High performance inorganic board production line and manufacturing process

Abstract

The application discloses a high-performance inorganic plate production line and manufacturing process, and the production line comprises a conveying mechanism and a coating mechanism, wherein the coating mechanism is composed of a slurry feeding device, a unwinding device and a scraping device; the slurry feeding device is equipped with a slurry feeding box with a special structure, and through the cooperation of a gradient blanking hole, a vibrating device and a V-shaped swing plate, uniform laying and self-adaptive feeding of slurry are realized; the scraping device adopts multi-stage scrapers with gradually changed angles, so that the surface of the slurry is ensured to be smooth and flat; and the process flow covers the steps of feeding, water spraying, slurry feeding, laying a mesh cloth, scraping, drying and discharging. Through the formation of a uniform slurry and mesh cloth reinforcing layer on the surface of the gas evolution plate, the breaking strength and the crack resistance of the plate are significantly improved, the problems of easy breaking and high carrying loss of the existing gas evolution plate are effectively solved, and the application is particularly suitable for application scenarios with high strength requirements, such as cores of fireproof doors.

Description

Technical Field

[0001] This invention relates to the field of inorganic board production technology, and in particular to high-performance inorganic board production lines and manufacturing processes. Background Technology

[0002] Aerated concrete panels are lightweight porous boards made primarily from siliceous materials (fly ash or silica sand) and calcareous materials (lime, cement), with the addition of a foaming agent (aluminum powder). The process involves batching, mixing, pouring, foaming expansion, pre-curing, cutting, and autoclaving. Due to the numerous uniformly distributed closed pores within, aerated concrete panels possess outstanding advantages such as low density, excellent thermal insulation, and superior fire resistance. Their excellent fire resistance, in particular, makes them an ideal choice for fire door core materials.

[0003] However, the steam-cured and cut steam-formed panels are relatively brittle and hard, both on the surface and in their overall internal structure, with low flexural strength and poor toughness. Especially when the panels are large, they are prone to cracking or even breaking during handling, transportation, and installation due to slight bumps or uneven stress, resulting in a high material loss rate. This severely restricts the widespread use of steam-formed panels in applications such as fire door cores where the integrity of the panels is critical.

[0004] To address the aforementioned issues, there is an urgent need for a high-performance inorganic board production line and its manufacturing process that can achieve uniform slurry application, adaptive feeding, efficient leveling, and smooth conveying. By applying slurry and mesh coating to the surface, the overall strength of the gas-generating board can be effectively improved, making it less prone to breakage during handling and meeting the usage requirements of applications such as fire door cores. Summary of the Invention

[0005] The present invention addresses the problems in the prior art. The technical problem to be solved by the present invention is to provide a high-performance inorganic board production line and manufacturing process.

[0006] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: A high-performance inorganic board production line includes a conveying mechanism and a coating mechanism. The conveying mechanism is used to transport the gas-generating boards, and the coating mechanism is used to coat the surface of the gas-generating boards with a slurry. The coating mechanism includes: The slurry feeding device, which is located above the conveying mechanism, is used to supply slurry to the surface of the gas generating plate, and has a slurry feeding box; An unwinding device, on which a mesh cloth is wound, is used to supply the mesh cloth laid on the surface of the gas generating plate; A leveling device, located above the conveyor, includes several scrapers with adjustable angles and vertical positions, the angle between the scrapers and the horizontal plane gradually decreasing from the front end to the rear end, and is used to gradually level the slurry.

[0007] Preferably, the system also includes an oven mounted on a conveying mechanism, through which the gas-generating plate, after being coated with slurry and covered with mesh cloth, is conveyed by the conveying mechanism, dried, and then transported out.

[0008] Preferably, the conveying mechanism includes a roller conveyor for linear or 90-degree turning conveying of the gas-generating plate.

[0009] Preferably, the conveying mechanism also includes a belt conveyor, which is located behind the leveling device. It includes three parallel rows. The second row includes a disconnected front section and a rear section. A lifting and rotating device is provided in the gap between the front and rear sections. After the slurry on the gas generating plate is leveled, it is conveyed to the lifting and rotating device through the second row. The lifting and rotating device rises and lifts the gas generating plate and rotates it 90 degrees. Finally, it is lowered and placed on the first and third rows and continues to be conveyed by the two.

[0010] Preferably, a water spraying device is also included, which is located above the conveying mechanism and in front of the scraping device, for spraying water onto the air-generating plate before coating.

[0011] Preferably, the system also includes a feeding mechanism and a discharging mechanism, which are mounted on a gantry frame. Both the feeding mechanism and the discharging mechanism have multi-hole vacuum suction cups, which are used to generate negative pressure to hold the gas generating plate in place and to feed and discharge the material respectively.

[0012] A high-performance inorganic board manufacturing process, characterized by using the aforementioned high-performance inorganic board production line, includes the following steps: S1, Loading material; S2, water spray, is used to spray water on the top surface of the air-generating plate to increase humidity and prevent the slurry from absorbing too much water during the pouring process; S3, Slurry application: A layer of slurry is applied to the top surface of the gas generating plate using a slurry application device; S4, Lay the mesh fabric: Lay the mesh fabric flat on the moist mortar, ensuring that the mesh fabric is embedded in the mortar; S5, Scraping: The slurry surface is smoothed and polished in multiple stages using a scraping device; S6, Drying: Continue conveying the boards into the drying oven for drying; S7, Unloading: Unload the dried board material; After flipping the board over, repeat steps S1-S7 to lay the mesh cloth on the back of the board again and apply the slurry; in addition, the gas generating board is conveyed by a conveying mechanism throughout the process.

[0013] Preferably, the slurry feeding process is configured as follows: the slurry feeding tank is divided into a first chamber and a second chamber from top to bottom; the first chamber is a pre-stabilization and compaction zone, specifically, a partition is horizontally provided on the upper side of the first chamber, and several material dropping holes are opened on the partition. The diameter of the material dropping holes is distributed in a gradient that gradually increases from the middle to both sides to balance the falling resistance of the material. The bottom of the first chamber is a conical flow guide structure with a narrow opening at the bottom end; the outer wall of the conical flow guide structure is provided with a compaction device for pre-compacting and breaking the arches of the falling slurry, so that it falls into the narrow opening as a uniform material curtain; The second chamber is a gravity-adaptive and dynamic feeding zone. Specifically, the top of the second chamber has a flared structure to receive slurry from a narrow opening. At the bottom of the flared structure, two V-shaped swing plates are symmetrically hinged via a through-type pivot. The bottom sides of the two swing plates are movably connected to the frame via a two-stage linkage mechanism, forming a discharge port. A return spring is fitted on the linkage to provide an upward restoring torque. Wear-resistant rubber or polyurethane scrapers are provided at both ends of the swing plates, forming a dynamic seal by tightly fitting against the side wall of the lower slurry tank. Each of the two swing plates has a vibrator at its bottom. The two vibrators operate at the same frequency but in opposite directions. During operation, the dual vibrators generate opposing excitation forces, driving the two swing plates to oscillate around the through-type rotating shaft at a high frequency, resulting in a high-frequency, horizontal kneading motion. The total flow area of ​​the discharge holes, the flow area of ​​the narrow opening, and the maximum designed total opening area of ​​the two swing plates under the balance of their own weight and the return spring decrease in a progressively decreasing relationship. During slurry feeding, the slurry is first evenly distributed in the first cavity through the gradient discharge holes and falls to the conical guide structure. After being pre-compacted by the compaction device, it falls through the narrow opening to form a stable material curtain. The slurry enters the second chamber; under the constraint of the progressively decreasing flow channel, the slurry forms flow damping at the two swing plates and naturally slows down. Driven by two counter-vibrators, it generates high-frequency reciprocating torsional kneading on the two swing plates, which disperses the lumps in the slurry and further homogenizes the material. Then, it is discharged from the discharge port of the two swing plates at a stable flow rate. At the same time, as the weight of the slurry changes, the two swing plates adaptively overcome the tension of the reset spring and flip downward to dynamically adjust the opening size. With the continuous excitation of the dual vibrators, the slurry is continuously, stably, and adaptively fed with precision.

[0014] Preferably, a conical guide umbrella is provided at the top of the partition so that the slurry falls on the conical surface and slides down the inclined surface to the discharge hole.

[0015] Compared with the prior art, the present invention has the following advantages: 1. Significantly improves the handling performance of the gas-generating board: By coating the surface of the gas-generating board with slurry and laying mesh cloth, a surface reinforcement layer is formed after drying, which effectively improves the overall flexural strength and crack resistance of the gas-generating board. This makes the gas-generating board less prone to breakage during handling, transportation and installation, and solves the technical problem of high breakage rate of large-size boards due to the brittleness and hardness of the material. This enables the gas-generating board to meet the use requirements of application scenarios with high requirements for the integrity of the board, such as fire door cores.

[0016] 2. Uniform Slurry Discharge and Adaptive Feeding: The first chamber utilizes a gradient discharge hole and a conical guide structure in conjunction with a compaction device to achieve pre-uniform distribution and pre-compaction of the slurry. The second chamber's V-shaped oscillating plate, coupled with dual vibrators operating in opposite directions, generates a high-frequency torsional kneading effect, effectively dispersing lumps in the slurry and further homogenizing the material. Simultaneously, the V-shaped oscillating plate adaptively adjusts its opening size under the slurry's own weight, achieving dynamic balance in the feed rate and ensuring continuous and uniform slurry output, thereby guaranteeing the consistent quality of the surface reinforcement layer.

