in place of toothed belts 24. A mechanical synchronization can be achieved in that the perforated belts 27 are led or diverted across wheels 26 provided with pins (see Fig. 6). The wheels 26 can preferably be connected in a manner so as to conduct rotary momentum to a drive shaft (not shown) for the carrying belt 11.

[0042] Fig. 8 shows a forming web 12 in a preferred embodiment in a side view.

[0043] The forming web 12 according to Fig. 8 is (essentially) trapezoidal in cross-section, while a base line of the trapezium can be 80 mm to 200 mm (see arrow 40). A shorter side parallel to this can be 30 mm to 80 mm (see arrow 41). On the whole, the trapezium (see Fig. 5) can have a relatively small base 42 of 0.5 mm (0.2 mm to 0.8 mm).

[0044] The forming web 12 of Fig. 8 results in likewise trapezoidal recesses in the gypsum layer. If the gypsum layer is sawn through roughly in the middle of the trapezoidal recess, the result is an inwardly directed edge. Preferably, in a further sawing (or cutting) step, the projecting edge is removed, so that the edge of the resulting gypsum board is bevelled.

List of reference symbols: [0045] 10 Conveyor belt device 11 Carrying belt 12 Forming web 13 Applicator device 14 First deflecting unit 15 Second deflecting unit 16 Gypsum layer 17 Recess 18 First cardboard strip 19 Gypsum 20 Second cardboard strip 21 Arrow 22 Board forming belt 23 Deflecting unit 24 Toothed belts 25 Edge 26 Wheel 27 Perforated belt 28 Longitudinal forming webs 29 Recesses 40 Arrow 41 Arrow 42 Base 50 External side 60 Internal side

Claims (10)

A plasterboard manufacturing plant comprising at least one rotary conveyor belt (10) for receiving a plaster layer (16) and forming and curing the plaster layer (16), wherein the conveyor belt (0) has a support belt (11) for supporting the plaster layer (16), and having an outer surface (50) to which the plaster layer (16) is applied during operation and an inner surface (60), characterized in that there is at least a plurality of mold combs (12) in which the mold combs (12) are disposed on the outside of the the conveyor belt (11) equally spaced across a travel direction of the conveyor belt (10) and forming part of the outer surface (50) of the conveyor belt (10) such that the mold combs (12) run around with the conveyor belt, characterized in that the conveyor belt (10) ) has a circumferential plate molding belt (22) which runs around the carrier belt (11) with the conveyor belt and having spacers arranged at each other spaced apart, wherein the carrier belt (11) turns around via carrier belt assembly (14, 15) and the plate molding belt (22) turns around pladeformebå applicators (23). Plasterboard fabrication plant according to claim 1, characterized in that the mold combs (12) are formed of flexible material, preferably plastic. Gypsum board manufacturing system according to claim 1 or 2, characterized in that the gypsum board manufacturing system comprises at least one conveyor (10) after the conveyor belt, wherein the mold combs (12) are preferably arranged solely on the conveyor belt (10). Plasterboard manufacturing plant according to any of the preceding claims, characterized in that the conveyor belt (10) has a length of at least 10 m, preferably at least 50 m, further preferably at least 30 m, and / or at most 98 m, preferably at most 30 m, more preferably not more than 15 m. Plasterboard manufacturing plant according to any one of the preceding claims, characterized in that the mold combs (12) have a triangular or trapezoidal or rectangular cross section. Plasterboard fabrication system according to claim 5, characterized in that the plate molding strip (22) has laterally two longitudinal mold cams (28), each of which are connected to the distal ends of the mold combs (12), particularly permanently or even integrally, so that the plasterboard string gets a tear at its longitudinal edges. as well as at the mold cams (12) at predetermined intervals in the transverse direction. Plasterboard fabrication system according to claim 5, characterized in that the plate molding strip (22) has laterally two tooth straps (24) which are in each case detachably, permanently or integrally connected to the distal ends of the mold combs (12). Plasterboard fabrication plant according to any of the preceding claims, characterized in that one or more smoothing devices are provided for smoothing the plaster layer (16) on a side facing away from the mold combs (12). Plasterboard manufacturing plant according to any of the preceding claims, characterized in that the mold combs (12) have a height of 0.2 to 2.8 mm, in particular 1.8 to 2.5 mm, and / or a maximum width of 80 to 200 mm, especially 120 to 160 mm. A method of making a gypsum board, comprising the steps of: - providing a gypsum board making plant according to any one of the preceding claims, - applying a layer of gypsum (16) of predetermined viscosity and a set curing time on the outside (50) of the conveyor belt (10) , such that, due to the weight of the plaster layer (16), the mold combs (12) are pressed into this.