BRPI1003927A2 - process for making very thin ceramic tiles - Google Patents
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Abstract
PROCESSO PARA FABRICAR AZULEJOS CERÂMICOS MUITO FINOS. A presente invenção se refere a um processo para fabricar azulejos cerâmicos muito finos, o qual compreende as etapas de: comprimir uma mistura em uma matriz, mistura essa compreendendo componentes argilosos plásticos com um módulo de ruptura verde de pelo menos 11 kg/cm2 e um módulo de ruptura a seco de pelo menos 40 kg/cm2. Um primeiro aquecimento dos azulejos é realizado a uma temperatura entre 80O<198> C e 1.000<198> C. A vitrificação do azulejo, pelo uso de meios conhecidos, é realizada depois do primeiro aquecimento, e, então, realiza-se um segundo aquecimento do azulejo a uma temperatura entre 1.150<198> C e 1.200<198> C.PROCESS TO MAKE VERY FINE CERAMIC TILE. The present invention relates to a process for making very thin ceramic tiles which comprises the steps of: compressing a mixture into a matrix, which mixture comprises plastic clay components having a green break modulus of at least 11 kg / cm2 and a dry break modulus of at least 40 kg / cm2. First heating of the tiles is carried out at a temperature of between 80 ° C and 1,000 ° C. Glazing of the tile by known means is performed after the first heating, and then a second heating the tile to a temperature between 1,150 <198> C and 1,200 <198> C.
Description
7栉. Relatorio Descritivo da Patente de Inven9acS ^^: para ePROCESSO PARA FABRICAR AZULEJOS )¾ CERAMICOS MUITO FINOS '.7 栉. Invention Patent Descriptive Report for Process for Manufacturing Tiles) 'Very Fine Ceramics'.
A presente ίηνβηςείο se refere a um processo para fabricar azulejos ceramicos muito finos.This ίηνβηςείο relates to a process for making very thin ceramic tiles.
No campo da ceramica industrial, prensas normais costumam ser usadas para produzir azulejos, seja com uma superficie esmaltada Iisa ou com uma superficie "irregular", isto e, com algumas partes em relevo e outras rebaixadas, normalmente conhecidos como azulejos estruturados, que tem uma espessura de um centimetro ou mais. Quanto aos azulejos esmaltados de superficie Iisa5 usados principalmente como revestimento, sao obtidos azulejos de 6 a 7 milimetros de espessura. Abaixo dessa espessura,ο acabamento dos azulejos torna-se bastante complicado ja que ο barro comprimido em espessuras menores produz azulejos nao-aquecidos, que sao muito dificeis de transportar e esmaltar. Nem mesmo a tecnica de aquecimento duplo oferece resultados satisfatorios ja que ο suporte aquecido, ja tendo sido dificil de transportar antes do aquecimento, torna-se tao fragil que e dificil de envia-lo para asIn the field of industrial ceramics, normal presses are often used to produce tiles, either with an Iisa enamelled surface or an "uneven" surface, that is, with some raised and lowered parts, commonly known as structured tiles, which have a thickness of one centimeter or more. As for the enamelled Iisa5 surface tiles used mainly as a coating, 6 to 7 millimeter thick tiles are obtained. Below this thickness , the finish of the tiles becomes quite complicated as the compressed clay in smaller thicknesses produces unheated tiles, which are very difficult to transport and enamel. Not even the double heating technique offers satisfactory results as the heated support, having been difficult to carry before heating, becomes so fragile that it is difficult to send it to
etapas de trabalho seguintes.following work steps.
A fim de obter azulejos muito finos,isto e, de ate cerca de 2 a 3 milimetros,ha conhecimento de um processo que usa barros especiais laminados em grandes placas, possivelmente serigrafadas antes de serem aquecidas para a gresifica9ao; assim, obtem-se uma placa de consistencia vitrea, que e entao cortada em azulejos com as dimensoes desejadas. O-- processo requer maquinas e unidades especificas e,portanto, e particularmente caro; alem disso, embora produza azulejos de alta resistencia, em virtude de sua consistencia vitrea,e dificil de trabalhar mecanicamente neles para realizar opera9oes de corte e perfura9ao necessarias durante ou apos ο assentamento. Ademais, os azulejos obtidos usando esse metodo tem superficies iisas, tipicas de acabamentos com lamina^o e aquecimento a temperaturas elevadas,que leva os barros a um estado plastico e que tende a tornar a superficie da placa uniforme.In order to obtain very thin tiles, i.e. up to about 2 to 3 millimeters, there is knowledge of a process using special slabs rolled into large slabs, possibly screen-printed before being heated for grinding; Thus, a glass-like plate is obtained, which is then cut into tiles of the desired dimensions. The process requires specific machines and units and is therefore particularly expensive; In addition, although it produces high strength tiles because of their glassy consistency, it is difficult to work mechanically on them to perform cutting and drilling operations necessary during or after laying. Moreover, tiles obtained using this method have smooth surfaces, typical of laminate finishes and heating at elevated temperatures, which brings the clay to a plastic state and tends to make the surface of the plate uniform.