[0017] 3. Excellent leveling effect: The leveling device uses multiple adjustable angle and vertical position scrapers, and the angle between the scraper and the horizontal plane decreases step by step along the conveying direction, realizing multi-stage progressive leveling and smoothing of the slurry surface, effectively improving the flatness and smoothness of the slurry surface, and making the surface reinforcement layer and the gas generating plate more tightly bonded.

[0018] 4. Smooth conveying and high production efficiency: Through the reasonable combination of roller conveyors and belt conveyors, and with the lifting and rotating device, the gas generating plate can be rotated 90 degrees for conveying, making the production line layout more compact, the conveying process smoother, and improving production efficiency.

[0019] 5. High-quality slurry coating and good bonding strength: By setting up a water spraying device to pre-treat the surface of the gas-generating board before slurry coating, the gas-generating board is effectively prevented from absorbing the moisture in the slurry too quickly, ensuring the full bonding between the slurry and the board, and improving the bonding strength and durability of the surface reinforcement layer. Attached Figure Description

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and preferred embodiments. However, those skilled in the art will understand that these drawings are drawn only for the purpose of explaining the preferred embodiments and therefore should not be regarded as a limitation on the scope of the present invention. In addition, unless otherwise specified, the drawings are not necessarily drawn to scale.

[0021] Figure 1 This is a perspective view of the present application; Figure 2 This is a perspective view of a portion of this application; In the diagram: 01, feeding mechanism; 02, conveying mechanism; 021, roller conveyor; 022, belt conveyor; 03, slurry feeding device; 031, slurry feeding box; 04, leveling device; 041, scraper; 05, water spraying device; 06, lifting and rotating device; 07, drying oven; 08, feeding mechanism; 09, roller. Detailed Implementation

[0022] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Those skilled in the art will appreciate that these descriptions are merely descriptive and exemplary and should not be construed as limiting the scope of protection of the present invention.

[0023] It should be noted that similar labels in the following figures indicate similar items; therefore, once an item is defined in one figure, it may not be further defined and explained in subsequent figures. Example

[0024] This embodiment mainly describes the title of the high-performance inorganic board production line, as follows: Main structure of high-performance inorganic board production line like Figure 1-2 As shown, it includes a conveying mechanism 02 and a coating mechanism. The conveying mechanism 02 is used to convey the gas generating plate, and the coating mechanism is used to coat the surface of the gas generating plate with slurry.

[0025] The coating mechanism includes a coating device 03, an unwinding device, and a leveling device 04.

[0026] The slurry feeding device 03 is located above the conveying mechanism 02 and is used to supply slurry to the surface of the gas generating plate. The slurry feeding device 03 has a slurry feeding box 031. The slurry is evenly spread on the top surface of the gas generating plate through the slurry feeding box 031.

[0027] The unwinding device has a mesh fabric wound on it for supplying and laying the mesh fabric onto the surface of the gas generating plate. The mesh fabric is preferably alkali-resistant glass fiber mesh fabric, which has good alkali resistance and tensile strength, and can form a surface reinforcement layer together with the slurry, effectively improving the overall crack resistance and impact resistance of the gas generating plate, making it less prone to breakage during handling. The unwinding device is located behind the slurry feeding device 03 (along the conveying direction), so that the mesh fabric is immediately covered after the slurry is laid, ensuring that the mesh fabric is embedded in the moist slurry.

[0028] The leveling device 04 is positioned above the conveying mechanism 02 and includes several scrapers 041 with adjustable angles and vertical positions. The angle between the scrapers 041 and the horizontal plane gradually decreases from the front end to the rear end, used to progressively level and smooth the slurry. Specifically, along the conveying direction, the front scrapers 041 have a larger angle with the horizontal plane—such as 45°~60°—and mainly perform rough scraping and leveling; the rear scrapers 041 gradually decrease in angle with the horizontal plane to near the horizontal—such as 5°~15°—and mainly perform fine scraping and smoothing. Through the progressive leveling by the multi-stage scrapers 041, the smoothness and gloss of the slurry surface are effectively improved, ensuring a uniform thickness and smooth surface of the surface reinforcement layer, which is beneficial for the subsequent processing and use of the fire door core. The angle and vertical position of scraper 041 can be flexibly adjusted by an adjustment mechanism (such as screw adjustment, cylinder adjustment, etc.). The attached diagram shows the use of a cylinder in conjunction with a lifting slider for adjustment. The angle is adjusted by rotation and then locked during installation to adapt to different slurry thicknesses and different process requirements.

