DE60212763T2 - Method and device for producing tiles, in particular Venetian floor tiles and the like - Google Patents

Abstract

A method for the making of tiles able to be used as surfacing and support plane, which reproduce, in their motifs and techniques employed, so-called Venetian style floors, comprises the phases of: laying a first layer of grout on a planar support; vibrating the grout; placing a quantity of gravel on the surface of said first layer of grout; subjecting said support to sussultatory vibrations, determining the partial burying of the gravel in said first layer of grout; laying, onto said first layer of grout, a second layer of grout obtaining a semi-finished tile; vibrating the whole semi-finished tile; and drying said semi-finished tile. <IMAGE>

Description

The The present invention relates to a method of producing tiles and the like, suitable for use as a cover and backing layer suitable and so-called in their motives and techniques used to imitate Venetian floors.

The The invention further relates to an apparatus for manufacturing of tiles and a plant for their production.

This Type of ground for known for its aesthetic qualities is in direct order of a layer of semi-liquid binder material on the ground of the ceiling, which takes up the ground.

The Material known to the technician and those who use this special type of floor embarrassed, is with its conventional Name "grout" called. there it is a mixture consisting essentially of water, Cement, marble dust or the like. The properties of the mixture to be changed, to meet the requirements of the laying process, in particular in terms of porosity, specific weight, color, etc.

At the Solidification takes it as properties of considerable hardness and resistance as well as suitability for grinding and polishing, so that a glossy surface is created. In the liquid State it has the properties of a liquid-plastic fluid with low viscosity, so that it can flow.

On the layer of grout, those with uniform thickness is applied to the ground, single elements are made crushed gravel applied, and this process of application becomes conventional as sowing referred to the gravel, the elements are small pieces of different Shapes and sizes Stone, marble, granite, glass, etc., which vary in color, size, and size Effect selected be generated on the ground.

It it is understood that when the gravel is applied it is possible to create a mixture of different colors and stones, however also an orderly and correct design on a mosaic structure and also all conceivable intermediate solutions.

To The application of the gravel is then accurately an additional Layer of grout applied, which dries in the air, this process many Can take days.

After this the entire layer applied to the substrate after complete drying out of the cement, which lasts at least one month, sufficient Hardness and Has achieved compactness, it can be sanded and polished, with started with grinding wheels with coarse grain and with grinding wheels for polishing is completed.

The Removing the previously created irregular surface allows it on the one hand, a flat surface to produce, free from irregularities, shiny and is compacted and as a floor high resistance across from facings and other wear through Friction, the ingress of liquids and other harmful ones Has elements. On the other hand, it allows polishing that the gravel layer completely emerges, so that during of the created motifs are completely visible and their whole aesthetic and in many cases also artistic effect unfold.

Out It will be understood from the above description that this type of floor, the for their high value appreciated will, only for those who are determined the high cost and time can afford associated with such a manual installation process are.

Therefore Methods for producing tiles have been developed and known, which, if mislaid, have the above-described Type of floor can simulate.

These Methods are generally based on the preparation of a mixture from grout and Gravel, which, when dried, is cut into tiles can.

at other method becomes a carrier level used on the grout and gravel are poured and layered.

This Procedure allows However, only the production of marble-like tiles or Baulöcken with inserted stones, different from the so-called Venetian Floors considerably differ.

So For example, Japanese Patent No. 04 112003 A uses Formwork on which a first layer of concrete is formed, then decorative stones are applied and vibration the upper ends can match them so that they have the same height. After all a second layer of concrete is poured.

US Pat. No. 3,324,213 describes a method for producing decorative tiles using a mixture of synthetic resins and de korative stones, which is cast on a support, and a step of moving a pressing and vibrating element on the surface of the mixture to evenly distribute the stones.

Of Further possible It this system to produce tiles whose gravel in a disorderly Matrix is arranged without patterns can be generated. Farther is when the tiles are complete are laid, although the thickness of the gap can be minimized, the transition between a tile and the other due to the irregular arrangement of tiles that cut each other at the edge of the tile itself are visible, yet visible.

