Title of Invention

AN APPARATUS AND PROCESS FOR RECTIFYING AND CHAMFERING OF TILES

Abstract This invention relates to an improved apparatus for rectifying and chamfering of ceramic and vitrified tiles comprising two sets of squaring spindles unit connected in the fandom by tile transporter which rotates the tile 90o during the traverse of tiles from one squaring unit to other ; two chamfering spindles one on each unit is mounted on linear guide ways with constant pressure air springs; the said tile transporter unit which moves on a linear guide way having its axis perpendicular to the axis of the diamond grinding wheel; a beam provided to mount the spindle assembly with diamond grinding wheels which is adjustable to swivel in and swivel out as required to set width of the tiles accurately as also to account for diamond wear cut over a period of time ; tile entering the squaring unit are first centered and then firmly clamped by the tile transporter ; the inclined conveyer (11) convey the tiles, hold cylinder (13), the centralizer (14), the clamp (10) operates and brought to diamond grinder (9) to grind two sides ; the tile transporter rotaler the tiles 90o to please the other sides of tiles to diamond grinder which is subsequently champared (15) and conveyed to delivery of accurate tile of square or rectangular shape.
Full Text FORM 2
THE PATENT ACT 1970 (39 of 1970)
&
The Patents Rules, 2003 COMPLETE SPECIFICATION
See Section 10, and rule13)
1. TITLE OF INVENTION
A PROCESS AND APPARATUS FOR RECTIFYING AND CHAMFERING OF CERAMIC AND VITRIFIED TILES AND ALSO NATURAL STONE TILES OF GRANITE, MARBLE, SAND STONE, SLATE AND ARTIFICALSTONE AND THE LIKE MATERIAL.
2. APPLICANT(S)
a) Name : SWAPAN MANILAL SHAH
b) Nationality : INDIAN National
c) Address : KARAMCHAND MANSION,
BARRACK ROAD, BEHIND METRO CINEMA,
MUMBAI - 400 020 MAHARASHTRA
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed : -

A PROCESS & APPARATUS
The following specification particularly describes and ascertains the nature of this invention and the manner in which it is performed :-
This invention relates to a process and a machine for rectifying and chamfering of tiles of ceramic, porcelain, granite, marble, sand stone, resin and like materials.
Artificial products like ceramic and porcelain tiles are pressed in a kiln, then calibrated and polished I stages.
Natural stones like granite, marble sand stone, lime stone and the likes are quarried from the mines and are then dressed and sawn to required width. For making floor, wall and other decorative tiles, the sawn slabs are calibrated, polished and then are cut into square or rectangular sizes.
For laying wall and floor tiles, it its necessary that the sides of the tiles are square within reasonable accuracy.
A process and an apparatus for rectifying and chamfering of porcelain and ceramic tiles and natural stone tiles of marble, granite and sand stone and like
material.
The tiles, as they come out of the kiln in case of ceramics and vitrified porcelain or due to previous processes, as in the case of natural stones, are out of square or rectangle due to many inherent errors in the tile manufacturing processes and hence, need correction before laying on to the floor or on the wall.
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DESCRIPTION OF THE EXISTING UNIVERSALLY ACCEPTED SYSTEM FOR RECTIFYING & CHAMFERING TILES :
The present conventional universally accepted system is to pass the tiles through a number of juxtaposed rectifying spindles with diamond grinding wheels or other grinding wheels to progressively cut the first two sides of the tiles to the required size. The tiles are fed by a conveyor.
These machines consist of 2 modules. Each module has many sets of squaring spindles (see fig. 1).
The squaring spindles are so adjusted that they progressively grind the two parallel edges of the tile to the required dimension. Before entering the machine, the tile is centered, so that equal material is removed from each side (see Fig. lc). After the two parallel sides of the tiles are ground to the required dimension in the first unit, they are rotated through 90o before entering the 2nd unit and the other two sides are also ground to the required size in the second unit. At the inlet of the second unit, there is a centering device as well as a "pusher" which aligns the tile at 90o before feeding it into the squaring spindles (see Fig. la).
During the squaring operation, the tiles are conveyed on a belt and held in position by pressure rollers or a belt drive system (see Fig. lb).
These clamping systems, however, do not have a positive lock on the tile. As a result, the tile can "Move" during the squaring operation, resulting in inaccurate sizing as well as being out of square.
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In order to get an accurate level of squareness and size, a constant vigil and continuous adjustment of the machine becomes a necessity. Despite this, there is no assurance that all the tiles will be accurate within acceptable tolerance levels.
The above system has the following drawbacks :-
i) tile squareness cannot be guaranteed, with the result that the machine needs frequent adjustments to get the tiles of reasonable accuracy.
ii) Since the finishing of tiles is a continuous process and also involves calibration and polishing along with size specification, the constant adjustments required, as mentioned above, result in substantial loss of production.
iii) Since there is no guarantee of squareness, the process needs stringent monitoring to get a quality product.
iv) Due to the above shortcomings, the whole process remains under utilized and is very difficult and cumbersome to manage
THE NEW CONCEPT FOR RECTIFYING & CHAMFERING TILES:
This invention envisages a novel and economical process to rectify ceramic and porcelain tiles as well as tiles of natural stones and like materials accurately, without the defects and limitations of the conventional process outlined above. This invention also ensures square tiles without the need for frequent monitoring thus eliminating all the constraints in the conventional process.
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a) SQUARING AND CHAMFERING :-
This invention makes use of a machine, consisting of 2 modules. The new process is explained in the following paragraph (see Layout Fig. 6) - tiles entering the squaring machie are first centered and then firmly clamped by the "Tile Transporter" which carries the tiles through a pair of squaring spindles. Thus, one pair of parallel sides is ground to the required size. The squared and sized tiles are then passed through the first set of chamfering spindles mounted on linear guide-ways with constant pressure air springs.
In this invention, the tiles are now conveyed to the second set of squaring spindles after being rotated through 90o. Once again, they are rigidly clamped at 90o to the previous sides and "Carried" through the second set of squaring spindles. The tiles then pass through the 2nd set of chamfering spindles mounted on linear guide-ways with constant pressure air springs. The complete process ensures accurate size control and excellent squareness of the tiles.
In this invention, instead of using multiple sets of squaring spindles, as in the conventional system, only one set of spindles is used in each module. The spindles are large & amply powered, and capable of rapidly grinding the edges of the tiles. The machine consists of 2 such units and each unit consists of a pair of spindles (see Fig. 4).
This invention makes use of the two spindles which can be adjusted to "Swivel In" and "Swivel Out" as required, to set the width of the tiles accurately as also to account for diamond wear out over a period of time (see Fig. 5).
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Layout (Fig. 6) shows one module of the Squaring & Chamfering Machine of this invention and the layout (Fig. 7) shows the complete Squaring & Chamfering Machine of this invention comprising of the two modules connected by a 90o tile
rotating unit.
According to this invention, there is provided a process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material by passing them through a pair of two diamond grinding wheels which can be positioned to give correct width as also to provide for wear compensation of the diamond grinding wheels. There being a beam provided to mount the spindle assembly with diamond grinding wheels and to adjust them in the transverse axis as per tile width.
According to another feature of the machine, there is provided an apparatus for picking up, clamping and transporting the tiles through the diamond grinding wheels and then releasing them on to the conveyor belt for the next operation. This unit is referred to as the "Tile Transporter". While transporting, the tile is also located in a manner that it is presented to the diamond grinding wheel at right angles to its movement. This ensures accurate processing of tiles with the four sides at right angles to each other.
