EP1321256B1 - Method and plant for manufacturing ceramic tiles and slabs - Google Patents

Method and plant for manufacturing ceramic tiles and slabs Download PDF

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Publication number
EP1321256B1
EP1321256B1 EP02080172A EP02080172A EP1321256B1 EP 1321256 B1 EP1321256 B1 EP 1321256B1 EP 02080172 A EP02080172 A EP 02080172A EP 02080172 A EP02080172 A EP 02080172A EP 1321256 B1 EP1321256 B1 EP 1321256B1
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EP
European Patent Office
Prior art keywords
bodies
plant
mass
compacted
generally
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02080172A
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German (de)
English (en)
French (fr)
Other versions
EP1321256A3 (en
EP1321256A2 (en
Inventor
P. c/o SACMI-Cooperativa Meccanici Imola Acerbi
S. c/o SACMI-Cooperativa Meccanici Imola Valli
E c/o SACMI-Cooperativa Meccanici Imola Vandelli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sacmi Imola SC
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Sacmi Imola SC
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Filing date
Publication date
Application filed by Sacmi Imola SC filed Critical Sacmi Imola SC
Publication of EP1321256A2 publication Critical patent/EP1321256A2/en
Publication of EP1321256A3 publication Critical patent/EP1321256A3/en
Application granted granted Critical
Publication of EP1321256B1 publication Critical patent/EP1321256B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
    • B28B3/123—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/044—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with glaze or engobe or enamel or varnish
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/06—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with powdered or granular material, e.g. sanding of shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads

Definitions

  • This invention relates to the manufacture of ceramic construction materials, generally tiles but also large-dimension slabs intended to be used either as such or to obtain therefrom one or more elements of lesser dimensions and/or generally different shapes.
  • the invention also relates to the means for implementing said method and to the materials obtained with them.
  • the ceramic tile manufacturing sector is known to be constantly seeking new and innovative ornamental motifs, with current emphasis on decorations reproducing the appearance of natural stone and rock, such a marble, which knowingly presents elongate veining and striations of various form and colour.
  • Decorative motifs reproducing said aesthetic element typical of natural stone or rock such as marble or granite can be obtained by the modern ceramic manufacturing technology typical of porcellainized stone, well known to the expert of the art, which will not be described in detail.
  • Such decorative motifs can concern either the whole mass, i.e. the whole thickness, of the tile or slab, or only that layer at the exposed face of said tile or slab.
  • the first of which uses a not particularly valuable base material intended to form the support part of the tile
  • the second uses a finishing material possessing properties able to provided the desired characteristics for the exposed face of the tile or slab.
  • Said second material can consist of at least two ceramic materials generally in powder form which are at least partly mixed together and have different characteristics, generally different colours.
  • Document WO-A-9615888 discloses a method and relative apparatus for compacting powders for manufacturing pressed ceramic tiles.
  • the method comprises the operations of forming a layer of powders on conveying means which conveys it to a die, isolating a portion of said layer inside a frame of said die, by bringing said frame adjacent to said conveying means, and compacting the portion of said layer isolated by said frame, by means of a punch of said die, descending inside said frame.
  • the apparatus for carrying out the above method comprises conveying means for conveying a layer of powders to a die, said die comprising a punch movable in a substantially orthogonal direction to said layer, associated with a relative cross-member to cause the pressing of the powders and a frame, movable in a substantially orthogonal direction to said layer independently of said punch, inwardly slidably engageable with said punch, serving as isolating means for isolating a portion of said layer on said conveying means.
  • natural stone and rock in general for example marble
  • natural stone and rock in general are generally characterised by elongate veining and striations of various form and colour generated by agglomerations of natural elements of various type which are amassed and distributed irregularly, or rather randomly.
  • the appearance of said natural stone and rock such as marble is further characterised by inclusions, nodules and masses of various kinds which are generally very different at least in terms of colour from the base matrix of the respective stone or rock.
  • the main object of this invention is to provide means by which ceramic construction materials can be obtained, generally tiles and slabs, having the aforesaid multi-colour appearance typical of natural stone and rock such as marble, in particularly a decoration which in addition to veining and striations of various shapes and colours also presents circumscribed zones of generally irregular shape having an appearance different from that of the surrounding general matrix, and possibly at least partly surrounded by a band or halo of usually irregular width, generally provided with at least one coloration at least partly different from that or those of the zones situated inside and outside it.
  • zones also known as stains, constitute the aforesaid inclusions, nodules or masses typical of natural stone and rock such as marble.
  • a decorative ceramic product is prepared consisting of preformed congruent bodies acting as inserts for the final product.
  • said bodies are generally of irregular shape and have relatively small dimensions, by which is meant dimensions generally much less than those of the tiles and slabs which are to be obtained.
  • the said bodies generally consist of at least one ceramic material generally in conveniently compacted powder form, which are intended to be added to ceramic materials generally in powder form for manufactures of porcellainized stone type as explained in the introduction.
  • Said at least one ceramic material generally in powder form has different characteristics from said porcellainized stone type material, generally a different colour.
  • said bodies of said decorative product can be at least partly covered with at least one ceramic preparation, generally glaze, which has different properties, generally a different coloration, from that or those of the constituent materials of said bodies and the support material of the final product, i.e. the tile or slab.
  • Said bodies can have discretionary shapes and dimensions.
  • this is generally irregular and preferably elongate.
  • the outer surface of said elongate shape is preferably generally smooth, i.e. virtually free from cusps or other sharp edged projections.
  • the tiles or slabs, with their support material incorporating said bodies preferably only within their surface layer, are subjected to a surface finishing operation, generally a smoothing operation, to expose their external face, which can be partially or totally as described, and of one or more colours.
  • Said smoothing is preferably effected immediately after the forming by the press, Alternatively it can be effected after firing.
  • Figure 1 is a side view of the invention.
  • Figure 2 is a view taken from above the preceding figure.
  • Figure 3 is the section III-III indicated in Figure 2 but on an enlarged scale.
  • Figure 4 is a perspective view of the elements of Figure 3.
  • Figure 5 is the section V-V indicated in Figure 4.
