Aluminum Buffer with Hard Anodization for Ceramic Tile Molds
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Solution Overview
Problem
Current ceramic tile molds made of C40 steel are heavy, time-consuming to prepare, and have a short lifespan due to wear, requiring frequent machining and welding, which affects the accuracy and durability of the tiles produced.
Innovation Solution
A buffer for the mold made of aluminum with a hard anodization treatment on the surface exposed to wear, providing a thickness of 70-80 microns, which reduces weight, processing time, and eliminates the need for welding and grinding, while enhancing mechanical resistance and durability through a specialized edge geometry that distributes wear evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If buffers are made of C40 steel, then mechanical strength and durability are improved, but weight increases and handling becomes difficult
Solution Approach 1:
The patent uses aluminum as a base material with hard anodization coating to create a composite structure that combines the light weight of aluminum with the surface hardness and wear resistance of the anodized layer, replacing traditional C40 steel buffers
Solution Approach 2:
The patent changes the material parameters by selecting aluminum with specific properties (light weight, good machinability) and applying hard anodization to achieve the required surface hardness, fundamentally altering the material composition from steel to aluminum-based composite
2Strength
If C40 steel buffers are used, then mechanical resistance is sufficient, but preparation time increases due to multiple machining operations
Solution Approach 1:
The patent changes the material parameters by selecting aluminum with specific properties (light weight, good machinability) and applying hard anodization to achieve the required surface hardness, fundamentally altering the material composition from steel to aluminum-based composite
Solution Approach 2:
The hard anodization process is applied as a preliminary surface treatment that provides wear resistance before the buffer enters service, eliminating the need for subsequent welding and grinding operations that would otherwise be required on C40 steel buffers
3Strength
If C40 steel buffers are used, then initial strength is adequate, but service life decreases due to wear and frequent welding
Solution Approach 1:
The patent uses aluminum as a base material with hard anodization coating to create a composite structure that combines the light weight of aluminum with the surface hardness and wear resistance of the anodized layer, replacing traditional C40 steel buffers
Solution Approach 2:
The hard anodization process is applied as a preliminary surface treatment that provides wear resistance before the buffer enters service, eliminating the need for subsequent welding and grinding operations that would otherwise be required on C40 steel buffers
4Reliability
If buffers are made of C40 steel, then wear resistance can be improved by welding, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameters by selecting aluminum with specific properties (light weight, good machinability) and applying hard anodization to achieve the required surface hardness, fundamentally altering the material composition from steel to aluminum-based composite
Solution Approach 2:
The hard anodization process is applied as a preliminary surface treatment that provides wear resistance before the buffer enters service, eliminating the need for subsequent welding and grinding operations that would otherwise be required on C40 steel buffers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The aluminum buffer with hard anodization significantly reduces the weight and preparation time of the mold, extends its operational life, and maintains the necessary mechanical resistance for ceramic tile production, improving the accuracy and longevity of the tiles produced.
Implementation Method 1
at least said external profile area (35) is treated with hard anodization in such manner to obtain a hard superficial layer (F) with thickness from 70 to 80 microns
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a buffer (30) for a mold (1) for the ceramic industry comprising a body (34) with concave portion (31) adapted to be the bottom of an injection chamber (8) of raw materials for production of a ceramic tile (M), said concave portion (31) being perimetrally defined by an edge (33) protruding from said body (34) and wherein said edge (33) comprises an external profile area (35) on one side of the edge (33) opposite to the side facing said concave portion (31), wherein said buffer (30) is made of aluminum or aluminum alloy, at least said external profile area (35) being treated with hard anodization process.