Modular Ceramic Press With Segmented Punches
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Solution Overview
Problem
Industrial presses for large-size ceramic products, such as tiles and plates, face challenges in achieving uniform shape and finish during the pressing step, requiring subsequent mechanical processing and resulting in increased production costs and waste disposal difficulties due to non-uniform structural tension.
Innovation Solution
A modular industrial press with a portal-like structure and conveyor belt system that uses a combination of upper and lower holding means and a pressing element to form a sealed work chamber, allowing for uniform pressing and elimination of the need for further processing by directly achieving the desired shape and finish during the pressing step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydraulic presses with portal-like structure are used for pressing ceramic materials, then the pressing operation can be performed, but the perimeter portion of the pressed product is not uniform and regular, requiring subsequent mechanical processing
Solution Approach 1:
The pressing system is segmented into multiple independent pressing units arranged in parallel between the upper and lower punches. Each pressing unit can be independently controlled to apply pressure to different regions of the ceramic material, allowing precise control over the perimeter portions while maintaining uniformity across the entire product.
Solution Approach 2:
Different regions of the pressing system are assigned different functions: the central pressing unit applies pressure to the central portion of the material, while the peripheral pressing units specifically target the perimeter portions. This local differentiation ensures that each region receives the appropriate pressure to achieve uniform and regular perimeter portions without requiring subsequent mechanical processing.
2Strength
If conventional pressing methods are used, then the pressing operation is simpler, but the pressed product has non-uniform tensional/structural state between central and perimeter portions, affecting resistance to stresses
Solution Approach 1:
The pressing force distribution is segmented into multiple zones through the parallel pressing units. Each unit applies pressure to a specific region, enabling independent control of the structural state in different portions of the product. This ensures uniform density and eliminates non-uniform tensional states between central and perimeter portions.
Solution Approach 2:
The pressing system allows independent adjustment of pressing parameters (force, pressure, duration) for each pressing unit. By optimizing these parameters for different regions, the system achieves uniform structural state and density throughout the product, enhancing its resistance to mechanical stresses.
3Manufacturing precision
If mechanical removal of perimeter portion is performed to achieve desired shape and finish, then the product meets specifications, but production costs increase and scrap disposal becomes difficult
Solution Approach 1:
The pressing operation itself is designed to preliminarily form the perimeter portions to the desired shape and finish during the initial pressing step. The peripheral pressing units specifically mold the edge regions to achieve the final required geometry, eliminating the need for subsequent mechanical removal and preventing scrap generation.
Solution Approach 2:
Instead of treating the perimeter portions as excess material to be removed (harm), the invention utilizes them as functional elements to be precisely formed (benefit). The peripheral pressing units convert what would be scrap material into the desired finished product features, eliminating waste while meeting specifications.
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 press achieves finished products with uniform perimeter and structural integrity, reducing production costs and waste disposal issues by eliminating the need for additional mechanical processing and ensuring uniform resistance to mechanical stresses.
Implementation Method 1
power members adapted to exercise the pressing force on the material to be formed
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A press for large-size ceramic products comprises a modular structure (2) defined by a plurality of annular plates (3), aligned in succession one after the other, and provided with a through seat (4) which has a lower portion (5) and an upper portion (6) opposite one another, a bed (7) supported by the annular plates (3) at the lower portion (5) and a head (8) connectable to the upper portion (6), wherein the bed (7) and the head (8) delimit a work chamber (9) for housing power elements (10) suitable for carrying out the operations of pressing a material to be pressed, and a conveyor belt (12) that passes through the through seat (4) along a longitudinal direction (C) of the modular structure (2), wherein the power elements (10) comprise at least one upper punch (14), first lateral holding elements (15) and second lateral holding elements (16) for the powder material to be pressed, movable with respect to one another and suitable for delimiting during use a work chamber where such powder material is pressed.