Further characteristics and advantages of the invention will better emerge from a reading of the following description, which is provided by way of non-limiting example with the help of the figures of the drawings, in which:
Figures from 1 to 7 show a die 1 destined to be associated to a ceramic press for coining a lower or laying surface of tiles.
The die 1 comprises a metal body 2 with a rectangular plan shape, formed by three superposed plates which are fixed by screws, of which a front plate 200, an intermediate plate 201 and a back plate 202 (see
The metal body 2 exhibits an active face 20 destined to face towards the lo forming cavity of the ceramic press to which the die 1 will be associated.
As shown in
A second concentric hollow 23 is afforded on the bottom of the first hollow 21, which second hollow 23 has a constant depth which in plan view generally exhibits a regular grid shape (see
In particular, the grid 23 comprises a plurality of cells 24′ which are uniformly distributed and which are reciprocally connected by means of straight channels 24″.
In plan view the cells 24′ are generally square with longer sides than the width of the straight channels 24″.
In this way, a plurality of generally cross-shaped relief zones are defined between the cells 24′, a top of which is at the same level as the bottom of the first hollow 21.
Finally, a third hollow 26 is afforded on the bottom of the second hollow 23, which third hollow 26 is formed by a grid having straight, reciprocally perpendicular channels.
The straight channels are narrower than the channels 24″ of the second hollow 23, and develop along the channels 24″ such as to groove and cross each single cell 24′.
A grid 3 made of an elastically deformable material, which is separately prepared, is positioned internally of the second hollow 23.
As illustrated in
In particular, the grid 3 comprises a plurality of forms 30 which corresponding to the cells 24′ and which are joined by straight tracts 31 which correspond to the channels 24″.
The grid 3 has a constant thickness which is slightly less than the depth of the second hollow 23, and is preferably made of an elastomer material.
In transversal section, the grid 3 comprises a first layer which is inserted snugly internally of the second hollow 23 of the metal body 2 in contact with the bottom thereof, on which is laid a second layer having a same shape with a smaller width (see
The face of the grid 3 in contact with the bottom of the second hollow 23 closes the channels of the third hollow 26, such as to define a free space which in plan view is a labyrinth grid.
A plurality of vertical holes 4 are afforded in the metal body 2, each of which vertical holes 4 centrally crosses a respective cross-zone 25 and opens onto the bottom of the first hollow 21.
A guide bushing 5 made of wear-resistant hard material is press-inserted, or inserted using other known fitting systems, internally of each vertical hole 4. The bushing is provided with a head 50 having a greater diameter which projects with respect to the bottom of the first hollow 21, and a top of which is generally in line with the upper edge of the metal body 2.
In particular, the projecting head 50 exhibits an undercut circumferential channel 51 along the lateral surface thereof.
The internal cavity 52 of each guide bushing 5 defines a breather mouth which sets the relative vertical hole 4 in communication with the outside.
Note that the rigid guide bushings 5 could alternatively be in a single piece together with the metal body 2, for example in the form of further salient appendages rising up from the cross zone 25.
As illustrated in
After the guide bushings 5 and the grid 3 have been coupled to the metal body 2, a layer of a mastic or of a suitable adhesive glue is applied on the metal body 2.
In particular, the layer of mastic is laid on the bottom of the first hollow 21, on the perimeter strip 22, on the portions of the lateral walls of the channels 24″ and the cells 24′ not covered by the grid 3, on the free faces of the grid 3 and on the lateral surface of the projecting heads 50 of the guide bushings 5.
Thus, internally of the first hollow 21 a fluid resin normally used in the sector is dropped, which, after hardening, realises an elastically-deformable membrane 6.
In this way, the posterior face of the elastic membrane 6 exhibits a grid in relief which is sealedly coupled internally of the grid 23 of the metal body 2. Further, it also exhibits a series of through-holes, each of which receives the projecting head 50 of a respective guide bushing 5 and is provided with a circumferential rib 60 which couples to the undercut channel 51 and solidly anchors the guide bushing 5 to the membrane 6.
During forming, a grid of identical crossed channels 62 is formed on the external active face 61 of the membrane 6, which crossed channels 62 are for shaping the feet of the tiles (see
In particular, the crosspoints of the crossed channels 62 are vertically superposed on the cross-zones 25 of the metal body 2, and are identified by a series of prominences 63 having a generally circular plan shape.
A relative guide bushing 5 is located at the centre of each prominence 63, a top of which bushing 5 is in line with the top of the prominence 63.
Thanks to the mastic, the elastic membrane 6 is strongly gripped to all the parts of the metal body 2, the grid 3 and the guide bushings 5, on which the mastic has been previously applied.
