MIXING AND SHAKING DEVICE FOR PLASTER PASTE, METHOD FOR MIXING AND SHAKING PLASTER PASTE, AND, METHO

专利摘要:
1 / 1 abstract “Mixing and stirring device for gypsum slurry, method for mixing and stirring gypsum slurry, and method and apparatus for making lightweight gypsum boards†[problem] prevent irregularities, deviation or variation in the density distribution of gypsum paste on a base paper for a gypsum board by reducing the swirl of the gypsum paste flowing into the gypsum paper. base for a plasterboard. [solution] A mixing and stirring device (10) for gypsum slurry has a circular housing (20) to form a mixing region, and also has a rotating plate (32) ) arranged inside the accommodation. the mixing and stirring device (10) additionally has a tubular passage (50, 90, 95, 96, 97, 97') for supplying the slurry in the base paper (1) to a plasterboard. a chute has flow passage parts (60, 61, 91, 92) which are provided with flow passage cross sections asymmetrical with respect to the central axis (c, c1) of the passage tube, or alternatively, the chute has flow passage parts (98, 99) in which the position of the central axis of the tubular passage is changed by changing or shifting the section cross flow passage. an axially symmetric swirling flow that is generated as a swirling flow in the tube (f) inside the tubular passage collapses in the flow passage parts and, as a result, the plaster slurry (3) that flows out onto the base paper for a gypsum board substantially does not flow in a swirling motion which causes non-uniformity or instability of density distribution.
公开号:BR112015012984B1
申请号:R112015012984-6
申请日:2013-11-27
公开日:2020-06-23
发明作者:Yasutoshi Ueno；Hitoshi INENAGA；Yutaka Matsuzaki
申请人:Yoshino Gypsum Co., Ltd.；
IPC主号:

专利说明:

