"PLANT FOR THE PRODUCTION OF CERAMIC SANITARY WARES, AS WELL

AS CORRESPONDING METHOD"

Designated inventor: Roberto Manzini

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a plant for the production of sanitary wares by means of a high pressure casting process.

In particular, the present invention relates to a plant for the production of simple or complex design sanitary wares , possibly comprising undercut portions, as well as the relative production method.

STATE OF THE ART

In the field of ceramic sanitary wares, such as toilet bowls, bidet, sinks or the like, plants are known for pressure casting of a fluid, typically slip, within suitable moulds, from which, after their moulding, they are extracted.

With reference to the production of sanitary wares having complex design the use of moulding machines is known comprising specific moulds suitably configured for the production, by means of a single casting step, also of possible undercut portions which otherwise could not be moulded, since they would prevent the extraction of the item from the mould itself.

The equipping of a plant for production of sanitary wares comprising such machines is particularly expensive, due to the complexity of the moulds itself used therein.

Although such moulds allow the moulding of sanitary wares having a complex design, without requiring substantially further mechanical processing of the products moulded therein, their use is however limited due to the high supply cost.

In the field the need is felt for a production plant for producing more ceramic sanitary wares simultaneously, according to a solution having reduced implementation and operating costs, with respect to the plants of traditional type disclosed herein.

OBJECTS OF THE INVENTION

The main object of the present invention is that of providing a plant for the production of ceramic sanitary wares which allows bringing improvement to the state of the art. According to such an object, the task of devising a plant for the production of ceramic sanitary wares having different design is presented, according to a solution with reduced equipping costs with respect to traditional solutions.

A further object of the present invention is that of develop a plant for the production of ceramic sanitary wares which are obtainable by means of the reciprocal assembly of two or more ceramic parts.

Another object of the present invention is that of devising a plant for the production of ceramic sanitary wares having complex design, possibly provided with at least one undercut portion, according to a solution easy to implement.

A further object of the present invention is that of developing a plant for the production of ceramic sanitary wares which is able to optimize the production times, reducing the inactivity periods between the moulding of a ceramic ware and the next.

This task and this object are reached by a plant for production of sanitary wares according to the enclosed claim 1.

The present invention then relates to a method for the production of ceramic sanitary wares which can be performed by means of the above mentioned production plant according to the enclosed claim 7.

Further advantageous features are described in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention will be better understood by every skilled person in the art by the following description and the enclosed tables of drawings, given as non-limiting example, wherein:

figure 1 is a schematic elevation view of a plant for the production of ceramic sanitary wares according to the present invention;

figure 2 is a schematic elevation view of a plant for the production of ceramic sanitary wares of figure 1 , in a further operational configuration;

figure 3 is a schematic elevation view of a plant for the production of ceramic sanitary wares of figure 1 , in another operative configuration.

EMBODIMENTS OF THE INVENTION

With reference to the enclosed figure 1 , one plant for the production of ceramic sanitary wares is wholly indicated with 1.

In the following description explicit reference will be made to a plant for the production of ceramic sanitary bowls having a lower element, comprising at least one reservoir and one siphon for flushing a washing fluid, and an upper element or "rim" defining a path for the washing fluid supplied within the reservoir. According to a further version, not shown herein, the production plant 1 can be configured for the production of ceramic sanitary bowls similar to those previously indicated, and comprising an integrated washing system or "flush tank", configured as a tank for a washing fluid to be entered within the vase reservoir.

It is observed that the present production plant can be used for the production of further sanitary wares such as bidet or sinks or column elements, etcetera, without any limitation.

The production plant 1 according to the present invention is of the kind configured for the high pressure casting of a fluid, known as "slip", inside moulding means, according to the methods described below.

The moulding means comprise a plurality of moulds, arranged in battery or series, along the production plant in order to form a battery of moulds.

Such a plurality of moulds comprises first and second moulds for the production of respective ceramic or semi-finished ceramic components having a different design from each other, to be assembled after their moulding in order to obtain a finished sanitary ware.

To that regard, it is noted how within the above mentioned battery the first and second moulds are arranged in succession to one another, preferably in alternated order with each other, so as to allow the production of ceramic components of different design in reciprocally alternated positions along the moulds battery.

Such arrangement of the moulds allows simplifying and speeding up the following steps of extraction and reciprocal joining between the single semi-finished items, as better described below.

By the use of easy implementable moulds, the production plant 1 allows for the manufacturing of more finished ceramic sanitary wares having also complex design, according to methods unfeasible in production plants of traditional type, which use simple geometry moulds.

The production plant 1 according to the present invention essentially comprises a frame 2, associable in use to moulding means 3 and to clamping means 10.