Note that the grid 3 and the elastic membrane 6 are constituted by elastomer resins having generally different elastic characteristics. Preferably the resin of the elastic membrane 6 is more elastic and flexible than that of the grid 3 which is therefore more rigid.
A cylindrical valve body 7 is slidably housed in each guide bushing 5, which valve body 7 partially obstructs the breather mouth 52, leaving a small fissure communicating with the underlying vertical hole 4.
The small fissure is of an entity such as to enable passage of the air, while it effectively obstructs any leaking of the ceramic powder, which is compacted lo during the forming of the tiles.
The opening can be obtained by realising the cylindrical valve body 7 with a slightly smaller diameter with respect to the breather mouth 52 of the guide bushing 5, for example by specially calibrating the working tolerances.
For example, the diameter of the cylindrical valve body 7 can be made less by about 0.2 mm than the diameter of the breather mouth 52.
Each valve body 7 is borne at the end of a stem 70 which is slidable internally of the vertical hole 4, the posterior end of which is associated to respective means for activating which cause the posterior end to slide at each pressing cycle.
The means for activating comprise a brass plate 71 fixed to the posterior end of the stem 70 and slidably received internally of a cylindrical seating 41 which is afforded in the intermediate plate 201 of the metal body 2, posteriorly with respect to the discharge conduit 9.
In particular, the cylindrical seating 41 is arranged coaxially of the hole 4 and has a greater diameter with respect to the width of the discharge conduit 9.
A seal ring 72 is placed between the plate 71 and the lateral wall of the cylnidrical seating 41, while a dust ring 73 is located between the lateral wall of the cylindrical seating 41 and the stem 70, which dust ring 73 rests on the edges of the discharge conduit 9.
A compression spring 74 is interposed between the dust ring 73 and the plate 71, which spring 74 maintains the valve body 7 in the rest position illustrated in
In this position the valve body 7 is in line with the top of the guide bushing 5 and thus also with the prominence 63 of the elastic membrane 6, while the plate 71 is at the posterior endrun position.
As illustrated in
The operating fluid acts on the face of the plate 71 opposite the compression spring 74, such as to push the stem 70 and cause the valve body to extend completely with respect to the active face 61 of the elastic membrane 6.
In this embodiment, the conduit 8 places all the cylindrical seatings 41 of the die 1 in reciprocal communication, such that the activating of the valve bodies 7 occurs contemporaneously; however it is possible to connect the cylindrical seatings 41 via independent conduits in order to activate different valve bodies 7 on different areas of the die 1 according to need.
In the illustrated embodiment of
In particular, the die 1 is destined to form a laying face of the tiles and is located superiorly of a die 11 of a traditional type, which is destined to form the in-view face of the tile.
Obviously the invention is well suited to other types of press, for example a mobile matrix press. Further, the arrangement of the dies 1, 11 can be different from what is illustrated, as can their shape and function. In particular, with slight modifications the die 1 could be used for forming the in-view face of the tiles.
Before installing the dies in the press 10, the free space formed by the channels 26 covered by the grid 3 is filled with an incompressible fluid, generally pressurised hydraulic oil, and is then sealedly closed.
The introduction of oil is done by special conduits such as those indicated with a broken line and denoted by 13 in
The introduction of the pressurised oil leads to corresponding elastic deformations of the grid 3 and the elastic membrane 6 (see
The membrane 6 is however gripped to the perimeter strip 22 of the metal body 2, at the top of the cross zones 25 and at all the other zones on which the glue has been applied. Therefore it substantially tends to arch only at the position of the cells 24′, assuming a generally lumpy surface appearance. In this way, the die 1 functions as an isostatic die which enables a uniform density of the ceramic material of the compacted tile to be achieved.
At the same time, the presence of the grid 3 enables the well-known phenomenon of “transparency”, in which underlying structures of the rest base of the tile are apparent from the tile in-view surface, to be prevented from occurring.
During this stage, the operating fluid circulating in the conduit 8 is discharged, so that the compression spings 74 maintain the valve bodies 7 in the rest position, with the tops thereof coplanar to the active face 61 of the elastic membrane 6.
The air imprisoned in the forming cavity 12 can therefore exit freely through the slim fissures defined between the valve bodies 7 and the breather mouths 52 of the relative guide bushings 5; then the air flows through the vertical holes 4, and from there reaches the outside environment, crossing the horizontal discharge conduits 9 (see
In this way, a singly-directed air current from the centre to the periphery of the forming cavity 12 is not established and an undesirable re-distribution of the ceramic powders contained in the forming cavity 12 is prevented. Notwithstanding the small size of the fissures, the air may draw some particles of ceramic material with it.