Field of the Invention
[001] The present invention relates to a mixing and stirring device, a mixing and stirring method, and a method for making light plasterboard and, more specifically, to such devices and methods that can control or restrict the movement of rotation of gypsum paste which is poured on a sheet of paper to a plasterboard coating in order to obtain uniformity of density distribution of the gypsum paste on the sheet. Fundamentals of Technique
[002] Plasterboard is known as plasterboard core covered with sheets of paper for plasterboard covering, and is widely used in various types of construction as architectural interior finishing materials, due to its advantageous ability to fire resistance and fire protection, sound insulation performance, workability, cost performance and so on. In general, plasterboard is produced by a casting process and continuous paste distribution. This process comprises a step of mixing and stirring of grouping calcined plaster, adhesive auxiliary agent, setting accelerator, foam (or foam agent) and so on with mixing water in a mixing and stirring device; a step of forming poured calcined plaster paste prepared in the device (referred to as "paste" below) in an area between sheets of upper and lower paper for plasterboard coating and casting them in a continuous belt type formation; and a drying and cutting step of roughly dividing the solidified belt-like layer formation, forcibly drying it and then cutting it to the size of a product.
[003] Typically, a fine circular type centrifugal mixer is used as the mixing and stirring device to prepare the paste. This type of mixer comprises a flat circular coating and a rotating disk positioned rotationally in the coating. A plurality of material feed openings for feeding the materials mentioned in the mixer is arranged in a central region of an upper cover or an upper coating plate, and a paste outlet opening is provided to deliver the mix (paste) of the mixer on a periphery of the coating or a lower plate (lower cover) of the same. Typically, a rotating mechanical axis is connected to the disk to rotate the disk, and the mechanical axis is connected with a rotary drive device. The top plate of the cladding is equipped with a plurality of upper pins (stationary pins) hanging on it to the vicinity of the disc. The disk is equipped with lower pins (movable pins) that are vertically fixed to the disk and extend to the vicinity of the upper plate. The upper and lower pins are arranged in radially alternating positions. The ingredients to be mixed are supplied to the disc through the respective feed openings, and are stirred and mixed while being moved radially outward on the disc by the action of centrifugal force, and then delivered from the mixer through the paste outlet opening, which are positioned on the periphery or on the bottom plate (bottom cover). The mixer with this arrangement is called a pin-type mixer, which is disclosed, for example, in International PCT Application Publication No. WO00 / 56435 (Patent Literature 1).
[004] As regards a method for delivering the paste prepared in the mixer to the outside of the mixer, the following three types of methods are mainly known in the art:
(1) A vertical gutter, which is also called a "tube", is attached to a paste outlet opening provided in an annular wall of the liner, and the paste on the rotating disc is delivered to the gutter by the action of centrifugal force, by fonna that the paste that flows into the chute is gravitationally poured onto the sheet of paper (International PCT application publication No. W02004 / 026550 (Patent literature 2)); (2) A tubular passage to transport the paste is transversely connected to the paste outlet opening provided in the annular wall of the coating, so that the paste is poured into the paper sheet using a mixer delivery pressure. US Patent No. 6,494,609 (Patent Literature 3)); (3) A tubular paste delivery passageway is vertically connected to the paste outlet opening provided in the bottom liner, so that the paste is gravitationally poured into the sheet of paper through the delivery passageway (Japanese patent publication open No. 2001-300933 (Patent Literature 4)).
[005] In general, foam or foaming agent is fed into the paste in the mixer in order to regulate or adjust the specific gravity of the plasterboard. Proper mixing of the foam or foaming agent in the paste is considered an essential material in a method to produce light plasterboard. Therefore, in the method of producing plasterboard in recent years, a technique for properly mixing an appropriate amount of foam or foaming agent with the paste is considered especially important. As regards the reduction in the amount of foam supply or foaming agent (referred to as the "amount of foam" below) and uniform mixing of the paste and foam, a relationship between a method of feeding the foam or foaming agent in the paste and a method for delivering the paste (Patent Literature 2 and 3).
[006] Each of the US patent specification No. 6,742,922 (Patent literature 5) and international publication of PCT application No. W02004 / 103663 (Patent literature 6) reveals a technique designed to achieve homogeneous dispersion and distribution of the foam or foaming agent in the paste using a swirling flow of paste in a vertical chute.
[007] A circular fluid passage in the vertical channel is provided with an orifice element in a lower part of the passage, in relation to the mixer intended for homogeneous dispersion and distribution of the foam in the paste by means of a swirling flow of paste generated in the channel. . The orifice element has an orifice or constriction (referred to as the "orifice" below.) The orifice acts as a fluidic resistance against a vertical movement of the paste, so that the paste flowing into said chute does not immediately flow down through the gravitationally and therefore the flow in an intratubular swirl of paste is certainly created in an intratubular area of the trough.
[Quote List] [Patent literature] [Patent literature 1] International publication of PCT application No. WOOO / 56435 [Patent literature 2] International publication of PCT application No. W02004 / 026550 [Patent Literature 3] U.S. Patent Publication No. 6,494,609 [Patent literature 4] Publication of Japanese patent open No. 2001-300933 [Patent literature 5] U.S. patent publication No. 6,742,922 [Patent literature 6] International publication of PCT application No. W02004 / 103663 Summary of the Invention [Technical problem]
[008] The orifice of the aforementioned orifice element consists of a horizontal opening in the form of a perfect circle, the center of which coincides with a central axis of the rail. As described in patent literature 5, the swirl flow of paste generated in an upper area above the orifice is temporarily reduced in its swirling radius of motion and increased in its fluid velocity in the orifice, and then on one side downstream from the orifice, the paste flow is increased in its swirling movement radius and reduced in its fluid velocity, so that the radius and speed of the swirling flow before entering the orifice is practically recovered or regenerated. A turbulent flow is locally generated in the orifice section by such changes in the radius and speed of the flow, whereby the mixture of the paste and foam is promoted.
[009] However, in experiments carried out by the present inventors, it was noticed that, when measuring the specific gravity of the paste leaked through the gutter on the plasterboard paper sheet, there is a relatively significant poor distribution, deviation or irregular dispersion in the pulp density distribution considered along the width direction of the paper sheet, as shown in the comparative examples of FIGS. 14-17. Additionally, according to the experiments of the present inventors, such deviation or irregular dispersion is most significantly observed when the amount of foam is increased to reduce the weight of the plasterboard. Therefore, in a case where light plasterboard has to be produced, it is particularly important to certainly prevent such poor distribution, deviation or irregular dispersion in the distribution of specific gravity.
[0010] Additionally, the technique revealed in patent literature 5 and 6 is arranged in such a way as to promote the mixing of the paste and the foam using the swirl flow generated in an intratubular area of the trough as a central vertical geometric axis. A similar phenomenon is also observed in a tubular paste transport passage transversely connected in the paste outlet opening in the annular wall of the coating (Patent Literature 3), or a tubular paste delivery passage vertically connected in the paste outlet opening of the bottom plate of the coating (Patent Literature 4)), in which the circumferential flow occurs at the opening of the paste discharge from the tubular passage when the paste is poured into the sheet of paper. This is considered to be caused by the effects of the rotary movement of the slurry in the internal mixing area of the mixer, an axisymmetric vortex flow generated as an intratubular swirl flow of slurry in an intratubular area of the tubular passage, and so on.
[0011] It is an object of the present invention to provide a mixing and stirring device, a mixing and stirring method, and a method for making light plasterboard, which can restrict the circular movement of the plaster paste that is poured into the sheet. paper for a plasterboard coating, thereby preventing bad distribution, deviation or irregular dispersion in the distribution by specific gravity of the paste on the paper sheet. Solution to the Problem
[0012] The present invention provides a mixing and stirring device for plaster paste, which has a circular coating forming a mixing area for mixing plaster paste, a rotating disk positioned in the coating and rotated in a predetermined rotational direction, and a tubular passageway for delivering the plaster paste provided outside the coating in order to feed the paste from the mixing area on a sheet of plasterboard paper,
wherein said tubular passage includes a fluid passage part with its non-axisymmetric cross section with respect to a central axis of the tubular passage, to interrupt an axisymmetric vortex flow of the plaster paste generated in the tubular passage as an intratubular swirl flow , on a fluid passage part varying the position of the central axis of the tubular passage by changing or lateralizing the cross section of the fluid passage, to cause the action of interrupting said flow in an axisymmetric vortex.
[0013] The present invention also provides a method for mixing and stirring gypsum paste, using a mixing and stirring device for the gypsum paste with a circular coating forming a mixing area for mixing the gypsum paste, a disk rotary positioned in the coating and rotated in a predetermined rotational direction, and a tubular passage for delivery of the plaster paste provided outside the coating in order to feed the paste from the mixing area on a sheet of plasterboard coating paper, comprising the steps of:
form a fluid passage part of the tubular passage that has its non-axisymmetric cross section with respect to a central axis of said tubular passage, or a fluid passage part of the tubular passage that changes the position of the central axis of the tubular passage by changing or lateralization of the cross section of the fluid passage; and interrupting the flow in an axisymmetric vortex, which is generated in said tubular passage as an intratubular swirl flow, by changing the cross section and / or the center of the fluid passage, thereby restricting the regeneration or generation of the intratubular swirl flow. in an intratubular area of a part of the discharge tube of said tubular passage located on one side downstream of the fluid passage part.
[0014] In the understanding of the present inventors, non-uniformity, instability and the like with regard to the density distribution of paste leaking on the paper sheet result from a phenomenon in which ingredients of the mixture with relatively high specific gravities are predisposed to an external part of the swirl flow and mix ingredients with relatively low specific gravities are predisposed to an internal part of the swirl flow, because of the intratubular swirl flow generated in the tubular passage to feed the slurry. Therefore, in a case where the paste includes a relatively large amount of foam or foaming agent that has a relatively low specific gravity, the phenomenon of non-uniformity or instability is significantly observed. According to the present invention, an axysymmetric vortex flow generated as the intratubular swirl flow in the tubular slurry feed passage is interrupted at least partially by the non-axisymmetric fluid passage cross section or the change or lateralization of the cross section fluid flow to change the position of the center of the tubular passage, whereby the flow of the slurry is considerably disturbed in a fluid passage part like this. Thus, the intratubular vortex flow after passing through this fluid passage part does not regenerate its condition before entering this passage part, or the vortex flow is difficult to be generated on the downstream side of the fluid passage part. The whirl movement practically disappears on the downstream side of the fluid passage part, and the whirl movement, which possibly can cause the non-uniformity or instability of the specific gravity distribution, does not remain in the paste that is poured from the pipe part. discharge on the sheet of paper. According to the experiments of the present inventors, in a case where the pulp with its restricted swirling motion is poured into the sheet of paper, the specific gravity distribution is uniform and stable, even in a case where the pulp includes a relatively large amount foam or foaming agent and, therefore, the aforementioned problem of non-uniformity or instability of the density distribution can be overcome.
[0015] The term “interruption” does not always mean complete interruption of the flow in an axisymmetric vortex, but it does mean that the flow in an axisymmetric vortex is interrupted at least partially to the point where the intratubular eddy flow is prevented from being regenerated or caused by part of the discharge tube that discharges or leaks the paste onto the sheet of paper. In addition, the term “fluid flow cross section” means a cross section perpendicular to a flow direction of the plaster paste.
