Processing Mold and Processing Method for a Ceramic Insulator

Abstract

The present invention discloses a processing mold and a processing method for a ceramic insulator. The processing mold includes a working panel, an upper pressing member, a lower pressing member, and a middle rod. The working panel is provided with a through-hole type master mold; the upper pressing member is provided with a first recessed portion, a first through-hole is provided at the bottom of the first recessed portion, the bottom edge of the first recessed portion is a first bottom arc surface, and the top edge of the first recessed portion is a first top arc surface; the lower pressing member is provided with a second recessed portion, a second through-hole is provided at the bottom of the second recessed portion, the bottom edge of the second recessed portion is a second bottom arc surface, and the top edge of the second recessed portion is a second top arc surface; the upper pressing member and the lower pressing member form an insulator forming cavity in the through-hole type master mold, and the middle rod passes through the insulator forming cavity from the first through-hole to the second through-hole. The present invention does not require processes such as high-temperature calcination, the process is simple, and at the same time, it can avoid the phenomenon of poor powder fluidity and small local density during the pressing process, effectively solving the problems of inconsistent density at both ends of the ceramic insulator and loose quality at the waist.

Description

Technical Field

[0001] The present invention relates to the technical field of insulators, and in particular to a processing mold and a processing method for ceramic insulators. Background Art

[0002] An insulator is a device installed between conductors at different potentials or between a conductor and a grounding member, which can withstand voltage and mechanical stress and play an important role in overhead transmission lines. At present, the processing of insulators mainly adopts the extrusion molding process, in which insulating materials such as ceramics are calcined at high temperature into a liquid or semi-liquid state and then extruded into shape. However, this process is complex in operation and requires processes such as high-temperature calcination, resulting in high production costs. Summary of the Invention

[0003] The present invention provides a processing mold and a processing method for ceramic insulators to solve the technical problem of the complex current insulator processing technology.

[0004] To solve the above technical problem, in a first aspect, the present invention provides a processing mold for ceramic insulators, including a working panel, an upper pressing member, a lower pressing member, and a middle rod. The working panel is provided with a through-hole type female mold adapted to the upper pressing member and the lower pressing member;

[0005] One end face of the upper pressing member is provided with a first recess, the bottom of the first recess is provided with a first through-hole adapted to the middle rod, the bottom edge of the first recess is a first bottom arc surface, and the top edge of the first recess is a first top arc surface; one end face of the lower pressing member is provided with a second recess, the bottom of the second recess is provided with a second through-hole adapted to the middle rod, the bottom edge of the second recess is a second bottom arc surface, and the top edge of the second recess is a second top arc surface;

[0006] The upper pressing member and the lower pressing member are respectively inserted into the through-hole type female mold from both ends to form an insulator forming cavity, and the middle rod passes through the insulator forming cavity from the first through-hole to the second through-hole.

[0007] In some embodiments, the arc length of the first bottom arc surface is less than the arc length of the first top arc surface, and the arc length of the second bottom arc surface is less than the arc length of the second top arc surface.

[0008] In some embodiments, both the first top arc surface and the second top arc surface are multi-layer arc surfaces with a stepped transition.

[0009] In some embodiments, the arc lengths of the multi-layer arc surfaces increase sequentially from the inside to the outside.

[0010] In some of these embodiments, the other end of the upper pressing member is a first boss extending outward, and the diameter of the first boss is greater than the diameter of one end of the upper pressing member; the other end of the lower pressing member is a second boss extending outward, and the diameter of the second boss is greater than the diameter of one end of the lower pressing member.

[0011] In some of these embodiments, the through-hole type female mold is made of an alloy material.

[0012] In some of these embodiments, a bevel is provided on one side of the working panel close to the through-hole type female mold.

[0013] In a second aspect, the present invention further provides a processing method for a ceramic insulator, which is applied to the processing mold for the ceramic insulator as described above. The processing method includes:

[0014] Move the working panel upward by a preset distance until one end of the upper pressing member is partially embedded in the through-hole type female mold of the working panel, and then fill the through-hole type female mold with ceramic powder. In a normal state, one end of the upper pressing member after inserting the middle rod is completely embedded in the through-hole type female mold;

[0015] Insert the lower pressing member into the through-hole type female mold, insert the middle rod into the lower pressing member, and then apply pressure to the upper pressing member and the lower pressing member to press the ceramic powder into a ceramic insulator;

[0016] Remove the lower pressing member from the through-hole type female mold, and then move the working panel downward so that the upper pressing member moves upward relative to the working panel to push the ceramic insulator out of the through-hole type female mold to obtain the ceramic insulator.

[0017] In some of these embodiments, filling the through-hole type female mold with ceramic powder includes:

[0018] Pour the ceramic powder of a preset mass into the through-hole type female mold, and while pouring, use an auxiliary rod to tamp the powder to make the ceramic powder evenly fill the through-hole type female mold.

[0019] In some of these embodiments, applying pressure to the upper pressing member and the lower pressing member includes:

[0020] Use a pressure forming machine to apply pressure to the upper pressing member and the lower pressing member multiple times according to a preset program, and the pressure applied each time gradually increases.

[0021] Compared with the prior art, the present invention has at least the following beneficial effects:

[0022] The present invention realizes compression molding through a processing mold for ceramic insulators, without processes such as high-temperature calcination, reducing the process complexity. At the same time, the arc surface is used as the transition surface in this processing mold, which is beneficial to improving the fluidity of ceramic powder in the insulator forming chamber, so as to avoid the phenomenon of uneven distribution of ceramic powder caused by poor powder fluidity during the pressing process, resulting in a small local density of the ceramic insulator, and effectively solving the problems of inconsistent density at both ends of the ceramic insulator and loose quality at the waist. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a schematic structural diagram of a processing mold for a ceramic insulator shown in an embodiment of the present invention;

[0024] Figure 2 is a schematic cross-sectional view of a processing mold for a ceramic insulator shown in an embodiment of the present invention;

[0025] Figure 3 shown in an embodiment of the present invention Figure 2 partial perspective view;

[0026] Figure 4 is an exploded perspective view of a processing mold for a ceramic insulator shown in an embodiment of the present invention;

[0027] Figure 5 is a schematic structural diagram of an upper pressing member shown in an embodiment of the present invention;

[0028] Figure 6 shown in an embodiment of the present invention Figure 5 partial perspective view;

[0029] Figure 7 is a schematic structural diagram of a lower pressing member shown in an embodiment of the present invention;

[0030] Figure 8 shown in an embodiment of the present invention Figure 7 partial perspective view;

[0031] Figure 9 is a schematic structural diagram of a ceramic insulator shown in an embodiment of the present invention;

[0032] Figure 10 is a schematic plan view of a ceramic insulator processed by related technologies shown in an embodiment of the present invention;

[0033] Figure 11 is a schematic flow chart of a processing method for a ceramic insulator shown in an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0035] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there can also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. On the contrary, when an element is referred to as being "directly on" another element, there is no intermediate element. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which the present invention belongs. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0037] As described in the background art, the current processing of ceramic insulators mainly uses the extrusion molding process. However, due to the complexity of the extrusion molding process, some technologies consider using the pressing molding process to process ceramic insulators. However, the actually pressed ceramic insulators, as Figure 10 shown, have the problems of inconsistent density at both ends and loose quality at the waist (shown as "B" in Figure 10 ). Therefore, the present application provides a processing mold for ceramic insulators and a processing method for ceramic insulators using the processing mold to improve the processing quality of ceramic insulators and simplify the processing process.

