EP4104990B1 - Method and plant for manufacturing ceramic products - Google Patents
Method and plant for manufacturing ceramic products Download PDFInfo
- Publication number
- EP4104990B1 EP4104990B1 EP22176124.0A EP22176124A EP4104990B1 EP 4104990 B1 EP4104990 B1 EP 4104990B1 EP 22176124 A EP22176124 A EP 22176124A EP 4104990 B1 EP4104990 B1 EP 4104990B1
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- European Patent Office
- Prior art keywords
- ceramic powders
- accumulation
- ceramic
- compaction
- feeding
- Prior art date
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- 239000000919 ceramic Substances 0.000 title claims description 121
- 238000004519 manufacturing process Methods 0.000 title claims description 29
- 238000000034 method Methods 0.000 title claims description 29
- 239000000843 powder Substances 0.000 claims description 107
- 238000009825 accumulation Methods 0.000 claims description 31
- 238000005056 compaction Methods 0.000 claims description 31
- 230000000694 effects Effects 0.000 claims description 20
- 229910010293 ceramic material Inorganic materials 0.000 claims description 18
- 238000003825 pressing Methods 0.000 claims description 11
- 238000000151 deposition Methods 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 9
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 230000005484 gravity Effects 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 8
- 238000012512 characterization method Methods 0.000 claims description 5
- 239000003086 colorant Substances 0.000 claims description 3
- 238000010411 cooking Methods 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 3
- 230000008021 deposition Effects 0.000 claims 1
- 239000004575 stone Substances 0.000 description 3
- 239000004579 marble Substances 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000010438 granite Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000013517 stratification Methods 0.000 description 1
Images
Classifications
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- 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
- B28B13/022—Feeding several successive layers, optionally of different materials
-
- 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
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/005—Devices or processes for obtaining articles having a marble appearance
-
- 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
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/0063—Control arrangements
- B28B17/0081—Process control
-
- 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
-
- 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 generally relates to a method and a plant for manufacturing ceramic products and, in particular, a method and a plant for preparing and distributing, according to a plurality of predefined layouts, ceramic powders for the production of slabs and/or tiles.
- Natural stones Plants for manufacturing ceramic slabs and/or tiles that faithfully reproduce the appearance, or layout, of natural stones, such as marble and/or granite, are known from the prior art. Natural stones are in fact provided with internal striations or veining, distributed randomly within their thickness, which are highly appreciated by customers, especially when these natural stones are used as a covering material for floors, walls, worktops, etc.
- the aforesaid plants typically comprise devices for feeding and metering atomized and coloured ceramic powders. These feeding and metering devices usually operate by gravity. The ceramic powders are then deposited, in a controlled and programmable way through a proper electronic control system, on a conveyor belt so that a continuous strip of ceramic powder with a predefined layout is formed. The continuous strip of ceramic powder is then sent to an accumulation and compaction device where, again by gravity, the ceramic material which is still in powder "stratifies” in a controlled manner. In this way the compacted ceramic powder can take on the final appearance of the slab and/or tile, which will be effectively and definitively formed after further operations of pressing on the ceramic material still in the powder form, cutting the ceramic material to size and final cooking.
- Document WO 2020/058891 A1 discloses a method for manufacturing ceramic products according to the preamble of claim 1 and a plant for manufacturing ceramic products according to the preamble of claim 6. Another plant for manufacturing ceramic products according to the prior art is disclosed in document US 5056998 A .
- Document CN 109927161 A discloses a method for manufacturing slabs and/or tiles starting from ceramic powders.
- a first drawback of the known plants for manufacturing ceramic products can even occur in the respective ceramic powders feeding and metering device.
- this feeding and metering device operates by gravity and is designed for the inlet of a large amount of powders in a limited time unit, it can be subject to clogging.
- Another drawback of the known plants for manufacturing ceramic products is then due to the fact that the ceramic material to be processed, being initially formed by more or less compacted ceramic powder, can undergo deformations and/or alterations within the various devices of the system, so as to compromise the final aesthetic appearance of the finished slabs and/or tiles.
- the object of the present invention is therefore to provide a method and a plant for manufacturing ceramic products, in particular a method and a plant for preparing and distributing, according to a plurality of predefined layouts, ceramic powders for producing slabs and/or tiles, which are capable of solving the aforementioned drawbacks of the prior art in an extremely simple, economical and particularly functional way.
- Another object of the present invention is to provide a method and a plant for manufacturing ceramic products that are capable of avoiding clogging and/or other possible malfunctions of the plant due to an uncontrolled management of the powders used for manufacturing slabs and/or tiles.
- FIG. 1 a preferred embodiment of a plant for manufacturing ceramic products according to the present invention is shown.
- the plant is indicated as a whole with the reference number 10.
- the plant 10 is designed to provide a method for manufacturing ceramic products T which sequentially comprises a plurality of operative steps.