  • Figure 6 is a section showing part of a load deposited into the cavity of a mould for forming tiles or slabs according to the invention.
  • Figure 7 is a view totally similar to the preceding, showing the compacted tile or slab in section.
  • Figure 8 shows the same tile after smoothing.
  • Figure 9 is a view taken from above the preceding figure.
  • Figure 10 is the computerized representation of a decoration of marble type according to the invention.
  • FIGS. 1 to 5 show the upstream part of a ceramic tile or slab manufacturing plant, the downstream part of which, not shown for simplicity, comprises essentially, in succession: a supply station for the starting materials, into which the part shown in Figure 1 extends; a forming station, which can be of the single or double pressing type; possibly a smoothing or lapping station; a firing station, for example of the carriage type with single-layer or multi-layer translating tiles; and a smoothing or lapping station if not already provided downstream of the forming station.
  • a supply station for the starting materials into which the part shown in Figure 1 extends
  • a forming station which can be of the single or double pressing type
  • possibly a smoothing or lapping station possibly a smoothing or lapping station
  • a firing station for example of the carriage type with single-layer or multi-layer translating tiles
  • a smoothing or lapping station if not already provided downstream of the forming station.
  • That part of the plant shown in Figures from 1 to 5 constitutes a processing line for forming generally irregular bodies used as decorative inserts (see Figures from 6 to 10) for the finished product, i.e. ceramic tiles and slabs.
  • Said bodies are generally of relatively small dimensions, and are of preferably elongate form, generally of peanut shape as shown in said figures.
  • said bodies 1 have an average transverse dimension and an average longitudinal dimension of 5-15 mm and 10-50 mm respectively.
  • Said processing line comprises essentially a compacting station 2, a chopping and finishing station 3, a coating station 4, and a collection and removal system 5.
  • the compacting station 2 comprises a motorized belt 20, for example driven by a gearmotor unit with incorporated speed variator, the upstream end of which lies below a vertical dispensing tube 21.
  • an adjustable valve member (not shown), preferably controlled by the system controlling the speed of the belt 20.
  • Each individual conduit 22 feeds to the underlying tube 21 at least one ceramic material generally in powder form which mixes more or less extensively with that (or those) fed by the other conduits 22.
  • the materials fed by the individual conduits 22 can consist of atomized, ground or micronized powders obtained from ceramic, semi-glaze or glaze mixes, and mixtures thereof.
  • said materials generally of powder form will have different characteristics, generally different colorations, from those of the ceramic materials generally in powder form provided to form the matrix 100 of the body of the final tile or slab (see Figure 10), to form a decoration of natural stone or rock type such as marble, the veining or striations of which are indicated by 10 in said figure.
  • the belt 20 is constructed in such a manner as to be able to deform elastically for the reasons which will be apparent hereinafter, for example it can consist of a rubber belt with suitable filler mixtures in line with its elastic deformability and its mechanical strength.
  • said ring 23 and said unit 24 provide a generally funnel-shaped constriction (Figures 4 and 5), upstream and downstream of which the outward branch of the belt 20 substantially assumes the form of two channels which gradually narrow and widen respectively ( Figures 1 and 2).
  • Said ring 23 is carried by a support 25 which is positioned on the support structure of the belt 20 ( Figure 4), the inner surface of said ring 23 being shaped as a cone frustum the minor base of which is situated downstream and has a circumference smaller than the width of the belt 20 (see Figure 5).
  • Said ring 23 and said support 25 are also provided upperly with respective cuts for the insertion and extraction of the belt 20 ( Figures 4 and 5).
  • at least the ring 23 can be divided into at least two mutually engagable mating parts.
  • the compactor unit 24 comprises a circumferential set of equidistant idle wheels 240, four in number in the illustrated example, which are arranged to roll along the tubular portion of the belt 20 leaving the ring 23 ( Figures 1-5).
  • two wheels 240 lie in a horizontal plane, the other two lying in a vertical plane which intersects the preceding along the longitudinal axis of said ring 23, each wheel 240 being constantly elastically urged against the tubular portion of the belt 20 by a respective thrust member schematically indicated by 241 in Figures 1 and 2.
  • Said thrust member 241 can consist of a hydraulic or pneumatic cylinder-piston unit, a flat helical or spiral spring, a leaf spring or equivalent.
  • the outer shape of the wheels 240 is cylindrical but there is nothing to prevent it being configured in another manner, for example with a circumferential groove of circular arc cross-section.
  • a mass of loose ceramic material 210 is loaded upstream of the belt 20 without discontinuity and is made continuously consistent by the compactor unit 24, from the exit of which there emerges a cord which divides naturally into pieces 11 ( Figures 1 and 2) of various shapes and dimensions when the two previously superposed longitudinal edges of the belt 20 open out.
  • said cord is compacted with a specific pressure less than that used to compact the final tile or slab, in general substantially one half of this latter.
  • the said pieces are fed to a chute 12 which discharges into the chopping and finishing station 3, between the downstream end of the belt 20 and said chute 12 there being provided an overflow for collecting and removing those pieces of agglomerate of too small dimensions.