[0038] See Figures 1 to 8 , Figure 1 The present invention provides a processing mold for ceramic insulators, including a working panel 1, an upper pressing member 2, a lower pressing member 3 and a middle rod 4. The working panel 1 is provided with a through-hole type female mold 11 adapted to the upper pressing member 2 and the lower pressing member 3;

[0039] A first recessed portion 21 is provided at one end surface of the upper pressing member 2, a first through hole 211 adapted to the middle rod 4 is provided at the bottom of the first recessed portion 21, a bottom edge of the first recessed portion 21 is a first bottom arc surface 212, and a top edge of the first recessed portion 21 is a first top arc surface 213; a second recessed portion 31 is provided at one end surface of the lower pressing member 3, a second through hole 311 adapted to the middle rod 4 is provided at the bottom of the second recessed portion 31, a second bottom arc surface 312 is provided at the bottom of the second recessed portion 31, and a second top arc surface 313 is provided at the top edge of the second recessed portion 31;

[0040] The upper pressing piece 2 and the lower pressing piece 3 are respectively embedded from both ends of the through-hole type female mold 11 to form an insulator molding cavity 5 , and the middle rod 4 passes through the first through-hole 211 through the insulator molding cavity 5 to the second through-hole 311 .

[0041] In this embodiment, the first top arc surface of the upper pressing piece and the second top arc surface of the lower pressing piece are both specifically inclined surfaces with arcs, so that the flowability of the ceramic powder in the insulator molding chamber is better, which effectively solves the problem of the waist of the insulator (such as Figure 9 The problem of looseness due to insufficient powder filling (shown as "A"), while the fluidity of the ceramic powder in the insulator is enhanced, the distribution of the ceramic powder in the insulator molding chamber is more uniform, and the phenomenon of large density differences at both ends of the ceramic insulator is effectively avoided. The processing mold of this embodiment only needs to cooperate with the pressure molding machine for pressing and molding, and does not require a high-temperature calcination process, which greatly reduces the complexity of the process.

[0042] In some embodiments, Figure 6 and Figure 8 As shown, the arc length of the first bottom arc surface 212 is smaller than the arc length of the first top arc surface 213, and the arc length of the second bottom arc surface 312 is smaller than the arc length of the second top arc surface 313. Since the bottom arc surface is affected by gravity, the ceramic powder can easily fill the entire bottom, and the top arc surface corresponds to the waist of the ceramic insulator. In order to prevent the waist of the ceramic insulator from being loose, the top arc surface is set as an inclined surface with a longer arc length, so as to increase the flow range of the ceramic powder, thereby improving the dispersion uniformity of the ceramic powder.

[0043] In some embodiments, Figure 6 and Figure 8 As shown, the first top curved surface 212 and the second top curved surface 312 are both multi-layer curved surfaces with step-like transitions. The multi-layer curved surface has a step-like transition to ensure that the waist of the ceramic insulator is filled with enough ceramic powder. Compared with a single continuous curved surface, it can further effectively prevent the ceramic powder from continuously sliding down due to gravity, resulting in insufficient ceramic powder filling at the waist.

[0044] In some embodiments,Figure 6 and Figure 8 As shown in Figure 8 , the arc lengths of the multi-layered arc surfaces increase successively from inside to outside, so that the flow of the ceramic powder is smoother.

[0045] In some embodiments, as Figure 5 and Figure 7 shown, the other end of the upper pressing member 2 is a first boss 22 extending outwards, and the diameter of the first boss 22 is greater than the diameter of one end of the upper pressing member 2; the other end of the lower pressing member 3 is a second boss 32 extending outwards, and the diameter of the second boss 32 is greater than the diameter of one end of the lower pressing member 3. Providing bosses on the upper and lower pressing members can play a role in limiting and positioning, preventing the upper and lower pressing members from having different embedding depths in the through-hole type female mold and affecting the force on both ends of the ceramic insulator during pressure maintaining and forming; at the same time, the boss structure facilitates the operation of the upper and lower pressing members.

[0046] In some embodiments, the through-hole type female mold 11 is made of an alloy material, and the upper and lower pressing members can also be made of an alloy material, so that the mold has sufficient rigidity during the pressure maintaining and forming of the ceramic insulator to avoid deformation.

[0047] In some embodiments, as Figure 1 shown, one side of the working panel 1 close to the through-hole type female mold 11 is provided with an inclined surface, so that the ceramic insulator can be quickly stored along the inclined surface after processing.

