Self-leveling gypsum base plate, production equipment and production process
By designing self-leveling gypsum substrates and their production equipment, the problems of gypsum substrate flatness and production efficiency are solved, an efficient, energy-saving and automated production process is achieved, and the stability and consistency of product quality are ensured.
Patent Information
- Application Number
- CN202510795362.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-15
- Publication Date
- 2025-09-05
AI Technical Summary
The flatness of existing gypsum substrates is difficult to ensure during construction, and the production equipment is inefficient, energy-intensive, and has an insufficient degree of automation, resulting in unstable product quality.
Design self-leveling gypsum substrates and their supporting production equipment, using specially formulated base and self-leveling layer materials, and processing them through efficient automated production equipment, including raw material transportation, mixing, molding and drying systems, and precisely controlling production parameters.
It improves the flatness and strength of the gypsum base plate, reduces production energy consumption, achieves stability and consistency of product quality, and improves production efficiency.
Smart Images
Figure CN120590135A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of building materials, and in particular to a self-leveling gypsum base plate, production equipment and a production process. Background Art
[0002] In the field of building decoration and renovation, gypsum substrates are widely used due to their lightweight, fireproof, and soundproof properties. However, existing gypsum substrates present numerous challenges. For example, during floor or wall construction, the smoothness of conventional gypsum substrates is difficult to maintain, compromising the quality of subsequent decorative layers (such as flooring and wall paint). This not only increases the difficulty of construction but can also lead to unevenness and hollowing of the decorative layers. Furthermore, existing gypsum substrate production equipment suffers from low production efficiency, high energy consumption, and insufficient automation, making it difficult to meet growing market demand. Furthermore, during the production process, inaccurate control of raw material mixing, molding pressure, and temperature results in inconsistent quality and makes it difficult to guarantee product stability and consistency.
[0003] In order to solve the above problems, it is urgent to develop a self-leveling gypsum base plate that can automatically level and has high flatness, and at the same time design a set of supporting high-efficiency, energy-saving, and highly automated production equipment to improve the production quality and efficiency of the gypsum base plate. Summary of the Invention
[0004] The present invention addresses the deficiencies in the prior art and provides a self-leveling gypsum base plate and production equipment thereof. The self-leveling gypsum base plate has good flatness, high strength and good durability. At the same time, the production equipment can realize automated production, improve production efficiency, reduce energy consumption, accurately control various parameters in the production process, and ensure the stability and consistency of product quality.
[0005] In order to solve the above technical problems, the present invention is solved through the following technical solution: a self-leveling gypsum substrate, which includes a base layer and a self-leveling layer; wherein, calculated by weight, the base layer includes 100 parts of building gypsum, 0.2-0.4 parts of a composite retarder, 0.3-0.7 parts of a high-performance polycarboxylic acid water reducer, 6-12 parts of mixed fiber, and 15-25 parts of a functional filler; the self-leveling layer includes 80-120 parts of hemihydrate gypsum, 2-6 parts of redispersible latex powder, 0.1-0.5 parts of cellulose ether, 0.05-0.2 parts of a defoaming agent, 0-5 parts of a pigment, and 30-60 parts of water; the self-leveling layer materials are evenly mixed and laid on the formed base layer.
[0006] In the above technical solution, preferably, the composite retarder is a mixture of citric acid and sodium tartrate in a mass ratio of 1:1; the water reduction rate of the high-performance polycarboxylic acid water reducer is not less than 30%; the mixed fiber is a mixture of glass fiber and polypropylene fiber in a mass ratio of 2:1, and the length of the glass fiber is 3-6 mm, and the length of the polypropylene fiber is 2-4 mm; the functional filler is a mixture of calcium carbonate and quartz sand in a mass ratio of 3:2, wherein the particle size of the calcium carbonate is 100-200 mesh, and the particle size of the quartz sand is 50-100 mesh.
[0007] In the above technical solution, preferably, a bonding layer is provided between the base layer and the self-leveling layer, the bonding layer is an emulsion-type adhesive, and the emulsion-type adhesive is provided with epoxy resin microcapsules.
