Ware shaping apparatus

Abstract

 Ware shaping apparatus (10) comprising a carousel (12) with eight arms (14) each of which mounts at its free end a mould (16) made of a porous plastic material. The moulds (16) are selectively movable between a clay loading device (20), a shaping device in the form of a roller head (22), a mould release dryer (28) including a back stamping device (34), and a mould release stage where the shaped ware can be blown onto a conveyor (30).

Description

[0001] This invention concerns improvements in orrelat- ing to apparatus for shaping ware, and particularly but not exclusively for shaping holloware and flatware, and also tiles.

[0002] Conventionally holloware and flatware have been shaped on a roller machine. With such a machine a plaster of paris mould is loaded onto the machine. With holloware the mould is held in a metal mould carrier. A piece of clay is placed onto the mould which is then spun and a counter-rotating shaped roller head is brought into contact with the clay to provide the required shape. The ware carrying mould is then removed from the machine and placed in a drier to obtain mould release. Disadvantages are encountered with this system in that the moulds have a relatively short working life. Furthermore, a large number of moulds are required which thus occupy a relatively large area in a production area. Also, plaster of paris is not readily disposed of and thus costs are incurred when disposing of used moulds.

[0003] According to the present invention there is provided ware shaping apparatus, the apparatus comprising a porous plastic mould upon which a portion of clay can be loaded, means for shaping the clay carried on the mould, and means for automatically releasing the shaped clay from the mould.

[0004] The apparatus preferably comprises a clay loading station, a clay shaping station, and a shaped clay release station; and means for moving the mould between the respective stations.

[0005] A plurality of moulds are preferably provided such that different moulds can simultaneously be located at different stations.

[0006] The moulds may be carried on a carousel or an endless conveyor, or they may be carried on a bed and movable by one or more linear acutators.

[0007] Below ambient pressure may be provided on an interior side of the mould at the loading and/or shaping stations to hold clay on the mould.

[0008] Above ambient pressure may be provided at the clay release station to blow the clay from the mould. The above ambient pressure is preferably provided by pressurised air, and the air may be warmed. The release means may release the shaped clay onto a conveyor.

[0009] The apparatus may include means for carrying out additional processes on the clay, and drying means may be provided between the shaping station and the clay release station. Back stamping means may also be provided.

[0010] The shaping means may comprise a rolling head for shaping flatware or holloware. Means may be provided for spinning a mould during shaping of the clay. Alternatively, a ram press could be provided for shaping articles such as tiles.

[0011] The or each mould may be made of an acrylic plastics material and preferably an acrylic bead. The plastics material is preferably mounted on a metal carrier.

[0012] The or each mould is preferably releasably mounted on the apparatus to permit different shape moulds to be used. Means are preferably provided for automatically changing the moulds being used. Mounting means such as a screw thread or bayonet fitting may be provided on the moulds, and the mounting means is preferably provided on the metal carrier.

[0013] Means may be provided for automatically loading a portion of clay onto a mould as is required and the loading means may automatically provide the required quantity of clay for any particular mould.

[0014] An embodiment of the present invention will now be described by way of example only with reference to the accomanying drawings, in which:-

Fig. 1 is a diagrammatic side view of mould shaping apparatus; and

Fig. 2 is a view along the line A-A in fig. 1.

[0015] The drawings show ware shaping apparatus 10 suitable for shaping flatware such as plates and saucers. The apparatus comprises a carousel 12 rotatable about a horizontal axis and having eight hollow arms 14, only four of which are fully shown in fig. 1 for clarity. Each of the arms 14 is hollow and mounts at its free end a mould 16. Each mould 16 is made of a porous plastics material which is held on a metal carrier (not shown). The plastics material may be an acrylic bead which may be set on the carrier during forming. The centre 18 of the carousel comprises a manifold permitting above or below ambient pressure to be applied to the interior of each of the arms 14 and hence respective moulds 16 as is required, and this will be outlined in more detail below.

[0016] The mould 16Aon the arm 14 which points to the right as shown in fig. 1 is located adjacent a clay loading device 20 which incorporates a mould changing device which will be described in further detail below. The device 20 automatically loads a required amount of clay onto the mould 16A. The manifold 18 is arranged such that below ambient pressure is applied to the mould 16A at this point to hold the clay thereonto.

[0017] The mould 16B on the end of the arm 14 which points upwardly in fig. 1 is located adjacent to and in cooperation with a roller head 22. A drive mechanism 24 is provided for rotating the roller head 22 and mould 16B in opposite directions. The manifold 18 is arranged such that again below ambient pressure is provided in the arm 14 which mounts the mould 16B to hold the clay 26 onto the mould 16B.

[0018] A mould release dryer 28 is provided on the left hand side of the manifold 18 as shown in fig. 1. The mould 16C mounted on the arm 14 which points to the left hand side as shown in fig. 1 is located within the dryer 28. Again the manifold 18 is arranged to provide below ambient pressure to hold the clay 26 on the mould 16C.

[0019] Mounted immediately below the mould 16D on the arm 14 pointing downwardly in fig. 1 is a ware removal conveyor 30. The manifold 18 is arranged such that above ambient pressure air is provided in the arm 14 mounting the mould 16D such that the ware 26 is blown off the mould 16D onto the conveyor 30. The manifold 18 may be arranged such that the air in the arm 14 mounting the mould 16D is warmed. The warm air helping to dry the mould 16D and the release agent obviously assisting release of clay therefrom.

[0020] As noted above the loading device 20 also comprises a mould changing device. This mould changing device is coupled to a mould storage magazine 32 and permits automatic changing of the moulds 16 such that the apparatus 10 may be rapidly changed to produce different shaped articles. The moulds 16 and arms 14 may be provided with suitable releasable mounting means such as a screw thread and/or bayonet coupling. The fitting on the moulds 16 may be provided on the metal carrier part of the mould 16.

[0021] Other processes may be applied to the day whilst on the carousel 12. For example, in the described example back stamping is carried on by a suitable device 34 in the dryer 28.

[0022] In use, a required amount of clay is loaded by the device 20 onto the mould 16Aand held thereon by the below ambient pressure in the respective arm 14. The mould 16A is then rotated in an anti-clockwise direction to the position occupied in fig. 1 by the mould 16B. Here the clay is shaped as required by the roller head 22. The mould 16A is then rotated through the dryer 28 to achieve mould release as is required past the position shown in fig. 1 occupied by mould 16C. When the mould 16A reaches the position shown by mould 16D in fig. 1, the below ambient pressure in the arm 14 is replaced by above ambient pressure to blow the clay 26 onto the conveyor 30 for removal to a further drying stage or direct to a biscuit firing.

[0023] There is thus described ware shaping apparatus with a number of advantageous features. The present apparatus uses a greatly reduced number of moulds, thus providing a considerable saving of space. The use of plastics mould provides for a much longer mould life. With plastic moulds no thermal shock problems are encountered and thus faster drying can be used. Due to the strength of plastics the moulds are generally smaller and lighter thus improving storage. The moulds also have a lower heat capacity therefore requiring less energy consumption for drying. As the plastics moulds are smaller they will tend to hold less water and also the below ambient pressure which is applied for a considerable part of the shaping process removes much of the water from the moulds.

[0024] Plastics moulds provide for easier release of the clay and shrinkage is not necessary as with plaster of paris moulds. The plastic moulds do not present the disposal problems encountered with plaster of paris moulds and can in fact be recycled for other uses. These moulds are dimensionally reproducable thus providing for quality products.

[0025] The provision of changeover of moulds permits the machine to be rapidly changed to shaping different products. It allows for economical small production runs. The automatic release of the clay is advantageous in providing greater automation and repro- ducability in the forming process.

[0026] Various modifications may be made without departing from the scope of the invention. For example, the carousel could pivot about a vertical axis. Furthermore, the moulds could be carried on an indexed continuous conveyor running on chains or belts. Alternatively, the carriers could be moved on a bed by one or more linear actuators. In some instances with using the plastic moulds, it would not be necessary to provide a drier before releasing the clay from the mould. Accordingly the drier could be omitted from the apparatus or simply not used. Different shaping methods could be used other than a roller head. For example, a ram press could be used for making articles such as tiles.

[0027] Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1. Ware shaping apparatus (10), characterised in that the apparatus (10) comprises a porous plastic mould (16) upon which a portion of clay (26) can be loaded, means (22) for shaping the clay (26) carried on the mould (16), and means (30) for automatically releasing the shaped clay (26) from the mould (16).

2. Apparatus according to claim 1, characterised in that the apparatus (10) comprises a clay loading station (20), a clay shaping station (22), and a shaped clay release station (30); and means (12) for moving the mould (16) between the respective stations (20,22,30).

3. Apparatus according to claim 2, characterised in that a plurality of moulds (16) are provided such that different moulds (16) can simultaneously be located at different stations (20,22,30).

4. Apparatus according to claim 3, characterised in that the moulds (16) are carried on any of a carousel (12); an endless conveyor; or on a bed and movable by one or more linear actuators.

5. Apparatus according to any of claims 2 to 4, characterised in that below ambient pressure is provided on an interior side of the mould (16) at the loading and/or shaping stations (20,22) to hold clay (26) on the mould (16).

6. Apparatus according to any of claims 2 to 5, characterised in that above ambient pressure is provided at the clay release station (30) to blow the clay (26) from the mould (16).

7. Apparatus according to claim 6, characterised in that the above ambient pressure is provided by warmed pressurised air.

8. Apparatus according to any of claims 2 to 7, characterised in that the release means (30) releases the shaped clay (26) onto a conveyor (30).

9. Apparatus according to any of claims 2 to 8, characterised in that the apparatus includes means (28,34) for carrying out additional processes on the clay (26).

10. Apparatus according to claim 9, characterised in that drying means (28) are provided between the shaping station (22) and the clay release station (30).

11. Apparatus according to claims 9 or 10, characterised in that back stamping means (34) are provided.

12. Apparatus according to any of claims 2 to 11, characterised in that the shaping means comprises a rolling head (22) for shaping flatware or holloware.

13. Apparatus according to any of claims 2 to 12, characterised in that means (24) are provided for spinning a mould (16) during shaping of the clay (26).

14. Apparatus according to any of claims 2 to 11, characterised in that a ram press is provided for shaping articles such as tiles.

15. Apparatus according to any of the preceding claims, characterised in that the or each mould (16) is made of an acrylic plastics material.

16. Apparatus according to claim 15, characterised in that the plastics material is mounted on a metal carrier.

17. Apparatus according to any of the preceding claims, characterised in that the or each mould (16) is releasably mounted on the apparatus (10) to permit different shape moulds to be used.

18. Apparatus according to claim 17, characterised in that means (32) are provided for automatically changing the moulds (16) being used.

19. Apparatus according to claims 17 or 18, characterised in that mounting means such as a screw thread or bayonet fitting are provided on the moulds (16).

20. Apparatus according to any of the preceding claims, characterised in that means (20) are provided for automatically loading a portion of clay (26) onto a mould (16) as is required.

21. Apparatus according to claim 20, characterised in that the loading means (20) automatically provides the required quantity of clay (26) for any particular mould (16).

Drawing