DE69918511T2 - Method and device for transferring granular material - Google Patents

Abstract

A method includes preparing together first layer means (112, 209, 256) and seconds layer means (108) in order to form layer means (108, 112; 108, 209; 108, 256) of ceramic granular material on support means (102), subjecting at least a portion of said layer means (108, 112; 108, 209; 108, 256) to a vacuum, to transfer together said first layer means (112, 209, 256) and said second layer means (108) of at least a portion of said layer means (108, 112; 108, 209; 108, 256) and pressing said at least a portion of said layer means (108, 112; 108, 209; 108, 256) in order to obtain a ceramic tile (104); an apparatus includes preparing means (206, 213, 210) arranged in order to prepare together first layer means (108) and second layer means (112; 209, 256) of layer means (108, 112; 108, 209; 108, 256) of ceramic granular material on support means (102) and transfer means (114) arranged to transfer together said first layer means (108) and said second layer means(112; 209, 256) into pressing means (118) through vacuum means in order to obtain a ceramic tile (104). <IMAGE>

Description

The The invention relates to a method and a related apparatus for the controlled transfer of granular material to means, which are designed to accommodate the same. The invention can in particular applied to the loading of a die for molding ceramic tiles become.

in the Context of the present description is a "flowable loose product" under "granular material" understood by powder, grains of any shape and size, Sinter, small tesserae or any mixture of these elements formed is.

Of the Need of converting granular material especially after the younger one Commercial success of the so-called "gres porcellanato "products especially desirable, which require that the overall aesthetic effect of the surface when Pressing without the aid of a subsequently applied by glazing coating is obtained.

Therefore there is the problem of being able to be well-defined and controllable Decorations using "dry" material in the context of a suitable high productivity to reproduce.

A of the technologies that are the solution of this technical problem is in the Italian patent for commercial Inventions No. 1269368, wherein a membrane is provided is that convert the decorative powder into a ceramic mold, the otherwise it was charged with basic powders. This system makes it possible not that the base position at the same time with the decoration layers is used in the mold. At least two loading operations are therefore required, the first for the base and the second for the decorative Location, which increases the press cycle time noticeably. There are two different ones Form loaders are required, moreover, one on the front and the other at the back be placed in the press, which is a noticeable complication brings.

IT-A-1104301 describes a device in which a layer of a cementitious material through a suction cup to another already inside a cavity a position positioned press mold is moved.

Also this device brings with it the requirement, the situation and to load the further situation at successive times, with the Consequence that provided a very complex and expensive rotary press is to an excessive loss in productivity to avoid.

In the Italian patent applications for industrial inventions RE96A000061 and RE96A000080 are methods of filling the mold by a tape described the powder directly into the cavity of the mold supplies. In both cases is it additional for the difficult control of the uniformity of thickness in the Form charged position not possible To obtain patterns with defined contours, since the powder one Path is subjected to a noticeable free fall.

In the Italian patent for Industrial Inventions No. 1287519 is the adoption of a decorative Picture provided in the form of an implementation, directly into the mold the tile is inserted. Such a method allows one good definition of the decorative pattern to be obtained, however, brings a significant increase in costs, first and foremost of the Fact depends that inserting the converter into the mold is necessarily before or after the insertion of the powder forming the body of the tile got to. A larger number at events When loading the form is therefore necessary, what the duration of the Work cycle significantly increased. In the second place, the costs are further increased, because the translators previously by external specialized companies need to be prepared with any resulting problems associated with the Transport, storage, etc. are connected. In third place is the converter always connected to a support film, the following must be separated from the pressed tile, which is still not simple interventions and also ecological problems, since such a transport foil must be disposed of subsequently.

EP-A-0858873 discloses a machine for forming and pressing powders, in particular for producing ceramic tiles, with at least one unit for Introducing a charge of loose powder into a tray, at least forms a charge receiving chamber, which is substantially a corresponding Cavity corresponds to a mold, at least one unit for Transfer the charge into the cavity of the mold without mutual Movements among the components of the cargo and at least one Press for compacting loose powders and obtaining the pressed Product.

EP-A-0860256 discloses a method for converting ceramic powder from a pick-up area to a use area, which is capable of settling the ceramic powder on a porous medium which is permeable to air but not to the powder so as to form a layered array of powder , arranging a porous membrane on the layered arrangement which is permeable to air but not to the powder , connecting the membrane to a suction source so that a portion of the layered assembly having preset dimensions adheres continuously to the membrane comprises translating the portion to the usage area and connecting the suction membrane to a positive pressure air source such that the section separates from the porous membrane and settles on the area.

One Purpose of the present invention is the known systems for the implementation of grainy Material to improve. In particular, the just described Problems largely or partially overcome and be solved i.e. the insertion of a decorative layer, such as a Reaction, within a mold simultaneously with the powder, that the body the tile forms should be possible with work cycles that are essentially those are the same for a normal tile without decorations are required.

One Another purpose of the present invention is the implementation directly during the productive cycle associated with pressing, to be able to get.

One Another purpose of the present invention is to realize a device which can also be applied to presses used for molding of ceramic tiles more common, i. e. such presses, which have a shape of the type in which the die, the lateral Frame and the stamp are always aligned, which is in a production cycle with single pressing a filling of the mold cavity without allows relative movements between the grains themselves, i.e. allows, different grainy ones Materials in just one filling process to introduce into the mold also according to the well-defined patterns in the layer arrangement and the surface, without the presence of excesses of Powders that need to be recycled and without loss of productivity.

One Another purpose of the present invention is the illustrated technology improve to overcome their shortcomings, and put it first to enable that a mold can be filled with only one loading process can, with a well-defined and controlled stratigraphic and factory assembly of various powders.

According to one The first aspect of the present invention is a method with provided the features of claim 1.

According to one second aspect of the present invention is a device provided with the features of claim 11.

On this way it is possible both the base material and the decorative material at the same time to convert to a ceramic press.

This allows compared to the loading systems where only the decorative Material or only the base material to be implemented individually, a higher Productivity.

Furthermore is due to the lack of a mix between the decorative Material and the base material during the implementation of an optimal definition of the decorative pattern.

The The invention may be better understood with reference to the accompanying drawings, which are exemplary and non-limiting embodiments represent, be better understood and executed, wherein:

1 a schematic side view of a device according to the invention, which is used for filling a mold by means of conversion, and that at the end of the filling step of the transfer means, with sections shown in section and broken;

2 a partial view of the device as in 1 during a translation step of the conversion means;

3 a view of the device as in 2 during a filling step of the mold;

4 a view of the device as in 2 during a return step of the conversion means;

5 a view of the device as in 2 during the filling step of the conversion means;

6 a view of the device as in 1 but according to another version;

7 a partial view of the device as in 6 during the filling step of the conversion means;

8th a view of the device as in 6 during a translation step of the conversion means;

9 a view of the device as in 6 in a filling step of the mold;

10 a schematic and interrupted a side view of an end portion of the device according to another version;

11 a sectional, greatly enlarged side view of the detail in the frame K in 10 is;

12 . 13 and 14 Views of the device in 10 during various operating steps;

15 a schematic side view of another version of the device according to the invention is;

16 Fig. 3 is a schematic sectional view of a version of the apparatus wherein the powder material is reacted while the carrier belt is moving.

A device 101 ( 1 ) has an endless band 102 made of an air-permeable material, such as a fine wire mesh or braided material on the outside with some partitions 103 provided, the subdivisions form, the dimensions corresponding to those of the tile 104 having the tape in a controlled manner by rolling 105 is moved.

grains 108 be between the partitions 103 on the tape 2 arranged, which form a base layer on which a different granular material 112 is arranged, which forms a decorative pattern, and to an end portion 113 of the band 102 be advanced, with sucker-shaped Umsetzmitteln 114 interacts.