[0008] In the above technical solution, preferably, the particle size of the microcapsules is within 50-100 μm; the wall material of the microcapsules is a gelatin-gum arabic composite film with a thickness of 2-3 μm, and the core material is epoxy resin and curing agent with a mass ratio of 2:1.
[0009] A production device for a self-leveling gypsum base plate comprises a raw material conveying system, a mixing and stirring system, a molding system, a drying system, a semi-finished product conveying system, and an intelligent control system. The raw material conveying system is used to transport raw materials to the mixing and stirring system. The semi-finished product conveying system transports semi-finished products from the mixing and stirring system and the molding system to the next workstation. The mixing and stirring system is used to thoroughly mix and stir various raw materials. The molding system is used to form the mixed raw materials into the shape of a self-leveling gypsum base plate. The drying system is used to dry the molded self-leveling gypsum base plate. The intelligent control system is used to monitor and adjust the operating parameters of each system.
[0010] In the above technical solution, preferably, the mixing and stirring system includes a first processing part and a second processing part, and the first processing part and the second processing part both include a premixer and a fine mixer connected in sequence, and the premixer adopts a double propeller structure with a pitch of 150 mm and a rotation speed of 80±5 r / min; the fine mixer adopts a colloid mill and an ultrasonic vibration device is arranged outside the cylinder.
[0011] In the above technical solution, preferably, the molding system includes a spraying device, a mold, a vibration device and a flattening device; the vibration device is used to vibrate the mold after the raw material is injected into the mold; the flattening device is used to flatten the surface of the raw material after vibration to ensure the flatness of the substrate surface; the mold has a built-in pressure sensor and a thermocouple.
[0012] In the above technical solution, preferably, the drying system includes a drying kiln, a hot air circulation device, a drying box and a transport track connected at the end; the drying kiln includes a preheating zone, a constant temperature zone and a cooling zone, and a waiting area is provided outside the drying kiln. Each zone is independently connected to the hot air circulation device by airflow, and the working parameters of each zone can be set independently without interfering with each other; the temperature of the constant temperature zone is controlled at 70±1°C, the humidity is 50±3%RH, and the wind speed is 1.5±0.2m / s; several mobile platforms are arranged on the transport track; the self-leveling gypsum substrate to be processed is placed on the mobile platform.
[0013] In the above technical solution, preferably, the drying box is provided with an auxiliary air inlet pipe and an air supply pipe, the auxiliary air inlet pipe is used to connect to the outside air intake; the air supply pipe is connected to the cooling zone; the cooling air outlet pipe of the cooling zone is connected to the preheating zone; the preheating air outlet pipe of the preheating zone is connected to the hot air circulation device; the hot air circulation device heats the air and dries it again, and then transports it to the constant temperature zone through the hot air pipe; the constant temperature air outlet pipe of the constant temperature zone is connected to the preheating zone.
[0014] A production process for a self-leveling gypsum substrate comprises the following steps: a raw material conveying system conveys building gypsum, a composite retarder, a high-performance polycarboxylic acid-based water-reducing agent, mixed fibers, and functional fillers to a first processing section of a mixing and stirring system according to the number of portions; and at the same time, the raw material conveying system conveys semi-hydrated gypsum, redispersible latex powder, cellulose ether, defoaming agent, pigment, and water to the first processing section of the mixing and stirring system according to the number of portions; a second step, the mixing and stirring system starts working to stir the raw materials in the first processing section and the second processing section to fully mix them; a third step, after the mixing and stirring system is completed, the semi-finished product conveying system First, the base mixture is transported to the mold of the molding system, and then the vibration device is started to vibrate the mold to make the base mixture dense; Step 4, after the base is processed, the spraying device evenly sprays the bonding layer on it; Step 5, after the spraying work is completed, the semi-finished product conveying system evenly lays the self-leveling layer mixture on the bonding layer, and the flattening device slowly presses down to flatten it, and then allows it to stand for treatment; Step 6, after the standing treatment is completed, the worker removes the gypsum substrate from the mold and transports it to the drying kiln for drying treatment; Step 7, after the drying treatment is completed, the finished self-leveling gypsum substrate is obtained.