[0029] Water spray device 05 and oven 07 A water spraying device 05 is positioned above the conveying mechanism 02 and in front of the leveling device 04—that is, before the slurry application device 03—to spray water onto the air-generating board before slurry application. The water spraying device 05 draws in tap water via a pump and sprays it out through a row of nozzles. Because the air-generating board is a porous material with high water absorption, without pretreatment, the water in the slurry will be rapidly absorbed by the board, leading to premature water loss, shrinkage, and cracking. This affects the bonding strength between the slurry and the board, and consequently, the reinforcing effect of the surface reinforcement layer. Pre-wetting the surface of the air-generating board with water by the water spraying device 05 effectively slows down the loss of moisture from the slurry, ensuring sufficient hydration reaction time during curing, thereby improving the quality and bonding strength of the surface reinforcement layer and ensuring that it does not peel off during use.

[0030] Oven 07 is mounted on conveyor mechanism 02. The gas-generating board, after being coated with slurry and covered with mesh fabric, is conveyed through oven 07 by conveyor mechanism 02, dried, and then transported out. Oven 07 can be heated by electricity, gas, or steam. The drying temperature and time can be adjusted according to the slurry formula and the board thickness. After drying, the moisture in the slurry evaporates, the slurry solidifies, and forms a strong bond with the gas-generating board, creating a complete surface reinforcement layer and effectively improving the overall strength of the gas-generating board.

[0031] Specific structure of conveyor mechanism 02 The conveying mechanism 02 includes a roller conveyor 021, which is located upstream of the production line—before the slurry feeding device 03—for conveying the gas-generating plates. The roller conveyor 021 consists of multiple parallel rollers, on which the gas-generating plates slide or roll forward. The roller conveyor 021 can be configured for straight-line conveying or 90-degree turning conveying according to the production line layout requirements—that is, the roller conveyor 021 is divided into two sections, with the end of the first section perpendicularly connected to the second section, achieving a 90-degree turn in the conveying direction. The preferred option is the 90-degree turn because the gas-generating plates are initially horizontal after feeding and need to be rotated 90 degrees to a longitudinal position for slurry application. The narrower longitudinal width helps save width space and reduces the longitudinal length of the slurry.

[0032] The conveying mechanism 02 also includes a belt conveyor 022, which is located behind the leveling device 04—that is, the conveying section after leveling. The belt conveyor 022 includes three parallel rows of conveyor belts: a first row, a second row, and a third row. The second row includes a discontinuous front section and a rear section, with a lifting and rotating device 06 located in the gap between the front and rear sections. The lifting and rotating device 06 includes a lifting cylinder and a rotating cylinder mounted on the lifting cylinder, with a support plate having several rubber protrusions on its top surface at the output end of the rotating cylinder.

[0033] The width of the second row matches the width of the gas generating plate, and it is used to receive and convey the leveled gas generating plate. After the slurry on the gas generating plate is leveled, it is conveyed through the front section of the second row to the lifting and rotating device 06. The lifting and rotating device 06 rises to lift the gas generating plate, causing it to detach from the conveyor belt of the second row, then rotates 90 degrees, and finally descends to place the gas generating plate on the first and third rows, from which it continues to be conveyed forward and sent into the drying oven 07.

[0034] The spacing between the first and third rows should meet the following conditions: before rotation, the length of the gas-generating plate should span between the first and third rows—the spacing should be less than the length of the gas-generating plate but greater than its width, so that the gas-generating plate, after rotating 90 degrees, can be stably placed on the first and third rows for continued conveying. This structure enables 90-degree turning conveying of the gas-generating plate on the production line, making the production line layout more compact and flexible.

[0035] Feeding mechanism 01 and unloading mechanism 08 The loading mechanism 01 and the unloading mechanism 08 are mounted on the gantry. The loading mechanism 01 is located at the beginning of the production line and is used to pick up the gas-generating plates to be processed from the stacking position and place them on the conveying mechanism 02. The unloading mechanism 08 is located at the end of the production line—after the oven 07—and is used to pick up the processed gas-generating plates from the conveying mechanism 02 and stack them into the finished product area.

[0036] Both the loading mechanism 01 and the unloading mechanism 08 are equipped with porous vacuum suction cups. A vacuum generator produces negative pressure, which is then used to adhere the surface of the gas-generating plate. Compared to traditional large-area suction cups, the porous vacuum suction cups are better able to adapt to slight unevenness on the surface of the gas-generating plate, resulting in more reliable adhesion. The loading mechanism 01 and the unloading mechanism 08 can move laterally and longitudinally on the gantry frame, enabling precise loading and unloading of the gas-generating plate.

