EP2036694B1 - Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness - Google Patents

Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness Download PDF

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Publication number
EP2036694B1
EP2036694B1 EP07116535.1A EP07116535A EP2036694B1 EP 2036694 B1 EP2036694 B1 EP 2036694B1 EP 07116535 A EP07116535 A EP 07116535A EP 2036694 B1 EP2036694 B1 EP 2036694B1
Authority
EP
European Patent Office
Prior art keywords
slurry
pattern forming
pattern
tray
forming unit
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.)
Not-in-force
Application number
EP07116535.1A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2036694A1 (en
Inventor
Terdwong Jamrussamee
Arag Himtong
Wittaya Chuajiw
Watthanakun Phabutta
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.)
SCG Building Materials Co Ltd
Original Assignee
SCG Building Materials Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by SCG Building Materials Co Ltd filed Critical SCG Building Materials Co Ltd
Priority to PT71165351T priority Critical patent/PT2036694E/pt
Priority to ES07116535.1T priority patent/ES2470140T3/es
Priority to PL07116535T priority patent/PL2036694T3/pl
Priority to EP07116535.1A priority patent/EP2036694B1/en
Priority to MX2007011554A priority patent/MX2007011554A/es
Priority to TW096135120A priority patent/TWI401146B/zh
Priority to KR1020070096056A priority patent/KR20080027449A/ko
Priority to MYPI20071579A priority patent/MY154412A/en
Priority to CA002603282A priority patent/CA2603282A1/en
Priority to JP2007243497A priority patent/JP5435851B2/ja
Priority to AU2007216889A priority patent/AU2007216889A1/en
Priority to CN2007103051147A priority patent/CN101186080B/zh
Priority to BRPI0705308-8A priority patent/BRPI0705308B1/pt
Priority to RU2007135042/03A priority patent/RU2443551C2/ru
Priority to US11/859,684 priority patent/US8333916B2/en
Publication of EP2036694A1 publication Critical patent/EP2036694A1/en
Application granted granted Critical
Publication of EP2036694B1 publication Critical patent/EP2036694B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/06—Moulds with flexible parts
    • 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
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/022—Feeding several successive layers, optionally of different materials
    • 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
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/0275—Feeding a slurry or a ceramic slip
    • 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
    • B28B13/0295—Treating the surface of the fed layer, e.g. removing material or equalization of the surface
    • 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
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
    • B28B5/021—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of definite length
    • B28B5/022—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of definite length the moulds or the moulding surfaces being individual independant units and being discontinuously fed
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
    • B28B7/46—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying

Definitions

  • One of the known methods of doing this is by loading dry soil powder inside a container and then discharging said content through the opening of discharging tubes of the said container into a vertical compartment forming layers of different types and colors of soil powder inside said compartment.
  • the said compartment is then rotated 90 degrees to transfer the content to a horizontal mold.
  • the content is then pressed together under high pressure forming it into a ceramic tile.
  • Different layers of different types of soil powder and colors translate into the tile pattern.
  • the problem associated with this method is that there are difficulties with controlling the amount of soil powder released into the compartment resulting in an inability to regulate and vary the width of color band.
  • the patterns that can be obtained are limited.
  • the rotation of the compartment causes the soil granules to shift, resulting in distortion of the pattern.
  • the obtained tiles must be subjected to further surface treatment after firing to reveal the pattern.
  • European Patent No. EP1273408 and International Publication No. W02004071733 disclosed a technique to make continuous veining of patterns extending through the entire thickness of tiles or slabs.
  • materials on the surface layer will mix together, causing the desired pattern to be distorted.
  • European Patent EP 1334811 disclosed a technique for making patterns throughout the mass of the ceramic tiles which is characterized by a double-pressing that comprises of first a low pressure compacting.
  • the compacted ceramic tiles are subsequently decorated by an ink-jet system to apply, according to the design, special ceramic colors which can penetrate into the tile mass.
  • appearance of the patterns in the tile mass is somewhat blurred or partial and the level of depth of pattern penetration is not deep enough to provide the pattern to the lowest layer of the tile mass.
  • Documents CN2054409U , CN100546788C and CN1083799A disclose methods and apparatus for forming a pattern on a green ceramic tile.
  • compositions are mixed imperfectly such as to generate a pattern which does not run through the entire thickness of the body; because the matrial is not first fed to a pattern forming unit before being delivered to the filter pressing.
  • the scope of the invention is to provide an apparatus and method for forming a pattern in ceramic tiles with prescribed thickness, wherein the pattern runs through the entire thickness of the tiles or slabs.
  • the method of forming the pattern imitates natural rock formation so that the obtained pattern closely resembles a pattern of natural rocks.