The moulding means 3 are operatively associated to the frame 2.

Analogously the clamping means 10 are associated to the frame 2 and they are used to reciprocally clamp the moulds comprised in the moulding means 3.

The moulding means 3 comprise at least one first mould 4 and at least one second mould 5, each configured to define internally one cavity for moulding a respective component or element A, B of the sanitary ware to be produced.

With reference to the enclosed figures, the moulding means 3 comprise three first moulds 4 alternated with three second moulds 5.

However, further versions of the present invention are possible, comprising a higher or lower number of first moulds 4 and second moulds 5 with respect to what illustrated in the enclosed figures, or also comprising further moulds configured in a different way with respect to the above mentioned first moulds 4 and second moulds 5, without departing for this reason from the scope of protection of the present invention.

The production plant 1 comprises a moulding area 6 wherein the moulding means 3 are arranged.

The at least one first mould 4 and the at least one second mould 5, in use, are arranged in battery, that is they are placed along the moulding area 6, aligned in succession to each other substantially along one axis 7.

According to one version of the present invention, the at least one first mould 4 and the at least one second mould 5 are foreseen in adjacent and alternated position with respect to each other, along the above mentioned battery.

According to another version of the present invention, the at least one first mould 4 and the at least one second mould 5 can be arranged adjacent in small groups, for example two or three moulds of the first type or first moulds 4 adjacent and alternated to other two or three moulds of the second type or second moulds 5.

In other words, it is possible to have one group of two or three first moulds 4 followed in an adjacent way by another group of two or three second moulds 5.

Moving means are also foreseen, which after the unmoulding of the respective component or element A and B, place the second element B in abutment with or on the first element A.

Since the first moulds 4 and the second moulds 5 are adjacent or very close to each other, the procedure of placing the second element B in abutment with or on the first element A occurs in a simple and fast way.

More in detail, the first mould 4 can comprise at least two parts 8, reciprocally connectable, for defining within the first mould 4 the cavity for moulding a first element A and releasable from each other to allow the extraction of the at least one element A, after the moulding thereof. When element A to be moulded has a complex design, such as for example a bowl, the first mould 4 can comprise an upper part 81 and a lower part 82 (figure 2), which can serve also as support base for element A.

Analogously to what indicated above, the at least one second mould 5 can comprise at least two parts 9 reciprocally connectable or releasable, for the moulding and subsequent extraction of at least one second element B.

According to one aspect of the present invention, with reference to what illustrated in the enclosed figures and in particular in the enclosed figures 2 and 3, the at least one first element A presents a shape different from that on the second element B.

By way of an illustrative and non-limiting example, in the case wherein the sanitary ware to be produced is a sanitary bowl, the at least one first element A can comprise at least one reservoir for containing one washing fluid and a discharging siphon of such washing fluid, while the at least one second element B can comprise an upper portion - also known as "rim'" - of the sanitary bowl to be produced.

The production plant 1 comprises clamping means, globally indicated with 10, configured for reciprocally clamping the moulds 4, 5 comprised in the moulding means

In particular, the clamping means 10 are configured to reciprocally clamp/release from each other parts 8, 81 , 82 of the at least one first mould 4, parts 9 of the at least one second mould 5, as well as the at least one first mould 4 against the at least one second mould 4.

According to one version of the present invention, the clamping means 10 can be configured as a jaw device comprising one arm element 1 1 movable along one portion of the frame 2, and an abutment element 12, constrained fixedly to the frame 2, reciprocally approachable/movable away.

The operation of the clamping means 10 is controlled by suitable actuator means not illustrated in the enclosed figures.

In practice, the clamping means 10 are operable between a first operative position, wherein they are reciprocally moved closer until they firmly abut against opposite sides along axis 7 of the moulding means 3 (figure 1 ) and a second operative position, wherein they are reciprocally separated away from the moulding means (figures 2 and 3).

According to one version of the present invention, the arm element 1 1 can be slidably associated to the frame 2 as better described below.

For this purpose, the arm element 1 1 can present at one first end 13 thereof, proximal in use to the frame 2, one carriage 14 slidably associated along a rail 15 provided along one portion of the frame 2.

The arm element 1 1 can present at one second end 16 thereof, abutment means 17 configured to abut, in use, against at least one end portion of the moulding means 3. More in detail, the clamping means 10 are configured to abut against the opposite ends of the moulding means 3 aligned along axis 7, firmly clamping parts 8 of the at least one first mould 4 and parts 9 of the at least one second mould 5 with each other, as well as the at least one first mould 4 and the at least one second mould 5 comprised in the moulding means 3.

In such way, the correct tightness of the cavities delimited within moulds 4 and 5 or, of possible not illustrated further moulds, comprised in the moulding means 3, is guaranteed.

According to one aspect of the present invention, the production plant 1 can possibly comprise blocking means, globally indicated with 18, of the clamping means 10, configured to selectively block the position of the clamping means 10 themselves with respect to the moulding means 3, along a direction identified by axis 7.

In use, with the abutment element 12 arranged in abutment against one end of the mould battery of the moulding means 3, the blocking means 18 restrict the mobility of the abutment element 12 itself along axis 7.

By way of illustrative and non-limiting example, according to one version of the present invention, the blocking means 18 can comprise one rod-like element 19 movably connected, in an articulated way, to frame 2.

To such purpose, the blocking means 18 can comprise one support element 20, for example configured as an arm, movably associated along frame 2, for the movable connection of the rod-like element 19 to frame 2 itself.

A rotatable joint 21 can be foreseen between the rod-like element 19 and the arm 20. The rotatable joint 21 is configured to allow the rotation of the rod-like element 19 with respect to the support element 20 around a substantially vertical rotation axis, between an operative position, wherein the rod-like element 19 is substantially aligned parallel to axis 7 and a non-engagement position, wherein the rod-like element 19 is substantially orthogonal to axis 7.

The clamping means 10 are configured to guarantee, in use, the tightness of the mould battery, wherein the single moulds can present substantially the same external volume or different external volumes without any limitation.

By way of example, according to one version of the present invention, the first moulds 4 can present an overall external volume equal or greater than about twice the external volume of the second moulds 5.

The production plant 1 comprises means for high pressure casting of a liquid - slip - within the moulding means 3, not shown in the enclosed figures.

The casting means are operatively associated to a feeding line of the slip to be injected within the moulding means 3, not illustrated in the enclosed figures, since they do not form object of the present invention.

To this end, the ceramic slip feeding line can comprise at least one feeding circuit controlled by a plurality of valves for the injection of the slip into moulds 4, 5 comprised in the moulding means 3. In practice, the slip can be fed within each mould 4, 5 comprised in the moulding means 3, through at least one respective feeding valve, not shown in the enclosed figures.

The production plant 1 according to the present invention also comprises demolding (extraction) means for the moulded components in the moulding means 3.

The unmoulding means are not illustrated in the enclosed figures for a better intelligibility of the same, being the type used in the production lines of ceramic sanitary wares of known type.

The unmoulding means are configured to allow the extraction of the ceramic items moulded in the at least one first mould 4 and in the at least one second mould 5. To that regard, the unmoulding means can comprise at least one gripping tool configured for the extraction of the items without damaging them.

It is observed, in fact, that a ceramic item in the moments subsequent the moulding is at a so called "green" state or "green-like", i.e. it contains also a high percentage of water which will be completely removed in the following processing steps (drying, firing, etc.). As such, a green ceramic item is easily deformable.

The at least one first mould 4 and the at least one second mould 5 can comprise at least one first part 22 and at least one second part 23, respectively, configured to act as support, during the unmoulding step, for the at least one ceramic first element A and for the at least one second element B, respectively, therein moulded.

The production plant 1 comprises also bonding means, not shown in detail in the enclosed figures, for the application of at least one layer of bonding material for bonding, according to predefined modes, ceramic elements A, B moulded by means of moulding means 3.

The bonding means can comprise means for the emission of a bonding material drivable in motion by means of a robot or a robotic am or automated devices of similar type.

For example, the layer of bonding material can be applied at a predefined connection portion of the at least one element A, moulded in the at least one mould 4, configured to be joined with a corresponding connection portion predefined in the at least one second item B, moulded in the at least one second mould 5.

As stated above, the production plant 1 comprises moving means, not shown in detail in the enclosed figures, such as for example one Cartesian robot with at least two axes, or also of different type, for moving the at least one first support part 22 with respect to the at least one second support part 23, or vice versa, to allow the reciprocal engagement of the ceramic items or ceramic semi-finished items moulded in the at least one first mould 4 and in the at least one second mould 5.

By way of illustrative but not limiting example, in the case wherein the sanitary ware to be produced is a bowl with a complex shape, comprising a closed rim, the at least one element A produced in the at least one first mould 4 can be the bowl lower portion, comprising the reservoir and the siphon, while the at least one element B produced in the at least one second mould 5 can be the rim.

In practice, the moving means are suitable for positioning the at least one first element A, supported on the at least one first part 22, in abutment with the at least one second element B, supported on the at least one second part 23, in such a way that the abutment between such elements A, B occurs along respective predefined portions thereof on which at least one layer of bonding material is present for their reciprocal bonding, in order to obtain the sanitaiy ware.