[0015] The present invention provides a self-leveling gypsum base plate and production equipment thereof. The self-leveling gypsum base plate has good flatness, high strength and good durability. At the same time, the production equipment can realize automated production, improve production efficiency, reduce energy consumption, accurately control various parameters in the production process, and ensure the stability and consistency of product quality. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be discussed below. Obviously, the technical solutions described in conjunction with the drawings are only some embodiments of the present invention. For ordinary technicians in this field, other embodiments and their drawings can be obtained based on the embodiments shown in these drawings without paying any creative work.
[0017] Figure 1 It is a schematic diagram of the structure of the molding system in the production device of the present invention.
[0018] Figure 2 It is a schematic diagram of the structure of the drying system in the production device of the present invention.
[0019] In the figure: mold 1, vibration base 11, base 12, top plate 13, bracket 14, motor platform 141, flattening device 15, pressing plate 151, drive motor 2, first screw 21, guide rod 22, spraying device 3, second screw 31, nozzle 31, drying kiln 4, preheating zone 41, preheating air outlet pipe 411, constant temperature zone 42, constant temperature air outlet pipe 421, cooling zone 43, cooling air outlet pipe 431, waiting area 44, mobile platform 45, hot air circulation device 5, main air inlet pipe 51, drying box 6, auxiliary air inlet pipe 61, air delivery pipe 62, working track 7. DETAILED DESCRIPTION
[0020] The following will provide a clear and complete description of the technical solutions of various embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments described in the present invention, all other embodiments derived by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0021] The self-leveling gypsum base plate of the present invention has been tested to have significantly improved compressive strength, reaching 32 MPa and 6.3 MPa, with a high base strength and excellent self-leveling layer flatness, meeting the requirements of architectural decoration and renovation projects. Furthermore, the production equipment of the present invention enables efficient and stable production of self-leveling gypsum base plates, improving production efficiency and product quality while reducing production costs. The high-strength base plates can meet the requirements of heavy-duty environments such as industrial plants and shopping malls.
[0022] Embodiment 1 of the present invention discloses a self-leveling gypsum substrate, comprising a base layer and a self-leveling layer. The base layer comprises 100 parts of building gypsum, 0.2 parts of a composite retarder, 0.3 parts of a high-performance polycarboxylate-based water-reducing agent, 6 parts of mixed fiber, and 15 parts of a functional filler. The self-leveling layer comprises 80 parts of hemihydrate gypsum, 2 parts of redispersible latex powder, 0.1 parts of cellulose ether, 0.05 parts of a defoamer, 1 part of a pigment, and 30 parts of water. The self-leveling layer materials are mixed evenly and then laid on the formed base layer. The pigment content is selected from 0 to 5 parts according to actual requirements.
[0023] Among them, the composite retarder is a mixture of citric acid and sodium tartrate in a mass ratio of 1:1; the water reduction rate of the high-performance polycarboxylic acid water reducer is not less than 30%; the mixed fiber is a mixture of glass fiber and polypropylene fiber in a mass ratio of 2:1, and the length of the glass fiber is 3-6 mm, and the length of the polypropylene fiber is 2-4 mm; the functional filler is a mixture of calcium carbonate and quartz sand in a mass ratio of 3:2, wherein the particle size of the calcium carbonate is 100-200 mesh, and the particle size of the quartz sand is 50-100 mesh.
[0024] Furthermore, a bonding layer is provided between the base layer and the self-leveling layer. The bonding layer is an emulsion-based adhesive containing epoxy resin microcapsules with a particle size of 50-100 μm. The wall material is a gelatin-gum arabic composite film with a thickness of 2-3 μm, and the core material is epoxy resin and curing agent in a mass ratio of 2:1.