  • the apparatus is equipped with means for controlling position, amount, and order of different types and different colors of slurry so as to form predetermined or desired patterns.
  • Another objective of the invention is that by employing the apparatus according to the principles described herein, the tile or slab obtained will be of consistent thickness and size.
  • the method of the invention provides the use of a material in slurry form instead of a material in powdery form.
  • the invention relates to an apparatus and method for forming a desired pattern on ceramic tiles with prescribed thickness starting from a material in slurry form.
  • the desired pattern is achieved by controlling the position, amount, and order of different type and colors of a slurry wherein a predetermined amount and order of the slurry are deposited in a predetermined position in a pattern receiving tray.
  • the slurry is then pressed in a filter press unit to form a green ceramic slab ready for further decoration and firing.
  • a preferred embodiment of the apparatus for forming desired patterns on ceramic tile with prescribed thickness (1) comprises slurry holding tanks (100), pattern forming unit (200) connected to the slurry holding tanks (100) by delivering tubes, pattern forming tray (300), pattern decorating accessories (400) and a filter press unit (500) which compatibly operates in a flow as shown in Fig. 1 .
  • the pattern forming unit dispenses a predetermined type, amount, colors of slurry at a predetermined order into the pattern forming tray to form a desired pattern, said slurry with desired pattern is pressed with the filter pressing unit to form ceramic tiles or slabs with a desired pattern running though its entire thickness.
  • the holding tank (100) is capable of holding soil slurry to be used to produce the tiles. There could be more than one holding tank (100) to contain different types and colors of the slurry.
  • the holding tank (100) has a means to reduce precipitation of the slurry so as to promote flow or plasticity of the slurry to the patterning forming unit.
  • the inside of the tank may be equipped with at least one agitator (110) to encourage movement of the slurry, or the holding tank (100) may sit on a movable base (not shown) so that movement of the holding tank (100) causes the content inside to move continuously.
  • the holding tank (100) may be equipped with heating unit (not shown) with a means to control the temperature of the slurry to a desired range so as to reduce viscosity of the slurry.
  • the pressure inside the holding tank (100) is maintained.
  • the holding tank (100) is connected to delivering tubes (105) to deliver the slurry to a pattern forming unit (200).
  • the pattern forming unit (200) is connected to the slurry holding tank (100) by delivering tubes (105).
  • the pattern forming unit (200) can accommodate more than one delivering tube (105) wherein the slurry under controlled pressure (or under controlled pressure and/or controlled temperature) is delivered.
  • the delivering tube (105) at the pattern forming unit (200) is fitted with a valve (205) in order to regulate the amount and the color of the slurry to be dispensed into the pattern forming unit (200).
  • the end of the delivering tube (105) inside the pattern forming unit (200) is fitted with removable end piece (210) with desired configurations and end configurations. Different configuration of the end piece (210) and its end contribute to vary the pattern being formed or to produce predetermined patterns.
  • the pattern forming unit (200) has a slurry holding portion (215) capable of holding the slurry dispensed from the delivering tubes (105). Different types and colors of the slurry are allowed to mix in this portion so as to create different lines and streaks.
  • the end of the pattern forming unit (200) is fitted with a removable dispensing member (220).
  • the opening end of the dispensing member (220) can be of any desired known configuration to create further variation of the lines and streaks once the slurry is dispensed into the pattern forming tray (300).
  • the dispensing member (220) maybe equipped with a valve (225) to regulate the amount and speed of the slurry being dispensed as shown in Fig. 2 .
  • the pattern forming unit (200) is fitted with more than one dispensing member (220).
  • the dispensing member (220) is capable of rotating in a circular motion in accordance with the predetermined position and the colors of the slurry to be deposited into the pattern forming tray (300).
  • the entire pattern forming unit (200) is also capable of moving in all directions, such as left, right, backward, and forward or in a circular motion relative to the shape and size of the pattern forming tray (300).
  • the movement of the pattern forming unit (200), the speed of the movement as a whole, the movement of the dispensing member (220), and the degree of opening of the valve (205) fitted at the delivering tubes and/or at the valve (225) end of the dispensing member (220) are regulated by a software application developed for this purposes wherein a desired pattern is pre-coded in the application.
  • the pattern forming unit (200) is fitted with a means to promote or maintain flow of the slurry.
  • the said means is defined as at least one agitator (230) situated inside the slurry holding portion (215).
  • the agitator (230) not only promotes and maintains the flow of the slurry, but also helps with the-mixing and blending of the slurry.
  • the configuration and the speed of the movement of the agitator (230) also helps to create patterns with different characteristics as the size and speed of the agitator will affect the size of the lines and streaks of the slurry being dispensed therefrom.
  • Fig. 4 shows further embodiment of the pattern forming unit (200).