[0048] Refer to Figure 11 , Figure 11 which is a schematic flow chart of a processing method of a ceramic insulator shown in an embodiment of the present invention. This processing method is applied to the processing mold of the ceramic insulator as described above. The processing method includes steps 101 to step S013, which are described in detail as follows:

[0049] Step 101, move the working panel 1 upward by a preset distance until one end of the upper pressing member 2 is partially embedded in the through-hole type female mold 11 of the working panel 1, and then fill the through-hole type female mold 11 with ceramic powder. In the normal state, one end of the upper pressing member 2 after inserting the middle rod 4 is completely embedded in the through-hole type female mold 11.

[0050] In this step, insert the middle rod into the first through-hole of the upper pressing member, and then completely embed the upper pressing member into the through-hole type female mold from one side of the working panel. The first boss of the upper pressing member plays a role in limiting the embedding of the upper pressing member into the through-hole type female mold. During processing, move the working panel upward by a certain distance. At this time, part of the upper pressing member is still in the through-hole type female mold, so as to leave space for filling the through-hole type female mold with ceramic powder and embedding the lower pressing member into the through-hole type female mold.

[0051] Optionally, the upper pressing piece can be fixed on the worktable surface of the pressure molding machine to keep the position of the upper pressing piece relative to the pressure molding machine unchanged, and the volume of the insulator molding chamber can be controlled by simply adjusting the working panel and the lower pressing piece.

[0052] In some embodiments, the step of filling the through-hole master mold 11 with ceramic powder includes:

[0053] A preset mass of the ceramic powder is poured into the through-hole type master mold 11 , and the powder is compacted by using an auxiliary rod while being poured, so that the ceramic powder is evenly filled in the through-hole type master mold 11 .

[0054] In this embodiment, the amount of ceramic powder is determined according to the specifications of the ceramic insulator to be processed. Since there are many gaps when the ceramic powder is initially poured into the through-hole type mother mold, an auxiliary rod is used to poke the powder to reduce the gaps and improve the uniformity of powder dispersion. Optionally, when pouring the ceramic powder, an auxiliary conical ring can be used to be placed in the orifice of the through-hole type mother mold to prevent the ceramic powder from spilling out, which is more convenient for operation.

[0055] Step S102, embedding the lower pressing piece 3 into the through-hole female mold 11, inserting the middle rod 4 into the lower pressing piece 3, and then applying pressure to the upper pressing piece 2 and the lower pressing piece 3 to press the ceramic powder into a ceramic insulator.

[0056] In this step, after the operation of step S101, the lower pressing piece is embedded into the through-hole type mother mold from the other side of the working panel, and the middle rod is inserted into the lower pressing piece. Before the lower pressing piece is embedded into the through-hole type mother mold, the height of the middle rod in the through-hole type mother mold is higher than the filling height of the ceramic powder to prevent the ceramic powder from entering the second through hole of the lower pressing piece and causing insufficient ceramic powder. Optionally, the pressure applied by the upper pressing piece and the lower pressing piece is completed by a pressure forming machine.

[0057] In some embodiments, applying pressure to the upper pressing member 2 and the lower pressing member 3 includes:

[0058] A pressure forming machine is used to apply pressure to the upper pressing member 2 and the lower pressing member 3 for multiple times according to a preset program, and the pressure and the duration of the pressure applied each time gradually increase.

[0059] In this embodiment, the specific pressure and specific duration of the pressure application actually applied by the pressure forming machine are related to the processing specifications of the ceramic insulator and are not limited thereto. This embodiment uses multiple pressurization methods to perform pressurization so that the ceramic powder can gradually flow evenly at a relatively low pressure in the early stage, ensuring that the density difference between the various parts of the ceramic insulator is small, and avoiding the phenomenon that a single high pressure causes local ceramic powder to be compacted, resulting in a decrease in the fluidity of the ceramic powder at the location of the second top arc surface.

[0060] Step S103: Move the pressing-down member 3 out of the through-hole type female mold 11, and then move the working panel 1 downward so that the pressing-up member 2 moves upward relative to the working panel 1 to push the ceramic insulator out of the through-hole type female mold 11, thereby obtaining the ceramic insulator.