[0037] Specific structure of the slurry feeding device 03 The interior of the lower slurry box 031 is divided into a first cavity and a second cavity from top to bottom.

[0038] The first chamber is the pre-stabilization and compaction zone. A horizontal baffle is installed on the upper side of the first chamber, with several material discharge holes. The diameter of the discharge holes exhibits a gradient distribution, gradually increasing from the center to both sides—that is, the discharge holes in the center of the baffle have smaller diameters, while those at the edges have larger diameters. This gradient design aims to balance the material's falling resistance: because the slurry accumulates more and forms a thicker layer in the center when falling into the baffle, the falling resistance is greater, so a smaller diameter in the center is sufficient to meet the flow requirements; while the edge areas have less slurry and a thinner layer, resulting in less falling resistance, requiring a larger diameter to ensure sufficient material flow. This gradient diameter design achieves uniform slurry falling across the entire baffle plane.

[0039] Preferably, the top of the partition is provided with a conical guide umbrella, so that after the slurry falls on the conical surface, it slides evenly to both sides along the inclined surface to the discharge hole, which further improves the uniformity of slurry distribution.

[0040] The bottom of the first chamber features a conical guide structure with a narrow opening at its base. This conical guide structure, shaped like a funnel (wider at the top and narrower at the bottom), collects the dispersed slurry and guides it towards the opening. The outer wall of the conical guide structure is equipped with a compaction device, such as a vibratory motor or pneumatic vibrator, to pre-compact and break up bridging in the falling slurry. The compaction device generates high-frequency vibrations, which on one hand expel air bubbles and homogenize the density of the slurry, and on the other hand, break up any potential slurry bridging, ensuring the slurry flows smoothly through the opening and forms a uniform slurry curtain.

[0041] The second chamber is a gravity-adaptive and dynamic feeding zone. The top of the second chamber has a flared structure with an opening area larger than that of the narrow opening, which is used to receive the slurry from the narrow opening and prevent the slurry from spilling.

[0042] The bottom of the flared structure is symmetrically hinged with two V-shaped swing plates via a through-type pivot. The bottoms of the two V-shaped swing plates are positioned opposite each other, forming a discharge port between them. The bottom sides of the two swing plates are movably connected to the frame via a two-stage linkage mechanism, and a return spring is fitted on the linkage to provide an upward restoring torque. When there is no slurry or a small amount of slurry, the return spring pulls the two swing plates upward, keeping the discharge port in a smaller opening state; when slurry falls into and accumulates on the swing plates, the weight of the slurry overcomes the tension of the return spring, causing the two swing plates to rotate downward around the through-type pivot, thereby widening the discharge port.

[0043] The two ends of the swing plate are provided with wear-resistant scrapers 041, which are preferably made of wear-resistant rubber or polyurethane. They are tightly fitted with the side wall of the lower slurry box 031 to form a dynamic seal and prevent slurry from leaking from the gap between the swing plate and the side wall of the lower slurry box 031.

[0044] Each of the two oscillating plates has a vibrator at its bottom. The two vibrators operate at the same frequency but in opposite directions—that is, they generate opposing excitation forces during operation. This reverse excitation configuration causes the two oscillating plates to generate high-frequency torsional oscillations around the through-type rotating shaft, meaning the two plates alternately oscillate up and down, forming a seesaw-like motion. This high-frequency torsional oscillation creates a horizontal kneading effect on the slurry accumulated on the oscillating plates, effectively dispersing clumps and further homogenizing the slurry.

[0045] The total flow area of ​​the discharge hole, the flow area of ​​the narrow opening, and the maximum designed total opening area of ​​the two swing plates under the balance of their own weight and the return spring, are in a progressively decreasing relationship. This progressively decreasing flow channel design causes the slurry to experience progressively increasing flow resistance as it flows through the lower slurry box 031, specifically manifested as follows: The slurry first falls into the first chamber through the discharge hole. After being pre-compacted by a vibratory compactor in the conical guide structure, it falls into the second chamber through a narrow opening to form a stable material curtain. Under the constraint of the progressively decreasing flow channel, the slurry experiences flow damping at the two swing plates, naturally reducing its velocity. This allows the slurry sufficient time to be kneaded by the vibrators on the swing plates. Driven by two counter-vibrators, the slurry undergoes high-frequency reciprocating torsional kneading on the two swing plates, dispersing any agglomerates and further homogenizing the material. It is then discharged from the discharge holes of the two swing plates at a stable flow rate.

[0046] Meanwhile, as the weight of the slurry changes, the two swing plates adaptively overcome the tension of the return spring and flip downwards to dynamically adjust the opening size—the opening automatically increases when there is more slurry and automatically decreases when there is less slurry. Combined with the continuous excitation of the dual vibrators, continuous, stable, adaptive, and precise feeding of the slurry is achieved.

