Appliance and process for forming ceramic manufactured articles

Abstract

Appliance (1) and method for forming ceramic manufactured articles, the appliance (1) comprising: - a conveyor surface (2) adapted to convey raw ceramic material (M) in the form of powder along a direction of forward movement (A); - pressing means (3) arranged along the conveyor surface (2) and configured to press the ceramic material (M) so as to form a compacted ceramic manufactured article; - de-aeration means (6) arranged upstream of the pressing means (3) with respect to the direction of forward movement (A) and adapted to interact with the ceramic material (M) to remove at least part of the air retained in the ceramic material (M); wherein the de-aeration means (6) are movable along a direction (Y) with respect to the conveyor surface (2) and configured to be displaced along this direction (Y) to remove the air retained in the ceramic material (M) when the conveyor surface (2) is stationary.

Description

[0001] APPLIANCE AND PROCESS FOR FORMING CERAMIC

[0002] MANUFACTURED ARTICLES

[0003] Technical Field

[0004] The present invention relates to an appliance and process for forming ceramic manufactured articles. Art

[0005] With particular reference to the ceramics industry, several machines are known to be used for forming ceramic manufactured articles of the type, e.g. of tiles or slabs.

[0006] Among the various types, a special category of machines is specifically built to carry out the technological forming process known as “dry compaction”.

[0007] Specifically, this production technique involves pressing the raw ceramic powder material (in jargon “soft”) with a certain force so as to give it cohesion and mechanical strength, causing it to take on a predetermined geometry.

[0008] To implement this process, the aforementioned appliances comprise one or more conveyor belts, on which the ceramic powder material is moved, and a press, located where a respective stretch of the conveyor belt is located, adapted to compact the ceramic material transported on the belt.

[0009] Known appliances suffer, however, from an important limitation related to their low production efficiency.

[0010] In fact, to date, such appliances impose rather prolonged work schedules for forming the ceramic manufactured articles, which negatively affect the performance of the appliance itself.

[0011] In light of this, the need is particularly felt to date to improve dry production techniques of the ceramic manufactured articles, thus reducing the time required for the same and thereby increasing the overall production output.

[0012] Description of the Invention

[0013] The main aim of the present invention is to devise an appliance for forming ceramic manufactured articles which allows reducing the time required for compacting the ceramic material to obtain ceramic manufactured articles.

[0014] Within the aforementioned main aim, one object of the present invention is to devise an appliance for forming ceramic manufactured articles which is very versatile in its use and adaptable to a plurality of different operating cases.

[0015] Another object of the present invention is to devise an appliance for forming ceramic manufactured articles which can overcome the aforementioned drawbacks of the prior art within the framework of a simple, rational, easy and efficient to use as well as cost-effective solution.

[0016] The aforementioned objects are achieved by this appliance for forming ceramic manufactured articles having the characteristics of claim 1.

[0017] Brief Description of the Drawings

[0018] Other characteristics and advantages of the present invention will become more apparent from the description of a preferred, but not exclusive, embodiment of an appliance for forming ceramic manufactured articles, illustrated by way of an indicative, yet non-limiting example in the attached tables of drawings in which: Figure 1 is an axonometric, overall view of the appliance according to the invention;

[0019] Figure 2 is a cross sectional view of the detail of the de-aeration device in a first embodiment;

[0020] Figure 3 is a cross sectional view of the detail of the de-aeration device in a second embodiment.

[0021] Embodiments of the Invention

[0022] With particular reference to these figures, reference numeral 1 globally denotes an appliance for forming ceramic manufactured articles.

[0023] The appliance 1 for forming ceramic manufactured articles comprises, first of all: at least one conveyor surface 2 adapted to convey the raw ceramic material M in the form of powder along a direction of forward movement A; pressing means 3 arranged along the conveyor surface 2 and configured to press the ceramic material M so as to form at least one ceramic manufactured article.

[0024] Specifically, the conveyor surface 2 is movable along the direction of forward movement A.

[0025] As for the pressing means 3, they comprise at least one press positioned where a respective stretch of the conveyor surface 2 is located and adapted to exert a predetermined force on the ceramic material M so as to impart cohesion and mechanical strength to the latter.

[0026] The press is preferably of the type of a pad press, but different types of the same known to the branch technician cannot be ruled out.

[0027] The appliance 1 then comprises a base frame 4 for resting on the ground (see, in this regard, Figure 1).

[0028] In this case, the conveyor surface 2 is associated with the base frame 4 and supported by weight by the latter.

