Compaction device for compacting layer of powder material

Abstract

The utility model provides a compacting device used for compacting a powder material layer, which comprises a conveying surface used for receiving the layer and enabling the layer to advance along an advancing direction; a belt-type compaction element defining, by its lower branch, a compaction surface facing the conveying surface; the lower pressing roller is matched with the conveying surface; an upper press roller parallel to and placed above the lower press roller and designed to press the compaction surface toward the conveying surface, thereby compacting the layer of powder material; a counter element; and a movement system for moving the counter element to adjust the inclination of the compaction surface with respect to the advancing direction.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the priority of Italian Patent Application No. 102024000002782 filed on February 9, 2024, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The utility model relates to a compacting device for compacting a powder material layer; the powder material layer is especially a ceramic powder material layer, that is, a powder material containing ceramic powder. Background Art

[0004] In the ceramic processing industry, a system is known for manufacturing ceramic products (such as ceramic panels or tiles), which system includes: a conveying component that defines a conveying surface; a ceramic powder feeding system, which is designed to gradually feed ceramic powder material (i.e., a defined amount of ceramic powder material) onto the conveying component, in particular onto the conveying surface, to form a ceramic powder layer.

[0005] The ceramic powder layer is advanced via the conveying surface through a series of compacting stations designed to compact the powder layer as it advances over the conveying surface, thereby forming a continuous strip of compacted ceramic powder.

[0006] Downstream of the compacting station there are usually further known processing stations, for example at least one cutting station at which the continuous strip of compacted ceramic powder is divided into individual panels or bricks, and further decoration and / or finishing stations.

[0007] Known compacting devices generally comprise two flexible compacting surfaces, one above the other and both able to slide in the same direction, thereby locking the ceramic powder layers between each other and compressing the ceramic powder layers as they advance through the compacting station.

[0008] In particular, the lower compaction station is typically arranged to be in direct contact with the conveying surface so as to support the conveying surface, or to coincide with the conveying surface; while the upper compaction surface is arranged to be parallel to the conveying surface and at a given distance (i.e., height) from the conveying surface, thereby defining a gap therebetween, which is designed to receive the ceramic powder layer to be compacted.

[0009] Each compacting surface is usually defined by a respective flexible sliding belt, usually made of steel, wound around a plurality of rollers with horizontal axes, usually powered rollers, pulleys and pressure rollers.

[0010] In more detail, the compacting device generally includes a pair of pressing rollers arranged one above the other, and in a predetermined compacting area, the pair of pressing rollers are designed to guide the compacting surface to locally keep the upper compacting surface pressed toward the lower compacting surface, thereby compressing the powder layer conveyed by the conveyor belt and forming the aforementioned compacted ceramic powder strip.

[0011] In the ceramic processing industry, the correct configuration and mutual arrangement of the compacting surfaces in the area immediately upstream of the above-mentioned predetermined compacting zone are crucial for ensuring that the ceramic powder is properly fed between the pressure rollers and for reducing the risk of unwanted air being trapped in the ceramic powder and / or the risk of other irregularities appearing in the ceramic powder feed, such as small pieces of ceramic powder, which could lead to defects and / or irregularities during the extrusion step or in subsequent processing steps, which, in the worst case, could lead to the rejection of the ceramic product. These phenomena are associated with unwanted deformations of the upper compacting surface in the area upstream of the predetermined compacting zone along the advancement direction, when the ceramic powder is fed between the two pressure rollers. In fact, when the powder material is fed towards the predetermined compacting zone (such as Figure 7 In the case of a cracked surface (schematically shown by the middle dashed line), the ceramic powder layer may cause deformation of the strip forming the upper compacting surface, in other words, inward bending of the steel strip constituting the upper compacting surface.

[0012] In particular, experiments have shown that in order to avoid these risks, during use (and therefore, even when the ceramic powder is fed between the two rollers), the upper compacting surface needs to be parallel to the conveying surface or inclined upward relative to the conveying surface and needs to remain parallel to the conveying surface or inclined upward relative to the conveying surface so as to gradually reduce the distance between the upper compacting surface and the conveying surface as it moves from a predetermined compacting area toward an upstream area along the material feed direction.

[0013] To this end, the applicant has provided two auxiliary devices in some known compacting devices, in particular two auxiliary rollers with horizontal axes, which are parallel to the above-mentioned pressing rollers, located upstream of the pressing rollers relative to the advancing direction of the powder material layer, and are designed to guide the pressing belts that respectively define the upper compacting surface and the lower compacting surface and keep them in appropriate positions.

[0014] In particular, in the known machine, the lower auxiliary roller is located upstream of the lower pressing roller, in a plane parallel to the direction of advancement, and is in contact with the steel belt of the lower compacting device to maintain the planar nature of the conveying surface and the lower compacting surface. On the other hand, the upper auxiliary roller is located upstream of the upper pressing roller and is designed to act on the pressing belt forming the upper compacting surface in order to keep it in the correct position, thereby minimizing the risk of deformation of said belt, or at least the degree of deformation, when the ceramic powder is fed between the two pressing rollers.

[0015] However, these compacting devices suffer from several disadvantages.

[0016] In fact, in order to be suitable for forming different types of ceramic products of different thicknesses, said known compacting devices offer the possibility of adjusting the mutual distance between the pressing rollers, usually by adjusting the height of the upper pressing roller. Such a movement of the upper pressing roller, in particular when it is used to reduce its distance from the lower pressing roller, inevitably leads to a movement of the pressing belt forming the upper compacting surface, which inevitably renders the upper auxiliary roller (when present) completely ineffective, at least in some operating configurations.

[0017] This results in an unavoidable kinking (bending) of the upper compacting belt, at least in these operating configurations, with all the above-mentioned risks associated therewith.

[0018] The utility model aims to provide a compacting device for compacting a ceramic powder material layer, which at least partially solves the problems caused by the devices in the prior art. Utility Model Content

[0019] According to the utility model, a compacting device for compacting a powder material layer is provided, wherein the powder material layer contains ceramic powder; the compacting device comprises: a conveying surface, which is configured to receive the powder material layer containing ceramic powder and make the powder material layer advance in a forward direction; an upper belt-type compacting element, which in turn comprises a plurality of rollers and an upper pressing belt, wherein each of the plurality of rollers has a corresponding rotation axis perpendicular to the forward direction, the upper pressing belt is wound around the plurality of rollers to define an upper compacting surface through its lower branch, the upper compacting surface basically faces the conveying surface and can move along the forward direction; a lower pressing roller, which has a rotation axis perpendicular to the forward direction, the lower pressing roller is arranged below the conveying surface and cooperates with the conveying surface; an upper pressing belt A roller, which is parallel to the lower pressing roller and placed above the lower pressing roller, and cooperates with the upper compacting surface to press the upper compacting surface toward the conveying surface at a predetermined compacting area, thereby compacting the powder material layer; and an upper antagonistic element, which is arranged upstream of the upper pressing roller along the forward direction, and is configured to act on the inner side of the lower branch of the upper pressing belt in an invitation area, and the invitation area extends upstream of the predetermined compacting area along the forward direction; the compacting device includes a moving system, which is configured to move the upper antagonistic element along a translation direction having at least one component perpendicular to the conveying surface, so as to adjust the inclination of the upper compacting surface relative to the forward direction at least at the invitation area.

[0020] The following describes the preferred embodiments of the present invention and forms an integral part of the description.

[0021] The upper pressing roller is configured to press the upper compacting surface toward the conveying surface so that at the predetermined compacting area, a gap with a defined thickness is defined between the conveying surface and the upper compacting surface; the moving system is capable of operating according to the defined thickness of the gap so that the upper antagonistic element acts on the inner side of the upper pressing belt so as to at least partially offset the stress transmitted to the upper pressing belt by the powder material layer advancing at the gap during use.

[0022] The movement system is configured to move the upper antagonistic element to a height that causes the upper compacting surface to form an angle in the invitation area relative to the advancement direction ranging from 0° to 15°.

[0023] The upper antagonistic element extends perpendicularly to the advancing direction and the translational direction so as to act on the inner side of the lower branch of the upper pressure belt, and the movement system comprises at least one actuator configured to move the upper antagonistic element along the translational direction.

[0024] The compacting device includes a frame for carrying the conveying surface and the upper belt compacting element; the moving system includes: a fixed support structure connected to the frame; a bracket connected to the fixed support structure in a sliding manner, the bracket carrying the upper counter element at its lower end; and a drive assembly operably inserted between the fixed support structure and the bracket, the drive assembly being configured to move the bracket relative to the fixed support structure along the translation direction.

[0025] The drive assembly includes: at least one actuator carried by the fixed support structure; and at least one articulated joint operably interposed between the actuator and the bracket.

[0026] The fixed support structure comprises two parallel side guides extending along the translation direction and arranged on opposite sides of the fixed support structure; and the frame comprises two tracks configured to receive the guides in a sliding manner so as to guide the movement of the bracket in use.

[0027] The upper counter element comprises an auxiliary roller, the rotation axis of which is perpendicular to the advancing direction.

[0028] The compaction device includes an additional lower belt compaction element, which in turn includes an additional plurality of rollers and an additional lower pressure belt, wherein the additional plurality of rollers each have a corresponding rotation axis perpendicular to the forward direction, and the additional lower pressure belt is wound around the additional plurality of rollers to define an additional lower compaction surface through its upper branches, the additional compaction surface basically faces the conveying surface and is in direct contact with the conveying surface, and can move along the forward direction; the additional lower compaction surface coincides with the conveying surface.

[0029] The compacting device includes an additional lower antagonistic element, which is arranged upstream of the lower pressure roller and cooperates with the additional lower pressure belt to support the additional lower compacting surface, thereby keeping the additional lower compacting surface basically parallel to the forward direction; the additional lower antagonistic element includes an additional auxiliary roller, the rotation axis of the additional auxiliary roller is perpendicular to the forward direction and basically parallel to the rotation axis of the lower pressure roller. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will now be described with reference to the accompanying drawings, which show some non-limiting embodiments of the present invention, in which:

[0031] - Figure 1 is a side view of a compaction device according to an embodiment of the present utility model;

[0032] - Figure 2 Shown along Figure 1 A vertical cross-sectional view of section II-II of the compacting device;

[0033] - Figure 2A is included in Figure 2 An enlarged scale view of the portion in the frame indicated by W in FIG.

[0034] - Figure 3 Shown along Figure 1 A cross-sectional view of the device taken along section III-III;

[0035] - Figure 3A and Figure 3B They are Figure 3 An enlarged scale view of the portion contained in the frame indicated by TA and TB;

[0036] - Figure 4 yes Figure 1 A side view of a compacting device in different operating configurations, wherein the compacting device can be used to produce ceramic products with greater thickness;

[0037] - Figure 5 Shown along Figure 4 A vertical cross-sectional view of the section VV of the compacting device;

[0038] - Figure 5A is an enlarged scale view of the portion of the device contained in the frame indicated by Z;

[0039] - Figure 6 According to the implementation of the utility model Figure 1 and Figure 4 A perspective view of a portion of a compacting device;

[0040] - Figure 7 is a schematic side view of a part of a known compacting device, which shows: an upper belt-type compacting element, a conveying surface on which a layer of powder material advances and - indicated by dashed lines - a possible deformation of the upper pressing belt after the layer of powder material has been fed in the compacting region;

[0041] - Figure 8 is a schematic side view of a part of a compacting device according to a first embodiment of the invention, schematically showing: an upper belt-type compacting element, a conveying surface on which a layer of powder material advances, and an upper antagonistic element in the form of a pre-pressing roller, which acts on the upper pressing belt to avoid or at least limit its deformation;

[0042] - Fig. 8A is a schematic side view of a portion of a compacting device according to a second embodiment of the invention, schematically showing: an upper belt-type compacting element, a conveying surface on which a layer of powder material advances, and an upper antagonistic element in the form of a pad with a curved contact surface, which acts on the upper pressing belt to avoid or at least limit its deformation;

[0043] - Figure 8B is a schematic side view of a portion of a compacting device according to another embodiment of the present invention, schematically showing: an upper belt-type compacting element, a conveying surface on which a layer of powder material advances, and an upper antagonistic element in the form of a pad with a substantially flat contact surface, which acts on the upper pressing belt to avoid or at least limit its deformation; and

[0044] - Figure 8C It is a schematic side view of a part of a compacting device according to another embodiment of the utility model, which schematically shows: an upper belt compacting element, a conveying surface on which a layer of powder material advances, and an upper antagonistic element composed of a series of rollers, which acts on the upper pressing belt to avoid or at least limit its deformation. DETAILED DESCRIPTION

[0045] In the drawings, reference numeral 1 generally denotes a compacting device for compacting a powder material; the powder material is particularly a powder material comprising ceramic powder; more particularly, a layer 2 of a powder material comprising ceramic powder (in Figure 7and Figure 8 Schematically shown in FIG.

[0046] The compacting device 1 can advantageously be used in a plant for manufacturing tiles or ceramic slabs (not shown in the drawings and of a known type).

[0047] It should be noted that in this specification, the terms "upper", "lower", "side", "right", "left" or "height" are used with reference to a device placed on a horizontal plane (e.g. placed on the ground or floor, for example). Figure 1 and Figure 4 The present invention relates to a compacting device 1 (shown in the figure), thus, for example, the terms "on top" or "on bottom" respectively mean "above" or "below", i.e. "further away" or "closer to" the horizontal plane, relative to another component of the compacting device 1 when the compacting device 1 is placed on the floor or on the ground, and therefore "further away" or "closer to" the floor or ground on which the compacting device 1 is placed. Similarly, "inside" and "outside" refer to the "inside" and "outside" of the compacting device 1. In addition, for the purposes of the present invention, the term "second" component does not mean the existence of a "first" component. In fact, these terms are merely used as labels to improve clarity and should not be interpreted in a restrictive manner.