O objetivo da presente invenpo e ο de eliminarThe purpose of the present invention is to eliminate
as desvantagens da tecnica anterior propondo um processo que permita obter azulejos muito finos,de ate 2 a 3 milimetros, usando prensas comuns no setor ceramico para comprimir barros.The disadvantages of the prior art are that it proposes a process for obtaining very thin tiles, up to 2 to 3 millimeters, using common ceramic presses to compress clay.
Outro objetivo da presente inven9ao eo de obter azulejos ceramicos muito finos que sejam resistentes e faceis de se trabalhar por meio de processos mecanicos que usemAnother object of the present invention is to obtain very thin ceramic tiles which are resistant and easy to work by mechanical processes using
ferramentas tradicionais.Traditional tools.
Uma vantagem da presente inven^o e a deAn advantage of the present invention is that
propor um processo que permite a produQao de azulejos muito finos cuja superficie pode ser trabalhada, isto e, munidas de partes em relevo e partes rebaixadas (conhecidos como azulejos "estruturados").propose a process that allows the production of very thin tiles whose surface can be worked, i.e. provided with raised and recessed parts (known as "structured" tiles).
A presente inven^o,conforme caracterizada nas reivindica0es em anexo, atinge esses objetivos e vantagens. Outras caracteristicas e vantagens da ίηνβηςδοτ ίThe present invention, as characterized in the appended claims, achieves these objects and advantages. Other features and advantages of ίηνβηςδοτ ί
transparecerao melhor com a leitura da descri^ao detalhada a ^ seguir de possiveis formas de realizar as etapas do processo da inven9ao.This will be best reflected by reading the following detailed description of possible embodiments of the process steps of the invention.
O processo produz azulejos ceramicos muito finos; ο processo descrito permite obter azulejos muito finos de 2 a 3 milimetros de espessura.The process produces very thin ceramic tiles; The described process makes it possible to obtain very thin tiles 2 to 3 millimeters thick.
O processo compreende uma etapa de comprimir uma mistura em uma matriz,mistura essa compreendendo componentes argilosos plasticos de um tipo normalmente usado para forn^oes por extrusao, a fim de obter um azulejo nao-aquecido da espessura desejada. Nessa etapa, sao usadas prensas ceramicas normais, preparadas com matrizes que sao cuidadosa e uniformemente preenchidas com a mistura, obviamente de uma maneira adequada para obter um suporte nao- aquecido da espessura desejada; ο preenchimento da matriz deve ser feito com bastante cuidado ja que, dada a espessura bastante modesta da mistura comprimida,ate mesmo pequenas diferen9as na densidade em varios pontos da matriz seriam dificeis de se compensar mesmo com ο uso de matrizes isostaticas. A mistura usada deve ser altamente resistente a flexao antes do aquecimento de modo a ser capaz de garantir um Ieve movimento das pe9as da prensa para ο processo de aquecimento sem que elas se quebrem ou rachem em decorrencia de vibra?5es ou impactos; a mistura tambem deve ter uma curva de gresifica9ao (naturalmente, quando a gresifica^o da mistura for obtida, conforme .The process comprises a step of compressing a mixture into a matrix, which mixture comprises plastic clay components of a type commonly used for extrusion supplies to obtain an unheated tile of the desired thickness. In this step, normal ceramic presses prepared with dies that are carefully and uniformly filled with the mixture are used, obviously in a suitable manner to obtain an unheated support of the desired thickness; Matrix filling should be done with great care since, given the rather modest thickness of the compressed mixture, even small differences in density at various points in the matrix would be difficult to compensate even with the use of isostatic matrices. The mixture used must be highly resistant to bending before heating in order to be able to ensure a slight movement of the press parts for the heating process without breaking or cracking due to vibration or impact; The mixture must also have a grammage curve (of course, when the grammage of the mixture is obtained, as per.
Fls.Pages
descreveremos em mais detalhes abaixo) para manter estabilidade de encolhimento durante ο aquecimento e uma curva dilatometrica perfeitamente coincidente com a dos esmaltes usados a fim minimizar os efeitos de deforma^o a planidade. Essas caracteristicas sao obtidas usando uma mistura com caracteristicas plasticas especificas; barros desse tipo sao conhecidos e normalmente usados em processos de forma9ao por extrusao. A caracteristica desses barros e que eles tem um modulo de ruptura verde de pelo menos 11 kg/cm2 e um modulo de io ruptura a seco de pelo menos 40 kg/cm .described in more detail below) to maintain shrinkage stability during heating and a dilatometric curve perfectly coincident with that of the enamels used in order to minimize the effects of deformation to flatness. These characteristics are obtained using a mixture with specific plastic characteristics; Such muds are known and commonly used in extrusion forming processes. The characteristic of such clay is that it has a green rupture modulus of at least 11 kg / cm2 and a dry rupture modulus of at least 40 kg / cm2.
Na pratica, sao usadas misturas adequadas para obter azulejos aquecidos so uma vez ainda que, como veremos mais adiante’ ο processo seja caracterizado, entre outras coisas, pelo uso de misturas de aquecimento unico, ainda que as submetaIn practice, suitable mixtures are used to obtain heated tiles only since, as we will see later on, the process is characterized, among other things, by the use of unique heating mixtures, although subjected to them.
ao aquecimento duplo.to double heating.
Essa etapa de compressao e realizada com umaThis compression step is performed with a
pressao de compressao especifica entre 500 e 650 kg/cm .specific compression pressure between 500 and 650 kg / cm.
Depois de obter ο azulejo nao-aquecido, ο processo compreende uma primeira etapa de aquecimento do azulejo realizada a uma temperatura inferior a temperatura de gresifica9ao; essa primeira etapa de aquecimento e realizada aquecendo ο azulejo nao-aquecido a uma temperatura entre 800 e 1.000。C, com um ciclo de aquecimento de 2.540 minutos. Nessa primeira etapa de aquecimento, os azulejos sao mantidos a temperatura maxima por um periodo inferior a 5 minutos. A primeira etapa de aquecimento produz um biscoito com -π Th.-After obtaining the unheated tile, the process comprises a first step of heating the tile carried out at a temperature below the grinding temperature; This first heating step is performed by heating the unheated tile to a temperature between 800 and 1,000 ° C, with a heating cycle of 2,540 minutes. In this first heating step, the tiles are kept at the maximum temperature for less than 5 minutes. The first heating step produces a cookie with -π Th.-
porosidade de cerca de 11 a 16%,isto έ,muito maior do que ^ Rub: mistura teria se submetida as temperaturas atingidas durante ο^τ^ζλ^' aquecimento unico (cerca de 2 a 3%),embora apresente a ν consistencia e a resistencia tipicas das misturas de aquecimento ύηίοο. Isso torna a etapa de vitrifica9ao seguinte possivel ja que a porosidade do biscoito permite que ο esmalte despa ao suporte.porosity of about 11 to 16% , this is much higher than ^ Rub : mixture would have undergone the temperatures reached during single heating (about 2 to 3%) , although it has the ν consistency and the typical resistance of heating mixtures ύηίοο. This makes the next glazing step possible as the porosity of the cookie allows the glaze to peel off the backing.
O curto periodo de tempo em que ο aquecimento permanece a temperatura maxima e a baixa temperatura maxima atingida nao levam ao amolecimento do io azulejo, que, portanto, mantem, nao obstante sua espessura limitada, as irregularidades desejadas (se realmente desejadas) da superficie que sera esmaltada e,portanto,produz azulejos estruturados.The short time in which heating remains at the maximum temperature and the low maximum temperature reached do not lead to the softening of the tile, which therefore, despite its limited thickness, maintains the desired (if really desired) surface irregularities. it will be enameled and , therefore , produces structured tiles.