[0029] Preferably, the appliance 1 comprises dispensing means 5 of the raw ceramic material M, e.g. of the type of a loading hopper, positioned upstream of the pressing means 3 with respect to the direction of forward movement A and adapted to dispense the ceramic material M onto the conveyor surface 2. In more detail, the dispensing means 5 are adapted to discontinuously release a predetermined amount of ceramic material M onto the conveyor surface 2 so as to form a “bed” of ceramic material M having predetermined dimensions. In other words, each bed of ceramic material M released on the conveyor surface 2 is spaced apart from the bed before it and from the bed after it.

[0030] The ceramic material M deposited by the loading hopper 5 on the conveyor surface 2 is, therefore, transported along the direction of forward movement A towards the pressing means 3 so as to be compacted by the latter to obtain the compacted ceramic manufactured article.

[0031] In this regard, the appliance 1 comprises de-aeration means 6 arranged upstream of the pressing means 3 with respect to the direction of forward movement A and adapted to interact with the ceramic material M to remove at least part of the air retained within it (between its interstices).

[0032] According to the invention, the de-aeration means 6 are movable by shift along a direction of movement Y with respect to the conveyor surface 2. Specifically, the de-aeration means 6 displace along the direction of movement Y to remove the air retained in the ceramic material M when the conveyor surface 2 is stationary. The de-aeration means 6 pass over the ceramic material M, interacting with it over its entire extension, so as to progressively remove the air contained within it.

[0033] Conveniently, the appliance 1 comprises movement means 8 associated with the de-aeration means 6 and adapted to move the latter with respect to the conveyor surface 2 along the direction of movement Y.

[0034] Specifically, the movement means 8 are adapted to move by alternating motion the de-aeration means 6 along the direction of movement Y.

[0035] In accordance with the preferred embodiment shown in the figures, the direction of movement Y is substantially parallel to the direction of forward movement A. For this purpose, the movement means 8 conveniently comprise: at least one sliding rail 8a extending along the direction of movement Y ; and at least one movable body 8b associated with the de-aeration means 6 and coupled to the sliding rail 8a in a sliding maimer along the direction of movement Y.

[0036] Specifically, the sliding rail 8a is formed on a respective crossbar of the base frame 4.

[0037] As visible in Figure 1, the movement means 8 preferably comprise: two sliding rails 8a and two movable bodies 8b, supporting the de-aeration means 6, each of which is associated with a respective sliding rail 8a.

[0038] The sliding rails 8a can be arranged either on top of the conveyor surface 2, as in Figure 1, or below it.

[0039] Advantageously, the appliance 1 comprises motor means, not visible in detail in the figures, operable to vary the speed of displacement of the de-aeration means 6 along the direction of movement Y, particularly during the phase of displacement in which they interact with the ceramic material M (the phase of de-aeration).

[0040] Depending on the speed of displacement of the de-aeration means 6, the amount of air removed from the bed of ceramic material M varies.

[0041] Preferably, the appliance 1 comprises a control and command unit operationally connected to the motor means and adapted to control the operation thereof to adjust the speed of shift of the de-aeration means 6.

[0042] Specifically, the de-aeration means 6 comprise at least one de-aeration device 6 arranged on top of the conveyor surface 2 and adapted to define, with the latter, at least one predetermined passageway gap 7 traversable by the ceramic material M.

[0043] As can be seen by observing Figure 2, the passage of the ceramic material M through the passageway gap 7 defined by the de-aeration device 6 results in the effect of compressing the ceramic material itself, compacting it and removing some of the air retained therein.

[0044] This special technical expedient proves to be crucial in increasing the efficiency of the appliance 1 over that of known appliances, thus remedying the drawbacks of the prior art complained of earlier.

[0045] In fact, the removal of the air retained in the ceramic material M by the deaeration means 6 reduces the resistance exerted by the ceramic material M to pressing, thus promoting the achievement of the ceramic manufactured article.

[0046] In this way, it is possible to reduce the time required to complete pressing and increase overall production output.

[0047] It should be noted, among other things, that such de-aeration means 6 allow for a preliminary compaction of the ceramic material M during the passage of the same through the passageway gap 7; this fact, operating synergistically with the air removal just discussed, allows for further reduction of the time required to obtain the ceramic manufactured article, thus increasing even more the production output of the appliance 1.

[0048] As visible in Figure 1, the passageway gap 7 extends transversely to the direction of forward movement A.

[0049] In this regard, the passageway gap 7 substantially extends over the entire transverse extension of the conveyor surface 2.

[0050] That said, different embodiments of the de-aeration means 6 cannot, however, be ruled out wherein the passageway gap 7 only partly covers the transverse extension of the conveyor surface 2.

[0051] In accordance with the preferred embodiment shown in the figures, the de- aeration device 6 comprises at least one revolving belt 16.

