Powder Pressing Mould with Fluid-Actuated Base Elements
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Solution Overview
Problem
Existing moulds for pressing powder materials, such as ceramic tiles, face challenges in achieving uniform pressure across all recesses due to uneven powder filling and non-uniform pressing force distribution, leading to variations in compacting and shrinkage during firing, resulting in non-constant product quality and increased production costs due to manual corrections and machine stoppages.
Innovation Solution
A mould design with independently adjustable chambers supplied with pressurized fluid allows for precise regulation of pressing force across all recesses by varying fluid pressure, enabling uniform pressure distribution without interrupting the pressing process, using a PLC-controlled system to adjust the position of base elements and punches to compensate for force differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional moulds with fixed punches are used, then the structure is simple and easy to manufacture, but the pressing force is non-uniform across different recesses leading to varying product quality
Solution Approach 1:
The mould system transitions from fixed, static punches to dynamic, adjustable punches. Each punch is mounted on a adjustable support that can be independently positioned along the press direction, allowing the pressing force to be dynamically balanced across all recesses. This dynamic adjustment capability enables uniform pressing force distribution while maintaining a relatively simple overall mould structure.
Solution Approach 2:
The invention applies local quality by providing individual adjustment mechanisms for each punch support. Instead of requiring a completely complex reconfigurable system, only the local components (supports and punches) need adjustment capability, while the rest of the mould remains simple and fixed. This allows precise local control of pressing force for each recess.
2Manufacturing precision
If shims are added under punches to correct pressing unevenness, then pressing uniformity improves, but machine stoppages and production costs increase
Solution Approach 1:
The mould system performs preliminary action by allowing adjustment of punch positions before the pressing operation begins. The supports can be repositioned and locked in place prior to loading powder and initiating the press cycle, eliminating the need to stop production mid-process for corrections. This advance preparation ensures uniform pressing force from the start.
Solution Approach 2:
The adjustable support system enables the mould to self-correct pressing unevenness without external intervention during operation. The mechanism allows operators to quickly adjust and lock punch positions before pressing, making the system self-sufficient and eliminating the need for continuous machine stoppages to add or remove shims.
3Manufacturing precision
If shims are placed under punches to compensate for force differences, then pressing uniformity improves, but the magnetic attraction force of the punch is reduced causing punch movement
Solution Approach 1:
The invention extracts the adjustment function from the magnetic fixation system. Instead of relying on magnetic attraction to hold punches in place, the system uses mechanical supports with adjustable positions that can be locked independently of the magnetic field. This separation allows the magnetic force to maintain reliable fixation while the mechanical adjustment mechanism provides the necessary positioning control.
Solution Approach 2:
The adjustable support acts as an intermediary between the press mechanism and the punch. It provides a stable, lockable mounting that transmits force uniformly while maintaining the magnetic attraction between the punch and its support. This intermediary structure protects the magnetic fixation from being compromised by shim placement.
4Manufacturing precision
If independent pressure control chambers are implemented, then uniform pressing force is achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The pressure control system is segmented into independent chambers, with each chamber corresponding to a specific recess or group of recesses. This segmentation allows individual pressure adjustment for each zone without requiring a completely independent control system for every single punch. The modular approach reduces overall system complexity while achieving uniform pressing force distribution.
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 solution ensures uniform pressing force across all recesses, reducing shrinkage variations and eliminating the need for manual corrections, thereby improving product quality and reducing production time and labor costs by maintaining continuous operation.
Implementation Method 1
respective chambers (15) which can be supplied with a pressurised fluid
Implementation Method 2
the pressure exerted by the buffer on the powder to be pressed is uniform
Implementation Method 3
The buffer comprises an elastic membrane that bounds a chamber filled with an incompressible liquid
Implementation Method 4
the presence of the incompressible liquid inside the chamber bounded by the elastic membrane means that in the pressing step the pressure exerted by the buffer on the powder to be pressed is uniform
Implementation Method 5
using a PLC-controlled system to adjust the position of base elements and punches to compensate for force differences
Data Source
Figure 1
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AI summary
A mould (1; 1') for pressing powder material comprises a die (3), or lower half mould, in which a plurality of recesses (4) is obtained that are intended for containing the powder material to be pressed, said die (3) comprising a basement plate (5) and an upper plate (13), supported by supporting elements (14; 22) fixed to the basement plate (5), to said basement plate (5) an ejecting block (6) being fixed that supports a plurality of base elements (7), each of which constitutes the bottom of a respective recess (4); between each base element (7) and the ejecting block (6) a respective chamber (15) is defined that is suppliable with a pressurised fluid, said base element floating on said pressurised fluid, each chamber (15) being supplied with said pressurised fluid independently of the other chambers (15).