- a first operative step consists in gravity feeding a mixture of one or more ceramic powders having features and/or colours different from one another, by means of at least one feeding device 12 and along at least one substantially vertical feeding direction A ( Figure 2 ).
- each feeding device 12 comprises at least one hopper 28 which is internally provided with a plurality of separator baffles 30, 32, 34, 36, 38 which, as will be better specified below, are configured to discharge the weight of the mixture of ceramic powders leaving the feeding device 12, so as to avoid clogging thereof.
- a micro metering step is provided for micro metering said ceramic powders fed by the hopper 28, by means of at least one metering device 14 controlled by at least one central processing unit 50, so as to divide said ceramic powders on the basis of predefined quality criteria.
- predefined quality criteria can consist, for example, of the particle size of the ceramic powders, humidity, flowability, flow rate, etc.
- Each metering device 14 is conveniently provided with a plurality of nozzles 40 whose predefined passage section is as small as possible, but is in any case suitable for gravity dropping the ceramic powders along the substantially vertical feeding direction A.
- the sectional views of Figures 3A, 3B and 3C show three possible embodiments of the metering device 14 and the respective nozzles 40, which are manufactured according to known technologies and are operated independently by the central processing unit 50 of the plant. 10.
- the step of micro metering the ceramic powders comprises at least one sub-step of removing those ceramic powders which do not satisfy one or more of the abovementioned predefined quality criteria.
- each metering device 14 is provided with one or more powder removal apparatuses 48, 60 arranged to remove at least part of the ceramic powders, such as too fine powders, from the main flow of ceramic powders passing through each nozzle 40.
- the powder removal apparatus 48, 60 of the metering device 14 can comprise one or more micro-filters 48, operatively associated with a respective nozzle 40 through which the main flow of ceramic powders passes, and one or more suction pumps 60, designed to suck the too fine powders through each micro-filter 48.
- Each metering device 14 can also be preferably provided with one or more shut-off valves 64, such as pinch valves.
- Each of these shut-off valves 64 can be installed along a respective nozzle 40 ( Figure 3A ), to intercept the main flow of the ceramic powders, and/or at one or more ducts 66 ( Figure 3B ) arranged for extracting the too fine powders from this main flow of ceramic powders.
- a dispensing and depositing step is provided, by means of at least one dispensing device 16 ( Figure 4 ), for dispensing and depositing said ceramic powders on a first transport device 18 which is substantially flat and movable along a substantially horizontal feeding direction B, so as to obtain a first layer L of ceramic powders having surface chromatic effects.
- the dispensing device 16 is positioned downstream of the metering device 14.
- said step of dispensing and depositing the ceramic powders comprises at least one sub-step of conveying, by means of at least one conveying element 24 of said dispensing device 16, said ceramic powders along a single dispensing direction F starting from a plurality of separate and distinct dispensing directions D, E.
- the ceramic powders can be dispensed on the first transport device 18 along the single dispensing direction F, in order to better control the flow rate of these ceramic powders by the central processing unit 50 of the plant 10, as well as to increase the characterization of the surface chromatic effects that can be seen on the first layer L of the ceramic powders.
- the first transport device 18 transfers the first layer L of powdered ceramic material towards the subsequent operative accumulation and compaction step.
- the first layer L of powdered ceramic material is accumulated and compacted by means of at least one accumulation and compaction device 20 controlled by the central processing unit 50, along an accumulation and compaction direction C, which, preferably and as shown in Figure 6 , is substantially vertical.
- an accumulation and compaction direction C which, preferably and as shown in Figure 6 , is substantially vertical.
- the second layer CL of ceramic powders compacted by the accumulation and compaction device 20 is transferred by means of a second transport device 42 which is substantially flat and movable along the same substantially horizontal feeding direction B as the first transport device 18, towards the subsequent operative pressing step.
- This pressing step is obtained by means of at least one pressing device 22 which compresses the second layer CL of compacted ceramic powders, so as to reduce its thickness and obtain the ceramic products T in the form of one or more slabs and/or tiles.
- the step of feeding the mixture of ceramic powders comprises at least one sub-step of feeding this mixture of ceramic powders along one or more feeding directions A1, A2, A3 which are inclined according to respective predefined angles with respect to the substantially vertical feeding direction A, so as to relieve the vertical load of this mixture of ceramic powders which weighs on the nozzles 40 of the metering device 14, which is located below the feeding device 12.
- the mixture of ceramic powders is diverted along one or more feed directions A1, A2, A3 which are inclined with respect to the substantially vertical feeding direction A: this diversion is due to the particular and innovative internal conformation of the hopper 28.
- this hopper 28 is in fact internally also provided with further separator baffles 34, 36, 38, which are operatively associated with the substantially vertical separator baffles 30, 32 and/or with the walls of the hopper 28 and which, as shown in Figure 2 , are oriented along respective directions A1, A2, A3 which are inclined according to respective predefined angles with respect to the substantially vertical feed direction A.
