Movable Contact Surface for Ceramic Demoulding
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Solution Overview
Problem
Current demoulding methods for ceramic products with wide, flat surfaces and small perpendicular dimensions are inefficient, requiring multiple suction cup units and trays, leading to high costs, storage issues, and risks of product damage and scrap due to non-uniform contact and shrinkage.
Innovation Solution
A demoulding method and apparatus that uses a dual-port extractor element with a movable contact surface, allowing for vacuum-assisted extraction and transfer of products directly to a work table without traditional trays, enabling quick and safe handling of products through a sequence of positioning, extraction, and transfer steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple suction cup units and trays are used for demoulding different sized products, then demoulding capability is improved, but device complexity and storage requirements increase
Solution Approach 1:
The extractor element incorporates a movable contact surface that can be dynamically repositioned along the extractor body. This dynamic adjustment allows a single extractor element to adapt to different product sizes and shapes, eliminating the need for multiple fixed suction cup units and trays for different product variants
Solution Approach 2:
The extractor element is designed as a universal component that can handle multiple product types through the movable contact surface. The same extractor element can be used for different sized ceramic products by adjusting the contact surface position, providing multi-functionality without requiring separate dedicated equipment for each product size
2Ease of operation
If trays are used to support products during demoulding and drying, then product support is improved, but storage space requirements and handling complexity increase
Solution Approach 1:
The invention extracts the essential support function from the traditional tray system. The movable contact surface of the extractor element provides direct support to the product during demoulding, and the product is transferred directly to the drying area without requiring intermediate tray support, thereby eliminating the need for large tray storage spaces
Solution Approach 2:
The movable contact surface acts as an intermediary between the mould and the drying area. It provides the necessary support and contact during the critical demoulding phase, then facilitates direct transfer to the drying position without requiring permanent tray structures, reducing overall storage requirements
3Reliability
If suction cup units make uniform contact with different sized products, then demoulding reliability is improved, but apparatus complexity and cost increase
Solution Approach 1:
The movable contact surface can be dynamically positioned to make optimal contact with different product sizes and shapes. This dynamic adjustment ensures reliable uniform contact during demoulding of various product variants without requiring complex multi-unit suction cup assemblies for each product size
Solution Approach 2:
The contact surface is segmented into multiple adjustable contact points that can be independently positioned. This segmentation allows the contact surface to adapt to different product geometries while maintaining reliable contact, eliminating the need for multiple complete suction cup units
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
This approach reduces product damage, eliminates the need for multiple trays, minimizes storage and handling issues, and enhances production efficiency by allowing immediate transfer and finishing of products, improving output capacity and product quality.
Implementation Method 1
the extractor element (3) is provided with means (6) for generating a negative pressure
Implementation Method 2
casted in customary porous moulds
Implementation Method 3
porous structure, made in particular from resins
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A demoulding method for extracting a ceramic product (1) from a half-part (2) of a mould comprises at least the following steps: positioning an extractor element (3), which has a contact surface (3s), at a visible surface (1a) of the product (1) partially housed in the mould half-part (2); extracting the product (1) and placing it in abutment against the contact surface (3s); dividing the contact surface (3s) into two separate, matching portions (3a, 3b) by moving a first portion of it (3a), which supports the product (1), away from its other portion (3b); releasing the product (1) onto a work and/or supporting element or table (4) matchingly shaped to be coupled to the first portion (3a) of the extractor element (3); moving the first portion (3a) and the supporting element or work table (4) away from each other. The invention also relates to an apparatus that implements this method. [Figure 3]