[0016] From another aspect of the invention, the present invention provides a method for making light plasterboard with a specific gravity less than or equal to 0.8, in which plaster paste is produced using a mixing and stirring device for gypsum paste, which has a circular coating forming a mixing area for mixing gypsum paste, a rotating disk positioned in the coating and rotated in a predetermined rotational direction, and a tubular passage for delivery of the gypsum paste provided outside the coating in order to feed the paste from the mixing area on a sheet of paper for plasterboard coating, and in which the paste from the mixing area is poured into said sheet of paper, comprising the steps of:
introducing said plaster paste into the effluent mixture area of the coating through a paste outlet opening arranged in the coating in said tubular passage together with foam or foaming agent to adjust the specific gravity, and generate an intratubular eddy flow in an area intratubular of the tubular passage circulating the paste in it so that the paste and the foam or foaming agent are mixed in the tubular passage by the swirl flow generated in the tubular passage; and form a fluid passage part of said tubular passage, which has a non-axisymmetric fluid passage cross section with respect to a central axis of the tubular passage, or which changes the central axis of the tubular passage by changing or lateralizing the cross section of the fluid passage, and cause an axysymmetric vortex flow to interrupt the flow in an intratubular vortex generated in said tubular passage, because of the change in the cross section of the fluid passage and / or in its center, thereby restricting regeneration or generating the flow in an intratubular vortex in a part of the discharge tube of said tubular passage located on one side downstream of said fluid passage part.
[0017] Preferably, the tubular passage is provided with an orifice passage that has the cross section of the non-axisymmetric fluid passage with respect to the central axis of the intratubular area and that locally restricts the fluid passage cross section, and the axisymmetric vortex. in the intratubular area it is interrupted in the orifice passage to restrict the regeneration or generation of the intratubular eddy flow in the part of the discharge tube of the tubular passage located on one side downstream of the orifice passage.
[0018] According to the presented arrangement of the present invention, the paste and the foam or foaming agent are mixed by the intratubular swirl flow generated in the tubular passage, and the foam or foaming agent in the paste is able to be predisposed radially into the eddy flow. However, such a predisposition into the foam or foaming agent is prevented from occurring because of the interruption of the flow in an axisymmetric vortex caused when the fluid flows through the aforementioned fluid passage or orifice part. Since the fluid passage part or the orifice passage restricts the regeneration or generation of the flow in an intratubular vortex in the part of the discharge tube on its downstream side, the paste is poured into the paper sheet by the part of the discharge tube in a condition where the foam or foaming agent is evenly dispersed in the paste. The present inventors recognized in the experiments that poor distribution, deviation or irregular dispersion could be prevented from occurring in the distribution of specific gravity, even when the specific gravity of the gypsum core of the plasterboard was considerably decreased (for example, in a case where the material mix ratio and production condition corresponding to the specific gravity of 0.4 were employed), as shown in the examples of FIGS. 14-17. [Advantageous Effects Of The Invention]
[0019] According to the present invention, a mixing and stirring device, a mixing and stirring method, and a method for making light plasterboard can be provided, which can restrict the circular movement of plaster paste that is poured on the paper sheet for a plasterboard coating, thereby preventing poor distribution, deviation or irregular dispersion in the distribution of the specific gravity of paste on the paper sheet. Brief Description of Drawings
[0020] FIG. 1 is an explanatory process diagram illustrating partially and schematically a plasterboard formation process.
[0021] FIG. 2 is a partial plan view showing schematically an arrangement of a plasterboard fabrication apparatus.
[0022] FIG. 3 is a plan view showing a complete mixer arrangement shown in FIGS. 1 and 2.
[0023] FIG. 4 is a perspective view illustrating the complete arrangement of the mixer.
[0024] FIG. 5 includes a cross-sectional view and a partially enlarged view showing an internal structure of the mixer.
[0025] FIG. 6 is a vertical cross-sectional view showing the internal structure of the mixer.
[0026] FIG. 7 is a fragmentary sectional view showing the internal structure of the mixer.
[0027] FIG. 8 includes a cross-sectional view and a perspective view of a vertical rail.
[0028] FIG. 9 is a longitudinal cross-sectional view of the vertical track.
[0029] FIG. 10 is a plan view of an orifice element.
[0030] FIG. 11 is a cross-sectional view of the orifice element taken along a line I-I of Fig. 10.
[0031] FIG. 12 is a cross-sectional view of the rail with an orifice of a comparative example.
[0032] FIG. 13 is a longitudinal cross-sectional view of the rail shown in FIG. 12.
[0033] FIG. 14 includes graphical diagrams showing results of measuring specific gravity distributions with respect to plaster cores, where a target value of the specific gravity of the core is 0.7.
[0034] FIG. 15 includes graphical diagrams showing the results of measuring the distributions of specific gravities in relation to the plaster core, where the target value of the specific gravity of the core is 0.6.
[0035] FIG. 16 includes graphical diagrams showing the results of measuring the distributions of specific gravities in relation to plaster cores, where the target value of the specific gravity of the core is 0.5.
[0036] FIG. 17 includes graphical diagrams showing the results of measuring the distributions of specific gravities in relation to plaster cores, where the target value of the specific gravity of the core is 0.4.
[0037] FIG. 18 includes plan views showing modifications to a plane outline of an opening shown in FIG. 10.
[0038] FIG. 19 includes plan views showing relationships between the aperture and an area of the central circle.
[0039] FIG. 20 includes partial perspective views of the orifice elements, which show configurations of the edge parts of the openings.
[0040] FIG. 21 includes a schematic perspective view and a schematic cross-sectional view illustrating arrangements for varying or deviating from a cross section of a fluid passage, or decentralizing the fluid passage. Description of Modalities
[0041] In a preferred embodiment of the present invention, the fluid passage part is the orifice passage that locally restricts the cross section of the fluid passage, and the orifice passage has a centroid of its cross section located in an eccentric position. to the central axis of the tubular passage. Preferably, the cross-sectional outline of the orifice passage is a simple figure or a composite figure consisting of a plurality of figures partially superimposed with each other. The centroid of the figure or composite figure is eccentric to the central axis of the tubular passage. For example, the composite figure consists of a plurality of circles (perfect circle, ellipse, elongated circle, and so on) with different diameters and / or different central positions, which are only partially overlapping each other (the composite figure does not includes figures with the same central position and completely overlapping, or two circles with one circle completely enclosed in the other circle, and so on).
[0042] In the present invention, the centroid eccentricity ratio "η = ΔE / r" is preferably established in a range greater than or equal to 0.06 (6%), where the centroid eccentricity ratio is defined as “ΔE / r”, “ΔE” is the distance between the centroid and the central axis of the tubular passageway, and “r” is the radius of the tubular passageway. If desired, the eccentricity ratio “η” can be established greater than or equal to 0.10 (10%). The centroid eccentricity ratio “η '” can be defined as “ΔE / Rmax”, where “Rmax” is a maximum value of the distance from the central axis of the tubular passage to the contour of the figure. In such a case, the eccentricity ratio "η" is preferably established greater than or equal to 0.10 (10%) and, if desired, the eccentricity ratio "η" can be established greater than or equal to 0.15 (15 %). According to the experiments of the present inventors, such eccentricities of the orifice passage do not prevent the creation of the eddy flow on the side upstream of the orifice passage.
[0043] According to a preferred embodiment of the present invention, materials for plasterboard including calcined plaster, mixing water and additives and mixing agents (such as adhesive agent, setting accelerator and so on) are fed into the device mixing and stirring. These ingredients are mixed together, still moving radially outward on the disk by the action of centrifugal force, and reaches a peripheral zone (paste retention area) of the device, as the paste is substantially mixed thoroughly. For example, the outlet opening is positioned on an annular wall of the circular coating in order to be subjected to the centrifugal force of the device. The specific gravity of the plaster paste depends on the amount of foam inclusion, if the mixing water quantity factor is not taken into account. Preferably, a foam feed opening, which feeds the foam or foaming agent into the paste to adjust the specific gravity of the plaster core, is located in the annular wall in order to feed the foam or foaming agent into the paste just before the paste drains. from the mixing area to the paste outlet opening; or the foam feed opening is located in a paste delivery section in order to feed the foam or foaming agent into the paste immediately after the paste drains from the mixing area through the paste outlet. That is, the foam mixed in the paste can be lost by defoaming or foam destroying action due to the stirring impact of the mixing and stirring device, but the required amount of foam or foaming agent can be noticeably reduced by feeding the foam. or foaming agent in the paste in the final stage of preparation of the paste, since the foam or foaming agent is not influenced by the impact of the stirring (therefore, the foam is efficiently mixed in the paste).
[0044] Preferably, the tubular passage includes a gutter that receives the plaster slurry from the liner through the slurry outlet opening of the liner. The chute forms the flow in an axisymmetric vortex around its vertical central axis in its intratubular area. The outlet (bottom) part of the gutter is connected with a part of the discharge tube that leaks the plaster paste onto the paper sheet. The paste generates the intratubular swirl flow in the tubular passage or in the chute, in relation to the variation in the cross section of the fluid passage, the direction of the fluid flow, the fluid speed and so on, when the paste flows from the area of mixing through the slurry outlet openings, when the slurry flows into the intratubular area between the slurry outlet opening and the trough, or when the slurry enters the trough. As a result, the axisymmetric vortex flow is formed in the intratubular area of the gutter around its central axis that extends vertically. The orifice passage is positioned in the lower area of the chute in order to interrupt the flow in an axisymmetric vortex that gravitationally moves downwards in the intratubular area. In such an arrangement, the paste and the foam or foaming agent can be mixed in the intratubular area of the gutter by the swirling flow in the gutter, and the gravitationally swirling flow down in it is interrupted by the orifice passage, in order to prevent that the swirl flow is regenerated or generated in the part of the discharge pipe on the downstream side or the bottom side of the orifice passage. This results in uniformity of the specific gravity of the paste that is poured into the sheet of paper. In one embodiment of the present invention, the paste outlet opening is located on the annular or peripheral wall of the liner, or the bottom plate or bottom cover of the liner, and the upper part of the gutter communicates with the paste outlet opening. by means of a tubular body, such as a resin tube. In addition, if desired, the central axis of the rail can be tilted with respect to the vertical direction.
[0045] According to a preferred embodiment of the method for making light plasterboard, the foam or foaming agent is supplied in the paste just before or immediately after the paste flows from the mixing area through the paste outlet opening, and the amount of foam or foaming agent fed into the paste is set to the amount to produce the plaster core of the plasterboard with a specific gravity in the range of 0.4 to 0.7.
[0046] Preferably, the orifice element with the orifice passage is located in the tubular passage, and the orifice element has an adjustment device to adjust the cross section of fluid passage, which rotates or moves the orifice element to adjust or control the intensity of the action to interrupt the axisymmetric vortex of the orifice passage. In such an adjustment device, the adjustment of the intensity of the action can be done by adjusting or establishing the cross section of the orifice passage. In the mixing and stirring device with such an orifice passage and its adjustment device, the action of the orifice passage can be finely adjusted or varied by the adjustment device, while the state or physical property of the paste fed into the paper sheet is observed or measured during device operation. This is very advantageous in practice. In the experiments of the present inventors described later, the condition or physical property of the paste fed in the sheet could be changed, when the orifice element is rotated around the central axis of the tubular passage at least 3 (three) degrees. That is, it was observed by the experiments of the present inventors that the intensity of the action of interruption of the axisymmetric vortex can be variably controlled or adjusted by the rotation of the orifice element at an angle of at least 3 degrees.
[0047] In another embodiment of the present invention, the tubular passage is a tubular paste transport passage that is connected to the paste outlet opening in the annular wall of the coating and extends transversely from there, or a tubular passage of paste delivery that is connected to the paste outlet opening of the bottom liner plate and is pending there. The downstream ends of these passages constitute the parts of the paste discharge tube that leak the paste into the sheet. The orifice passage is provided in the tubular passage to interrupt the axysymmetric vortex flow generated as the intratubular eddy flow in the passage. Modality
