ITMC20100112A1 - PROCESS OF MANUFACTURE OF THE "FRESH" PRODUCT FOR MARBLE MATERIALS AND OTHER TYPES OF CEMENT MANUFACTURED PRODUCTS, INCLUDING THE FILLING OF THE MIXTURES ON THE SINGLE MOLD, THE AUTOMATIC PRESSING, DEFROSTING AND UNLOADING OF THE PRODUCT CARRIED OUT IN THE ONLY AR - Google Patents

Description

Description

In support of a patent application for an industrial invention entitled:

Process of manufacturing the "fresh" product for tiles and other types of concrete products, including filling the compounds on the single mold, pressing, demoulding and automatic unloading of the product carried out in the only available area and use of a press without stations. Possible procedure of pouring the mixture into the molds in three phases with the possibility of pre-leveling the mixture.

SUMMARY

This procedure, developed for the manufacture of “fresh” tiles and artifacts, makes it possible to carry out all the operations necessary for forming the artifact in the only available area of the press. Possibly, a single-mold press is not necessarily used with particularities that make it possible to exclude the stations. The method makes it possible to use a press without stations thus reducing complications and costs compared to existing presses and maintaining high productivity. It allows you to create better quality products. Shorter maintenance time, cleaning and mold change compared to known presses. Investment reduced to a single mold for each shape or product format

Investment of a single mold for each shape or format produced.

TEXT OF THE DESCRIPTION

The present patent application for industrial invention relates to a manufacturing process of the "fresh" product for tiles and other types of concrete products, with the filling of the mixture (s) on the mold, the pressing, the demoulding and the automatic unloading of the product, carried out in the only work area available for all operations, and use of a monolithic single-mold press. Possible use of compound feeder also with additional functions, positioned on the side of the press.

State of the art:

1- products:

the production of concrete products and in particular that of cementitious floors such as grits, pavé, tiles and other types of products in

cement can take place in the two known systems:

- in monolayer (with suction / expulsion system of a good percentage of water during pressing with a special filter or with the mixing technique on wet ground): in this case the loading of the raw material into the frame, in a special station, it can be done manually or by means of an automatic dispenser, which takes the reshuffle from a mixer group (this procedure concerns the production of tiles).

- in double layer: behind the first aesthetic and walking layer, a substrate layer is applied.

The feeding of the material for the substrate must be carried out after loading the first layer, using a special dispenser and screed.

2-machines:

Manual machines normally consist of a loading station and a pressing and demoulding station. The material unloading phase must take place in the same loading station. These machines are versatile as they allow to produce both the single layer and the double layer.

The manufacturing time is long because the loading times of the material are added together, plus the pressing and drafting time plus the unloading time of the “fresh” product.

The unloading operation can give rise to waste, because it requires a certain expertise in its execution.

In the manufacture of the double layer, the operator loads the layer of aesthetic and treading material and then the substrate.

Among other operations, the operator must also carefully clean the frame from the residues of the background material, which, in the subsequent loading, could pollute the mixture of the first layer, altering its color.

The automatic machines are generally carousel: the processing phases are divided into various stations.

We will therefore have:

- loading station

-floor loading station

- pressing station

- demoulding and unloading station

- vibrating stations.

Automatic machines have very short production times as the operations in the individual stations take place simultaneously.

These machines are built by providing all possible product versions, with or without substrate, forcing a number of stations (high) sometimes higher than necessary: each station corresponds to a mold that may have to be changed as the type of product varies. The result is a high cost of equipment, long production changeover times, long cleaning times. It must also be considered that, in these machines, the pressing station is an integral part of the machine: the press generally has a large tonnage and consequently its massive structure conditions the whole machine which is massive and expensive.

Currently, linear presses have been developed with the automatic demoulding and unloading of the product carried out in the pressing station, it is a significant step forward but the problem of multi-tracked bulky molds remained, as well as dosing of complex compounds for the multiplicity of mobile molds. .

The above considerations have led to the need to devise a machine with a single mold, capable of also receiving the compound. To create this plant, it was necessary to devise a new manufacturing process.

Description of the manufacturing process of the fresh product for "tiles" with feeding, pressing, demoulding and automatic unloading in the single existing mold.

This procedure allows you to perform all the forming operations of the product in the area of the only existing mold including the filling of the mold itself with the mixture. The foregoing allows the use of a fully automatic single-mold press, which has lower operating and manufacturing costs.