Embora seja importante,durante a etapa de compressao e a primeira etapa de aquecimento, ο azulejo nao- aquecido, nao muito consistente, nao deva realizar trajetos longos, ο biscoito tem um bom nivel de resistencia e pode,portanto, seguir adiante,por meio de linhas de produ9ao normais,a proxima etapa de vitrifica^o,realizada usando tecnicas de vitrifica9ao normais e conhecidas. O ύηίοο requisito especial e que os esmaltes usados sejam compativeis com a curva dilatometrica do suporte a fim de minimizar efeitos de deforma9ao a planaridade. Esmaltes especialmente adequados ao objetivo sao, no entanto,conhecidos e facilmente encontrados noAlthough it is important , during the compression step and the first heating step, the unheated, not very consistent tile should not make long runs, the cookie has a good level of strength and can therefore move forward by of normal production lines , the next step of vitrification , is performed using normal and known glazing techniques. The special requirement is that the enamels used are compatible with the dilatometric curve of the substrate in order to minimize deformation effects to planarity. Enamels especially suited to the purpose are, however, well known and easily found in
mercado. 6 广\ A etapa de vitrifica^o nao traz nenhum,f)―〜 . yl $market. 6 广 \ The glazing stage does not bring any , f) ―〜. yl $
problkna visto que e realizada em um biscoito que, dada a suaproblkna since it is held in a cookie which, given its
porosidade por nao ter sido gresificado, absorve ο esmalte, mas \porosity because it has not been gresified, absorbs enamel, but \
que, justamente por ser aquecido, nao e sofre qualquerwhich, precisely because it is heated, does not suffer any
amolecimento causado pelo esmalte. Alem disso,embora οsoftening caused by enamel. Besides , though ο
suporte de azuiejo seja muito fmo, e possivel usar grandesTile support is very thin, it is possible to use large
quantidades de esmalte a fim de obter efeitos especiais equantities of enamel in order to obtain special effects and
decorativos que nao seriam possiveis em um suporte nao-that would not be possible on a non-metallic support.
aquecido tao fino. Se uma grande quantidade de esmalte fosseheated so thin. If a large amount of nail polish were
aplicada a um unico suporte fino ainda nao aquecido, a aguaapplied to a single thin unheated support, the water
contida no esmalte encharcaria ο suporte em si e ο amoleceria aocontained in the enamel would soak the support itself and soften
ponto de fazer com que ele perdesse a consistencia. Depois depoint of making him lose consistency. After
esmaltado,ο azuiejo e submetido a uma segunda etapa deenameled , ο azuiejo and subjected to a second stage of
aquecimento a temperatura de gresificagao. Essa segunda etapa deheating to gresification temperature. This second stage of
aquecimento e realizada a uma temperatura entre 1.150° C eheating and carried out at a temperature between 1,150 ° C and
1.200° C,com um ciclo de aquecimento entre 20 e 30 minutos.1,200 ° C , with a heating cycle of between 20 and 30 minutes.
Durante a segunda etapa de aquecimento, os azulejos sao mantidos a temperatura maxima por menos de 5 minutos a fim de impedir ο amolecimento ou a deforma9ao excessiva do material.During the second heating step, the tiles are kept at the maximum temperature for less than 5 minutes to prevent softening or excessive deformation of the material.
No segundo aquecimento, ο azuiejo chega a um nivel de porosidade inferior a 3%, caracteristico de lou9as vitrificadas esmaltadas.In the second heating, the azuiejo reaches a porosity level of less than 3%, characteristic of glazed glazed tableware.
Na segunda etapa de aquecimento, chegamos a caracteristicas de resistencia excelentes: por exemplo,em azulejosIn the second heating step, we came up with excellent strength characteristics: for example , in tiles
de 3 milimetros de espessura,obtemos niveis de resistencia 5 H3 millimeters thick , we get resistance levels 5 H
77th
:於气《 \ ν 々, ,V^ ‘: 於 气 《\ ν 々,, V ^ ‘
normalmente atingidos em azulejos de 7 a 8 milimetros de^·补―\ — espessura gragas ao aquecimento duplo (azulejos de、 revestimento).typically achieved on 7 to 8 millimeter-thick tiles thanks to double heating (、 cladding tiles).
Em suma? ο process。descrito permite: obter azulejos muito finos (de espessura inferior a 3 milimetros) com uma resistencia que, com a referida espessura, nao e atingivel em azulejos de aquecimento duplo tradicionais;In short? The described process allows to: obtain very thin tiles (of thickness less than 3 millimeters) with a resistance that, with said thickness, is not attainable in traditional double heating tiles;
eliminar dificuldades de transporte e vitrifica9ao que ocorrem com azulejos nao-aquecidos muito finos que serao aquecidos;eliminate transport and glazing difficulties that occur with very thin unheated tiles that will be heated;
permitir ο uso de grandes quantidades de esmalte a fim de obter efeitos tecnicos e decorativos desejados;allow the use of large quantities of enamel to achieve the desired technical and decorative effects;
tratar ο material com todas as aplica9oes de movimento,vitrifica9ao e decora0o conhecidas ate entao,treat material with all applications of movement, vitrification and decoration known until then,
incluindo em um suporte estruturado.including in a structured support.
Claims (7)
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BRPI1003927 BRPI1003927A2 (en) | 2010-10-22 | 2010-10-22 | process for making very thin ceramic tiles |
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BRPI1003927 BRPI1003927A2 (en) | 2010-10-22 | 2010-10-22 | process for making very thin ceramic tiles |
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