[0047] In the tail section of the conveying process, before unloading, the position of the board is calibrated by a pushing mechanism set on the conveying mechanism 02. The pushing mechanism includes a pushing cylinder set below the conveying rollers. The output end of the pushing cylinder is provided with a vertical plate extending from the gap between the conveying rollers. A roller 09 is connected above the vertical plate. During the conveying process, the pushing cylinder indirectly drives the roller 09 to squeeze the side wall of the board to calibrate the position, ensuring that the position is in the preset position when the board is picked up and unloaded at the tail end.

[0048] Example 2: High-performance inorganic board manufacturing process This embodiment provides a high-performance inorganic board manufacturing process, which is carried out using the high-performance inorganic board production line described in any one of embodiments one to five above. The process includes the following steps: S1, Loading: The multi-hole vacuum suction cup of the loading mechanism 01 generates negative pressure to pick up the gas-generating plate to be processed from the stacking position and place it on the conveying mechanism 02—roller conveyor 021. The entire loading process is driven by the moving mechanism on the gantry to move the loading mechanism 01 to the target position, achieving precise picking and placing.

[0049] S2, Water Spraying: The air-generating plate is conveyed by the conveying mechanism 02 to the area below the water spraying device 05. The water spraying device 05 sprays water onto the top surface of the air-generating plate to increase surface humidity. The amount of water sprayed should be moderate—too much water will cause the slurry to have excessive fluidity and be difficult to adhere; too little water will not effectively prevent the air-generating plate from absorbing too much water. Preferably, the amount of water sprayed is controlled to make the surface of the air-generating plate evenly wet but without obvious water accumulation. Through water spraying pretreatment, the excessive absorption of water in the slurry by the air-generating plate during subsequent slurry application is effectively prevented, ensuring that the slurry has enough water for hydration reaction and ensuring the bonding strength between the surface reinforcement layer and the air-generating plate.

[0050] S3, Slurry Feeding: The gas generating plate continues to convey slurry to the bottom of the slurry feeding device 03, where a layer of slurry is laid on the top surface of the gas generating plate. During the slurry feeding process, the slurry first enters the first cavity of the slurry feeding box 031, and after being evenly distributed through the gradient discharge holes, it falls into the conical guide structure. After being pre-compacted and arch-breaking by the vibration device, it falls into the second cavity through a narrow opening to form a stable material curtain. Under the constraint of the progressively decreasing flow channel, the slurry forms flow damping at the V-shaped swing plate and naturally slows down. Driven by two counter-vibrating vibrators, it generates high-frequency reciprocating torsional kneading on the V-shaped swing plate, which disperses the lumps in the slurry and further homogenizes the material. Then, it is discharged from the discharge port of the V-shaped swing plate at a stable flow rate and laid on the surface of the gas generating plate. At the same time, the V-shaped swing plate adaptively adjusts the opening size according to the slurry flow rate to achieve precise feeding.

[0051] S4, Laying the Mesh Fabric: After the slurry is laid, the gas-generating board continues to be conveyed to the unwinding device. The unwinding device releases the rolled mesh fabric and lays it flat on the moist slurry. During the laying process, auxiliary devices such as pressure rollers can be used to gently press the mesh fabric into the slurry, ensuring that the mesh fabric is embedded in the slurry rather than just floating on the surface. This fully utilizes the reinforcing effect of the surface reinforcement layer formed by the mesh fabric and the slurry, effectively improving the overall flexural strength and crack resistance of the gas-generating board. The mesh fabric is preferably alkali-resistant glass fiber mesh fabric.

[0052] S5, Smoothing: After the mesh fabric is laid, the gas-generating board continues to be conveyed to the leveling device 04, where the surface of the slurry is smoothed and finished in multiple stages. Specifically, along the conveying direction, the front scraper 041 has a larger angle with the horizontal plane (e.g., 45°~60°), performing initial smoothing and spreading of the slurry to ensure even distribution on the surface of the gas-generating board; the middle scraper 041 has a moderate angle (e.g., 30°~45°), further smoothing; the rear scraper 041 has a smaller angle (e.g., 5°~15°), approaching horizontal, performing fine smoothing and finishing of the slurry surface. Through the progressive smoothing by the multi-stage scrapers 041, the flatness and smoothness of the slurry surface are effectively improved, ensuring uniform thickness and a smooth surface of the surface reinforcement layer, which is beneficial for the subsequent processing and assembly of the fire door core. The vertical position of each scraper 041 can be independently adjusted according to the slurry thickness.

