Gypsum Board Lining Paper Moisture Control for Wrinkle Suppression
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Solution Overview
Problem
Conventional gypsum board production methods face issues with wrinkling on lining paper due to increased production speed and the use of lightweight paper, leading to defects and reduced yield, and require chemical agents that complicate and increase costs.
Innovation Solution
A method involving spraying water onto the top paper of the gypsum board laminate at a specific position between the forming machine and rough cutting machine to reduce swelling differences and suppress wrinkling, using lightweight paper without chemical agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveying belt speed is increased to enhance productivity, then production speed is improved, but wrinkling occurs more frequently on lining paper
Solution Approach 1:
The invention applies preliminary action by spraying water on the lining paper before it enters the forming machine, pre-moistening the paper to prevent wrinkling during high-speed conveyance and forming. This preliminary moisture application ensures the paper maintains dimensional stability throughout the high-speed production process without requiring speed reduction.
2Weight of moving object
If lightweight paper is used for lining paper to reduce weight, then material weight is reduced, but wrinkling occurs more easily on the paper surface
Solution Approach 1:
The invention changes the moisture parameter of the lining paper by spraying water on it before forming. This parameter change (increasing moisture content) compensates for the reduced weight and dimensional stability of lightweight paper, preventing wrinkling while maintaining the weight reduction benefits. The paper is sprayed with water at a controlled amount to achieve optimal moisture level for wrinkle prevention.
3Manufacturing precision
If a lubricant is applied on the lining paper or conveying belt to prevent wrinkling, then wrinkling is suppressed, but production steps become complicated and costs increase
Solution Approach 1:
The invention extracts and eliminates the need for chemical lubricants from the production process. Instead of applying lubricant substances, the invention uses a simple water spray system that provides the necessary moisture to prevent wrinkling without introducing chemical agents. This simplifies the production steps and reduces costs while maintaining effective wrinkle prevention.
4Manufacturing precision
If a lubricant is applied on the lining paper or conveying belt to prevent wrinkling, then wrinkling is suppressed, but chemical agents are left on the bottom paper
Solution Approach 1:
The invention replaces persistent chemical lubricants with a temporary water spray system. The water is applied only during the forming process and evaporates or is absorbed during subsequent drying, leaving no harmful chemical residues on the bottom paper. This approach maintains wrinkle suppression effectiveness while eliminating the harmful factor of chemical accumulation.
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
Effectively suppresses wrinkling on gypsum boards, enabling high-yield, efficient production even at increased speeds and with lightweight paper, expanding the range of lining paper options and improving productivity.
Implementation Method 1
water is sprayed or applied onto the top paper of lining paper for gypsum board... to supply moisture to the top paper... reducing the difference in swelling between the top paper and bottom paper
Data Source
Figure 1~2
AI summary
There is developed and provided a technique that: can effectively suppress, by a simple method without using a chemical substance, the occurrence of wrinkling on lining paper for forming a gypsum board product to be obtained by a method for producing a gypsum board and is applicable to actual continuous production processes for a gypsum board; and can stably produce a superior-quality gypsum board with high yield. This method for producing a gypsum board has a step of conveying a board-like laminate in which a gypsum material layer is laminated between tope paper and bottom paper of lining paper for gypsum board while forming the board-like laminate, wherein: the step has a series of processes of disposing the bottom paper on an operating conveying-and-forming belt, continuously pouring a gypsum slurry of a raw material for a gypsum material layer onto the bottom paper being conveyed, laminating the top paper on the gypsum slurry with a forming machine to mold the board-like laminate, and conveying the board-like laminate to a rough cutting machine with the conveying-and-forming belt; and water is sprayed or applied onto the top paper at a position: which is between the forming machine disposing position and the rough cutting machine disposing position; and whose distance from the forming machine disposing position is 1/4 of the distance therebetween, or at a position which is on the forming machine side that is the upstream side of the position whose distance from the forming machine is 1/4 of the distance between the forming machine disposing position and the rough cutting machine disposing position.