Ceramic Sheet Forming Apparatus with Dual-Zone Pressing
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Solution Overview
Problem
Existing systems for forming large-sized ceramic sheets with dimensions comparable to conventional tiles face challenges in achieving the desired thickness and efficiency, leading to increased production cycles and costs due to the need for high compression forces and complex machinery.
Innovation Solution
A conveyor belt-based apparatus with rotatable pressing rollers and linear actuators that exert pressure from both above and below, allowing for localized and balanced compression of ceramic powder, reducing the overall force required and enabling sheets of varying lengths and thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional press with robust structure is used to form large-sized ceramic sheets, then the desired compression force can be achieved, but the device complexity and cost increase significantly
Solution Approach 1:
The press is divided into multiple independent pressing units, each equipped with its own cylinder and plunger. Each pressing unit can independently apply compression force to a specific zone of the ceramic sheet, allowing the system to achieve high total compression force without requiring a single complex robust press structure
Solution Approach 2:
The pressing mechanism transitions from a single-point or single-zone pressing approach to a distributed multi-zone pressing system. By arranging multiple pressing units across the surface area, the system distributes the compression force application in space, reducing the complexity requirements of individual pressing components while maintaining overall high compression force
2Productivity
If the surface area of tiles to be obtained is increased, then the production efficiency improves, but the compression force required increases proportionally
Solution Approach 1:
The pressing system is segmented into multiple independent pressing units that can simultaneously operate on different zones of the ceramic sheet. This allows the total compression force to be distributed across multiple parallel operations, maintaining high productivity for large surface areas without requiring a single excessively large compression force from one press
3Manufacturing precision
If a pre-compacting step is added to the forming system, then the compacting quality improves, but the production cycle lengthens and overall dimensions increase
Solution Approach 1:
The multiple pressing units operate simultaneously on different zones of the ceramic sheet in a single integrated pressing cycle. This merges what would otherwise be sequential pre-compacting and final compacting operations into one parallel process, achieving high compacting quality without extending the production cycle
Solution Approach 2:
The distributed pressing units apply compression continuously across the entire surface area of the ceramic sheet in one operation. This eliminates idle time between sequential pressing steps and maintains continuous useful action throughout the pressing cycle, improving productivity while ensuring uniform compacting quality
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 apparatus achieves efficient and cost-effective production of large-sized ceramic sheets with thickness comparable to conventional tiles by distributing compression forces evenly, reducing operational costs and production time while maintaining high pressure on the ceramic material.
Implementation Method 1
pressing means consisting substantially of a lower half-die vertically movable in both directions so that once the conveyor belt has stopped it can press the corresponding surface portion of the aforesaid layer
Data Source
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AI summary
An apparatus for forming ceramic sheets comprising: a conveyor belt (2) having a rigid abutting deck (11) below an upper branch (2') thereof and adjacent to it; means (5) for feeding ceramic powder material (6a) so as to release a layer of ceramic powder material (6) onto said upper branch (2'); a first pressing roller (10) with a horizontal axis (10a) perpendicular to the direction of extension (X) of the conveyor belt (2) and which is disposed above said conveyor belt (2); driving means (27) for the first pressing roller (10) which determine the rotation thereof around its axis (10a); at least a second pressing roller (20) with a horizontal axis (20a) perpendicular to the direction of extension (X) of the conveyor belt (2) and which is disposed below said rigid abutting deck (11) and is designed to actively interact, in an opposite and contrary direction, with said first pressing roller (10) in order to compress said layer of ceramic powder material (6); support and moving means (13) for the first pressing roller (10) which are directly connected to and operatively interact with said at least second pressing roller (20) so as to move said first pressing roller (10) vertically and exert a vertical pressing force from above and simultaneously a vertical reaction from below on said abutting deck (11) and on said layer of ceramic powder material (6).