Hatschek Fiber Cement Plate Profiled Edge Density
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Solution Overview
Problem
Hatschek processes for producing fiber cement plates with profiled edges face challenges in achieving uniform density across the plate, leading to variations in physical properties due to the extra material removal step.
Innovation Solution
A Hatschek process involving an endless fiber cement multilayered slab with alternating monolayers of different widths, stacked and accumulated on a profiled accumulator roll with a recess, to create tapered or beveled edges with minimal density deviation across the plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a profiled accumulator roll is used to create tapered edges, then the plate profile is improved, but the density uniformity deteriorates
Solution Approach 1:
The monolayers are segmented into two types with different widths (W1 and W2), where the first type has narrower edges and the second type has wider edges. This segmentation allows different regions of the plate to have different material distributions, creating tapered edges while maintaining overall density uniformity through the alternating pattern.
Solution Approach 2:
Different regions of the plate are given different local qualities through the alternating monolayer widths. The edges have narrower monolayers creating tapered profiles, while the center maintains wider monolayers for structural integrity. This local differentiation achieves both profiled edges and density uniformity.
2Shape
If material is removed by grinding or cutting to create tapered edges, then the plate profile is improved, but the manufacturing cost increases
Solution Approach 1:
The tapered edge profile is created in advance during the plate formation process itself, rather than requiring subsequent removal operations. The alternating width monolayers are stacked to form the profiled shape before curing, eliminating the need for expensive grinding or cutting operations afterward.
Solution Approach 2:
The unnecessary material removal step is extracted from the manufacturing process. Instead of forming complete plates and then removing excess material through grinding or cutting, the process directly forms plates with the desired tapered profile through selective monolayer width variation.
3Shape
If uncured fiber cement is accumulated on a profiled accumulator roll, then the plate profile is improved, but the density variation increases
Solution Approach 1:
The monolayers are segmented into two types with different widths (W1 and W2), where the first type has narrower edges and the second type has wider edges. This segmentation allows different regions of the plate to have different material distributions, creating tapered edges while maintaining overall density uniformity through the alternating pattern.
Solution Approach 2:
The width parameter of the monolayers is changed between alternating layers, with the first type having width W1 and the second type having width W2. This parameter variation in the transverse direction creates the tapered profile while the alternating pattern compensates for density variations.
Data Source
AI summary
A Hatschek process for the production of profiled fiber cement plates is provided. The process comprises the steps of: (i) providing an endless fiber cement multilayered slab stacking at least one monolayer of a first type having a first width and at least one monolayer of a second type of monolayers having a second width, the at least one monolayer of a second type of monolayers extending in transverse direction beyond the at least one monolayer of a first type of monolayer: (ii) accumulating at least one layer of the endless fiber cement multilayered slab on a profiled accumulator roll having a recess along at least part of its circumference whereby the at least first monolayer is provided within the recess; (iii) removing the accumulated slab from the accumulator roll; and (iv) curing the uncured fiber cement plate.