Technical Field
[0001] The present invention relates to a device to load powders in a mould to make tiles,
and in particular a device comprising a so-called double-loading carriage, i.e. a
carriage of the type comprising a main grid which is filled with base powder material,
and a hopper or an auxiliary tray which is loaded with a small quantity of additional
powder material (for example a coloured powder material), which is deposited on the
surface intended to form the visible side, that is the top side of the tile, and which
provides the coloured pattern on the surface of the tile.
[0002] The invention also relates to a method of loading powders in a mould for the production
of ceramic tiles.
State of the art
[0003] In the field of ceramic tile production it is known to load the cavity of the mould
with a layer, of noteworthy thickness, constituted by a base material (for example
atomized clay) and intended to form the body of the tile, on which a small quantity
of a colouring material is deposited, generally constituted by a mixture of granules
of various colours and/or various effects.
[0004] The Italian patent application n. MO99A00141 describes a loading device for ceramic
presses to produce tiles with a technique of this type, which is provided with a carriage
with a loading grid, which is filled with the base material and which is then transferred
above the cavity of the mould to deposit the base material. Disposed in front of the
loading grid is a means to distribute a specific quantity of coloured powder material.
This means comprises a perforated flexible screen which slides in front of a hopper,
with a movement synchronized with the movement of the carriage, in order to distribute
the coloured material according to a specific pattern.
[0005] The Italian patent application n. MO99A000016 describes a similar device to the previous
one, wherein the coloured material is however distributed through a series of rotating
and perforated hollow cylinders inside which the coloured material is placed.
[0006] These two systems, although allowing noteworthy aesthetic results to be obtained
on the tiles, are complex, costly and subject to frequent maintenance operations.
[0007] EP-A-0444730 describes a device to load ceramic presses comprising:
- a carriage provided with alternate loading movement along a sliding surface;
- on said carriage, a main grid which receives a base powder material from a first loading
means and transfers said base powder material to a cavity in said mould;
- on said carriage, in front of said main grid, an auxiliary tray for loading a coloured
powder material.
[0008] The auxiliary tray is produced in the form of a hopper moving on the carriage, in
a direction parallel to the to-and-fro movement of the carriage. During this movement
the hopper passes over a mesh bearing a pattern, while the carriage remains still
in a position in which the mesh is above the cavity of the mould, in which a layer
of base material has previously been disposed.
[0009] This device and the relative production method have the problem of limited production
speed. In fact, the filling cycle of the mould cavity includes a first phase in which
the grid is positioned above the bottom punch of the mould and in which the latter
is lowered (performing a first lowering) to create the cavity which is filled with
the material contained in the grid. Following this first phase is a second phase in
which the carriage, after having travelled for a certain distance, stops to allow
movement of the hopper containing the coloured powders and their distribution through
the mesh onto the layer of material previously deposited in the mould cavity. The
punch must be lowered a second time, between the first and second phase.
[0010] EP-A-0941826 describes a loading device with a double-loading carriage, which comprises
a main grid, which receives the base material and transfers it to the mould, and a
hopper or tray provided with a controlled bottom closing component, to deposit the
coloured material on top of the base layer previously deposited in the mould cavity.
As the bottom punch of the mould must be lowered a second time, that is travel downwards
a second time, after the base material has been deposited on it and before the coloured
material is deposited, the carriage has an intermediate portion, between the main
grid and the hopper, with the object of spacing these two elements by a length corresponding
at least to the dimension of the mould cavity in the direction parallel to the direction
in which the carriage moves. This prolongs the production cycle and consequently reduces
productivity of the device.
Objects and summary of the invention
[0011] The object of the present invention is to provide a loading device for presses to
produce ceramic tiles, which overcomes entirely or in part the problems of the prior
art. In particular, the object of the invention is to provide a device which may reach
high production rates and which has a simple structure.
[0012] In substance, the device according to the invention includes a double-loading carriage,
with a main grid and an auxiliary tray, characterized in that these two elements are
placed on the carriage at a reciprocal distance independent from the dimension of
the mould and if necessary may be less than this, and in that the auxiliary tray has
a bottom closing component controlled in synchronism with the movement of the carriage
in relation to said mould.
[0013] Further advantageous characteristics and embodiments of the device according to the
invention are indicated in the attached dependent claims.
