[0001] The invention relates to a cutter unit configured to be used in a process of making
cuts through plasterboard as plasterboard passes over the cutter unit, and to be put
to a spinning motion about a longitudinal axis thereof in the process, which cutter
unit comprises a knife blade arranged and configured to intersect with the plasterboard
and to thereby cut the plasterboard one time per revolution of the spinning motion,
which knife blade extends substantially parallel to the longitudinal axis, at a radial
distance from the longitudinal axis. Further, the invention relates to a plasterboard
manufacturing device, which plasterboard manufacturing device comprises a cutter device
which is configured to cut pieces of plasterboard from a continuous supply of plasterboard
and which comprises the cutter unit as mentioned here before.
[0002] The invention is applicable to the field of manufacturing pieces of plasterboard,
especially the field of cutting pieces of plasterboard from a continuous supply of
plasterboard.
[0003] Plasterboards are plates particularly useful for albeit not restrict to the building
industry, comprising a core made of gypsum with various additives in minor amounts,
sandwiched between bottom and top facers, generally made of paper and / or glass mat.
[0004] A slurry of calcined calcium sulphate hemihydrate (or stucco) mainly β hemihydrate
in water with the desired additives, such as accelerators, fibrous reinforcements,
and the like, is continuously dispensed onto a bottom facer moving on a conveyor.
The thickness of the layer of slurry on the bottom facer is controlled and a top facer
is laid on top of a free surface of the slurry, such as to form a sandwich structure
with a core formed by the slurry sandwiched between bottom and top facers. The calcined
stucco in the core is allowed to undergo a hydration reaction to form a setting plasterboard
with calcium sulphate hemihydrate (CaS04.1/2H20) being progressively replaced by calcium
sulphate dihydrate (CaSC>4.2H20) as the hydration reaction proceeds.
Once the core has set to a reasonably hard structure, the continuous setting plasterboard
is cut to a desired length, prior to being moved into a drier to complete the hydration
reaction and remove any excess water present in the core.
[0005] DE2711446A1 discloses a cutter device for cutting continuously traveling plasterboard. The cutter
device comprises two cutter units which are spun in opposite directions during operation
of the cutter device. Each cutter unit is equipped with a knife blade extending in
a direction which is traverse to a traveling direction of the plasterboard, wherein
a width of the knife blade corresponds to the width of the traveling plasterboard.
The cutter units are held in stacked and opposite positioning in the cutter device,
and the plasterboard is guided between the cutter units during operation of the cutter
device, such that the knife blades of the cutter units are enabled to intersect with
the plasterboard and to thereby cut the plasterboard one time per revolution of the
opposite spinning motion of the cutter units. During the time that the knife blades
are outside of the area where the plasterboard is present, a length of the plasterboard
is made to travel between the cutter units until the knife blades reach into the plasterboard
again and make another cut through the plasterboard. Hence, in the process of a continuous
supply of plasterboard and continuous spinning motion of the cutter units, the plasterboard
is cut to pieces.
[0006] In the practice of manufacturing pieces of plasterboard, it appears that the plasterboard
has a tendency to get stuck in the cutter device and to thereby cause jamming of the
cutter device. Every time such jamming of the cutter device actually takes place,
the continuous supply of plasterboard needs to be stopped and valuable manufacturing
time is lost. This problem is especially prominent in case the plasterboard is relatively
soft. Therefore, in the present state of the art, a choice is made not to process
relatively soft plasterboard, which implies that in a plasterboard manufacturing device,
measures need to be taken to ensure that it takes a certain amount of time for the
plasterboard to move from a mixer outputting freshly made plasterboard to the cutter
device.
[0007] It is an objective of the invention to alleviate the practical problems related to
the present state of the art. In particular, it is an objective of the invention to
provide a way of reducing the risk that the cutter device gets jammed and to thereby
provide a practical possibility to process relatively soft plasterboard and to decrease
the amount of time needed for displacement of the plasterboard between the mixer and
the cutter device.