[0048] In particular, with reference to the accompanying drawings, the compacting device 1 advantageously includes: a frame 3; a conveying surface 4, which is advantageously but not restrictively carried by the frame 3 and is configured to receive a powder material layer 2 containing ceramic powder and advance it in the forward direction A; and an upper belt compacting element 5, which is advantageously but not restrictively carried by the frame 3 and includes a plurality of rollers 6a, 6b with horizontal axes (that is, each of these rollers has a corresponding horizontal rotation axis perpendicular to the forward direction A) and an upper pressure belt 7, in which there is (in particular, including) at least one powered roller and pulley, and the upper pressure belt 7 is wound around the plurality of rollers 6a, 6b to define an upper compacting surface 8 through its lower branch, and the upper compacting surface 8 basically faces the conveying surface 4 and can move along the forward direction A.

[0049] With particular reference to the accompanying drawings, the conveying surface 4 is configured to receive a powder material layer 2 containing ceramic powder and advance it in a forward direction A from a feed station (not visible in the accompanying drawings) through at least one predetermined compaction area 11 for compacting the powder material layer 2 and an invitation area 12 immediately upstream of the predetermined compaction area 11 to an output station 9, in which, as the conveying surface 4 advances in the forward direction, powder material containing ceramic powder (in particular, a measured amount of powder material) is fed onto the conveying surface 4 to form a powder material layer 2 containing ceramic powder, and in the output station 9, a continuous strip 10 of compacted ceramic powder material (in particular, a measured amount of powder material) is fed to the conveying surface 4 to form a powder material layer 2 containing ceramic powder. Figure 7 , Figure 8 , Fig. 8A , Figure 8B and Figure 8C ) is released from the compacting device 1 , advantageously but not limitingly towards a further processing station (not shown and of a known type).

[0050] In addition, the compacting device 1 advantageously includes: a lower pressing roller 13 having a horizontal rotation axis (i.e., perpendicular to the advancing direction A and parallel to the conveying surface 4) and being located below the conveying surface 4; and an upper pressing roller 14, which is parallel to the lower pressing roller 13 and is located above the lower pressing roller 13, and cooperates with the upper compacting surface 8 (in particular, with the pressing belt 7 forming the compacting surface 8) to press the upper compacting surface 8 toward the conveying surface 4 at a predetermined compacting area 11, thereby compacting the powder material layer 2 and forming the aforementioned continuous compacted ceramic powder material strip 10.

[0051] Advantageously, but not limitingly, in use, the lower pressing roller 13 and the upper pressing roller 14 are configured to keep the upper compacting surface 8 locally pressed towards the conveying surface 4, thereby compressing the layer of powder material 2 interposed therebetween.

[0052] More advantageously, but not limitingly, the upper pressing roller 14 is configured to press the upper compacting surface 8 toward the conveying surface 4 so that a gap of defined thickness is maintained therebetween at the predetermined compacting area 11 to form the aforementioned continuous strip 10 of compacted ceramic powder material.

[0053] It should be noted that the "thickness of the gap" refers to the extension of the gap perpendicular to the surface defining the gap, in this specific case, the distance between the upper compacting surface 8 and the conveying surface 4 (or, if applicable, as explained in more detail below, the lower compacting surface 16) at the predetermined compaction area 11. In other words, the "defined thickness" refers to the extension (i.e. the size) of the gap in the vertical direction (i.e. perpendicular to the conveying surface 4) (see Figure 2A and Figure 5A ).

[0054] According to some advantageous but non-limiting embodiments, such as those shown in the attached drawings, the compacting device 1 comprises a further lower belt compacting element 17, which in turn comprises a further plurality of rollers 18 with horizontal axes, and a further lower pressure belt 19, among which there is (in particular, comprises) at least one powered roller and one or more idle rollers (not visible in the attached drawings), said further lower pressure belt 19 being wound around said plurality of rollers 18 and being configured to define, by its upper branch, a further lower compacting surface 20 situated below the conveying surface 4. More advantageously, but non-limitingly, the lower compacting surface 20 is in direct contact with the conveying surface 4.

[0055] Advantageously, but not limitingly, the lower compacting surface 20 is advantageously operated by the above-mentioned powered rollers so as to slide in the same direction of advancement A as the conveying surface 4 and at substantially the same speed as the conveying surface 4 , so as to avoid relative scratching.

[0056] According to some advantageous but non-limiting embodiments, for example Figure 2 , Figure 5 , Figure 7 and Figure 8 In the embodiment shown, the lower compacting surface 20 coincides with the conveying surface 4 ; in more detail, advantageously but not limitingly, the lower compacting surface 20 defines at least a portion of the conveying surface 4 .

[0057] In this case (i.e. when the compacting device 1 comprises an additional lower belt compacting element 17), advantageously but not restrictively, in the predetermined compacting area 11, the upper pressing roller 14 is configured to press the upper compacting surface 8 towards the lower compacting surface 20, which is held in place by the upper pressing roller 14.

