Technical Field

The present invention relates to a production method of a plaster (gypsum) wall element with a cavity structure made of plaster, and a production line whereby the said plaster wall element is turned into a final product in intended dimensions by creating cavities in a moving reservoir without any interruptions in the production process.

Background of the Invention

Plaster is described as a material whereby a content which is used as a construction material and obtained by baking and grinding plaster at a relatively low temperature and then turns into a stone form again upon being mixed with water. Plaster is preferred as a construction material due to the fact that it is easy to obtain and solidifies quickly. Today, the field of application of plaster-based materials obtained by using plaster is quite widespread. Gypsum plasters, carton- pierre and plasterboards can be counted among them. Although plaster can be easily obtained and produced, the use of plaster as wall elements such as brick, gas concrete, pumice block is not common today, except for plasterboards and one of the most important reasons for this is that it is mandatory to keep the plaster in a mold until it solidifies and to wait for the intended cavity structure to form during this time. Today, plaster block machines are used to produce plaster as a wall element such as brick, pumice block with a cavity structure. In the said plaster block machines, there is a mold with cores that will form a cavity for the plaster blocks intended to be moulded and the pre-mixed plaster mixture intended to be solidified is poured into the said mold. After the plaster mixture is poured into the mold, the upper surface of the mold is smoothed by workers or automatic scrapers and the mold is left for solidification. After waiting for a certain period of time for the plaster to be solidified, the plaster blocks that have solidified and have formed cavities with cores are removed from the mold with the aid of hydraulic elements and plaster blocks with cavities are obtained. The use of plaster blocks is exceedingly rare, because this method of production requires a large amount of molds and manpower and it leads to loss of efficiency.

In the state of the art, the machines used for the production of plaster block elements with cavities are not suitable for mass and continuous process. It has not been possible to produce plaster wall materials such as bricks and pumice blocks so far, because the production of other wall materials is easier than the production of plaster blocks in terms of molding and/or continuous process. As energy becomes increasingly important in the world, there is a growing need for new products that require less energy and are produced with low carbon emissions.

Plaster-derived products are quite suitable for producing construction materials with low carbon emissions because they can be produced by using much less energy than other hydraulic binder construction materials.

Summary of the Invention

An objective of the present invention is to realize a production method which enables to produce plaster wall elements with a cavity structure in a continuous production process, rather than by means of molds. Another objective of the present invention is to realize a production line which enables to subject plaster wall elements with a cavity structure to a continuous production process without any interruption.

Detailed Description of the Invention

“A production method of plaster wall element and a production line whereby the said plaster wall element is produced” realized to fulfil the objectives of the present invention are shown in the figures attached, in which:

Figure l is a schematic view of the inventive production line.

Figure l is a view related to the input of the inventive production line.

Figure 3 is a view related to the output of the inventive production line.

Figure 4 is a view of the impeller in the inventive production line.

Figure 5 is a sectional view of the reservoir in the inventive production line.

The components illustrated in the figures are individually numbered, where the numbers refer to the following:

1. Production line

2. Mixer

3. Reservoir

4. Conveyor setting belt

5. Guiding belt

6. Stopper

7. Impeller

8. Core

9. First cutting station

10. Carrying conveyor 11. Second cutting station

12. Exit conveyor

The inventive production method (1) of plaster wall element for producing a plaster wall element containing cavities comprises the steps of

- preparing the plaster mixture intended to be included in the plaster wall element in a mixer (2);

- pouring the prepared plaster mixture into a reservoir (3) which has an open upper surface and also has a structure that moves along a line;

- immersing a plurality of cores (8) into the plaster mixture which is poured into the reservoir (3) and moves, in order to form a cavity;

- solidifying the plaster mixture wherein the core (8) is immersed, by moving together with the reservoir (3) while the core (8) is contained therein;

- subjecting the blocks, which are turned into plaster wall blocks by solidifying during the movement thereof in the reservoir (3) line, to a primary cutting process; and

- obtaining the plaster wall elements in intended dimensions from plaster wall blocks by repeating the cutting process optionally for multiple times.

In the inventive production method of plaster wall element, the intended amount of plaster, powdered chemicals, liquid chemicals and water to be included in the plaster wall element are mixed in a mixer (2) at first. The chemicals used may include all additives used in the production line of the plasterboards with state of the art. Specifically, it is possible to lighten the plaster wall element to be produced by adding foam into the plaster mixture and/or to increase its strength by adding glass fiber and/or to reduce its water absorption ratio by adding hydrophobic material. The plaster mixture is transferred from the mixer (2) to the reservoir (3) and the plaster both moves in a linear direction and the solidification process starts upon the movement of the reservoir (3). The plaster mixture moves by means of a conveyor setting belt (4) and two guiding belts (5) located on the edges of the conveyor setting belt (4). The width/height of the plaster mixture in the reservoir (3) can be adjusted according to the position of the guiding belt (5) relative to the conveyor setting belt (4). With this process, a plaster wall element of different dimensions in width and height can be produced on the same conveyor setting belt (4).

A plurality of cores (8) are immersed into the plaster mixture in order to form cavities in the said mixture moving by means of the conveyor setting belt (4) and the guiding belts (5) in the reservoir (3). The core (8) is immersed from the upper surface of the plaster mixture towards the setting belt (4) and the core (8) is removed from the plaster mixture by a continuous process once the plaster mixture has attained the intended rigidity. In the inventive method, a plurality of cores (8) are located on a rotating impeller (7) and they move at the speed of the plaster mixture due to the rotating structure of the impeller (7). Therefore, the shape of the cavity formed by the core (8) in the plaster mixture is maintained until the plaster mixture solidifies. The reservoir (3) may be subjected to vibration based on the density or the requirement of the plaster mixture along the previous line before solidification of the plaster in the reservoir (3) according to the requirement of complete settling therein.

Following the removal of the core (8) from the solidified plaster mixture, the plaster blocks having the width of reservoir (3) and containing a cavity therein are cut synchronously with the line. The plaster blocks are transferred to a second cutting station (11) with the aid of a carrying conveyor (10) in order to be able to obtain a plaster wall element having the intended dimensions. The plaster wall element that is cut in intended dimensions is separated from the production process with the aid of an exit conveyor (12). In this way, with the inventive method whereby the production process continues without interruption takes place, the plaster wall elements with cavities and intended dimensions are obtained. The plaster wall element obtained by the inventive method is used as a construction material. The said plaster wall elements are used in the construction of interior or exterior walls of all structures (housing, hospital, shopping mall, industrial building, etc.). Mortar is applied to the plaster wall elements to ensure that they adhere to each other. Thus, the wall is formed and the wall surface is made prepared for the coating material to be applied on it. Insulation material as well as cement-based plaster can be applied on the surface of numerous plaster wall elements formed into walls after exterior priming. Whereas for interior facades, the wall surface can be quickly made prepared for painting by applying gypsum plaster.

The inventive production line (1) for producing a plaster wall element with a cavity structure comprises

- at least one mixer (2) wherein the content of the plaster mixture is prepared and subjected to a mixing process;

- at least one reservoir (3) wherein the plaster mixture prepared by the mixer (2) is poured, which moves the plaster mixture and extends for at least until the solidification process of the plaster mixture is completed;

- at least one stopper (6) which is located at the end of the reservoir (3) where the mixer (2) is present and which keeps the plaster mixture in the reservoir (3);

- at least one impeller (7) which is located almost on top of the reservoir (3) and which has a plurality of cores (8) capable of forming cavities in the plaster mixture after immersing into the mixture;

- at least one first cutting station (9) wherein the first cutting process of the plaster block, that is obtained following the solidification of the plaster mixture located in the reservoir (3) while the cores (8) are contained therein, is carried out;

- at least one carrying conveyor (10) whereby the plaster block that is taken into the first intended dimension by the first cutting station (9) exits and is carried to another cutting station; - at least one second cutting station (11) wherein further cutting process is carried out in the intended dimensions for dimensioning the plaster block, that is subjected to the first cutting process, as a plaster wall element; and

- at least one exit conveyor (12) whereby the plaster wall elements obtained in the intended dimensions leave the production process as the final product.

In the inventive production line (1), the mixer (2) mixes the intended amount of plaster, powdered chemicals, liquid chemicals and water to be included in the plaster mixture. Foam material to lighten the plaster block and/or glass fiber to increase the strength and/or hydrophobic material to reduce the water absorption rate are also added into the mixer (2) and the plaster content is prepared to be poured into the reservoir (3).

The reservoir (3) accommodates the plaster mixture received from the mixer (2) and comprises at least one conveyor setting belt (4) for moving the plaster mixture and at least two guiding belts (5) extending upwards from both sides of the conveyor setting belt (4). The upper surface of the reservoir (3) is open upon the motion obtained as a result of moving the conveyor setting belt (4) and guiding belts (5) together and with the same movement speed. Thereby, the core (8) can be immersed and removed to form a cavity for the plaster mixture moving in the reservoir (3). On the other hand, shape, height and width of the plaster block are adjusted by changing the position of the guiding belts (5) relative to the conveyor setting belt (4). The plaster mixture moves linearly in the reservoir (3) and the solidification is carried out throughout this movement. The reservoir (3) is subjected to vibration based on the density and the requirement of the mixture in the previous state before solidification of the plaster therein, according to the requirement of complete settling. In the inventive production line (1), the stopper (6) is located at the end of the reservoir (3) wherein the mixer (2) is present. The stopper (6) is used to keep the plaster mixture in the intended amount and height in the reservoir (3).

In the inventive production line (1), the impeller (7) has a rotating structure and is located almost above the reservoir (3) with a plurality of cores (8) thereof. The impeller (7) rotates at the same speed with the speed of movement of the reservoir (3). Thereby, the cavities included in the plaster mixture with the core (8) therein can be formed in a uniform and standardized way without causing any deformation and they are removed from the plaster block at the end of the reservoir (3) wherein the plaster mixture solidifies. The size of the impeller (7) and the size of the reservoir (3) depending thereto can be changed based on criteria such as the intended solidification time, the length of the plaster blocks intended to be produced, and the number of plaster wall elements.

In a preferred embodiment of the invention, the first cutting station (9) is located at the part where the reservoir (3) terminates and the solidified plaster block exits the reservoir (3) without the core (8). The first cutting station (9) is used for easy processing of the plaster block, namely for cutting in an appropriate length before feeding into a second cut. The plaster blocks cut at the first cutting station (9) are taken to the second cutting station (11) by the carrier conveyor (10).

In the inventive production line (1), the carrying conveyor (10) is located between the first cutting station (9) and the second cutting station (11). The carrying conveyor (10) transmits the plaster block cut to the appropriate length at the first cutting station (9) to the second cutting station (11) in order to dimension it as plaster wall elements.

The second cutting station (11) is the part where the plaster wall elements are obtained as a final product by cutting the plaster blocks in intended dimensions. In the inventive production line (1), the intended amount of materials to be included in the plaster wall element for the production of the plaster wall element are mixed in the mixer (2) and then they are poured into the reservoir (3). The plaster mixture poured into the reservoir (3) remains in the reservoir (3) with the stopper (6) and moves towards the impeller (7) with the movement of the conveyor setting belt (4) and the guiding belts (5) together. The cores (8) are inserted into the plaster mixture that moves linearly in the reservoir (3) with an open upper surface with the rotation of the impeller (7) and the cores (8) remain in the plaster mixture until the end of the reservoir (3), namely they remain until the plaster solidifies. Upon the reservoir (3) is terminated and the cores (8) are removed from the plaster mixture, the plaster blocks that do not have the final product dimensions are obtained. The cores (8) removed from the solidified plaster block in the reservoir (3) can be applied with oil, soft soap etc. until the next time they enter the reservoir (3) and therefore it is provided that the core (8) can be removed easily and without any trace from the solidified plaster block for the next time. The said plaster blocks are cut at the first cutting station (9) to the appropriate dimension and then they are taken to the second cutting station (11) by the carrying conveyor (10). The cut plaster blocks are cut again at the second cutting station (11) and then they are taken out from the exit conveyor (12) as plaster wall elements.

With the inventive production line (1), a structure whereby plaster wall elements are obtained with much less energy and labour than the machines in the state of the art in terms of energy consumption and the production process is not interrupted, is formed. The design of the plaster wall element to be produced can be easily changed by simply changing the shape/dimensions of the cores (8) and the reservoir (3). It is possible to develop a wide variety of various embodiments of the inventive of the inventive production method and production line (1); the invention cannot be limited to examples disclosed herein and it is essentially according to claims.