EP4507864A1 - Système de fabrication et procédé de fabrication d'articles en céramique - Google Patents

Système de fabrication et procédé de fabrication d'articles en céramique

Info

Publication number
EP4507864A1
EP4507864A1 EP23722668.3A EP23722668A EP4507864A1 EP 4507864 A1 EP4507864 A1 EP 4507864A1 EP 23722668 A EP23722668 A EP 23722668A EP 4507864 A1 EP4507864 A1 EP 4507864A1
Authority
EP
European Patent Office
Prior art keywords
powder
compaction
circa
ceramic material
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23722668.3A
Other languages
German (de)
English (en)
Inventor
Andrea Valli
Paolo TESTI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sacmi Imola SC
Original Assignee
Sacmi Imola SC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sacmi Imola SC filed Critical Sacmi Imola SC
Publication of EP4507864A1 publication Critical patent/EP4507864A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/023—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities
    • B28B13/025—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities the feed box being vibrated, e.g. to promote discharging of the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/04—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with one ram per mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
    • B28B3/123—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
    • B28B5/026—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length
    • B28B5/027—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed

Definitions

  • the present invention relates to a manufacturing system and method to manufacture ceramic articles ; in particular, ceramic slabs and tiles .
  • the known methods and systems to manufacture ceramic articles provide feeding semi-dry powders (in particular, with a moisture content of circa 5 % - 7 % ) and subsequently pressing this ceramic powder to obtain a layer of compacted ceramic powder .
  • the compaction step is particularly delicate since an incorrect execution of this step may lead to the appearance of cracks and other defects , at least in part due to the failure to deaerate the ceramic powder during the compaction step .
  • the powder material typically used in the ceramic field having a grain si ze ranging from 200 to 600 pm, has a percentage of air therein that constitutes more than 50% of its total volume . Therefore , the processing of the powder ceramic material , and in particular the compaction thereof , requires firstly, during the so-called deaeration step, removing a large volume of intergranular air from the spaces between the ceramic powder particles or grains , and then applying a compaction pressure . In other words , in order to carry out a proper compaction, it is therefore necessary to firstly remove at least part of the high volume o f air from the intergranular spaces before proceeding with the actual compaction .
  • Such a deaeration step is generally carried out with a very gentle increase in compaction pressure , in order to give the air time to escape through the intergranular spaces .
  • this deaeration step is carried out by appropriately controlling the hydraulic circuits in order to correctly calibrate the piston displacement , both in terms of speed and applied force .
  • this deaeration step is carried out by placing the upper compacting belt as inclined with respect to the transit plane of the ceramic powder so as to form a progressive reduction of the port existing between the upper ( inclined) belt and the lower belt on which the ceramic powder transits , so as to gradually increase the compaction force, giving the air between the grains time to be expelled .
  • document CN201244859Y which relates to a feeding device for manufacturing ceramic coatings
  • document JPH10264134A which relates to a method and equipment for feeding powder material to a conventional- type discontinuous press
  • document CN205685520U which focuses on a grid for loading a conventional-type discontinuous press
  • document JP2008194987A which relates to a method for forming large-si zed ceramic articles using conventional-type presses .
  • WO2021048797A1 related to equipment for manufacturing ceramic and/or stone slabs
  • document KR20160149306A describing a method and system for manufacturing ceramic articles by means of a continuous compaction system .
  • Aim of the present invention is to provide a system and a process to manufacture ceramic articles , which make it possible to overcome , at least partially, the limitations of the prior art , while making it possible to increase the production speed and the thickness of the layer of ceramic powder that can be processed with the same compaction quality .
  • FIG. 1 shows a schematic side view of a part of a manufacturing system of ceramic articles according to an embodiment of the present invention
  • FIG. 2 shows a schematic side view of a part of a manufacturing system of ceramic articles according to a further embodiment of the present invention
  • Figure 3 shows a schematic side view of a part of a manufacturing system of ceramic articles according to yet another embodiment of the invention
  • Figure 4 shows a diagram of the particle size distribution of the ceramic powder used to manufacture ceramic articles.
  • ceramic articles T are substantially (but not necessarily) flat articles, in particular ceramic slabs; more precisely, ceramic tiles of different sizes, e.g. large sizes such as those having a cross-section of 1200/1800 x 2400/3600mm, or smaller sizes having a cross-section of 900/1200xl800/2000mm, up to 400x400mm) , etc., and a thickness ranging from circa 3 to circa 50mm, preferably from 6mm to circa 30mm.
  • the manufacturing system 1 of ceramic articles T comprises: a feeding assembly 2 configured to feed powder ceramic material CP to an input station 3; a compaction device 4 arranged at a compaction station 5, and configured to compact the powder ceramic material CP (in particular, as will be explained hereinafter, a layer of thickened powder S comprising -formed by - the powder ceramic material CP) so as to obtain (i.e. form) a layer of compacted powder KP; and a conveyor assembly 6 configured to transport the powder ceramic material CP along a given path P extending in a moving direction A at least from the input station 3 to the compacting station 5, and the layer of compacted powder KP along the same given path P at least out of the compaction station 5 (see Figures 1, 2 and 3) .