[0008] In view of the foregoing, the invention provides a cutter unit configured to be used
in a process of making cuts through plasterboard as plasterboard passes over the cutter
unit, and to be put to a spinning motion about a longitudinal axis thereof in the
process, which cutter unit comprises a knife blade arranged and configured to be put
to a functional cutting position for intersecting with the plasterboard and thereby
cutting the plasterboard one time per revolution of the spinning motion, which knife
blade extends substantially parallel to the longitudinal axis, at a radial distance
from the longitudinal axis, and which cutter unit further comprises a plasterboard
supporting surface arranged and configured to support the plasterboard during at least
a part of a revolution of the spinning motion outside of the time that the knife blade
is at the functional cutting position.
[0009] It is an insight of the invention that jamming of a cutter device in a plasterboard
manufacturing device takes place as a result of bending and sagging of the plasterboard
at the position of the cutter device. When the plasterboard is relatively soft, the
stiffness of the plasterboard is relatively low, and this effect of local deformation
of the plasterboard is more prominent than when the plasterboard is relatively hard.
The fact is that conventionally, a plasterboard manufacturing device comprises rollers
for the purpose of transporting the plasterboard through the plasterboard manufacturing
device. As seen in a direction of movement of the plasterboard through the plasterboard
manufacturing device, the rollers are arranged at a mutual distance which is sufficiently
small for realizing appropriate support of the plasterboard. According to the insight
of the invention, bending and sagging of the plasterboard can take place at the position
of the cutter device as a consequence of the fact that due to the space which is needed
for the spinning cutter units and their knife blades, the mutual distance of a roller
directly upstream of the cutter device and a roller directly downstream of the cutter
device is larger than the normal mutual distance, and in fact so large that deformation
of the plasterboard is far more likely to occur at a position between those rollers,
i.e. at the position of the cutter device, than at other positions in the plasterboard
manufacturing device. Adding one or more rollers at the position of the cutter device
is not possible for the same reason that space is needed for the spinning cutter units
and their knife blades.
[0010] A special feature of the invention is that the cutter unit is provided with a plasterboard
supporting surface arranged and configured to support the plasterboard during at least
a part of a revolution of the spinning motion outside of the time that the knife blade
is at the functional cutting position. On the basis of this feature, a possibility
to support the plasterboard at the position of the cutter unit is obtained, namely
by making clever use of the cutter unit as such. Advantageously, a dimension of the
plasterboard supporting surface in a direction about the longitudinal axis is chosen
such that the plasterboard supporting functionality of the cutter unit thus obtained
is realized over a major part of a revolution of the spinning motion. In any case,
the plasterboard supporting functionality of the cutter unit can be realized without
hindering the plasterboard cutting functionality of the cutter unit. In this respect,
it is noted that it is practical if, in a radial direction relative to the longitudinal
axis, the knife blade is at least partially above plasterboard supporting level defined
by the plasterboard supporting surface.
[0011] The invention can be realized without a need for complex measures, wherein it is
possible to upgrade an existing cutter unit with one or more add-ons for creating
the plasterboard supporting surface on the cutter unit. By enabling the cutter unit
to support plasterboard as the cutter unit is spun about the longitudinal axis, outside
of the time that the plasterboard is cut, bending and sagging of the plasterboard
at the position of a cutter device equipped with the cutter unit is prevented so that
jamming of the cutter device is far less likely to occur than in conventional situations,
or may even no longer occur at all.
[0012] In the context of the invention, the plasterboard supporting surface can be realized
on the cutter unit in any suitable way. According to one feasible option, the plasterboard
supporting surface is substantially circularly bent about the longitudinal axis. The
plasterboard supporting surface can be provided as one continuous surface, or can
be provided with one or more interruptions and/or can be composed of at least two
discrete subsurfaces.
[0013] One way of realizing the plasterboard supporting functionality of the cutter unit
without hindering the plasterboard cutting functionality of the cutter unit is shaping
and dimensioning the plasterboard supporting surface such that, in the direction about
the longitudinal axis, the plasterboard supporting surface is at a distance from the
knife blade, at both long sides of the knife blade. In the case that the plasterboard
supporting surface is substantially circularly bent about the longitudinal axis, it
is possible that the plasterboard supporting surface extends continuously along an
angle of at least 240° and less than 360° about the longitudinal axis. On the basis
of the angle of at least 240°, it is achieved that the plasterboard supporting functionality
of the cutter unit is realized over at least 2/3 of a revolution of the spinning motion
of the cutter unit. Another example of this angle is an angle of at least 280°, so
that the plasterboard supporting functionality of the cutter unit is even further
enhanced.
[0014] One way of actually realizing the case that the plasterboard supporting surface is
substantially circularly bent about the longitudinal axis and that, in the direction
about the longitudinal axis, the plasterboard supporting surface is at a distance
from the knife blade, at both long sides of the knife blade, involves further shaping
and dimensioning the plasterboard supporting surface such that the plasterboard supporting
surface extends continuously about the longitudinal axis apart from a single interruption.
In this respect, an embodiment of the cutter unit is possible in which, as seen in
the direction about the longitudinal axis, said single interruption is present in
the plasterboard supporting surface, and in which the knife blade is positioned in
said interruption. For example, it is possible that the cutter unit comprises a core
element and a knife body extending outwardly from the core element and supporting
the knife blade. In such a case, one or more elements having a surface for defining
the plasterboard supporting surface may also be arranged on the core element. In a
practical embodiment, the cutter unit comprises a core element and at least two ring
segments supported on the core element and surrounding part of the core element in
the direction about the longitudinal axis, wherein the plasterboard supporting surface
comprises curved exterior surfaces of the respective ring segments. In this embodiment,
the plasterboard supporting surface is not only interrupted in the direction about
the longitudinal axis, but also in the direction in which the longitudinal axis extends,
in case the ring segments are arranged at a mutual distance in the direction in which
the longitudinal axis extends. Generally speaking, in the context of the invention,
embodiments of the cutter unit are feasible in which, in the direction in which the
longitudinal axis extends, at least one interruption is present in the plasterboard
supporting surface.
[0015] The invention covers the use of any suitable type of knife blade in the cutter unit.
In this respect, a toothed knife blade is a practical example.
[0016] The invention further relates to a plasterboard manufacturing device comprising a
cutter device configured to cut pieces of plasterboard from a continuous supply of
plasterboard, comprising a combination of the above-described cutter unit which is
functional to support the plasterboard and another cutter unit comprising a knife
blade, and a frame configured to hold the cutter units in stacked and opposite positioning
in the cutter device, with the first cutter unit at a lower position than the second
cutter unit, and further comprising a drive mechanism configured to spin the cutter
units of the cutter device in opposite directions, and also a plasterboard transport
system configured to guide the plasterboard towards a cutting area between the cutter
units of the cutter device and away from the cutter device.
[0017] In order to realize an optimal cutting functionality of the cutter device, it is
a practical possibility that the drive mechanism comprises a mechanism configured
to synchronize the opposite spinning motion of the cutter units of the cutter device
and to thereby synchronize the way in which the knife blades of the cutter units move
so that the knife blades of the cutter units reach the cutting area at the same time
in a revolution of the spinning motion.
[0018] The drive mechanism can be composed by only one or two drivers.
[0019] It is a practical possibility that the plasterboard transport system comprises a
plurality of rollers arranged to support the plasterboard, as is known from conventional
situations.
[0020] The present invention will be further explained on the basis of the following description,
wherein reference will be made to the figures, in which equal reference signs indicate
equal or similar components, and in which:
figure 1 diagrammatically shows components of a plasterboard manufacturing device
and plasterboard to be transported through the plasterboard manufacturing device and
cut at the position of a cutter device, wherein the cutter device comprises a cutter
unit according to an embodiment of the invention as a bottom cutter unit;
figure 2 diagrammatically shows a side view of the bottom cutter unit, and also shows
a portion of plasterboard and a portion of a top cutter unit, for a situation in which
knife blades of the cutter units intersect with the plasterboard and thereby perform
a cutting action on the plasterboard;
figure 3 illustrates how the plasterboard is supported by a plasterboard supporting
surface of the bottom cutter unit in a situation between two cutting actions of the
bottom cutter unit on the plasterboard;
figure 4 diagrammatically shows an enlarged view of a portion of the bottom cutter
unit;
figure 5 diagrammatically shows a top view of the bottom cutter unit, for a situation
in which the knife blade of the cutter unit is up;
figure 6 diagrammatically shows a top view of the bottom cutter unit, for a situation
in which the knife blade of the cutter unit is down.
[0021] The figures are illustrative of the invention rather than limiting the invention.
Figure 1 diagrammatically shows components of a plasterboard manufacturing device
100 and plasterboard 1 to be transported through the plasterboard manufacturing device
100 and cut at the position of a cutter device 2, wherein the cutter device 2 comprises
a cutter unit 10 according to an embodiment of the invention as a bottom cutter unit.
In the present description, indications such as "bottom", "up" and "down" are to be
understood so as to be related to a normal operational orientation of the plasterboard
manufacturing device 100 and the components included in the plasterboard manufacturing
device 100, which is the orientation as shown in figure 1.
[0022] The cutter device 2 further comprises a top cutter unit 20. The bottom cutter unit
10 comprises a knife blade 11 for cutting the plasterboard 1 from a bottom side of
the plasterboard 1, and the top cutter unit 20 comprises a knife blade 21 for cutting
the plasterboard 1 from a top side thereof. The cutter units 10, 20 are held in a
frame 30, in stacked and opposite positioning, in such a way that the cutter units
10, 20 can be spun about their respective longitudinal axes A
L, in opposite directions. In figure 1, the directions of the spinning motion of the
respective cutter units 10, 20 are indicated by means of curved arrows. For the purpose
of driving the cutter units 10, 20 to perform their opposite spinning motion, the
plasterboard manufacturing device 100 comprises a drive mechanism 3.
[0023] During operation of the plasterboard manufacturing device 100, the cutter device
2 functions to receive a continuous supply of plasterboard 1 at one side, to make
a cut through the moving plasterboard 1 along an entire width of the plasterboard
1 at regular intervals, and to thereby eventually output pieces of plasterboard 1.
In figure 1, a direction of movement of the plasterboard 1 is indicated by means of
a straight arrow. For the purpose of transporting the plasterboard 1, the plasterboard
manufacturing device 100 comprises a plasterboard transport system 4. In the present
example, the plasterboard transport system 4 comprises rollers 45 arranged to support
the plasterboard 1 so that the plasterboard 1 is kept substantially horizontal throughout
the plasterboard manufacturing device 100. When it comes to the cutter device 2, the
plasterboard transport system 4 is functional to guide the plasterboard 1 towards
a cutting area 31 between the cutter units 10, 20 of the cutter device 2 and away
from the cutter device 2. Practical examples of the width of the plasterboard 1 are
600 mm, 900 mm and 1,200 mm. The cutter device 2 can be designed such that plasterboard
1 of different width can be processed by the device 3, wherein a dimension of the
knife blades 11, 21 of the respective cutter units 10, 20 in a direction in which
the longitudinal axis A
L extends is adapted to the largest width.
[0024] The design of the top cutter unit 20 is a conventional design according to which
the top cutter unit 20 comprises a core element 22 and a knife body 23 extending outwardly
from the core element 22 and supporting the knife blade 21. Likewise, the bottom cutter
unit 10 comprises a core element 12 and a knife body 13 extending outwardly from the
core element 12 and supporting the knife blade 11. In comparison to the top cutter
unit 20, the bottom cutter unit 10 comprises additional elements, namely three ring
segments 14, 15, 16 supported on the core element 12 and surrounding part of the core
element 12 in a direction about the longitudinal axis A
L. The ring segments 14, 15, 16 are of similar design and are arranged on the core
element 12 in a similar way, in a row with similar mutual spacing in the direction
in which the longitudinal axis A
L extends, as can be seen in figures 5 and 6. The ring segments 14, 15, 16 may be made
of a suitable plastic material, for example, while the knife blade 11, the core element
12 and the knife body 13 may be made of steel. The ring segments are preferably made
of polypropylene or polyethylene.
[0025] Generally speaking, a difference between the conventional design of the top cutter
unit 20 and the design of the bottom cutter unit 10 is that the bottom cutter unit
10 comprises a plasterboard supporting surface 17 which is functional to support the
plasterboard 1 during at least a part of a revolution of the spinning motion outside
of the time of intersection of the knife blade 11 with the plasterboard 1. In the
example in which the bottom cutter unit 10 is equipped with the three ring segments
14, 15, 16, the plasterboard supporting surface 17 comprises curved exterior surfaces
of the respective ring segments 14, 15, 16. An advantageous consequence of the capability
of the bottom cutter unit 10 to support the plasterboard 1 resides in counteracting
bending and sagging of the plasterboard 1 at the position of the cutter unit 3 and
thereby preventing jamming of the cutter unit 3. In the present example, each of the
ring segments 14, 15, 16 are dimensioned to extend along an angle of about 300° about
the longitudinal axis A
L. This means that as the bottom cutter unit 10 spins about the longitudinal axis A
L, the plasterboard 1 is supported during 5/6 of the revolution of the spinning motion.
[0026] Figure 2 illustrates a situation in which the bottom cutter unit 10 is in a position
in which the knife blade 11 is up and in which the top butter unit 20 is in a position
in which the knife blade 21 is down. Hence, this is a situation in which both knife
blades 11, 21 are in a functional cutting position for intersecting with the plasterboard
1 and thereby cutting the plasterboard 1. Starting from this situation, as the cutter
units 10, 20 perform their opposite spinning motion, the knife blades 11, 21 are moved
away from the cutting area 31 and the bottom side of the plasterboard 1 is contacted
by the plasterboard supporting surface 17 of the bottom cutter unit 10 at a certain
point. Figure 3 illustrates a situation in which the moving plasterboard 1 rests on
the plasterboard supporting surface 17 of the bottom cutter unit 10 and is thereby
supported at the position of the cutter device 2. During operation of the cutter device
2, a cycle in which the plasterboard 1 is alternately cut and supported is continually
repeated.
[0027] In the present example, as seen in the direction about the longitudinal axis A
L, the knife body 13 and the knife blade 11 supported on the knife body 13 extend in
an interruption of about 60° as present in the respective ring segments 14, 15, 16
and the associated plasterboard supporting surface 17. It may be practical and advantageous
to have a central positioning of the knife body 13 and the knife blade 11 in said
interruption, as can be seen in the figures. With reference to figure 4, it is noted
that in order to have both the plasterboard supporting functionality and the plasterboard
cutting functionality in the bottom cutter unit 10, it is practical if, in a radial
direction relative to the longitudinal axis A
L, the knife blade 11 is at least partially above a plasterboard supporting level P
defined by the plasterboard supporting surface 17. Further, in figure 4, both a radial
distance d
r between the longitudinal axis A
L and the knife blade 11 and a distance dt about the longitudinal axis A
L between the plasterboard supporting surface 17 and the knife blade 11, at both long
sides of the knife blade 11, are indicated. The plasterboard supporting level P defined
by the plasterboard supporting surface 17 is also indicated in figure 2.
[0028] It will be clear to a person skilled in the art that the scope of the present invention
is not limited to the examples discussed in the foregoing, but that several amendments
and modifications thereof are possible without deviating from the scope of the invention
as defined in the attached claims.
[0029] Notable aspects of the invention are summarized as follows. In a process of manufacturing
pieces of plasterboard 1, plasterboard 1 is moved continuously over a cutter unit
10 including a knife blade 11, and the cutter unit 10 is driven to perform a spinning
motion about a longitudinal axis A
L thereof so that the knife blade 11 is made to intersect with the moving plasterboard
1 at regular intervals. The cutter unit 10 is designed so as to not only be capable
of making cuts in the plasterboard 1, but to also be capable of supporting the plasterboard
1 between successive cutting actions. To this end, the cutter unit 10 is provided
with a plasterboard supporting surface 17 arranged and configured to support the plasterboard
1, particularly to do so during at least a part of a revolution of the spinning motion
outside of the time of intersection of the knife blade 11 with the plasterboard 1.
- 1
- Plasterboard
- 2
- Cutter device
- 3
- Drive mechanism
- 4
- Plasterboard transport system
- 10
- Bottom cutter unit
- 11
- Bottom knife blade
- 12
- Bottom core element
- 13
- Bottom knife body
- 14
- Ring segment 1
- 15
- Ring segment 2
- 16
- Ring segment 3
- 17
- Plasterboard supporting surface
- 20
- Top cutter unit
- 21
- Top knife blade
- 22
- Top core element
- 23
- Top knife body
- 30
- Frame
- 31
- Cutting area
- 45
- Rollers
- 100
- Manufacturing device
- AL
- Longitudinal axis
- P
- Plasterboard supporting level
- dr
- Radial distance
- dt
- Distance from the knife blade to the plasterboard supporting surface in a direction
about the longitudinal axis (AL)
1. A cutter unit (10) configured to be used in a process of making cuts through plasterboard
(1) as the plasterboard (1) passes over the cutter unit (10), and to be put to a spinning
motion about a longitudinal axis (A
L) thereof in the process, comprising:
- a knife blade (11) arranged and configured to be put to a functional cutting position
for intersecting with the plasterboard (1) and thereby cutting the plasterboard (1)
one time per revolution of the spinning motion, which knife blade (11) extends substantially
parallel to the longitudinal axis (AL), at a radial distance (dr) from the longitudinal axis (AL), and
- a plasterboard supporting surface (17) arranged and configured to support the plasterboard
(1) during at least a part of a revolution of the spinning motion outside of the time
that the knife blade (11) is at the functional cutting position.
