EP2583802B1 - An improved buffer for mold for ceramic industry and mold comprising said buffer. - Google Patents

An improved buffer for mold for ceramic industry and mold comprising said buffer. Download PDF

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Publication number
EP2583802B1
EP2583802B1 EP20120188877 EP12188877A EP2583802B1 EP 2583802 B1 EP2583802 B1 EP 2583802B1 EP 20120188877 EP20120188877 EP 20120188877 EP 12188877 A EP12188877 A EP 12188877A EP 2583802 B1 EP2583802 B1 EP 2583802B1
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EP
European Patent Office
Prior art keywords
buffer
mold
edge
thickness
concave portion
Prior art date
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EP20120188877
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German (de)
English (en)
French (fr)
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EP2583802A1 (en
Inventor
Mario Manenti
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Manenti SpA
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Manenti SpA
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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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/04—Anodisation of aluminium or alloys based thereon

Definitions

  • the present patent application for industrial invention relates to an improved buffer for a mold for the ceramic industry in accordance with the preamble of claim 1 and to a mold comprising said buffer.
  • mold for ceramic industry indicates a mold used to manufacture ceramic tiles or the like.
  • tile will be used in the following description to identify the finished product generated by said mold.
  • Said molds are used to inject raw material (normally clay, sand and composite materials), compress it and produce a ceramic tile with the desired shape and/or decorative pattern.
  • raw material normally clay, sand and composite materials
  • molds (1) comprise a base plate (6), an ejector block (5), a die (9) and buffers (2 and 3).
  • Buffers comprise an upper buffer (2) and a lower buffer (3) that are moved closed to each other and pressed during fabrication of the tile (M), in such manner to define the walls of a chamber (8) where raw material is injected (in the generic direction indicated by arrow IN) for fabrication of the ceramic tile (M).
  • the die (9) is provided with plates (7) that contribute to form the chamber (8) of the mold.
  • upper buffers (2) are usually mounted on a fixed frame of the machinery using the mold (1), whereas lower buffers (3) are mounted on a magnetic base (4) connected with the ejector block (5).
  • the buffers (3) mounted on the magnetic base (4) are defined as "upper”, thus creating some confusion in terms of part denomination. From now onwards (description and claims), the term “buffer” will be therefore used to indicate only the lower buffer, viz. the one mounted on the magnetic base (4) and adapted to form the finished surface of the tile (M).
  • the preparation of a C40 steel buffer normally requires the following steps: preliminary machining of raw semi-finished part made of C40 steel on a machine tool, welding of buffer parts subject to wear, grinding and finishing. Then buffers are covered with glue and/or resin for casting and mounted on the mold, where the casting process is started.
  • the casting process comprises the following steps: injection of material (sand, clay and the like) to form the tile, realization of chamber (8) formed of the two buffers (2 and 3) that are moved close, leakage of gaseous and solid residues between buffer and plates (7) mounted on die (9) and finally removal of tile (M).
  • a first drawback is related with the weight of buffers that, being made of C40 steel, are rather heavy and hinder handling and assembly on mold.
  • Another problem is related with the time needed to prepare C40 buffers. As mentioned above, said process is rather long and requires a plurality of machining operations that, in spite of being simple, must be carried out accurately in order to avoid errors in finished products.
  • Fig. 2 is an enlarged detailed view of Fig. 1 , i.e. part of a buffer (3) of known type and a plate (7).
  • the buffer (3) has an external profile (3D) extending in parallel direction to the surface of the plate (7) opposite to it, and an internal concave area (3A) that represents the bottom of the chamber (8).
  • the concave area (3A) is defined by a perimeter border (3B) having an upper edge (3C) parallel to the bottom surface of the concave area and perpendicular to the external profile (3D).
  • the gas flow from the production of the ceramic tile (M) comes out according to the direction of arrow FG of Fig. 2 , reaching buffer (3) and plate (7) in an area where they are especially close. This determines a high gas flow rate. It must be considered that gases are loaded with clay pulverulent residues that are able to cause early wear of the buffer (3) by friction.
  • the plate (7) is more resistant because it is formed of tempered ferrous materials that are harder than the buffer (3).
  • the wear of the buffer (3) in said area of the external lateral profile (3D) reduces accuracy of shape in ceramic tiles (M) and increases the space for passage of gas flow (FG), with additional wear and movement of buffers because of vibrations.
  • the perimeter border (3B) and in particular the external profile (3D) is covered by a carried-over layer of welding material, which is more wear resistant.
  • US2008/164402 discloses a mold for casting green ceramic bodies (transparent or optical ceramic) for optical lenses. Said document suggests using an anodized hardened aluminum mold only for gel casting. Instead, it suggests using steel molds for high-pressure die casting and hot pressing.
  • Gel casting is a wet casting process where gel is a liquid containing a small percentage of polymerizable binding agents added to the ceramic slip.
  • the ceramic body has low retraction and is obtained by means of low pressure (0.1 - 50 MPa) at ambient temperature or slightly higher temperature. For this reason, also an aluminum mold (which is notoriously more fragile than a steel mold) can be suitable.
  • Traditional anodization is a superficial anodization that is made only for 25-30 microns and provides resistance only on the external surface of the mold.
  • ceramic casting for tiles is made at high pressure. Casting is made with powders (therefore solid materials) combined with gases at medium and high temperature (from 70-80 degrees).
  • an aluminum mold is not suitable because of fragility. Although the aluminum mold is traditionally anodized, with anodization surface of 25-30 microns, such a mold would not be suitable; as a matter of fact, document US2008/164402 recommends a steel mold.
  • SU 1 560 416 discloses a mold for ceramic production with working surface made of porous aluminum oxide and non-working surface made of non-porous aluminum oxide. Porous aluminum oxide is treated with anodization process. Porous molds are suitable for slip casting and not for ceramic tile casting.
  • a first object of the present invention is a buffer for a mold for the ceramic industry as defined in claim 1 and which is able to solve the aforementioned drawbacks.
  • Another object of the present invention is a mold comprising said buffer.
  • the purpose of the present invention is to provide a buffer that is less heavy than a known buffer, equally resistant to the stress of ceramic tile fabrication process and faster to make.
  • the idea of the present invention is to realize the buffer with aluminum with hard anodization treatment, at least partially on the surface exposed to wear. Said anodization is made in such manner that the anodized surface has thickness of approximately 70-80 microns.
  • the use of the hard anodization treatment on an aluminum buffer allows it to withstand the working conditions of a mold for ceramic materials.
  • Another advantageous characteristic refers to the special configuration of the external profile of the buffer edge that, together with realization with hard anodized aluminum on the external profile of the edge, permits to increase the performance (i.e. production life) of the aluminum buffer according to the present invention.
  • a buffer (30) (adapted to replace buffer 3 of Figs. 1 and 2 ) is disclosed.
  • the buffer (30) comprises a body (34) with concave portion (31) adapted to be the bottom of the injection chamber (8) where raw materials are injected to obtain a ceramic tile (M).
  • the concave portion (31) comprises a bottom wall (32) adapted to preferably form the external surface of a ceramic tile (M) (the surface that remains visible when the ceramic tile is laid).
  • the bottom wall (32) is generally flat for at least part of its surface (except for special cases or relief decoration patterns).
  • the concave portion (31) is perimetrally defined by an edge (33) completely surrounding the bottom wall (32) and protruding from the body (34).
  • the edge (33) comprises an external profile area (35), facing the side of the edge (33) opposite to the side facing the concave portion (31).
  • the external profile area (35) is adapted to be faced towards the plate (7) of the die.
  • the buffer (30) is made of aluminum, preferably a Series 5000 or 6000 aluminum alloy.
  • At least said external profile area (35) is superficially treated with hard anodization process in such manner to obtain a hard superficial layer (F) with thickness from 70 to 80 microns.
  • Said hard superficial layer (F) is diagrammatically shown in Fig. 3 with a dotted area.
  • hard anodization indicates hard anodic oxidation that gives aluminum high resistance to wear and abrasion and superficial hardness of approximately 500 - 600 Vikers. Being of known type, the detailed description of said treatment is omitted. However, it must be noted that it comprises a transformation of part of the material surface into aluminum oxide, with minimum affected thickness of at least 25 - 30 micron.
  • the entire surface of the buffer (30) undergoes hard anodization in order to improve its characteristics, as shown in Fig. 3 .
  • Another advantageous characteristic of the buffer (30) according to the present invention relates to the special geometry of the edge (33).
  • the edge (33) comprises a wear portion (37) that differs from the rest of the buffer in that in said wear portion (37) the edge has a gradually increasing thickness from up down, meaning a material over-thickness.
  • the edge (33) widens on the side opposite the side facing said concave portion (31), starting from minimum thickness (Smin) (measured at the upper end of the edge) to maximum thickness (SMAX) substantially in correspondence of said body (34) of the buffer.
  • the difference (SMAX-Smin) between maximum thickness (SMAX) and minimum thickness (Smin) of the edge is preferably comprised between 0.05 and 0.08 mm.
  • proportions are intentionally misrepresented in the drawings, in order to make the wear portion (37) and its position on the edge (33) more visible.
  • the wear caused by the passage of gases (FG) between buffer (30) and plate (7) initially wears out only the wear portion (37) without affecting the minimum thickness (Smin) of the border (measured at the upper end).
  • the first point subject to wear is the most protruding point (P) of the wear portion (37).
  • Fig. 4 is a diagrammatic view showing that wear continues from point (P) for consecutive profile "slices” (37) until it reaches the point (P1) with minimum thickness (Smin), which will be affected only after the overmaterial of the wear portion (37) is completely worn out.
  • the friction area between plate (7) and edge (33) is always in correspondence of a point of the wear portion (37) where aluminum is protected by said superficial layer (F) treated with hard anodization, thus extending the wear time of the buffer (30).
  • the buffer (30) with wear portion (37) replaces the buffer (3) of the mold (1), i.e. the one mounted on the magnetic base (4) connected with the ejector block (5).
  • the other buffer (2) instead, is replaced with a buffer without wear portion (37), but likewise made of aluminum or preferably 5000 aluminum alloy with hard anodized surface with 70-80 micron thickness.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
EP20120188877 2011-10-19 2012-10-17 An improved buffer for mold for ceramic industry and mold comprising said buffer. Active EP2583802B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT000141A ITAN20110141A1 (it) 2011-10-19 2011-10-19 Tampone migliorato per stampo per l'industria ceramica e stampo comprendente un tale tampone.

Publications (2)

Publication Number Publication Date
EP2583802A1 EP2583802A1 (en) 2013-04-24
EP2583802B1 true EP2583802B1 (en) 2015-03-18

Family

ID=45757042

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20120188877 Active EP2583802B1 (en) 2011-10-19 2012-10-17 An improved buffer for mold for ceramic industry and mold comprising said buffer.

Country Status (2)

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EP (1) EP2583802B1 (it)
IT (1) ITAN20110141A1 (it)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102689351B (zh) * 2012-06-04 2015-08-26 上海卡贝尼精密陶瓷有限公司 一种带台阶吊臂的制备方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1560416A1 (ru) * 1988-04-11 1990-04-30 Украинский Научно-Исследовательский Институт Фарфоро-Фаянсовой Промышленности Способ изготовлени форм дл производства керамических изделий
IT1237568B (it) * 1989-10-02 1993-06-08 Mass Spa Dispositivo idraulico regolatore di pressione,tipicamente per stampi ceramici con matrice mobile e contromatrice
EP1944145A3 (en) * 2007-01-09 2011-11-30 Schott AG Moulding tool for moulding a ceramic green body and use of said moulding tool

Also Published As

Publication number Publication date
EP2583802A1 (en) 2013-04-24
ITAN20110141A1 (it) 2013-04-20

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