  • the pattern forming unit (200) is further equipped with a pattern receiving tray (235).
  • This particular embodiment is suitable for producing a ceramic tile or slab with assorted colors or patterns or a tile or slab with different color tones.
  • the slurry is dispensed from the dispensing member (220) into a pattern receiving tray (235) and is subsequently dispensed into the pattern forming tray (300) instead of being dispensed directly into the pattern forming tray (300).
  • the desired pattern is formed.
  • the pattern receiving tray (235) is movable across the pattern forming tray (300) and comprises a body (240) for containing the slurry, a means for mixing the slurry and driving the slurry toward the opening located at the bottom region of the pattern receiving tray (235),: said means is defined as a spiral screw (245) positioned across said opening in the bottom region.
  • the bottom of the pattern receiving tray (235) is fitted with an open-close member (260) through which the slurry is dispensed into the pattern forming tray (300).
  • the size of the pattern receiving tray (235) should correspond with the size of the pattern forming tray (300),: more preferably, the length of the body (240) should be around the same size as the width of the pattern forming tray (300) if the slurry is to be distributed into the pattern forming tray (300) lengthwise.
  • the body (240) of the pattern receiving tray (235) may be divided into smaller compartments (250) using the zoning board (255) wherein each compartment (250) can hold the slurry with different colors or different combination of colors or combination of colors with various tones or different based patterns formed within the slurry holding portion (215).
  • the zoning boards (255) are removably fixed to the body (240) so that the size of the compartment (250) may be adjusted by adding or removing the number of the zoning board (255) or by moving the zoning board (255) along the body (240). Zoning the body (240) of the pattern receiving tray (235) will improve the definition of the pattern as it reduces the degree that slurries with different colors and/or patterns mix with one another.
  • the spiral screw (245) which is located in the bottom region of the patter receiving tray (235) is set along the length of the body (240) of the pattern receiving tray (235).
  • the spiral screw (245) is capable of turning on its axis.
  • the number and size and distance of the spiral may be varied to create patterns with different sizes of color bands or streaks or lines or different variations of the pattern.
  • the movement of the spiral screw (245) may be controlled by suitable electronic devices or pre-coded in the software application.
  • the movement of the spiral screw (245) drives the slurry toward the opening at the bottom of the pattern receiving tray (235) for which the slurry is distributed in-to the pattern forming tray (300).
  • the speed of the movement of the spiral screw (245) contributes to variation of the pattern being formed as well.
  • the pattern forming unit (200) While the pattern forming unit (200), with or without the pattern receiving tray (235), dispenses the slurry into the pattern forming tray (300), the pattern forming unit (200) will move along and/or across the pattern forming tray (300) to evenly distribute the slurry.
  • the spiral screw (245) will turn continuously, driving the slurry through the opening of the open-close member (260) (see Fig. 5 ) located at the bottom of the pattern receiving tray (235) which will be in its open state when the slurry is being dispensed.
  • the amount of total weight of the slurry being dispensed is controlled by a weight sensor with the scale (not shown) underneath the pattern forming tray.
  • the pattern forming tray is positioned on a weighing device while the slurry is being distributed.
  • the weighing device is linked to the software application. Once the amount of the slurry reaches the predetermined weight, the weighing device will activate and the dispensing unit (200) will temporarily withhold dispensing and the open-close member (260) will move to a closed state and the pattern forming unit (200) will resume its starting location. The pattern forming unit (200) will resume dispensing when a fresh pattern forming tray (300) moves into position.
  • the amount of the slurry being dispensed from the dispensing member (220) into the pattern receiving tray (235) should correspond with the amount of the slurry being dispensed from the pattern receiving tray (235) to the pattern forming tray (300) so as to reduce the problem with overflow or shortage of the slurry.
  • Fig. 5 shows further embodiment of the pattern receiving tray (235).
  • This embodiment of the pattern receiving tray (235) is larger in size and capable of holding a larger quantity of the slurry for producing larger ceramic tiles or slabs.
  • the large quantity of the slurry creates higher pressure inside the tray making it difficult to control the flow of the slurry. Therefore, in this embodiment, the pattern receiving tray (235) is further provided with an open-closed lid (265) and a high definition pneumatics system (270). After the desired quantity of the slurry is transferred into the pattern receiving tray (235), the open-close lid (265) is then closed, and the air inside the tray is removed to create a vacuum environment.
  • the slurry is then dispensed by controlling the pneumatic system in combination with controlling the open-close member (260) at the bottom of the pattern receiving tray (235) to open and close as needed.
  • the opening of the open-close member (260), the speed of the spiral screw (245), and the pressure inside the pattern receiving tray (235) is then regulated and maintained by the software application to achieve the desired pattern.
  • the pattern forming tray (300) acts as a mold for the tiles or slabs as its shape and size must correspond with the shape and size of the desired tile or slab.
  • the pattern forming tray (300) comprises a frame (305) and a filter sheet (310) assembled on top of one another wherein the frame (305) forms into a border of the pattern forming tray (300).
  • a rectangular pattern forming tray (300) having an outer closed frame border is necessary to produce a rectangular tile or slab.
  • the pattern forming tray (300) comprises only an outer closed frame border.
  • Fig. 7 shows further embodiment of the pattern forming tray (300) with an empty space in the middle of the tray.
  • the forming tray comprises also at least one inner closed frame border at designated position defining an empty space inside the tray.
  • This embodiment of the pattern forming tray (300) is suitable for producing ready - to - use items, such as, sink counter or kitchen counter top, without having to modify the slab to suit the need.
  • the additional empty space featured in the pattern forming tray (300) includes but is not limited to square, rectangular, circular, oval, and other desired free forms to suit the utilization of the tile or slab.
  • the pattern forming tray (300) comprises a frame (305) and a filter sheet (310) assembled on top of one another.
  • the frame (305) may be of any desired shapes assembled on top of the filter sheet.
  • the frame (305) is made from a flexible material which can withstand high pressure and return to its original shape after the pressure is removed.
  • the frame (305) may be made from the material or combination of materials selected from natural rubber, natural polymer, synthetic rubber, thermoplastic elastomer, silicone rubber, butadiene rubber, ebonite rubber, elevated temperature vulcanized rubber, urethane rubber, fluorine rubber, neoprene rubber and the like or metal specifically designed to flex under high pressure.
  • the height of the frame (305) determines the maximum quantity of the slurry that can be held. Thus, the height of the frame (305) must be at least the height of the desired tile or slab.
  • the filter sheet (310) forming the bottom of the pattern forming tray (300) is a porous sheet capable of containing the slurry under normal conditions, but which allows water and particles smaller than the size of the pores of the filter sheet (310) to pass through when pressure or weight is applied. It is important that the filter sheet (310) should have suitably sized pores to prevent too many particles from passing through, resulting in the waste of the slurry.
  • the materials for making the filter sheet (310) may be selected from wool fiber, nylon, metal wire mesh, polypropylene, polyester, polybuthylene, and polyamide.
  • the pattern forming trays (300) should be connected to one another forming into a conveyer to support automatic or semi-automatic production.
  • each pattern forming tray (300) should preferably be detachable and replaceable when replacement or maintenance is needed.
  • the pattern decoration accessory (400) may be used to achieve the desired pattern effects.
  • the pattern decorating accessories (400) may operate synchronously with the pattern forming unit (200) or after the pattern forming unit (200) has completed its cycle of pattern formation.
  • the pattern decorating accessory (400) can be of various forms and shapes and configurations as long as it can perform by dragging, dipping, stirring, mixing or sweeping across or into the formed pattern.
  • Fig. 6 shows an example of the embodiment of the pattern decorating accessory (400).
  • the pattern decorating accessory (400) has a plurality of tooth - like extensions from a body.
  • the body is connected to an electronic device (not shown) which is capable of controlling the movement of the pattern decorating accessory (400).
  • the teeth may be connected to the body by simple locking or coupling elements or a snapped on joint so that the teeth may be replaced with a different configuration when needed.
  • the movement of the pattern decorating accessory (400) may be controlled by being pre-coded in the software application as with the pattern forming unit (200) so as to achieve a predetermined pattern.
  • the formed pattern inside the pattern forming tray (300) is ready for pressing.
  • the pattern forming tray (300) moves toward the filter pressing unit (500).
  • the filter pressing unit (500) as shown in Fig. 11 operates under the same principles as with a general hydraulic pressing machine, by applying pressure onto the object.
  • the filter pressing unit according to this invention is a wet pressing unit. The objective is to remove as much excess water from the slurry as possible, leaving a green ceramic tile or slab with the water content commonly known in the ceramic tile industry to be suitable for drying.
  • the filter pressing unit (500) comprises an upper punch (505), a lower punch (510), shape retaining frame (515), a vacuum pump (not shown), and may be further fitted with a heating and temperature control unit and a wind generator.
  • the upper punch (505) is made of metal, high strength ceramic, or composite materials with a flat face.
  • the surface of the flat face is porous, i.e. prepared with small holes distributed evenly throughout the face.
  • the face is fitted with a shape retaining frame (515).
  • the shape of the shape retaining frame (515) must correspond to the shape of the pattern forming tray (300).
  • the shape retaining frame (515) is rectangular to correspond with the rectangular pattern forming tray (300).
  • the upper punch (505) is prepared with a drain (not shown).
  • the upper punch (505) operates under hydraulics and is capable of moving toward a fixed lower punch (510) so as to press the slurry contained in the pattern forming tray (300) positioned between them.
  • the excess water and slurry particles smaller than the pore size of the filter sheet (310) will escape through the pores of the filter sheet (310) and through the holes prepared on the face of the upper punch (505) and will be collected in the drain for disposal.
  • the lower punch (510) is made of metal with a flat face.
  • the surface of the flat face is porous, i.e. prepared with small holes distributed evenly throughout the face.
  • the face is fitted with a shape retaining frame (515').
  • the shape of the shape retaining frame (515') must correspond to the shape of the pattern forming tray (300).
  • the lower punch (510) is fixed to a position and is also provided with a drain.
  • the shape retaining frame (515) on the upper punch should be at the same position as the retaining frame (515') on the lower punch such that during pressing the face of the shape retaining frame on the upper punch (505) meets or almost meets with the face of the shape retaining frame (515') on the lower punch (510) when maximum pressure is applied enclosing the pattern forming tray (300).
  • the shape of the shape retaining frames (515-515') must correspond to the shape of the pattern forming tray (300).
  • the size of the shape retaining frames (515-515') should be slightly larger than the pattern forming tray (300) because, during the pressing, the pattern forming tray (300) is positioned inside the shape retaining frames (515-515').
  • the frame of the pattern forming tray (300) which is made from flexible materials will distort under pressure which could cause distortion of the shape or the pattern of the tile or slab. Therefore, the shape retaining frames (515-515') will reduce this problem.
  • the shape retaining frames (515-515') on the incoming direction and out-going direction should be able to move up and down or forward or backward such that it is level with the surface of the lower punch (510).
  • the shape retaining frames (515-515') on the incoming direction will retract, allowing the pattern forming tray (300) to move into position.
  • the pattern forming tray (300) will stop moving and the incoming side of the shape retaining frames (515-515') will resume its position securing the pattern forming tray (300) inside.
  • the outgoing side of the shape retaining frames (515-515') will retract, allowing the pattern forming tray (300) to move forward out of the filter pressing unit (500). Thereafter, the incoming side of the shape retaining frames (515-515') will retract again to anticipate the incoming of the next pattern forming tray (300) and the out-going side will resume its position.
  • the shape retaining frames (515-515') are prepared with a means to adjust it height.
  • the height of the shape retaining, the height of the frame (305) of the pattern forming tray (300) and its ability to retract when pressed, the amount of the slurry contain inside the pattern forming tray (300) are all inter-dependent.
  • the ability to retract or reduce the height of the frame (305) when pressed at maximum pressure is a known value.
  • the height of the shape retaining frames (515-515') should be set at equal to or slightly lower than the height of the frame (305) after pressing so that during pressing the face of the upper punch (505) presses against the slurry contained in the shape forming tray (300) and against the frame (305). The pressure is gradually increased to a maximum pressure.
  • the frame At the maximum pressure the frame will reduce its height to a maximum level which is equal to or slightly higher than the height of the shape retaining frame (315') on the lower punch (510) and the face of the shape retaining frame (315) on the upper punch (505) will meet or almost meet with the face of the shape retaining frame on the lower punch (510) so that as much excess water is extracted from the slurry as possible.
  • the height of the shape retaining frames (515-515') may be adjusted accordingly and the height of the frame (305) may be adjusted by using a frame (305) with a different height or switching to a frame made from different materials which possess different retraction values.
  • the shape retaining frames (515-515') as well as the frame (305) may also be prepared with holes as with the upper punch (505) and the lower punch (510) so that the water may pass through faster and shorten the time needed to extract the water out of the slurry.
  • the shape retaining frame (515) is removable for maintenance and is replaceable when worn.
  • the excess water is collected in the drain of the upper punch (505) as well as in the drain of the lower punch (510). The water is then removed by the vacuum pump after pressing is completed. The wind generator helps to drive the excess water toward the drain.
  • the filter pressing unit (500) may be equipped with a heating unit with a temperature control device so as to reduce viscosity of the slurry, making it easier to extract the excess water out of the slurry.
  • the apparatus further preferably comprises a cleaning station wherein after pressing is completed and the green tile or slabs has been removed the filter and the pattern forming tray is cleaned before re-entering the production system
  • the method of forming a desired pattern in ceramic tiles or slabs according to this invention comprises the followings steps:
  • the slurry, in which a desired pattern has now formed, is pressed by a filter pressing unit.
  • Raw materials for producing ceramic tiles or slabs are ground in a wet ball mill to achieve the slurry.
  • the slurry comprise dry materials ranging from 30%-70% by weight to achieve slurry with suitable viscosity.
  • Additives or admixtures such as deflocculant, dispersant, flocculant, defoaming agent, or surfactant may or may not be added into the slurry depending on the characteristics and properties of the raw materials.
  • the particle size of the raw material after grinding, and the ratio of different types of raw materials are some of the factors to determine whether an additive or admixture is needed.
  • the desired property of the ceramic tile or slab can sometimes play a role in considering whether an additive is needed as well.
  • strength enhancing additives such as Polyvinyl alcohol (PVA), Polyvinyl acetate (PVAc), Carboxymethyl cellulose (CMC), Methylcelllulose, Ethylenevinyl acetate (EVA), starch, modified starch, cellulose fiber, organic fiber, inorganic fiber, etc.
  • PVA Polyvinyl alcohol
  • PVAc Polyvinyl acetate
  • CMC Carboxymethyl cellulose
  • starch modified starch
  • Ceramic pigments or flakes may be added to the slurry to achieve the desired colors.
  • the pigment may be added during grinding or added into the slurry after grinding is completed. The latter is preferred as the slurry obtained will have consistent colors creating higher quality products.
  • the slurry is held in a holding tank (100) separating different colors.
  • the pressure inside the tank is maintained.
  • the slurry is maintained at room temperature and or if required may be heated up to 70 degree Celsius.
  • the slurry is then continuously delivered to the pattern forming unit (200) by delivering tube while maintaining the pressure.
  • the flow rate of the slurry from the holding tank (100) to the pattern forming unit (200) is regulated by the pressure inside the holding tank (100) in combination with regulating the valves (205) at the end of the delivering tubes (105) at the pattern forming unit (200).
  • a predetermined quantity of the slurry in accordance with the predetermined values is then dispensed into the pattern forming unit (200).
  • the surplus amount of the slurry is returned back to the holding tank to maintain the quality of the slurry and to reduce precipitation and clogging of the delivering tube.
  • different types and colors of the slurry are delivered to the pattern forming unit (200). More than one type or color of slurry may be delivered to the pattern forming unit (200) at any one time. Different types or colors of the slurry are allowed to mix inside the pattern forming unit (200). The amount of the slurry with different colors, order of the colors, and position to be distributed will affect the outcome of the patterns. Accordingly, the values of these parameters are controlled by pre-coding these values into a software application, in combination with controlling the pressure inside the delivering tubes (105) and the valves (205) fitted at the end of the delivering tubes (105) at the pattern forming unit (200).
  • the slurry is then dispensed through the dispensing member (220) fitted at the bottom of the pattern forming unit (200).
  • the amount of the slurry being dispensed may be further controlled by regulating the valve fitted at the dispensing member (220).
  • the pattern forming unit (200) While dispensing the slurry, the pattern forming unit (200) will move in response to the pre-coded values to regulate movement of the pattern unit (200) in order to deposit and distribute the slurry to the predetermined position in the tray so as to achieve the desired pattern.
  • the pattern forming unit may be moved left, right, backward, forward, and or in circular motion (or in, x, y, z axis).
  • the pattern forming unit (200) is dispensing the slurry into the pattern forming tray (300), the differential in quantity, types, colors, lines, and streaks of the slurry will integrate to form a desired pattern. Accordingly, further and additional variation of the pattern may be achieved by varying the quantity, types, colors, lines, and streaks of the slurry to be deposit into the pattern forming tray (300).
  • Figs. 2 , 3 and 4 shows different embodiments of the pattern forming unit (200) so as to achieve different patterns.
  • One method of forming a desired pattern involves using the pattern forming unit (200) without an agitator as shown in Fig. 2 .
  • this method different types and colors of the slurry are delivered to the pattern forming unit (200).
  • the slurries according to the pre-coded values are allowed to mix freely inside the slurry holding portion (215) of the pattern forming unit (200).
  • the mixed slurry is then dispensed into the pattern forming tray (300) to form a desired pattern. Variation of the pre-coded values will results in different patterns. Further variation of the patterns according to this method can be achieved by changing the shapes and configurations of the end piece (210) fitted at the end of each of the delivering tube (105) or changing the shape and configurations of the dispensing member (220) or both.
  • Another method of forming a desired pattern according to the principles described herein involves using a pattern forming unit (200) with a means to further mixing the slurry inside the holding portion (215) of the pattern forming unit (200), i.e. a pattern forming unit (200) with an agitator (230) as shown in Fig. 3 .
  • This method works under the same principles and techniques as in the earlier described method. The difference is that, in this method, after slurries according to the pre-coded values are allowed to mix freely inside the slurry holding portion (215), the already mixed slurry is then purposely mixed further by the agitator (230). This techniques will derived a slurry mixes with finer lines and streaks resulting in finer and sharper pattern.
  • An additional method of forming a desired pattern according to the principles described herein involves using a pattern forming unit (200) further comprises a pattern receiving tray (235) as shown in Fig. 4 .