These Disadvantages are despite the reduction in costs associated with the laying process reduced to a simple tiling, so, that they significantly restrict the use of this type of flooring.

The technical problem underlying the present invention, is to provide a method of making tiles, that makes it possible the disadvantages mentioned above with reference to the prior art to overcome.

• – Verlegen einer ersten Vergussmörtelschicht auf einer ebenen Bettung;
• – Aufbringen einer Kiesmenge auf die Oberfläche der ersten Vergussmörtelschicht;
• – Aussetzen der Bettung den Rüttelschwingungen, die das teilweise Versenken der Kiesmenge in die erste Vergussmörtelschicht bestimmen;
• – Verlegen einer zweiten Vergussmörtelschicht auf der ersten Vergussmörtelschicht, wodurch eine halbfertige Fliese entsteht;
• – Einrütteln der gesamten halbfertigen Fliese; und
• – Trocknen der halbfertigen Fliese.

The problem is solved by a method as set forth in claim 1 and comprising the following phases:

• - Laying a first grout layer on a flat bedding;
• Applying a quantity of gravel to the surface of the first grout layer;
• Subjecting the bedding to vibrating vibrations which determine the partial sinking of the amount of gravel into the first grout layer;
• - Laying a second grout layer on the first grout layer, whereby a semi-finished tile is formed;
• - shaking the entire half-finished tile; and
• - drying the half-finished tile.

According to one execution According to the invention, the method comprises the additional phase of grinding a surface the semi-finished tile to a predetermined degree of finishing. Otherwise you can the grinding and polishing phases even after laying on an in suitably prepared underground.

One Partial grinding of the surface is possible, too. In this case allows a method of laying the tiles produced as described above Be, laying an extra thin layer from grouting mortar on the laid tiles, with the limited thickness of the additional layer their fast drying allows and followed by a polishing process, which leaves any trace of a gap between removed the tiles.

In In any case, the transition between a tile and the other difficult to see, as no cut stones are present at the edge of the tile.

The Application of the gravel in the process according to the invention can be done with any any degree of accuracy, i. from a mechanical and automated laying up to a manual laying that among other benefits, allows for the creation of distinct patterns and mosaics.

• – eine Schalenanordnung, die halbflüssigen Vergussmörtel aufnehmen kann,
• – eine Einrichtung zum Abgeben von halbflüssigem Vergussmörtel in die Schalenanordnung;
• – eine Einrichtung zum Abgeben von Vergussmörtel in die Schalenanordnung;
• – ein Schwingungselement, auf das die Schalenanordnung aufgesetzt ist; und
• – eine Einrichtung zum Erzeugen von Rüttelschwingungen.

According to the same inventive concept, an apparatus for producing tiles and the like for Venetian floors comprises:

• A tray arrangement capable of receiving semi-liquid grout,
• A means for dispensing semi-liquid grout into the shell assembly;
• A means for dispensing grout into the shell assembly;
• - A vibration element on which the shell assembly is placed; and
• - A device for generating Rüttelschwingungen.

A Plant for making Venetian floor tiles and the like includes the device defined above, a device for drying semi-finished Tiles as well as a device for finishing the surface of the raw tiles.

The The present invention will be described hereinafter in accordance with a preferred embodiment thereof along with some modifications that are considered non-limiting Example, described with reference to the accompanying drawings, at them:

1 to 6 . 7a . 7b . 8a and 8b schematically show some phases of the method according to the present invention in combination with details of a molding apparatus; and

9 a schematic plan view of a plant for implementing the method according to the present invention shows.

In 1 to 6 is a device 1 for making tiles partially restricted to the cutout in which the tile is made.

This device comprises a vibration element 2 ie, a planar support member passing through a vibration generator 8th is vibrated.

On the vibration element 2 includes the device 1 a shell arrangement 5 who, in turn, are a planned carrier 50 that covers through walls 3 is limited, which define a predetermined thickness. Between the vibration element 2 and the shell arrangement 5 a damping layer is arranged, whose function will be seen below.

The device 1 further comprises a dispenser 6 for dispensing a quantity of semi-liquid grout. The dispenser 6 Conveniently, it is constructed like a bulk container and receives the grout from a system for mixing and dispensing the grout itself.

In the device 1 For example, a first phase of the process according to the present invention comprises the phase of laying a first layer of grout 70 by giving a first predetermined amount 7 on grout with the dispenser 6 ( 1 ) is determined.

If the given amount 7 to grout in the shell arrangement 5 has been cast, the vibrating element 2 vibrated.

The vibration generating device 8th is constructed so that it comprises a pair of eccentric elements, which are conventional and therefore not shown here and are attached to parallel shafts, which are also parallel to the plane carrier 50 are and are rotatably connected for example by means of bearings or bushings with the vibration element.

These Waves become in opposite rotations with the same Spinning speed offset, in such a way that a vibration is generated, which ensures that laying the grout layer takes place evenly under the aspect of density and thickness.

The damping layer 4 serves to cancel out the effect of the second-order vibrations that should be generated along with the required shaking vibrations.

The term vibration vibrations refers to the vibrations that cause a reciprocating motion in a direction perpendicular to the vibration element 2 or to the intended carrier 50 is.

The thickness of the first grout layer 70 is about half the thickness of the walls 3 the shell arrangement 5 is determined. In the present embodiment, the thickness is 6-7 mm ( 2 ).

When laying the first layer 70 is completed, the process includes the phase of applying a quantity of gravel 9 on the first layer. Various systems can be used to apply the gravel, with the system that has proven to be the most accurate being the manual one with which it is possible, due to the experience of the craftsman employed, to have a "natural" appearance, or in contrast to achieve a precise design, which is given by appropriate templates.

In In any case, it is clear that this phase is also compatible with other installation systems, In particular, mechanical systems, can be performed, the given Drop amount of gravel.

It It is also clear that the gravel in question may be of irregular size, possibly also several different colors.

The laying process creates a structure in which the grout layer 70 is superficially covered with gravel, the pieces are partially embedded in the semi-liquid grout or sunk superficially ( 3 ).

At this point, the process according to the present invention comprises the phases in which the planar support 50 using a generator 8th Vibrating vibrations is exposed. Due to the special nature of the vibrations and the density of the grouting mortar 7 becomes the gravel with a substantially even distribution 10 ( 4 ) partially in the first layer of grout 70 embedded.

With the dispenser 6 In a subsequent phase of the present manufacturing process, a second predetermined amount 11 given to grout to the shell assembly 5 to the upper end ( 5 ) to fill. This second amount of grout then forms a second layer of grout applied to the previous one to form a semi-finished tile 12 to build.

To achieve this, the shell assembly is again subjected to shaking vibrations, the laying of the added grout and the uniform distri ment of the grout 9 over the entire thickness as well as over the entire surface of the semi-finished tile 12 cause ( 6 ).

The goes through half-finished tile at this point, to undergo the following processing operations to become, a phase in which it is dried. The drying process can of course or drain in an environment involving drainage and hardening (crystallization) of the grouting mortar promotes, so for example by means of steam baking at a controlled temperature.

During this phase, the semi-finished tile 12 in the cup arrangement 5 which, if disposable, is disposed of or reused. The separation between the tile to be finished and the shell assembly can be facilitated by placing the inner surface of the shell assembly 5 is lubricated before the first grout layer is laid.

To Notice that there are no cut gravel pieces on the edge of the half-finished Tile are present, as is the case when a whole block from solidified grout and gravel is cut to make tiles. The presence these cut parts would make it possible to look at it more closely the presence of a thin gap between the tiles to notice when the laying process is completed. Furthermore prevents uniform distribution, that the edge of the tile due to a thinning of the gravel at the edges detected can be. These qualities are very much appreciated since thereby the soil that is created by laying tiles, similar to the ground, with conventional Process is generated in which the grout and the gravel directly on be laid underground.

Farther It should be noted that this traditional effect is created can and while doing special preparation of the underground and the very long Time to dry the floor are bypassed on-site, and all of this at lesser Tile thickness less than 20 mm.