[0058] Advantageously but not limitingly, the upper pressing belt 7 comprises a metal material (particularly, is made of a metal material), such as steel. Alternatively or in combination, advantageously but not limitingly, the upper pressing belt 7 comprises a plastic material (particularly, is made of a plastic material).

[0059] Similar to the upper pressing belt 7 , the lower pressing belt 19 is also advantageously but not restrictively made of a metal material, such as steel, or of a plastic material or a combination thereof, such as a composite material including a metal material and a plastic material, when applicable.

[0060] In use, advantageously but not restrictively, the powder material layer 2 is advanced in a continuous manner via the conveying surface 4 through a predetermined compaction area 11, in which the powder material layer 2 is compacted as it advances along the advancing direction A due to the action of the lower pressing roller 13 and the upper pressing roller 14.

[0061] Advantageously, but not limitingly, the lower pressing roller 13 and the upper pressing roller 14 can be moved relative to each other to change the extension (in particular, thickness) of the gap defined between the upper compacting surface 8 and the conveying surface 4 or between the upper compacting surface 8 and the lower compacting surface 20 (when applicable) at the predetermined compacting area 11, so as to compact the powder material layer 2 advancing between them in use. More specifically, the lower pressing roller 13 and the upper pressing roller 14 can be moved relative to each other to bring the conveying surface 4 (more specifically, the lower compacting surface 20) and the upper compacting surface 8 closer to each other.

[0062] According to some advantageous but non-limiting embodiments, such as the one shown in the accompanying drawings, the lower pressing roller 13 is fixed, while the upper pressing roller 14 is connected to at least one jack (not visible in the accompanying drawings) or another movable system, which can change the height of the upper pressing roller 14, i.e. the distance from the lower pressing roller, for example according to the thickness of the powder material layer 2 to be compacted and / or the compaction pressure applied to the powder material layer 2.

[0063] According to some advantageous but non-limiting embodiments, for example, as shown in the embodiment shown in the accompanying drawings, the upper pressure roller 14 is inserted between the power roller and the idler wheel, and is in contact with the upper pressure belt 7 (in particular, in contact with the inner surface of the upper pressure belt 7). More advantageously, but not limitingly, in this case, the upper pressure roller 14 coincides with one of the multiple rollers 6a, 6b on which the upper pressure belt 7 is wound.

[0064] Similarly, advantageously but not limitingly, the lower pressing roller 13 is in direct contact with the conveying surface 4 .

[0065] When the above-mentioned additional lower belt compacting element 17 is provided, advantageously but not limitingly, the lower pressing roller 13 is in direct contact with the lower pressing belt 19. More advantageously but not limitingly, the lower pressing roller 13 coincides with one of the multiple rollers 18 of the lower belt compacting element 17 (in particular, one of the multiple rollers 18 of the lower belt compacting element 17).

[0066] Furthermore, the compacting device 1 advantageously comprises an upper antagonistic element 21 (i.e., a guiding element) which is arranged upstream of the upper pressing roller 14 along the advancing direction A and is configured to act on the inner side of the lower branch of the upper pressing belt 7 within the scope of the aforementioned invitation area 12 so as to limit the deformation to which the upper pressing belt 7 is subjected when feeding the powder material layer 2 within the scope of the invitation area when in use (see Figure 2 , Figure 2A , Figure 5 , Figure 5A , Figure 6 , Figure 8 , Fig. 8A , Figure 8B and Figure 8C ).

[0067] Advantageously, but not limitingly, said upper counteracting element 21 is arranged along the advancement direction A at a distance from the upper pressing roller 14 of at most about 1500 mm.

[0068] According to some advantageous but non-limiting embodiments, for example, Figure 2 , Figure 2A , Figure 5 , Figure 5A , Figure 6 and Figure 8As in the embodiment shown, the upper counter element 21 comprises (in particular consists of) an auxiliary roller having a horizontal axis of rotation perpendicular to the advancement direction A. Advantageously, but not limitingly, the diameter of the auxiliary roller ranges from about 50 mm to about 300 mm; more advantageously it is equal to about 150 mm.

[0069] Alternatively or in combination, according to other advantageous but non-limiting embodiments, for example, Figure 8C As in the embodiment shown, the upper antagonistic element 21 comprises (in particular, consists of) a series of auxiliary rollers, in the example shown here four auxiliary rollers, each having a horizontal axis of rotation perpendicular to the advancing direction and a diameter ranging from about 50 mm to about 300 mm; more advantageously, a diameter of about 100 mm. Advantageously, one or more rollers are used as the upper antagonistic element 21 (such as Figures 1 to 8 and Figure 8C The embodiment shown in the figure allows acting on the upper pressure belt 7 by rolling, thereby eliminating or at any rate minimizing possible scratches at the contact points between the upper antagonistic element 21 and the upper pressure belt 7, which has obvious advantages in terms of wear of the belt 7 and therefore in terms of the life of the upper pressure belt 7.

[0070] According to other advantageous but non-limiting embodiments, for example, Fig. 8A and Figure 8B As in the embodiment shown, the upper antagonistic element 21 comprises (in particular consists of) a suitably shaped pad, for example a rubber pad, which extends transversely to the conveying surface 4 and perpendicularly to the advancement direction A in a plane substantially parallel to the conveying surface 4 and is configured to act on the inner side of the press belt 7 in order to limit its deformation as much as possible. With particular reference to Fig. 8A According to some advantageous but non-limiting embodiments, the pad has a rounded contact surface to limit scratching when acting on the upper pressing belt 7. According to other non-limiting variants, for example, like Figure 8B As in the variant shown, the pad has a substantially flat contact surface.

[0071] According to another advantageous but non-limiting embodiment not shown herein, the upper antagonistic element 21 includes an antagonistic plate (in particular, consists of the antagonistic plate) extending above the conveying surface 4 perpendicular to the advancing direction A, or includes a profile of appropriate shape (for example, made of rubber) or a guide (in particular, consists of the profile or the guide), which extends transversely to the conveying surface 4 and perpendicular to the advancing direction A in a plane substantially parallel to the conveying surface 4, and is configured to act on the inner side of the press belt 7 so as to limit its deformation as much as possible.

[0072] More advantageously, the compacting device 1 comprises a movement system 22 configured to move the upper antagonistic element 21 along a translation direction B having at least one component perpendicular to the conveying surface 4 in order to adjust (at least partially) at least in said invitation zone 12 the inclination of the upper compacting surface 8 relative to the advancement direction A (see, for example, Figure 2 , Figure 2A , Figure 5 , Figure 5A , Figure 6 , Figure 8 , Fig. 8A , Figure 8B and Figure 8C ).

[0073] More advantageously but not restrictively, the moving system 22 can be operated to adjust the position (in particular, at least the height) of the upper antagonistic element 21 according to the defined thickness of the gap to ensure that the upper antagonistic element 21 acts on the inner side of the upper pressing belt 7, thereby at least partially offsetting the stress transmitted to the outer side of the upper pressing belt 7 by the powder material layer S advancing within the range of the gap during use.

[0074] According to some advantageous but non-limiting embodiments, for example, Figure 6 As in the illustrated embodiment, the moving system 22 is configured to move the upper antagonistic element 21 to a height (particularly, a distance from the conveying surface 4) that causes the upper compacting surface 8 to form a given angle α in the invitation area 12 relative to the advancing direction A (i.e., relative to the conveying surface 4) in a range from about 0° to about 15° (particularly, from about 4° to about 6°).

[0075] In fact, experiments have shown that the inclination angle α (in the range from about 0° to about 15°; in particular, from about 4° to about 6°) is an ideal angle to ensure the correct feeding of the ceramic powder material layer 2 within the gap and between the lower pressing roller 13 and the upper pressing roller 14, avoiding the risk of undesired accumulation of powder material upstream of the gap, which is due to the inclination angle in the event of deformation of the press belt 7 (see Figure 7The angle α1 is the angle formed by the excessive reduction of the angle formed by the compacting surface 8 with the advancing direction A as the pressing belt 7 is deformed and the angle α is the ideal angle for facilitating the exhaust of air (or at least the exhaust of most of the air). Before the ceramic powder material layer 2 is fed between the lower pressing roller 13 and the upper pressing roller 14, in the case where the extension of the invitation area 12 is insufficient (that is, in the case where the compacting surface 8 forms an insufficient angle with the advancing direction A, especially an angle less than the above-defined angle α), air may be trapped in the ceramic powder material layer 2. More advantageously, but not restrictively, the upper antagonistic element 21 extends perpendicularly to the advancing direction A and the translation direction B so as to act on the inner side of the lower branch of the pressing belt 7, and the moving system 22 includes at least one actuator 26, which is configured to move the upper antagonistic element 21 along the translation direction B.

[0076] According to some advantageous but non-limiting embodiments, for example, Figure 6 As in the embodiment shown, the mobile system 22 comprises: a fixed support structure 23 connected to the frame 3; a bracket 24 connected to the fixed support structure 23 in a sliding manner, the bracket 24 carrying the upper antagonistic element 21 at its lower end (in particular, Figures 1 to 8 In the embodiment of the invention, the auxiliary roller of the upper antagonistic element 21 is defined; or respectively in Fig. 8A and Figure 8B In the embodiment of the invention, the curved or flat contact surface of the pad of the upper antagonistic element 21 is defined; or in Figure 8C In an embodiment of the present invention, a series of auxiliary rollers are defined on the upper antagonistic element 21. The moving system 22 also includes a drive assembly 25, which is operably interposed between the fixed support structure 23 and the bracket 24 and is configured to move the bracket 24 relative to the fixed support structure 23 along the aforementioned translation direction B. More advantageously, but not limitingly, the moving system 22 is configured to allow movement (i.e., translation) along the translation direction B with an extension in the range from about 5 mm to about 200 mm.

[0077] More advantageously, but not limitingly, said drive assembly 25 comprises at least one actuator 26 carried by the fixed support structure 23; and at least one articulated joint 27 operatively interposed between the actuator 26 and the support 24. The presence of said articulated joint 27 advantageously increases the degree of freedom of the mobile system, thereby effectively compensating all the movements (however small) to which the fixed support structure 23 is subjected during use, for example due to vibrations transmitted during use by the remaining components.

[0078] According to some advantageous but non-limiting embodiments, for example, like the embodiment shown in the attached drawings, the fixed support structure 23 comprises a beam (in particular, consists of a beam), and the movement system 22 comprises a pair of actuators 26 and a pair of articulated joints 27, one at each lateral end of the fixed support structure 23, each articulated joint 27 being interposed between one of the two actuators 26 and a lateral end of the support 24. This configuration advantageously improves stability and allows the use of small-sized components to correctly move the support 24.

[0079] Advantageously but not limitingly, the actuator 26 (i.e. each of them) is of hydraulic type. More advantageously but not limitingly, (i.e. each) actuator 26 is in fluid communication with an operating assembly (not shown and of known type) comprising a tank from which the actuator 26 draws oil and a pump for pressurizing said oil, said oil being fed to the actuator 26 through a suitable delivery conduit.

[0080] It should be noted that, according to other advantageous but non-limiting embodiments, the actuator 26 (ie each of the actuators 26 ) is of the electric or hydraulic or pneumatic type.

[0081] Advantageously but not limitingly, the compacting device 1 also comprises an electronic control unit CU (in Figure 8 ), the electronic control unit is configured (i.e. programmed) to control the operation of the moving system 22, for example, in the case shown herein, to control the operation of the actuator 26, more advantageously but not restrictively, based on the thickness of the powder material layer 2 containing ceramic powder and / or the thickness of the gap to ensure that the upper antagonistic element 21 is tangential to the upper pressing belt 7 and opposes deformation of the upper pressing belt even if the operating configuration of the compacting device 1 is changed.

[0082] According to some advantageous but non-limiting embodiments, for example, like the one shown in the attached drawings, the above-mentioned fixed support structure 23 comprises two parallel lateral guides 28 extending along the above-mentioned translation direction B and arranged at the two lateral ends of the fixed support structure 23; the frame 3 comprises two corresponding rails 29 configured to receive the guides 28 in a sliding manner so as to guide (i.e., limit) the movement of the bracket 24 in use. In other words, the guides ensure the correct movement of the upper antagonistic element 21.

[0083] More advantageously, but not limitingly, the guide 28 and the track 29 extend parallel to (ie along) the translation direction B mentioned above.

[0084] According to some advantageous but non-limiting embodiments not shown herein, when the above-mentioned additional lower belt-type compacting element 17 is present, the compacting device 1 also comprises an additional lower antagonistic element (not visible in the attached drawings) arranged upstream of the lower pressing roller 13 and configured to cooperate with the lower pressing belt 19 to support the lower compacting surface so as to keep said additional lower compacting surface 20 substantially parallel to said advancement direction A. In other words, advantageously but not limitingly, in this case, said additional lower antagonistic element is located at a height such that the lower compacting surface 20 (when applicable) or - more generally - the conveying surface 4 remains plane. More advantageously but not limitingly, when applicable, said additional lower antagonistic element comprises (in particular consists of) an additional fixed roller (not visible in the attached drawings) having a horizontal axis of rotation parallel to the lower pressing roller 13.

[0085] Furthermore, according to some advantageous but non-limiting embodiments, the compacting device 1 also comprises an expansion antagonist plate 30 , arranged downstream of the predetermined compacting zone 11 along the advancement direction A and configured to maintain the planar nature of the conveying surface 4 .

[0086] The compacting device 1 of the present invention provides numerous advantages, among which the following are to be mentioned.

[0087] Due to the presence of the moving system 22 of the upper antagonistic element 21, the compacting device 1 of the utility model allows the position of the upper antagonistic element 21 to be precisely and accurately adjusted, especially in the vertical direction, to ensure that regardless of the operating configuration of the compacting device 1, that is, regardless of the thickness of the product to be processed by the compacting device 1, the upper antagonistic element 21 adheres to the upper pressing roller 14, thereby minimizing the risk of deformation (especially bending) of the upper pressing belt 7, thereby reducing the risk of forming irregularities when feeding the powder material layer 2 in the compacting area 11, and ensuring that the angle α formed by the lower compacting surface and the conveying surface is always maintained between 0° and 15°; more particularly, between 4° and 6°.