This however does not create drawbacks, since the particles are also expelled towards the outside; further, the abrasive action they tend to produce is mostly concentrated at the edges of the guide bushings 5, which are difficult to damage as they are made of materials that are particularly resistant to abrasion.
When the compacting is finished, as soon as the formed tile is removed and distanced, pressurised fluid is sent into the conduit 8 so as to make the plates 71 slide in the direction which causes the relative compression springs 74 to compress in the direction of the dust ring 73.
In this way, the valve bodies 7 are made to exit from the respective guide bushings 5, increasing the passage hole of the breather mouth 52 in order to allow removal and distancing of the ceramic material particles which might be blocked between the valve bodies 7 and the internal wall of the respective guide bushings 5 (see
Then the pressurised operating fluid present in the conduit 8 is immediately discharged so that the valve bodies 7 can return to the normal position, pushed by the compression springs 74, for a new compacting cycle.
Note that the above-mentioned compression springs 74 can be replaced by an auxiliary hydraulic circuit, which supplies a pressurised fluid to the cylindrical seatings 41, which fluid acts on the plates 71 on the opposite side with respect to the fluid coming from the conduit 8.
In this case, during the extraction of the valve bodies 7, the auxiliary circuit is kept charged up, and is activated to return the valve bodies 7 to the initial position.
In this variant, the internal cavity of each guide bushing 5 exhibits a tract 53 having an increased diameter located behind the mouth defining the breather mouth 52.
Further, each stem 70 is provided with a scraper body 75 which is substantially cylindrical and annular and which is positioned coaxially behind the valve body 7, and is distanced therefrom by a circumferential channel.
The scraper body 75 has a slightly bigger diameter than the valve body 7 but is in any case destined to pass internally of the breather mouth 52 defined by the mouth of the guide bushing 5.
For example, the diameter of the scraper body can be about 0.12 mm less than the diameter of the breather mouth 52.
When the valve body 7 is in the rest position, in which it occupies the breather mouth 52, the scraper body 75 is contained internally of the enlarged tract 53 of the guide bushing 5, such as to enable passage of air coming from the forming cavity.
When the stem 70 slides in the direction to cause the valve body 7 to exit from the guide bushing 5, the scraper body 75 passes internally of the breather mouth 52 and, by mechanical action, draws along with it the particles of ceramic material which might be imprisoned and discharges them to the outside.
In
In this case, the first hollow 21 is circumscribed by a channel 27 which runs along the edges of the metal body 2 and separates it from the perimeter strip 22.
The bottom of the first hollow 21 is grooved by a plurality of shaped cavities 28, which are separate from one another and do not reciprocally communicate.
The cavities 28 are all of the same depths and are generally rectangular in plan view with rounded ends.
A respective vertical hole 4 opens on the bottom of each cavity 28, which vertical hole 4 is generally located in the median point of the cavity 28. The grooved cavities 28 are, in general but not necessarily, arranged aligned along rows which are parallel to the lateral edges of the metal body 2, and along each of the rows they are orientated such as to be alternatively perpendicular to one another.
The width of each cavity 28 is smaller than the diameter of the projecting head 50 of the guide bushing 5 housed in the respective vertical hole 4, so that the projecting head 50 rests directly on the bottom of the first hollow 21. A layer of mastic or glue is spread on the perimeter strip 22 of the metal body 2, internally of the channel 27, internally of the grooved cavities 28 and on the projecting head 50 of the guide bushings 5.
Then, internally of the first hollow 21, the fluid resin realising the elastically deformable membrane 6′ is dropped.
In this way, the posterior face of the membrane 6′ exhibits a series of protuberances in relief which are sealedly coupled and solidly gripped each to the inside of a respective grooved cavity 28.
Further, a through-hole forms at the centre of each protuberance which houses the projecting head 50 of the guide bushing 5 and which is provided with a rib 60′ for coupling to the undercut channel 51, solidly anchoring the guide bushing 5 to the elastic membrane 6′.
Apart from the above, the die 1 of the present embodiment is the same as the die of the previously-described embodiment, and has the same function.
In this case too, the first hollow 21 is circumscribed by a channel 27 which runs along the edges of the metal body 2 and separates it from the perimeter strip 22.
A series of annular channels 29 are afforded on the bottom of the first hollow 21, each of which circumscribes a circular zone 290 at a centre of which a respective vertical hole 4 opens out.
A guide bushing 5″ is inerted internally of each vertical hole 4, slightly different from the guide bushings described herein above (see
In particular, the guide bushing 5″ has a generally constant diameter and is inserted in an enlarged tract 42 of the vertical hole 4, where the posterior end thereof rests on an intermediate shoulder.
The shoulder is positioned at a distance from the bottom of the first hollow 21 which is such that the guide bushing 5″ projects externally with a projecting tract 50″ exhibiting an undercut circumferential channel 51″.
A layer of mastic or glue is spread on the perimeter strip 22 of the metal body 2, internally of he channel 27 and the annular channels 29, on the top of all the circular zones 290 and on the projecting tract 450″ of the guide bushings 5″.
A fluid resin is then dropped, so as to realise an elastic membrane 6″ the posterior face of which exhibits a series of annuilar ribs in relief which couple sealingly and are each tightly gripped internally of a respective annular channel 29.
Further, the elastic membrane 6″ is strongly gripped also by the circular zones 290, where it forms a through-hole and a rib 60″ which couple with the projecting tract 50″ and respectively with the circumferential channel 51″ of the guide bushings 5″.
Apart from these particulars, the die 1 of the second alternative embodiment is the same as the previous die 1 and has the same type of functioning.
In figures from 14 to 18, a third alternative embodiment of the invention is illustrated, in which the isostatic die 1 is associated to an aspirating device (not shown) by means of as aspirating conduit 14.
The aspirating conduit 14 is in communication with the series of discharge conduits 9 afforded in the front plate 200 of the metal body 2, and which communicate with the breather mouths 52.
In particular, as illustrated in
A first end of each discharge conduit 9 opens internally of a transversal channel 90, also afforded in the front plate 200 of the metal body 2, which makes the discharge conduits 9 reciprocally communicating.
The second ends of the discharge conduits 9 are all in communication with a respective underlying opening 91, which is afforded in the intermediate plate 201 of the metal body 2, and opens onto an external flank thereof (see
A casing 92 is fixed to the external flank, which casing 92 defines a single aspirating manifold 93, which is hermetically closed and internally of which all the openings 91 terminate.
The aspirating manifold 93 communicates directly with the aspirating conduit 14.
As illustrated in
The auxiliary channel 94 is parallel to the discharge conduits 9 and is located in an intermediate position between two thereof, in order to be closed by the front plate 200.
The end of the auxiliary channel 14 located on the side of the opening 91 communicates with a vertical hole 95 opening into an elbow conduit 96 afforded in the posterior plate 202 of the metal body 2 (see also
The elbow conduit 96 terminates externally of the metal body 2, where it is connected to an entry conduit 97, which is connected to a usual compressed-air blower device (not illustrated).
The end of the auxiliary channel 14 which is opposite the vertical hole 95 is in communication with the connection channel 90 of the discharge conduits 90 such that the discharge conduits 90 are reached by the compressed air injected by the blower device.
The blower device is usually inactive during the pressing stage, and the air contained in the forming cavity can freely flow into the discharge conduits 9 and exit to the outside through the manifold 93 and the aspiration conduit 14. During these stages, the aspirating device might be kept on, so as to facilitate the degassing of the forming cavity; however this must be when the aspirating action does not cause an excessive entraining of ceramic particles, which can be the situation when the degassing causes clogging problems in the fissures between the breather mouth 52 and the valve body 7.
It can occur that after a high number of pressing cycles, large quantities of ceramic powder material leaked from the breather mouths 52 accumulate in the discharge conduits 9.
To clean the discharge conduits 9, each time the die 1 completes a predetermined number of pressing cycles, the aspirating device and the blower device are contemporaneously activated.
In this way, the compressed air passes into the auxialiry channel 94 and, through the transversal channel 90, runs along the discharge conduits 9, pushing the ceramic powder towards the opening 91, where it is sucked into the aspirating manifold 93 by the aspirating device.
Note that
The functioning of the isostatic die 1 is the same as the functioning of the die 1 described herein above.
However, in order to discharge the ceramic powder which might be trapped internally of the fissures between the valve bodies 7 and the mouths 5, the discharge conduits 9 are connected to a compressed-air blower device, in the same way as described for the previous embodiment.
The blower device enters into operation after each pressing cycle, so that the compressed air injected into the discharge conduits 9 tends to exit from breather mouths 52 and projects the trapped ceramic powder towards the forming cavity.
In order to perform this function, the blower device must however inject air into the discharge conduit 9 at a greater pressure than what is required in the third alternative embodiment of the invention.
Obviously an expert in the sector might bring numerous modifications or a technical-applicational nature to the isostatic dies described herein, without forsaking the ambit of the inventive idea as claimed herein below.
Number | Date | Country | Kind |
---|---|---|---|
RE2006A000091 | Jul 2006 | IT | national |
RE2006A000146 | Nov 2006 | IT | national |