[0052] In particular, the revolving belt 16 is associated with the base frame 4 in a revolving maimer.

[0053] Specifically, the revolving belt 16 has a longitudinal development which is transverse to the direction of forward movement A.

[0054] In particular, the revolving belt 16 has a longitudinal development which is substantially perpendicular to the direction of forward movement A.

[0055] In the case where the direction of movement Y is transverse (e.g., orthogonal) to the direction of forward movement A, the revolving belt 16 is selected so as to show a longitudinal development which is substantially parallel to the direction of forward movement A and to be, thus, moved along the transverse extension of the conveyor surface 2.

[0056] Advantageously, the revolving belt 16 is provided with at least one lower section 16a which is movable along a respective direction of sliding S and adapted to contact the ceramic material M (see Figure 2).

[0057] Preferably, the direction of sliding S has a way concordant to the direction of movement Y.

[0058] In fact, thanks to this expedient, the revolving belt 16 promotes the passage of the ceramic material M through the passageway gap 7.

[0059] In all cases, the opposite possibility cannot however be ruled out, that is, wherein the direction of sliding S has opposite way to the direction of movement Y.

[0060] As visible in the figures, the revolving belt 16 defines a closed profile.

[0061] Advantageously, as shown in the embodiment of Figure 3, the de-aeration device 6 comprises at least one de-aeration element 17 of the rigid type, which is arranged internally to the revolving belt 16 and which interacts with the lower section 16a to contact the ceramic material M during the displacement of the deaeration device 6 along the direction of movement Y.

[0062] The de-aeration element 17, the portion of which interacts with the lower section 16a preferably has a slab-shaped conformation, then interacts with the lower section 16a by varying the lying plane thereof with respect to its home configuration, so as to increase the portion contacting the ceramic material M and to achieve gradual de-aeration.

[0063] Preferably, the inclination of the de-aeration element 17 with respect to the conveyor surface 2 is adjustable. By adjusting the inclination of the de-aeration element 17, its position is also varied with respect to the lower section 16a and, therefore, the extension of its portion interacting with the ceramic material M.

[0064] More specifically, the varying means 18, e.g. of the type of slots defined on the de-aeration element 17 are provided, operable to adjust the inclination of the deaeration element itself

[0065] Advantageously, the de-aeration element 17 is movable vertically with respect to the lower section 16a.

[0066] More particularly, positioning means 19 are provided, e.g. of the type of a threaded coupling, operable to vary the height of the de-aeration element 17 with respect to the lower section 16a. Again, by varying the height of the de-aeration element 17, its position is varied with respect to the lower section 16a and, therefore, the extension of its portion interacting with the ceramic material M. Conveniently, the appliance 1 comprises driving means 11, 12 of the revolving belt 16 comprising at least one motorized roller 11 around which the revolving belt 16 is at least partly wound.

[0067] Specifically, the motorized roller 11 is rotatable around a respective direction of rotation R.

[0068] In this regard, the motorized roller 11 is connected to a suitable motorization unit 60, given by way of example in Figure 1, which enables the rotation thereof around the direction of rotation R.

[0069] Again, the driving means 11, 12 comprise at least one supporting wheel 12, the revolving belt 16 being wound around the motorized roller 11 and around the supporting wheel 12 (see Figures 2 and 3).

[0070] In the embodiment of Figure 2, two supporting wheels 12 are provided, it is easy to appreciate, however, how the number of supporting wheels 12 may differ and be, e.g., even greater than two.

[0071] The supporting wheels 12 are preferably idle wheels, i.e. they are driven into rotation only as a result of the drag induced to them by the revolving belt 16. Specifically, the supporting wheels 12 are of the type of idler pulleys.

[0072] In the embodiment of Figure 3, the de-aeration element 17 is positioned between the motorized roller 11 and the supporting wheel 12 and is arranged where the lower section 16a is located.

[0073] Specifically, the revolving belt 16 is wound around the motorized roller 11 and around the supporting wheel 12 with enough tension to ensure the effective compaction of the ceramic material M transported along the conveyor surface 2. Conveniently, the appliance 1 comprises abutment means 10 arranged in a position opposite the revolving belt 16 with respect to the conveyor surface 2 and adapted to support the latter during the passage of the ceramic material M through the passageway gap 7.

[0074] In actual facts, the abutment means 10 define a mechanical stop that, by holding the conveyor surface 2, operates in conjunction with the de-aeration means 6 to enable effective compaction of the ceramic material M transported along the conveyor surface 2.

[0075] As visible in Figure 2, the abutment means 10 comprise at least one abutment roller 10 operable in rotation around a respective direction of drive W.