  • the feeding assembly 2 comprises at least one feeding device 7 of the known type and not further described herein, e.g. a hopper, for feeding a (dosed) quantity of powder ceramic material CP at the input station 3.
  • a feeding device 7 of the known type and not further described herein, e.g. a hopper, for feeding a (dosed) quantity of powder ceramic material CP at the input station 3.
  • the ceramic articles T comprise (in particular, are formed by) powder ceramic material CP comprising clay, sand, feldspars and other minerals , which are ground together and atomised to obtain a homogenous composition .
  • such powder ceramic material CP comprises ( in particular, is formed by) semi-dry ceramic powder having a moisture content ranging from circa 5% to circa 10% and a measured particle si ze ranging from circa 200 pm to circa 600 pm, as can be seen from the particle si ze curve shown in Figure 4 , which shows in the abscissa the si ze , in particular the equivalent diameter, of the particles forming the powder ceramic material CP and in the ordinate the % of material having such si ze characteristics included in the above-mentioned powder ceramic material CP .
  • this particle si ze curve was constructed by means of a sieving device comprising sieves with ports having a decreasing si ze ranging from circa 600 pm to circa 63 pm .
  • the manufacturing system 1 of ceramic articles T also includes at least one ceramic article firing kiln (known as such and not further described or shown herein) configured to fire base ceramic articles CB, which comprise the layer of compacted ceramic powder KP (in particular, they are formed from at least part of the layer of compacted ceramic powder KP ) , to obtain the finished ceramic articles T , i . e . ceramic slabs or tiles .
  • at least one ceramic article firing kiln known as such and not further described or shown herein
  • the manufacturing system 1 of ceramic articles T comprises a deaeration unit 8 ( i . e . a thickening unit 8 ) which is arranged ( in particular, immediately) upstream of the compaction device 4 along the given path P and is configured to transmit a vibrational action ( schematically shown in Figures 1 to 3 ) to the powder ceramic material CP which, in use , is located ( i . e . passes/ transits ) at a segment PA of the given path P so as to thicken the powder ceramic material CP and obtain a layer of thickened powder S , which, as mentioned above , is then compacted by the compaction device 4 .
  • the compaction device 4 is conf igured to transmit a compaction pressure to the layer of thickened powder S to obtain the above-mentioned layer of compacted powder KP .
  • said segment PA of the given path P concerned with the aforementioned vibrational action extends ( immediately) upstream of the compaction station 5 and has an extension ranging from at least circa 0 . 5 m up to circa
  • such a segment PA of the given path P extends between the input station 3 and the compaction station 5 , even more advantageously such a segment PA comprises a part of the given path P which starts ( i . e . begins ) immediately after the input station 3 and extends for a length ranging from circa 0 . 5 m to circa 2 m in the moving direction A.
  • the conveyor assembly 6 comprises : an upper conveyor device , for example a conveyor belt extending along a first branch of the path P determined from the input station 3 to a discharge station; a lower conveyor device , which is arranged at a lower height than the upper conveyor device and extends along a second branch of the path P determined downstream of the first branch, and a so-called pen device arranged at the discharge station, immediately downstream of the upper conveyor device and immediately upstream of the lower conveyor device along the path P determined and configured to receive the layer of thickened powder S from the upper conveyor device and guide it onto the lower conveyor device .
  • the segment PA of the given path P concerned with the aforementioned vibrational action i . e . at which the is transmitted
  • the discharge station has an extension ranging from at least circa 0.5 m to circa 2 m; in particular, from 1 m to circa 1.5 m.
  • the segment PA is, advantageously, dimensioned to ensure the thickening of the powder material CP that, in use, lies and moves along this segment PA, thanks to the vibrational action transferred by the aforementioned deaeration (i.e. thickening) unit 8.
  • the conveyor assembly 6 is configured to move the powder ceramic material CP at least along the segment PA with a moving speed ranging from circa 1 metre per minute (in particular, from circa 5 metres per minute) to circa 100 metres per minute (in particular, to circa 12 metres per minute) . This ensures that the powder ceramic material CP is subjected to the vibrational action for a time sufficient to ensure the proper thickening of the powder ceramic material CP itself, i.e. the removal of at least part of the intergranular air contained between the grains of the powder ceramic material CP.
  • the expression deaeration, i.e. thickening, of the powder ceramic material CP refers to the evacuation of at least part (advantageously, most) of the air present between the grains of the powder ceramic material CP.
  • the above- mentioned vibrational action used to achieve such deaeration/ thickening has a vibration frequency ranging from circa 1 Hz (in particular, from circa 10 Hz) to circa 1000 Hz (in particular, to circa 200 Hz) .
  • the aforementioned vibrational action has at least one (in particular, it is a substantially) sussultatory component.
  • said vibrational action comprises at least one movement component along a vertical direction (in particular, said vertical direction is substantially perpendicular to the moving direction A; even more particularly, said vertical direction is substantially perpendicular to a moving plane de fined by the conveyor assembly 6 along the aforementioned given path P ) ; more particularly, said vibrational action compri ses ( in particular, is ) a substantially vertical action .
  • the conveyor assembly 6 comprises at least one transporter 9 extending from the input station 3 to the at least one compaction station 5 passing through at least the segment PA of the given path P, and the deaeration/ thickening unit 8 comprises at least one vibration generator 10 to generate the aforementioned vibrational action, and at least one transmission element 11 in connection ( advantageously, but not limitatively, mechanically) with the transporter 9 to trans fer the vibrational action from the vibration generator 10 to the transporter 9 ( e . g .
  • the vibration generator 10 comprises ( in particular, consists of ) an eccentric motor o f the known type and not further described herein, adapted to generate the above-described vibrational action .
  • the vibration generator 10 comprises ( in particular, consists of ) a mechanical system adapted to vibrate a mass of at least circa 0 . 1 kg and less than circa 10 kg with a vibration frequency of at least circa 1 Hz , in particular ranging from at least circa 1 HZ to circa 1000 Hz ( in particular, from at least circa 10 Hz to circa 200 Hz ) .
  • the vibration generator 10 could be of the electromagnetic, pneumatic, or piezoelectric type conveniently put in (advantageously mechanical) communication with the transporter 9 at least at the segment PA of the given path P.
  • the transmission element 11 comprises (in particular, is formed by) a plate (advantageously but not limitatively) arranged under and in contact with the transporter 9.
  • a plate advantageously but not limitatively, has a length (i.e. an extension along said moving direction A) ranging from at least circa 0.5 m to circa 2 m so as to affect and transmit the vibrational action to the powder ceramic material CP along the entire segment PA.
  • the vibration generator 10 is arranged under and in contact with the transmission element 11, in particular with the plate, which in turn is in contact with the transporter 9.
  • the vibration generator 10 is arranged spaced apart (in other words, not in contact) with respect to the transmission element 11 and the manufacturing system 1 (in particular, the deaeration/ thickening unit 8) comprises a mechanical transmission system configured to transmit the vibration to the transmission element 11; for example, the vibration generator 10 could be arranged above the conveyor assembly 6 to facilitate access thereof, for example in case of adjustment, maintenance operations, etc.
  • the vibration generator 10 comprises (in particular, consists of) an acoustic wave generator, e.g. a loudspeaker adapted to generate acoustic waves of a suitable frequency arranged so as to transfer this vibration and generate the aforementioned vibrational action.
  • the vibration generator 10 could be arranged so as to trans fer the vibrational action to the powder ceramic material CP immediately downstream of the feeding station 2 , in particular of the feeding device 7 , so as to thicken powder ceramic material CP as soon as it is fed ( even before it arrives ) on the conveyor assembly 6 .
  • the conveyor assembly 6 is configured to transport the powder ceramic material CP, the layer of thickened powder S and the layer of compacted powder KP along the given path P in a substantially continuous manner .
  • the conveyor assembly 6 is configured to move the layer of thickened powder S and the layer of compacted powder KP along the given path P at a speed ranging from circa 1 m per minute to circa 10 metres per minute .
  • the compaction device 4 (known in itsel f ) comprises : an upper compaction belt 13 , which is arranged above the transporter 9 at the compaction station 5 and cooperates with the transporter 9 to compact the layer of thickened powder S in a substantially continuous manner so as to obtain said layer of compacted powder KP .
  • the conveyor assembly also comprises an additional transporter 9 ' arranged downstream of the transporter 9 along the given path P to receive the layer of compacted powder KP and guide it to a cutting station 14 , as will be further explained below . Even more advantageously but not limitatively, between the transporter 9 and the subsequent transporter 9 ' there is an intermediate conveyor advantageous ly with rollers ( see Figure 2 ) .
  • the compaction device 4 (known in itsel f ) comprises : a lower compacting belt 12 in contact with the transporter 9 and an upper compacting belt 13 , which is arranged above the transporter 9 at the compaction station 5 and cooperates with the lower compacting belt 12 to compact the layer of thickened powder S in a substantially continuous manner so as to obtain said layer of compacted powder KP .
  • the transporter 9 comprises ( in particular, is formed by) a conveyor belt that advantageously, but not limitatively, encloses therein this lower compaction belt 12 and extends from the input station 3 to the outlet from the compaction station 5 passing through the segment PA of the given path P .
  • this segment PA extends ( immediately) upstream of the compaction belts 12 and 13 along the given path P so that the powder ceramic material , in use , is firstly thickened by the vibrational action trans ferred at the segment PA and only then, once thickened, is compacted by the compaction device 4 ( as explained above ) .
  • the manufacturing system 1 of ceramic articles T provides feeding the powder ceramic material CP via two di f ferent feeding devices 7 arranged in sequence along the given path P and thickening the powder ceramic material CP at two separate times .
  • the segment PA of the given path P comprises ( in particular, is subdivided into ) two parts T1 and T2 which are advantageously subsequent to each other without interruption along the moving direction A ( see Figure 2 ) and the feeding assembly 2 compri ses a first feeding device 7 configured to feed a first quantity of powder ceramic material CP in the area of the first part T1 of the segment PA, and a second feeding device 7 arranged downstream of the first feeding device 7 along the given path P and configured to feed a second quantity of powder ceramic material CP (on the first quantity of powder ceramic material CP that, in use, will be fed) in the area of the second part T2 of the segment PA, downstream of the first part T1 along the given path P (see Figure 2) .
  • the deaeration/cooling unit 8 comprises at least one further transmission element 11' , arranged downstream of the transmission element 11 along the given path P and in (advantageously mechanical) connection with the transporter 6 to transfer the vibrational action from the vibration generator 10 or 10' to the transporter 6.
  • the transmission element 11' is arranged to transfer the vibrational action to the transporter 9 to the first part T1 of the segment PA so as to thicken, in use, the first quantity of powder ceramic material CP; and the further transmission element 11' is arranged to transfer the vibrational action to the transporter 9 to the second part T2 of the segment PA so as to thicken, in use, the second quantity of powder ceramic material CP fed on the first quantity.
  • the deaeration/ thickening unit 8 comprises the vibration generator 10 in connection with the transmission element 11 (e.g. as shown arranged immediately below the transmission element 11) and a further vibration generator 10' , similar to the previous one, arranged downstream along the given path P and immediately below the further transmission element 11' .
  • the manufacturing system 1 of ceramic articles T comprises at least one cutting station 14 arranged downstream of the compaction station 5, along the given path P, wherein a cutting device 15 (known in itself and not further described herein) cuts the layer of compacted ceramic powder KP to obtain a plurality of base ceramic articles BC, which will then be fired in a firing kiln (not shown) , as mentioned above , to obtain the final ceramic articles T .
  • the manufacturing system 1 of ceramic articles T is of the discontinuous type .
  • the compaction device 4 is a press of the discontinuous type and comprises , in turn, a die 16 , a drive unit (not shown) to operate the die 16 and impart , in use , a defined compaction pressure to the layer of thickened powder S .
  • the die 16 comprises , in turn, a lower hal f-die 17 and an upper hal f-die (not visible in Figure 3 ) arranged facing and mutually movable closer to and away from each other, in particular along a vertical direction, to define between them a compaction chamber 18 intended to receive the layer of thickened powder S to be compacted .
  • the transporter 9 is a movable distribution grid between a loading position C, at which it receives a given quantity of powder ceramic material CP, and a release position R, at which it releases the given quantity of powder ceramic material CP into the compaction chamber 18 .
  • the transporter 9 also comprises ( in particular, is formed by) a carriage , that may be operated by the aforementioned drive unit , to move the distribution grid between the loading position C and the release position R ( see Figure 3 wherein the distribution grid in the release position R is shown in dashed lines ) and the feeding device 7 comprises ( in particular, is formed by) a hopper with an adj ustable discharge opening to adj ust the quantity of powder ceramic material CP to be fed on the transporter 9 , in particular within the distribution grid .
  • the transporter 9 (in particular, the above-mentioned carriage ) is configured to move the distribution grid between the loading position C and the release position R at a speed ranging from circa 5 metres per minute to circa 150 metres per minute ( in particular, to circa 120 metres per minute ) .
  • the segment PA of the given path P extends at said loading position C .
  • the transmission element 11 of the deaeration/ thickening unit 8 comprises a sliding plate arranged at said loading position C below the transporter 9 to trans fer the above-described vibrational action to the given quantity of powder ceramic material CP which is loaded into the distribution grid to thicken it and obtain the layer of thickened powder S .
  • the layer of compacted powder KP coincides with a basic ceramic article CB, as the distribution grid is loaded by the feeding device 7 with a dosed quantity of powder ceramic material CP, which is such that it forms a base ceramic article CB, once it has been thickened and compacted .
  • the compaction device 4 also comprises an ej ection device (known in itsel f and not shown or further described herein) which may be operated by the drive unit , to ej ect the layer of compacted powder KP ( in particular, the base ceramic article CB ) from the compaction station 5 to the outlet along the given path P .
  • an ej ection device known in itsel f and not shown or further described herein
  • a manufacturing process of ceramic articles T which provides a feeding step, during which a feeding assembly 2 ( advantageously but not limitatively of the type described above in relation to the manufacturing system 1 of ceramic articles T ) feeds powder ceramic material CP to an input station 3 ; a compaction step, during which a compaction device 4 ( advantageously but not limitatively of the type described above in relation to the manufacturing system 1 of ceramic articles T ) is operated to obtain a layer of compacted powder KP, compacting a layer of thickened powder S as will be explained below; and a conveying step, during which a conveying unit 6 ( advantageously but not limitatively of the type described above in relation to the manufacturing system 1 of ceramic articles T ) transports the powder ceramic material CP along the aforementioned given path P in the aforementioned moving direction A from the input station 3 to the compaction station 5 and the layer of compacted powder KP along the given path P at least at the outlet of the compaction station .
  • a feeding assembly 2 advantageously but not limitatively of the type described
  • the manufacturing process of ceramic articles T also comprises a deaeration step ( i . e . a thickening step ) , ( at least partially) preceding the compaction step and ( at least partially) following the feeding step, during which a deaeration/ thickening unit 8 , which is arranged upstream of the compaction device ( 4 ) along said given path ( P ) , transmits a vibrational action to the powder ceramic material CP so as to obtain a layer of thickened powder S , which is compacted during the compaction step, when the compaction device 4 compacts the layer of thickened powder S to obtain said layer of compacted powder KP .
  • a deaeration step i . e . a thickening step
  • a deaeration/ thickening unit 8 which is arranged upstream of the compaction device ( 4 ) along said given path ( P ) , transmits a vibrational action to the powder ceramic material CP so as to obtain a layer of thickened powder S
  • the deaeration/ thickening unit 8 transmits the aforementioned vibrational action for a period ranging from at least circa 3 seconds to circa 20 seconds ( in particular, for a period ranging from circa 5 seconds to circa 15 seconds ; even more particularly, for a period of circa 12 seconds ) .
  • a transporter 9 ( advantageously of the type described above ) moves the powder ceramic material CP through a segment PA o f said given path P ; which, as already mentioned above in relation to the manufacturing system 1 of ceramic articles T , extends ( immediately) upstream of the compaction station 5 and has an extension ranging from at least circa 0 . 5 m to at least circa 2 m, in particular from circa 1 m to circa 1 . 5 m .
  • the deaeration ( i . e . thickening) step comprises a vibration generation sub-step, during which the aforementioned vibrational action is generated ( advantageously but not limitatively by means of a vibration generator 10 made according to one of the embodiments described above ) , and a trans fer sub-step, during which a transmission element 11 ( advantageously but not limitatively of the type described above ) in connection ( advantageously mechanically) with the conveyor assembly 6 , in particular with the transporter 9 , trans fers the vibrational action to the conveyor assembly 6 , in particular to the transporter 9 , to the segment PA to thicken the powder ceramic material CP which, in use , is located and moves to said segment PA.
  • a vibration generation sub-step during which the aforementioned vibrational action is generated ( advantageously but not limitatively by means of a vibration generator 10 made according to one of the embodiments described above )
  • a trans fer sub-step during which a transmission element 11 ( advantageously but not limitatively of the type described
  • this vibrational action has a vibration frequency ranging from circa 1 Hz to circa 1000 Hz ; in particular, from circa 10 Hz to circa 200 Hz .
  • the conveyor assembly 6 transports the powder ceramic material CP, the layer of thickened powder S , and the layer of compacted powder KP along the given path P in a substantially continuous manner ; in this case , the compaction step and the deaeration/ thickening step are ( at least partially) simultaneous with the conveying step .
  • the layer of thickened powder S is compacted by a continuous compaction device 4 , which advantageously but not limitatively is implemented as described above in relation to the manufacturing system 1 of ceramic articles T .
  • the continuous compaction device 4 comprises at least one upper compacting belt 13 , arranged above the transporter 9 , and during the compaction step, the transporter 9 and the upper compacting belt 13 cooperate to compact the layer of thickened powder S in a substantially continuous manner so as to obtain the layer of compacted powder KP .
  • the continuous compaction device 4 comprises at least a lower compacting belt 12 arranged below in contact with the transporter 9 and an upper compacting belt 13 arranged above the transporter 9 , and during the compaction step, the lower compacting belt 12 and the upper compacting belt 13 cooperate to compact the layer of thickened powder S in a substantially continuous manner so as to obtain the layer of compacted powder KP .
  • the feeding step provides for a first feeding substep, during which a first feeding device 7 feeds a first quantity of powder ceramic material CP to an area of a first part T1 of said segment PA and a second feeding sub-step ( at least partially) subsequent to the first feeding step, during which a second feeding device 7 arranged downstream of the first feeding device 7 along the given path P, feeds ( on the first quantity of already thickened powder ceramic material CP ) a second quantity of powder ceramic material CP to an area of a second part T2 of the segment PA, downstream of the first part Tl .
  • the deaeration/ thickening step comprises a first deaeration ( i . e . thickening) sub-step, which is ( at least partially) subsequent to the first feeding step and ( at least partially) prior to the second feeding step, during which the first quantity of powder material CP is thickened, and a second deaeration (i.e. thickening) sub-step, which is (at least partially) subsequent to the first deaeration (i.e. thickening) sub-step and the second feeding sub-step, during which the second quantity of powder material CP is thickened.
  • the conveying step comprises a first transport sub-step, during which the transporter 9, which in this case comprises (in particular, is formed by) a movable distribution grid, receives a given quantity of powder ceramic material CP, at a loading position C, and transports it along the aforementioned segment PA to a release position R.
  • the deaeration (i.e. thickening) step is (at least partially) simultaneous with the first transport sub-step; more particularly (advantageously but not necessarily) , the deaeration (i.e. thickening) step occurs while the transporter 9 is at the loading position C.
  • the layer of thickened powder S is compacted in a discontinuous die 16 (advantageously but not limitatively, of the type described above, i.e. having at least one lower half-die 17 and a second, not shown upper half-die arranged facing each other and mutually movable closer to and away from each other) to compact the layer of thickened powder S and obtain the layer of compacted powder KP, in particular a base ceramic article CB as explained above in relation to the manufacturing system 1 of ceramic articles T.
  • a discontinuous die 16 advantageousously but not limitatively, of the type described above, i.e. having at least one lower half-die 17 and a second, not shown upper half-die arranged facing each other and mutually movable closer to and away from each other
  • the manufacturing process and system 1 of ceramic articles T of the present invention have several advantages, including the following.
  • the deaeration/ thickening unit at least part (in particular, most) of the air present between the grains of the ceramic powder material CP is evacuated before the powder material CP is subjected to the pressure necessary to be compacted.
  • This makes it possible to settle the particles (i.e. grains) of powder ceramic material CP, facilitating and speeding up the subsequent compacting action, resulting in an advantageous increase in compaction efficiency, considered as the maximum compaction ratio that can be achieved as a function of the final density of the ceramic article T.
  • the result is an increase in the production speed for the same thickness of powder ceramic material CP to be compacted or an increase in the thickness of powder ceramic material CP to be compacted for the same production speed.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