The sac-shaped conversion means 114 comprise a porous membrane 115 that of a room 116 capable of being subjected to vacuum by known means and overhung by side walls comprising a frame 117 form with respect to the porous membrane 115 is axially movable.

The sac-shaped conversion means 114 are horizontally movable and move translationally from a position in which they are above the end section 113 of the band 102 hang (as in 1 . 5 . 6 and 7 ) to a position within the open mold 118 (as in 3 and 9 ), and vice versa.

Form 118 is through a die 119 with side frame, a lower die 120 and an upper punch 121 educated. Obviously, a mold of the type known as a "double mirror", ie a mold with two axially movable, side frame dies, or any other suitable shape may be used.

For every pull and translational cycle of the sac-shaped conversion means 114 puts the tape 102 a step forward, creating a new section of granular mass 108 . 112 in a position suitable for collecting them.

In 6 to 9 is a modification of the device without partitions 103 shown, so therefore on the tape 102 a continuous layer of grains 108 is formed while the different grains 112 are arranged only in the areas which are adapted to, through the sac-shaped conversion means 114 to be taken off.

The conversion means 114 are with side walls 122 provided with the porous wall 115 are connected and to the band 102 protrude. The walls 122 have a comparatively thin thickness, ie which is suitable in a mass of grains 108 penetrate without significantly disturbing them, or have a cross-section shaped as a "wedge" with the point pointing downwards.

In this version, some surpluses of grains 123 generated, which can be recycled directly.

The possible disadvantage of installing means of transport for the excesses of grains 123 will be compensated in any case if the device is designed to produce tiles of different sizes. In this case, the mechanical processes of resizing are indeed simple and quick, as it is simply necessary to frame 122 and, if necessary, to influence the settings of the decorative means. For this purpose, the side walls 122 removable on the structure of the permeable wall 115 attached so that they can be easily replaced.

As in 8th can be seen, during translation of the trigger-shaped Umsetzmittel 114 a lower level on the grains 108 can be adjusted to remove any surplus or their surface by a scraper 124 to level. Such material will automatically with the other surpluses of grains 123 verbinnden.

Regarding 10 . 11 . 12 . 13 and 14 a layer of low permeability is provided by a carrier sheet 203 formed and between the base position 108 and the band 102 is interposed.

A decorative layer of granular material 208 will be between the location 203 low permeability and the base position 108 interposed, the decorative layer 208 together with the carrier foil 203 that forms what as implementation 209 is defined. Furthermore, a station F1 is provided, which means 206 equipped, which are suitable, the implementation 209 to cover with powders in a funnel chamber 206 are included and the base position 108 the tile 104 form.

The Decoration can be like in the example with powder or granular material be carried out in a dry state, or with powder or grainy Material according to known Technologies with liquid Means is mixed. In the first case is preferably a another station (not shown) for fixing the decorative Material, for example by applying a fixing substance, in the second case, preferably, a subsequent drying station (not shown) may be present.

As in 10 and 11 is highlighted, lies the entire section of the tape 102 before the end section 113 on a permeable carrier 214 due, for example, to the presence of small holes 215 is permeable. The carrier 214 surrounds with a sealing wall 216 a room 217 within which a slight vacuum is maintained by known means, not shown. This vacuum has the function, the film 203 and the respective implementation 209 firmly held in position on the belt 201.

The operation of the device in 10 to 14 is analogous to the operation, with reference to 6 to 9 has been described.

The combination just described, ie the implementation of the powder layer 108 and the location 203 low permeability using the vacuum device 114 is particularly effective and beneficial because the fact that the low permeability layer forms a substantially impermeable wall allows the powders to be made 108 on the inside of the device 114 By means of a "static vacuum" of a small amount, without the layer of low permeability would instead have a higher and more dynamic vacuum to hold the powder 108 be required, that is obtained by an air flow, which is continuously through the powder 108 what separates under the different granulometric fractions of the powders 108 and could cause a deterioration of the aesthetic appearance of the decor.