According to this invention, there is provided a pair of flat conveyor belts with a prime mover for conveying the tiles from the inclined roller table upto the "Tile Transporter" There is also provided a separate prime mover for the to and from movement of the "Tile Transporter" unit which moves on a linear guide-way having it s axis perpendicular to the axis of the diamond grinding wheel.
Necessary pneumatic actuated stoppers and positioners are provided for the movement of the tiles. The tiles are conveyed one by one to the "Tile
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Transporter" unit. According to this invention, the "Tile Transporter" is provided with a pneumatic clamp and rubber inserts to hold the tile rigidly.
The "Tile Transporter" conveys the clamped tile through the diamond grinding wheels. The tile is then declamped and released on to the conveyor belt. The empt transfer device returns at a rapid speed to position itself in readiness to pick up the next tile.
The released tile is conveyed through the pair of chamfering spindles to impart the necessary chamfer to the tile on the rectified sides.
According to this invention, this tile is then indexed through 90o and then passed through the second module wherein the remaining two sides of the tiles are ground at right angles to the previously rectified sides.
The invention will now be described with respect to the accompanying Isometric drawings, wherein
Fig. A shows the complete machine.
Fig. B shows details of pushers and clamping arm.
Fig. C is the elevation of the machine &
Fig. D is the plan of the machine.
Referring to Fig. A and B : The machine consists of a close grain cast iron beam on which there are two slides operated by a right hand & left hand lead screw respectively. The lead screw mounted in heavy bearings is provided to set the
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slides for different width of the tiles ranging from 200 mm to 600 mm. It is also possible to have various models rnging in widths from 50mm. upto 3000 mm. or as per requirement. Two Hand wheels are provided on the lead screws to set the desired gap between the slides.
A girder is provided on each slide. Squaring spindles SI & S2 with their respective prime movers are mounted on the slides. These spindles are provided with degree setting, fine forward and reverse adjustment. There is also provided a small transverse adjustment for lateral shifting of spindles in case it is required.
The two girders (Item 9, Fig. B) mounted on the slides carry the conveyors belt, belt support and drive to transport the tiles. Two flat endless belts are provided for transporting the tiles.
A slider (Item 3, Fig. B) running on a pair of precision linear guideways is provided over the belt conveyor belt. This slider carries a pair of fingers (Item 1, Fig. B) and a clamp (Item 10, Fig. B) for orienting and transporting the tiles through the spindles carrying the diamond grinding wheels or such like tools.
The to and fro motion of the slider is imparted through a timing belt and pulleys or such drive mechanism. A prime mover is provided with a necessary speed reducer to drive the belt.
Inclined table (Item 11, Fig. B) with pneumatic stoppers (Item 12 & 13, Fig. B) are provided for feeding the tiles by gravity.
To impart chamfer to the rectified tiles, Air spring operated slides (Item 8, Fig, B) running on linear guideways are provided. These slides carry the inclined chamfering spindles. These slides are also mounted on the girder (Item 9, Fig. B).
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The above "floating" slide carries a pair of rollers which are always in contact with the tile and thus allow the grinding tool to follow the contour of each and every tile as it passes through the spindles.
OPERATION OF THE MACHINE
In operation the tiles are fed one after the other on the inclined table (Item 11, Fig. B) manually or automatically. Tiles moving under gravity are arrested by stopper (Item 13, Fig. B) which releases the tiles one by one as per the programme. When the first tile is released on to the machine conveyor by pneumatic stopper (Item 12, Fig. B), the tiles behind the first tile are stopped by Pneumatic stopper (Item 13, Fig. B). This is to ensure that tiles are released one by one with predetermined gap.
The released tile moves along with the conveyor belt till the stopper (Item 14, Fig. B) while the conveyor belt moves continuously.
The tile is picked up by the "Tile Transporter" (Item 3, Fig. B) and firmly held between three tungsten carbide buttons.
Now this tile which is being carried by the "Tile Transporter" is transported through a pair of diamond grinding wheels or any other appropriate cutting tools after centering. The centering mechanism is shown as Item 14, Fig. B. The grinding wheels are set at an angle consistent with the excess stock available on the tile for machining. The size can also be set as per requirement.
After passing through the diamond grinding wheel the tile is released back on to the conveyor belt. After releasing the tile, the slide returns rapidly to pick up the next tile. After sizing, the tile moves under a set of pressure rollers, and is
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presented to the pair of chamfering grinding wheels where the required chamfer is given. The floating head ensures that the chamfering grinding wheel truly follows the contour of tile and thus imparts a uniform chamfer all over.
Sensors like counting proximity switches & limit switches or other sensing devices are provided on conveyor and the "Tile Transporter" to monitor the tile position and the "Tile Transporter" movement respectively.
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I CLAIM:
1. An improved apparatus for rectifying and chamfering of ceramic and vitrified tiles comprising two sets of squaring spindles units connected in fandom by tile transporter which rotates the tile through 90o during the traverse of tiles from one squaring unit to other ; two chamfering spindles one on each unit is mounted on linear guide ways with constant pressure air springs; the said tile transporter unit which moves on a linear guide way having its axis perpendicular to the axis of the diamond grinding wheel ; a beam provided to mount the spindle assembly with diamond grinding wheels which is adjustable to swivel in and swivel out as required to set the width of the tiles accurately as also to account for diamond wearcut over a period of time; tile entering the squaring unit are first centered and then firmly clamped by the tile transporter; the inclined conveyer (11) convey the tiles, hold cylinder (13), the centralizer (14), the clamp (10) operates and brought to diamond grinder (9) to grind two sides ; the tile transporter rotaler the tiles 90o to please the other sides of tiles to diamond grinder which is subsequently champared (15) and conveyed to conveyer to delivery of accurate tile of square or rectangular shape.
2. An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material consists of a close grain cast iron beam on which there are two slides operated by a right hand and left hand lead screw respectively; the lead screw mounted in heavy bearings is provided to set the slides for different width of the tiles ranging from 200 mm to 600
mm. It is also possible to have various models ranging in widths from 50
11

mm upto 3000 mm or as per requirement. Two hand wheels are provided on the lead screws to set the desired gap between the slides.
An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein, a girder is provided on each slide. Squaring spindles SI and S2 with their respective prime movers are mounted on the slides. These spindles are provided with degree setting, fine forward and reverse adjustment. There is also provided a small transverse adjustment for lateral shifting of spindles in case it is required.
An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein, the two girders (Item 9, Fig. B) mounted on the slides carry the conveyor belt, belt support and drive to transport the tiles. Two flat endless belts are provided for transporting the tiles.
An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein, a slider (Item 3, Fig. B) running on a pair of precision linear guideways is provided over the belt conveyor belt. This slider carries a pair of fingers (Item 1, Fig. B) and a clamp (Item 10, Fig. B) for orienting and transporting the tiles through the spindles carrying trhe diamond grinding wheels or such like tools.
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6. An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein, the to and fro motion of the slider is imparted through a timing belt and pulleys or such drive mechanism. A prime mover is provided with a necessary speed reducer to drive the belt.
7. An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein, inclined table (Item 11, Fig. B) with pneumatic stoppers (Item 12 & 13 Fig. B) are provided for feeding the tiles by gravity.
8. An apparatus for rectifying and chamfering of ceramic and vitrified tiles and also natural stone tiles of granite, marble, sand stone, slate and artificalstone and the like material as claimed in claim 1 wherein to impart chamfer to the rectified tiles, Aire spring operated slides (Item 8, Fig B) running on linear guideways are provided. These slides carry the inclined chamfering spindles. These slides are also mounted on the girder (Item 9, Fig. B). The above "floating" slide carries a pair of rollers which are always in contact with the tile and thus allow the grinding tool to follow the contour of each and every tile as it passes through the spindles.
9. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material by passing them through a pair of two diamond grinding wheels which can be positioned to give correct width as also to provide for wear compensation of the diamond grinding wheels. There being a beam provided to mount the spindle assembly with
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diamond grinding wheels and to adjust them in the transverse axis as per tile width.
10. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material as claimed in claim 1 wherein, picking up, clamping and transporting the tiles through the diamond grinding wheels and then releasing them on to the conveyor belt for the next operation. This unit is referred to as the "Tile Transporter". While transporting, the tile is also located in a manner that it is presented to the diamond grinding wheel at right angles to its movement. This ensures accurate processing of tiles with the four sides at right angles to each other.
11. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material as claimed in claim 1 wherein, a pair of flat conveyor belts with a prime mover for conveying the tiles from the inclined roller table upto the "Tile Transporter". There is also provided a separate prime mover for the to and fro movement of the "Tile Transporter" unit which moves on a linear guide-way having its axis perpendicular to the axis of the diamond grinding wheel.
12. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material as claimed in claim 1 wherein, necessary pneumatic actuated stoppers and positioners are provided for the movement of the tiles. The tiles are conveyed one by one to the "Tile Transporter" unit. According to this invention the "Tile Transporter" is provided with a pneumatic clamp and rubber inserts to hold the tile rigidly.
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13. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material as claimed in claim 1 wherein, the "Tile Transporter" conveys the clamped tile through the diamond grinding wheels. The tile is then declamped and released on to the conveyor belt. The empty transfer device returns at a rapid spped to position itself in readiness to pick up the next tile.
14. A process of rectifying non parallel sides of tiles of ceramic, glass, resin, marble, granite or like hard material as claimed in claim 1 wherein, the released tile is conveyed through the pair of chamfering spindles to impart the necessary chamfer to the tile on the rectified sides.
Dated this 3rd day of January, 2007.


