CN113735560A

CN113735560A - Model (model)

Info

Publication number: CN113735560A
Application number: CN202110508328.4A
Authority: CN
Inventors: 黄忠万; 莫哈末·塔祖尔·阿克马尔·本·莫哈末·塔利卜; 阿迪巴·宾蒂·阿里
Original assignee: Top Glove International Sdn Bhd
Current assignee: Top Glove International Sdn Bhd
Priority date: 2020-05-29
Filing date: 2021-05-11
Publication date: 2021-12-03
Also published as: MY197179A

Abstract

The application discloses a model, it includes: clay in an amount ranging from 37% to 41% by weight of the model; a plasticizer in an amount ranging from 15% to 20% by weight of the model. A refractory agent in an amount ranging from 16% to 20% by weight of the model; a fluxing agent in an amount ranging from 20% to 24% by weight of the model; and a filler in an amount ranging from 2% to 6% by weight of the model.

Description

Model (model)

Technical Field

The present invention relates to a mold (former), and more particularly, to an energy saving mold having improved thermal conductivity.

Background

Ceramics are a class of inorganic and non-metallic solids that are subjected to high temperatures during manufacture and use. Modeling is part of the ceramic industry. In the glove manufacturing process, the model is also referred to as a hand model or hand model. There are many types of materials used to produce models, such as aluminum or wood, and porcelain is the primary type of material used in glove manufacturing processes due to its durability and cost effectiveness.

The molds used in the glove manufacturing process typically involve high temperatures (in the presence of many ovens), particularly during the drying and curing process. More ovens are used to ensure uniform heating of the latex film on the former and to produce gloves with fewer defects. Uneven drying or curing can cause problems such as syneresis of the coagulant in the latex dip tank, which ultimately results in defective gloves due to the presence of lumps in the latex dip tank and beneath the cured gloves. On the other hand, using more ovens results in high consumption of gas and energy. Thus, it is evident from the above that the glove manufacturing industry is facing several challenges that need to be overcome.

Thus, a method can be developed to determine suitable materials with enhanced thermal conductivity for making an energy saving model and suitable methods for making an energy saving model, making it cost effective for the glove manufacturing industry.

Disclosure of Invention

The invention relates to a model comprising:

clay in an amount ranging from 37% to 41% by weight of the model;

a plasticizer in an amount ranging from 15% to 20% by weight of the model.

A refractory agent in an amount ranging from 16% to 20% by weight of the model;

a fluxing agent in an amount ranging from 20% to 24% by weight of the model; and

a filler in an amount ranging between 2% and 6% by weight of the model.

Other aspects, features and advantages of the present invention will become apparent to those of ordinary skill in the art upon consideration of the following detailed description of the preferred embodiments of the invention.

Detailed Description

Detailed descriptions of preferred embodiments of the invention are disclosed herein. However, it is to be understood that the embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. Numerical data or ranges used in the specification are not to be construed as limitations.

In this context, a former refers to a hand model used to make gloves made from natural, synthetic rubber materials, or combinations thereof. Moreover, it should be understood that the embodiments described herein may be used to prepare any ceramic object, such as, but not limited to, tiles, floor and roof tiles, refractory materials, white ceramics, pottery, and terracotta. The model is represented as a representative example of an object that can be prepared using the methods described herein.

The present invention relates to a model, and more particularly, to a model that is an energy saving model that is lighter in weight and has improved thermal conductivity. The model has a low porosity, such evidence being observed in the example section. The model can also be, but is not limited to, a model that is non-textured, textured with fingers, and textured with palms.

In summary, the first embodiment of the present invention introduces an energy saving model. The energy saving model includes (i) clay, (ii) plasticizer, (iii) refractory, (iv) flux, and (v) filler.

The clay is any one selected from the group consisting of kaolin, calcined china clay and any combination thereof, and is preferably kaolin. The amount of clay used is in the range of from 37% to 41% by weight of the model, preferably from 38% to 40% by weight of the model, more preferably 39% by weight of the model.

The plasticizer is a spherical clay. The amount of plasticizer used is in the range of 15% to 20% by weight of the model, preferably 16% to 18% by weight of the model, and more preferably 17% by weight of the model.

The refractory is any one selected from the group consisting of alumina and kaolin, and preferably alumina. The amount of the refractory is in the range of 16% to 20% by weight of the model, preferably 17% to 19% by weight of the model, and more preferably 18% by weight of the model.

The flux is any one selected from the group consisting of potassium feldspar, nepheline syenite and any combination thereof, and preferably potassium feldspar. The amount of fluxing agent used is in the range of 20% to 24% by weight of the model, preferably 21% to 23% by weight of the model, more preferably 22% by weight of the model.