It can also be beneficial instead of implementing it 209 to use a thin sheet of paper, plastic material or a layer of low permeability, designed to keep said substantially impermeable wall for holding the powders 108 while the decorative materials may be placed in a different position, for example over the powders 108 and directly in contact with the permeable wall 115 ,

The implementations 209 can be prepared in advance.

The slides 203 may have a circumferential dimension corresponding to the dimensions of the tile 104 However, they may also be formed by a thin continuous band, for example made of a heat-meltable plastic material, automatically through the frame 220 which has been heated to a suitable temperature, can be cut to the correct size.

As in 15 the low permeability layer can be shown by spreading a first layer 253 of powder material 254 on the tape 102 are obtained, preferably by isolated areas having a circumferential extent, which is about the circumferential dimension of the tile 104 equivalent.

The powder material 254 is not necessarily composed of decorative materials, but may be the same material 108 be that to making the body of the tile 104 or any other material which has specific suitable properties for the treatment to which it is to be subjected and for the function which it is intended to perform.

The location 253 can be subjected to a compaction process by passing them through the rollers 255 Run, so the location 253 low permeability, the layer then through the powder 108 and by optional decorative layers 112 is covered. The powders 256 can advantageously have a particle size that is less than the grain size of the powder layer 108 , The thus formed bundle of layers is then as already described by the sac-shaped conversion means 114 taken off and to the form 118 implemented.

The decorative situation 112 and the location 253 can with known distribution agents 213 be distributed.

The advantage of such a version is based on the fact that even if the conversion means 114 have a mode of operation with a "static vacuum", no foreign material is present, that of the pressed tile 104 must be replaced and removed as the location 253 an integral Part of the tile 104 forms. Compacting the situation 253 moreover, it is particularly easy, since the layer has a small thickness, so that rollers with large diameters are not required. Noticeable press forces are also not required as the currently pressed area is somewhat limited.

In addition, it allows the small thickness of the situation 253 to obtain a good compaction effect in the peripheral regions of the sheet even in the absence of walls for lateral encasing of the powder.

The ribbon 102 can also be advantageously divided into two parts in this version, wherein the first part, at which the compaction takes place, has an impermeable surface, while the second part has a permeable surface, so as to the operation of the conversion means 114 to facilitate.

The location of low permeability can also be by treating the location 253 be obtained with suitable impregnating substances.

As in 16 The translation of the device can be shown 114 to the form 118 also take place by the frame 122 in contact with the tape 102 is held and the tape is also moved synchronously. Such a method may be advantageous in order to prevent air from entering under the base layer 108 to favor. In fact, the air penetrates when the device 114 increasingly from the end of the tape 1 projects. It could therefore be possible a band 102 to use, which is made of a material impermeable to air.

Claims (19)

