Functional gradient gypsum board production system and preparation method thereof

Abstract

The invention relates to a functional gradient gypsum board production system and a preparation method thereof. The functionally gradient gypsum board production system comprises a mixing machine, a calcined gypsum slurry distributor, N composite material distribution units, M functional material storage bins and a forming device, wherein N > = 1, and M > = N. Under the condition that different functional materials are not stirred by a mixing machine, various functional materials can be uniformly distributed in gypsum slurry, uniform and ordered distribution in three dimensions of length, width and thickness of a gypsum board is realized, the functional materials are thoroughly prevented from being damaged in a mixing link, and the production efficiency of the gypsum board is improved. The product percent of pass and the production efficiency of the functional gypsum board are improved, and flexible switching of the functional gypsum board in the production process is supported.

Description

Technical Field

[0001] This article relates to the field of building materials production technology, specifically a production process, equipment, and method for functional gypsum board, and in particular a method and system for preparing functional gradient gypsum board based on ultrathin multilayer micro-area stacking technology. Background Technology

[0002] As a green building material widely used in interior partition walls and ceiling systems, the functionalization of paper-faced gypsum board is a significant trend in the current industry development. By adding specific functional particles to the core material of gypsum board, such as lightweight insulation particles (vitrified microspheres, expanded perlite), phase change material microcapsules, porous shaped phase change particles, insect repellents, fragrances, and elastic polymer particles, gypsum board can be endowed with new functions such as heat insulation, energy storage, insecticidal and insect-repellent properties, fragrance and odor removal, and enhanced toughness, significantly improving product added value and market competitiveness.

[0003] Currently, the common practice for introducing functional particles into gypsum board production lines is to feed the functional particles, calcined gypsum powder, foaming agent, water, and other components into a high-speed mechanical mixer. The strong shearing force generated by the high-speed rotating rotor inside the mixer forms a homogeneous slurry, which is then spread onto the facing paper using a single spreading device. However, this traditional mechanical mixing method has significant limitations for many of the aforementioned functional particles: (1) Damage to the structure of functional particles: On the one hand, most functional particles have low physical strength and are brittle and hard, making them easily damaged after stirring. For example, lightweight thermal insulation aggregates such as vitrified microspheres and expanded perlite are easily broken under the impact and shearing of high-speed rotors, resulting in loss of function. On the other hand, the damage to the coating layer of functional particles during stirring leads to the failure of active ingredients. For example, functional particles in the form of microcapsules (such as phase change microcapsules, insect repellent microcapsules, and aromatherapy microcapsules) have their core functional substances (phase change materials, insect repellents, and fragrances) leaking prematurely due to the damage to the outer shell. This not only causes the product to lose its expected function (such as the inability to store energy or the inability to repel insects / release fragrance for a long time), but the leaked substances may also pollute the production environment (such as the escape of volatile organic compounds), react adversely with gypsum slurry or accelerate degradation, and even affect the hydration and hardening process of gypsum itself.

[0004] (2) Functional homogeneity and singularity: Expensive functional additives need to be added to the mixer and stirred together with the gypsum slurry to be evenly distributed throughout the core of the board. However, when multiple functional additives need to be added, the existing technical solutions cannot achieve the required gradient distribution of functional additives in the thickness direction of the board, resulting in high cost and low efficiency.

[0005] (3) Poor adaptability to flexible production: Switching product formulas requires emptying the entire mixing system, which is cumbersome and makes it impossible to achieve flexible production.

[0006] Therefore, there is an urgent need to develop a non-mechanical mixing solution that can achieve uniform mixing of functional materials with gypsum slurry without damaging the functional materials, be compatible with the mainstream continuous production process of the paper-faced gypsum board industry, and enable rapid switching of flexible production of functional gypsum boards. Summary of the Invention

[0007] The following is an overview of the subject matter described in detail herein. This overview is not intended to limit the scope of protection of this application.

[0008] The purpose of this application is to provide a non-mechanical mixing method and system for manufacturing functional graded gypsum board based on existing gypsum board production lines. This method enables the uniform distribution of various functional materials in gypsum slurry without the need for mixing, and achieves a uniform and orderly distribution in the length, width, and thickness of the gypsum board. This completely avoids damage to functional materials during the mixing process, improves the product qualification rate and production efficiency of functional gypsum board, and supports flexible switching of functional gypsum board during the production process.

[0009] To achieve the above objectives, the first aspect of this application provides a functionally graded gypsum board production system, comprising: A mixer that supplies calcined gypsum slurry along the production line direction; A calcined gypsum slurry distributor is located downstream of the mixer outlet along the production line direction; the calcined gypsum slurry distributor is provided with N outlets to evenly divide the calcined gypsum slurry into N portions of calcined gypsum thin slurry. N composite fabric units, located downstream of the mixer along the production line direction, are used to receive the calcined gypsum slurry and functional materials, and to mix the functional materials with the calcined gypsum slurry. M functional material storage bins, which supply functional materials to the composite fabric unit; and The forming device is located downstream of the composite fabric unit along the production line direction.

[0010] In one exemplary embodiment, the number N of the composite fabric units is greater than or equal to 1.

[0011] In one exemplary embodiment, the number of functional material storage bins M ≥ N.

[0012] In an exemplary embodiment, when N=1, in order to ensure that the ultra-thin gypsum slurry curtain formed by the composite fabric unit can fall on the already spread gypsum slurry and to achieve a good non-mechanical mixing effect, the gypsum slurry distributor is also provided with a traditional gypsum slurry outlet for supplying gypsum slurry along the production line direction, thus solving the slurry supply problem; and a leveling roller or vibrating table is also provided between the composite fabric unit and the mixer to ensure that the gypsum slurry curtain sprayed by the composite fabric unit can fall on the already spread traditional gypsum slurry.

[0013] In one exemplary embodiment, when N≥2, the composite fabric units are arranged sequentially along the production line direction.