- the step of dispensing and depositing the ceramic powders on the first transport device 18 comprises at least one sub-step of separating these ceramic powders along a plurality of channels longitudinal and parallel to the feeding direction B of the first transport device 18. In this way the dispersion by falling of the ceramic powders is avoided, while maintaining the characterization of the surface chromatic effects on the first layer L of the ceramic powders and set through the central processing unit 50 of plant 10.
- the first transport device 18 consists of a closed loop conveyor belt, the transport surface of which comprises (see Figure 5 ) a plurality of longitudinal protrusions 44, i.e., oriented along the feeding direction B, interspersed by a corresponding plurality of longitudinal grooves 46, also oriented along the feeding direction B.
- both the longitudinal protrusions 44, and the corresponding longitudinal grooves 46 have a cross-sectional triangular or pyramidal shape, i.e. a section perpendicular to the feeding direction B.
- the first layer L of the powdered ceramic material deposited on the first transport device 18 has a very reduced thickness, so as to obtain a greater characterization of the layout even in the subsequent accumulation and compaction step, adapted to form the second layer CL of compacted ceramic powders.
- the step of accumulating and compacting the first layer L of powdered ceramic material comprises at least one sub-step of dynamic variation of the accumulation and compaction direction C with respect to a substantially vertical plane, so as to control the formation of both the surface chromatic effects, and the chromatic effects in the thickness of the second layer CL of compacted ceramic powders.
- the accumulation and compaction device 20 consists of at least one hopper (or “drawer") with a substantially vertical development, sized to allow therein an adequate flow of the powders which form the first layer L of ceramic material during the respective stratification step leaving the first transport device 18.
- an important aspect is linked to the fall height of the ceramic powders which form the first layer L of ceramic material inside the hopper 20. This determines the success of the layout of the slab and/or tile T in the process of formation, especially when this layout reproduces the typical veining of marble throughout the thickness of this slab and/or tile T.
- the hopper 20 is conveniently provided with at least one pivoting mechanism 52 configured to rotate this accumulation and compaction device 20 about a horizontal axis which is substantially perpendicular with respect to said feeding direction B.
- the angle ⁇ ( Figure 8 ) between the substantially horizontal plane on which said first transport device 18 lies and the plane passing through said accumulation and compaction device 20 at the respective upper loading opening 54 are obtained.
- An angle ⁇ less than 90° helps to improve control of the formation of both the surface chromatic effects, and the chromatic effects in the thickness of the second layer CL of compacted ceramic powders.
- the step of accumulation and compaction of the first layer L of powdered ceramic material can also comprise at least one sub-step of controlling, by means of at least one control sensor 26 for controlling the hopper 20, the quantity of powdered ceramic material contained inside this hopper 20.
- the control sensor 26 is preferably positioned at the upper loading opening 54 of the hopper 20.
- the hopper 20 can be provided with at least one arch shaped lower unloading opening 56, placed at the second transport device 42 ( Figure 8 ).
- the radius of curvature of this arch shaped lower unloading opening 56 is preferably equal to 2.5 times the average thickness S of the passage section for the passage of the ceramic powders inside the hopper 20, for the purpose of a correct positioning of the second layer CL of compacted ceramic powders on the second transport device 42.
- the hopper 20 can also be provided with at least one gate 62 designed to selectively close the respective arch shaped lower unloading opening 56 under certain operating conditions of the plant 10.
- This gate 62 for example, can be kept closed during the step of the first filling of the hopper 20 with the powders coming from the first layer L of ceramic material transported by the first transport device 18.
- the gate 62 can be opened to allow the formation of the second layer CL of compacted ceramic powders on the second transport device 42.
- the second layer CL of compacted ceramic powders undergoes the pressing step for the formation of ceramic products T in the form of one or more slabs and/or tiles.
- This pressing step can take place at a third transport device 58, yet oriented along the same substantially horizontal feeding direction B of the first two transport devices 18 and 42.
- this pressing step can be followed by at least one subsequent cooking step, in proper furnaces (not shown), of the ceramic products T in the form of one or more slabs and/or tiles, as well as a possible cut to size of the ceramic products T.
Description
- The present invention generally relates to a method and a plant for manufacturing ceramic products and, in particular, a method and a plant for preparing and distributing, according to a plurality of predefined layouts, ceramic powders for the production of slabs and/or tiles.
- Plants for manufacturing ceramic slabs and/or tiles that faithfully reproduce the appearance, or layout, of natural stones, such as marble and/or granite, are known from the prior art. Natural stones are in fact provided with internal striations or veining, distributed randomly within their thickness, which are highly appreciated by customers, especially when these natural stones are used as a covering material for floors, walls, worktops, etc.
- The aforesaid plants typically comprise devices for feeding and metering atomized and coloured ceramic powders. These feeding and metering devices usually operate by gravity. The ceramic powders are then deposited, in a controlled and programmable way through a proper electronic control system, on a conveyor belt so that a continuous strip of ceramic powder with a predefined layout is formed. The continuous strip of ceramic powder is then sent to an accumulation and compaction device where, again by gravity, the ceramic material which is still in powder "stratifies" in a controlled manner. In this way the compacted ceramic powder can take on the final appearance of the slab and/or tile, which will be effectively and definitively formed after further operations of pressing on the ceramic material still in the powder form, cutting the ceramic material to size and final cooking.
- Document
WO 2020/058891 A1 discloses a method for manufacturing ceramic products according to the preamble of claim 1 and a plant for manufacturing ceramic products according to the preamble of claim 6. Another plant for manufacturing ceramic products according to the prior art is disclosed in documentUS 5056998 A . DocumentCN 109927161 A , on the other hand, discloses a method for manufacturing slabs and/or tiles starting from ceramic powders. - A first drawback of the known plants for manufacturing ceramic products can even occur in the respective ceramic powders feeding and metering device. As this feeding and metering device operates by gravity and is designed for the inlet of a large amount of powders in a limited time unit, it can be subject to clogging.
- Another drawback of the known plants for manufacturing ceramic products is then due to the fact that the ceramic material to be processed, being initially formed by more or less compacted ceramic powder, can undergo deformations and/or alterations within the various devices of the system, so as to compromise the final aesthetic appearance of the finished slabs and/or tiles.
- The object of the present invention is therefore to provide a method and a plant for manufacturing ceramic products, in particular a method and a plant for preparing and distributing, according to a plurality of predefined layouts, ceramic powders for producing slabs and/or tiles, which are capable of solving the aforementioned drawbacks of the prior art in an extremely simple, economical and particularly functional way.
- In detail, it is an object of the present invention to provide a method and a plant for manufacturing ceramic products that are capable of improving the appearance of the slabs and/or tiles as much as possible.
- Another object of the present invention is to provide a method and a plant for manufacturing ceramic products that are capable of avoiding clogging and/or other possible malfunctions of the plant due to an uncontrolled management of the powders used for manufacturing slabs and/or tiles.
- These objects according to the present invention are achieved by providing a method and a plant for manufacturing ceramic products as set forth in the independent claims. Further features of the invention are highlighted by the dependent claims, which are an integral part of this description.
- The features and advantages of a method and a plant for manufacturing ceramic products according to the present invention will be clearer from the following, exemplifying and non-limiting description, referring to the attached drawings, wherein:
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Figure 1 is a perspective view of a preferred embodiment of a plant for manufacturing ceramic products according to the present invention; -
Figure 2 is a sectional view showing a component of the plant ofFigure 1 , designed to carry out a step of feeding the powders in the method for manufacturing ceramic products according to the present invention; -
Figures 3A, 3B and3C are sectional views showing respective embodiments of another component of the plant ofFigure 1 , designed to carry out a step of micro metering the powders in the method for manufacturing ceramic products according to the present invention; -
Figure 4 is a sectional view showing a further component of the plant ofFigure 1 , designed to carry out a step of conveying the powders in the method for manufacturing ceramic products according to the present invention; -
Figure 5 is a perspective view showing a further component of the plant ofFigure 1 , designed to carry out a step of controlled depositing the powders in the method for manufacturing ceramic products according to the present invention; -
Figure 6 is a sectional view showing further components of the plant ofFigure 1 , designed to carry out a step of controlled accumulating powders in the method for manufacturing ceramic products according to the present invention; -
Figure 7 is a perspective view showing a further component of the plant ofFigure 1 , designed to carry out a step of controlling the constant maintenance of the level of powders in the method for manufacturing ceramic products according to the present invention; and -
Figure 8 is a sectional view showing a further component of the plant ofFigure 1 , designed to carry out a step of checking the thickness of the final layer of powders that will form the ceramic products upon completion of the method for manufacturing ceramic products according to the present invention. - With reference to
Figure 1 , a preferred embodiment of a plant for manufacturing ceramic products according to the present invention is shown. The plant is indicated as a whole with thereference number 10. Theplant 10 is designed to provide a method for manufacturing ceramic products T which sequentially comprises a plurality of operative steps. - A first operative step consists in gravity feeding a mixture of one or more ceramic powders having features and/or colours different from one another, by means of at least one