Brief description of the drawings
[0014] The finding shall now be better understood by following the description and attached
drawing, which shows a non-limiting practical embodiment of the invention. In greater
detail, in the drawing:
Fig.1 shows a side view of a press with a loading device according to the invention;
and
Figs.2A-2D schematically show successive phases of the cycle to load the powders in
the mould.
Detailed description of an embodiment of the invention
[0015] With initial reference to Fig.1, the system comprises a press generically indicated
with 1, equipped with a mould 3 with a bottom punch or pad 5 and a top punch or pad
7 carried by a moving crosspiece 9. The bottom punch 5 moves inside a die 11 to define
together with it a cavity which must be filled with powders, which are subsequently
pressed by the two punches of the mould to form the tile.
[0016] At the side of the press 1 a powder loading device, indicated as a whole with 15,
is provided. This comprises a carriage 17 moving in the direction of the arrow f17,
controlled by an actuator, not shown, along a sliding surface 19, the top surface
of which is flush with the top surface of the die 11. On the opposite side of the
mould, in relation to the loading device 15, a continuous conveyor with belts or strips
22 is disposed, to remove the tiles formed by the press 1.
[0017] Disposed on the carriage in sequence from right to left are: a base grid or main
grid 23, a first scraper 25, an auxiliary tray 29, a second scraper 32 with an actuator,
not shown, to raise it and lower it in relation to the surface 19, and a cylindrical
brush 31, controlled by an actuator, not shown, suitable to raise and lower it, for
reasons explained hereunder. The auxiliary tray 29 is closed at the bottom by a gate
valve 29A, the opening and closing of which are controlled by an actuator 30 controlled
by a central control unit in synchronism with the movement of the carriage 17.
[0018] During the phase to fill the main grid 23 and the auxiliary tray 29, shown in Fig.1,
the carriage 17 is in a position in which the main grid 23 is placed below a base
hopper 33, extending orthogonal to the plane of the figure for a width equal to the
width of the main grid 23 and equipped with a bottom opening closed by a gate valve
35 controlled by a piston-cylinder actuator 37. The hopper 33 is filled with a base
powder material, for example atomized clay, through a duct 39 connected to an overhead
silo containing the material, not shown. The duct 39 is carried by a slide 41 equipped
with alternate movement parallel to the hopper 33 and therefore orthogonal to the
plane of the drawing and to the movement according to f17 of the carriage 17. The
transverse movement of the duct 39 guarantees uniform filling of the main hopper 33.
[0019] When the carriage 17 is in the position in Fig. 1 the gate valve 35 to close the
hopper 35 is opened to fill the main grid 23. This is divided internally, in a per
se known way, by a series of vertical slats orthogonal to the direction of movement
of the carriage 17, or if necessary distributed according to another pattern, to obtain
a desired distribution of the base material in the mould cavity of the press 1. In
the example shown the main grid 23 is of the so-called tray type, that is of noteworthy
height and with a reduced dimension in the direction parallel to the movement of the
carriage 17, that is a dimension lower than the corresponding dimension of the mould
cavity. However, it may also be possible to use traditional grids, of a lesser height
and greater length in the direction of forward movement of the carriage.
[0020] In this case filling of the main grid 23 is completed during the first length of
the travel towards the press 1 of the carriage 17, so that most of the compartments
into which the grid is divided by the respective slats are filled completely. In this
case the gate valve 35 may not be required, as the carriage has a seal-plate behind
the grid 23.
[0021] When the carriage 17 is in the position in Fig.1, the auxiliary tray 29 is below
the preload hopper 51 closed at the bottom by a gate valve 53 controlled by an actuator
55. The preload hopper 51 is filled with coloured powder material (for example a mixture
of enamels) through a mixer 57 moving along guides 59 transverse in relation to the
movement of the carriage 17. The mixer 57 is filled with coloured powders from the
silos overhead, not shown, through flexible ducts 61. These loadings take place at
any time, irrespective of the position of the carriage.
[0022] When the auxiliary tray 29 is in the position shown in Fig.1, the gate valve 53 can
be opened to load the coloured material into the tray 29.
[0023] The base material with which the main grid 23 is filled forms the base of the tile,
while the coloured material (enamel or the like) which is loaded into the auxiliary
tray 29 forms the surface layer of the visible face of the tile.