[0014] In one exemplary embodiment, the composite fabric unit is composed of a gypsum slurry wide fabric subunit and one or more functional material wide fabric subunits integrated together to achieve collision, wetting and mixing of calcined gypsum slurry and one or more functional materials; Optionally, various functional materials can be distributed along the width of the gypsum board, such as adding different types of functional materials to the edges and the middle of the core of the board.

[0015] In one exemplary embodiment, the length of the functional material storage bin is slightly greater than the width of the finished sheet material, and a partition is provided inside to divide the interior of the functional material storage bin into several independent storage spaces for storing different types of functional materials.

[0016] In one exemplary embodiment, the gypsum slurry wide-width fabric subunit independently controls the fabrication of the calcined gypsum thin slurry.

[0017] In one exemplary embodiment, the calcined gypsum slurry distributor divides the calcined gypsum slurry into N portions and then injects them into the corresponding gypsum slurry wide-width fabric sub-units.

[0018] In one exemplary embodiment, the wide-width gypsum slurry distribution subunit is a storage tank for storing gypsum slurry, consisting of two symmetrically structured slurry bins, bin A and bin B, each with a piston capable of alternating vertical reciprocating motion. The pistons are configured such that when the piston in bin A or bin B moves vertically downwards, the thin layer of calcined gypsum slurry is squeezed out. Simultaneously, the piston in the other bin moves vertically upwards, drawing in thin layer of calcined gypsum slurry from the calcined gypsum slurry distributor under negative pressure. Through the coordination of bins A and B, the wide-width gypsum slurry distribution subunit can continuously extrude thin layer of calcined gypsum slurry, thereby forming an ultra-thin gypsum slurry curtain.

[0019] In one exemplary embodiment, the bottom side of the A slurry bin and the B slurry bin are respectively provided with inlets for injecting calcined gypsum slurry.

[0020] In one exemplary embodiment, the bottom of the A slurry bin and the B slurry bin are provided with a common slurry extrusion nozzle for extruding a thin slurry of calcined gypsum to form an ultra-thin gypsum slurry curtain that moves vertically downward.

[0021] In one exemplary embodiment, a slurry alternating injection control device is provided at the feed inlet.

[0022] In one exemplary embodiment, the alternating slurry injection control device includes a slurry rotary distributor, a grouting pipe, and a baffle. The slurry rotary distributor controls the baffle and the grouting pipe to reciprocate between the inlets of the two slurry bins, such that when the grouting pipe is connected to the inlet of slurry bin A or slurry bin B, the baffle blocks the inlet of the other slurry bin, thereby achieving continuous relay feeding.

[0023] In one exemplary embodiment, the slurry extrusion nozzle is provided with a high-pressure nozzle connected to a high-pressure cleaning pipe for cleaning the bottom of the slurry tank before production and after production stoppage.

[0024] In one exemplary embodiment, an opening control device is provided at the slurry extrusion nozzle.

[0025] In one exemplary embodiment, the opening control device is an adjustable gate structure to control the thickness of the ultrathin gypsum slurry curtain.

[0026] In one exemplary embodiment, the piston is a hydraulically or pneumatically driven piston pusher, used to extrude the slurry under pressure under the action of the piston pusher.

[0027] In one exemplary embodiment, the piston is provided with multiple sealing grooves or sealing strips.

[0028] In one exemplary embodiment, a gas-liquid mixing nozzle and a high-pressure cleaning pipe connected to the gas-liquid mixing nozzle are provided between the sealing groove or sealing strip, for realizing dynamic real-time cleaning during piston movement.

[0029] In one exemplary embodiment, the functional material wide-width fabric subunit includes: A belt conveyor for receiving and transporting functional materials from corresponding functional material storage bins, causing the functional materials to fall under gravity to form a curtain of functional materials; and A spray nozzle is located below the belt metering conveyor.

[0030] In one exemplary embodiment, the spray nozzle includes one or more rows of nozzles for subjecting the functional material to a horizontal humidifying airflow toward the ultrathin gypsum slurry curtain during its descent under gravity. This wets the surface of the functional material particles while forming a functional material curtain with initial kinetic energy and a stable, directional orientation, thereby reducing the surface free energy when in contact with the gypsum slurry and enabling the dispensing paths of the ultrathin gypsum slurry curtain and the functional material curtain to intersect in the air.

[0031] In one exemplary embodiment, the slurry extrusion nozzle is an elongated nozzle, and the sidewall of the slurry extrusion nozzle is provided with one or more holes or slits. The functional material wide-width fabric subunit includes: A gear cylinder, the top of which intersects with a hole or gap in the side wall of the slurry extrusion nozzle, is used to receive functional materials from the corresponding functional material storage bin. The functional materials in the gear groove are injected into the unextruded gypsum slurry through the hole or gap before the slurry is extruded. Then, the composite slurry curtain mixed with functional materials is extruded from the slurry extrusion nozzle, falls and forms a multi-layer functionalized slurry layer. The gear cylinder injects a fixed amount of functional materials into the unextruded gypsum slurry in a restricted injection manner, so that the fixed amount of functional materials are mixed with the corresponding amount of gypsum slurry in a non-mechanical stirring manner to form a functional slurry.

[0032] In one exemplary embodiment, the gear cylinder has an air hole in the gear groove that connects to the gear cylinder shaft, and the gear cylinder shaft can be continuously evacuated or pressurized to change the air pressure in the gear groove.

[0033] In one exemplary embodiment, the gear of the gear cylinder is wrapped with a polymer elastic membrane, and the polymer elastic membrane is firmly bonded to the sidewall of the gear groove by a polymer adhesive, so that the polymer elastic membrane can be depressed or bulged by the change of air pressure in the gear groove. When the polymer elastic membrane is depressed, it is tightly attached to the gear groove, and when the polymer elastic membrane is bulged, the bulging surface formed is higher than the top of the gear.

[0034] In one exemplary embodiment, the gear cylinder may be one or more, and each corresponds to one of the holes or slots.

[0035] In one exemplary embodiment, the composite fabric unit further includes a baffle device, which is a reverse hydrophobic blocking device that prevents splashing and buffers the functional slurry containing the functional material and the thin slurry of calcined gypsum (used to eliminate the potential energy of the functional slurry curtain and prevent the slurry from staying on the baffle for a long time, so that it falls gently onto the previous layer of gypsum slurry), or a baffle cover located outside the gear of the gear cylinder and close to the slurry extrusion nozzle (used to form a partially closed area to cover the functional material in the gear groove for transfer to the slurry extrusion gap).

[0036] In one exemplary embodiment, the functional material storage bin is provided with a distribution wheel at the bottom for distributing functional materials during descent.

[0037] In one exemplary embodiment, the functional material wide fabric subunit may correspond to one or more functional material storage bins: when the functional material wide fabric subunit corresponds to one functional material storage bin, the functional material storage bin and the functional material wide fabric subunit are in one-to-one correspondence; When the functional material wide-width fabric subunit corresponds to two or more functional material storage bins at the same time, multiple functional material storage bins can share one functional material wide-width fabric subunit. By adjusting the width of the discharge nozzle at the bottom of the functional material storage bin, the uniform feeding of multiple functional materials along the width direction of the gypsum board can be achieved, and the fabrication of one or more functional materials can be independently controlled.

[0038] In one exemplary embodiment, the mixer includes a feeding pipe, a mixing device, a motor, and a slurry discharge pipe.

[0039] In one exemplary embodiment, the slurry discharge pipe is a rubber hose in which a vibrator is installed.

[0040] In one exemplary embodiment, the functionally graded gypsum board production system further includes a surface material feeding device, which includes an upper surface material feeding device and a lower surface material feeding device.

[0041] In one exemplary embodiment, the conventional calcined gypsum slurry outlet is located on the undercoating material feeding device.

[0042] In one exemplary embodiment, since the calcined gypsum slurry is extruded under pressure, in order to prevent the extruded slurry from falling onto the previous layer of slurry and disrupting it, the outlet of the slurry extrusion nozzle is located close to the undercoating material.

[0043] In one exemplary embodiment, the covering material is a protective paper, fiberglass mesh, or other covering material.

[0044] In one exemplary embodiment, the functionally graded gypsum board production system can be used to produce paper-faced gypsum board or paperless gypsum board.

[0045] The second aspect of this application provides a method for preparing functionally graded gypsum board using the above-described functionally graded gypsum board production system.

[0046] In one exemplary embodiment, the method includes the following steps: S1. The basic formula raw materials are added to a mixer and stirred to obtain a calcined gypsum slurry; wherein, the basic formula raw materials do not include functional materials; The S2 plaster slurry distributor evenly divides the plaster slurry into N portions of plaster thin slurry and injects them into the corresponding composite fabric units. M functional material storage bins simultaneously provide functional materials to the corresponding composite fabric units. S3 simultaneously activates N composite fabric units to mix functional materials with gypsum slurry to form a multi-layer functionalized slurry layer, which is then sequentially spread onto the underlying surface material. After S4 is layered with N composite fabric units, the multi-layer functional slurry layer is compacted by rollers, defoamed by micro-vibration, and covered with a topcoat material to form a wet board core with an N-layer functional gradient structure. After solidification, drying, and cutting, the functional gradient gypsum board is obtained.

[0047] In one exemplary embodiment, step S2 includes: The calcined gypsum slurry distributor evenly divides the calcined gypsum slurry into N portions of calcined gypsum thin slurry; The piston in either the A or B slurry bin of the gypsum slurry wide-width fabric subunit moves from the lowest point to the highest point, drawing in and filling the calcined gypsum thin slurry under negative pressure; simultaneously, M functional material storage bins supply functional materials to the functional material wide-width fabric subunit of the composite fabric unit.

[0048] In one exemplary embodiment, step S3 includes: S31 initiates the first composite fabric unit, including: S311 The piston in the A or B slurry silo moves vertically downward from the highest point. The slurry extrusion nozzle at the bottom of the A or B slurry silo expels and empties the calcined gypsum slurry. At this time, the piston in the other slurry silo moves vertically upward from the lowest point and draws in the calcined gypsum slurry again under negative pressure and fills it. Through the cooperation of the A and B slurry silos, the gypsum slurry wide-width fabric subunit of the first composite fabric unit continuously expels calcined gypsum slurry, forming a continuous and stable vertically falling first ultra-thin gypsum slurry curtain. S312 The first composite fabric unit's functional material wide fabric subunit receives the functional material discharged from the functional material storage bin, mixes the functional material with the calcined gypsum slurry before or after extrusion, and falls together and spreads on the underlayment material to form the first layer of functionalized slurry layer. S32 simultaneously activates the remaining composite fabric units, forming multiple functionalized slurry layers and superimposing them on top of the previous layer.

[0049] In one exemplary embodiment, when the functional material is mixed after extruding the calcined gypsum slurry, the wide-width fabric subunit of the functional material includes a spray nozzle, and step S312 includes: The functional material is discharged from the functional material storage bin, falls onto the belt conveyor and falls to form a vertically downward first curtain of functional material; the spray nozzle provides a horizontal humidifying airflow toward the first curtain of ultra-thin gypsum slurry during the fall of the first curtain of functional material, so that the surface of the functional material is wetted and has a concentrated and stable initial kinetic energy. The functional material and the spreading path of the calcined gypsum slurry intersect in the air and collide, wet and mix, and fall together to form the first layer of functionalized slurry.

[0050] In one exemplary embodiment, when the functional material is mixed before the calcined gypsum slurry is extruded, the wide-width fabric subunit of the functional material includes a gear cylinder, and step S312 includes: When no functional material is installed, a negative pressure channel is formed by decompression through the air holes in the gear groove, causing the polymer elastic film on the gear cylinder to be recessed and close to the gear groove wall; The functional material is discharged from the functional material storage bin, passes through the functional material injection port of the gear cylinder, and is then received in the gear groove. The rotating gear cylinder transports the functional material in the gear groove to the intersection of the gear and the slurry extrusion nozzle. The air pressure through the vent creates a positive pressure channel, causing the polymer elastic membrane to bulge outward. The functional material in the gear groove is then injected into the slurry extrusion nozzle, mixed with the unextruded plaster slurry, and then extruded through the slurry extrusion nozzle to form a composite slurry curtain mixed with functional material, thus forming the first functionalized slurry layer.

[0051] In one exemplary embodiment, the thickness of the ultrathin gypsum slurry curtain may be 0.1-3 mm.

[0052] In one exemplary embodiment, the composition of each functional material in the multilayer functionalized slurry layer may be the same or different.

[0053] In one exemplary embodiment, in step S1, the basic formulation ingredients include calcined gypsum powder, water, starch, chopped glass fiber, and other additives.

[0054] In one exemplary embodiment, the basic formulation raw materials may further include long glass fibers.

[0055] In one exemplary embodiment, when the basic formulation raw materials include long glass fibers, in order to avoid them being unable to be extruded in the mixer, glass fiber mesh rolls can be added in two adjacent composite fabric units to embed the long glass fiber bundles into the middle of the core.

[0056] In one exemplary embodiment, the fiberglass mesh roll is located between the N / 2th composite fabric unit and the N / 2+1th composite fabric unit.

[0057] The third aspect of this application provides a functionally graded gypsum board produced by the above method.

[0058] In one exemplary embodiment, the functional gradient gypsum board includes multiple functionalized slurry layers, each of which may contain the same or different compositions of functional materials.

[0059] Compared with the prior art, the beneficial effects of this application are as follows: (1) Achieving flexible mixing of functional materials: By developing a process for layered distribution of gypsum slurry and functional particles, the mixing method of gypsum slurry and functional materials is optimized from mechanical stirring in a mixer to first mixing thin layers of gypsum slurry and thin layers of particles, and then stacking them into multi-layer composite slurry. This improvement effectively avoids the problem of functional particles being damaged by mechanical shearing force in a high-speed mixer, ensuring the physical integrity of functional particles, and thus improving the reliability of product functions.

[0060] (2) The length of the functional material storage silo should be slightly greater than the width of the gypsum board (1.2m), and the design of setting up partitioned rooms in the silo makes it possible to implement several different functional materials for a specific slurry layer. This can be easily achieved by relying on the special design of the functional material storage silo.

[0061] (3) Gradual distribution of multifunctional gypsum board core: The functional gradient mixing process of gypsum slurry was developed. Through the design of multi-layer superposition of thin-layer gypsum functional slurry, the uniform distribution of multiple functional materials in the core of gypsum board was realized, and the orderly arrangement of different functional materials in the length, width and thickness of gypsum board was realized. Functional paper-faced gypsum board with multiple functions and gradient distribution can be prepared, and the product quality is stable and controllable.

[0062] (4) High compatibility with production processes: As a modular and mobile unit, the system can be directly embedded between the mixer and molding station of the existing gypsum board production line without changing the original core process. The transformation cost is low. It can also be moved between different production bases, supporting different gypsum board factories to produce functional boards. It is easy to implement and promote.

[0063] In summary, the functionally graded gypsum board production system and method described in this application provide a novel production method for gypsum boards. It allows for the addition of functional materials with different or significantly different properties between different specific layers of the core, enabling the designable distribution of various functional materials and customized production of the core. This eliminates the limitations of existing functional gypsum board production technologies, is simple in method, and saves production costs. Furthermore, this application employs a "3D printing" production method, providing new ideas for the production of gypsum boards and other types of boards.

[0064] Other features and advantages of this application will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the application. Other advantages of this application can be realized and obtained by means of the embodiments described in the description and the accompanying drawings. Attached Figure Description

[0065] The accompanying drawings are used to provide an understanding of the technical solutions of this application and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions of this application.

[0066] Figure 1 A schematic diagram of the production process of ordinary gypsum board; Figure 2 A front view of a functional gradient gypsum board production system including spray nozzles; Figure 3 for Figure 2 A top view of the functional gradient paper-faced gypsum board production system shown. Figure 4 for Figure 2 A partial enlarged view of the composite fabric unit of the functional gradient gypsum board production system shown; Figure 5 for Figure 2 A schematic diagram of the gypsum slurry wide-width fabric distribution subunit of the functional gradient paper-faced gypsum board production system is shown. Figure 6 This is a schematic diagram of the gear cylinder and slurry extrusion nozzle in the wide-width fabric subunit of the functional material in this application; Figure 7 This is a schematic diagram of the structure of the wide-width fabric subunit of the functional material in this application, which includes multiple gear cylinders. Figure 8 A schematic diagram of the structure of the functional gradient paper-faced gypsum board produced in this application.

[0067] Explanation of reference numerals in the attached figures: 1—Paper on gypsum board; 2—Pulling device; 3—Paper under gypsum board; 4—Indentation device; 5—Mixing device; 6—Feeding pipe; 7—Molding machine device; 8—Molding board device; 9—Initial and final setting of slurry; 10—Conveyor belt device; 11—Motor; 12—Slurry discharge pipe; 13—Functional material storage bin; 14—Distribution wheel; 15—Belt quantitative conveyor; 16—Sealing groove or sealing strip; 17—Spray nozzle; 18—Hydraulic cylinder; 19—Hydraulic cylinder oil outlet pipe; 20—Piston; 21—Slurry; 22—Baffle port; 23—High-pressure cleaning pipe; 24—Slurry distributor; 25—Ultra-thin gypsum slurry curtain; 26—Negative pressure air pipe; 27—Polymer elastic membrane; 28—Baffle cover. Detailed Implementation

[0068] The technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this invention.

[0069] The raw materials used in this application are all conventional products on the market.

[0070] Unless otherwise specified, all materials and reagents used in the embodiments of this invention are commercially available.

[0071] Experimental methods not specified in the examples are generally performed under standard conditions or as recommended by the manufacturer.

[0072] Example 1: A process for preparing phase change gypsum board In this embodiment, the basic formulation ingredients are calcined gypsum powder, water, starch, glass fiber, etc.; the functional material is expanded vermiculite-based paraffin-loaded porous shaped phase change particles with a particle size of 0.5-1mm and an enthalpy of about 130J / g.

[0073] The phase change gypsum board preparation process of this embodiment includes the following steps: S1: Provides upper and lower protective paper moving along the production line direction and a mixer discharging material along the production line direction, wherein calcined gypsum powder, water, starch and glass fiber and other additives are added to the mixer and stirred to obtain calcined gypsum slurry; S2: Above the lower protective paper and behind the mixer outlet, three composite fabric units are arranged in parallel along the production line direction; each composite fabric unit is composed of a gypsum slurry wide fabric sub-unit and a functional material wide fabric sub-unit, wherein each gypsum slurry wide fabric sub-unit independently controls the fabrication of gypsum slurry, and each functional material wide fabric sub-unit independently controls the fabrication of porous shaped phase change particles; S3: Behind the discharge port of the mixer and above the three composite fabrication units in step S2, there is a calcined gypsum slurry distributor and three functional material storage bins. The calcined gypsum slurry distributor evenly divides the calcined gypsum slurry provided in step S1 into three portions and injects them into the slurry bin of each gypsum slurry wide fabrication sub-unit. The functional material storage bins provide porous shaped phase change particles to the corresponding functional material wide fabrication sub-unit. S4: Start the first composite fabric unit: S41: The gypsum slurry distributor evenly divides the gypsum slurry provided in step S1 into N portions, and then injects them into the slurry chamber A of the first gypsum slurry wide fabric subunit of the first composite fabric unit. The piston in the slurry chamber A moves downward from the highest point, squeezing the gypsum slurry out through the slurry extrusion nozzle, forming the first ultra-thin slurry curtain moving downward. At this time, the piston in the slurry chamber B moves upward from the lowest point, sucking in the slurry from the gypsum slurry distributor under negative pressure and filling it. At the same time, the piston in the slurry chamber A moves to the lowest position to empty the slurry. S42: Simultaneously, the porous shaped phase change particles fall onto the belt of the belt conveyor in the first functional material wide-width fabric subunit of the first composite fabric unit via the distribution wheel at the bottom of the functional material storage. They then fall from the belt, forming the first curtain of functional material moving downwards. During the falling process, the spray nozzles in the functional material wide-width fabric subunit provide a horizontal humidifying airflow toward the first curtain of functional material, which wets the surface of the functional material particles and forms the first curtain of functional material with initial kinetic energy and a stable and concentrated direction. This allows the spreading paths of the first curtain of functional material and the first curtain of ultra-thin gypsum slurry to intersect in the air, causing the functional material and the calcined gypsum slurry to collide, impregnate, and mix in the air, falling together to form the first layer of functionalized slurry, which is then spread on the lower cover paper. S5: Start the second composite fabric unit: S51: The second gypsum slurry wide-width fabric sub-unit squeezes out the second gypsum slurry, forming a downward-moving second ultra-thin slurry curtain; S52: The second functional material wide fabric subunit discharges the second functional material to form a downward-moving second functional material curtain; wherein, the spreading path of the second functional material curtain and the spreading path of the second ultra-thin slurry curtain intersect in the air, causing the functional material and gypsum slurry to collide, wet and mix in the air, fall together and spread on the first functional slurry layer to form the second functional slurry layer; S6: In this manner, the third composite fabric unit is started in sequence to form the third functional slurry layer and superimpose it on the previous layer; S7: After the three composite fabric units are stacked layer by layer, the three layers of porous shaped phase change granular gypsum slurry are compacted by subsequent rolling rollers, defoamed by micro-vibration, and covered with an upper protective paper to form a wet board core with a three-layer functional gradient structure. After solidification, drying, and cutting, the phase change paper-faced gypsum board is obtained.

[0074] The cross-section of the board was observed using scanning electron microscopy (SEM). The results showed that over 95% of the phase change shaped particles maintained their intact shape, with no shell cracking or leakage of contents observed. This demonstrates a significant advantage compared to traditional mixing processes (where the breakage rate is typically >10%). This embodiment successfully achieved high-precision and high-uniformity dispersion of porous phase change particles in a gypsum matrix without compromising their external integrity. It avoids the problem of porous shaped particles breaking due to mechanical shear forces generated by mixers in traditional processes, thus improving the performance stability and yield of the phase change gypsum board.

[0075] Example 2: A production process for thermal insulation phase change gypsum board In this embodiment, the basic formula raw materials are calcined gypsum powder, slurry water, starch, glass fiber, etc.; the first functional material is expanded vermiculite-based paraffin-loaded porous shaped phase change particles with a particle size of 0.5-1mm and an enthalpy of about 130J / g; the second functional material is vitrified microspheres with a particle size of 0.5mm-1.5mm.

[0076] The phase change gypsum board preparation process of this embodiment includes the following steps: S1: Provides upper and lower protective paper moving along the production line direction and a mixer discharging material along the production line direction, wherein calcined gypsum powder, water, starch and additives are added to the mixer and stirred to obtain calcined gypsum slurry; S2: Above the lower protective paper and behind the mixer outlet, three composite fabric units are arranged in parallel along the production line direction; each composite fabric unit is composed of a gypsum slurry wide fabric sub-unit and a functional material wide fabric sub-unit. S3: Behind the discharge port of the mixer and above the three composite fabrication units in step S2, there is a calcined gypsum slurry distributor and three functional material storage bins. The calcined gypsum slurry distributor evenly divides the calcined gypsum slurry provided in step S1 into three portions and injects them into the slurry bins of each gypsum slurry wide fabrication sub-unit. The first and second functional material storage bins provide porous shaped phase change particles to the corresponding functional material wide fabrication sub-units, and the last functional material storage bin provides vitrified microspheres to the corresponding functional material wide fabrication sub-units. S4: Start the first composite fabric unit: S41: The first gypsum slurry wide fabric sub-unit squeezes out the gypsum slurry through the slurry extrusion nozzle to form the first ultra-thin slurry curtain moving downwards; S42: The porous shaped phase change particles are discharged from the functional material storage bin and fall onto the belt of the belt quantitative conveyor in the first functional material wide fabric sub-unit of the first composite fabric unit. They are transported to the functional material injection port of the gear cylinder. Then the gear cylinder rotates and transports the porous shaped phase change particles in the groove to the intersection of the gear cylinder and the slurry extrusion nozzle. The porous shaped phase change particles are injected into the gypsum slurry before extrusion. Then the slurry is extruded by the slurry extrusion nozzle to form a composite slurry curtain mixed with porous shaped phase change particles. It falls to form the first functionalized slurry layer, that is, the gypsum slurry layer containing porous shaped phase change particles, and spreads on the lower cover paper. S5: Same as step S4, start the second composite fabric unit to form the second functionalized slurry layer, namely the gypsum slurry layer containing porous shaped phase change particles; S6: Same as step S4, start the third composite fabric unit in sequence to form the third functional slurry layer, namely the gypsum slurry layer containing vitrified microspheres, and superimpose it on the previous layer. S7: After the three composite fabric units are stacked layer by layer, the two layers of porous shaped phase change gypsum slurry and one layer of gypsum slurry containing vitrified microspheres are compacted by subsequent rolling rollers, defoamed by micro-vibration, and covered with an upper protective paper to form a wet board core with a three-layer functional gradient structure. After solidification, drying and cutting, the thermal insulation phase change paper-faced gypsum board is obtained.

[0077] Compared to traditional processes, this embodiment achieves a functionally graded distribution of insulation and phase change layers within the gypsum board core. This addresses the shortcomings of using phase change gypsum board for interior wall insulation, specifically the insufficient insulation performance of the gypsum board surface facing the exterior wall, leading to energy leakage from the interior. Based on the manufacturing process provided in this embodiment, the insulation performance of the gypsum board surface facing the exterior wall can be improved, enhancing the building's thermal insulation and energy storage performance, contributing to building energy conservation, and increasing the product's market competitiveness.

[0078] Example 3: An online additive system for producing insect-repellent gypsum board In this embodiment, the basic formulation ingredients are calcined gypsum powder, slurry water, starch, glass fiber, etc.; the functional material is insect repellent slow-release microcapsules with a particle size of 10-100μm, the core of which is a natural or synthetic insect repellent (such as pyrethroids), and the outer shell is a polymer wall material (such as polyurea, melamine resin).

[0079] The gypsum board preparation process in this embodiment includes the following steps: S1: Provides upper and lower protective paper moving along the production line direction and a mixer discharging material along the production line direction, wherein calcined gypsum powder, water, starch and additives are added to the mixer and stirred to obtain calcined gypsum slurry; S2: Above the lower protective paper and behind the mixer outlet, five composite fabric units are arranged in parallel along the production line direction; each composite fabric unit is composed of a gypsum slurry wide fabric sub-unit and a functional material wide fabric sub-unit, wherein each gypsum slurry wide fabric sub-unit independently controls the fabrication of the slurry, and each functional material wide fabric sub-unit independently controls the fabrication of the insect repellent slow-release microcapsules; S3: Behind the discharge port of the mixer and above the five composite fabric units involved in step S2, there is a gypsum slurry distributor and five functional material storage bins. The gypsum slurry distributor evenly divides the gypsum slurry provided in step S1 into five portions and injects them into the slurry bin of each gypsum slurry wide fabric sub-unit. The functional material storage bins provide insect repellent slow-release microcapsules to the corresponding functional material wide fabric sub-unit. S4: Start the first composite fabric unit: S41: The first gypsum slurry wide-width fabric sub-unit squeezes out the gypsum slurry through the slurry extrusion nozzle, forming the first ultra-thin slurry curtain moving downwards; S42: The first functional material wide fabric subunit discharges the insect repellent slow-release microcapsules, forming a downward-moving first curtain of functional material; as in step S42 of embodiment 1, the spreading path of the first curtain of functional material and the spreading path of the first curtain of ultra-thin slurry intersect in the air, causing the functional material and gypsum slurry to collide, wet and mix in the air, fall together and form the first layer of functionalized slurry, that is, the gypsum slurry layer containing insect repellent slow-release microcapsules, which is spread on the protective paper; S5: Start the second composite fabric unit: S51: The second gypsum slurry wide-width fabric sub-unit squeezes out the gypsum slurry, forming a downward-moving second ultra-thin slurry curtain; S52: The second functional material wide fabric subunit discharges the functional material to form a downward-moving second functional material curtain; in the same step S42, the spreading path of the second functional material curtain and the spreading path of the second ultra-thin slurry curtain intersect in the air, causing the functional material and gypsum slurry to collide, wet and mix in the air, fall together and spread on the first functional slurry layer to form the second functional slurry layer; S6: Following this pattern, the fifth composite fabric unit is activated in sequence. Through the coordinated work of its integrated slurry and functional material sub-units, a fifth functionalized slurry layer is formed and superimposed on the previous layer. S7: After the five composite fabric units are stacked layer by layer, the five layers of gypsum slurry containing insect repellent slow-release microcapsules are compacted by subsequent rolling rollers, defoamed by micro-vibration, and covered with an upper protective paper to form a wet board core containing insect repellent slow-release microcapsules. After solidification, drying, and cutting, the insect repellent paper-faced gypsum board is obtained.

[0080] Compared with traditional processes, this embodiment achieves the uniform addition of high-value insect-repellent slow-release microcapsules to the core of gypsum board through layered and multiple additions. This avoids the risk of damage to the outer shell of the microcapsules due to mechanical stirring in the mixer, improves the product performance stability and pass rate of insect-repellent paper-faced gypsum board, and enhances the product's market competitiveness.

[0081] In summary, compared with the prior art, the beneficial effects of this application are as follows: (1) Achieving flexible mixing of functional materials: By developing a process for layered distribution of gypsum slurry and functional particles, the mixing method of gypsum slurry and functional materials is optimized from mechanical stirring in a mixer to first mixing thin layers of gypsum slurry and thin layers of particles, and then stacking them into multi-layer composite slurry. This improvement effectively avoids the problem of functional particles being damaged by mechanical shearing force in a high-speed mixer, ensuring the physical integrity of functional particles, and thus improving the reliability of product functions.

[0082] (2) The length of the functional material storage silo should be slightly greater than the width of the gypsum board (1.2m), and the design of setting up partitioned rooms in the silo makes it possible to implement several different functional materials for a specific slurry layer. This can be easily achieved by relying on the special design of the functional material storage silo.

[0083] (3) Gradual distribution of multifunctional gypsum board core: The functional gradient mixing process of gypsum slurry was developed. Through the design of multi-layer superposition of thin-layer gypsum functional slurry, the uniform distribution of multiple functional materials in the core of gypsum board was realized, and the orderly arrangement of different functional materials in the length, width and thickness of gypsum board was realized. Functional paper-faced gypsum board with multiple functions and gradient distribution can be prepared, and the product quality is stable and controllable.

[0084] (4) High compatibility with production processes: As a modular and mobile unit, the system can be directly embedded between the mixer and molding station of the existing gypsum board production line without changing the original core process. The transformation cost is low. It can also be moved between different production bases, supporting different gypsum board factories to produce functional boards. It is easy to implement and promote.

[0085] In summary, the functionally graded gypsum board production system and method described in this application provide a novel production method for gypsum boards. It allows for the addition of functional materials with different or significantly different properties between different specific layers of the core, enabling the designable distribution of various functional materials and customized production of the core. This eliminates the limitations of existing functional gypsum board production technologies, is simple in method, and saves production costs. Furthermore, this application employs a "3D printing" production method, providing new ideas for the production of gypsum boards and other types of boards.

[0086] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A functionally graded gypsum board production system, comprising: A mixer that supplies calcined gypsum slurry along the production line direction; A calcined gypsum slurry distributor is located downstream of the mixer outlet along the production line direction; The calcined gypsum slurry distributor is equipped with N outlets to evenly divide the calcined gypsum slurry into N portions of calcined gypsum thin slurry. N composite fabric units are located downstream of the mixer along the production line direction; M functional material storage bins, which supply the functional materials to the composite fabric unit; as well as A molding device is located downstream of the composite fabric unit along the production line direction; Where N≥1, M≥N.

2. The functionally graded gypsum board production system according to claim 1, wherein, When N=1, the gypsum slurry distributor also has a traditional gypsum slurry outlet, and a leveling roller or vibrating table is provided between the composite fabrication unit and the mixer; when N≥2, the composite fabrication units are arranged sequentially along the production line direction; and / or The composite fabric unit is composed of a gypsum slurry wide-width fabric sub-unit and one or more functional material wide-width fabric sub-units. The gypsum slurry distributor evenly divides the gypsum slurry into N portions and injects them into the corresponding gypsum slurry wide-width fabric sub-units; and / or The length of the functional material storage bin is slightly greater than the width of the finished sheet material, and its interior is divided into several independent storage spaces by partitions.

3. The functionally graded gypsum board production system according to claim 2, wherein, The gypsum slurry wide-width fabric distribution subunit consists of two slurry bins, A and B, with the same volume and symmetrical structure. Each of the slurry bins is equipped with a piston that can alternately move vertically up and down. The bottom of the sides of each of the slurry bins is provided with a feed inlet. The bottom of the slurry bins is provided with a common slurry extrusion nozzle. Optionally, a slurry alternating injection control device is provided at the feed inlet; Optionally, the slurry extrusion nozzle is provided with a high-pressure nozzle; Optionally, an opening control device is provided at the slurry extrusion nozzle; Optionally, the piston is a hydraulically or pneumatically driven piston pusher; Optionally, the piston is provided with multiple sealing grooves or sealing strips.

4. The functionally graded gypsum board production system according to claim 3, wherein, The alternating slurry injection control device includes a slurry rotary distributor, a grouting pipe, and a baffle. The slurry rotary distributor controls the baffle and the grouting pipe to reciprocate between the inlets of the two slurry bins, such that when the grouting pipe is connected to the inlet of bin A or bin B, the baffle blocks the inlet of the other slurry bin; and / or The opening control device is an adjustable gate structure; and / or A gas-liquid mixing nozzle is provided between the sealing groove or sealing strip, and the gas-liquid mixing nozzle is connected to the high-pressure cleaning pipe.

5. The functionally graded gypsum board production system according to any one of claims 2 to 4, wherein, The functional material wide-width fabric subunit includes: A belt conveyor receives and transports functional materials from the functional material storage silo, causing the functional materials to fall under gravity to form a functional material curtain; and A spray nozzle is located below the belt metering conveyor; Optionally, the spray nozzle includes one or more rows of nozzles.

6. The functionally graded gypsum board production system according to any one of claims 2 to 4, wherein, The sidewall of the slurry extrusion nozzle is provided with one or more holes or gaps, and the functional material wide fabric subunit includes: a gear cylinder, the top of the gear of the gear cylinder intersecting with the holes or gaps; Optionally, the gear groove of the gear cylinder is provided with an air hole that communicates with the shaft of the gear cylinder, and the shaft of the gear cylinder can be continuously evacuated or pressurized, so that the air pressure in the gear groove changes. Optionally, the gears of the gear cylinder are wrapped with a polymer elastic membrane, and the polymer elastic membrane is firmly bonded to the sidewall of the gear groove by a polymer adhesive, so that the polymer elastic membrane can be concave or bulge in response to changes in air pressure in the gear groove. When the polymer elastic membrane is concave, it is tightly attached to the gear groove, and when the polymer elastic membrane is bulging, the bulging surface formed is higher than the top of the gear. Optionally, there may be one or more gear cylinders, each corresponding to one of the holes or slots.