feeding device 12 and along at least one substantially vertical feeding direction A (Figure 2 ). As shown in the sectional view ofFigure 2 , eachfeeding device 12 comprises at least onehopper 28 which is internally provided with a plurality ofseparator baffles feeding device 12, so as to avoid clogging thereof. - Further to the feeding step, a micro metering step is provided for micro metering said ceramic powders fed by the
hopper 28, by means of at least onemetering device 14 controlled by at least onecentral processing unit 50, so as to divide said ceramic powders on the basis of predefined quality criteria. These predefined quality criteria can consist, for example, of the particle size of the ceramic powders, humidity, flowability, flow rate, etc. - Each
metering device 14 is conveniently provided with a plurality ofnozzles 40 whose predefined passage section is as small as possible, but is in any case suitable for gravity dropping the ceramic powders along the substantially vertical feeding direction A. The sectional views ofFigures 3A, 3B and3C show three possible embodiments of themetering device 14 and therespective nozzles 40, which are manufactured according to known technologies and are operated independently by thecentral processing unit 50 of the plant. 10. - According to the invention, as shown in
Figures 3A, 3B and3C , the step of micro metering the ceramic powders comprises at least one sub-step of removing those ceramic powders which do not satisfy one or more of the abovementioned predefined quality criteria. For this purpose, eachmetering device 14 is provided with one or morepowder removal apparatuses nozzle 40. For example, as shown inFigure 3B , thepowder removal apparatus metering device 14 can comprise one or more micro-filters 48, operatively associated with arespective nozzle 40 through which the main flow of ceramic powders passes, and one ormore suction pumps 60, designed to suck the too fine powders through eachmicro-filter 48. - Each
metering device 14 can also be preferably provided with one or more shut-offvalves 64, such as pinch valves. Each of these shut-offvalves 64 can be installed along a respective nozzle 40 (Figure 3A ), to intercept the main flow of the ceramic powders, and/or at one or more ducts 66 (Figure 3B ) arranged for extracting the too fine powders from this main flow of ceramic powders. - Further to the ceramic powders micro metering step, a dispensing and depositing step is provided, by means of at least one dispensing device 16 (
Figure 4 ), for dispensing and depositing said ceramic powders on afirst transport device 18 which is substantially flat and movable along a substantially horizontal feeding direction B, so as to obtain a first layer L of ceramic powders having surface chromatic effects. Thedispensing device 16 is positioned downstream of themetering device 14. - As shown in
Figure 4 , said step of dispensing and depositing the ceramic powders comprises at least one sub-step of conveying, by means of at least one conveyingelement 24 of saiddispensing device 16, said ceramic powders along a single dispensing direction F starting from a plurality of separate and distinct dispensing directions D, E. In this way, the ceramic powders can be dispensed on thefirst transport device 18 along the single dispensing direction F, in order to better control the flow rate of these ceramic powders by thecentral processing unit 50 of theplant 10, as well as to increase the characterization of the surface chromatic effects that can be seen on the first layer L of the ceramic powders. - The
first transport device 18 transfers the first layer L of powdered ceramic material towards the subsequent operative accumulation and compaction step. In this operative step, the first layer L of powdered ceramic material is accumulated and compacted by means of at least one accumulation andcompaction device 20 controlled by thecentral processing unit 50, along an accumulation and compaction direction C, which, preferably and as shown inFigure 6 , is substantially vertical. In this way a second layer CL of compacted ceramic powders is obtained, which has both surface chromatic effects and chromatic effects in the thickness. - Further to the accumulation and compaction step, the second layer CL of ceramic powders compacted by the accumulation and
compaction device 20 is transferred by means of asecond transport device 42 which is substantially flat and movable along the same substantially horizontal feeding direction B as thefirst transport device 18, towards the subsequent operative pressing step. This pressing step is obtained by means of at least onepressing device 22 which compresses the second layer CL of compacted ceramic powders, so as to reduce its thickness and obtain the ceramic products T in the form of one or more slabs and/or tiles. - According to the invention, the step of feeding the mixture of ceramic powders comprises at least one sub-step of feeding this mixture of ceramic powders along one or more feeding directions A1, A2, A3 which are inclined according to respective predefined angles with respect to the substantially vertical feeding direction A, so as to relieve the vertical load of this mixture of ceramic powders which weighs on the
nozzles 40 of themetering device 14, which is located below thefeeding device 12. - The mixture of ceramic powders is diverted along one or more feed directions A1, A2, A3 which are inclined with respect to the substantially vertical feeding direction A: this diversion is due to the particular and innovative internal conformation of the
hopper 28. In addition to one or more substantiallyvertical separator baffles hopper 28 is in fact internally also provided withfurther separator baffles vertical separator baffles hopper 28 and which, as shown inFigure 2 , are oriented along respective directions A1, A2, A3 which are inclined according to respective predefined angles with respect to the substantially vertical feed direction A. - Again according to the invention, the step of dispensing and depositing the ceramic powders on the
first transport device 18 comprises at least one sub-step of separating these ceramic powders along a plurality of channels longitudinal and parallel to the feeding direction B of thefirst transport device 18. In this way the dispersion by falling of the ceramic powders is avoided, while maintaining the characterization of the surface chromatic effects on the first layer L of the ceramic powders and set through thecentral processing unit 50 ofplant 10. - The ceramic powders are separated due to the fact that the
