FI67673C - FOERFARANDE OCH ANORDNING FOER TILLVERKNING AV PLATTOR ELLER SKIVOR AV GIPS - Google Patents

Description

· ro. ANNOUNCEMENT „„ ^ „B 11 UTLÄGGNINGSSKRIFT 676 7 3 C (45) Γ 'cnJ.13 Z5 2? J3 (51) Kv.lk. * / Lnt.CI. * B 28 B 13/00, 1/52 (21 ) Patent application - Patentansökning 7904 1 1 (22) Filing date - Ansöknlngsdag 07 02 79 '' (23) Starting date - Giltighetsdag 07.02.79 (41) Published public - Blivit offentlig Qg Qg yg

National Board of Patents and Registration Date of publication and publication. -

Patent- och registerstyrelsen '' Ansökan utlagd och utl.skriften publicerad 31.01.85 (32) (33) (31) Pyydetty etuoikeus — Begärd priority 08.02.78

France-France (FR) 7803 ^ 75 (71) Saint-Gobain Industries, 62, Bd Victor-Hugo, F-92209 Neuilly sur Seine,

France -F rankrike (FR) (72) Adrien Delcoigne, Chantilly, Jacgues Lanneau, Breui1 -1e-Vert,

The present invention relates to a method and an apparatus for the production of gypsum tiles or boards. This invention relates to a method and an apparatus for the production of gypsum boards or boards. from a running evolutionary product.

A fluid evolutionary product is a liquid in which a reaction takes place that results in a physical or chemical change, such as the formation of a solid phase or a change in the properties of the solid phase originally contained in the liquid.

Plates or tiles are made by casting an evolutionary product running on a moving casting platform. A mixture of gypsum powder and water is a representative example of such a product. As soon as the gypsum powder is mixed with water, it quickly begins to evolve until it hardens completely. The continuous production of gypsum building elements requires control of the gypsum reaction phase at all times and in all stages of mixing, from the initial feeding of the powdered gypsum flour and water, to the end of the line where the finished building elements are ready for use.

When the consistency of the evolutionary product is pasty, a way to control its evolution within a tooth-type mixer is known and a way to continuously apply it to a conveyor with a conveyor belt to form a more or less flat gypsum strip that can be continuously placed in molds. But working with the paste requires heavy equipment, because the cohesion forces that can be overcome are large, and the adjustment of the paste flow and the measurement of the paste level are anything but accurate. As a result, there is an unevenness in the quantity of product delivered to the mobile conveyor and, as a result, an unevenness in the quality of the finished product.

When the consistency of an evolutionary product is fluid, as in the case of gypsum, the only known way to use it to make building elements is a non-continuous process. It is poured into molds in which it is left until the gypsum hardens. To date, the liquid gypsum mixture has not been used in a continuous process, partly due to the difficulty encountered in attempting to keep the liquid gypsum during mixing inside the standard mixer by means of a valve without mass curing deposits in the narrow channel formed by the valve, and partly due to occurs in an attempt to preserve an evolutionary product such as gypsum in a continuous casting plant without premature mass curing of the gypsum within the plant. In connection with the invention, a flow control of the flowing gypsum mixture exiting the mixer has now also been carried out for the first time. Reference should be made in this connection to Finnish Patent Application No. 79,0409 and Finnish Patent No. 63535, which are incorporated herein by reference.

When it was possible to adjust the residence time of a flowable evolutionary product such as a liquid gypsum powder and water mixture in a mixer by adjusting the exit flow of said mixture as it exited the mixer, the aim was to the accuracy of level detection, more even distribution of the mixture, and lighter equipment.

It is known to pour the product onto a moving substrate and allow it to spread on its own, whereby the thickness of the plates thus produced is a function of the velocity of the vessel layer. But when working with its evolutionary 67673 product, it is difficult to control its spread, and difficulties are encountered in the manufacture of thick sheets. To limit and control the spread, devices commonly used when casting non-evolutionary products can be considered. They generally comprise a bottomless container placed above a running conveyor so that a gap is formed between said conveyor and the lower edge of the slab forming the downstream wall of the container.

The container is filled with product so that a storage load is formed above the conveyor, and the product flows onto the conveyor through the gap in the bottom of the container. If a mixture of gypsum powder and water were cast with this device, it would harden, first along the walls of the tank and then from the edges of the gap, and the casting device would soon become clogged.

In the gypsum board or board manufacturing process of the present invention, this clogging is avoided by casting an evolutionary flowable product consisting essentially of a mixture of gypsum and water with a FLS fluidity of more than 120 on a uniformly moving horizontal casting platform from a tank or tanks immediately on the casting platform. through a parallel to and adjacent to the ladle, a gap formed below the inlet wall of the tank or tanks, characterized in that the fresh product is continuously introduced into the tank or tanks in a plurality of streams submerged in the mass of the product substantially directed horizontal in the opposite direction to the direction of travel of the casting platform.