The finishing of the semi-finished tile 12 may include different phases depending on the type of installation for which the tiles are intended. In general, finishing involves a series of grinding operations using increasingly fine grain grinding wheels until a shiny surface is achieved.

Of the The purpose of the grinding process is also the gravel pieces, the emerge from the semi-finished tile surface, level and unify.

Finishing may involve a first phase of rough grinding with a first grinding wheel device 14 which acts on a raw tile P acting on a support 13 is up. This will be an irregular surface 15 generated, which can be used in the laying process.

The raw tile P can be routed normally, leaving a uniform, however not shiny surface is produced.

On this area can with conventional systems, such as spatulas, applied a thin layer of grout which can dry very quickly. Subsequently, the floor thus created can the shiny one Surface honed be so that any gap or transition between the tiles is eliminated.

If a more noble tile is desired, it is possible with a second grinding phase with a second grinding wheel device 16 continue with fine and very fine grain to a shiny surface 17 to create ( 9 ). With this tile, quick laying can be carried out, which is completely similar to that carried out with ceramic tiles, creating a Venetian floor.

With reference to 9 becomes a plant 20 for producing Venetian floor tiles according to the method described above. The plant includes a forming line 22 on which the cup arrangements 5 be moved and go through a number of substations, some of which are equipped with vibration generating equipment 8th are provided.

The distance 22 includes an inlet 22 holding the empty cup arrangement 5 receives. Then it includes a first substation 35 in which the cup assemblies are lubricated, as well as a second substation 36 for laying the first grout layer 70 , For this purpose, the plant comprises containers 25 with liquid Mate rial for the composition of the grout in predetermined proportions. The containers 25 feed mixing equipment 26 in which the grout is mixed to a distributor 27 to feed, in turn, a pair of discharge lines 23 . 24 feeds the first or the second layer of grout 70 embarrassed.

In This part of the system determines the color of the grouting mortar. The coloring usually stays the same for a batch of tiles. In any case, extreme flexibility is possible.

lubrication can take place manually or automatically.

The first delivery line 23 represents the second substation 36 to which a third substation 37 follows, in the vibration generating equipment 8th used to make the first grout layer 70 evenly laid, grout ready.

In a fourth substation 38 the grout is superficially preferably distributed manually by an experienced worker who also attaches any templates as a guide during installation.

To It should be noted that this method makes it possible to produce individual parts, with which made floors can be the extraordinary have complex design. The worker can use templates for example, made of sheared cardboard and automatically be produced by means of a computerized CDA / CAM system with which the floor itself is drawn and designed.

In a fifth substation 39 carry vibration generating equipment 8th to embed the gravel in the grout with a precise process, and the worker is immediately able to check that the gravel, which in this phase adheres significantly to the grout, occupies the required position.

In all the phases in which vibrations work, and especially there, where the gravel in the grout embedded, the duration of exposure from tile to tile can be embedded controlled by the worker to ensure a consistent level of quality To reach by also the amount of gravel, the piece size, the Density of the gravel, the complexity the pattern etc. changed become.

For mass production otherwise the duration of the oscillation can be preset.

Subsequently, in a sixth substation 40 coming from the second delivery line 24 the putty is fed, the semi-finished tile with the second amount of grout 11 and in a seventh substation 41 generates the vibration generating device 8th a semi-finished tile with the required thickness.

The fourth substation 38 That is, the one in which craftsmanship is concentrated, which can be used with the present method, may be divided into several substations for applying different types of gravel. It will be appreciated that in each case the same manufacturing quality can be achieved with a mechanical laying system using for example sieves equipped with stencils to make patterns with the gravel, as well as conventional systems for transporting the gravel. The same mechanical system can work for the mass production of tiles with the mentioned CAD / CAM system.

After the seventh substation 41 the shell arrangements become suitable treatment rooms 29 transported for curing the tiles. Conveniently, the room includes a variety of shelves 28 for stacking the tray assemblies which simultaneously enable the flow of air and steam generated by a suitable controlled temperature processing system.