first transport device 18 consists of a closed loop conveyor belt, the transport surface of which comprises (seeFigure 5 ) a plurality oflongitudinal protrusions 44, i.e., oriented along the feeding direction B, interspersed by a corresponding plurality oflongitudinal grooves 46, also oriented along the feeding direction B. Preferably, both thelongitudinal protrusions 44, and the correspondinglongitudinal grooves 46 have a cross-sectional triangular or pyramidal shape, i.e. a section perpendicular to the feeding direction B. The particular conformation of the transport surface of thefirst transport device 18, with alternatinglongitudinal protrusions 44 andlongitudinal grooves 46, helps to contain the ceramic powders leaving thenozzles 40 of themetering device 14 and the conveyingelement 24 of thedispensing device 16, avoiding its dispersion by falling and thus maintaining a good characterization of the layout of the slab and/or tile T in the process of formation. It should also be noted that the first layer L of the powdered ceramic material deposited on thefirst transport device 18 has a very reduced thickness, so as to obtain a greater characterization of the layout even in the subsequent accumulation and compaction step, adapted to form the second layer CL of compacted ceramic powders. - The step of accumulating and compacting the first layer L of powdered ceramic material comprises at least one sub-step of dynamic variation of the accumulation and compaction direction C with respect to a substantially vertical plane, so as to control the formation of both the surface chromatic effects, and the chromatic effects in the thickness of the second layer CL of compacted ceramic powders. For this purpose, the accumulation and
compaction device 20 consists of at least one hopper (or "drawer") with a substantially vertical development, sized to allow therein an adequate flow of the powders which form the first layer L of ceramic material during the respective stratification step leaving thefirst transport device 18. - As shown in
Figure 6 , an important aspect is linked to the fall height of the ceramic powders which form the first layer L of ceramic material inside thehopper 20. This determines the success of the layout of the slab and/or tile T in the process of formation, especially when this layout reproduces the typical veining of marble throughout the thickness of this slab and/or tile T. The lower the fall height of the ceramic powders, the higher the resolution of the layout, as it avoids a mixing of the ceramic powders due to a possible excessively high drop height. - To obtain the dynamic variation of the accumulation and compaction direction C of the powdered ceramic material, the
hopper 20 is conveniently provided with at least onepivoting mechanism 52 configured to rotate this accumulation andcompaction device 20 about a horizontal axis which is substantially perpendicular with respect to said feeding direction B. In this way, not only is the dynamic variation of the accumulation and compaction direction C of the powdered ceramic material with respect to a substantially vertical plane, but also a variation of the angle α (Figure 8 ) between the substantially horizontal plane on which saidfirst transport device 18 lies and the plane passing through said accumulation andcompaction device 20 at the respectiveupper loading opening 54 are obtained. An angle α less than 90°, in fact, helps to improve control of the formation of both the surface chromatic effects, and the chromatic effects in the thickness of the second layer CL of compacted ceramic powders. - The step of accumulation and compaction of the first layer L of powdered ceramic material can also comprise at least one sub-step of controlling, by means of at least one
control sensor 26 for controlling thehopper 20, the quantity of powdered ceramic material contained inside thishopper 20. Thecontrol sensor 26 is preferably positioned at the upper loading opening 54 of thehopper 20. - Preferably, the
hopper 20 can be provided with at least one arch shapedlower unloading opening 56, placed at the second transport device 42 (Figure 8 ). The radius of curvature of this arch shapedlower unloading opening 56 is preferably equal to 2.5 times the average thickness S of the passage section for the passage of the ceramic powders inside thehopper 20, for the purpose of a correct positioning of the second layer CL of compacted ceramic powders on thesecond transport device 42. - Again preferably, as shown in
Figure 8 , thehopper 20 can also be provided with at least onegate 62 designed to selectively close the respective arch shapedlower unloading opening 56 under certain operating conditions of theplant 10. Thisgate 62, for example, can be kept closed during the step of the first filling of thehopper 20 with the powders coming from the first layer L of ceramic material transported by thefirst transport device 18. Once a predefined quantity of powdered ceramic material has been reached inside thehopper 20, in which this predefined quantity can be indicated for example by thecontrol sensor 26, thegate 62 can be opened to allow the formation of the second layer CL of compacted ceramic powders on thesecond transport device 42. - Outgoing from the
second transport device 42, the second layer CL of compacted ceramic powders, provided with chromatic effects on the surface and/or the thickness thereof, pre-set by thecentral processing unit 50 of theplant 10, undergoes the pressing step for the formation of ceramic products T in the form of one or more slabs and/or tiles. This pressing step can take place at athird transport device 58, yet oriented along the same substantially horizontal feeding direction B of the first twotransport devices - It has thus been seen that the method and the plant for manufacturing ceramic products according to the present invention achieve the previously highlighted objects.