  • Said belt 20 can also be positioned in combination with at least one other totally similar belt, to compact a loose starting material with different properties, generally at least one different coloration from that (or those) of the loose material 210 compacted by the belt 20.
  • said at least one other belt is shown schematically by a dashed-line rectangle indicated by 101, and can discharge either onto the chute 12 as indicated by the arrow A, or onto the collection and removal system as indicated by the arrow B.
  • the chopping and finishing station 3 comprises an inclined cylinder 30 of off-horizontal axis which is rotated about itself by a suitable drive system 31, such as a gearmotor with incorporated speed variator.
  • the interior of said cylinder 30 contains means (not shown for simplicity) with two functions: one is to break the pieces 11 into smaller bodies 1, having for example the aforesaid shapes and dimensions, the other being to smooth the sharp edged parts which said bodies 1 possess after breakage of said pieces 11.
  • Said double-function means can for example comprise fins of various shapes and dimensions, pins, and/or similar means.
  • apertures with sharp edges.
  • said apertures are equal and are of rhomboid shape, but this is purely by way of example.
  • Said cylinder 30 discharges into the coating station 4, into which there also discharges, by way of a metering valve, not shown, a vertical dispensing tube 42 for a ceramic preparation consisting of at least one material generally in powder form having different properties, at least one different coloration, from that (or those) of the loose starting mass 210.
  • Said preparation can consist of powders or granules of different kinds, for example chromophore oxides, or atomized, ground or micronized powders obtained from ceramic, semi-glaze or glaze mixes, and mixtures thereof.
  • Said coating station 4 comprises an inclined cylinder 40 of off-horizontal axis which is rotated about itself by a suitable drive system 41, such as a gearmotor with incorporated speed variator.
  • said means In the interior of said cylinder 40 there are provided means (not shown for simplicity) to aid the coating of said bodies 1 with said preparation, said means possibly consisting of ribs or projections of various shapes and dimensions.
  • both the thickness and the extent of the coating covering the bodies 1 can be selected.
  • the non-covered bodies 1 can be obtained either by temporarily closing the dispensing tube 42 while maintaining or not maintaining the cylinder 40 in operation, or by bypassing this latter by means of a suitable deviator and directly feeding the product leaving the station 3 to the collection and removal system 5.
  • the aforedescribed chopping and finishing station 3 can be bypassed, while either excluding or not excluding the coating step.
  • the coating takes place substantially dry, but there is nothing to prevent different methods being used.
  • the product leaving the cylinder 30 can be fed onto a mesh belt and be subjected to either spraying or dripping with suitably fluidized glazes, then either be dried before being fed to the collection system 5, or be fed directly to the loading means of the plant pressing station.
  • said mesh belt can pass either through a cascading sheet or a bath of ceramic glaze, at its exit from which a suitable fan can be provided.
  • the treated bodies 1 originating from the station 4 can be subjected for example to a subsequent spraying or drip-coating operation, by which the coating on the bodies 1 will comprise a (complete or partial) inner layer consisting of a first ceramic preparation, such as a glaze, and a (complete or partial) outer layer of a second ceramic preparation, such as a glaze having different properties from those of the preceding, typically a different colour.
  • a first ceramic preparation such as a glaze
  • a second ceramic preparation such as a glaze having different properties from those of the preceding, typically a different colour.
  • At least one deviator device arranged, when required, to deviate at least a part of the arriving bodies 1 towards a coating site (glazing) either by spraying, by dripping or by immersion.
  • a chute 52 Between the cylinder 40 and the upstream belt 50 there is provided a chute 52, between this latter and said belt 50 there being an overflow (not visible in the figures) for collecting and recirculating excess glaze powder.
  • the bodies 1 obtained in this manner are fed to the supply system of the plant forming station, and can be used as explained hereinafter.
  • said bodies 1 can be:
  • the aforestated is also valid for two-stage forming systems, i.e. if the generally soft mass for producing a tile or slab is compacted as desired with two successive pressings within two press units.
  • the bodies 1 can also be deposited onto the product on leaving the first press unit, i.e. before the second or final pressing.
  • This direct deposition onto said soft mass or onto said product can be effected by any suitable device, for example a distributor belt or a hopper with a strewing device.
  • the formed tile or slab can be subjected to at least one surface finishing operation, generally smoothing or lapping, after which it is fired.
  • said smoothing or lapping can be effected on the fired product.
  • the bodies 1 according to the invention can be generally used for manufactures of porcellainized stone type, in particular for manufacturing tiles or slabs with decorations of natural stone or rock type, such as marble, as shown by way of example in Figure 10. This however is not limiting.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Catalysts (AREA)
  • Mixers Of The Rotary Stirring Type (AREA)
EP02080172A 2001-12-21 2002-12-09 Method and plant for manufacturing ceramic tiles and slabs Expired - Lifetime EP1321256B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT2001RE000127A ITRE20010127A1 (it) 2001-12-21 2001-12-21 Metodo ed impianto per la fabbricazione di piastrelle e lastre ceramiche, e piastrelle e lastre ottenute con detti
ITRE20010127 2001-12-21