Fresh product streams enter the product in the container with such force that they cause confusion along closed flow lines in the product mass in the container.

It is advantageous to make the distance of the streams entering the tank such that the lines of confusion flow converge and spread in the plane of the streams over the entire surface of the tank.

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It is advantageous if the walls of the tank are vibrated. Some reinforcement can be fed into the product discharged from the tank and several layers of product can be discharged onto the casting base.

The invention also comprises a device by means of which the method can be carried out. This device, which comprises a bottomless tank or tanks resting on a movable horizontal casting base with a slot delimited by the casting base and the lower edge of the plate forming the front wall of the tank, is characterized in that several product supply pipes are arranged on the outside of the front wall. into the tank or tanks through the front wall.

The method according to the invention makes it possible to produce gypsum board with layers of different densities, which may or may not be provided with reinforcements. It is also possible to produce decorative gypsum boards as well as thin gypsum panels with a thickness of less than 3 mm.

Figure 1 is a schematic drawing of a complete gypsum board production line; Figure 2 is a sketchy representation of a gypsum casting device; Fig. 3 is a view of a receiving tank into which the mixture exiting mixing flows; Fig. 4 is a dispenser with a plurality of outlets which distributes the mixture to a plurality of production lines or to different locations on a single line; Figure 5 shows a casting head; Fig. 6 shows a detail of the front plate of the casting head; Fig. 7 shows a detail of the head plate of the casting head; Fig. 8 shows different ways of placing the reinforcement; Fig. 9 shows a multiple casting head; Fig. 10 is a partially exploded side view of a gypsum board according to the invention; Fig. 11 is a partially exploded side view of a gypsum board according to the invention with three layers of different densities; Fig. 12 is a partially exploded side view of a plasterboard 67673 according to the invention with three layers of different densities and a reinforcement between adjacent layers; Fig. 13 is a partially exploded side view of a gypsum board according to the invention in which a reinforcement is embedded; Fig. 14 is a partially exploded side view of a gypsum board according to the invention with a fiberglass fiber panel attached to one side thereof; Fig. 15 is a partially exploded side view of a three-layer reinforced gypsum board according to the invention; Fig. 16 is a view of an alternative embodiment of the receiving container shown in Fig. 3; Fig. 17 shows another way of placing the reinforcement; Fig. 18 is a partially exploded side view of a gypsum board reinforced with a continuous filament mat sandwiched between two layers of fiberglass mesh; Fig. 19 shows a gypsum board with a reinforcing layer of chopped glass fibers; and Fig. 20 is a vertical side view of a gypsum board attached to a glass wool insulation pad.

Figure 1 shows a manufacturing plant for the production of gypsum board building elements reinforced with, for example, glass fibers. This plant comprises a device for producing a mixture of gypsum and water and a device according to the present invention, which makes it possible to continuously pour this mixture onto a moving conveyor and, if desired, to strengthen it.

The gypsum powder in the hopper 1 is applied to a weight-sensitive conveyor belt 2 preset for a predetermined gypsum powder flow P, and then conveyed to a vibrated trough 3, through which it falls into a mixer M. A water supply controller 4 comprising a valve 4A and a flow meter 4B, discharges water to the mixer M by the flow W. The mixer M is a mixer comprising a turbine 5 and a cylindrical, vertical tank 6 with a converging bottom wall 6A. The intermediate base 7A of the container is formed by the upper surface of the core 7 of the rotating body, which tapers downwards and which is also placed inside a tapered housing formed by the wall 6A of the lower part of the container 6. The center line of this core 7 coincides with the center line of the container 6 and its dimensions are such that an annular space is left between it and the wall 6A, by which the mixture can drain away. In a certain type of construction, the lower part of the container 6 is conical and the core 7 is a cone placed downwards with its tip downwards, the flat base 67673 of which forms the intermediate base. The mixture exiting the mixer M is received by an ejection device 8 comprising a conical housing 9 with the tip pointing upwards and a planar base 10. The collecting tube 11 protrudes from the ejector device 8 in the plane of the base 10 tangentially in the direction of rotation of the receiving tank 9 turbine 5. The outlet flow of the mixture is controlled by a valve 12 mounted in the collecting pipe 11. This valve comprises a rigid, cylindrical housing 13, an internal flexible sleeve 14 and a medium inlet pipe 15 communicating with the space between the rigid housing 13 and the sleeve 14. This medium inlet tube 15 communicates with a source of (usually air) medium; the pressure of the medium is adjusted to provide the desired compression of the flexible sleeve 14, followed by a certain setting of the valve 12 to close. In order to prevent any deposition in the narrow channel formed by the valve, the pressure of the medium adjusting the transparency of said valve 12 is modulated continuously to change the shape of the sleeve 14.