Claims (10)
- A method for manufacturing ceramic products (T) comprising in sequence the steps of:- gravity feeding a mixture of two or more ceramic powders having different features and/or colours from one another, by means of at least one feeding device (12) and along at least one substantially vertical feeding direction (A);- micro metering said ceramic powders, by means of at least one metering device (14) controlled by at least one central processing unit (50), so as to divide said ceramic powders on the basis of predefined quality criteria;- dispensing and depositing, by means of at least one dispensing device (16) positioned downstream of said at least one metering device (14), said ceramic powders on a first transport device (18) which is substantially flat and movable along a substantially horizontal feeding direction (B) and consists of a closed loop conveyor belt, so as to obtain a first layer (L) of ceramic powders having surface chromatic effects;- accumulating and compacting said first layer (L) of powdered ceramic material along an accumulation and compaction direction (C), by means of at least one accumulation and compaction device (20) controlled by said central processing unit (50), so as to obtain a second layer (CL) of compacted ceramic powders having both surface chromatic effects, and chromatic effects in the thickness; and- pressing said second layer (CL) of compacted ceramic powders, by means of at least one pressing device (22), so as to obtain said ceramic products (T) in the form of one or more slabs and/or tiles,wherein said dispensing and depositing step comprises at least one sub-step of separating said ceramic powders along a plurality of channels which are longitudinal and parallel to said feeding direction (B), so as to avoid dispersion by falling of said ceramic powders and to maintain the characterization of said surface chromatic effects, the method being characterized in that:- said feeding step comprises at least one sub-step of feeding said ceramic powders along one or more feeding directions (A1, A2, A3) which are inclined according to respective predefined angles with respect to said substantially vertical feeding direction (A), so as to relieve the vertical load of said ceramic powders which weighs on said metering device (14);- said separating sub-step is implemented by said first transport device (18), said closed loop conveyor belt having a transport surface with a plurality of longitudinal protrusions (44) interspersed by a plurality of longitudinal grooves (46), all oriented along said feeding direction (B);- said accumulation and compaction step comprises at least one sub-step of dynamic variation of said accumulation and compaction direction (C) with respect to a substantially vertical plane, so as to control the formation of both said surface chromatic effects, and said chromatic effects in the thickness of said second layer (CL) of compacted ceramic powders; and- said step of micro metering the ceramic powders comprises at least one sub-step of removing those ceramic powders which do not satisfy one or more of said predefined quality criteria, said removing sub-step being implemented by one or more powder removal apparatuses (48, 60) of said metering device (14).
- The method according to claim 1, wherein said step of dispensing and depositing the ceramic powders comprises at least one sub-step of conveying, by means of at least one conveying element (24) of said dispensing device (16), said ceramic powders along a single dispensing direction (F) starting from a plurality of separate and distinct dispensing directions (D, E), so that said ceramic powders are dispensed on said first transport device (18) along said single dispensing direction (F).
- The method according to claim 1 or 2, wherein said accumulation and compaction step comprises at least one sub-step of variation of the angle (α) between the substantially horizontal plane on which said first transport device (18) lies and the plane passing through said accumulation and compaction device (20) at the respective upper loading opening (54), wherein an angle (α) less than 90° helps to improve control of the formation of both said surface chromatic effects and said chromatic effects in the thickness of said second layer (CL) of compacted ceramic powders.
- The method according to any claims 1 to 3, wherein said accumulation and compaction step comprises at least one sub-step of controlling, by means of at least one control sensor (26) for controlling said accumulation and compaction device (20), the quantity of powdered ceramic material contained inside said accumulation and compaction device (20).
- The method according to any claims 1 to 4, further comprising, after said pressing step, at least one step of cooking said ceramic products (T) in the form of one or more slabs and/or tiles.