7. The functionally graded gypsum board production system according to claim 5, wherein, The composite fabric unit also includes a reverse hydrophobic barrier device that provides splash protection and buffering for the functional slurry after the functional materials and calcined gypsum thin slurry are mixed.

8. The functionally graded gypsum board production system according to claim 6, wherein, The composite fabric unit also includes a baffle located outside the gear and near the slurry extrusion nozzle.

9. The functionally graded gypsum board production system according to any one of claims 1 to 4, wherein, The functional material storage silo is equipped with distribution wheels at its bottom; and / or The functional material wide-width fabric subunit corresponds to one or more functional material storage bins; and / or The mixer includes a feeding pipe, a mixing device, a motor, and a slurry discharge pipe; and / or The slurry discharge pipe is a rubber hose, in which a vibrator is installed.

10. The functionally graded gypsum board production system according to any one of claims 1 to 4, wherein, The functional gradient gypsum board production system also includes a surface material feeding device, which includes an upper surface material feeding device and a lower surface material feeding device. Optionally, the outlet of the slurry extrusion nozzle is located close to the undercoating material; Optionally, the covering material is a protective paper, fiberglass mesh, or other covering material; Optionally, the functionally graded gypsum board production system is used to produce paper-faced gypsum board or paperless gypsum board.

11. A method for preparing functionally graded gypsum board using the functionally graded gypsum board production system as described in any one of claims 1 to 10, comprising the following steps: S1. The basic formula raw materials are added to a mixer and stirred to obtain a calcined gypsum slurry; wherein, the basic formula raw materials do not include functional materials; The S2 plaster slurry distributor evenly divides the plaster slurry into N portions of plaster thin slurry and injects them into the corresponding composite fabric units. M functional material storage bins simultaneously provide functional materials to the corresponding composite fabric units. S3 simultaneously activates N composite fabric units to mix functional materials with gypsum slurry to form a multi-layer functionalized slurry layer, which is then sequentially spread onto the underlying surface material. After S4 is layered with N composite fabric units, the multi-layer functional slurry layer is compacted by rollers, defoamed by micro-vibration, and covered with a topcoat material to form a wet board core with an N-layer functional gradient structure. After solidification, drying, and cutting, the functional gradient gypsum board is obtained.

12. The method according to claim 11, wherein, Step S2 includes: The calcined gypsum slurry distributor evenly divides the calcined gypsum slurry into N portions of calcined gypsum thin slurry; The piston in either the A or B slurry bin of the gypsum slurry wide-width fabric subunit moves from the lowest point to the highest point, drawing in and filling the calcined gypsum thin slurry under negative pressure; simultaneously, M functional material storage bins supply functional materials to the functional material wide-width fabric subunit of the composite fabric unit.

13. The method according to claim 12, wherein, Step S3 includes: S31 initiates the first composite fabric unit, including: S311 The piston in the A or B slurry silo moves vertically downward from the highest point. The slurry extrusion nozzle at the bottom of the A or B slurry silo expels and empties the calcined gypsum slurry. At this time, the piston in the other slurry silo moves vertically upward from the lowest point and draws in the calcined gypsum slurry again under negative pressure and fills it. Through the cooperation of the A and B slurry silos, the gypsum slurry wide-width fabric subunit of the first composite fabric unit continuously expels calcined gypsum slurry, forming a continuous and stable vertically falling first ultra-thin gypsum slurry curtain. S312 The first composite fabric unit's functional material wide fabric subunit receives the functional material discharged from the functional material storage bin, mixes the functional material before or after the extrusion of the calcined gypsum thin slurry, and falls together and spreads it on the underlayment material to form the first layer of functionalized slurry layer. S32 simultaneously activates the remaining composite fabric units, forming multiple functionalized slurry layers and superimposing them on top of the previous layer.

14. The method according to claim 13, wherein, When the functional material is mixed after the calcined gypsum slurry is extruded, the wide-width fabric subunit of the functional material includes a spray nozzle, and step S312 includes: The functional material is discharged from the functional material storage bin, falls onto the belt quantitative conveyor and falls to form a vertically downward first curtain of functional material; the spray nozzle provides a horizontal humidifying airflow toward the first curtain of ultra-thin gypsum slurry during the fall of the first curtain of functional material, so that the surface of the functional material is wetted and has a concentrated and stable initial kinetic energy. The functional material and the spreading path of the calcined gypsum slurry intersect in the air and collide, wet and mix, and fall together to form the first layer of functionalized slurry layer; When the functional material is mixed before the calcined gypsum slurry is extruded, the wide-width fabric subunit of the functional material includes a gear cylinder, and step S312 includes: When no functional material is installed, a negative pressure channel is formed by depressurizing the air holes in the gear groove, causing the polymer elastic membrane of the gear cylinder to be recessed and close to the gear groove wall; The functional material is discharged from the functional material storage bin, passes through the functional material injection port of the gear cylinder, and is then received in the gear groove. The rotating gear cylinder transports the functional material in the gear groove to the intersection of the gear and the slurry extrusion nozzle. The positive pressure channel is formed by the air pores, causing the polymer elastic membrane to bulge outward. The functional material in the gear groove is injected into the slurry extrusion nozzle, mixed with the unextruded plaster slurry, and then extruded from the slurry extrusion nozzle to form a composite slurry curtain mixed with functional material, which falls to form the first functionalized slurry layer.

15. The method according to any one of claims 11 to 14, wherein, In step S1, the basic formula ingredients include calcined gypsum powder, water, starch, chopped glass fiber, and other additives; and / or The thickness of the ultrathin gypsum slurry curtain is 0.1-3 mm; and / or In the multi-layer functionalized slurry, the composition of each layer of functional material may be the same or different.

16. A functional gradient gypsum board produced by the method of any one of claims 11 to 15, the functional gradient gypsum board comprising multiple layers of functionalized slurry, wherein the composition of functional materials in each functionalized slurry layer is the same or different.

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