The production plant 1 according to the present invention, allows the production of more sanitary wares, in case also of complex shape, according to a solution characterized by a reduced implementation complexity with respect to the plants of traditional type, since moulds with a limited geometrical complexity are used.

The production plant 1 according to the present invention is thus characterized by a high productivity and lower equipping costs than the solutions of traditional type.

Below, a description of the method for the production of sanitary wares obtained by bonding at least one first ceramic element A with at least one second ceramic element B, implemented by means of the production plant 1 according to the present invention, is provided.

By way of example, the above mentioned method can be implemented for the production of a bowl with rim.

It is intended that the production plant 1 can nevertheless be used for the production of different sanitary wares, such as bowls with rim and integrated flush tank, vases with integrated flush tank or, yet, bidet with rim, etcetera, without any limitation.

The method for the production of sanitary wares according to the present invention comprises one initial step of providing a production plant 1 comprising one frame 2, to which moulding means 3 are operatively associated, clamping means 10 of the moulding means 3, casting means, demoulding means of the ceramic moulded items, bonding means and moving means designed to move and bring in reciprocal abutment the ceramic items previously moulded, to be joined to one another.

The moulding means 3 can comprise at least one first mould 4 and at least one second mould 5 aligned in succession between them, along an axis 7 so as to form a moulds battery.

The method comprises one step of positioning the clamping means 10, substantially configured as a jaw, in abutment against opposite ends of the moulding means 3.

Such step foresees to reciprocally approach the movable arm element 1 1 and the fixed abutment element 12 of the jaw device until the correct clamp of parts 8, 81 , 82 and 9, which form moulds 4 and 5 of the moulding means 3 respectively, is guaranteed.

The action exerted by the clamping means 10 against the moulding means 3 guarantees the tightness within the moulds therein provided, preventing leakage or unwanted seeping of slip from the moulds themselves from occurring during the subsequent casting step.

Thereafter, the casting means are actuated, for the high pressure injection of slip within the moulds which form the moulding means 3.

When the casting step has ended, the clamping means 10 are, in turn, released from the moulding means 3 in order to be able to proceed to the opening of the latter.

The movable ami element 1 1 of the clamping means 10 is moved away from the abutment element 12 until the at least one arm 1 1 is separated from the moulding means 3.

Then, the moulding means 3 are opened and, by means of the unmoulding means, the extraction of the ceramic items from the respective moulds 4, 5 is carried out.

In particular, the unmoulding means are operated in order to open the first mould 4 and unmould the at least one first element A moulded therein, leaving it resting on a first support part 22.

The element A is then extracted from the mould by a moving system not shown in the enclosed figures. Then, bonding means proceed with the deposition of at least one layer of bonging material on a predefined portion of the al first element A.

The unmoulding means then proceed with the opening of a second mould 5, positioned after the first mould 4.

After the opening step, the at least one second element B is extracted from the second mould 5 and kept associated to a second support part 23 of the at least one second mould 5.

Then, moving means proceed with moving the at least one first element A close to the at least one second element B.

In particular, the pre-established connection portions for the at least one first element A and the at least one second element B are reciprocally approached until they are brought in abutment.

Then, the at least one first element A and the at least one second element B are kept in position until their joint is obtained.

At this point, the moving means provide for the release of the second support part 23 from the at least one second element B.

The ceramic item thereby assembled is, then, evacuated from the production plant 1 to undergo further processing steps.

The method comprises to iterate the previously described steps, until the assembling of all the ceramic items produced in the moulding means 3 is completed.

As stated, the method previously described is foreseen for the production of sanitary wares obtained by the assembling of two ceramic elements A, B.

In is intended that, if the sanitary wares to be produced have a greater number of elements to be assembled with each other, it is to proceed by repeating in succession the moulding steps, the application of the bonding material and the bonding of the single ceramic components, until the complete assembling of the ceramic item is obtained. For example, in the case wherein the production of a ceramic sanitary ware such as a bowls with rim and integrated flush tank is foreseen, besides the moulding step of the bowl and the rim, and the relative bonding, the moulding and bonding steps of the flush tank to the bowl according to modes analogous to those previously described are foreseen.

From the above, it is perceived that the production plant 1 according to the present invention is suitable for achieving the predetermined objects.

The production plant 1 , in fact, by foreseeing the use of more moulds for the production of single ceramic elements to be joined with each other, allows to easily produce sanitary wares of complex design, albeit in the context of a solution of simple implementation and reduced production costs with respect to the solutions of traditional type.

The present invention has been described according to preferred embodiments but equivalent variants can be conceived without exiting the scope of protection offered by the following claims.