Method for continuously producing molded members from a mixture of gypsum and fibrous material

A method of continuously producing molded members as plaster-of-Paris construction plates or panels from a mixture of calcinated gypsum having porous granular structure and dry fibrous material purposely added thereto;

• measuring respective measured-out quantities of said calcinated gypsum and said dry fibrous material which in a first mixing stage are then subjected to scattering as strewn out for being fervently and thoroughly mixed together, weighing the still dry calcinated gypsum/dry fibrous material mixture and subsequently then moistening the mixture by stepwise adding of water beginning in a second mixing stage by supplying water added as dosaged thereto in conformity with the measured weight of said dry mixture with only so much water being added at least as far as to a stoichiometric water quantity as necessary for absorption by the calcinated gypsum/dry fibrous material mixture for setting and curing thereof while continuously mixing the gypsum/fibrous material to assure said second mixing stage proceeding without any clumping or granulation of the gypsum-fibrous mixture arising therewith;
• dispersing the moistened mixture subsequently onto a support means including a forming line to progressively form multi-layer molded members, with the surface of each molded member being subjected to additional moistening with an over-stoichiometric quantity of water so that curing is assured with transport of calcium-sulfate ions in all directions so that said molded members as plaster-of-Paris construction plates or panels have only a small or nominal bonding or binding-off and drying time, and the latter then being compacted;
• said method further includes the improvement in combination therewith comprising the steps of:
• dividing a mass flow of said calcinated gypsum/dry fibrous material mixture into several independent partial mass flows separate from each other such that via said dividing into partial mass flows there is attained a result whereby solely further post-wetting or subsequently moistening is made possible respectively in an adequate uniform manner;
• dispersing a first one of said partial mass flows onto said forming line of said support means as a first layer of a given one of said molded members;
• respectively dispersing a second and subsequent ones of said partial mass flows progressively onto said first and subsequent layers of said given molded member as a second and subsequent layers thereof;
• additionally and subsequently moistening each of said layers respectively each with water individually prior to dispersing a subsequent layer thereon, with the total quantity of water supplied for a given molded member including intentionally aimed setting and adjustment of an over-stoichiometric water content equalling only up to a maximum of 25% based on mass of said dry calcinated gypsum above the stoichiometric quantity of water mathematically and analytically necessary for bonding or binding of the calcinated gypsum-dry fibrous material as required for curing of the calcinated gypsum/dry fibrous material mixture dispersed to form said given molded member;
• providing high strength in the molded member even with brief curing-drying time and only nominal deviation;
• assuring that surface uniformity exists in the entire molded member when finished free of any pocks and pitting;
• growing crystals together in situ for assuring uniformity and smoothness of the surface of the molded members;
• and
• simultaneously matting the layers together and interlocking the crystals to result in a continuous high mechanical strength over entire surfaces and cross section of the produced molded member finished as the plaster-of-Paris construction plate or panel with this high mechanical strength thereof simultaneously also having only a small or nominal deviation or divergence accordingly to be uniform over and throughout the entire plaster-of-Paris construction plate or panel with very smooth surfaces being obtained.