[0061] In this step, after the pressing-down member is moved out of the through-hole type female mold and the working panel is moved downward, the ceramic insulator is pushed out and then rolls down along the inclined plane to the product storage part, completing the processing of the ceramic insulator. It should be noted that subsequent processes for the ceramic insulator may also include surface grinding, glazing, etc., which are not limited herein.

[0062] The specific embodiments described above further elaborate on the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above are only specific embodiments of the present invention and are not used to limit the protection scope of the present invention. In particular, for those skilled in the art, any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A processing mold for a ceramic insulator, characterized in that: It includes a working panel, an upper pressing piece, a lower pressing piece and a middle rod, wherein the working panel is provided with a through-hole female mold adapted to the upper pressing piece and the lower pressing piece; A first recessed portion is provided on one end surface of the upper pressing member, a first through hole adapted to the middle rod is provided at the bottom of the first recessed portion, a bottom edge of the first recessed portion is a first bottom arc surface, and a top edge of the first recessed portion is a first top arc surface; a second recessed portion is provided on one end surface of the lower pressing member, a second through hole adapted to the middle rod is provided at the bottom of the second recessed portion, a bottom edge of the second recessed portion is a second bottom arc surface, and a top edge of the second recessed portion is a second top arc surface; The upper pressing piece and the lower pressing piece are respectively embedded from both ends of the through-hole type female mold to form an insulator molding cavity, and the middle rod passes through the insulator molding cavity from the first through-hole to the second through-hole; the arc length of the first bottom arc surface is smaller than the arc length of the first top arc surface, and the arc length of the second bottom arc surface is smaller than the arc length of the second top arc surface; the first top arc surface and the second top arc surface are both multi-layer arc surfaces with a step-like transition; the arc length of the multi-layer arc surface increases successively from the inside to the outside.

2. The processing mold for ceramic insulators according to claim 1, characterized in that: The other end of the upper pressing piece is a first boss extending outward, and the diameter of the first boss is larger than the diameter of one end of the upper pressing piece; the other end of the lower pressing piece is a second boss extending outward, and the diameter of the second boss is larger than the diameter of one end of the lower pressing piece.

3. The processing mold for ceramic insulators according to claim 1, characterized in that: The through-hole type master mold is made of alloy material.

4. The processing mold for ceramic insulators according to claim 1, characterized in that: A side of the working panel close to the through-hole type female mold is provided with an inclined surface.

5. A method for processing a ceramic insulator, characterized in that: A processing mold for a ceramic insulator according to any one of claims 1 to 3, wherein the processing method comprises: The working panel is moved upward by a preset distance until one end of the upper pressing piece is partially embedded in the through-hole type mother mold of the working panel, and then the through-hole type mother mold is filled with ceramic powder, wherein under normal conditions, one end of the upper pressing piece after the middle rod is inserted is completely embedded in the through-hole type mother mold; The lower pressing piece is embedded in the through-hole type female mold, and the middle rod is inserted into the lower pressing piece, and then pressure is applied to the upper pressing piece and the lower pressing piece to press the ceramic powder into a ceramic insulator; The lower pressing piece is moved out of the through-hole type female mold, and then the working panel is moved downward, so that the upper pressing piece moves upward relative to the working panel to push the ceramic insulator out of the through-hole type female mold, thereby obtaining a ceramic insulator.

6. The method for processing a ceramic insulator according to claim 5, characterized in that: The step of filling the through-hole master mold with ceramic powder comprises: The ceramic powder of a preset mass is poured into the through-hole type master mold, and the powder is compacted by using an auxiliary rod while being poured, so that the ceramic powder is evenly filled in the through-hole type master mold.

7. The method for processing a ceramic insulator according to claim 5, characterized in that: The step of applying pressure to the upper pressing member and the lower pressing member comprises: A pressure forming machine is used to apply pressure to the upper pressing piece and the lower pressing piece for multiple times according to a preset program, and the pressure applied each time gradually increases.

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