Publications (3)

Publication Number Publication Date
EP1321256A2 EP1321256A2 (en) 2003-06-25
EP1321256A3 EP1321256A3 (en) 2004-05-26
EP1321256B1 true EP1321256B1 (en) 2006-08-09

Family

ID=11454167

Family Applications (1)

Application Number Title Priority Date Filing Date
EP02080172A Expired - Lifetime EP1321256B1 (en) 2001-12-21 2002-12-09 Method and plant for manufacturing ceramic tiles and slabs

Country Status (9)

Country Link
EP (1) EP1321256B1 (it)
CN (1) CN1298521C (it)
AT (1) ATE335578T1 (it)
BR (1) BR0205312A (it)
DE (1) DE60213749D1 (it)
ES (1) ES2269605T3 (it)
IT (1) ITRE20010127A1 (it)
MX (1) MXPA02012390A (it)
PT (1) PT1321256E (it)

Families Citing this family (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1391811B1 (it) * 2008-11-21 2012-01-27 Coem S P A Procedimento per la fabbricazione di manufatti ceramici sostanzialmente piastriformi
ITRE20110081A1 (it) * 2011-10-07 2013-04-08 Sacmi Dispositivo e metodo per il trattamento di uno strato di materiale in polvere
ITBO20120470A1 (it) * 2012-09-05 2014-03-06 Lacu S R L Piastrella in sughero e metodo per realizzarla.
CN104690817B (zh) * 2013-12-05 2017-08-11 江西斯米克陶瓷有限公司 一种多纹理组合陶质砖的布料装置及工艺
CN104400896B (zh) * 2014-12-04 2017-02-01 广西利升石业有限公司 嵌入式花纹纹路人造大理石自动生产线
CN105108796A (zh) * 2015-06-26 2015-12-02 汤雄跃 一种多色岗石辅色物料分割控制系统
ITUA20164452A1 (it) * 2016-06-16 2017-12-16 System Spa Dispositivo compattatore per la pressatura di manufatti ceramici
CN106738292B (zh) * 2017-02-23 2023-12-12 佛山市东鹏陶瓷有限公司 一种用于向块状料表面喷浆的设备及使用其的加工系统
CN108943350A (zh) * 2017-05-19 2018-12-07 胡辉雄 圆形碗盆搪粉胚胎自动涂边机
IT201800003939A1 (it) 2018-03-26 2019-09-26 System Ceramics S P A Metodo per la pressatura di lastre ceramiche
CN109135784A (zh) * 2018-09-20 2019-01-04 华蓥市职业教育培训中心 一种自动运料的碳化设备
CN110774429B (zh) * 2019-11-29 2021-07-16 佛山森蒂泰珂科技有限公司 一种齿轮驱动式瓷砖生产用高效喷釉设备
CN111646788B (zh) * 2020-05-22 2022-03-08 福建德胜新建材有限公司 一种大规格陶瓷岩板及其制备方法
IT202000018514A1 (it) * 2020-08-04 2022-02-04 P F M Srl Piastrella a rugosita' superficiale differenziata

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Publication number Priority date Publication date Assignee Title
US1390244A (en) * 1918-12-14 1921-09-06 Bas Willem Jacobus De Process of producing artificial stone
DE719772C (de) * 1938-10-12 1942-09-01 Gerhardt Raupach Dipl Ing Strangpresse fuer keramische und andere bildsame Massen
IT1269274B (it) * 1994-11-22 1997-03-26 Carlo Antonio Camorani Metodo per la formatura di piastrelle ceramiche ed impianto relativo
US5795513A (en) * 1995-12-28 1998-08-18 Mark Austin Method for creating patterns in cast materials
AU2564797A (en) * 1996-04-02 1997-10-22 Dening Yang Stereo ceramic granite and marble
CN1091756C (zh) * 1997-11-13 2002-10-02 杨德宁 瓷质颗粒立体图案花岗石
CN1211311C (zh) * 2001-09-10 2005-07-20 杨德宁 瓷质粉料烧结的三维彩色图案板材

Also Published As

Publication number Publication date
ES2269605T3 (es) 2007-04-01
BR0205312A (pt) 2004-07-20
ATE335578T1 (de) 2006-09-15
DE60213749D1 (de) 2006-09-21
PT1321256E (pt) 2006-11-30
MXPA02012390A (es) 2004-12-13
EP1321256A3 (en) 2004-05-26
EP1321256A2 (en) 2003-06-25
CN1298521C (zh) 2007-02-07
ITRE20010127A1 (it) 2003-06-21
CN1426881A (zh) 2003-07-02

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