Sputtering targets are used in PVD coating (PVD = physical vapor deposition) as a source for the coating material, which through the bombardment with high energy particles transfers into the gas phase and is then deposited in extremely thin layers on different surfaces. By this method, coatings with special optical, electrical or other characteristics are being achieved for example on large plasma screens, displays of laptops, mobile phones or architectural glass.
With the Alpha 4200, having a maximum pressing force of 42 000 kN (= 4200 t), large sputtering targets with dimensions up to about 1600 mm in length and 500 mm width with a thickness of only 8-14 mm, can be pressed with uniform density. The PH 6500 with a pressing force of 6 500 t can produce sputtering targets even larger, up to approx. 0.8 m². The Alpha 800 (pressing force = 800 t) is used for the production of sputtering targets with smaller dimensions. Materials to be used are indium tin oxide (ITO), alumina doped zinc oxide (AZO) and others. AZO powder for this application as well as supports for the firing process can be produced by the LAEIS subsidiary ALPHA CERAMICS in Aachen.
Having already sold several presses for this application to different customers in Korea over the recent years, now all the major manufacturers of sputtering targets in Korea trust in the LAEIS shaping technology, and other producers in East Asia, Europe and USA have started to follow.

22-03-2011

EKO consists of a series of thermal modules called "cells" in which the fumes exchange thermal energy with the material in an "optimized" manner compared to traditional kilns. EKO also reduces the volume of toxic fumes that need to be filtered and, for the first time, it is possible to differentiate fumes, manage small amounts and subject them to "targeted" purification treatment of contaminants, with obvious benefits in terms of a simplified process and respect for the environment. The use of cells enables the firing curve profile to be better controlled while allowing stable pressures and temperatures to be maintained even when the volume of tiles in transit varies. If production is reduced cells that are not required can be deactivated: this amounts to having a variable-length. EKO is equipped with self-recuperative burners which extract the hot fumes from the kiln chamber and use them to reheat the combustion air (700°C) as a countercurrent.
However, SACMI’s great innovations also concern the pressing department, with the new PH3200 press (32,000 kN pressing force, 2450 mm clearance), the first in a new range of machines featuring the innovative system of preloaded alloy tie rods, providing a reliable connection with the simplicity of traditional tie rods. The structure was designed using the latest optimization software, which allows for stress limits, thereby ensuring greater reliability and increased rigidity (improved compaction uniformity). The new hydraulic system, equipped with sophisticated settings, allows even the most difficult materials to be compacted, and the new self-diagnosis software allows faults to be detected very quickly. The press will also be equipped with the innovative DCL2450 powder feeder model.
The other big news in the area of continuous grinding is the new L CUBE (Long Life Lining) anti-wear coating for mills, achieved with vulcanized rubber around aluminium bricks specially developed in collaboration with Bitossi and B & B. L CUBE allows an increase in production (5%) for the same energy consumption, and the coating lasts at least three times longer than traditional types.
Also on display will be the DDD175 digital decoration system, specially developed by SACMI for the controlled application of powders on a ceramic base, with no special limitations in terms of particle size, moisture and colour. The flexibility of digital systems is thus combined with the free use of materials that are typically used in the sector. The system consists of a series of independent decoration units, one for each colour, placed in sequence along a conveyor belt. Using the data from a graphic management program to coordinate the various units, it is possible to apply the desired decoration to the material as it travels along the belt.
Finally, there will also be innovations in automatic handling and end-of-line automation: Sima will be exhibiting its own machines for storing unfired ware on roller boxes and fired products on pallets, suitable for items of ever increasing sizes, and state-of-the-art laser guided vehicles; Nuova Fima will be exhibiting an automatic sorting and palletizing line suitable for the production of items up to 1200 x 1500 mm, with fully automatic and computerised format change, equipped with all the necessary accessories for handling and packaging slabs of these dimensions; Surface Inspection will be exhibiting a new machine for producing the 1200 x 1500 format, using increasingly advanced software capable of identifying more defects than ever in relation to the increasingly popular digital decoration technology while Sacmi will showcase the Sidepack packaging system, which drastically reduces the use of packaging materials for disposal on building sites, thereby offering financial and environmental benefits to both manufacturers and users. The principle of the new packager is based on a simple method consisting in protecting the side corners and the packager is now capable of packaging extremely large slabs up to 3 meters in length.