It is preferred to perform this modulation by an adjustable, discharge type pneumatic mechanism associated with a power balance beam 16 supporting a mixer M at one end and the other end controlling the discharge of a pneumatic circuit supplying compressed air to the valve between the beam head 16A and the nozzle 18. in line 18A connected to pressure supply line 17, which is also connected to medium inlet line 15. Small movements of the beam 16 caused by vibrations due to the movement of the turbine 5 of the mixer M are detected and converted into signals by means of vibrations with respect to the nozzle 18 of the beam 16. These oscillation signals modulate the pressure of the control medium supplied to the valve. As a result, the shape of the flexible sleeve 14 of the valve 12 is constantly changed, which prevents any stagnation of the gypsum and thus all hardening of the mixture in the narrow channel of the valve.

In order to produce a flowable mixture of gypsum and water with a certain flow rate Fo from continuous operation, the procedure is as follows. First, a mixture ratio Wo / Po is selected which gives the fluidity Fo, in which the expression Wo is the water flow and Po is the gypsum powder flow, and the mixture is fed to the mixer M, where Fo is a value expressed in millimeters and obtained by FLS test. This FLS test is often used by gypsum manufacturers and indicates the behavior of gypsum 67673 when casting it. The test is carried out by filling with water-mixed gypsum a hollow cylinder 60 mm in diameter and 59 mm high, set upright in the center of a polished metal or glass plate. After time t from the time "to" when the first contact between the gypsum and water took place, the cylinder is raised, thus releasing the gypsum, which spreads on the slab and forms a disc whose diameter is measured. The size of this diameter forms the fluidity F parameter for time t.

The gypsum powder and water supply flow rates to the mixer M are set to Po and Wo. The time To is selected as the residence time of the gypsum mixture in the mixer M. The mixer outlet is closed. The turbine of mixer M is started. Water is fed to the mixer M by flowing Wo time To and then gypsum is fed by flowing Po also time To from the end of the water supply. Then, after mixing, at the same time, the gypsum powder feed is set to flow Po and the mixer outlet is opened so that the mixture can drain away, with valve 12 set to such outflow that the amount of product in the mixing tank remains constant. The modulation of the valve control medium is given by the oscillations of the mixer M. In this way, a continuous driving situation is achieved. A flowable mixture of gypsum powder and water, the FLS value of which, measured at time t = 1 min 15 sec, can be selected as low as 120, can be used in the following described casting plant according to the invention. With regard to further details, the above-mentioned Finnish patents can be used.

The continuous casting plant, shown in its entirety in Figures 1 and 2, comprises the mixture dispensing components D, the casting head C which enables the gypsum to be applied to the conveyor and the reinforcement feeder R. The mixture dispensing components D located downstream of the valve 12 under the mixer M include 19, which has a structure as shown in Figs. 3 or 16, a pump 20, a dispenser 21 according to Fig. 4, and pipes 22 (Fig. 1). The receiving tank 19 causes a load at the outlet of the valve 12 and thus isolates the mixer from the downstream part of the plant, so that it is possible to weigh said mixer separately from the equipment on the downstream side of the pipe 23. It communicates with two vertical tubes 23 and 24 (Fig. 3) located at the same centerline. The tubes 23 pass freely through the cover 25A of the housing 25 and the tube 24 is attached to the bottom 26 of the housing. The space between the two tubes 23 and 24 is enclosed in the housing 25. The subordinate tube 24 extends into said housing 24 above its base 26. A water inlet pipe 27 terminating in a spray nozzle 28 inserts a housing 25 for flushing out any gypsum splashes. The lower part of the base 26 of the housing 25 has drainage holes 29 for this washing water. The submerged pipe 24 leads the mixture to the pump 20. The pump 20 must be a pump capable of operating without load, capable of absorbing the entire effluent of mixer M, tolerating a certain amount of random air circulation and capable of transferring sufficient energy to the mixture to prevent mass build-up inside the system. to handle the load no matter what. Thus, it is suitable to use a rotary pump with gears or cams or a plastic tube pump t, the tube of which is compressed by rollers or an eccentric nozzle which pushes the mixture out into the outlet openings of said pump.

The pump 20 may be directly connected to the casting head C up to the pipe 22. However, since the mixture is supplied from a single mixing unit to several casting ends C (Fig. 2) and since the pump flow is always constant, a dispenser 21 is mounted on the pressure side of the pump 20 to equalize the flow and divide the mixture flow supplied by the pump 20 into several smaller equal flows. The dispenser 21 (Fig. 4) is funnel-shaped and connected at its smaller end to the pressure side of the pump 20 and at its wider end closed by a lid 31 to radial outlet or dispensing tubes 32 starting from the top of the funnel wall near the cover 31. To obtain similar dispensing flows, symmetrically about the center line of the funnel and the dispenser is mounted so that its center line is vertical. To save space, the distribution pipes 32 are inclined downwards. Connected to each dispensing tube 32 is a tube 22 which carries the mixture to the casting head (or heads) C. A typical multi-outlet dispensing device 21 for a flow rate of 60 kg / min has a funnel with an upper diameter of 40 mm and a lower diameter of 14 mm and in which there are 4 outlet pipes, each with a diameter of 8 mm. These outlet pipes are at an angle of 15 ° to the vertical. The funnel is 40 mm high and the outlet pipes are connected to the funnel 10 mm below its wide upper end 31.