[0053] S6, Drying: The leveled gas-generating plate continues to be conveyed by the conveying mechanism 02, and then turns 90 degrees at the lifting and rotating device 06 (if necessary), before entering the drying oven 07 for drying. The drying temperature and time in the drying oven 07 are set according to the slurry formula and the thickness of the board. Generally, the temperature is controlled between 60 degrees and 120 degrees, and the drying time is between 30 minutes and 120 minutes, until the slurry is completely cured and a strong surface reinforcement layer is formed.

[0054] S7, Unloading: The dried gas-generating boards are output from the drying oven 07. Negative pressure is generated by the multi-hole vacuum suction cup of the unloading mechanism 08, which picks up the finished gas-generating boards from the conveying mechanism 02 and stacks them in the finished product area. After surface coating with slurry and mesh, the overall flexural strength and crack resistance of the gas-generating boards are significantly improved, making them less prone to breakage during subsequent handling, transfer, and fire door core processing, effectively reducing material loss.

[0055] After flipping the gas-generating plate, repeat steps S1 to S7 above to lay mesh cloth and apply slurry on the back of the plate again, achieving double-sided reinforcement treatment of the gas-generating plate and further improving the overall strength of the plate. Throughout the process, the gas-generating plate is continuously conveyed by the conveying mechanism 02, including roller conveyor 021 and belt conveyor 022.

[0056] Detailed control of the slurry application process During the slurry feeding process, the slurry first enters the first chamber. At the top of the baffle, a conical guide umbrella evenly guides the slurry to the surrounding areas, ensuring that the slurry is evenly distributed on the baffle. Because the diameter of the discharge holes is distributed in a gradient from small in the center to large at the edges, the amount of slurry falling across the entire baffle plane remains uniform.

[0057] After the slurry falls through the discharge hole into the conical guide structure at the bottom of the first chamber, the compaction device starts working, applying high-frequency vibration to the slurry. The vibration of the compaction device causes air bubbles in the slurry to rise and be expelled, increasing the slurry's density; it also breaks up any bridging that may form in the slurry, ensuring smooth flow. The compacted slurry then falls from the narrow opening into the second chamber in the form of a uniform curtain.

[0058] After the slurry falls into the second chamber, it accumulates on the V-shaped oscillating plates. Under the action of the slurry's own weight, the V-shaped oscillating plates overcome the tension of the return spring and flip downwards, automatically widening the discharge port. At the same time, two vibrators operate at the same frequency but in opposite excitation directions, driving the two V-shaped oscillating plates to generate high-frequency torsional oscillations around the through-type rotating shaft—that is, the two oscillating plates alternately oscillate up and down. This oscillation produces a horizontal kneading effect on the slurry accumulated on the oscillating plates, further dispersing the clumps in the slurry and making the material more homogenized.

[0059] As the slurry is continuously discharged from the discharge port, the weight of the slurry on the oscillating plate gradually decreases. The return spring pulls the oscillating plate back upwards, and the discharge port narrows accordingly. This dynamic balancing mechanism ensures that the opening size of the discharge port always matches the current slurry supply, achieving adaptive and precise feeding. Combined with the continuous excitation of the dual vibrators, this ensures that the slurry is discharged from the discharge port at a continuous, stable, and uniform flow rate and spread on the surface of the gas generating plate, providing a uniform slurry foundation for subsequent mesh fabric laying and leveling processes.

[0060] In the description of this invention, it should be noted that the terms "upper," "lower," "front," "rear," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the sequential relationship of the process. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

Claims

1. A high-performance inorganic board production line, comprising a conveying mechanism and a coating mechanism, wherein the conveying mechanism is used to convey gas-generating boards, and the coating mechanism is used to coat the surface of the gas-generating boards with a slurry, characterized in that, The coating mechanism includes: The slurry feeding device, which is located above the conveying mechanism, is used to supply slurry to the surface of the gas generating plate, and has a slurry feeding box; An unwinding device, on which a mesh cloth is wound, is used to supply the mesh cloth laid on the surface of the gas generating plate; A leveling device, located above the conveyor, includes several scrapers with adjustable angles and vertical positions, the angle between the scrapers and the horizontal plane gradually decreasing from the front end to the rear end, and is used to gradually level the slurry.

2. The high-performance inorganic board production line according to claim 1, characterized in that, It also includes an oven set on the conveying mechanism. The gas-generating plate, after being coated with slurry and covered with mesh cloth, is conveyed by the conveying mechanism, dried in the oven, and then transported out.

3. The high-performance inorganic board production line according to claim 1, characterized in that, The conveying mechanism includes roller conveyors, which are used for linear or 90-degree turning conveying of the gas-generating plates.