The procedure is obtained through a special function that has the pressing pad (D) function that makes it possible to obtain a cavity at the top of the press that allows the passage of the mixture and thanks to the pressing body Fig.l-H placed at the bottom alternatively, not necessarily, even using a press with a pressing body from top to bottom Fig. 2 with the aid of an application in the dispenser that feeds the mold through a "sliding drawer" horizontally placed on one side of the compact press, below of the dispenser (figure 2 -Z and fig. 2 X).

The horizontal distribution drawer in Fig.2X is an alternative to that of detail Z in Fig.2.

The aforementioned cavity from above is obtained thanks to the horizontal movement of the pressing pad (D) which in the return position frees the passage of the mixture. In turn, the horizontal movement of the pressing pad is possible thanks to its simplification, having first separated the pressing pad from the hydraulic piston (H) and positioning the hydraulic piston in the lower part Fig.l-1K-1Y.

Consequently, the molds (F) at the moment of pressing are pushed from the bottom upwards to press with the mobile pressing pad D in turn blocked by the anvil (C). This movement is the exact opposite of the normal presses in use.

The pressing from the bottom up also simplifies the mechanisms of the pressing body. In fact, in traditional presses (pressing from top to bottom) it is necessary to overcome the force of gravity of the weight of the piston body and pressing pads at the moment of recall at the top. To do this, various methods are used such as return springs or hydraulic counterpressures which, among other things, decrease the hydraulic power. In this case, such complex and expensive auxiliary mechanisms are not needed since the weight of the pad itself returns to its starting position by gravity.

This press and this manufacturing process of the fresh product of the tiles allows you to carry out, in the only available area, all the operations necessary to build a fresh product. In fact, the great innovation of the machinery is the total elimination of the stations, consequently all the slides or tracks on which the trolleys / mold slide, the double compound doser or the movement with its tracks of a single mobile doser are eliminated. Basically we are in the presence of a special compact press that innovates the field by placing itself as an alternative to both linear and rotary presses.

The elimination of these appendages (slides, tracks, etc ...) as well as lowering the production costs of the machine, reduces complications and therefore wear, accelerates the production process thanks to the zeroing of the time necessary for the rotation of the trolleys / mold in the pressing station. Time partly occupied by the small movement of the mobile pad (D).

There are also further advantages such as greater precision in the measurement and baptism between one product and another, a single mold means in fact repetition of the same or the product is formed by a single mold instead of multiple molds which imply possible differences between one and the other. You have the advantage of time in changing the mold, to switch from one format to another. It is different to change a mold or to change the molds, especially if you consider that the shape change is unproductive since it is carried out when the machine is stopped. Maximum cost-effectiveness in the investment of molds which are very expensive, in fact for each size or shape a mold is sufficient and no more molds.

Again with regard to the improvements compared to existing presses, the extreme compactness and very small spaces and volumes of this super compact press should be mentioned.

Up to now, the state of the art has conceived the pressing body from top to bottom, this required that, to fill the mold, it was necessary to remove the mold itself from the pressing area since the pressing body completely hid the spaces from the high necessary to make the compound "rain". This invention, to obviate this complication, has positioned the pressing body (HG) at the bottom and has made the pressing pad (D) movable horizontally.

In substance (D) through slide guides or wheels (H) and through actuator / s (L) it moves backwards, freeing the area that allows the passage of the mixture. At the end of the passage of the mixture, -D- returns to its original position (fig.lK) to allow the pressing phase. During the pressing phase, the piston and the hydraulic cylinder (H) the mold surface (G) and the mold (F) are raised up to oppose the pressing pad (D) which in turn presses on the anvil (C), pressing the mixture and forming the artifact.

The fall of the mix (mold filling) can be guided by retractable telescopic conveyors (B). Said conveyors, if applied, must be retractable and not fixed so as to allow the passage of (D). We would therefore have the conveyors in the closed position when (D) is present inside the press and performs its function. On the contrary, the conveyors will be in an extended position at the time of pouring the mixture when (D) is out of the work area. The use of retractable conveyors can be avoided by using "medium conveyors". They consist of simple tubes that guide the compound ejected from the dispenser up to a medium height in the direction of the mold. The height of this conveyor must allow the coming and going of the pressing pad (D). In the drawing in figure 1 and figure 1K, the separate conveyors (hatched) in letter (B) are made with two tubes that can be inserted into each other. In the case of "medium conveyor", only one of the two sectors must be understood, clearly the one connected to the dispenser (A).

In the second process, that is the one with the application of a horizontally sliding drawer to a dispenser (fig. 2 and 2X), the constructive process of the present invention does not substantially change. Likewise, all phases take place in the only available area. The difference is given by the fact that since I do not feed the mixture from above, I can also use a press with a pressing body (H) placed at the top with consequent pressure from the top downwards (Fig. 2).

The drawer (Z or Fig.2X) placed under the dispenser, next to the press, carries out a horizontal movement from the dispenser to the center of the molds, subsequently, through mechanical movement, the "basins", integral parts of the drawer, as many as there are cavities in the mold they turn over and, aided by a jet of compressed air or vibration, pour the mixture into the molds. As an alternative to the revolving or openable containers, a further horizontal distributor has been developed, different from the one described, only in particular Z, in fact the drawing 2X only describes F as an alternative to Z. In this case the mobile container 2X copies the format of the die. The comb-like opening bottom (Venetian blind type) allows the mixture to be contained first, and after having transported it for the short horizontal section, and pre-vibrated, to unload it by opening the combs with mechanical movement and further vibration. With this system there is the advantage of having a distribution of the mixture in the mold ready. In this case, all traditional dosers pour the mixture in a spheroidal or in any case formless form, in the presence of tiles to be almost always quadrangular, the vibrator of the mold must act a lot because this "meatball" of mixture must stretch out until it occupies all the corners of the form . In option (Z), as described above, the previbration takes place in the time in which the previous product is being pressed, therefore in a time that is not added to the production time. In addition, some defects found in the product caused by excessive vibration in the mold of the so-called single-layer product are eliminated, since the porous surface of the bottom mold does not allow a smooth sliding of the compound up to the corners.

Both in the bottom-up pressure hypothesis with mobile pad, and in the top-down one with three-way feeding, the demoulding of the product takes place in the same way: once the pressing phase is finished, the frame (F) is part of the mold (excluding the vibrating bottom "G"), which contains the semi-solid products, is raised, the extraction blade (O) enters the press, positioning itself between the mold bottom (G) and the mold frame (F). At this point we have the extraction blade (O) which, due to its position, acts as the bottom of the mold, the mold frame (F) in the center and, finally, above the pressing pad (D). The mold frame and the blade shelf (which as seen in figure lk is equipped with a pneumatic piston) are raised in unison just enough to reposition the shapes of the product just pressed to press again with the pressing pad which, this time , acts as an ejector of the product from the mold frame (F). Now I have positioned the artifacts in the extraction blade (O) which returns to its natural height position and, by mechanical movement, exits the area of the press with the artifacts ready for subsequent handling (basic position, fig. 2). In the hypothesis of pressure from top to bottom, the ejection movement of the product from the mold frame can also be done by a small lowering of the pressing pad as it is connected directly to the piston.

If you want to make a product with more than one compound (multilayer) in the solid frame (N), two windows (Q) are provided (one on the right side and one on the left side).

One or two traditional distributors can be placed side by side with the compact press, which will perform their function already known in the state of the art, a function suitable for obtaining products made with more than one layer.

These two possibilities constitute a real revolution in the field. Until yesterday it was unthinkable to conceive such a simple and fast procedure implemented with a super-compact and extremely economical press. Even the first manual presses of the early 20th century of insignificant production consisted of at least two stations: filling the mold, sliding the mold into the pressing station, pressing.

The revolution of this method consists in having found the way to feed the mold into the pressing station. This possibility makes it possible to reduce complex machinery to small “boxes” that are much cheaper and advantageous also due to the low consumption of electricity and materials. It should also be said that the reduction of mechanisms and complexities reduce breakdowns, wear and therefore production stops which often, added together, contribute to raising the cost of the finished product.

Claims (5)

CLAIMS 1. The filling of the mixture on the mold, the pressing, the demoulding and the unloading take place in the only available area. 2. Use of a monolithic press without single mold stations. 3. Use of a monolithic press without stations and with the ram located at the bottom (pressure from bottom to top) under the mold, and vertically fixed and horizontally movable pressing pad positioned above the mold. 4. Use of a dispenser positioned on the side of the press with drawer designed to fill the mold with horizontal movement. Transfer of the mix in 3 phases: from the dispenser vertically to the container horizontally to above the mold, from above the mold vertically to the mold. To allow the use of a monolithic press without stations with the ram placed at the top. 5. Use of a dispenser with aforementioned container which allows the mixture to be pre-leveled before the last casting on the mold.