Arcuate Forming Table for Uniform Gypsum Slurry Spread
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Solution Overview
Problem
Existing gypsum board forming devices fail to achieve uniform slurry distribution adjacent a pinch point, leading to voids and reduced strength and durability in the resulting boards.
Innovation Solution
A gypsum board forming device with an arcuate or angled forming table and hinge plate design promotes uniform slurry distribution by transitioning from an arcuate profile to a planar profile before the extruder plate, ensuring adequate slurry spread and eliminating eddies, thereby enhancing board quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional flat forming table is used, then the device structure is simple, but the slurry distribution is non-uniform leading to voids and reduced board quality
Solution Approach 1:
The forming table is designed with an arcuate cross-section profile that transitions to a planar profile near the pinch point. This curved geometry promotes uniform slurry distribution by eliminating eddies and ensuring adequate slurry spread across the board width, directly resolving the non-uniform distribution issue while maintaining structural feasibility
2Manufacturing precision
If the forming table has an arcuate profile throughout, then slurry distribution is improved, but the board flatness and thickness uniformity deteriorate
Solution Approach 1:
The forming table profile is segmented into distinct zones: an arcuate section that promotes slurry distribution, and a planar section near the pinch point that ensures board flatness and thickness uniformity. This segmentation allows each zone to fulfill its specific function without compromising the other
Solution Approach 2:
Different cross-sectional profiles are applied at different locations along the forming table. The arcuate profile is used where slurry distribution is needed, while the planar profile is used where board flatness is critical, optimizing local conditions for each functional requirement
Data Source
AI summary
Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate.