EP0414149B1 - Keramikplatte mit eingelegtem Ornament und Verfahren zu deren Herstellung - Google Patents

Keramikplatte mit eingelegtem Ornament und Verfahren zu deren Herstellung Download PDF

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Publication number
EP0414149B1
EP0414149B1 EP19900115808 EP90115808A EP0414149B1 EP 0414149 B1 EP0414149 B1 EP 0414149B1 EP 19900115808 EP19900115808 EP 19900115808 EP 90115808 A EP90115808 A EP 90115808A EP 0414149 B1 EP0414149 B1 EP 0414149B1
Authority
EP
European Patent Office
Prior art keywords
pattern
inlaying
tile
ceramic tile
sheet
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
EP19900115808
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English (en)
French (fr)
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EP0414149A3 (en
EP0414149A2 (de
Inventor
Mitsuo Morishita
Shogo Kamiya
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.)
Inax Corp
Original Assignee
Inax Corp
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Filing date
Publication date
Application filed by Inax Corp filed Critical Inax Corp
Publication of EP0414149A2 publication Critical patent/EP0414149A2/de
Publication of EP0414149A3 publication Critical patent/EP0414149A3/en
Application granted granted Critical
Publication of EP0414149B1 publication Critical patent/EP0414149B1/de
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
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0285—Feeding the unshaped material to moulds or apparatus for producing shaped articles the material being prearranged on a sheet, e.g. using a decal
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
    • 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
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/26—Inlaying with ornamental structures, e.g. niello work, tarsia work

Definitions

  • This invention relates to a method for producing a pattern-inlaid ceramic tile and to the resulting pattern-inlaid tile.
  • the inlaid tile can maintain the inlaid pattern semi-permanently even when the tile surfaces are worn out, and is useful for decorative tiles such as floor tile and wall tile.
  • Such a pattern-inlaid tile has been conventionally produced with handwork, for example, by (a) press-molding a colored tile body material at a lower pressure into small pieces for inlaying, (b) placing a tile body material in a press mold and then the colored pieces thereon in a desired pattern with manual operation, and press-molding them at a higher pressure into a pattern-embedded green tile body, and (c) firing the green body.
  • Such a conventional method needs several pressmolds for desired inlaying patterns, and manual operation for arranging the pattern on the tile body material. Moreover, it is difficult to produce fine precise patterns and also to reproduce the same inlaying patterns.
  • the main object of the present invention is to provide a method for producing a pattern-inlaid ceramic tile with less manual operation and with reproducible fine precise patterns.
  • a method for producing a pattern-inlaid ceramic tile which comprises the steps of: preparing a paste mixture consisting essentially of a sintering inorganic powder, a pigment, a binder and a solvent, and depositing the paste mixture onto a substrate sheet in a predetermined pattern and drying the deposited mixture to form an inlaying pattern sheet; placing in a mold the inlaying sheet and a body material for ceramic tile in such a fashion that the inlaying pattern contacts the body material, and press-molding them into a green tile body having the inlaying pattern embedded on the surface of the tile body; and then firing the resulting green embedded body to a sintering temperature.
  • the pattern-inlaid tile having natural stone tones can be obtained by combining the inlaying pattern with a tile body having colored dots.
  • a color-dotted tile body is produced from a substantially homogeneous mixture of two or more kinds of different-color particles for the tile body material.
  • two or more different-color paste mixtures are deposited in turn on the substrate sheet twice or more times through predetermined pattern openings to obtain a multicolored inlaying pattern sheet.
  • FIG.1 is a schematic cross-sectional view showing deposition, of an inlaying paste mixture onto a substrate sheet through a mask plate
  • FIG.2 is a schematic cross-sectional view of press-molding in a mold
  • FIG.3 is a schematic cross-sectional view of a green pattern-embedded tile body
  • FIG. 4 is a schematic cross-sectional view of a pattern-inlaid ceramic tile.
  • a sintering inorganic powder having a sintering temperature similar to that of a tile body material is used for the inlaying pattern sheet.
  • the sintering powder is selected to have a sintering shrinkage coefficient and a thermal expansion coefficient similar to those of the tile body material to be used, for example, within 5% in difference between those coefficients. It is generally convenient to use for the inlaying pattern a sintering inorganic powder similar to or identical with the tile body material, in view of the coefficients and good bonding properties between them.
  • the pigment for the inlaying pattern can be used those pigments conventionally, used for coloring ceramics.
  • the pigment is generally used in an amount of 0.5 to 30% by weight of the sintering inorganic powder.
  • the binder contained in the inlaying mixture is preferably those which can be burnt away at a sintering temperature of the ceramic tile body material and/or inlaying material, and is exemplified by carboxymethyl cellulose, methyl cellulose, starch paste, oil and the lake. Such binder is generally used in the paste mixture in an amount of 0.5 ⁇ 10% by weight of the inlaying mixture.
  • the solvent used to prepare the paste mixture includes, for example, water and aqueous solutions of lower alcohols.
  • the amount of the solvent is such that makes a paste mixture for screen-printing or depositing the paste onto the substrate (e.g. 3 to 20% by weight), as known by those skilled in the art.
  • additives conventionally used for ceramic tile materials may also be incorporated into the inlaying mixture.
  • the inlaying sheet 12 can be prepared by applying the paste mixture 3 onto a substrate sheet 1 in a desired pattern and thickness, for example, through a mask plate 2 having pattern openings or by means of screen printing to deposit the mixture, followed by drying.
  • the masking deposition can be effected by spraying or brush-coating.
  • the substrate sheet 1 is generally of flexible permeable materials such as pulp paper, paper board, woven or non-woven fabrics, etc. When a combustible substrate sheet is used, the sheet 1 is not always peeled off before firing. When incombustible substrate sheets are used, the sheet is normally peeled off prior to firing.
  • the ceramic tile body material 8 used herein consists essentially of sintering inorganic materials such, as pottery materials (e.g. a mixture of clay, agalmatolite and lime) or stoneware/porcelain materials (e.g. a mixture of talc, feldspar and clay).
  • the material 8 may contain a binder (e.g. C.M.C.) and 0.1 to 10% by weight of pigments as necessary.
  • colored finer particles contained in the tile body material 8 are apt to sink with non-uniform distribution in the mold, and may form a nonuniformly dotted pattern at the bottom of the tile body but a uniformly dotted pattern on the embedded top surface.
  • a tile body having granite tones can be obtained by using a homogeneous mixture of a particulate tile material containing black pigment and a white particulate material containing no pigment.
  • a tile body having semiprecious stone tones can be obtained by using a homogeneous mixture of two or more kinds of different-color particles for the tile body material.
  • the tile body material 8 and inlaying pattern sheet 12 are placed in a mold with either the inlaying pattern 4 on the tile body material 8 or the inlaying pattern 4 under the body material 8.
  • the materials in the mold 7 are press-molded usually under a pressure of 200 to 400 kgf/sq.cm to form a green tile body having the inlaying pattern 4 embedded on the surface of the tile body.
  • the resulting embedded tile body is then fired in a kiln or oven to a sintering temperature, usually 1000 to 1400°C.
  • the resulting pattern-embedded tile body 10 may be coated with a substantially transparent glaze agent after biscuit-firing to a temperature of usually from 1000 to 1300°C.
  • the glaze-coated tile body is then fired to a glazing or sintering temperature of usually about 1000 ⁇ 1400 °C, to produce a glazed pattern-inlayed ceramic tile.
  • the size of the pattern-inlaid ceramic tile 11 is usually in a range of 50mm ⁇ 50mm to 1000mm ⁇ 1000mm.
  • the thickness thereof is usually 5 to 35mm.
  • the thickness of the inlaid pattern layer is usually 0.3 to 5mm and generally about 1/10 to 1/4 of the whole thickness of the inlaid ceramic tile 11.
  • the total surface area of the inlaid pattern layer is usually 1 to 80% of the top surface area of the inlaid ceramic tile.
  • the level of the inlaid pattern 4 is substantially identical with or slightly lower than uninlaid top surfaces of the tile body. The inlaid patterns are thus durable against wearing and exhibit sharp pattern lines, even when glazed.
  • the inlaid patterns having desired designs and thickness can be readily formed on a ceramic tile simply by changing the pattern of the mask 3 or screen for the deposition and the thickness of the inlaying material on the sheet. Moreover, the shape of the pattern can be retained by the binder contained in the inlaying material and the binder can be burnt away after firing of the embedded ceramic tile. Since inlaying patterns 4 are formed by depositing the inlaying material 3 through a mask plate 3 or screen onto a substrate sheet 12, the same patterns can be readily reproduced with fine precise tones.
  • An inlaying material was prepared by mixing 100 parts of an inorganic sintering powder comprising 60% of talc, 30% of feldspar and 10% of clay, with 15 parts of a purple pigment, 6 parts of starch paste (a binder) and water to give a paste mixture 3.
  • the binder serves to bond these materials to one another and to maintain the shape of the resulting inlaying pattern.
  • a masking plate 2 having openings of curved line patterns was placed on a non-woven fabric substrate sheet 1 as shown in FIG. 1.
  • the inlaying material 3 was applied by spraying it onto the substrate sheet 1.
  • the inlaying material 3 was then dried to such a water content (e.g. 4%) as low as that of a tile body material, to obtain an inlaying pattern sheet 12.
  • a porcelain tile body material 8 was placed in a mold cavity 7 formed by a lower mold portion 5 and side mold portions 6.
  • the body material 8 was prepared by mixing 60% of talc, 30% of feldspar, 9% of clay, 1% of CMC and water, and spray-drying the mixture to give particles (mean particle size: 0. 4mm).
  • the inlaying pattern sheet 12 was placed on the tile body material 8 in the mold with the pattern layer 4 downwards.
  • An upper mold portion 9 was applied onto the substrate sheet.
  • the materials in the mold were press-molded with a pressure of 320 kgf/sq.cm to give a molded tile body 10 wherein the inlaying patterns 4 were embedded as shown in FIG.3.
  • the molded tile body 10 was dried and then fired to a maximum temperature of 1250°C in a roller hearth kiln. During firing, the substrate sheet 1 and binder were burnt away. Thus, there was obtained an inlaid tile 11 of 300 ⁇ 300 ⁇ 8mm (thickness) having purple curved line patterns 4 of about 2mm thick inlaid onto the surface of the tile 11. The area of the pattern layer 4 was about 2% of the top tile surface area. Cracks and deformation such as warping were not observed in the resulting inlaid tile.
  • Example 1 The processes of Example 1 were repeated except the following steps to obtain a glazed multi-color pattern inlaid tile.
  • inlaying paste materials were prepared, which contained 10 parts by weight of green, purple and yellowish green pigments to 100 parts of the sintering powder, respectively.
  • Flower petal patterns were screen-printed through three different screens in turn on a pulp paper substrate with the green, purple and yellowish green paste materials, wherein each printed layer was 0.3mm thick and overprinted layers were 0.9mm thick, followed by drying to obtain an inlaying pattern sheet.
  • Three colored porcelain materials were prepared by mixing 0.5 part of yellow pigment, 5 parts of red pigment and 5 parts of black pigment, respectively with 100 parts of the porcelain material powder. Each colored material was spray-dried into particles of 0.4mm in mean size. A tile body material was then prepared by homogeneously mixing 25% of the yellow particles, 50% of the red particles and 25% of the black particles.
  • the resulting mixed tile body material was placed in the mold, and the resulting inlaying sheet was placed on the tile body material with the inlaying pattern downwards.
  • the materials in the mold were press-molded as in Example 1.
  • the pulp paper substrate sheet was peeled off from the green molded article.
  • the green pattern-embedded tile was fired to 1100°C.
  • the top surface of the biscuit-fired tile was coated with a substantially transparent glaze agent and then fired to a maximum temperature of 1250°C in a roller hearth kiln.
  • a glazed multi-color pattern inlaid tile 300 ⁇ 300 ⁇ 8mm (thickness) was obtained, which had petal patterns of green, purple and yellowish green colors of about 0.3 to 0.9mm thick inlaid onto a tile body having semiprecious stone tones composed of yellow, red and black dots.
  • the area of the inlaid patterns was about 30% of the top tile surface area. Cracks and deformation such as warping were not observed in the resulting inlaid tile.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Finishing Walls (AREA)

Claims (9)

  1. Verfahren zur Herstellung einer Keramikplatte (11) mit eingelegtem Ornament mit den Schritten:
       Zubereiten einer Pastenmischung (3), die im wesentlichen aus anorganischem Sinterpulver, einem Pigment, einem Binder und einem Lösemittel besteht, und Aufbringen der Pastenmischung (3) auf eine Trägerunterlage (1) durch eine vorgegebene Ornamentschablone und Trocknen der aufgebrachten Mischung, um eine Unterlage (12) mit dem Einlegeornament zu bilden;
       Einbringen der Einlegeornamentunterlage (12) und eines Körpermaterials (8) für Keramikplatten in eine Form (7) in der Art, daß das Einlegeornament (4) mit dem Körpermaterial (8) in Berührung steht, und Formpressen dieser zu einem Plattenkörperrohling (10), in dessen Oberfläche das Einlegeornament (4) eingebettet ist; und dann
       Brennen des entstandenen Einbettungskörperrohlings (10) bis zu einer Sintertemperatur.
  2. Verfahren nach Anspruch 1, bei dem eine im wesentlichen homogene Mischung aus zwei oder mehr Arten Plattenkörpermaterialen mit verschiedenen Farbteilchen als das Körpermaterial für die Keramikplatte verwendet werden.
  3. Verfahren nach Anspruch 1 oder 2, bei dem das Körpermaterial für die Keramikplatte in die Form eingebracht wird und dann die Einlegeornamentunterlage darauf in der Art aufgebracht wird, daß das Einlegeornament mit dem Körpermaterial in Berührung steht.
  4. Verfahren nach Anspruch 1, 2 oder 3, bei dem die Pastenmischung auf die Trägerunterlage mittels einer Ornamentmaskenschablone aufgebracht wird.
  5. Verfahren nach Anspruch 1, 2 oder 3, bei dem die Pastenmischung auf die Trägerunterlage mittels Siebdruck aufgebracht wird.
  6. Verfahren nach einem der Ansprüche 1 bis 5, bei dem zwei- oder mehrfarbige Pastenmischungen abwechselnd auf der Trägerunterlage zweimal oder mehrere Male aufgebracht werden, um eine vielfarbige Einlegeornamentunterlage zu erhalten.
  7. Verfahren nach einem der Ansprüche 1 bis 6, bei dem der Plattenkörperrohling mit dem eingebetteten Ornament glühgebrannt wird, dann mit einem im wesentlichen transparenten Glasurmittel beschichtet wird und dann fertig gebrannt wird.
  8. Keramikplatte mit eingelegtem Ornament, die nach einem der Ansprüche 1 bis 7 herstellbar ist.
  9. Keramikplatte nach Anspruch 8, bei der die Keramikplatte mit dem eingelegten Ornament eine im wesentlichen transparente Glasurschicht auf ihrer Oberseite aufweist.
EP19900115808 1989-08-19 1990-08-17 Keramikplatte mit eingelegtem Ornament und Verfahren zu deren Herstellung Expired - Lifetime EP0414149B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP21391989A JPH0620734B2 (ja) 1989-08-19 1989-08-19 象嵌模様タイルの製造方法
JP213919/89 1989-08-19