[0025] A second embodiment of the present invention discloses a self-leveling gypsum substrate, comprising a base layer and a self-leveling layer. The base layer comprises 100 parts of building gypsum, 0.3 parts of a composite retarder, 0.5 parts of a high-performance polycarboxylate-based water reducer, 10 parts of mixed fiber, and 20 parts of a functional filler. The self-leveling layer comprises 100 parts of hemihydrate gypsum, 4 parts of redispersible latex powder, 0.4 parts of cellulose ether, 0.1 parts of a defoamer, and 45 parts of water. The self-leveling layer materials are mixed evenly and then laid on the formed base layer. The pigment content is selected from 0 to 5 parts according to actual requirements.
[0026] The composite retarder is a mixture of citric acid and sodium tartrate in a mass ratio of 1:1; the water reduction rate of the high-performance polycarboxylic acid water reducer is not less than 30%; the mixed fiber is a mixture of glass fiber and polypropylene fiber in a mass ratio of 2:1, and the length of the glass fiber is 3-6 mm, and the length of the polypropylene fiber is 2-4 mm; the functional filler is a mixture of calcium carbonate and quartz sand in a mass ratio of 3:2, wherein the particle size of the calcium carbonate is 100-200 mesh, and the particle size of the quartz sand is 50-100 mesh.
[0027] Furthermore, a bonding layer is provided between the base layer and the self-leveling layer. The bonding layer is an emulsion-based adhesive containing epoxy resin microcapsules with a particle size of 50-100 μm. The wall material is a gelatin-gum arabic composite film with a thickness of 2-3 μm, and the core material is epoxy resin and curing agent in a mass ratio of 2:1.
[0028] The third embodiment of the present invention discloses a self-leveling gypsum substrate, comprising a base layer and a self-leveling layer. The base layer comprises 100 parts of building gypsum, 0.4 parts of a composite retarder, 0.7 parts of a high-performance polycarboxylate-based water reducer, 12 parts of mixed fiber, and 25 parts of a functional filler. The self-leveling layer comprises 120 parts of hemihydrate gypsum, 6 parts of redispersible latex powder, 0.5 parts of cellulose ether, 0.2 parts of a defoamer, and 60 parts of water. The self-leveling layer materials are mixed evenly and then laid on the formed base layer. The pigment content is selected from 0 to 5 parts according to actual requirements.
[0029] The composite retarder is a mixture of citric acid and sodium tartrate in a mass ratio of 1:1; the water reduction rate of the high-performance polycarboxylic acid water reducer is not less than 30%; the mixed fiber is a mixture of glass fiber and polypropylene fiber in a mass ratio of 2:1, and the length of the glass fiber is 3-6 mm, and the length of the polypropylene fiber is 2-4 mm; the functional filler is a mixture of calcium carbonate and quartz sand in a mass ratio of 3:2, wherein the particle size of the calcium carbonate is 100-200 mesh, and the particle size of the quartz sand is 50-100 mesh.
[0030] Furthermore, a bonding layer is placed between the base layer and the self-leveling layer. This bonding layer is an emulsion-based adhesive containing epoxy resin microcapsules. These microcapsules have a particle size of 50-100 μm. The wall material is a gelatin-gum arabic composite film with a thickness of 2-3 μm, and the core material is epoxy resin and curing agent in a mass ratio of 2:1. When the microcapsules rupture in contact with water, the bond strength increases to over 1.5 MPa, ensuring that the self-leveling layer adheres well to the base layer.
[0031] Embodiment 4 of the present invention discloses a production device for a self-leveling gypsum base plate, comprising a raw material conveying system, a mixing and stirring system, a molding system, a drying system, a semi-finished product conveying system, and an intelligent control system; the raw material conveying system is used to transport raw materials to the mixing and stirring system; the semi-finished product conveying system transports the semi-finished products of the mixing and stirring system and the molding system to the next workstation; the mixing and stirring system is used to fully mix and stir various raw materials; the molding system is used to form the mixed raw materials into the shape of a self-leveling gypsum base plate; the drying system is used to dry the molded self-leveling gypsum base plate; and the intelligent control system is used to monitor and adjust the working parameters of each system.
[0032] The mixing and stirring system includes a first processing part and a second processing part, each of which includes a premixer and a fine mixer connected in sequence. The premixer adopts a double-screw structure with a pitch of 150 mm and a rotation speed of 80±5 r / min; the fine mixer adopts a colloid mill and an ultrasonic vibration device is arranged outside the cylinder.
[0033] The mixing and stirring system includes a first processing section and a second processing section, one for the base layer raw material mixture and the other for the self-leveling layer raw material mixture, respectively. The raw material conveying system of this device also includes two raw material conveyor belts, one for conveying the base layer raw material and the other for conveying the self-leveling layer raw material. The raw material conveyor belts are equipped with hoppers, and above them are drop hoppers for each component. Each drop hopper has a material tray below its discharge port, and a weighing mechanism is installed at the bottom of the tray. A flipping mechanism is hinged on the side of the tray, and the flipping mechanism is equipped with a detection probe. When the detection probe detects the hopper passing below, the tray flips, allowing the raw materials to fall into the hopper below.
[0034] The raw material conveyor belt transports the respective hoppers to above the feed ports of the first processing section and the second processing section, and then introduces the raw materials into the feed ports, thereby entering the corresponding first processing section and the second processing section.
[0035] The semi-finished product conveying system also features two conveyor belts, each equipped with an intermediate silo. The base layer and self-leveling layer mixtures, after mixing in the first and second processing sections, are poured into the corresponding intermediate silos and transported by the conveyor belts to the molding system for further processing.
[0036] As attached Figure 1 The figure shows a schematic structural diagram of the molding system, which includes a spraying device, a mold 1, a vibration device and a flattening device 15; the vibration device is used to vibrate the mold 1 after the raw material is injected into the mold; the flattening device 15 is used to flatten the surface of the raw material after vibration to ensure the flatness of the substrate surface; the mold 1 has a built-in pressure sensor and a thermocouple.
[0037] The vibration device includes a vibrator and a vibration base 11 : the vibrator drives the vibration base 11 to vibrate. The mold 1 is mounted on the vibration base 11 . The vibration device is fixed on the base 12 .
[0038] A bracket 14 is provided around the base 12, and the bracket includes four columns. The four columns are divided into two groups, with the transport direction of the raw material conveyor belt as the boundary, and the columns on the same side are one group. A first screw 21 and a guide rod 22 are provided between the columns of one group, and two guide rods 22 are provided between the columns of the second group. A motor platform 141 is provided on one of the columns of the first group, and a drive motor 2 is provided on the motor platform 141. The drive motor 2 drives the first screw 21 to rotate. A first movable seat is provided on the first screw 21, and the movable seat is passed through by the guide rod 22 on the same side and provided with a guiding function. The drive motor drives the second screw 21 to rotate, thereby driving the first movable seat to move.
[0039] A second movable base is mounted on the two guide rods 22 of the second set of columns. A second lead screw 31 and a guide rod 22 are fixedly mounted between the first and second movable bases. A spraying device 31 is movably mounted on the second lead screw 31. Several spray heads 31 are mounted at the bottom of the spraying device 31. Each spray head 31 is equipped with a flow meter to calculate the spray volume of that spray head 31.
[0040] A feed pipe and a power transmission pipe are installed on top of the spraying device 31. The feed pipe is used to supply the emulsion adhesive, while the power transmission pipe contains a power line that provides power to the spraying device 31 and a signal line for signal transmission. The signal line is connected to a flow meter. A drive mechanism is installed within the spraying device 31 to cooperate with the second lead screw 31 to move the spraying device 31 along the second lead screw 31.
[0041] A flattening device 15 is installed above the mold 1. This device is equipped with a pressing plate 151. This pressing plate 151 presses downward onto the self-leveling layer's raw material mixture, ensuring that its diffusion surface rests on the base sheet. A pressure sensor detects the pressure within the mold 1 and controls the downward force of the pressing plate, maintaining it at a specific operating pressure, thereby enhancing the strength of the finished product.