From the shelves 28 become the cup arrangements 5 taken, the hardened tiles included and can be transported to a finishing plant, denoted overall by the reference numeral 42 is characterized and an inlet 30 with a device 43 for removing the half-finished tile from the respective shell arrangement 5 which, when intended for reuse, is cleaned.

From the removal device 43 branches off a transport route, with which the half-finished tiles are moved through a plurality of finishing stations.

In the embodiment described here includes the finishing plant 42 successively a first and a second calibration station 31 and 32 which are provided with coarse-grained grinding wheels, so that it is possible to produce a raw tile, which is already suitable for laying in the field on-site finishing.

Subsequently, the plant has a third finishing station 34 It uses a series of fine and very fine grain grinding wheels to create a shiny surface that makes the tiles suitable for laying a finished floor.

Out the above description will be readily apparent that with the manufacturing process and the plant not only floor tiles but also any ceramic-like plane, such as Tiles for Floors, rubbing strips, Steps, walls, Bathroom, kitchen and Badeinbauten, various decorations, etc. manufactured can be.

The formats can be completely different and can be adapted to specific requirements. That is, the tray assemblies described above can be made on-site using sheets of plastic material that will heat to the required size can be shaped.

On this way it is possible Avoid cutting the tiles made by the cut the above explained establish the transitions between Tiles could become visible.

At A person skilled in the art will be able to add numerous additional advantages to the process described above Modifications and changes make extra and to meet special requirements, all in the Scope of the present invention are included as he by the attached claims is defined.

Claims (12)

A method for producing tiles and the like, which can be used as floor and support surface and reproduce in the used motifs and techniques so-called Venetian floors, the method comprising the phases: laying a first grout layer ( 70 ) on a flat bedding ( 50 ); Application of a quantity of gravel ( 9 ) on the surface of the first grout layer ( 70 ); Exposing the flat bedding ( 50 ) the Rüttelschwingungen, the partial sinking of the amount of gravel ( 9 ) into the first grout layer ( 70 ) determine; Laying a second layer of mortar on the first layer of mortar ( 70 ) by a semi-finished tile ( 12 ) is received; Shaking the entire half finished tile; and drying the semi-finished tile ( 12 ). Method according to claim 1, wherein the first layer of mortar ( 70 ) is moved by application of Rüttelschwingungen. The method of claim 1, wherein the second layer of mortar by using vibration vibrations is relocated. Method according to Claim 1, in which the laying on of Gravel is made according to a design and by means of a template. The method of claim 1, wherein a phase of the Grinding a surface the half-finished tile to a predetermined degree of finishing is provided. The method of claim 1, wherein partially grinding a surface the half-finished tile is provided. The method of claim 1, wherein a phase of the curing by drying with steam at a controlled temperature is. Method according to claim 1, wherein the flat bedding ( 50 ) is lubricated before the first layer of mortar ( 70 ). Investment ( 20 ) for producing Venetian floor tiles according to the method of claim 1, comprising a molding line ( 22 ), along which tray arrangements ( 5 ) are moved; with an inlet ( 21 ); a first substation ( 35 ) in which the cup assemblies are lubricated; a second substation ( 36 ) for laying a first layer of mortar ( 70 ); a third substation ( 37 ) with a vibration generating device ( 8th ) for the uniform laying of the first layer of mortar ( 70 ); a fourth substation ( 39 ) for distributing gravel ( 9 ) on the surface; a fifth substation ( 39 ) with a vibration generating device ( 8th ) for sinking gravel in the mortar; one with a second amount of mortar ( 11 ), sixth secondary station ( 40 ); and a seventh substation ( 41 ) with a vibration generating device. Investment ( 20 ) according to claim 9, wherein the fourth substation ( 38 ) is divided into several substations for placing different types of kies. Plant according to claim 9, the storage rooms ( 29 ) for hardening the tiles with a variety of shelves ( 28 ) to the cup assemblies ( 5 ), but which allow the passage of the air and the vapor generated by a suitably controlled air conditioning system. Investment ( 20 ) according to claim 9, having a transport path to move the semi-finished tiles through a plurality of finishing stations.