Method in which layering agent ( 108 . 209 ; 108 ; 256 ) of granular ceramic material on supports ( 102 ), at least part of the layer means ( 108 . 209 ; 108 . 256 ) is subjected to a vacuum which comprises at least a part of the layer means ( 108 . 209 ; 108 . 256 ) by means of conversion means ( 114 ), by the means ( 102 ), wherein the at least one part comprises a loose product, and wherein the at least one part of the layer means ( 108 . 209 ; 108 . 256 ) is pressed to prevent compression of the layer means ( 108 . 209 ; 108 . 256 ) a ceramic tile ( 104 ), wherein the providing comprises providing first layer means ( 108 ) distal to the carriers ( 102 ) together with second layer means ( 209 . 256 ) proximally of the carriers ( 102 ) to the sheet means ( 108 . 112 ; 108 . 209 ; 108 . 256 ), the second layer means ( 209 . 256 ) a lower permeability to a fluid flow than the first layer means ( 108 ), wherein the translating comprises converting the first layer means ( 112 . 209 . 256 ) together with the second layer means ( 108 ) of the at least part of the layer means ( 108 . 112 ; 108 . 209 ; 108 . 256 ). The method of claim 1, wherein the providing comprises distributing the first layer means ( 108 ) on the carriers ( 102 ) to a base body of the tile ( 104 ) to build. The method of claim 2, wherein the providing comprises distributing the second layer means ( 256 ) on the carriers ( 102 ) before the first layer means ( 108 ). A method according to claim 2 or 3, further comprising powder material ( 253 ) is pressed to the second layer means ( 256 ) to obtain. Method according to one of claims 2 to 4, wherein the second layer means ( 209 . 256 ) a smaller grain size than the first layer means ( 108 ) exhibit. Method according to one of claims 2 to 5, wherein the second layer means ( 256 ) a tile decorative pattern ( 104 ) define. Method according to one of the preceding claims, wherein the second layer means ( 209 ) form a coherent situation. Method according to one of the preceding claims, wherein the providing comprises arranging the layer means ( 108 . 209 ; 108 . 256 ) in cavities of the carrier means ( 102 ). The method of any one of the preceding claims, wherein said translating comprises moving said carrier means ( 102 ) with the layer means ( 108 . 112 ; 108 . 209 ; 108 . 256 ), which are arranged on this, while the vacuum on the layer means ( 109 . 209 ; 108 . 256 ) is applied. Method according to one of the preceding claims, wherein prior to the conversion, cutting off the at least one part of the layer means ( 108 . 209 ; 108 . 256 ) is provided. Device with delivery means ( 206 . 213 . 210 ), which are designed to be layered ( 108 . 209 ; 108 . 256 ) of granular ceramic material on supports ( 102 ), with conversion means ( 114 ), by the means ( 102 ) are different and are adapted to the layer means ( 108 . 209 ; 108 . 256 ) in pressing means ( 118 ) by vacuum means to form a ceramic tile ( 104 ), the layer means ( 108 ; 209 ; 108 ; 256 ) have a loose product, the Be providing means ( 206 . 213 . 210 ) are formed so that they first layer means ( 108 ) distal to the carriers ( 102 ) together with second layer means ( 209 . 256 ) proximally of the carriers ( 102 ), the second layer means ( 209 . 256 ) have a lower permeability to a fluid flow than the first layer means ( 108 ), the conversion means ( 114 ) are formed so that they the first layer means ( 108 ) together with the second layer means ( 209 . 256 ) implement. Apparatus according to claim 11, wherein said providing means ( 206 . 213 . 210 ) Medium ( 206 . 210 ) for distributing the first layer means ( 108 ) on the carrier ( 102 ) to form a base body of the tile ( 104 ) to build. Apparatus according to claim 11 or 12, wherein the providing means ( 206 . 213 . 210 ) additional funds ( 213 ) for distributing the second layer means ( 209 . 256 ) on the carriers ( 102 ). Device according to one of claims 11 to 13, further comprising means ( 255 ) for pressing powder material ( 253 ) to the second layer means ( 256 ) to obtain. Device according to one of claims 10 to 13, wherein the conversion means ( 114 ) Sucking agent ( 115 . 116 ). Apparatus according to claim 15, wherein the suction means ( 115 . 116 ) Framework ( 117 ) within which the Hutzmittel ( 115 . 116 ) are displaceably actuated. Device according to one of claims 11 to 16, wherein the carrier means ( 102 ) with furrows ( 103 ) defining hollow means in which the ply means ( 108 . 209 ; 108 . 256 ) are included. Device according to one of claims 11 to 17, wherein the provisioning means are designed such that second layer means ( 209 ), which form a coherent situation. Device according to one of claims 11 to 18, wherein the conversion means are designed such that they at least a part of the sheet means ( 108 . 209 ; 108 . 256 ) cut off.