[0048] With reference to the accompanying drawings, preferred embodiments of the present invention are described below.
[0049] FIG. 1 is a diagram of partial and schematic explanatory process illustrating a plasterboard forming process, and FIG. 2 is a partial plan view showing schematically an arrangement of a plasterboard fabrication apparatus.
[0050] A sheet of bottom paper 1, which is a sheet of paper for a plasterboard covering, is transferred along a production line. A mixer 10 is located in a predetermined position with respect to a transfer line, for example, in a position above the transfer line. Powdered materials P (calcined plaster, adhesive agent, setting accelerator, additives, mixing product and so on) and liquid (water) L are fed into mixer 10. Mixer 10 mixes these materials and discharges paste (plaster paste) calcined) 3 on sheet 1 by means of a paste delivery section 4, a paste discharge tube 7 and fractionation conduits 8 (8a, 8b). The paste delivery section 4 is located so as to receive the effluent paste from a periphery of the mixer 10 and introduce the paste into the tube 7. Foam M produced by the foaming device (not shown) is fed into section 4. The tube 7 is positioned to leak the paste from section 4 into a central area in the direction of the width of the sheet 1 (a core area) through a paste discharge opening 70. Conduits 8a, 8b are arranged so pour in the end parts in the width direction (edge zones) of the sheet 1, the paste 3 effluent from the periphery of the mixer 10. Instead of foam M, a foaming agent can be directly fed into the paste, so that the foam can be produced inside the paste by a foaming action of the foaming agent in the paste.
[0051] The sheet 1 is transferred together with the paste 3 to reach a pair of forming rollers 18 (18a, 18b). An upper sheet of paper 2 partially displaces around the periphery of the upper roll 18a to convert its direction into a transfer direction. The deflected sheet 2 comes into contact with the paste 3 in the lower sheet 1 and is transferred in the transfer direction to be substantially parallel with the lower sheet 1. A continuous three-layer belt-like formation 5 consisting of the sheets 1, 2 and the paste 3 is formed on one side downstream of the rollers 18. This formation 5 is continuously arranged at a transfer speed V while there is a pick up reaction of the paste 3, and reaches coarse cut rolls 19 (19a, 19b). If desired, a variety of forming devices can be employed, instead of forming rollers 18, such as the forming device using a direct pass action of an extinguisher, an entrance channel with a rectangular opening, and so on.
[0052] The cutting rollers 19 divide the continuous formation into plates of a predetermined length, in order to produce plates with a plaster core covered with the sheets of paper, that is, green plates. Then, the green plates are transferred through a dryer (not shown) that is located in a direction shown by the arrow J (on one side downstream in the transfer direction), whereby the green plates are subjected to forced drying in the dryer. Then, they are cut into slabs, each with a predetermined product length, and thus plasterboard products are successively produced.
[0053] FIGS. 3 and 4 are plan and perspective views illustrating the entire arrangement of the mixer 10, and FIGS. 5, 6 and 7 are cross-sectional and vertical sectional views and a fragmentary cross-sectional perspective view showing an internal structure of the mixer 10,
[0054] As shown in FIGS. 3 and 4, the mixer 10 has a flat cylindrical housing or liner 20 (referred to as "liner 20" below). The liner 20 has a horizontal plate 21 upper plate or upper cover (referred to as "upper plate 21" below), a horizontal plate lower lower plate or cover 22 (referred to as "lower plate 22" below), and a annular wall or external peripheral wall 23 (referred to as "annular wall 23" below) which is positioned on the peripheral parts of the upper and lower plates 21, 22. The plates 21, 22 are positioned, vertically spaced at a predetermined distance, in a way that an internal mixing area 10a for mixing the powdered materials P and liquid (water) L is formed in the mixer 10. A circular opening 25 is formed in a central part of the upper plate 21.A widened lower end part 31 of a rotatable vertical mechanical axis 30 extends through opening 25. Mechanical axis 30 is connected with a rotary drive device, such as an electric drive motor (not shown), and rotated in one direction predetermined rotational (clockwise and seen from the top side, in this mode). If desired, a variable speed device, such as a gear mechanism or variable speed belt assembly, can be arranged between mechanical axis 30 and an output mechanical axis of the rotary drive device.
[0055] A powder supply conduit 15 to feed area 10a with the powdered materials P to be mixed is connected to the top plate 21. A water supply conduit 16 to supply a quantity of mixing water L in area 10a it is also connected to the upper plate 21. If desired, an internal pressure regulator (not shown) to limit excessive increase in internal pressure and so on can be additionally connected to the upper plate 21.
[0056] On an opposite side of section 4, fractionation openings 48 (48a, 48b) are provided in the annular wall 23. Conduits 8a, 8b are connected to openings 48a, 48b, respectively. The openings 48a, 48b are positioned spaced at a predetermined angle to each other. Feeding openings of conduits 15, 16 open within a range of angle a in a central region of the upper plate 21, respectively.
[0057] As shown in FIG. 5, a paste outlet opening 45 of the paste delivery section 4 is positioned on the annular wall 23, spaced at a predetermined angle [3 of the fractionation opening 48a in the y-rotational direction (downstream side). Opening 45 opens on an inner circumferential surface of wall 23. A foam feed conduit 40, which feeds foam M into the paste to adjust the specific gravity of the paste, is connected to a hollow connection part 47 of section 4 A foam feed opening 41 of conduit 40 opens on an inner wall surface of connection part 47. Opening 41 is positioned on one side downstream of opening 45 in proximity thereto. If necessary, foam feeding openings (not shown) can be additionally provided in the openings 48 (48a, 48b) to feed the paste with foam M to adjust the specific gravity of the paste.
[0058] As shown in FIGS. 5 to 7, a rotating disk 32 is rotationally positioned in the liner 20. A lower face of the end portion 31 of the mechanical axis 30 is fixedly attached to a central part of the disk 32. The central axis 10b of the disk 32 coincides with a geometric axis of rotation of the mechanical axis 30. The disk 32 is rotated with rotation of the mechanical axis 30 in a direction indicated by the arrow y (clockwise).
[0059] Numerous lower pins (movable pins) 38 are arranged on the rotating disk 32 in a plurality of rows extending generally in their radial direction. The lower pins 38 are vertically fixed to the upper surface of the disk 32 in its inwardly facing zone. Disc 32 is formed with numerous toothed configurations 37 in its peripheral zone, in this modality. The toothed configurations 37 act to move or energize the mixed fluid (paste) in an outward and rotational direction. A plurality of pins 36 is vertically fixed in each of the toothed configurations 37.
[0060] As shown in FIGS. 6 and 7, a number of upper pins (stationary pins) 28 are attached to the upper plate 21 to hang from it in the internal mixing area 10a. The upper pins 28 and lower pins 38 are alternately arranged in the radial direction of the disk 32 so that the pins 28, 38 make relative movements to mix and agitate the plasterboard materials in the liner 20 when the disk rotates.
[0061] When plasterboard is produced, the rotary drive device of the mixer 10 is operated to rotate the rotating disk 32 in the direction of the arrow y, and the ingredients (powder materials) P and the mixing water L to be mixed in the mixer 10 they are fed into the mixer 10 through the powder supply conduit 15 and the water supply conduit 16. The ingredients and water are introduced into the inner region of the mixer 10, agitated in it and mixed together, still moving radially outward of disk 32 by the action of centrifugal force and moving circumferentially in the peripheral zone.
[0062] A portion of the pulp produced in area 10a flows to conduits 8a, 8b through the fractionation openings 48a, 48b, and the pulp is discharged through conduits 8a, 8b in the border areas of the bottom sheet 1 (FIG. 1 ). In this embodiment, each of the openings 48a, 48b is not provided with a foam feeding opening and, therefore, the paste 3b (FIG. 2) fed into the edge areas through the openings 48a, 48b, which do not include foam, has a relatively high specific gravity, compared to the paste 3a (FIG. 2) fed into the core area through the hollow connection part 47. If each of the openings 48a, 48b is provided with a foam feed opening (not shown ), a small amount of foam is fed into the slurry in each of the openings 48 a, 48b. Even in such a case, slurry 3b fed into the edge areas through the openings 48a, 48b usually has a relatively high specific gravity, compared to the slurry 3a fed into the core through the hollow connection part 47.
[0063] Most of the pulp produced in the mixing area 10a is displaced out and forward in the rotational direction by the toothed configurations 37, and the pulp flows out through the pulp outlet opening 45 of the pulp delivery section 4 in an approximately tangential direction, as shown by the arrows in a partially enlarged view of Fig. 5. The hollow connecting part 47 is constructed of a vertical side wall 47a on the upstream side, a vertical side wall 47b on the downstream side, a horizontal top wall 47c and a horizontal base wall 47d. The wall 47a extends in the approximately tangential direction with respect to the annular wall 23. The opening 45 and the connecting part 47 open to the internal mixing area 10a of the mixer 10, so that they receive the paste from the area 10a in general in approximately tangential direction. The paste delivery section 4 additionally includes a vertical track 50 with a cylindrical shape. The open end upstream of the connecting part 47 is connected to the edge part of the opening 45. The open end downstream of the part 47 is connected to an upper opening 55 formed in an upper part of a cylindrical wall of the trough 50,
[0064] The paste flows from the opening 45 to a passage of paste fluid 46 from the connection part 47, and then flows into the vertical rail 50 through the opening 55. The foam feed opening 41 is located on the wall 47a on the side upstream in the rotational direction, so that the foam M is fed into the paste immediately after entering passage 46 through opening 45.
[0065] As shown by dotted lines in FIG. 5, the foam feed conduit 40 can be replaced with a foam feed conduit 40 ', which is connected to the annular wall 23 and which has an opening of the foam feed opening 41' on an inner circumferential wall surface of the wall 23. In an arrangement like this to feed the foam, the foam is fed into the paste that is about to drain out through the opening 45. The paste in the peripheral area, which is fed with the foam, flows readily through the opening 45 to passage 46 in an approximately tangential direction, immediately after mixing the foam in the paste, and then the paste flows from passage 46 to the chute 50.
[0066] As shown in FIG. 5, the vertical rail 50 has an internal area D residing on one side upstream of an orifice element 60 (referred to as "internal area upstream D" below), and the internal area upstream D has a round cross section with a radius r, the center of which is a central axis extending vertically C. The connection part 47 is connected to the rail 50 in an eccentric condition on one side (in the eccentric position on the side close to the wall 23 in this embodiment). Therefore, passage 46 opens to the inner area upstream D in an eccentric position on one side. In this invention, the rail can have a central axis C inclined with respect to the vertical direction. In addition, as shown by the dotted lines in FIGS. 5 and 6, one end (upstream end) of a tube 47 ', 47 ", such as a resin tube, can be connected to a paste outlet opening provided in the annular wall 23 or the bottom plate 22, and the the other end (downstream end) of the tube 47 ', 47 "can open to an upper space within the rail.
[0067] The paste and the foam that enter the internal area upstream D revolve around the central axis C of the chute 50, so that the paste swirls along a circumference wall surface! internal area D. Due to the swirling or circular movement of the paste in area D, the paste and the foam are subjected to a shear force, whereby they are mixed together, so that the foam is uniformly dispersed in the folder. The paste in the chute 50 flows gravitationally downwards in order to be discharged in the central area in the direction of the width of the lower sheet 1 through the tube 7 (FIG. 1). Thus, part 47, chute 50 and tube 7 constitute a tubular passage for feeding the paste into the plasterboard sheet of paper.
[0068] FIGS. 8 and 9 include a cross-sectional view, a perspective view and a vertical cross-sectional view showing the structure of the vertical rail 50, where the liner 20 and the connecting part 47 are shown by imaginary lines (dotted lines).
[0069] The vertical track 50 consists of a cylindrical body 51 made of metal and with a radius r (internal dimension), a circular top plate 52 made of metal and closing the circular top opening of the body 51, a part of annular flange 53 protruding integrally and out of a periphery of a lower end edge of the body 51, and an orifice element 60 located in a lower part of the inner area upstream D. The discharge tube 7, which is a L-shaped tube made of rubber or resin and which is also called “boot (s)”, is connected on the downstream side of the chute 50 in series. Tube 7 includes a vertical tubular part 71 and a part of the annular flange 72 protruding integrally and out of a periphery of an upper end edge of the tubular part 71. The flange part 72 is secured between the flange part 53 and an annular metal plate 76 by the clamping force of screw-nut assemblies 77, so that the tubular part 71 and the body 51 are integrally connected to each other. The tube 7 additionally includes a part of the curved tube (elbow tube) 73 continuous with the tubular part 71, and a tubular part extending transversely 74 continuous with the part 73. The tubular part 74 opens at the discharge outlet folder 70 (FIG. 2).
[0070] The orifice element 60 is an integrally formed metal article, which has a generally flat columnar configuration. Orifice element 60 has an opening 61 for communication between the inner area D upstream of the rail 50 and an inner area K of the tube 7 on the downstream side of the orifice element 60 (referred to as the “inner downstream area K” below) ). FIG. 10 is a plan view of the orifice element 60, and FIG. 11 is a cross-sectional view taken along a line I-I of Fig. 10. The base view of the orifice element 60 is the same as its plan view.
[0071] Orifice element 60 has a perfect circle profile of radius R (a diameter 2R) in its plan view. The radius R is substantially the same as the radius r of channel 50, or slightly less than the radius r. Therefore, an outer circumferential surface 62 of the orifice element 60 is in contact with the inner circumferential surface 51a of the body 51 without creating a gap between them, or in sliding contact with the surface 51a.
[0072] As shown in FIG. 10, the aperture 61 of the orifice element 60, which forms an orifice passage, has an outline of a composite figure which is constituted by overlapping circular openings 61a, 61b, 61c, each with a radius RI, R2, R3 , respectively. In the X-Y coordinate system (i.e., the horizontal rectangular coordinate system with its origin on the central axis C) as shown in FIG. 10, the positions of the centers Cl, C2, C3 of the respective circular openings 61a, 61b, 61c are displaced in the direction of the X axis and / or in the direction of the Y axis. That is, with respect to the central axis C of the orifice element 60 , the center C1 of the circular opening 61a is shifted + E1 in the direction of the X axis, the center C2 of the circular opening 61b is shifted E2 in the direction of the X axis and + E3 in the direction of the Y axis, and the center C3 of the circular opening 61c -E2 direction of the X axis and -E3 direction of the Y axis and therefore the centroid or center of gravity G in the composite figure formed by the circular openings 61a, 61b, 61c is shifted + AE in the direction of the X axis. a case where the eccentricity ratio q of aperture 61 is defined as the "eccentric distance AE / radius r from the area upstream D", the eccentricity ratio q can preferably be established in a range greater than or equal to 0.06 (if in the range greater than or equal to 0.10). In a case where the eccentricity ratio q 'of aperture 61 is defined as the "eccentric distance AE / maximum value Rmax", the eccentricity ratio value q' can preferably be established in the range greater than or equal to 0.1 (if desired, in the range greater than or equal to 0.15), where the maximum value of the distance between the central axis C and the contour of the composite figure (the opening edge 61) is defined as Rmax.
[0073] As shown in FIG. 11, opening 61 is positioned liorizontally at the height of H / 2, where H represents the overall height of orifice element 60. Inclined surfaces 68, 69 formed in the shape of a pestle or conical surface extend between opening 61 and the upper and lower circular edges 63, 64 of the outer circumferential surface 62.
[0074] As shown in FIGS. 8 and 9, the orifice element 60 is located in a lower position of the cylindrical body 51. The screw 58 is screwed into the screw hole 57 of the body 51 and a tip of the screw 58 is pressed against the outer circumferential surface 62 with a clamping force of the screw 58. The orifice element 60 is locked at the bottom of the body 51 by means of the screw 58.
[0075] Several screw holes 65, which are circumferentially spaced from each other (shown by dotted lines in FIG. 8), are provided on the outer peripheral surface of the orifice element 60. A lower part of the peripheral wall of the body 51 is provided with a circumferentially elongated rectangular opening 54. A tip portion of the thread of the screw 56 is fitted with the screw hole 65 of the orifice element 60 which is positioned in an area of the opening 54. The screw 56 extends out of the cylindrical body 51 through the opening 54. The orifice element 60 can be manually rotated about the center axis] C by temporarily bending the tightening force of the screw 58 and pressing a part of the head of the screw 56 to the left or to the right. The directional property (anisotropy) or the relative position of the opening 61 can be changed with respect to the tubular passage (the internal upstream area D) by rotating the orifice element 60, whereby the intensity of the action or vortex interruption function axisymmetric can be controlled or adjusted. In other words, the mechanism for rotating orifice element 60 (screw hole 65, opening 54, and screw 56) constitutes the cross-section adjustment device for the orifice passage, which variably controls or adjusts flow in action or interruption function of the axisymmetric vortex of the orifice passage.
[0076] Variation or adjustment of the cross section of the fluid passage due to the rotation of the orifice element 60 can be performed not only before the operation of the mixer 10, but also during operation of the mixer 10, With the use of such adjustment device for adjust the cross section of the orifice passage, a delicate change or fine adjustment can be performed to optimize the action or function of the orifice passage, still observing or measuring the condition or physical property of the paste 3a flowing from the mixer 10 to the bottom sheet 1. This is very useful in practice. According to the inventor's experiments, the condition or physical property of the paste 3a fed into the bottom sheet 1 can be changed when the orifice element 60 is rotated about the central axis C by at least 3 degrees. Therefore, the intensity of the flow in the action of interrupting the axisymmetric vortex can be variably controlled or adjusted by the rotation of the orifice element 60 at an angle of at least 3 degrees.
[0077] As shown in FIG. 8, the whirling power or rotational power is given to the pulp flowing into the internal area upstream D, because of the eccentricity of area D and the flow of pulp fluid 46. As a result, the pulp flows gravitationally downwards while vortex along the inner circumferential wall surface of area D, as shown by an intratubular vortex flow F (shown by dotted arrows in FIG. 9), whereby an axisymmetric vortex flow in the form of a helical or cyclone is generated in area D. The direction of rotation of the paste (counterclockwise) is opposite the rotational y direction of the rotating disk 32 (FIG. 5). The paste is subjected to a mixing or stirring action in area D, because of its swirling motion. The turning radius of the swirl flow F is gradually reduced as the cross section of area D is reduced by the inclined surface 68 and the opening 61.
[0078] The configuration of opening 61 in its plan view, which is the composite figure constituted by the circular openings 61a, 61b, 61c overlapping each other, is not axisymmetric with respect to the central axis C. Additionally, opening 61 has the center of lateralized gravity G + AE in the direction of the X axis, as shown in FIG. 10. Therefore, the axisymmetric vortex flow (rotationally symmetrical) produced by the intratubular eddy flow F is collapsed at opening 61. The eddy flow F after passing through opening 61 gradually increases its radius, since the cross section of the passage of fluid is enlarged according to the configuration of the inclined surface 69. As a result, the swirl flow F is able to regenerate its original formation of the swirl flow F in the downstream area K. However, the axisymmetric vortex flow (the intratubular vortex flow F) is collapsed at opening 61, so that the flow of paste is disturbed at or near opening 61. Therefore, the swirl flow like flow F is not regenerated in the area downstream K, and a considerably weak swirl flow, which has a small component of revolving speed compared to the swirl flow F, is merely regenerated in one flow field of the area downstream K. A swirling motion like this practically disappears during flow through the tubular part that extends transversely 74. Therefore, the pulp flow, which practically loses its component of revolving speed, flows through the opening for discharging paste 70 (FIG. 2) to the bottom sheet 1.
[0079] FIGS. 12 and 13 are cross-sectional and longitudinal views of the trough 50 with an orifice element 100 which is a comparative example, where the liner 20 and the connecting part 47 are shown by imaginary lines (dotted lines).
[0080] The chute 50 with an orifice element 100 with a conventional structure is shown as the comparative example in FIGS. 12 and 13. Similar to orifice element 60, orifice element 100 has an outer peripheral configuration which is a perfect circle of radius R (diameter 2R) in its plan view, and its outer circumferential surface 102 is adapted to stay in contact with the internal circumferential surface of the chute 50 without a gap between them, or in sliding contact with them. An opening 101 of the orifice element 100 has a contour 105 which is a perfect circle of radius R1, the center of which is the central axis C. The opening 101 is positioned horizontally at the height of H / 2 where H represents an overall height of the element orifice 100, similarly to orifice element 60. Inclined surfaces 108, 109 formed in a pestle shape or conical surface shape extend from the upper and lower circular edges 103, 104 of the orifice element 100 to the circular opening.
[0081] As presented here, the paste that flows into the inner area upstream D is the axisymmetric vortex flow in a helical or cyclone flow shape illustrated as the intratubular eddy flow F (shown by the dotted arrows), which flow gravitationally downward, still swirling along an inner circumferential wall surface of area D. The turning radius of the intratubular swirl flow F is gradually reduced in area D as the cross section of area D is reduced by the sloping surface 108 and opening 101. After passing through opening 101, the swirl flow F gradually increases its turning radius as the cross section of the fluid passage is widened by the inclined surface 109, until an intratubular swirl flow similar to the flow F is covered in the area downstream K. Thus, the swirl flow similar to the flow in swirl F is regenerated in the flow field of the area downstream K. Although the flow in swirl the F 'regenerated in the downstream area K is an axisymmetric vortex flow attenuated in its rate of rotation component compared to flow F, the rate of rotation rate of flow F' does not disappear during the flow through the tubular part 74 and, therefore, the rotating speed component remains substantially in the paste discharge opening 70 (FIG. 2). Thus, the circumferential flow of paste flows through the opening 70 (FIG. 2) to the bottom sheet 1.
[0082] FIGS. 14-17 are graphical diagrams showing the test results obtained measuring the distribution of the specific gravity of the plaster core, in relation to a plasterboard fabrication apparatus with orifice element 60 (embodiment of the present invention) as shown in FIGS . 8-11 and the plasterboard fabrication apparatus with orifice element 100 (comparative example) as shown in FIGS. 12 and 13, respectively.
[0083] The present inventors experimentally produced plasterboard using the plasterboard fabrication apparatus with the orifice element 60 being installed in the vertical rail 50 (embodiment of the present invention). In addition, the present inventors experimentally produced plasterboard using the same apparatus with the conventional orifice element 100 (comparative example) being installed instead of orifice element 60. The production condition and the mixing ratio of materials are the same in these experiments. The boards produced are standard plasterboard, each 910 mm wide, 1,820 mm long and 12.5 mm thick.
[0084] In FIGS. 14 (C) and 14 (D), a method for obtaining specimens for measuring the specific gravity distribution is shown schematically. The present inventors cut an intermediate part of the plasterboard produced M and extracted from it a zone along the width of the board with a dimension along the length of 150 mm. In addition, the inventors cut N side edge parts from the extracted part in order to remove specific high gravity parts made of the fractionated paste. The dimension of the side edge part N is 50 mm. These edge parts correspond to the edge parts of a plasterboard. Thus, the inventors obtain a test piece Q in a rectangular plate shape, which is 810 mm long and 150 mm wide, as shown in FIG. 14 (D). The test part Q thus obtained is cut into ten pieces S (S1-S10), each 81 mm wide and 150 mm long, and the specific gravity of each of the pieces S (S1-S1O) is measured.
[0085] The specific gravity values actually measured in relation to the plaster core are shown in FIGS. 14 (A) and 14 (B), in which the measured specimens S (S1-S10) were extracted from plasterboard, which were experimentally produced in a material mixing ratio and a production condition to establish gravity plaster core specificity at 0.7 (a target value). In FIGS. 14 (A) and 14 (B), the horizontal geometric axes represent the positions in the width direction in the plasterboard, which correspond to the respective specimens S1-S10 shown in FIG. 14 (D), and the vertical geometric axes represent the actual measured values of specific gravity. FIG. 14 (A) shows the test results with respect to the plasterboard produced by the plasterboard fabrication apparatus provided with orifice element 60 (embodiment of the present invention), and FIG. 14 (B) shows the test results with respect to the plasterboard produced by the same apparatus provided with the orifice element 100 (comparative example).
[0086] As is apparent from the test results in FIGS. 14 (A) and 14 (B), the specific gravity of the core produced by the apparatus with the orifice element 100 (comparative example) varies considerably from 0.712 to 0.674 in the direction of the plate width, whereas the specific gravity of the core produced by the apparatus with the orifice element 60 (embodiment of the present invention) varies merely in a range of 0.697-0.694 and, therefore, the specific value of the core represents substantially constant distribution in the direction of the width of the plate (embodiment of the present invention). This means the following:
(1) In a case where orifice element 100 (comparative example) is used, a relatively intense swirl flow is generated in the passage of fluid on the downstream side of orifice 100, so that the paste tends to flow into the sheet paper in a condition where the pulp and foam are partially separated: (2) On the other hand, in the case where orifice element 60 (embodiment of the present invention) is used, the paste flows through the paste discharge tube 7 into the sheet in a condition where the separation of the paste and foam is substantially eliminated altogether.
[0087] In FIGS. 15-17, values of reagent specific gravity measured from the plaster cores are shown in relation to the S1-S10 specimens extracted from the produced plates, in which the plaster plates were experimentally produced in the proportion of mixtures of materials and production conditions for establish the specific gravities of the nuclei at 0.6, 0.5, and 0.4 (target values). In each of FIGS. 15-17, the diagram indicated by “(A)” shows the test results in relation to the plasterboard produced by the apparatus with the orifice element 60 (embodiment of the present invention), and the diagram indicated by “(B)” shows the test results in relation to the plasterboard produced by the device with the orifice element 100 (comparative example).
[0088] As can be understood by the experimental results presented in FIGS. 15-17, in the case where orifice element 100 (comparative example) is used, the deviation of the specific gravity distribution is significantly increased when the target value of the specific gravity of the core is established less than or equal to 0.6. Especially, when the target value of specific gravity is set at 0.4, the difference between the maximum measured value and the minimum measured value exceeds 15% of the target value. On the other hand, in the case where the orifice element 60 (embodiment of the present invention) is employed, the deviation of the specific gravity distribution is not increased and, therefore, plasterboard with a substantially constant specific gravity distribution can be produced. For example, even when the target value of the specific gravity of the core is set at 0.4, the difference between the maximum measured value and the minimum measured values is merely about 2% of the target value. Therefore, the use of orifice element 60 is extremely effective in reducing the weight of plasterboard.
[0089] FIG. 18 is a plan view showing changes in the plane contour of aperture 61.
[0090] In the aforementioned embodiment, the outline of the opening 61 of the orifice element 60 has a composite figure consisting of the three partially overlapping openings 61a, 61b, 61c, each with a perfect circle shape. Alternatively, the contour of aperture 61 can be a single circle in the form of a perfect circle which is generally shifted to move the center (the centroid G) of aperture 61 to an eccentric position with respect to the central axis C, as shown in FIG . 18 (A). The centroid G of the opening 61 can be moved to an eccentric position with respect to the central axis C by deviating or deforming the outline of the opening 61, as shown in FIG. 18 (B). Aperture 61 can be a composite figure which is a combination of two perfect circles (center C1: C2, radius R1: R2, eccentricity + E1: -E2) as shown in FIG. 18 (C), or a composite figure that is a combination of four perfect circles (center Cl: C2: C3: C4, radius Rl: R2: R3: R4, eccentricity + E1: -E2: + E3, + E5: + E4, - E6) as shown in FIG. 18 (D). As can be understood from these modifications, the outline of the opening 61 can be properly modified without departing from the scope of the invention.
[0091] Areas of the central Umin circle are shown in FIG. 18, each of the circles being a perfect circle with a radius Rmin, whose center is on the central axis C. A relationship between a non-circular contour of aperture 61 and the area of the central circle Umin is shown in FIG. 19 (A). As shown in FIG. 19 (A), aperture 61 contains the Umin area of radius Rmin and aperture 61 is contained in an area of the maximum Umax circle in the form of a perfect circle with radius Rmax. Preferably, the radius Rmin is established greater than or equal to 0.15 x the radius r, and the radius Rmax is established less than or equal to 0.85 x the radius r. Therefore, the contour of aperture 61 can be varied in the range of 0.15r to 0.85r, preferably in the range of 0.2r to 0.8r, where "r" is the aforementioned radius.
[0092] In FIG. 19 (B), a condition is shown in which aperture 61 in the form of a perfect circle with a radius RI is significantly decentralized from the central axis C. The central axis Cl (the centroid G) of opening 61 is positioned in an annular zone in a range of 0.2r to 0.8r and, therefore, the area of the central circle Umin is not contained in opening 61 and the area Umin extends out of opening 61. However, in a condition like this, the flow helical or cyclone in axisymmetric vortex is desirably generated in the inner area upstream D. This means that the axisymmetric vortex flow to mix the paste and foam can be generated in area D, even if the contour of the opening 61 is significantly deformed or the aperture center 61 is significantly decentralized. However, even if the Umin area extends out of the opening 61, it is preferable that the central axis C is positioned inside the opening 61.
[0093] FIG. 20 is a partial perspective view showing configurations of the edge portions of the openings 61. The opening 61 shown in FIG. 20 (A) has an edge portion 67 in a linear or square shape across its circumference, and the aperture 61 shown in FIG. 20 (B) is provided with the inclined surfaces 68, 69, each with a constant inclination angle predetermined throughout its circumference. In the case where the opening 61 has the edge portion 67 in the linear shape or shape shown in FIG. 20 (A), the angle of inclination on each of the surfaces 68, 69 varies according to the contour of the opening 61. On the other hand, when each of the inclined surfaces 68, 69 has a predetermined constant inclination angle, an edge of the flat face 66 is inevitably formed at least partially in an edge region of the opening 61. At one edge of the flat face 66, a tendency is observed that a rigid mass of plaster paste is produced there and adhered to it, because of the stagnation and solidification of the paste. Therefore, from a standpoint of preventing the addition of the solidified paste mass to the opening 61, the opening 61 is preferably provided with the edge portion 67 in the linear shape or shape shown in FIG. 20 (A).
[0094] FIG. 21 includes perspective and cross-sectional views showing arrangements for varying the position of the central axis C of the tubular passageway by varying or lateralizing the cross section of the fluid passageway.
[0095] As previously presented, two methods for delivering the mixer paste 10 without the use of the chute are known in the art, one being a method in which a paste transport passage such as the tubular passage 47 'shown in FIG.5 it is transversely connected in a paste delivery opening in the annular wall 23 of the liner 20 so that the paste is delivered directly to the bottom sheet 1 under the delivery pressure of the mixer 10, and the other being a method in which a delivery passage of paste such as the tubular passage 47 "shown in FIG. 6 is vertically connected to a paste delivery opening of the bottom plate 22 of the liner 20, so that the paste in the mixer 10 is directly discharged into the bottom sheet 1 with the effect The concept of the present invention is applicable to tubular passages in these methods, and such arrangements are schematically illustrated in Figure 21. If desired, a rail similar to the aforementioned rail 50 can be duly interposed in the folder transport ticket or in the folder delivery ticket.
[0096] A tubular passageway 90 shown in FIG. 21 (A) in general has a cross section in the form of a perfect circle, but the passage 90 is locally provided with fluid passage parts 91, 92, each with a cross section with a non-asymmetric relation to the central axis C of the passage 90. Each of the passage parts 91, 92 shown in FIG. 21 (A) has an elliptical cross section that has a main geometric axis directed vertically or horizontally. The axisymmetric vortex flow F produced as an intratubular eddy flow is at least partially interrupted, so that the eddy flow on the downstream side of passage part 91, 92 does not recover its condition on the upstream side of the passage parts 91, 92, or a whirlwind flow is not able to be regenerated on the downstream side of the passage part 91, 92.
[0097] The tubular passage 95 shown in FIG. 21 (B) includes tubular passage parts 96, 97, each with a perfect circular cross section. The radius RI of the passage part 96 differs from the radius R2 of the passage part 97. The passage part 97 with a relatively small radius is lateralized to one (the bottom side in FIG. 21 (B)) in a connection part ( fluid passage part) 98 between the tube passage parts 96, 97. Central lines Cl, C2 of the tube passage parts 96, 97 are decentralized in the connection part 98 (eccentricity + AE) and, therefore, the vortex flow axisymetric F produced as an intratubular eddy flow is interrupted at least parially by such a change or lateralization of the cross section of the fluid passage. As a result, the flow on the downstream side of this fluid flow part does not regenerate its condition on its upstream side, or a swirl flow is not able to occur on the downstream side of the fluid flow part. Alternatively, a tubular portion of passage 97 'with a relatively large diameter (radius R2') can be connected to the tubular portion of passage 96 in a connecting portion (fluid passage portion) 99 as shown by the dotted lines in FIG. 21 (B) in order to decentralize the central lines C1, C2 'of the passage parts 96, 97' (eccentricity -AE ') to one side (the upper side in FIG. 21 (B)). In addition, another tubular passage part 96 or the like can be connected at one end downstream of passage part 96, 97 'so as to produce a section locally or transiently reduced or enlarged by the passage part 96, 97'.
[0098] Although the present invention has been described as preferred embodiments and examples, the present invention is not limited to this, but can be carried out in any of the various modifications or variations without departing from the scope of the invention defined in the appended claims.
[0099] For example, the arrangement of the device according to the present invention can also be applied to a mixer other than the pin type mixer, such as a pinless mixer (a pallet mixer or the like).
[00100] Additionally, the cross section of the trough intratubular passage, transport passage or delivery passage is not limited to a strictly perfect circle, but it can be a circle with a little mismatch, distortion, localized deformation and so on. If desired, the center axis of the chute can be tilted with respect to the vertical direction, or the chute may be in communication with the mixing area of the mixer by a pipe, such as a flexible pipe.
[00101] In addition, the mixer in the aforementioned modality has the fractionation opening for the paste with a relatively high specific gravity, but the present invention is applicable to a mixer without the fractionation opening or a mixer that feeds the paste with a gravity relatively low specificity through the opening of fractionation.
[00102] Additionally, the mixer in the aforementioned mode is arranged to feed the foam into the paste in the hollow connection part, but the foam can be fed into the paste in the chute or in the mixing area. Furthermore, the mixer in the aforementioned mode is arranged so that the foam produced by a foaming action of the foaming agent in the foaming device is fed into the paste, but the foaming agent can be directly fed into the paste so that the foam is produced in the paste by its foaming action on the paste. If desired, the direction of turning the paste on the chute can be set to the opposite direction to the direction shown in FIG. 5 by changing the positional relationship between the hollow connection part and the rail.
[00103] In addition, the opening of the orifice element that defines the orifice passage is positioned horizontally to change or lateralize the cross section of the fluid passage in the aforementioned modality. However, the opening can be altered or lateralized by tilting the opening generally or partially, or the angle of inclination of the opening can be varied variably with respect to the horizontal plane for changing or lateralizing the cross section of the fluid passage, thereby changing the position of the central axis of the tubular passage. In a case where the cross section is altered or lateralized by such an angle change, interchangeable adjustment of the inclination angle by at least 3 degrees is required. Industrial Applicability
[00104] The present invention can be applied to a mixing and stirring device, a mixing and stirring method, and a method for making light plasterboard. According to the present invention, the circular movement of the gypsum paste that is poured into the sheet of paper for a plasterboard coating can be restricted, whereby it can prevent misdistribution, deviation or irregular distribution in the distribution specific gravity of the paste on the sheet of paper.
[00105] The present invention is very effective in the production of light plasterboard with a specific gravity of 0.4-0.7, since the density distribution of the plaster core can be made uniform. Therefore, taking into account the tendency to reduce the weight of plasterboard in recent years, the advantages of the present invention are notable in practice. List of Reference Numbers
1 sheet of bottom paper 2 top sheet of paper 3 folder 4 folder delivery section 5 continuous three-layer belt formation 7 paste discharge tube 8 conduits for fractionation 10 mixer 20 coating (housing) 23 annular wall 40 foam feed conduit 41 Foam feed opening 45 Folder outlet opening 46 paste fluid flow 47 hollow connection part 50 chute 51 cylindrical body 54 aperture 55 top opening 56, 58 screw 57, 65 screw hole 60 orifice element 61 opening (hole passage) 62 outer circumferential surface 63 circular edge 68, 69 inclined surface 70, 80 Opening of paste discharge 90, 95 tubular passage 91, 92 part of fluid passage 96, 97, 97 'tubular part of the passage 98, 99 connection part (fluid passage part) C central axis D intratubular area within the channel (internal area upstream) F swirl flow in circular tube G hole passage centroid H overall height of the orifice K paste discharge tube intratubular area (internal downstream area) P Powder materials L liquid (water) M foam r R radius

权利要求:
Claims (15)
[0001]
Mixing and stirring device (10) for plaster paste, which has a circular coating (20) forming a mixing area (10a) for mixing plaster paste (3), a rotating disk (32) positioned in the coating and rotated in a predetermined rotational direction (y), and a tubular passageway (7, 47, 50) for delivering the plaster paste that is provided outside the coating in order to feed the paste from the mixing area onto a sheet of paper for the plasterboard covering (1), and
wherein the tubular passageway includes a chute (50) which receives the plaster slurry from the liner (20) through a slurry outlet (45) provided in the liner and which allows the slurry (3) to flow down gravitationally therein, so that the paste has an intratubular area (D) of the gutter, and in which an outlet part of the gutter is connected with a discharge tube portion (7) of the tubular passage to spout the paste on the sheet of paper (1),
characterized by the fact that:
the tubular passageway includes a fluid passageway portion which is an orifice passageway with a locally restricted fluid passageway cross section and being positioned in an area of the outlet portion of the channel; and,
the orifice passage has a centroid (G) of a figure from its cross section located in an eccentric position in relation to the central axis (C) of the tubular passage, so that the orifice passage breaks at least partially an axisymmetric vortex flow , which is an intratubular vortex flow (F) that occurs in the intratubular area (D) around a central axis that extends vertically and moves in the chute, before the flow enters the discharge tube (7) gravitationally .
[0002]
Device according to claim 1, characterized by the fact that an outline of the cross section of the orifice passage (61) is a composite figure constituted from a plurality of figures partially overlapping each other.
[0003]
Device according to claim 2, characterized by the fact that the composite figure consists of a plurality of circles (61a, 61b, 61c) with different diameters (R1, R2, R3) and / or different central positions (C1, C2 , C3), the circles being overlapped only partially.
[0004]
Device according to any one of claims 1 to 3, characterized in that an eccentricity ratio η = ΔE / r of the centroid is established to be equal to or greater than 0.06, or an eccentricity ratio η '= ΔE / Rmax is set to be equal to or greater than 0.1, and where ΔE is a distance between the centroid (G) and the central axis (C) of the tubular passageway, r is a radius of the tubular passageway, and Rmax is a maximum value of a distance from the central axis of the tubular passage to the contour of the figure.
[0005]
Device according to any one of claims 1 to 4, characterized by the fact that a foam feeding opening (41), which feeds a foam or foaming agent (M) to the paste for adjusting the specific gravity of the foam core. plaster, is located in an annular wall (23) of the coating (20) in order to feed the foam or foaming agent to the paste just before the paste flows into the paste outlet opening (45) from the mixing area (10a); or the foam feed opening is located in a paste distribution section on one side downstream of the mud outlet opening (45), in order to feed the foam or foaming agent to the paste immediately after the paste flows through of the paste outlet opening (45) from the mixing area.
[0006]
Device according to any one of claims 1 to 5, characterized in that an orifice element (60) with the orifice passage (61) is provided in the tubular passage (50), and the orifice element (60) has adjusting device (54, 56, 65) to adjust the cross section of the fluid passage, which rotates or moves the orifice element to adjust or control the intensity of the axysymmetric vortex flow interrupting action.
[0007]
Method for mixing and stirring the plaster paste, using a mixing and stirring device (10) for the plaster paste with a circular coating (20) forming a mixing area (10a) for mixing the plaster paste (3 ), a rotating disk (32) positioned in the coating and rotated in a predetermined rotational direction (y), and a tubular passage (7, 47, 50) for delivering the plaster paste that is provided outside the coating in order to feed the paste from the mixing area on a sheet of plasterboard paper (1),
wherein a paste outlet orifice (45) is positioned in said liner (20) and the tubular passageway is at least partially formed by a chute (50), so that the plaster paste from the effluent mixing area of the port paste outlet (45) is introduced into the chute in order to flow gravitationally into the chute,
characterized by the fact that it comprises the steps of:
form a fluid passage portion through a through hole (61), which locally builds a cross section of the fluid passage and which has a centroid (G) of a figure from its cross section located in an eccentric position in relation to the axis central (C) of the tubular passage; and at least partially break an axisymmetric vortex flow, which is an intratubular eddy flow (F) that occurs and moves in an intratubular area of the gutter,
wherein foam or foaming agent (M) for adjusting a specific gravity is mixed with the plaster paste in said tubular passage via said intratubular vortex flow (F), and
where the orifice passage is positioned in an outlet portion of the chute, and the axisymmetric vortex flow is broken through the through-hole, to restrict the regeneration or generation of the intratubular vortex flow in a portion of the discharge tube (7) of the tubular passage, the discharge tube portion (7) being located on one side downstream of the orifice passage.
[0008]
Method according to claim 7, characterized in that an eccentricity ratio η = ΔE / r of the centroid is established to be equal to or greater than 0.06, or an eccentricity ratio η '= ΔE / Rmax is established to be equal to or greater than 0.1, and where ΔE is a distance between the centroid (G) and the central axis (C) of the tubular passageway, r is a radius of the tubular area, and Rmax is a maximum value of a distance between the central axis of the tubular passage and the contour of the figure.
[0009]
Method according to either of claims 7 or 8, characterized in that a foam feeding port (41), which feeds the foam or foam agent (M) to the paste for adjusting the specific gravity of the plaster core, is located on the annular wall (23) of the liner (20), in order to feed the foam or foaming agent to the paste just before the paste flows into the paste exit port (45) from the mixing area (10a ); or
the foam feed port is located in a paste feed section on one side downstream of the paste outlet opening (45) in order to feed the foam or foam agent to the mud immediately after the mud flows through the mud outlet opening (45) from the mixing area
[0010]
Method according to any one of claims 7 to 9, characterized in that the amount of foam supply or foaming agent (M) fed into the plaster paste (3) is established in the amount to produce a plaster core of the plasterboard. plaster with a specific gravity in a range of 0.4 to 0,
[0011]
Method according to any one of claims 7 to 10, characterized in that the intensity of an action to interrupt the axysymmetric vortex flow of the orifice passage is adjusted or controlled by changing or lateralizing a position or cross section configuration of the orifice. orifice passage.
[0012]
Method for making light plasterboard with a specific gravity less than or equal to 0.8, characterized in that the plaster paste is produced using a method of mixing and agitating the plaster paste as defined in any of the claims 7 a
[0013]
Method according to claim 12, characterized in that the mixing and stirring device (10) has an adjustment device (54, 56, 65) to adjust the fluid flow cross section, which varies a position or configuration of the fluid. through-hole (61) with respect to the rail (50) to adjust or control the action of interrupting the flow of the axisymmetric vortex of the orifice passage, and the intensity of the action is adjusted or controlled by the adjustment device, during the operation of the device mixing and agitation, in relation to the condition or physical property of the plaster paste fed on the sheet of paper (1).
[0014]
Method according to either of claims 12 or 13, characterized in that the foam or foaming agent (M) is fed to the paste (3) just before or after the paste from the mixing area flows through the paste outlet (45), with the method further comprising:
introducing the plaster paste of the effluent from the coating mixing area through the paste outlet opening (45), into the channel (50) together with the foam or foaming agent (M), and generating the said swirl flow intratubular (F) in said intratubular area (D) by rotating the paste therein.
[0015]
Apparatus for manufacturing light plasterboard, characterized by the fact that it has the mixing and stirring device as defined in any one of claims 1 to

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同族专利:

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公开号 | 公开日

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CA2892024C|2021-01-19|

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US9856168B2|2018-01-02|

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AU2013355870A1|2015-07-02|

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MX2015006886A|2015-09-16|

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EP2929996B1|2019-04-24|

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KR102039523B1|2019-11-01|

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DK2929996T3|2019-06-24|

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ES2734000T3|2019-12-03|

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EP2929996A4|2017-01-11|

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BR112015012984A2|2017-07-11|

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WO2014087892A1|2014-06-12|

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TR201910115T4|2019-07-22|

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KR20150094591A|2015-08-19|

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RU2015126871A|2017-01-13|

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CN104853892A|2015-08-19|

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AU2013355870B2|2017-04-13|

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JPWO2014087892A1|2017-01-05|

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RU2635811C2|2017-11-16|

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JP6211535B2|2017-10-11|

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CA2892024A1|2014-06-12|

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BR112015012984B8|2020-07-14|

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US20150315074A1|2015-11-05|

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MX358918B|2018-09-07|

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CN104853892B|2017-10-20|

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EP2929996A1|2015-10-14|

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PL2929996T3|2019-10-31|

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法律状态:
2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-02-04| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-05-12| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-06-23| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 27/11/2013, OBSERVADAS AS CONDICOES LEGAIS. |

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2020-07-14| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2581 DE 23/06/2020 QUANTO AO ENDERECO. |

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2021-09-21| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 8A ANUIDADE. |

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2021-10-13| B24D| Patent annual fee: restoration after fee payment|

优先权:

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申请号 | 申请日 | 专利标题

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JP2012-265921|2012-12-05|

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JP2012265921|2012-12-05|

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PCT/JP2013/081872|WO2014087892A1|2012-12-05|2013-11-27|Mixing and stirring device, mixing and stirring method, and method for manufacturing lightweight gypsum board|

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