The filler is any one selected from the group consisting of calcined china clay, mullite and any combination thereof, and is preferably calcined china clay. The filler is used in an amount ranging from 2% to 6% by weight of the model, preferably from 3% to 5% by weight of the model, more preferably 4% by weight of the model.

Table 1 shows the chemical compositions (as described above) and their compositions used to prepare the energy saving model of the present invention.

Table 1: chemical compositions and their compositions for preparing the energy saving models of the present invention

Chemical product	Working Range (%)	Preferred range (%)	Typical value (%)
				Clay clay	37 to 41	38 to 40	39
Plasticizer	15 to 20	16 to 18	17
				Refractory agent	16 to 20	17 to 19	18
Fluxing agent	20 to 24	21 to 23	22
				Filler material	2 to 6	3 to 5	4

The energy saving models of the present invention are prepared using the above formulation using a method generally known in the modeling industry, the method comprising the steps of:

i. compounding components comprising (i) clay, (ii) plasticizer, (iii) fire retardant, (iv) fluxing agent and (v) filler, so as to obtain a compounded mixture;

(ii) casting the composite mixture obtained from step (i) so as to obtain a cast model, wherein the duration of the casting ranges between 20 minutes and 25 minutes, preferably between 21 minutes and 24 minutes;

(iii) demoulding from the cast mould obtained in step (ii) to obtain a demoulded mould, wherein demoulding is performed after a duration of 50 to 60 minutes (preferably 55 minutes) after back-slip (return slip) pouring;

oven drying the demoulded mould obtained from step (iii) in order to obtain a dried mould, wherein the oven drying is carried out at a temperature between 50 ℃ and 60 ℃ for a duration between 50 minutes and 60 minutes, preferably between 52 minutes and 58 minutes;

(iv) trimming the dried model obtained from step (iv) to obtain a trimmed model, wherein trimming is performed by trimming the seam area visible on the model;

sponge wiping the trimmed model obtained from step (v) to form a sponge wiping model, wherein sponge wiping is performed by any conventional sponge wiping method, such as, but not limited to, manually by wiping the trimmed model with a wet sponge to make the entire surface smooth;

(vii) blasting the sponge-wiped model obtained from step (vi) to obtain a blasted model, wherein blasting is performed by conventional methods using abrasive materials, such as, but not limited to, glass beads or ceramic beads, preferably ceramic beads;

(viii) inspecting the quality of the blasting model obtained by step (vii) using a quality control step, wherein the quality control step comprises a visual inspection, a bending inspection and a weight inspection;

base dipping (base dipping) the models obtained by step (viii) in order to obtain dipped models, wherein the base dipping is carried out by dipping the models from base in coloured glaze for a length, in order to mark the models according to their size, wherein the length is (but not limited to) 50 cm;

baking the infusion model obtained from step (ix) in order to obtain the energy saving model of the invention, wherein the baking is carried out using, but not limited to, a gas kiln at a baking temperature between 1250 ℃ and 1350 ℃ (preferably 1300 ℃) for a duration between 6 hours and 10 hours.

The following examples are constructed to illustrate the invention in a non-limiting sense.

Examples of the invention

Energy-saving model

The energy saving model comprises clay, plasticizer, fire retardant, fluxing agent and filler.

The energy saving models of the present invention are prepared using the above formulations using methods generally known in the modeling industry, the details of which are described above.

The energy-saving model of the invention is analyzed for physical properties. The energy saving model of the present invention is evaluated based on a comparison between the conventional model and the energy saving model. The results are summarized in tables 2 to 6 below:

table 2 shows physical properties, such as model weight, thickness and flexural modulus at break (MOR), of the conventional model and the energy saving model of the present invention with different casting times.

Table 2: model weight, thickness and bending MOR of conventional model and inventive energy saving model with different casting times

Conventional model samples 1 and 2 are two sets of models with the same composition and characteristics used to obtain the average results.

Inventive energy saving model samples 1 and 2 are two sets of models with the same composition and characteristics for obtaining average results.

From table 2 it is clear that a lower casting time results in a lower thickness of the model of the invention, which directly results in a lighter weight of the model as well. In summary, a lower thickness will in particular reduce the thermal variation between the inner and outer sides of the mould, resulting in an increased thermal conductivity.

It is also clear that lower thickness will provide lower MOR. Although the thickness of the energy saving model of the present invention is 14.8% thinner than that of the conventional model, averaging 3.28mm, the strength of the energy saving model of the present invention is 9.5% higher than that of the similar conventional model with an averaging thickness of 3.85 mm.

Table 3 shows the differences in physical properties, such as water absorption, chemical resistance, calcined density, and thermal shock resistance, between the conventional model and the energy-saving model of the present invention.

Table 3: physical property differences between the conventional model and the energy-saving model of the present invention

Conventional model samples 1 and 2 are control group models without calcinating china clay and without reducing casting time. Conventional models 1 and 2 are two sets of models with the same composition and characteristics for obtaining average results.

Conventional model samples 3 and 4 are conventional models without calcinated china clay and with reduced casting time. Conventional models 3 and 4 are two sets of models with the same composition and characteristics for obtaining an average result.

The energy saving model sample 1 and the model sample 2 of the present invention are two sets of models having the same composition and properties for obtaining an average result.

According to table 3, the conventional model samples 3 and 4 with reduced casting time cannot satisfy the minimum required values for the calcined density, the water absorption test, the chemical resistance test, and the thermal shock resistance at 180 ℃. This is because when the casting time is shortened, slip penetrates into the surface of the gypsum pattern due to lack of slip particle densification.

Meanwhile, the results of the water absorption test, the chemical resistance test, the calcined density test, and the thermal shock resistance test of the energy-saving model samples 1 and 2 of the present invention represent the comparison results compared to the conventional model samples 1 and 2. These tests are performed according to internal parameters set for the model in order to guarantee an optimal shelf life of the model. Therefore, it was shown that the energy saving model of the present invention can satisfy the internal physical properties set for the model and is suitable for use as a model in a glove manufacturing process.

Table 4 shows the model temperatures recorded on-line during the glove manufacturing process for the conventional model and the energy saving model of the present invention.

Table 4: online model temperatures for conventional model and energy-saving model of the invention

The data in table 4 were collected under actual glove manufacturing conditions. A device called a data logger is inserted into the mold to record the actual applied temperature of the mold as manufacturing parameters are controlled. The results in table 4 were obtained with the oven temperature set at 150 ℃.

According to the results obtained, the energy-saving model of the invention is capable of heating up to a temperature approximately 14 ℃ higher than the conventional model, at the same heating temperature and duration. This clearly shows that the energy saving model of the present invention has better thermal conductivity than the conventional model. Therefore, it will be possible to change the manufacturing parameters of the glove, thereby precisely reducing the online oven temperature.

Table 5 shows a comparison of elements between all raw materials used by the above-described conventional model and the energy-saving model of the present invention.

Table 5: element comparison of conventional model and energy-saving model of the invention

From table 5, it is apparent that the alumina content is higher in the energy saving model of the present invention compared to the conventional model. In addition to being lighter in weight, this also helps to increase the thermal conductivity of the energy saving model of the invention.

Table 6 shows the thermal conductivity and hardness values of the chemical components present in the energy saving model of the present invention.

Table 6: thermal conductivity and hardness values of chemical components

According to table 6, the calcined china clay has the second highest thermal conductivity and hardness next to alumina. This shows that the use of calcined china clay can improve MOR and thermal conductivity of the energy saving model of the present invention, which is thinner and lighter in weight. This is because the calcined china clay includes a higher alumina content, which helps to enhance the thermal conductivity of the energy saving model of the present invention.

In general, the energy saving model of the present invention can overcome the conventional disadvantages because the model of the present invention can reduce gas and energy consumption by using a suitable material (such as, but not limited to, calcined china clay) as a chemical component to increase the thermal conductivity of the model of the present invention, which directly requires only minimal energy consumption to increase the temperature of the model to the optimum value for operation.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It should also be understood that additional or alternative steps may be used. The use of the expression "at least" or "at least one" is to suggest the use of one or more elements, as the use in one embodiment may be used to achieve one or more desired purposes or results.

Claims

1. A model, the model comprising:

clay in an amount ranging between 37% and 41% by weight of the model;

a plasticizer in an amount ranging from 15% to 20% by weight of the model;

a refractory agent in an amount ranging from 16% to 20% by weight of the model;

the dosage of the fluxing agent is in the range of 20-24% of the weight of the model; and

a filler in an amount ranging between 2% and 6% by weight of the model.

2. The model of claim 1, wherein: the clay is selected from the group consisting of kaolin, calcined china clay and combinations thereof.

3. The model of claim 1, wherein: the amount of clay used ranged between 38% and 40% of the model weight.

4. The model of claim 1, wherein: the plasticizer is a spherical clay.

5. The model of claim 1, wherein: the plasticizer is used in an amount ranging from 16% to 18% by weight of the model.

6. The model of claim 1, wherein: the refractory is selected from the group consisting of alumina and kaolin.

7. The model of claim 1, wherein: the amount of the refractory is in the range of 17% to 19% by weight of the model.

8. The model of claim 1, wherein: the flux is selected from the group consisting of potassium feldspar, nepheline syenite, and combinations thereof.

9. The model of claim 1, wherein: the amount of flux used ranged between 21% and 23% of the model weight.

10. The model of claim 1, wherein: the filler is selected from the group consisting of calcined china clay, mullite, and combinations thereof.

11. The model of claim 1, wherein: the amount of filler used ranged from 3% to 5% by weight of the model.