[0024] As can be seen in Fig. 1, the auxiliary tray 29 is at a distance from the main grid
23 lower than the dimension, in the direction of movement of the carriage 17, of the
mould cavity 5, that is than the dimension of the tile produced by the press 1. The
distance between the auxiliary tray 29 and the main grid 23 is sufficient to house
the scraper 25.
[0025] Operation of the device described hereinbefore shall now be described with reference
to Figs. 2A-2D. In Fig. 2A the carriage 17 is in the filling position, the crosspiece
of the press is raised and the bottom punch 5 has been raised until it is flush with
the top surface of the die 11 and therefore with the sliding surface 19 of the carriage
17. A tile P1 produced in the previous pressing cycle is laid on the top surface of
the bottom punch 5 to be ejected by the carriage 17 during its movement to enter the
press 1.
[0026] In Fig.2B the carriage 17 has moved to its most forwardly position. The auxiliary
tray 29 is beyond the mould cavity, the main grid 23 is in proximity to the outlet
edge of the mould cavity, that is the edge nearest to the conveyor 22. The tile P1
has been pushed by the carriage 17 out of the press 1 to the conveyor 22, by which
it is removed and conveyed towards the firing kiln.
[0027] As during the forward movement of the carriage 17 from the position in Fig.2A to
the position in Fig.2B the bottom punch 5 is positioned with its top face flush with
the sliding surface 19, the powder material contained in the main grid 23 is not unloaded.
On the contrary, the material contained in the tray 29 is held there by the respective
closing gate valve.
[0028] In the subsequent phase (Fig.2C) the bottom punch 5 is lowered (so-called first lowering
of the mould) to form between its top surface and the die 11 the mould cavity which
must be filled with the powders destined to form the tile. The powder material contained
in the main grid 23 starts to fill the mould cavity. Sometimes the first lowering
is anticipated to improve loading of the front part of the cavity.
[0029] As in the example shown the grid is a tray grid, of reduced longitudinal dimension,
filling of the mould cavity is completed with reverse movement of the carriage 17,
towards the original filling position (Fig.2A). The height of the main grid 23 is
sufficient to house the quantity of powder material required to fill the entire mould
cavity.
[0030] While the carriage 17 moves back from the position in Fig.2C towards the position
in Fig.2A, passing through the position in Fig.2D, the main grid 23 "sweeps" the entire
area of the cavity delimited by the die 11 and by the bottom punch 5, and the top
surface of the layer of base powder material deposited by the main grid 23 in the
mould cavity is levelled by the scraper 25.
[0031] A layer MC of coloured powder material or of another additional material (enamel
or the like) is deposited by the auxiliary tray 29 on the free and levelled surface
of the layer of base material MB deposited by the base grid 23. For this purpose the
auxiliary tray is promptly opened in order to start unloading the coloured material
contained in it starting from the edge of the mould cavity nearest to the outlet of
the press. For this purpose it may be necessary to anticipate opening slightly, according
to the speed of the carriage 17.
[0032] As the bottom punch 5 is preferably not lowered again, the layer MC of coloured powders
formed by the auxiliary tray 29 is positioned above the surface defined by the top
surface of the die 11. To prevent it from being removed the brush 31 is promptly raised
before it starts to pass over the mould cavity, to be lowered again as soon as it
has exceeded the area of the cavity. The auxiliary tray 29 is also promptly closed
as soon as it reaches the inlet edge of the mould cavity, that is the edge opposite
the conveyor 22.
[0033] As can be seen in Fig.1 and in Fig.2D, a door or trap 63 is provided between the
die 11 and the filling position of the carriage 17, along the sliding surface 19 of
the carriage, which is opened when the second scraper 32 travels over it; this is
lowered onto the sliding surface 19, after it has passed through the area of the mould
cavity during the return travel of the carriage. The scraper 32 will unload through
the opening thus formed in the sliding surface 19 all the residual powder material,
and in particular the enamel powders, collected during the return travel of the carriage
17. This prevents subsequent contamination of the loading system by enamel powders
which may have aggressive chemical properties and the presence of which on the rear
face or brand of the tiles must be avoided to prevent problems from arising during
the firing phase of the tile in the kiln.
[0034] The cylindrical brush 31 has the function of cleaning the top punch during the return
travel of the carriage and for this purpose is promptly raised by the relative driving
actuator.
[0035] As may be understood from the Figs.2A-2D, the loading cycle of the mould is very
brief, as the bottom punch must perform a single lowering movement and not two lowering
movements as is the case in traditional devices. Even if, for the purpose of preventing
the layer MC of coloured powders from extending beyond the top surface of the die
11, the bottom punch 5 implements a second downward travel, this operation does not
prolong the time of a cycle. In fact, the second lowering of the mould may be implemented
as soon as the main grid 23 has left the loading area of the mould cavity, when the
auxiliary tray 29 is already above the cavity. In fact, the quantity of coloured material
deposited on the top surface of the tile is not determined by the distance between
the outlet of the tray and the free surface of the layer of base material, but by
the speed at which the carriage moves, by the amplitude to which the gate valve of
the auxiliary tray 29 opens and by the flowability of the material applied.
[0036] Moreover, the carriage 17 is extremely short, thanks to the fact that the auxiliary
tray 29 may be disposed very close to the main grid 23.
[0037] It is understood that the drawing purely shows a possible embodiment of the invention,
the forms and layouts of which may vary, without however departing from the scope
of the concept underlying the invention.
1. A device for loading powders in a mould to form tiles, comprising:
- a carriage equipped with an alternate loading movement along a sliding surface;
- on said carriage, a main grid which receives a base powder material from a first
loading means and transfers said base powder material to a cavity of said mould;
- on said carriage, in front of said main grid, an auxiliary tray for loading an additional
powder material, such as a coloured enamel or the like;
characterized in that: said auxiliary tray is located at a distance from the main grid, in the direction
of movement of the carriage, independent from the dimension that the mould cavity
has in said direction and preferably less than this, and
in that said auxiliary tray has a bottom closing component controlled in synchronism with
the movement of the carriage in relation to the mould.
2. Device as claimed in claim 1, characterized in that a first scraping component is disposed between said main grid and said auxiliary
tray, to level the base material deposited in the mould cavity by the main grid of
the carriage.
3. Device as claimed in claim 1 or 2, characterized in that it comprises, on the opposite side of the auxiliary tray to said first scraping component,
a second scraping component associated with an actuator which controls raising and
lowering in synchronism with the position of the carriage in relation to the mould.
4. Device as claimed in claim 3, characterized in that said second scraping component is a scraper with a raising mechanism.
5. Device as claimed in one or more of the previous claims, characterized in that the auxiliary tray has a bottom opening at a greater height than the sliding surface
of the carriage.
6. Device as claimed in one or more of the previous claims, characterized in that provided along said sliding surface of the carriage, between the mould and a station
for loading the material into the carriage, is an unloading opening which may be opened
in synchronism with the movement of the carriage, to unload any powder material removed
by said first and/or said second scraping element.
7. Method for loading powders into a mould cavity to form tiles, comprising the phases
of:
- loading a layer of base material (MB) into said cavity;
- distributing, on said layer of base material (MB), by means of an auxiliary tray
(29) which translates on said mould, a layer of colouring material (MC) destined to
form the visible surface of the tile;
- pressing said layer of base material and said layer of colouring material in said
cavity to form a tile;
- ejecting the tile from the cavity;
characterized by levelling the free surface of the layer of base material deposited in the mould cavity
and depositing by dropping the colouring material from said auxiliary tray onto the
levelled surface of the layer of base material, said layer of colouring material projecting
beyond the edge of said cavity.
8. Method as claimed in claim 7, characterized in that the quantity of colouring material (MC) distributed by said auxiliary tray is determined
by the speed of movement of the tray and by the amplitude of opening of a gate valve
to close the auxiliary tray and by the flowability of the material.
9. Method as claimed in claim 7 or 8,
characterized by:
- disposing a quantity of base material on a main grid;
- disposing a quantity of colouring material in said auxiliary tray;
- translating said main grid and said auxiliary tray from a loading position to a
position to fill the mould cavity, in which the auxiliary tray is positioned, in relation
to the mould, on the opposite side to said loading position;
- translating in the opposite direction said main grid and said auxiliary tray, filling
said cavity with a layer of base material;
- when the auxiliary tray is at or in proximity to said cavity, opening the auxiliary
tray in a controlled way and distributing by dropping from said auxiliary tray a controlled
quantity of colouring material onto the free surface of said layer of base material.