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Fig. 5 shows in detail the casting head C mounted above the conveyor S and the casting base S moving relative to each other. For simplicity, the casting head C and all its supply pipes are preferably kept stationary and thus the conveyor S is a running conveyor. The conveyor S is made of, for example, a strip of stainless steel or a rubber strip. Two side strips 33 (Fig. 2) having the same movement as the conveyor S are mounted vertically on both sides of the conveyor S.

The casting head C (Fig. 5) essentially comprises two barrier plates 34 and 35 which, together with the conveyor S and the side strips 33, form a container in the shape of a small trough 34A and located transversely to the direction of movement of the conveyor S so that the plate 34 is a downstream plate and the plate 35 is an upstream counter plate, the upstream and downstream sides being determined with respect to the direction of travel of the conveyor.

The downstream plate 34 is provided on its outer surface with a series of feed tubes 36 distributed over its entire width and piercing through it, opening into a small trough 34A. Each of these supply pipes 36 is connected to a distribution pipe 32, either a distribution pipe 32 which is connected to only one supply pipe 36 or a distribution pipe 32 which is connected to two supply pipes by means of a Y-connector 37 (Fig. 5). The two distribution pipes 32 may be connected to only one supply pipe 36. The supply pipes 36 should preferably be horizontally extending and as they pass through the downstream barrier plate 34 so as to form the distribution nozzles 36A. The height at which the tubes 36 reach the downstream plate 34 and their spacing depend on the operating conditions: the flow of the mixture, the flowability of the mixture and the surface height of the mixture inside the trough; similarly, the distance between the two plates 34 and 35 depends on the operating conditions. The downstream plate 34 is raised relative to the conveyor S to form a gap whose height, which is adjustable, is at most equal to the thickness of the intended gypsum run. Both plates are provided with side rubber flaps 38 which contact the passing side strips 33. The upstream plate 35, at its lower part, has a seal 39 for sealing it against the conveyor S. Both plates 34 and 35 have a vibrator 40 mounted at the top, for example a pneumatic vibrator which generates a vibration in a vertical direction, at right angles to the direction of travel of the conveyor S - I: 10 67673. Both plates 34 and 35 are fastened with machine screws (not shown) through two lateral slots 41a in the lugs 41 mounted on the general frame (not shown) of the plant. Each plate 34 or 35 can be moved along the two holding slots, independently of one another. The plates 34 and 35 are fixed to the lugs 41 through vertical, elongate slots 43 in the lugs 41 by screws 42A provided with resilient stops 42 fitted between the plates and the lugs. Said elongate slots 43 in the vertical parts of the fastening lugs 41 make it possible to position both plates 34 and 35 in the height direction. The downstream plate 34 may be provided with a guide plate 44 (Fig. 5) which is approximately at right angles to the plane of the plate 34 outside the small trough 34A bounded by both plates 34 and 35. Preferably, this guide plate 34 is set at a small angle of about 7 ° to divert upwards from the direction of travel of the conveyor S. The upstream side plate may be provided with a reinforcement guide plate 46, (Fig. 5), which possibly controls the feeding of the reinforcement 45 into or onto the gypsum boards (Fig. 2). This plate 46 may be a flange (Figures 2 and 8A) mounted obliquely outside said small trough, transverse to the conveyor S, and connected to the upstream barrier plate 35 in the plane of its lower edge. In this case, this guide 46 can be inclined by about 45 ° with respect to the conveyor S, depending on the position of the reinforcement relative to the barrier plates. Reinforcement 45 may be available in rolls. Another way to facilitate the supply of reinforcement may comprise a rounded cushion 47 (Fig. 8B) covering the lower edge of the upstream barrier plate 35. A similar padding shown at 47 'in Figures 8C and 8G may be attached to the lower edge of the downstream side plate 34. It is also possible to use one of the separate guides 46A, 48, 48A, 50, 49, 51 or 48 shown in Figures 8D, 8E, 8F, 8H, 81, 8J, 8K, respectively, which are not attached to the upstream plate 35. In a separate the guide, as shown at 49 in Figures 2 and 81, may have a curved, inclined upstream portion 49A similar to the guide 46 attached to the upstream plate 35 of the casting head C, a horizontal portion 49B and a guide portion 49C in a very small upwardly inclined portion. , at an angle of about 7 ° to the conveyor S and similar to the guide plate 44 of the casting head C.

In the case of the embodiment according to Fig. 8G, the reinforcement 45 is fed 11 67673 in the tangential direction of the rounded pad 47 'and thus cleans this, thus keeping the pad between the pad current 47' forming the lower edge of the downstream side and the conveyor constant.