- A plant (10) for manufacturing ceramic products (T) by implementing the method according to any claims 1 to 5, the plant (10) comprising:- at least one central processing unit (50);- at least one feeding device (12), which is arranged for gravity feeding a mixture of two or more ceramic powders having different features and/or colours from one another and comprises at least one hopper (28);- at least one metering device (14), which is designed for carrying out the micro metering of said ceramic powders and is provided with a plurality of nozzles (40) having a predefined passage section suitable for gravity dropping said ceramic powders along a substantially vertical feeding direction (A);- a first transport device (18), which is substantially flat and movable along a substantially horizontal feeding direction (B) and which consists of a closed loop conveyor belt;- at least one dispensing device (16) for dispensing said ceramic powders, which is positioned downstream of said at least one metering device (14) and which is designed for carrying out the dispensing and deposition of a first layer (L) of said ceramic powders on said first transport device (18);- at least one accumulation and compaction device (20), which is arranged for carrying out accumulation and compaction of said ceramic powders along an accumulation and compaction direction (C) into a second layer (CL) of compacted ceramic powders having both surface chromatic effects and chromatic effects in the thickness;- a second transport device (42), which is substantially flat and movable along said substantially horizontal feeding direction (B) and on which said second layer (CL) of compacted ceramic powders coming out of said accumulation and compaction device (20) is transferred; and- at least one pressing device (22), which is designed to press said second layer (CL) of compacted ceramic powders, so as to obtain said ceramic products (T) in the form of one or more slabs and/or tiles,the plant (10) being characterized in that said at least one dispensing device (16) is provided with at least one element (24) for conveying said ceramic powders along a single feeding direction (F) starting from a plurality of separated and distinct feeding directions (D, E),- wherein said hopper (28) is internally provided with both one or more substantially vertical separator baffles (30, 32), and further separator baffles (34, 36, 38) which are operatively associated with said one or more substantially vertical separator baffles (30, 32) and/or with the walls of said hopper (28), and wherein said further separator baffles (34, 36, 38) are oriented along respective directions (A1, A2, A3) which are inclined according to respective predefined angles with respect to said substantially vertical feeding direction (A);- wherein the transport surface of said closed loop conveyor belt comprises a plurality of longitudinal protrusions (44), i.e., oriented along said feeding direction (B), interspersed by a corresponding plurality of longitudinal grooves (46), also oriented along said feeding direction (B);- wherein said accumulation and compaction device (20) is provided with at least one pivoting mechanism (52) configured to rotate said accumulation and compaction device (20) about a horizontal axis which is substantially perpendicular with respect to said feeding direction (B), so as to cause a dynamic variation of said accumulation and compaction direction (C) with respect to a substantially vertical plane;- wherein said metering device (14) is provided with one or more powder removal apparatuses (48, 60) arranged to remove at least part of the ceramic powders from the main flow of ceramic powders passing through each nozzle (40), namely those ceramic powders which do not satisfy one or more predefined quality criteria.
- The plant (10) according to claim 6, wherein both said longitudinal protrusions (44), and the corresponding longitudinal grooves (46) have a triangular or pyramidal shape in cross-section, i.e., a section perpendicular to said feeding direction (B).
- The plant (10) according to claim 6 or 7, wherein said accumulation and compaction device (20) consists of a hopper equipped with at least one control sensor (26) for controlling the quantity of ceramic powders contained inside said hopper (20), said at least one control sensor (26) being preferably positioned at the upper loading (54) of said hopper (20).
- The plant (10) according to claim 8, wherein said hopper (10) is provided with at least one arch shaped lower unloading opening (56), located at said second transport device (42), wherein the radius of curvature of said arch shaped lower unloading opening (56) is equal to 2.5 times the average thickness (S) of the passage section for the passage of the ceramic powders inside said hopper (20).
- The plant (10) according to claim 9, wherein said hopper (10) is provided with at least one gate (62) designed to selectively close said arch shaped lower unloading opening (56) under certain operating conditions of the plant (10).
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IT102021000015521A IT202100015521A1 (en) | 2021-06-15 | 2021-06-15 | METHOD AND PLANT FOR THE MANUFACTURE OF CERAMIC PRODUCTS |
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NL8701601A (en) * | 1987-07-08 | 1989-02-01 | Mosa Koninkl Bv | FLOOR TILE SET, METHOD FOR PRODUCING A FLOOR TILE FOR THE SET AND APPARATUS FOR CARRYING OUT THE METHOD |
IT1298598B1 (en) * | 1998-03-06 | 2000-01-12 | Marazzi Ceramica | MACHINE FOR THE PRODUCTION OF TILES WITH COLOR CHANGE IN THE MASS |
IT1316916B1 (en) * | 2000-07-20 | 2003-05-13 | Lo Scalino S R L | FEEDING SYSTEM OF A CERAMIC PRESS. |
CN100463788C (en) * | 2005-11-03 | 2009-02-25 | 唐君 | Material distribution method of marbling imitated ceramic brick and material distribution equipment |
ITRE20050130A1 (en) * | 2005-11-16 | 2007-05-17 | Sacmi Scrl | METHOD FOR FORMING TILES OR REPRODUCING CERAMIC SHEETS THE CHARACTERISTICS OF NATURAL STONES AND ITS APPARATUS |
ITRE20110080A1 (en) * | 2011-10-07 | 2013-04-08 | Ativa | DEVICE FOR THE TREATMENT OF A LAYER OF MATERIAL POWDER |
WO2020058891A1 (en) * | 2018-09-20 | 2020-03-26 | Scg Building Materials Co., Ltd. | Apparatus and method for feeding granular material to a plant for the production of slabs or tiles |
CN109927161B (en) * | 2018-12-26 | 2021-06-11 | 广东清远蒙娜丽莎建陶有限公司 | Full-through micro-powder intelligent multi-tube distribution ceramic tile and preparation method thereof |
CN212312328U (en) * | 2020-04-14 | 2021-01-08 | 浙江根根陶瓷有限公司 | Ceramic tile material distribution system with abundant texture patterns |
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