Publications (3)

Publication Number Publication Date
EP0414149A2 EP0414149A2 (de) 1991-02-27
EP0414149A3 EP0414149A3 (en) 1991-10-16
EP0414149B1 true EP0414149B1 (de) 1993-12-29

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP19900115808 Expired - Lifetime EP0414149B1 (de) 1989-08-19 1990-08-17 Keramikplatte mit eingelegtem Ornament und Verfahren zu deren Herstellung

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EP (1) EP0414149B1 (de)
JP (1) JPH0620734B2 (de)
DE (1) DE69005561T2 (de)

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2057717T3 (es) * 1990-11-30 1994-10-16 Inax Corp Metodo para la fabricacion de alfareria vidriada provista de motivos veteados o jaspeados.
IT1257499B (it) * 1992-05-07 1996-01-25 Mass Spa Stampo per la formatura di materiali ceramici, tipicamente piastrelle pressosmaltate, e relativi mezzi di carico
IT1257498B (it) * 1992-05-07 1996-01-25 Mass Spa Stampo ceramico per la formatura di piastrelle, e relativi mezzi di carico
IT1263440B (it) * 1993-06-21 1996-08-05 Rodiero Alieri Procedimento per decorare piastrelle ceramiche e piastrelle cosi' ottenute.
JP3406105B2 (ja) * 1995-01-13 2003-05-12 横浜ゴム株式会社 空気入りタイヤ
KR100360624B1 (ko) * 1999-08-27 2002-11-18 한국민예 주식회사 건축마감재용 도판의 제조방법 및 그 제품
DE10108327C1 (de) * 2001-02-21 2002-09-05 Klingenberg Dekoramik Gmbh Verfahren zum Dekorieren von Formkörpern und Vorrichtung zur Durchführung des Verfahrens
WO2002070217A2 (en) * 2001-03-02 2002-09-12 Shouldice Designer Stone Ltd. Method for creating concrete blocks with the appearance of natural fossil stone
JP4756216B2 (ja) * 2005-12-02 2011-08-24 株式会社ウイルコ 返信用封筒付き用紙
WO2011021673A1 (ja) * 2009-08-19 2011-02-24 相田化学工業株式会社 木目金模様を備える装飾金属物品の製造方法および木目金模様を備える装飾金属物品
GB2569118B (en) * 2017-12-05 2021-02-17 Bentley Motors Ltd Automotive components comprising ceramics, novel inlays and methods of forming same

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1963834A (en) * 1933-01-14 1934-06-19 Moto Mcter Gauge & Equipment C Method of ornamentation
US4085176A (en) * 1972-08-18 1978-04-18 Japan Non-Slip Pavement Co., Inc. Method of manufacturing non-slip pavement blocks
US4254077A (en) * 1979-09-10 1981-03-03 Fontana John D Method for making decorative inlaid concrete blocks
FR2567292A1 (fr) * 1984-07-09 1986-01-10 Hutchinson Procede et dispositif de fabrication d'elements de commande et/ou d'identification et elements de commande et/ou d'identification obtenus par ces procede et dispositif
ES2006499A6 (es) * 1986-09-24 1989-05-01 Azienda Srl Metodo para la realizacion de una baldosa ceramica vitrificada o esmaltada

Also Published As

Publication number Publication date
JPH0376602A (ja) 1991-04-02
EP0414149A3 (en) 1991-10-16
JPH0620734B2 (ja) 1994-03-23
DE69005561D1 (de) 1994-02-10
EP0414149A2 (de) 1991-02-27
DE69005561T2 (de) 1994-07-21

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