The separate guide may also be a single inclined plate 50 (Fig. 6H) which is curved and similar to the plate 46 attached to the casting head plate. The separate guide may also comprise a combined pad 51 (Fig. 8J) parallel to the conveyor and at right angles to its direction of travel. and either attached to a plate 51A, the plane of which is parallel to the plane of the casting head C as shown in Fig. 8J, or is separated and made of a simple rod kept at a distance from the conveyor equal to the height at which the reinforcement is to be fed into the manufactured products, as shown at 48, 48A and 48B in Figures 3E, 8F and 8K, respectively. Several guides of the type described above can be used simultaneously, to supply several reinforcements at different height levels to the gypsum layer cast from a single casting head. In addition, a plurality of casting heads, each of which may be connected to one or more guides, may follow each other on the same building board production line; then each casting head C may be independent as shown in Fig. 2 or instead dependent on subsequent casting heads as shown in Fig. 9, wherein the downstream side plate of one pouring head forms the upstream side plate of the next pouring head. Thus, it is possible to use a single pouring head C for building boards or several successive pouring heads C, each of which casts a strip of a certain thickness, the first immediately on the conveyor S and the next casting their strips on the gypsum strip cast by the previous casting head.

The procedure is as follows.

The flowable gypsum mixture is charged to the mixer M, and its outflow is controlled by the control valve 12. The mixture flows out through the receiving tank 19. Water is sprayed from the spray nozzle 28 to flush out any gypsum splashes from inside the receiving tank 19.

This rinsing water drains through the drain openings 29. Since the opening of the lower tube 24 is above the base 26 inside the housing 25, this rinsing water cannot mix with the gypsum mixture and does not cause any change in the mixing ratios. In order to facilitate the start-up of the gypsum mixture production station, during which phase slight variations in the flowability of the gypsum can be observed, it may be desirable to release the mixture out of the production line to avoid possible mass curing at said lines where it is not intended. In this case, the flexible hose 23 coming from the device 12 is taken out of the container 19 and directed towards the outside, and then put in place once the fluidity has stabilized. During normal operation, the mixture that has passed through the receiving tank 19 is led to the pump 20. The pump 20 makes it possible to pump the mixture to its various operating positions, sometimes many tens of meters away. Then, as the case may be, the mixture is either taken immediately to one of the casting heads C or sent to a multi-branch dispenser 21. Inside the dispenser 21, the mixture first rises to the cover 31 and then enters the radial dispensing tubes 32 evenly and continuously. The mixture passes rapidly through the tubes 22, preventing any mass curing inside said tubes, and then enters the feed tubes 36, from which it divides into a small trough 34A bounded by a plate 34, plate 35, conveyor S and edge strips 33, arriving in the opposite direction. than the direction of travel of the conveyor S. The dispenser 21 makes it possible to feed from a single mixing station, with the same weight distribution, all areas dependent on a single casting head, whatever their width, makes it possible to divide the mixture stream into many smaller streams which together give the same total flow and also makes it possible to feed several casting heads.

The mixture accumulates in a small tray 34A, forming a homogeneous storage load therein. The gypsum streams coming through the nozzles 36A of the supply pipes 36 pass across the trough, collide with the slab 35, strike back and flow back towards the downstream slab 34 and so on until their energy is depleted. Thus, they form vortices that confuse the mixture and prevent the formation of backwater zones. The length of the distances between the supply pipes 34, the gypsum inlet velocity and the height at which said supply pipes 36 are mounted must be selected or adjusted so that this rotation in the trough between the downstream plate 34 and the upstream plate 35 is preferably submerged in the mixture; and in such a way that each flow line forming a reciprocating motion from the supply pipe 36 and causing a reciprocating movement is associated with the nearest rotation from the adjacent pipe 36 so that no backlash zone is left between the two flow lines. The immobility of the gypsum in any part of the trough would cause a lack of homogeneity in the mixture, which would be detrimental to the quality of the product produced and favor mass curing that would spread and eventually clog the entire casting head.

The nozzles 36A of the supply pipes 36 diverge horizontally so that the currents coming out of them cause confusion which is distributed over a wider area, so that the depth of confusion is limited and so that splashing is avoided. The water resistance of the upstream plate 35 in connection with the moving conveyor S is achieved by means of a seal 39, but it is useful to allow a small leak under the plate to prevent the formation of backwater zones in the corners of a small trough near said plate. In this case, a circular bead is formed at the rear, which is constantly re-formed due to the continuous advancement of the casting layer, which contributes to the perfection of water resistance. Such a ball is shown at 46B in Figure 8D. The downstream barrier plate 34 is raised when the screws 42a securing it to the lugs 41 are loosened to provide a gap of height e between it and the conveyor S.

In the case of thin panels, tile 44 is preferably used; this plate 44 facilitates keeping the load inside the trough 34A and prevents, when the surface height in said trough is very low, the spread of confusion which occurs therein downstream of the plate 34. It is useful to prevent the gypsum from forming deposits or mass hardening on the slabs 34, 35, subjecting them to a vertical oscillating movement at right angles to the conveyor S by the vibrators 40.