Documents:

19-mum-2007-abstract(13-11-2007).pdf

19-MUM-2007-ABSTRACT(16-12-2010).pdf

19-mum-2007-abstract(granted)-(7-2-2011).pdf

19-mum-2007-cancelled pages(13-1-2007).pdf

19-MUM-2007-CANCELLED PAGES(16-12-2010).pdf

19-mum-2007-cancelled pages(7-2-2011).pdf

19-mum-2007-claims(13-11-2007).pdf

19-MUM-2007-CLAIMS(AMENDED)-(16-12-2010).pdf

19-mum-2007-claims(granted)-(7-2-2011).pdf

19-mum-2007-claims.doc

19-mum-2007-claims.pdf

19-mum-2007-correspondance-received-ver-040107.pdf

19-mum-2007-correspondance-received-ver-080107.pdf

19-mum-2007-correspondence(13-11-2007).pdf

19-MUM-2007-CORRESPONDENCE(16-12-2010).pdf

19-mum-2007-correspondence(ipo)-(27-7-2007).pdf

19-mum-2007-correspondence(ipo)-(7-2-2011).pdf

19-mum-2007-description (complete).pdf

19-mum-2007-description(complete)-(13-11-2007).pdf

19-mum-2007-description(granted)-(7-2-2011).pdf

19-mum-2007-drawing(13-11-2007).pdf

19-mum-2007-drawing(granted)-(7-2-2011).pdf

19-mum-2007-drawings.pdf

19-mum-2007-form 1(13-11-2007).pdf

19-mum-2007-form 13(16-12-2010).pdf

19-mum-2007-form 2(13-11-2007).pdf

19-mum-2007-form 2(granted)-(7-2-2011).pdf

19-mum-2007-form 2(title page)-(13-11-2007).pdf

19-mum-2007-form 2(title page)-(granted)-(7-2-2011).pdf

19-mum-2007-form 3(13-11-2007).pdf

19-mum-2007-form-1.pdf

19-mum-2007-form-18.pdf

19-mum-2007-form-2.doc

19-mum-2007-form-2.pdf

19-mum-2007-form-26.pdf

19-mum-2007-form-3.pdf

19-mum-2007-form-9.pdf

19-MUM-2007-REPLY TO EXAMINATION REPORT(16-12-2010).pdf

19-MUM-2007-SPECIFICATION(AMENDED)-(16-12-2010).pdf

abstract-1.jpg


Patent Number 245948
Indian Patent Application Number 19/MUM/2007
PG Journal Number 06/2011
Publication Date 11-Feb-2011
Grant Date 07-Feb-2011
Date of Filing 04-Jan-2007
Name of Patentee SWAPAN MANILAL SHAH
Applicant Address KARAMCHAND MANSION, BARRACK ROAD, BEHIND METRO CINEMA, MUMBAI.
Inventors:
# Inventor's Name Inventor's Address
1 SWAPAN MANILAL SHAH KARAMCHAND MANSION, BARRACK ROAD, BEHIND METRO CINEMA, MUMBAI- 400 020.
PCT International Classification Number B24B23/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA