Isostatic Tile Punch with Pressure Compensation for Uniform Density
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Solution Overview
Problem
Existing isostatic punches for forming tiles are unable to produce tiles with abutment feet having greater height than those of prior art, resulting in tiles with reduced mass and high energy consumption during drying and firing processes, and are prone to breakage due to non-uniform compression.
Innovation Solution
An isostatic punch with a compaction body featuring projecting portions and recesses, combined with a compensation circuit that forms pockets of pressurized fluid at recesses to uniformly distribute compression, allowing for tiles with high-height abutment feet and reduced mass, and a process that includes a pressing step to form tiles with a high ratio of void volume to solid volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional punches are used for compacting clay powder, then the structure is simple, but density non-uniformities occur in the compacted powder leading to deformations during firing
Solution Approach 1:
The compaction body is segmented into multiple zones with different compaction forces applied to different regions. The compensation circuit divides the compaction pressure into distinct zones (first zone with higher pressure, second zone with lower pressure) to achieve uniform density distribution across the compacted powder, preventing deformations during firing.
Solution Approach 2:
Different regions of the compaction body are assigned different local properties through the compensation circuit. The first zone applies higher compaction pressure while the second zone applies lower pressure, creating localized quality variations that result in overall density uniformity throughout the compacted tile.
2Manufacturing precision
If isostatic punches with compensation circuits are used, then density uniformity is improved, but the ability to form high-height abutment feet is limited
Solution Approach 1:
The compensation circuit creates local quality differences in pressure distribution, with the first zone providing higher pressure for dense compacting and the second zone providing lower pressure that allows formation of high-height abutment feet. This localized pressure variation enables both density uniformity and versatile tile geometries.
Solution Approach 2:
The compaction process uses dynamic pressure control through the compensation circuit, adjusting pressure distribution during compaction to first achieve uniform density and then allow formation of high-height abutment feet in specific zones where lower pressure is applied.
3Use of energy by moving object
If tiles with reduced mass and high void volume ratio are produced, then energy consumption for drying and firing is reduced, but the tiles may be more prone to breakage
Solution Approach 1:
The compensation circuit uses pressurized fluid (pneumatic/hydraulic system) to control the compaction process, creating uniform pressure distribution that produces tiles with optimized porosity. This controlled porosity reduces mass and energy consumption while maintaining structural integrity through uniform density distribution.
Solution Approach 2:
The compaction process changes physical parameters (pressure, density, porosity) through the compensation circuit to produce tiles with optimized characteristics. By controlling the pressure distribution and resulting porosity, the system achieves reduced mass and energy consumption while maintaining sufficient strength through uniform density.
4Manufacturing precision
If uniform pressure distribution is applied during compaction, then density uniformity is achieved, but the ability to form complex tile geometries with high-height features is reduced
Solution Approach 1:
The compensation circuit segments the pressure distribution into multiple zones, allowing different pressure levels in different regions. This segmentation enables formation of complex geometries with high-height abutment feet in low-pressure zones while maintaining density uniformity in high-pressure zones.
Solution Approach 2:
Different regions of the compaction body are assigned different local pressure qualities through the compensation circuit. The first zone provides high pressure for uniform density while the second zone provides low pressure for forming high-height features, achieving both density uniformity and geometric versatility.
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 solution enables tiles with high-height abutment feet that are less prone to breakage and require lower energy for drying and firing, while allowing integration of filler materials for insulation and fireproof covers, reducing material usage and production costs.
Implementation Method 1
the pressure which the isostatic punch exerts on the clay powders to be compacted is distributed, by the oil present in the compensation circuit F, in a uniform manner on the compaction surface D
Implementation Method 2
a compaction body C made of polyurethane elastomeric resin, which substantially fills the volume of the containment tank and is fixed to the bottom wall B and to the perimeter wall
Data Source
AI summary
Process for forming tiles which provides for pressing a building material in a cell of a mold of a press by means of an isostatic punch, in which the punch has a compaction surface that is elastically deformable and provided with projections in order to attain cavities on an internal face of a tile and with recesses in order to shape feet projecting on the internal face, in which such punch comprises means for feeding a pressurized fluid and a pressure compensation circuit shaped in order to form pockets of the aforesaid fluid at the recesses.