The procedure for casting head C is as follows. The dimensions of the plate to be produced at a given conveyor speed determine the amount of mixture that the mixing station must deliver and that must be cast on the conveyor S, and thus the total flow at the outlet of the feed pipes 36 as they discharge into the tray 34A. The cross section of each feed pipe 36, the size of the nozzles 36A, the number of feed pipes 36 and pipes 22 are selected so as to provide a speed in these pipes and supply pipes which does not allow deposits, i.e. in the case of gypsum, a speed greater than 10 cm / sec. Mixture 67673 14 is received in tray 34A. The height e of the gap is set below the plate 34, and the distance between the upstream plate 35 and the downstream plate 34 is adjusted so as to provide a constant surface height and satisfactory confusion in the trough and the tubes 36 are submerged in the mixture in the trough. Confusion of the mixture in the corners of the upstream plate 25 is achieved by raising this plate slightly so as to form a round ball about 5 cm long in the middle.

The following table shows two sets of casting head operating parameters as examples.

Example 1 Example 2

Conveyor speed m / min 2.50 2.50

Mixture FLS mm 230 230

Diameter of casting head supply pipes mm 8 10

Number of supply pipes per head 4 4

Width and height of the outlet of the nozzles of the supply pipes 12 15

Spacing of openings through the front plate, mm 83-150-150-150-83 83-150-150-150-83 Location of these openings from the conveyor, mm 13 17

Casting head width, mm 616 616

Distance between upstream slab and downstream slab, mm 90 110

Height of the mixture in a small trough, mm 15 20

Height of the round bead under the back plate, mm 2.5 2.5

Casting gap height e, mm, above conveyor 4 8

Thickness of manufactured panels, mm 5 10

When there are several consecutive casting heads, as in Fig. 2, they are arranged separately and in the same way because they are independent of each other.

When the casting heads are connected to each other, as in Fig. 9, the upstream casting head is set first, and then the next casting head, the height of the casting end of one end being at the same time the height of the round end of the next end, for example component 60 is constructed of gypsum board. 62, 64, and 66, whose densities are either equal or different. When several casting heads C follow one another, they can all be fed 67673 either the same product or gypsum mixtures with different densities and / or with different finely split or chopped reinforcing fibers which are added during mixing.

One or more reinforcements 45 may be fed to the sheets to be manufactured to different heights of their body and at different points on the manufacturing line. The term "reinforcement" as used herein means any material which can be applied inside or on the surface of the panels, whether they act as actual reinforcements to improve the resistance of the forces applied to said panels or to form a decorative or protective coating. In addition to strip or continuous reinforcements, other discontinuous reinforcements, such as chopped or finely divided fibers, can be fitted to the boards. Examples of reinforcements are paper, cardboard, metallic films such as aluminum foil, glass cloth, fabrics, nonwoven organic materials, continuous yarns such as glass wires or metal wires, continuous wire sheets mixed with glass, layers of zinc-shock continuous glass yarns, etc. These the reinforcements can be fed upstream of the casting head using separate guides as shown in Figures 8D and 8E. For example, the reinforcing material 45 supplied in rolls is stretched to the guide, threaded between this guide and the conveyor S and placed under the casting head C. When it adheres to the gypsum, it pulls it with it, causing the roll to be subjected to continuous drawing so that it unloads at the speed of the production line. In this way, the reinforcement can be fitted either to the underside of the panel to be manufactured by attaching the guide very close to the conveyor or to the plate frame at a distance above the conveyor equal to the height at which the reinforcement is to be placed on the plate, but not exceeding the minimum height. the upstream plate 35 and the lower plate 34 are raised relative to the conveyor. Several reinforcements can similarly be fed to different heights by several separate guides located upstream of the casting head. The reinforcements can also be fitted to the lower surface of the plate or its body by guiding them through guides 46 and 47 attached to the upstream plate 35, as shown in Figures 8a and 8B, however, the height of the reinforcement in the plate body is limited by the casting gap below the downstream plate. The guide 47 '(Fig. 80 may also be attached to the downstream side plate 34 and the height position of the reinforcement is determined by the height of the gap below the downstream side plate 34.

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The reinforcement can be fed inside the trough between the downstream plate 34 and the upstream plate 35. The height position of the reinforcement can then be determined by means of a rod-shaped guide 43, as shown in Fig. 8F, or by a circular pad 47 'attached to a downstream plate (Fig. 8G). The reinforcement fed by this method must be as permeable to gypsum as possible in order to minimize confusion inside the trough.

The reinforcement can also be fed after the gypsum layer has been cast, either on or into the gypsum surface, by a separate guide 50, 49, 51 or 48B located downstream of the casting head as in Figures 8H, 81, 8J and the like. 8K is shown. When the reinforcement is applied to the surface of the layer, it can be either porous or impermeable to a flowable gypsum mixture. When placed in the gypsum layer mass, it should preferably be porous so that the flowable mixture can penetrate through it to avoid cracking of the reinforced sheet along the level of the reinforcement. Continuous metal or other wires in layers of zigzag shock can be used to achieve a satisfactory distribution of the reinforcement throughout the gypsum mass of the reinforcement and good adhesion of the gypsum and reinforcement and to allow the gypsum to easily pass through the reinforcement.