2. The cutter unit (10) according to claim 1, wherein, in a radial direction relative
to the longitudinal axis (AL), the knife blade (11) is at least partially above a plasterboard supporting level
(P) defined by the plasterboard supporting surface (17).
3. The cutter unit (10) according to claim 1 or 2, wherein the plasterboard supporting
surface (17) is substantially circularly bent about the longitudinal axis (AL).
4. The cutter unit (10) according to any of claims 1-3, wherein, in a direction about
the longitudinal axis (AL), the plasterboard supporting surface (17) is at a distance (dt) from the knife blade
(11), at both long sides of the knife blade (11).
5. The cutter unit (10) according to claim 4 insofar as dependent on claim 3, wherein
the plasterboard supporting surface (17) extends continuously along an angle of at
least 240° and less than 360° about the longitudinal axis (AL).
6. The cutter unit (10) according to claim 4 insofar as dependent on claim 3, wherein
the plasterboard supporting surface (17) extends continuously along an angle of at
least 280° and less than 360° about the longitudinal axis (AL).
7. The cutter unit (10) according to any of claim 4 insofar as dependent on claim 3,
claim 5 and claim 6, wherein the plasterboard supporting surface (17) extends continuously
about the longitudinal axis (AL) apart from a single interruption.
8. The cutter unit (10) according to claim 7, wherein the knife blade (11) is positioned
in the interruption in the plasterboard supporting surface (17).
9. The cutter unit (10) according to claim 8, comprising a core element (12) and a knife
body (13) extending outwardly from the core element (12) and supporting the knife
blade (11).
10. The cutter unit (10) according to any of claims 1-9, wherein, in a direction in which
the longitudinal axis (AL) extends, at least one interruption is present in the plasterboard supporting surface
(17).
11. The cutter unit (10) according to any of claims 1-10, comprising a core element (12)
and at least two ring segments (14, 15, 16) supported on the core element (12) and
surrounding part of the core element (12) in a direction about the longitudinal axis
(AL), wherein the plasterboard supporting surface (17) comprises curved exterior surfaces
of the respective ring segments (14, 15, 16).
12. The cutter unit (10) according to any of claims 1-11, wherein the knife blade (11)
is a toothed knife blade.
13. A plasterboard manufacturing device (100), comprising:
a cutter device (2) configured to cut pieces of plasterboard (1) from a continuous
supply of plasterboard (1), comprising a combination of the cutter unit (10) according
to any of claims 1-12 and another cutter unit (20) comprising a knife blade (21),
and a frame (30) configured to hold the cutter units (10, 20) in stacked and opposite
positioning in the cutter device (2), with the cutter unit (10) according to any of
claims 1-12 at a lower position than the other cutter unit (20),
a drive mechanism (3) configured to spin the cutter units (10, 20) of the cutter device
(2) in opposite directions, and
a plasterboard transport system (4) configured to guide the plasterboard towards a
cutting area (31) between the cutter units (10, 20) of the cutter device (2) and away
from the cutter device (2).
14. The plasterboard manufacturing device (100) according to claim 13, wherein the drive
mechanism (3) comprises a mechanism configured to synchronize the opposite spinning
motion of the cutter units (10, 20) of the cutter device (2) and to thereby synchronize
the way in which the knife blades (11, 21) of the cutter units (10, 20) move so that
the knife blades (11, 21) of the cutter units (10, 20) reach the cutting area (31)
at the same time in a revolution of the spinning motion.
15. The plasterboard manufacturing device (100) according to claim 13 or 14, wherein the
plasterboard transport system (4) comprises a plurality of rollers (45) arranged to
support the plasterboard (1).