[0042] As attached Figure 1 The figure shows a schematic structural diagram of the drying system: the drying system includes a drying kiln, a hot air circulation device, a drying box and a transport track connected at the end; the drying kiln includes a preheating zone, a constant temperature zone and a cooling zone, and a waiting area is provided outside the drying kiln. Each zone is independently connected to the hot air circulation device by airflow, and the operating parameters of each zone can be independently set without interfering with each other; the temperature of the constant temperature zone is controlled at 70±1°C, the humidity is 50±3%RH, and the wind speed is 1.5±0.2m / s; a number of mobile platforms 45 are arranged on the transport track; the self-leveling gypsum substrate to be processed is placed on the mobile platform 45.
[0043] The hot air circulation device 5 is provided with a main air intake pipe 51, an air pump, a dehumidification and dust removal unit, and a heating unit. The air pump draws air from the outside through the main air intake pipe 51, then transports it to the dehumidification and dust removal unit for filtration and dehumidification, and finally heats it in the heating unit before transporting it to the constant temperature zone 42.
[0044] The drying oven 6 is equipped with a secondary air inlet pipe 61 and an air supply pipe 62. The secondary air inlet pipe 61 is used to connect to the outside world and draw in air. After drying, the air drawn into the drying oven 6 is connected to the cooling zone 43 via the air supply pipe 62. The cooling outlet pipe 431 of the cooling zone 43 is connected to the preheating zone 41. The preheating outlet pipe 411 of the preheating zone 41 is connected to the hot air circulation device 5. The hot air circulation device 5 heats and dries the air again before transporting it to the constant temperature zone 42 via the hot air pipe 52. The constant temperature outlet pipe 421 of the constant temperature zone 42 is connected to the preheating zone 41. This device recycles the output air from the cooling zone 43 and the constant temperature zone 42, directing it into the preheating zone 41 for full utilization and preheating. The recovery mechanism implemented in this device achieves an energy consumption of ≤55 kWh per square meter of substrate drying, saving over 30% energy compared to traditional processes.
[0045] Furthermore, the drying kiln 4 of this device is equipped with three preheating zones 41, each of which is connected to a constant temperature zone 42. The drying process of gypsum substrates is quite time-consuming, so by having three preheating zones and three constant temperature zones, continuous operation can be achieved 24 hours a day, greatly improving work efficiency.
[0046] The drying kiln 4 includes a cooling zone 43, where the self-leveling gypsum substrates are placed for cooling after being processed in the three constant temperature zones 42. The cooling process is not time-limited but rather determined by temperature. Therefore, a single cooling zone is sufficient to meet demand. Once the temperature in the cooling zone drops to room temperature, the self-leveling gypsum substrates are transported to the waiting area for packaging and shipment.
[0047] Based on the drying system's aforementioned structural design, the transport track also features three working tracks, connecting the three preheating zones 41 with the three constant temperature zones 42, and connecting the three constant temperature zones with a cooling zone 43. The working tracks exiting the cooling zone 43 connect to the waiting zone 44; finally, the working tracks exiting the waiting zone 44 recirculate and connect to the preheating zone 41. Each working track is equipped with several mobile platforms 45, which are used to place the self-leveling gypsum substrate to be dried.