SACMI MOLDS & DIES - Technology and innovation

For many years Sacmi Molds & Dies has been performing innovation and research activity in the ceramic world. The advanced technology set-up the base for its leadership; right for this, the customers can always find innovative solutions, coming from the steady research activity, resulting in the best products available on the market.

These are the reasons for the growing international expansion of this business unit within Sacmi Group, that has chosen Tecnargilla 2010 to exhibit some important innovations as for press accessories. During this international exhibition, the company will display universal bases for large sized presses and the innovative floating module system.

Universal upper and lower bases:
The main advantage of the use of universal bases is the warranty for a larger modularity during size change, with high savings on costs. As a matter of fact, using these bases the customer does not need to buy complete mould and dies, rather he can purchase the "size kit" only, formed by die boxes (upper and/or lower type) with liners, shimming bases, punches (upper and lower type).
The difference between universal upper and lower bases is remarkable: upper bases can be produced both for the electronic lifting device and for the traditional lifting unit, designed by Sacmi Molds & Dies to follow the lifting of the press supplied to the customer; in addition, they can be designed to handle the fixed die box moulds, to be used with entering punch dies or with mobile die box, for upper forming dies set, SFS type, for traditional mirror dies, for overturned mirror dies and for semi-entering dies.
Upper universal bases, on the other hand, use the hydraulic technology and serve as upper part for the SFS die set; when used with entering, semi-entering, mirror and overturned mirror punch dies, work as the upper plate for punch fastening.

Floating modules
Floating modules represent the evolution of the standard compensation system with isostatic punches. They are widely used if the tile size parameters are strict because, sometimes, the compensation coming from the use of connected isostatic punches could be insufficient.
They can be adapted to any type of mould and size.
Floating modules are in two parts: a hydraulic plate and a magnetic support; they can be hydraulically connected.
This innovation features two advantages compared with similar and available systems: they perfectly match with the upper universal base and have an external hydraulic connection. Therefore, they can be individually replaced in case of damage.

Firstly, both robots on the wet side had to be replaced by two new robots with higher effective ca-pacity. Due to the higher effective capacity larger grippers could be used, allowing the handling of larger loads. Despite the higher effective capacity this new type of robot is faster, achieving a work-ing cycle with maximum load in less than 10 seconds. The robots are controlled by a control device with vibration control and are equipped with an integrated 2D visualisation system with 3D updating possibility.

Furthermore, the control system allows for the downloading and uploading of programmes from the central server unit. Product changes are realized by the simple input of the dimensions of the prod-uct to be produced. By further optimisations in the area of the cutting and wet side system, the effi-ciency of the plant could be improved. Both robots, which are no longer used on the wet side, were equipped with other grippers to feed pallets in the palletizing area.

In order to facilitate the handling of the kiln cars and to improve the quality of the products during firing, the following measures were taken:

The loaded kiln cars pass through a newly installed preheater, preheating the products before enter-ing the tunnel kiln.
The kiln car transport equipment was completely replaced.
The kiln was extended by 5 kiln cars.
The complete burner plant was replaced by a new plant.
The complete kiln is now controlled by the Keller K-matic control system.
All kiln cars were replaced by new kiln cars.

To safeguard the investment, kiln car cleaning equipment was installed to vacuum the draught blocks as well as the kiln car deck after the removal of the draught blocks.
This newly developed kiln car cleaner was installed in Italy for the first time and works as follows:
After cleaning the flat draught blocks, the draught block rows are stacked one upon the other. Then the complete stack is removed. Afterwards, the kiln car deck is cleaned by suction devices and brushes and the draught block rows are returned. Using this procedure a perfect cleaning of the kiln car deck, a better quality of the final product as well as energy savings can be achieved. By clean-ing the kiln cars the growth of the kiln car deck is minimised and a longer life of the kiln cars is as-sured.

By modernising the plant and considering the variety of products as well as the high flexibility of all equipment in the relevant production areas, the quality of the products could be increased signifi-cantly.
Furthermore, the application of new standards for energy saving could be realized.

Thanks to the constructive and creative cooperation and the experience of Gruppo Fauci and Keller HCW the project was successfully completed.

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EDITORIAL CICLO, REVISTA CERAMICA Y CRISTAL
Esteban de Luca 2252 dto.2 - (1246) Buenos Aires, Argentina - Tel./Fax: (54-11) 4943-5799, (rot.) - ciclo@ceramicaycristal.com.ar
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