EP2263842B1 - Verfahren und Anlage zur Herstellung eines Keramikprodukts - Google Patents

Verfahren und Anlage zur Herstellung eines Keramikprodukts Download PDF

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Publication number
EP2263842B1
EP2263842B1 EP10166462.1A EP10166462A EP2263842B1 EP 2263842 B1 EP2263842 B1 EP 2263842B1 EP 10166462 A EP10166462 A EP 10166462A EP 2263842 B1 EP2263842 B1 EP 2263842B1
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EP
European Patent Office
Prior art keywords
negative pressure
slip
mould
cavity
pipe
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.)
Not-in-force
Application number
EP10166462.1A
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English (en)
French (fr)
Other versions
EP2263842A1 (de
Inventor
Vasco Mazzanti
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
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Sacmi Imola SC
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Publication date
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Priority to PL10166462T priority Critical patent/PL2263842T3/pl
Publication of EP2263842A1 publication Critical patent/EP2263842A1/de
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Publication of EP2263842B1 publication Critical patent/EP2263842B1/de
Not-in-force legal-status Critical Current
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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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B28B1/265—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor pressure being applied on the slip in the filled mould or on the moulded article in the mould, e.g. pneumatically, by compressing slip in a closed 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
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/04—Discharging the shaped articles
    • B28B13/06—Removing the shaped articles from moulds
    • B28B13/067—Removing the shaped articles from moulds by applying blows or vibrations followed by, or during, the removal of a mould part
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0002—Auxiliary parts or elements of the mould
    • B28B7/0014—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps
    • B28B7/0023—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps using vacuum

Definitions

  • This invention relates to a method and installation for making a ceramic product, in particular ceramic sanitaryware.
  • ceramic sanitaryware are made by pressure casting a liquid mixture, known as slip, consisting of water, clay and very small quantities of other substances, in "shell” moulds made preferably of porous resin.
  • the mould gives the article of sanitaryware the required shape and after a certain length of time (necessary to draw out the water) the article is extracted from the mould in a defined form and further processed according to a well-known sequence of steps until it is completely finished.
  • Sanitaryware made in this way can be broadly divided into two main categories, namely: “solid cast” products and “liquid cast” products, as they are known in the jargon of the trade.
  • the first category of products (solid cast), typical examples of which are lidded cisterns, are thus defined because the thickness of the product wall is formed between the surfaces of the male and female parts of the mould.
  • the second category of sanitaryware that is, liquid cast sanitaryware allows maximum freedom of form for the cistern and lids (referring again to this type of product).
  • the mould may have different dimensional ratios within it and the casting cavities may be very large.
  • the casting cavity is not divided between a male and a female part, as in the previous case, but the walls of the product are formed by a single surface within the mould.
  • Products of this type are made in installations of known type comprising the above mentioned mould and designed to utilize a high-pressure casting process which, in its simplest and most basic form, comprises the following steps:
  • the casting cycle starts with the mould closed and the moulding cavity perfectly clean and empty and ends with the mould closed but with the cavity containing the product just made and whose mechanical strength must be sufficient for it to bear its own weight when it is extracted from the mould.
  • the production cycle must, as is known, include a step of closing the mould prior to casting, and a step of demoulding the product after it has been formed.
  • the "female" mould is provided with two separate channels at the bottom of it, one for feeding in the slip and the other for discharging the used slip after the thickness of the ceramic product has been formed.
  • the slip can be discharged more quickly by introducing air into the mould cavity via the slip feed channel.
  • the moisture content, or gradient rises considerably from the surface of the cast that is in contact with the mould to the opposite surface of the cast.
  • the final cross section of the cast (that is, when the cast has reached the desired thickness, estimated using defined process parameters based on the shape and size of the ceramic ware to be made) can be divided into a "drier" (outermost) part and an inner part where the moisture content of the cast is still high compared to that of the drier part.
  • the casting cycle normally includes steps of pre-drying the cast by allowing it to stand for specified lengths of time, which, however, not only do not significantly reduce the moisture gradient but tend to cause the outer surface of the cast to solidify to a greater extent than the inner portion without effectively reducing the moisture differential through the cross section of the cast.
  • This invention therefore has for an aim to overcome the above mentioned drawbacks by providing a method for making a ceramic product which is capable of reducing the overall moisture content of the product while remaining within standard process cycle times.
  • Another aim of the method according to the invention is to harmonize, or at least make more uniform, the moisture content in all the sections of the product just cast.
  • a further aim of the invention is to provide a method for making ceramic products where the uniformity of the moisture content is obtained without modifying the basic structure of the casting installations and moulds used to make the ceramic products. Accordingly, this invention achieves this aim by providing a method and an installation for making ceramic products, in particular for making ceramic sanitaryware and comprising the technical characteristics set out in claims 1 and 8.
  • the method according to the invention is used for manufacturing ceramic products, in particular but not limited to, ceramic sanitaryware (such as, for example, washbasins, washbasin pedestals, toilet bowls, bidets, shower trays, and the like) using a liquid mixture known as slip.
  • ceramic sanitaryware such as, for example, washbasins, washbasin pedestals, toilet bowls, bidets, shower trays, and the like
  • slip a liquid mixture known as slip.
  • the installation denoted in its entirety by the numeral 5, basically comprises:
  • the mould 1 comprises two parts 2, 3 (male and female) made of porous resin and forming three cavities 4, each used to make a washbasin pedestal (in this situation, the moulds are liquid casting moulds).
  • the method according to the invention comprises the following steps:
  • the step of emptying the excess slip is followed by a step of applying a negative pressure, indicated by the arrows D inside the cavity 4 in order to reverse the direction DE of the pressure previously applied to separate the water from the rest of the slip.
  • the reversed direction enables the moisture content of the ceramic product M to be reduced.
  • applying a high negative pressure for a short time in the cavity or cavities 4 has the effect of making the moisture content along the thickness S of the cast product M more uniform, and hence of reducing the differences between the moisture contents of the product M along its thickness S, where the limit values of moisture content are those at the surface in contact with the mould (lowest moisture content) and at the innermost portion of the cavity (highest moisture content).
  • the negative pressure applied in the cavity 4 reduces the moisture of the innermost zone of the thickness S, thereby causing a general reduction in the moisture content through the product M as a whole.
  • the step of applying a negative pressure may be performed in different ways and according to parameters that depend also on the type of product, that is to say, on the thickness of the product.
  • this step of applying suction is performed during the step of pre-drying the interior (with the mould closed), which may take several minutes.
  • a first option is to apply a negative pressure in a single step in a space of time T of between 1 and 100 seconds with a negative pressure value D of between 0.05 and 1 bar.
  • the step of applying the negative pressure is performed in a shorter space of time T, for example between 1 and 10 seconds, again with negative pressure values D of between 0.05 and 1 bar.
  • the graph shows a first possibility, illustrated by the continuous line, with a time T of one second (products with reduced thickness) at a negative pressure of one bar, or, illustrated by a dashed line, with a time T of two seconds at one bar.
  • Another possibility is that of performing the step of applying a negative pressure D in at least two sub-steps S1 and S2 separated by a pause P.
  • the dot-dashed lines in the graph show by way of a non-limiting example a first sub-step S1 of applying a negative pressure D in a space of time T1 of between 1 and 50 seconds (in this particular case, 3 seconds) and a second sub-step S2 performed in a space of time T2 again of between 1 and 50 seconds (in this case, one and a half seconds, for example) separated by a short pause P.
  • the two sub-steps S1 and S2 of applying the negative pressure D may, again, be performed with negative pressure values D of between 0.05 and 1 bar: as shown in the graph, the negative pressure applied in both the sub-steps S1 and S2 may be one bar.
  • the installation 5 described above comprises a unit 10 for generating the negative pressure D (illustrated as a block) equipped with a second pipe 11 leading into the cavity or cavities 4.
  • the unit 10 applies suction which extracts gaseous fluid through the second pipe 11 from the inside of the cavity 4 when the latter is emptied of the residual slip.
  • the unit 10 extracts gaseous fluid in a direction D opposite the above mentioned direction DE in which the watery part is separated from the rest of the slip while the thickness of the product is being formed.
  • the unit 10 is connected to and controlled by the casting control unit 9 of the installation 5 to enable suction to be applied after the cavity has been emptied of the used or residual slip.
  • the pipe 11 is connected to and passes through one of the parts 2, 3 of the mould 1 (in this case, the female part 3) and leads into the cavity 4 in a different zone from that of the first pipe 7 for feeding / discharging the slip.
  • the second pipe 11 is connected to and passes through the top of the female mould part 3 on the side opposite that where the first pipe 7 is positioned.
  • the control unit 9 activates the negative pressure D after the used slip is discharged and the first pipe 7 is shut off to prevent any slip from flowing back into the cavity 4.
  • a method and an installation as described above fully achieve the above mentioned aims thanks to the negative pressure in the product moulding cavity which partly dries the inner portions of the product or, rather, reduces the overall moisture content, making the moisture content more uniform along the thickness of the product.
  • the negative pressure is applied for a very short length of time compared to the total pre-drying time and does not therefore have a negative effect on process times but does significantly reduce the stresses on the product when it is removed from the mould and thus reduces the risk of having to scrap the product.

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Claims (11)

  1. Verfahren zur Herstellung von Keramikprodukten, wobei das Verfahren mindestens folgende Schritte umfasst:
    - Füllen einer porösen Form (1), bestehend aus mindestens zwei Teilen (2, 3), die miteinander gekoppelt sind, um mindestens einen Formungshohlraum (4) zu bilden, mit einer Flüssigkeitsmischung oder einer geschlämmten Tonmasse unter Druck;
    - Formen der Dicke (S) des Keramikprodukts (M) durch Eingießen von mehr geschlämmter Tonmasse, sodass Wasser aus der Mischung abgeschieden und durch die Wände der Form (1) abgeführt wird, d. h. in eine Richtung (DE) außerhalb des Hohlraums (4);
    - Entleeren der überschüssigen geschlämmten Tonmasse aus der Form (1); wobei das Verfahren dadurch gekennzeichnet ist, dass es nach dem Schritt zum Entleeren der überschüssigen geschlämmten Tonmasse einen Schritt zum Anwenden eines negativen Drucks (D) im Hohlraum (4) umfasst, um zu ermöglichen, dass der Feuchtigkeitsgehalt des Keramikprodukts (M) reduziert wird.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Schritt zum Anwenden eines negativen Drucks (D) nach vorgegebenen Zeiten durch eine Steuereinheit (9) durchgeführt wird, um dafür zu sorgen, dass der Feuchtigkeitsgehalt entlang der Dicke (S) des Gussprodukts (M) gleichmäßiger ist.
  3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der negative Druck in einem einzelnen Schritt in einem Zeitraum (T) von 1 bis 100 Sekunden mit einem negativen Druckwert (D) von 0,05 bis 1 bar angewandt wird.
  4. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der negative Druck in einem einzelnen Schritt in einem Zeitraum (T) von 1 bis 10 Sekunden mit einem negativen Druckwert (D) von 0,05 bis 1 bar angewandt wird.
  5. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Schritt des Anwendens eines negativen Drucks (D) in mindestens zwei Unterschritte (S1, S2), die durch eine Pause getrennt sind, unterteilt ist.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass der erste Unterschritt (S1) zum Anwenden eines negativen Drucks in einem Zeitraum (T1) von 1 bis 50 Sekunden durchgeführt wird und der zweite Unterschritt (S2) in einem Zeitraum von 1 bis 50 Sekunden durchgeführt wird.
  7. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass der erste und der zweite Unterschritt (S1, S2) zum Anwenden des negativen Drucks bei negativen Druckwerten (D) von 0,05 bis 1 bar durchgeführt werden.
  8. Anlage zur Herstellung eines Keramikprodukts nach Anspruch 1 bis 7, wobei die Anlage (5) mindestens umfasst:
    - eine poröse Form (1), bestehend aus mindestens zwei Teilen (2, 3), die miteinander gekoppelt werden können, um einen Hohlraum (4) zum Eingießen des Keramikprodukts (M) zu bilden;
    - eine Einheit (6) zum Zuführen/Abführen der geschlämmten Tonmasse bei vorgegebenen Drücke und umfassend ein erstes Rohr (7), verbunden an einem Ende mit einem Tank (8), enthaltend die geschlämmte Tonmasse, und am anderen Ende mit mindestens einem der Teile (2, 3) der Form (1) ;
    - eine Einheit (9) zur Steuerung des Gusszyklus des Produkts (M), verbunden mit mindestens der ersten Einheit (6) zum Zuführen/Abführen der geschlämmten Tonmasse, eine Einheit (10) zum Erzeugen eines negativen Drucks (D), gesteuert durch die Steuereinheit (9), wobei die Anlage dadurch gekennzeichnet ist, dass die Einheit (10) zum Erzeugen eines negativen Drucks (D) mit einem zweiten Rohr (11) ausgestattet ist, das in den aus der Form (1) bestehenden Hohlraum (4) führt, um Flüssigkeit aus dem Innenraum des Hohlraums (4) zu entziehen, und ausgelegt, um aktiviert zu werden, nachdem die gebrauchte geschlämmte Tonmasse abgeführt wurde und das erste Rohr (7) abgesperrt wurde, um den Rückfluss von geschlämmter Tonmasse in den Hohlraum (4) zu verhindern.
  9. Anlage nach Anspruch 8, dadurch gekennzeichnet, dass das zweite Rohr (11) mit einem der Teile (2, 3) der Form (1) verbunden ist und durch diesen in den Hohlraum (4) in eine andere Zone als das erste Rohr (7) zum Zuführen/Abführen der geschlämmten Tonmasse führt.
  10. Anlage nach Anspruch 8, dadurch gekennzeichnet, dass das zweite Rohr (11) mit einem der Teile (2, 3) der Form (1) verbunden ist und durch diesen in eine Zone des Hohlraums (4) führt, die gegenständig zu der angeordnet ist, an der das erste Rohr (7) positioniert ist.
  11. Anlage nach einem der vorhergehenden Ansprüche 8 bis 10, dadurch gekennzeichnet, dass das zweite Rohr (11) mit einem Formteil (3) an der Oberseite des Formteils verbunden ist und durch diesen führt, das gegenständig zu der Stelle angeordnet ist, an der das erste Rohr (7) positioniert ist.
EP10166462.1A 2009-06-19 2010-06-18 Verfahren und Anlage zur Herstellung eines Keramikprodukts Not-in-force EP2263842B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL10166462T PL2263842T3 (pl) 2009-06-19 2010-06-18 Sposób i instalacja do wytwarzania produktu ceramicznego

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ITBO2009A000401A IT1394372B1 (it) 2009-06-19 2009-06-19 Metodo per la realizzazione di un manufatto in materiale ceramico.

Publications (2)

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EP2263842A1 EP2263842A1 (de) 2010-12-22
EP2263842B1 true EP2263842B1 (de) 2015-08-05

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EP10166462.1A Not-in-force EP2263842B1 (de) 2009-06-19 2010-06-18 Verfahren und Anlage zur Herstellung eines Keramikprodukts

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EP (1) EP2263842B1 (de)
ES (1) ES2550804T3 (de)
IT (1) IT1394372B1 (de)
PL (1) PL2263842T3 (de)

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4591472A (en) * 1982-03-17 1986-05-27 Keramik Holding Ag Laufen Process for the preparation of blanks
US5427722A (en) * 1993-06-11 1995-06-27 General Motors Corporation Pressure slip casting process for making hollow-shaped ceramics
ITBO20050514A1 (it) * 2005-07-29 2007-01-30 Sacmi Stampo per la realizzazione di un prodotto sanitario in materiale ceramico

Also Published As

Publication number Publication date
ES2550804T3 (es) 2015-11-12
PL2263842T3 (pl) 2015-12-31
ITBO20090401A1 (it) 2010-12-20
EP2263842A1 (de) 2010-12-22
IT1394372B1 (it) 2012-06-15

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