[0048] The fifth embodiment of the present invention discloses a production process for a self-leveling gypsum base plate, comprising the following steps: a raw material conveying system conveys building gypsum, composite retarder, high-performance polycarboxylic acid water-reducing agent, mixed fiber and functional filler according to the number of portions to the first processing part of the mixing and stirring system; and at the same time, the raw material conveying system conveys semi-hydrated gypsum, redispersible latex powder, cellulose ether, defoaming agent, pigment and water according to the number of portions to the first processing part of the mixing and stirring system; a second step, the mixing and stirring system starts working to stir the raw materials in the first processing part and the second processing part to make them fully mixed; a third step, after the mixing and stirring system is completed, the semi-finished product conveying system first mixes the base material raw materials The mixed liquid is transported to the mold of the molding system, and then the vibration device is started to vibrate the mold to make the base raw material mixture dense and form a base board; Step 4. After the base board is processed, the spraying device evenly sprays the bonding layer on it; Step 5. After the spraying work is completed, the semi-finished product conveying system will lay the self-leveling layer raw material mixture on the bonding layer, and it will spread to the surroundings due to its own characteristics. The flattening device will then slowly press down to flatten it, and then let it stand; Step 6. After the standing treatment is completed, the worker will take the gypsum base plate out of the mold and transport it to the drying kiln for drying; Step 7. After the drying treatment is completed, the finished self-leveling gypsum base plate is obtained.
[0049] During the mixing process in step 2, the operating parameters for the base material mixture and the self-leveling layer mixture are different. The base material mixture is stirred in the premixer for 3-5 minutes and in the fine mixer for 5-8 minutes, with the ultrasonic vibration device operating at a frequency of 40±5kHz. The self-leveling layer mixture is stirred in the premixer for 4-6 minutes and in the fine mixer for 8-10 minutes, with the ultrasonic vibration device operating at a frequency of 60±5kHz.
[0050] In step three, the vibrating device vibrates the mold containing the base mixture for 5-7 minutes.
[0051] In step five, after the flattening device is used to flatten the surface, the surface is left to stand for 24-30 hours, and the self-leveling layer is deemed to be free of visible dripping from the edge within 15 seconds.
[0052] In step six, the drying time is 12-18 hours.
[0053] After step six is completed, a whole piece of self-leveling gypsum base is obtained and finally transported by a transport device.
[0054] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive. The scope of the present invention is defined by the appended claims, not the foregoing description, and it is intended that all variations within the meaning and range of equivalents of the claims be encompassed within the present invention. Any reference numerals in the claims should not be construed as limiting the claim to which they relate.
[0055] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.
Claims
1. A self-leveling gypsum substrate, characterized in that: The self-leveling gypsum substrate includes a base layer and a self-leveling layer; wherein, calculated by weight, the base layer includes 100 parts of building gypsum, 0.2-0.4 parts of a composite retarder, 0.3-0.7 parts of a high-performance polycarboxylic acid water reducer, 6-12 parts of mixed fiber, and 15-25 parts of a functional filler; the self-leveling layer includes 80-120 parts of hemihydrate gypsum, 2-6 parts of redispersible latex powder, 0.1-0.5 parts of cellulose ether, 0.05-0.2 parts of a defoaming agent, 0-5 parts of a pigment, and 30-60 parts of water; and the self-leveling layer materials are evenly mixed and laid on the formed base layer.
2. The self-leveling gypsum substrate according to claim 1, characterized in that: The composite retarder is formed by mixing citric acid and sodium tartrate in a mass ratio of 1:1; the water reduction rate of the high-performance polycarboxylic acid-based water reducer is not less than 30%; the mixed fiber is formed by mixing glass fiber and polypropylene fiber in a mass ratio of 2:1, and the length of the glass fiber is 3-6 mm, and the length of the polypropylene fiber is 2-4 mm; the functional filler is formed by mixing calcium carbonate and quartz sand in a mass ratio of 3:2, wherein the particle size of the calcium carbonate is 100-200 mesh, and the particle size of the quartz sand is 50-100 mesh.
3. The self-leveling gypsum substrate according to claim 1, characterized in that: A bonding layer is provided between the base layer and the self-leveling layer. The bonding layer is an emulsion-type adhesive, and the emulsion-type adhesive is provided with epoxy resin microcapsules.
4. The self-leveling gypsum substrate according to claim 3, characterized in that: The particle size of the microcapsule is within 50-100 μm; the wall material of the microcapsule is a gelatin-gum arabic composite film with a thickness of 2-3 μm; the core material is epoxy resin and curing agent with a mass ratio of 2:
1.
