Air Cushion Forming Table for Building Board Friction Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for constructing building boards suffer from friction damage between the facing material and forming tables, leading to unsuitable boards and uneven slurry distribution, resulting in weak edges prone to chipping or disintegration.
Innovation Solution
The use of pressurized air nozzles integrated into forming tables to reduce friction and promote uniform slurry distribution by creating an air cushion between the board and the table, allowing for smooth transportation and even slurry spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the building board is assembled over forming tables with facing material, then the board can be manufactured, but friction between the facing material and forming table damages or mars the resulting board
Solution Approach 1:
A air cushion is introduced as an intermediary between the facing material and the forming table. The air cushion acts as a mediator that reduces direct contact and friction between the facing material and the forming table surface, thereby preventing damage while allowing the manufacturing process to continue
Solution Approach 2:
The invention uses pressurized air (pneumatics) to create the air cushion. Air nozzles deliver pressurized air to the forming table surface, generating a pneumatic cushion that lifts the facing material slightly and reduces friction during the assembly process
2Ease of manufacture
If overhead mixer deposits cementitious slurry on facing material, then the board can be formed, but slurry disproportionally accumulates along the center line and edges are insufficiently strong
Solution Approach 1:
The invention applies different air pressure zones across the forming table surface. Air nozzles are positioned to create localized air cushion zones that vary in pressure and lift force across the width of the board, with higher lift at the edges and lower lift at the center. This local variation in air cushion pressure promotes uniform slurry distribution across the entire board surface, preventing accumulation at the center line and ensuring adequate slurry coverage at the edges
3Ease of operation
If friction is present during board transportation, then the board can be moved along forming tables, but the board surface is damaged or marred
Solution Approach 1:
The air cushion serves as an intermediary layer between the board and the forming table during transportation. This air layer reduces direct mechanical contact and friction, allowing the board to be transported along the forming tables without surface damage or marring while maintaining controlled movement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes board damage, ensures uniform slurry distribution, and enhances edge strength, reducing the need for additional finishing materials and time, while potentially eliminating the need for external dryers by aiding in the drying process.
Implementation Method 1
The use of pressurized air nozzles integrated into forming tables to reduce friction and promote uniform slurry distribution by creating an air cushion between the board and the table
Implementation Method 2
pressurized air to reduce the friction between the board and the underlying forming tables
Data Source
AI summary
A method for producing building boards includes unwinding a facing sheet from a supply roll of facing sheet over top of a forming table that includes a series of nozzles. A volume of cementitious material is deposited from a slurry mixing device to the unwound facing sheet. Pressurized air is supplied from an air source to the series of nozzles, whereby a cushion of air is created between the unwound facing sheet and the forming table.