  • the slurry is dispensed into the pattern receiving tray (235) and subsequently into the pattern forming tray (300).
  • the pattern forming unit (200) employs the same principles and techniques as in the earlier described method where the slurry is dispensed by the pattern forming unit (200) without the agitator (230).
  • the distinct character of this method lies in the elements featured in the pattern receiving tray (235).
  • the slurry is allowed to be mixed together first in the slurry holding portion (215) and subsequently in the pattern receiving tray (235) so that further variations and more intricate patterns can be created.
  • this method is particularly, suitable for forming patterns in which various colors are formed into a desired pattern, or patterns with more than one sub-set of patterns, or patterns with several color tones or shades.
  • the slurry is dispensed into compartment(s) (250) of the pattern receiving tray (235).
  • a plurality of pattern forming units (200) may be dispensing the slurry into the pattern receiving tray (235) at any one time.
  • Each compartment (250) may be filled with just one particular tone or shade, or a combination of shades, or a combination of sub-set (base) of patterns (different mixes of lines, streaks resulting from the mixing of the slurry inside the slurry holding portion (215).).
  • the zoning boards (255) which divides the pattern receiving tray (235) into smaller compartments (250) help to reduce unwanted mix of the slurry so that pattern with higher definition (where two colors, or tones or sub-set of patterns meet) is achieved.
  • the position, amount, combination, and colors/shades of the slurry dispensed into the pattern receiving tray are in accordance with the value pre-coded in the software application.
  • the slurry in each compartment is then distributed into the pattern forming tray (300) by rotation of the spiral screw (245) feeding the slurry to the opening at the bottom of the pattern receiving tray (235) to form desired patterns.
  • the pattern forming unit (200) moves synchronously with the pattern receiving tray (235) relative to the width and length of the pattern forming tray (200). Further variation of the pattern according to this method involves variation of the size of the spiral, the size of the compartment, the speed of the spiral screw (245), and the speed of the movement of the pattern forming unit (200) and the pattern receiving tray (235).
  • One yet further method of forming desired patterns according to the principles described herein involves using the embodiment of the pattern receiving trays as shown in Fig. 5 .
  • This method employs similar techniques as with the embodiment of the pattern forming unit (200) shown in Fig. 4 .
  • the pattern receiving tray is larger in size and thus capable of holding a large bulk of slurry.
  • This method is suitable for forming patterns to produce on larger tiles or slabs.
  • the pattern receiving tray (235) may or may not be fitted with the zoning boards (255). Due to the fact that a large quantity of the slurry is dispensed into the pattern receiving tray (235), it creates higher pressure inside the tray making it difficult to control the flow of the slurry.
  • the distribution of the slurry involves using the pattern receiving tray (235) which is further provided with an open-closed lid (265) and a high definition pneumatics system (270).
  • the open-close lid (265) is then closed, and the air inside the tray is removed to create a vacuum environment.
  • the slurry is then dispensed by controlling the pneumatic system (270) in combination with controlling the open-close member (260) at the bottom of the pattern receiving tray (235) to open and close as needed to form desired patterns.
  • the principle of forming the desired pattern according to the invention is to allow the slurry according to types and colors and/or combination of colors or sub set of pattern to mix at pre-coded values at controlled parameters employing the apparatus according to the invention. It is very important the mixing of the slurry of more than one types, colors, or combination of colors at any one point during pattern formation is not allowed to be homogeneous prior to dispensing the resultant slurry into the pattern forming tray (300), but still maintaining individual colors, lines, or streaks to the extent that the desired pattern is formed from the integration of mixed colors and lines, streak of individual colors.
  • the slurry is dispensed into the pattern forming tray (300) simultaneously with the operation of the agitator (230) and/or the spiral screw (245) so that the slurry will not become homogeneous.
  • An example of one of the method of forming a desired pattern according to the invention is that the agitator runs at 30-100 rpm while the pattern forming unit (200) continuously dispensed the slurry into the pattern forming tray (300). Consequently, the slurry will remain in the pattern forming unit (200) for only about 5-10 seconds so that the slurry will not become homogeneous.
  • the speed of the agitator will be regulated and varied corresponding to the pre-coded values in accordance with the desired pattern.
  • the slurry is dispensed into a pattern forming tray (300) to form a desired pattern.
  • the dispensed slurry is contained within the frame (305) of the pattern forming tray. Accordingly, the shape and size of the frame (305) will determine the shape and size of the tile or slab. In addition, the height of the frame (305) will determine the maximum quantity of the slurry which can be contained, which will in turn determine the maximum thickness of the tile or slab.
