Vacuum Vibro-Compression Apparatus with Entry and Exit Chambers
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Solution Overview
Problem
The existing vacuum vibro-compression process for mixes is inefficient due to the lengthy time required to establish and restore vacuum conditions, leading to high energy consumption and prolonged cycle times, especially with large slabs, resulting in reduced productivity and increased costs.
Innovation Solution
An apparatus with an entry and exit chamber system connected to vacuum generating means, allowing for continuous vacuum maintenance within the bell, enabling the mix to be pre-deaerated in the entry chamber before being transferred to the bell for vibro-compression, and then transferring the compacted slab to an exit chamber for atmospheric pressure restoration, minimizing exposure to vacuum and atmospheric conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum conditions are established and restored after each vibro-compression cycle, then proper deaeration and compaction are achieved, but cycle time and energy consumption increase significantly
Solution Approach 1:
The invention introduces a preliminary vacuum treatment step before vibro-compression where the mix is deaerated in the mould cavity under vacuum conditions. This preliminary action removes air bubbles and gases from the mix before the actual compaction process, eliminating the need for extended vacuum maintenance after compression and reducing overall cycle time.
Solution Approach 2:
The invention maintains continuous vacuum conditions throughout the entire vibro-compression cycle rather than establishing and restoring vacuum repeatedly. The vacuum pump operates continuously during the process, allowing the mix to remain under vacuum while being compressed, thus eliminating downtime for vacuum restoration and maintaining continuous productive action.
2Speed
If high power vacuum pumps are used to reduce vacuum establishment time, then vacuum is achieved faster, but energy consumption increases
Solution Approach 1:
By performing deaeration before compression in a preliminary vacuum step, the system achieves adequate air removal with lower vacuum pump power requirements. The mix is pre-treated under vacuum conditions, reducing the need for high-power pumps during the main compression phase and thereby lowering overall energy consumption.
Solution Approach 2:
The invention applies vacuum treatment partially during the process - specifically during the preliminary deaeration phase and continuously at lower intensity during compression - rather than maintaining full vacuum strength throughout the entire cycle. This partial application of vacuum reduces energy requirements while still achieving the necessary deaeration and compaction quality.
3Volume of moving object
If large slab dimensions are produced, then product size increases, but vacuum bell volume and cycle time increase
Solution Approach 1:
The preliminary vacuum deaeration step allows large slabs to be treated under vacuum conditions before compression, ensuring thorough air removal from the entire volume. This upfront action compensates for the larger volume by treating it early when the vacuum system can work efficiently, preventing the need for extended vacuum maintenance times after compression of large slabs.
Solution Approach 2:
For large slab production, the invention maintains continuous vacuum conditions throughout the vibro-compression process rather than interrupting to restore atmospheric pressure. This continuous action allows the vacuum system to work efficiently on the entire large volume without repeated establishment and restoration cycles, reducing total cycle time despite the increased slab size.
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 significantly reduces cycle time and energy consumption by maintaining continuous vacuum conditions, allowing for immediate vibro-compression and efficient slab production, thereby enhancing productivity and reducing costs.
Implementation Method 1
a press with a vibrating ram located in an environment suitable for being placed under vacuum conditions, with very low residual pressure values, in the region of 5-40 mbar
Implementation Method 2
a press with a vibrating ram located in an environment suitable for being placed under vacuum conditions
Implementation Method 3
once the vacuum condition has been reached, a press ram is lowered onto the mix and vibration of the ram is activated
Data Source
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AI summary
An apparatus for vacuum vibro-compression of mixes arranged on a support comprises a press (12) provided with a press ram (18) having vibratory devices (22), and a pressing surface (16). The press (12) comprises a vacuum bell (24). The apparatus is characterized in that it comprises an entry chamber (44) in the region of the inlet opening (36) of the bell (24) having a first opening (48) which can be controllably closed and opened with a first gate (50) adapted to prevent fluid communication between the outside and inside of the entry chamber (44) and a second gate (52) able to be controllably opened and closed, in the region of the inlet opening (36) of the bell (24), and adapted to prevent fluid communication between entry chamber (36) and the inside of the bell (24) or to allow the passage of the support with the mix from the entry chamber (36) to the inside of the bell (24). The apparatus also comprises an exit chamber (46) in the region of the outlet opening (38), having a third gate (54) provided in the region of the outlet opening (38), able to be controllably closed and opened and adapted to prevent fluid communication between the inside of the bell (24) and the inside of the exit chamber (46) or to allow the passage of the support with the compacted slab from inside the bell (24) to the exit chamber (46), and a second opening (56) which can be controllably closed and opened with a fourth gate (58) which is adapted to prevent fluid communication between the inside of the exit chamber and the outside. A method for vacuum vibro-compression of mixes contained inside a mould, comprising the steps of: inserting a support with the mix inside the entry chamber (44) and closing the first gate (50); generating a given vacuum value inside the entry chamber (44) with the first gate (50) and the second gate (52) closed; opening the second gate (52) and inserting the support inside the bell (24) where a given vacuum value is already present; closing the second gate (52) and performing vacuum vibro-compression of the mix with the second and third gates (52, 54) closed; once vibro-compression has been completed, opening the third gate (52) and transferring the support into the exit chamber (46) where a given vacuum value is already present; closing the third gate (54), restoring the atmospheric pressure inside the exit chamber (46); opening the fourth gate (58) and discharging the support.