[0088] Furthermore, the possibility of moving the upper antagonistic element 21 in the vertical direction also facilitates the operation of replacing the upper press belt 7. In fact, during the operation of removing the press belt 7 to be replaced, the possibility of lifting the upper antagonistic element allows to loosen the belt in a faster and more efficient way.

Claims

1. A compacting device for compacting a powder material layer, wherein the powder material layer comprises ceramic powder; the compacting device comprises: a conveying surface configured to receive the layer of powder material comprising ceramic powder and to advance the layer of powder material in an advancing direction; an upper belt compacting element, which in turn comprises a plurality of rollers and an upper pressing belt, each of the plurality of rollers having a respective rotation axis perpendicular to the advancing direction, the upper pressing belt being wound around the plurality of rollers to define, by its lower branch, an upper compacting surface, the upper compacting surface substantially facing the conveying surface and being movable along the advancing direction; a lower pressing roller having a rotation axis perpendicular to the advancing direction, the lower pressing roller being arranged below the conveying surface and cooperating with the conveying surface; an upper pressing roller, which is parallel to and placed above the lower pressing roller and cooperates with the upper compacting surface to press the upper compacting surface toward the conveying surface at a predetermined compacting area, thereby compacting the powder material layer; as well as an upper antagonistic element, which is arranged upstream of the upper pressing roller along the advancement direction and is configured to act on the inner side of the lower branch of the upper pressing belt in an invitation area, which extends upstream of the predetermined compaction area along the advancement direction; Characterized in that the compacting device comprises a movement system configured to move the upper antagonistic element along a translation direction having at least one component perpendicular to the conveying surface so as to adjust the inclination of the upper compacting surface relative to the advancement direction at least in the invitation area.

2. The compacting device according to claim 1, characterized in that: the upper pressing roller being configured to press the upper compacting surface toward the conveying surface so that a gap having a defined thickness is defined between the conveying surface and the upper compacting surface at the predetermined compacting area; The movement system is operable according to the defined thickness of the gap so that the upper antagonistic element acts on the inner side of the upper press belt to at least partially offset the stress transmitted to the upper press belt by the layer of powder material advancing at the gap during use.

3. The compacting device according to claim 1, characterized in that: The movement system is configured to move the upper antagonistic element to a height that causes the upper compacting surface to form an angle in the invitation area relative to the advancement direction ranging from 0° to 15°.

4. The compacting device according to any one of claims 1 to 3, characterized in that: The upper antagonistic element extends perpendicularly to the advancing direction and the translational direction so as to act on the inner side of the lower branch of the upper pressure belt, and the movement system comprises at least one actuator configured to move the upper antagonistic element along the translational direction.

5. The compacting device according to claim 1, characterized in that: including a frame for carrying the conveying surface and the upper belt compacting element; The moving system includes: a fixed support structure connected to the frame; a bracket connected to the fixed support structure in a sliding manner, the bracket carrying the upper counter element at its lower end; and a drive assembly operably inserted between the fixed support structure and the bracket, the drive assembly being configured to move the bracket relative to the fixed support structure along the translation direction.

6. The compacting device according to claim 5, characterized in that The drive assembly includes: at least one actuator carried by the fixed support structure; and at least one articulated joint operably interposed between the actuator and the bracket.

7. The compacting device according to claim 5, characterized in that: The fixed support structure comprises two parallel side guides extending along the translation direction and arranged on opposite sides of the fixed support structure; and the frame comprises two tracks configured to receive the guides in a sliding manner so as to guide the movement of the bracket in use.

8. The compacting device according to claim 1, 2, 3 or 5, characterized in that: The upper counter element comprises an auxiliary roller, the rotation axis of which is perpendicular to the advancing direction.

9. The compacting device according to claim 1, 2, 3 or 5, characterized in that: comprising an additional lower belt compacting element, the additional lower belt compacting element in turn comprising an additional plurality of rollers and an additional lower pressing belt, the additional plurality of rollers each having a respective rotation axis perpendicular to the advancing direction, the additional lower pressing belt being wound around the additional plurality of rollers to define an additional lower compacting surface by its upper branch, the additional compacting surface substantially facing the conveying surface and in direct contact with the conveying surface and being movable along the advancing direction; The further lower compacting surface coincides with the conveying surface.

10. The compacting device according to claim 9, characterized in that comprising a further lower antagonistic element disposed upstream of the lower pressing roller and cooperating with the further lower pressing belt to support the further lower compacting surface so as to keep the further lower compacting surface substantially parallel to the advancing direction; The further lower counter element comprises a further auxiliary roller, the rotation axis of which is perpendicular to the advancement direction and substantially parallel to the rotation axis of the lower pressing roller.

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