Procédé et système (1) de fabrication d'articles en céramique (T). Le système de fabrication (1) comprend : un ensemble d'alimentation (2) pour fournir un matériau céramique en poudre (CP); un dispositif de compactage (4); un ensemble transporteur (66) pour transporter un matériau céramique en poudre (CP) le long d'un trajet donné (P) dans une direction de déplacement (A); un ensemble de désaération (8) disposé en amont du dispositif de compactage (4) le long dudit trajet donné (P), pour transmettre une vibration avec au moins une composante sussultatoire, c'est à dire dans une direction verticale, au matériau céramique en poudre (CP) qui, lors de l'utilisation, est disposé au niveau d'un segment (PA) dudit trajet donné (P) de façon à épaissir ledit matériau céramique en poudre (CP) et obtenir une couche de poudre épaissie (S) qui est ensuite compactée par le dispositif de compactage (4). Le segment (PA) a une longueur comprise entre 0,5 m et 2 m.
EP23722668.3A 2022-04-14 2023-04-11 Système de fabrication et procédé de fabrication d'articles en céramique Pending EP4507864A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT202200007550 2022-04-14
PCT/IB2023/053695 WO2023199218A1 (fr) 2022-04-14 2023-04-11 Système de fabrication et procédé de fabrication d'articles en céramique