4. The high-performance inorganic board production line according to claim 3, characterized in that, The conveying mechanism also includes a belt conveyor, which is located behind the leveling device. It includes three parallel rows. The second row includes a disconnected front section and a rear section. A lifting and rotating device is provided in the gap between the front and rear sections. After the slurry on the gas generating plate is leveled, it is conveyed to the lifting and rotating device through the second row. The lifting and rotating device rises and lifts the gas generating plate and rotates it 90 degrees. Finally, it is lowered and placed on the first and third rows and continues to be conveyed by the two.

5. The high-performance inorganic board production line according to claim 1, characterized in that, It also includes a water spraying device, which is located above the conveying mechanism and in front of the scraping device, for spraying water onto the air-generating plate before coating.

6. The high-performance inorganic board production line according to claim 1, characterized in that, It also includes a feeding mechanism and a discharging mechanism, which are mounted on a gantry frame. Both the feeding mechanism and the discharging mechanism have multi-hole vacuum suction cups, which are used to generate negative pressure to firmly hold the gas generating plate and to feed and discharge the material respectively.

7. A high-performance inorganic board manufacturing process, characterized in that, The production process using the high-performance inorganic board production line according to any one of claims 1-6 includes the following steps: S1, Loading material; S2, water spray, is used to spray water on the top surface of the air-generating plate to increase humidity and prevent the slurry from absorbing too much water during the pouring process; S3, Slurry application: A layer of slurry is applied to the top surface of the gas generating plate using a slurry application device; S4, Lay the mesh fabric: Lay the mesh fabric flat on the moist mortar, ensuring that the mesh fabric is embedded in the mortar; S5, Scraping: The slurry surface is smoothed and polished in multiple stages using a scraping device; S6, Drying: Continue conveying the boards into the drying oven for drying; S7, Unloading: Unload the dried board material; After flipping the board over, repeat steps S1-S7 to lay the mesh cloth on the back of the board again and apply the slurry; in addition, the gas generating board is conveyed by a conveying mechanism throughout the process.

8. The high-performance inorganic board manufacturing process according to claim 7, characterized in that, The slurry feeding process is configured as follows: the slurry feeding tank is divided into a first chamber and a second chamber from top to bottom; the first chamber is a pre-stabilization and compaction zone, specifically, a horizontal baffle is provided on the upper side of the first chamber, and several material drop holes are opened on the baffle. The diameter of the material drop holes is gradually increased from the middle to both sides to balance the falling resistance of the material. The bottom of the first chamber is a conical guide structure with a narrow opening at the bottom end; the outer wall of the conical guide structure is equipped with a compaction device for pre-compacting and breaking arches of the falling slurry, so that it falls into a uniform material curtain through the narrow opening; the second chamber... The body is a gravity-adaptive and dynamic feeding zone. Specifically, the top of the second chamber has a flared structure to receive slurry from a narrow opening. At the bottom of the flared structure, two V-shaped swing plates are symmetrically hinged via a through-type rotating shaft. The bottom sides of the two swing plates are movably connected to the frame via a two-stage linkage mechanism, forming a discharge port. A return spring is fitted on the linkage to provide an upward restoring torque. Wear-resistant rubber or polyurethane scrapers are provided at both ends of the swing plates, forming a dynamic seal by tightly fitting against the side wall of the lower slurry tank. Each of the two swing plates has a vibrator at its bottom. The vibrators operate at the same frequency but with opposite excitation directions. During operation, the dual vibrators generate opposing excitation forces, driving two swing plates to oscillate around the through-type rotating shaft at high frequency, creating a high-frequency, horizontal kneading motion. The total flow area of ​​the discharge holes, the flow area of ​​the narrow opening, and the maximum designed total opening area of ​​the two swing plates under the balance of their own weight and the return spring decrease in a progressively decreasing relationship. During slurry feeding, the slurry is first evenly distributed in the first cavity through the gradient discharge holes and falls to the conical guide structure. After being pre-compacted by the compaction device, it falls into the narrow opening as a stable material curtain. The second chamber, under the constraint of progressively decreasing flow channels, causes the slurry to naturally slow down due to flow damping at the two swing plates. Driven by two counter-vibrators, it generates high-frequency reciprocating torsional kneading on the two swing plates, which disperses the lumps in the slurry and further homogenizes the material. Then, it is discharged from the discharge port of the two swing plates at a stable flow rate. At the same time, as the weight of the slurry changes, the two swing plates adaptively overcome the tension of the reset spring and flip downward to dynamically adjust the opening size. Combined with the continuous excitation of the dual vibrators, continuous, stable, adaptive and precise feeding of the slurry is achieved.

9. The high-performance inorganic board manufacturing process according to claim 8, characterized in that, A conical guide umbrella is provided at the top of the partition so that the slurry falls on the conical surface and slides down the slope to the discharge hole.

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