[0076] Preferably, the direction of drive W is opposite to the direction of rotation R of the motorized roller 11.

[0077] Advantageously, the appliance 1 comprises adjustment means 9 for adjusting the position of the de-aeration means 6 along a direction of adjustment Z which is transverse to the direction of forward movement A.

[0078] Preferably, the direction of adjustment Z is substantially orthogonal to the direction of forward movement A and, therefore, to the direction of movement Y. In the present case, the adjustment means 9 are adapted to vertically move the deaeration means 6 away from / close to the conveyor surface 2 so as to increase / decrease the size of the passageway gap 7.

[0079] By being able to vary the size of the passageway gap 7, the adjustment means 9 allow increasing and decreasing the compression exerted by the de-aeration means 6 onto the ceramic material M and, with it, the amount of air removed.

[0080] As visible in the enlarged view from Figure 1, the adjustment means 9 comprise a plurality of adjustment holes 9 cut on the movable body 8b and arranged along at least the direction of adjustment Z.

[0081] More precisely, the adjustment means 9 comprise a first plurality of adjustment holes 9 cut on one of the movable bodies 8b and a second plurality of adjustment holes 9 cut on the other of the movable bodies 8b.

[0082] It is, therefore, enough to fix the revolving belt 16 on the movable bodies 8b where specific adjustment holes 9 are located to vary the size of the passageway gap 7 and, consequently, the compressive force exerted on the ceramic material M in a completely easy and intuitive maimer.

[0083] In the embodiment of Figure 3, the de-aeration element 17 moves locked together with the driving means 11, 12 along the direction of adjustment Z.

[0084] The operation of the appliance in carrying out the process according to the invention is as follows.

[0085] The process according to the invention first involves the dispensing of a raw ceramic material M in the form of powder, which can be of one type or different types, on the conveyor surface 2.

[0086] Preferably, the phase of dispensing is carried out by discontinuously releasing a predetermined amount of ceramic material M onto the conveyor surface 2 so as to form a bed of ceramic material M having predetermined dimensions.

[0087] Then a phase of de-aeration of the ceramic material M is carried out.

[0088] According to the invention, the phase of de-aeration is carried out by moving the de-aeration means 6 along the direction of movement Y while keeping the conveyor surface 2 stationary.

[0089] The de-aeration device 6 then moves along the full extension of the bed of ceramic material M so dispensed.

[0090] Once the de-aeration device 6 has finished its stroke, the conveyor surface 2 resumes moving by displacing the bed of ceramic material M along the direction of forward movement A.

[0091] Next, the ceramic material M is pressed to obtain a compacted ceramic manufactured article.

[0092] It has in practice been ascertained that the described invention achieves the intended objects.

[0093] In particular, the fact is emphasized that the special expedient of providing deaeration means upstream of the pressing means with respect to the direction of forward movement makes it possible to reduce the time required for compacting the ceramic material to obtain the ceramic manufactured articles.

[0094] In particular, the movement of the de-aeration device with respect to the conveyor surface, which remains stationary, allows for effective and gradual de-aeration of the ceramic material.

[0095] Again, the special expedient of providing adjustment means for adjusting the position of the de-aeration means with respect to the conveyor surface and movement means of the de-aeration means makes it possible to obtain an appliance which is particularly versatile in its use and adaptable to a plurality of different operational cases.