Publications (1)

Publication Number Publication Date
EP4507864A1 true EP4507864A1 (fr) 2025-02-19

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EP (1) EP4507864A1 (fr)
CN (1) CN119255898A (fr)
WO (1) WO2023199218A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1002265A (en) * 1962-09-10 1965-08-25 Yvon Trudeau Tile products of plastics materials and method of and apparatus for producing such products
EP1266734A2 (fr) * 2001-06-11 2002-12-18 Venix S.r.l. Procédé et appareil pour la fabrication de carreaux, en particulier de carrelages vénitiens pour revêtement de sol et similaires
US20150151456A1 (en) * 2012-05-24 2015-06-04 Glasseco Llc Method of manufacturing a surface apparatus and apparatus therefore

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE69117230T2 (de) * 1990-08-27 1996-08-22 Cca Inc Verfahren zur Herstellung von gemusterten geformten Gegenständen
JPH10264134A (ja) * 1997-03-27 1998-10-06 Sumitomo Metal Ind Ltd 粉末充填方法および粉末充填装置
EP2942208A1 (fr) * 2014-05-09 2015-11-11 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural ou de sol décoré
IT201900016103A1 (it) * 2019-09-11 2021-03-11 Siti B & T Group Spa Attrezzatura per la realizzazione di lastre in materiale ceramico e/o lapideo

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1002265A (en) * 1962-09-10 1965-08-25 Yvon Trudeau Tile products of plastics materials and method of and apparatus for producing such products
EP1266734A2 (fr) * 2001-06-11 2002-12-18 Venix S.r.l. Procédé et appareil pour la fabrication de carreaux, en particulier de carrelages vénitiens pour revêtement de sol et similaires
US20150151456A1 (en) * 2012-05-24 2015-06-04 Glasseco Llc Method of manufacturing a surface apparatus and apparatus therefore

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO2023199218A1 *

Also Published As

Publication number Publication date
CN119255898A (zh) 2025-01-03
WO2023199218A1 (fr) 2023-10-19

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