Vibratory Angled Plate Thickness Control for Cementitious Panels

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Solution Overview

Problem

The production of fiber-reinforced cementitious panels faces challenges in achieving uniform thickness, leading to excess material and increased processing steps, which result in waste and reduced efficiency due to the need for additional sanding and finishing to achieve the desired thickness.

Innovation Solution

A thickness control device with an adjustable angled rigid plate and mounting frame is employed to apply uniform pressure and smooth the surface of the panels as they exit the headbox or embedment device, ensuring consistent thickness without damaging the panels, thereby reducing the need for grinding and sanding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple alternating layers of slurry and glass fibers are deposited to achieve desired thickness, then the panel reaches the target thickness, but thickness variation increases and uniformity deteriorates

Engineering Contradiction:

Improvethickness uniformityVSAvoidexcess material

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent applies preliminary action by using a thickness control device with a rigid plate and vibrator during the forming process to pre-level the panel surface before it sets. This preliminary thickness control prevents the need for excessive material deposition and eliminates the requirement for subsequent grinding and sanding operations, thereby reducing waste while maintaining uniform thickness

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs mechanical vibration through a vibrator attached to the rigid plate of the thickness control device. The vibration is transmitted to the panel surface to improve leveling and smoothing effects during the forming process, enabling better thickness uniformity with less material and reducing the need for post-processing

Inventive Principle:

Principle #18Mechanical vibration

2Manufacturing precision

If additional sanding and finishing steps are applied to achieve desired thickness, then thickness uniformity is improved, but production time increases and efficiency decreases

Engineering Contradiction:

Improvethickness uniformityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The thickness control device performs preliminary thickness control and surface leveling during the forming process itself, before the panel sets. This eliminates the need for subsequent grinding and sanding operations, thereby maintaining thickness uniformity while significantly reducing production time and improving efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts or removes the post-processing sanding and grinding steps from the production sequence by implementing thickness control during forming. This eliminates unnecessary processing steps that consume time and resources, directly improving productivity while maintaining quality

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If a rigid plate with vibrator is used to smooth the panel surface, then thickness uniformity is improved, but the risk of damaging the panel increases

Engineering Contradiction:

Improvethickness uniformityVSAvoidpanel damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The vibrator attached to the rigid plate applies mechanical vibration to the panel surface during smoothing. This vibration reduces the risk of damage by preventing the rigid plate from directly impacting the panel, while still achieving effective thickness control and surface leveling through the vibratory motion

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent changes the operational parameters of the thickness control device by adjusting the vibration frequency and amplitude, as well as the plate position and pressure. These parameter adjustments enable effective thickness uniformity control while minimizing the risk of panel damage through optimized operating conditions

Inventive Principle:

Principle #35Parameter changes

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

This solution achieves a more uniform panel surface profile, reduces waste and processing time, and decreases raw material usage, leading to cost savings and improved production efficiency.

Implementation Method 1

The plate is vibrated to reduce thickness variation

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS11674317B2Apparatus and process with a vibratory angled plate and/or fixed horizontal plate for forming fiber-reinforced cementitious panels with controlled thickness

Publication Date: 2023.06.13 UNITED STATES GYPSUM CO

AI summary

A production line and process including a moving carrier web for transporting the panel, and a device for controlling thickness of a formed, but not yet set, fiber reinforced cementitious panel slurry on the web. The thickness control device may include an angled rigid plate for contacting a downstream end of the angled plate with the slurry on the moving carrier web and a mounting stand for mounting the angled rigid. The thickness control device may include a flat horizontal plate at a fixed height over the moving carrier for contacting the entire lower surface of the horizontal plate with a facer on the slurry on the moving carrier web. Or, the thickness control device may include the angled plate and include the horizontal plate that contacts the facer.