Ceramic Tile Compaction with Two-Stage Pressing Against Delamination
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Solution Overview
Problem
Manufacturing large format ceramic tiles or slabs with significant amounts of calcium silicate materials, such as wollastonite, diopside, and tremolite, is challenging due to difficulties in compaction, leading to delamination, high scrap generation, and low productivity.
Innovation Solution
A two-step compaction process involving a continuous press at 50-100 kg/cm² followed by a uniaxial hydraulic press at 350-500 kg/cm² is employed to compact ceramic agglomerates, ensuring efficient manufacturing of large thickness tiles or slabs with low defects and high productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If calcium silicate materials (wollastonite, diopside, tremolite) are incorporated into ceramic formulations to improve cuttability and reduce firing temperature, then cutting behavior is significantly improved and energy consumption is reduced, but compaction becomes more difficult leading to delamination and high scrap generation
Solution Approach 1:
The compaction process is divided into two distinct stages: a first compaction stage applying 50-100 kg/cm² pressure, and a second compaction stage applying 350-500 kg/cm² pressure. This segmentation allows each stage to perform its specific function - the first stage creates initial density without excessive force, while the second stage achieves final high density, thereby preventing delamination caused by applying full pressure too early
Solution Approach 2:
The first compaction stage performs a preliminary compaction action at lower pressure (50-100 kg/cm²) before the final high-pressure compaction. This preliminary action prepares the ceramic layer by removing large air pockets and establishing initial structural integrity, making the material more resistant to delamination during the subsequent high-pressure second stage
2Strength
If high compaction pressure is applied to achieve high density and low porosity, then mechanical strength and chemical resistance are improved, but delamination occurs and productivity decreases
Solution Approach 1:
The compaction process is divided into two distinct stages: a first compaction stage applying 50-100 kg/cm² pressure, and a second compaction stage applying 350-500 kg/cm² pressure. This segmentation allows each stage to perform its specific function - the first stage creates initial density without excessive force, while the second stage achieves final high density, thereby preventing delamination caused by applying full pressure too early
Solution Approach 2:
The first compaction stage performs a preliminary compaction action at lower pressure (50-100 kg/cm²) before the final high-pressure compaction. This preliminary action prepares the ceramic layer by removing large air pockets and establishing initial structural integrity, making the material more resistant to delamination during the subsequent high-pressure second stage
3Temperature
If calcium silicate materials are used in ceramic formulations, then firing temperature can be reduced to 1,100-1,200°C, but compaction difficulties increase leading to higher defect rates
Solution Approach 1:
The compaction process is divided into two distinct stages: a first compaction stage applying 50-100 kg/cm² pressure, and a second compaction stage applying 350-500 kg/cm² pressure. This segmentation allows each stage to perform its specific function - the first stage creates initial density without excessive force, while the second stage achieves final high density, thereby preventing delamination caused by applying full pressure too early
Solution Approach 2:
The first compaction stage performs a preliminary compaction action at lower pressure (50-100 kg/cm²) before the final high-pressure compaction. This preliminary action prepares the ceramic layer by removing large air pockets and establishing initial structural integrity, making the material more resistant to delamination during the subsequent high-pressure second stage
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 method enables the production of large format ceramic tiles or slabs with improved cuttability and reduced defects, allowing faster cutting without tool damage, and increased production efficiency.
Implementation Method 1
a first continuous type press, generally consisting of at least one roller - or compactor belt - which effects a first pressing of the ceramic powders (or agglomerates) on an opposed flexible belt
Implementation Method 2
a uniaxial hydraulic press at 350-500 kg/cm² is employed to compact ceramic agglomerates
Implementation Method 3
the compacted layer can be dried to reduce its humidity content, before it is fired with a temperature profile having a maximum in the range 1,000-1,200 °C
Data Source
Figure 1
AI summary
The invention relates to a method for the manufacture of tiles or slabs comprising a fired ceramic material, the method comprising a pre-compacting step followed by an ultra-compacting step. The invention is also directed to a tile or slab obtainable by said method.