Claims

CLAIMS1) Appliance (1) for forming ceramic manufactured articles, comprising: at least one conveyor surface (2) adapted to convey raw ceramic material (M) along a direction of forward movement (A); pressing means (3) arranged along said conveyor surface (2) and configured to press said ceramic material (M) so as to form at least one compacted ceramic manufactured article; de-aeration means (6) arranged upstream of said pressing means (3) with respect to said direction of forward movement (A) and adapted to interact with the ceramic material (M) to remove at least part of the air retained in the ceramic material (M); characterized by the fact that said de-aeration means (6) are movable by shift along a direction of movement (Y) with respect to said conveyor surface (2), said de-aeration means (6) displacing along said direction of movement (Y) to remove the air retained in the ceramic material (M) when said conveyor surface (2) is stationary.2) Appliance (1) according to claim 1, characterized by the fact that it comprises movement means (8) associated with said de-aeration means (6) and adapted to move the latter with respect to said conveyor surface (2) along a direction of movement (Y).3) Appliance (1) according to claim 2, characterized by the fact that said movement means (8) comprise: at least one sliding rail (8a) extending along said direction of movement (Y); and at least one movable body (8b) associated with said de-aeration means (6) and coupled to said sliding rail (8a) in a sliding maimer along said direction of movement (Y).4) Appliance (1) according to one or more of the preceding claims, characterized by the fact that said de-aeration means (6) comprise at least one deaeration device (6) arranged on top of said conveyor surface (2) and adapted to define, with the latter, at least one predetermined passageway gap (7) traversableby said ceramic material (M).5) Appliance (1) according to claim 4, characterized by the fact that said passageway gap (7) extends transversely to said direction of forward movement (A) substantially over the entire extension of said conveyor surface (2).6) Appliance (1) according to claim 4 or 5, characterized by the fact that said de-aeration device (6) comprises at least one revolving belt (16) provided with at least one lower section (16a) movable along a respective direction of sliding (S) and adapted to contact said ceramic material (M).7) Appliance (1) according to claim 6, characterized by the fact that said direction of sliding (S) has a way concordant to said direction of movement (Y).8) Appliance (1) according to claim 6 or 7, characterized by the fact that said revolving belt (16) defines a closed profile and by the fact that said de-aeration device (6) comprises at least one de-aeration element (17) of the rigid type, which is arranged internally to said revolving belt (16) and which interacts with said lower section (16a) to contact the ceramic material (M) during the displacement of said de-aeration device (6) along said direction of movement (Y).9) Appliance (1) according to claim 8, characterized by the fact that said deaeration element (17) has a slab-shaped conformation.10) Appliance (1) according to claim 8 or 9, characterized by the fact that the inclination of said de-aeration element (17) with respect to said conveyor surface (2) is adjustable.11) Appliance (1) according to one or more of claims 8 to 10, characterized by the fact that said de-aeration element (17) is movable vertically with respect to said lower section (16a).12) Appliance (1) according to one or more of claims 6 to 11, characterized by the fact that it comprises driving means (11, 12) of said revolving belt (16) comprising at least one motorized roller (11) and at least one supporting wheel (12), said revolving belt (16) being wound around said motorized roller (11) and around said supporting wheel (12).13) Appliance (1) according to claim 12, characterized by the fact that said deaeration element (17) is positioned between said motorized roller (11) and saidsupporting wheel (12), where said lower section (16a) is located.14) Appliance (1) according to one or more of the preceding claims, characterized by the fact that it comprises adjustment means (9) for adjusting the position of said de-aeration means (6) along a direction of adjustment (Z) which is transverse to said direction of forward movement (A) and are adapted to vertically move said de-aeration means (6) away from / close to said conveyor surface (2) so as to increase / decrease the size of said passageway gap (7).15) Appliance (1) according to claim 14, characterized by the fact that said adjustment means (9) comprise a plurality of adjustment holes (9) cut on said movable body (8b) and arranged along at least said direction of adjustment (Z).16) Appliance (1) according to claim 14 or 15, characterized by the fact that said de-aeration element (17) is movable locked together with said driving means (11, 12) along said direction of adjustment (Z) as a result of the operation of said adjustment means (9).17) Appliance (1) according to one or more of the preceding claims, characterized by the fact that it comprises abutment means (10) arranged in a position opposite said revolving belt (6) with respect to said conveyor surface (2) and adapted to support the latter during the passage of said ceramic material (M) through said passageway gap (7).18) Appliance (1) according to claim 17, characterized by the fact that said abutment means (10) comprise at least one abutment roller (10) operable in rotation around a respective direction of drive (W).19) Appliance (1) according to claim 17 or 18, characterized by the fact that said motorized roller (11) is rotatable around a respective direction of rotation (R) having a way of rotation opposite said direction of drive (W).20) Appliance (1) according to one or more of the preceding claims, characterized by the fact that it comprises dispensing means (5) of the raw ceramic material (M) placed upstream of said de-aeration means (6) with respect to said direction of forward movement (A) and adapted to discontinuously release a predetermined amount of ceramic material (M) onto said conveyor surface (2) so as to form a bed of ceramic material (M) having predetermined dimensions.21) Process for forming ceramic manufactured articles, comprising the following phases of: providing an appliance (1) according to one or more of the preceding claims; dispensing a raw ceramic material (M) onto said conveyor surface (2); - de-aerating said ceramic material (M); pressing said ceramic material (M) to obtain a compacted ceramic material; characterized by the fact that said phase of de-aeration is carried out by moving said de-aeration means (6) with respect to said conveyor surface (2) along said direction of movement (Y) while keeping said conveyor surface (2) stationary. 22) Process according to claim 21, characterized by the fact that said dispensing is carried out by discontinuously releasing a predetermined amount of ceramic material (M) onto said conveyor surface (2) so as to form a bed of ceramic material (M) having predetermined dimensions.

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