Slurry Roller Conveyor for Uniform Gypsum Board Deposition
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Solution Overview
Problem
Existing slurry distribution systems in gypsum board production suffer from non-uniform layer deposition due to flushing effects, leading to weakened functional areas and reduced quality, and require frequent maintenance.
Innovation Solution
A slurry distributing device with parallel rotatable rollers, driven by variable speed drives, ensures uniform slurry deposition and minimizes flushing by controlling slurry spread and speed, eliminating the need for multiple hoses and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If slurry is deposited on a lower layer by means of one or more hoses, then the next layer can be deposited before the preceding layer has fully set, but flushing effects occur causing non-uniform layer deposition
Solution Approach 1:
A water-soluble polymer additive is introduced as an intermediary substance between the slurry and the lower layer. This polymer forms a protective interface that prevents the high-speed slurry from directly flushing away the underlying layer, thereby maintaining both high deposition speed and layer uniformity
Solution Approach 2:
The chemical composition of the slurry is modified by adding water-soluble polymers (such as polyacrylamide, carboxymethyl cellulose, or starch derivatives). This parameter change alters the rheological properties and interfacial behavior of the slurry, reducing its flushing effect on the lower layer while maintaining depositability
2Manufacturing precision
If delivery pressure and cross-section of delivery hoses are increased to reduce flushing effects, then layer uniformity improves, but device complexity and maintenance requirements increase
Solution Approach 1:
Instead of investing in complex, expensive hose systems with multiple discharge lines and large cross-sections, the invention uses a simple, inexpensive chemical additive that can be easily mixed into the slurry. The polymer additive acts as a temporary, consumable solution that requires no structural modification to the delivery system
Solution Approach 2:
The mechanical approach of increasing hose diameter and delivery pressure is replaced by a chemical approach using water-soluble polymers. This substitution eliminates the need for complex mechanical modifications to the hose system while achieving the same goal of reducing flushing effects
3Manufacturing precision
If multiple discharge hoses are used to distribute slurry, then deposition uniformity improves, but maintenance frequency and cleaning difficulty increase
Solution Approach 1:
The slurry flow is naturally segmented into multiple streams by the polymer additive's flow-control properties, creating uniform deposition patterns without requiring multiple physical hoses. The single hose delivers slurry that self-segments as it exits, maintaining deposition uniformity while simplifying the hose system to a single line that is easier to clean and maintain
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
The system achieves uniform slurry distribution, reduces flushing effects, and decreases water usage while allowing for easier cleaning and maintenance, resulting in higher-quality gypsum boards.
Implementation Method 1
the parallel rollers are provided in a series of at least two, typically two to five, preferably three or four, roller sections, wherein each roller section has three or more, preferably 6 to 20, more preferably 6 to 10, typically 7 or 8, adjacent said parallel rollers
Implementation Method 2
adapt a speed of the slurry to a conveying device speed and to distribute the slurry uniformly over a desired width of an upper surface of the rollers
Data Source
AI summary
A slurry distributing device including a roller conveyer having a series of roller sections, each section driven by a respective motor and employing a combination of direct drive and belt drive. The slurry distributing device is used for the uniform and low-speed flow distribution of slurries. The invention also relates to a conveyor line for the continuous production of gypsum drywall boards employing the slurry distributing device. The invention also relates to a method for the continuous production of gypsum drywall boards employing the slurry distributing device.