Once the gypsum strip has been cast, it proceeds on a conveyor S framed by side strips 33 until the gypsum has hardened sufficiently for handling and cutting. The strip then moves to another conveyor. Conveyor S and side strips 33 are flushed during their return.

As is already known, it is possible to address the various stages of the gypsum reaction by adding agents which delay or accelerate curing, either before casting or after casting. The temperature of the conveyor S can also be influenced.

The products made by the method and apparatus described above can be simple gypsum or, for example, glass fiber reinforced gypsum. They can be used alone or in combination with other materials for use as a cover layer or decorative tile. They can be made as thin gypsum panels with a thickness of less than 3 mm, reinforced with continuous glass fibers, or unreinforced, or thicker panels with reinforcement to improve durability or left unreinforced, and may be covered or uncoated. It is possible to cast a very thin plaster film with a thickness of up to only 1 mm for use in coating the bottom and sides of glass fiber ceiling panels. In this case, it is possible to fresh or newly gypsum lasivillaliuska film on the immediately downstream side of the casting head, wherein the gypsum itself to hold the glass wool concerns over the commitment kovet-tumisensa, or glass wool can be molded substrate itself. Such a plate 90 is shown in Figure 20 and includes a gypsum board strip 92 attached to a glass wool pad 94.

Gypsum boards one cm thicker can be used as decorative boards for the construction of clad partitions. Hitherto, such partitions have been made of glass wool boards provided with a gas-tight barrier layer of asphalt-impregnated paper and reinforced gypsum board provided with a cover layer of cardboard. From now on, as an application of the method according to the present invention, a partition can be made of a glass wool panel, without a gas-tight barrier layer and thus without any asphalt, and with a fiberglass-reinforced gypsum board, without a cardboard top layer, the bond between the glass and the gypsum itself -is attached to fiberglass. Such clad partitions offer better fire retardant properties compared to older partitions because they leave out paper cladding boards that pose a fire risk. The method and device according to the invention make it possible not only to cast gypsum, but also to cast other evolutionary products, i. products whose physical or chemical properties change, and all non-evolutionary products such as cement.

A finished gypsum board panel 100 made using the method and apparatus described above is shown in Figure 10 and is suitable for use in construction purposes, for example.

As shown in Figure 11, the gypsum boards 102 have layers 104, 106, and 108, each layer having a different density than the other two layers. Thus, for example, the densities of the layers 104, 106 and 108 may be 1000 kg / m 2, 200 kg / m 2 and 800 kg / m 2, respectively, since the densities can be adjusted from 150 kg / m to 2000 kg / m 18 by adding in a manner known per se, a forming agent.

As shown in Fig. 12, the gypsum board 112 has layers 114, 116, and 118. The density of each layer is different from that of the other two layers, for example, so that the densities of layers 114, 116, and 118 are 800 kg / m 2, 300 kg / m 2, and 900 kg / m 2. The woven reinforcement fabric 120 is between the layers 114 and 116, similarly the woven reinforcement fabric 122 is between the layers 116 and 118. The fabrics 120 and 122 are porous enough for the gypsum to penetrate between the yarns forming the fabrics.

Embedded in the center of the gypsum board 126 of Fig. 13 is a woven reinforcing fabric 128, such as fiberglass.

The panel 132 shown in Fig. 14 comprises a gypsum board 134 and a glass-fiber mat coating 136 on said board, such that the fibers 138 of the mat 136 are sunk into the board 134 and shown enlarged.

Figure 15 shows a gypsum board 142 having layers 144, 146 and 148 of gypsum, of which layers 144 and 148 are reinforced with thin aluminum sheets 150 and the like. 152.

All of the above plates and their numerous variations are easy to make using the apparatus and method described above and are useful, for example, as building elements.

A preferred receiving tank 200 to replace the receiving tank 19 is shown in Figure 16. The upper end 202 of the tank 200 is open and receives an outlet flow from a pipe 23 having a valve 204 used to close the flow mixer M during start-up delivery so that the valve 12 setting can be left to rest after the previous run, if it is manual or can be left connected to an automatic valve setting device which operates, for example, controlled by the weight of the mixer M. The receiving tank 200, which is physically separate from the mixer M but still provides a continuous flow, allows the mixer M to be weighed to determine the amount of material it contains.

In the embodiment of Figure 16, a funnel 206 is connected to the upper end of the tube 24 for collecting the outlet flow of the tube 23. The hopper 206 ensures the collection of all parts of the outflow of the pipe 23 which, when discharged, disintegrate beyond the diameter of the pipe 23.