5. A production device for a self-leveling gypsum substrate, characterized in that: It includes a raw material conveying system, a mixing and stirring system, a molding system, a drying system, a semi-finished product conveying system and an intelligent control system; the raw material conveying system is used to transport raw materials to the mixing and stirring system; the semi-finished product conveying system transports the semi-finished products of the mixing and stirring system and the molding system to the next workstation; the mixing and stirring system is used to fully mix and stir various raw materials; the molding system is used to form the mixed raw materials into the shape of a self-leveling gypsum substrate; the drying system is used to dry the self-leveling gypsum substrate after molding; and the intelligent control system is used to monitor and adjust the working parameters of each system.
6. The production device according to claim 5, characterized in that: The mixing and stirring system includes a first processing part and a second processing part, each of which includes a premixer and a fine mixer connected in sequence. The premixer adopts a double-screw structure with a pitch of 150 mm and a rotation speed of 80±5 r / min; the fine mixer adopts a colloid mill and an ultrasonic vibration device is arranged outside the cylinder.
7. The production device according to claim 5, characterized in that: The molding system includes a spraying device, a mold, a vibration device and a flattening device; the vibration device is used to vibrate the mold after the raw material is injected into the mold; the flattening device is used to flatten the surface of the raw material after vibration to ensure the flatness of the substrate surface; the mold has a built-in pressure sensor and thermocouple.
8. The production device according to claim 5, characterized in that: The drying system includes a drying kiln, a hot air circulation device, a drying box, and a transport track connected to the end. The drying kiln includes a preheating zone, a constant temperature zone, and a cooling zone. A waiting area is provided outside the drying kiln. Each zone is independently connected to the hot air circulation device by airflow, and the operating parameters of each zone can be independently set without interfering with each other. The constant temperature zone is controlled at 70±1°C, 50±3%RH, and a wind speed of 1.5±0.2m / s. Several mobile platforms are installed on the transport track; the self-leveling gypsum substrate to be processed is placed on the mobile platforms.
9. The production device according to claim 8, characterized in that: The drying box is provided with an auxiliary air inlet pipe and an air supply pipe, the auxiliary air inlet pipe is used to connect to the outside to inhale air; the air supply pipe is connected to the cooling zone; the cooling air outlet pipe of the cooling zone is connected to the preheating zone; the preheating air outlet pipe of the preheating zone is connected to the hot air circulation device; the hot air circulation device heats the air and dries it again, and then transports it to the constant temperature zone through the hot air pipe; the constant temperature air outlet pipe of the constant temperature zone is connected to the preheating zone.
10. A production process for a self-leveling gypsum substrate, characterized by: The process comprises the following steps: the raw material conveying system conveys building gypsum, composite retarder, high-performance polycarboxylic acid water-reducing agent, mixed fiber and functional filler to the first processing part of the mixing and stirring system according to the number of portions; and the raw material conveying system conveys semi-hydrated gypsum, redispersible latex powder, cellulose ether, defoaming agent, pigment and water to the first processing part of the mixing and stirring system according to the number of portions; the mixing and stirring system starts working to stir the raw materials in the first processing part and the second processing part to make them fully mixed; the mixing and stirring system is completed, and the semi-finished product conveying system first delivers the base mixture to the mixing and stirring system; the semi-finished product conveying system first delivers the base mixture to the mixing and stirring system; the semi-finished product conveying system delivers the semi-hydrated gypsum, redispersible latex powder, cellulose ether, defoaming agent, pigment and water to the first processing part of ... It is transported to the mold of the molding system, and then the vibration device is started to vibrate the mold to make the base mixture dense; Step 4, after the base is processed, the spraying device evenly sprays the bonding layer on it; Step 5, after the spraying work is completed, the semi-finished product conveying system evenly lays the self-leveling layer mixture on the bonding layer, and the flattening device slowly presses down to flatten it, and then allows it to stand; Step 6, after the standing treatment is completed, the worker removes the gypsum substrate from the mold and transports it to the drying kiln for drying; Step 7, after the drying treatment is completed, the finished self-leveling gypsum substrate is obtained.