Slurry Distribution Rollers for Uniform Drywall Board Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conveyor lines for producing gypsum plasterboards suffer from non-uniform layer deposition due to flushing effects, which degrade the quality of the end product, especially in boundary layers, and require frequent maintenance and cleaning.
Innovation Solution
A slurry distributing device that actively transports slurry using rollers or a combination of rollers and a process belt, ensuring uniform distribution and minimizing flushing effects by controlling the slurry speed and reducing impact, with self-cleaning features to minimize maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the slurry delivery pressure and flow rate are increased to improve deposition speed, then productivity increases, but flushing effects worsen causing non-uniform layer deposition
Solution Approach 1:
The slurry delivery system is segmented into multiple separate nozzles arranged in a specific pattern, allowing the slurry to be deposited in multiple streams simultaneously. This segmentation reduces the impact velocity of each individual stream while maintaining overall deposition productivity, thereby preventing flushing effects on the underlying layer.
Solution Approach 2:
An intermediary distribution plate or manifold is introduced between the delivery hose and the deposition point. This intermediary component distributes the slurry flow across multiple nozzles and controls the flow velocity, acting as a buffer that reduces the direct impact force on the underlying layer while maintaining efficient deposition.
2Manufacturing precision
If the hose diameter is increased to reduce delivery pressure and minimize flushing effects, then layer uniformity improves, but the self-cleaning capability of hoses deteriorates leading to blockages
Solution Approach 1:
Instead of using a single large-diameter hose, the system uses multiple smaller-diameter hoses or nozzles. Each small hose maintains adequate flow velocity for self-cleaning, while the collective output of multiple nozzles achieves the desired low impact pressure and uniform layer deposition.
Solution Approach 2:
The system uses slightly higher flow rates through multiple small nozzles compared to a single large hose, ensuring that each nozzle maintains turbulent flow conditions for self-cleaning. The excess flow capacity distributed across multiple nozzles prevents blockages while the distributed nature of the flow reduces individual impact pressure.
3Manufacturing precision
If the number of discharge hoses is increased to distribute slurry more evenly, then layer uniformity improves, but device complexity increases
Solution Approach 1:
Multiple nozzle outlets are merged into a single integrated distribution plate or manifold assembly. This combining approach achieves even slurry distribution across the deposition area while maintaining a compact, unified structure that does not significantly increase device complexity. The nozzles are arranged in a fixed geometric pattern on the plate.
Solution Approach 2:
The distribution plate serves multiple functions simultaneously: it acts as a flow distributor, a structural support, a nozzle mounting platform, and a flow velocity controller. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving improved layer uniformity.
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
Achieves uniform slurry deposition across the width of the layer, significantly reducing flushing effects and maintenance needs, while maintaining production efficiency and product quality.
Implementation Method 1
The rollers are arranged in a common plane and are rotatably mounted about their longitudinal axes... adapt the speed of the slurry to a conveyor belt speed
Implementation Method 2
a discharge roller at the end of the roller conveyor in the delivery direction of the slurry, wherein the uppermost point of the discharge roller is disposed at a small distance from the surface of the lower layer
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a conveyor line for the continuous production of drywall boards as well as a slurry distributing device which is used in this conveyor line. The distributing device is used for the uniform and low-speed flow distribution of slurries.