As shown in Fig. 17, the casting head 3 has a vertical upstream side plate 220 and a curved downstream side plate 222 with a rounded lower edge 224 with a reinforcement 45 to keep the plate 222 clean, including the lower edge 224, and a constant distance between the plate 222 and the conveyor 226.

As shown in Figure 18, the preferred gypsum board 240 has a reinforcing layer consisting of a continuous filament mat 242 with layers of fiberglass mesh 244 and 246, respectively, above and below, to limit the layer 242 and prevent it from spreading apart. This gypsum board is advantageous because the mat 242 makes the board very strong.

As shown in Fig. 19, the gypsum board 250 has a reinforcing layer of chopped glass fibers 242 between the upper fiberglass mesh layer 254 and the lower fiberglass mesh layer 256. This sheet is advantageous because the chopped fibers are less expensive than the mat 242 and still give the sheet 250 high strength. The nets 254 and 256 restrict the glass fibers 252 and prevent them from escaping from the sheet and being pushed to the sides from the side edges of the sheet 250. This is very important especially on a thin plate.

Claims (20)

A method of manufacturing plaster or boards of plaster by casting an evolutionary liquid product consisting of a mixture substantially of gypsum and water, and having a FLS flowability exceeding 120, on a horizontal casting base (S), which moves uniformly from one or more containers (34A) arranged directly on the casting base and the load casting base, through a transverse gap which is parallel to and adjacent to the casting base (S) and is provided under the downstream wall of the container (s) (34). -characterized by continuously introducing fresh product into the container (s) (34A) in the form of a plurality of masses of product streams which are directed substantially horizontally in the direction opposite to the direction of the feed substrate (S) feeding direction. Process according to claim 1, characterized in that the streams of the fresh product are arranged horizontally side by side. 3. A method according to claim 1 or 2, characterized in that the energy of the streams of the fresh product stirs the product in the container in accordance with reciprocating flow lines. Method according to claim 3, characterized in that the distance between the currents arriving in the container (34A) is such that the stirring lines intersect and spread in the plane of the currents over the entire surface of the container. Method according to claim 3 or 4, characterized in that the height of the inlets of the currents in the container (34A) is such that the flow lines project into the free surface of the product in the container. Method according to any of claims 1-5, characterized in that the walls (34, 35) of the container (34, 35.) are subjected to vibration. 7. A method according to any one of claims 1-6, characterized in that the rear wall (35) of the container (34A) is raised from the casting base (S) to allow the formation of a bead (35A) of material behind the container. 8. A process according to any one of claims 1-7, characterized in that several product layers are successively cast in the same line for the manufacture of plates or sheets, the first of these directly on the casting substrate and the following on the already cast layer or layers. already cast layers. Apparatus for applying the method according to claims 1-8 in the manufacture of tiles or sheets of gypsum by casting an evolutionary liquid product consisting of a mixture essentially of gypsum and water, the apparatus comprising one or more containers (34A) without the bottom resting on a movable horizontal casting base (S) and which device has a gap bounded by the casting base and by the lower edge of the plate forming the front wall (34) of the container, characterized in that the outside of the front wall (34) is provided with a a plurality of tubes (36) for feeding the product, which tubes open into the container (s) (34A) through the front wall (34). Device according to claim 9, characterized in that the feed pipes (36) are parallel immediately before their passage through the front wall (34). 11. Device according to claim 9 or 10, characterized in that the feeding ends of the tubes (36) at the side of the front wall (34) of the container (34A) lie in the same horizontal plane. 12. Apparatus according to any one of claims 9-11, characterized in that the joint points of the feeding tubes (36) located transversely over the front wall (34) are distributed along the entire length of this wall. 25 67673 13. Apparatus according to any of the claims 9-12, characterized in that the container (34A) is formed of two vertical plates which are perpendicular to the direction of feeding of the casting base (S) and which form a front wall (34) and a rear wall (35), and of two movable side straps (33) which are adapted to move at the same speed as the casting base and which have their ends attached to the front and rear wall. Device according to claim 13, characterized in that the front wall (34) and the rear wall (35) are adapted to be attached to a support frame by angles (41) provided with elongated fastening heels (43) allowing modification of its height, wherein the rear wall (35) is also adjustable in the forward direction of the casting support (S). Device according to claim 13 or 14, characterized in that the front wall (34) and the rear wall (35) are provided with vibrators (40). Device according to any of claims 13-15, characterized in that the outlet ends of the supply pipes (36), which are connected to the front wall (34), have nozzles (36A) which diverge laterally. Device according to any of claims 9-16, characterized in that the front wall (34) is provided with a guide plate (44) externally of the container (34A), which plate is connected to the front wall (34) in level with its lower edge and is approximately parallel to the casting base (S), such that the outer edge of the guide plate (44) is not lower than the edge connected to its front wall (34). Apparatus according to any of claims 9-17, characterized in that the feeding tubes (36) are connected to the manufacturing device of the product to be cast by a pump (20).