  • the pattern forming tray (300) is fed into the manufacturing system and is positioned at the weighing station or scale prior to the slurry is being dispensed into it. A predetermined amount of the slurry is then dispensed into the pattern forming tray (300). Once it reaches the predetermined weight, a weighing sensor will activate causing the pattern forming unit (200) or the pattern receiving tray (235) to temporally withhold dispensing so that each tile or slab will have consistent thickness and consistent quality.
  • the formed patterns may be further decorated or modified by using the pattern decorating accessory (400) previously described.
  • the pattern decorating accessory (400) performs by dragging, dipping, stirring, mixing or sweeping across or into the formed pattern.
  • the motion of the pattern decorating accessory (400) may be controlled by a suitable electronic device or this maybe performed manually.
  • the pattern decorating accessory (400) may perform in synchronously with the pattern forming unit (200) to achieve the desired patterns.
  • the pattern forming tray (300) moves to the next step of the production which is pressing.
  • the slurry dispensed or distributed into the pattern forming tray (300) which now includes different types, lines, streaks, tones or shade will be pressed to extract and remove water from the slurry to form a green ceramic tile or slab.
  • the different types, lines, streaks, tones, or shades will transform into a desired pattern extending through the entire thickness of the tile or slab.
  • the pattern forming tray (300) will position at the filter pressing unit (500), more specifically, on the lower punch (510) of the filter pressing unit (500). Thereafter, the filter sheet (600) which is formed into a conveyer like, will move into position so as to cover the pattern forming tray (300) prior to pressing and while pressing is in progress as shown in Figs 1 , 7 , 8 . Thereafter, the slurry contained inside the pattern forming tray is pressed by the upper punch (505).
  • the excess water including slurry particles smaller than the pore size of the filter sheet (310) will escape through the pores of the filter sheet (310) and through the holes prepared on the face of the upper punch (505) or in alternative embodiment, through the holes on the shape retaining frame (515) as well.
  • the upper punch continues to press to extract as much water as possible until it reaches a predetermined values (the height of the frame (305) the height of the shape retaining frame (315), the ability to retract of the frame (305) or pressure value per square inch) such that during pressing at maximum pressure, the shape retaining frame (515) on the upper punch should be at the same position with the retaining frame (515') on the lower punch and that the face of the shape retaining frame on the upper punch (505) meets or almost meets with the face of the shape retaining frame (515') on the lower punch (510) enclosing the pattern forming tray (300).
  • the shape retaining frames (515-515') will retain the shape of the flexible frame from becoming distorted upon application of the pressure which could distort the shape and pattern of the tile or slab.
  • the water and slurry particles smaller than the pores of the filter sheet (310) Upon pressing the water and slurry particles smaller than the pores of the filter sheet (310) will escape through such pores and through the hole prepared on the surface of the upper punch (505) and lower punch (510) and will be collected in the drain for disposal.
  • care is taken by gradually increasing pressure in order to distribute the pressure evenly so that water is removed evenly reducing distortion of the pattern and maintaining thickness consistency of the green tile or slab.
  • the water collected in the drain should be disposed by vacuum pump only after the pressing is completed so as to reduce clogging of the particle at the filter sheet (310, 600) as clogging could result in difficulties in extracting further water from the slurry.
  • the slurry may be heated and maintain the temperature at suitable level so as to ease water removal and shorten the pressing time.
  • the shape and configuration of the pattern forming tray (300) will also determined the shape and configuration of the final products. Accordingly, the pattern forming tray (300) may be modified as needed to obtain the desired shape, configuration, and size of the final products.
  • the pattern forming tray (300) may be modified to contain empty space at designated position for suitable utilization. For example, the empty space can be selected from square, rectangle, oval, circle, and desired free-form shapes. The same effect may be achieved by placing a soft flexible mold (made of the same material or possessing the same property as with the frame (305) and is re-usable) of such shapes into the pattern forming tray (300) prior dispensing the slurry into the pattern forming tray (300).
  • the soft flexible mold will take up space inside the pattern forming tray (300), thus leaving space of corresponding shape after pressing and the soft flexible mold is removed.
  • the tile or slab produced according to this technique can be used as sink counter, kitchen countertop, etc. without having to cut or, drill or saw away certain portions as in conventional tiles or slabs.
  • the pattern forming tray (300) will move out of the filter pressing unit (500) and the green tile or slab is removed for further treatments as needed to achieve the desired effects such as surface decoration, cutting to size, firing, and/or polishing.
  • the pattern forming tray (300) continues to move and proceed to cleaning station to be cleaned and re-enter the production line.
  • the filter sheet (600) is also moved to cleaning station in a similar manner.
  • a green tile or slab After pressing is completed and a green tile or slab is obtained, they may be subject to further treatment to achieve desire effects. For example, they may be subject to surface decoration to give dimension, print, spray, paint, or apply ceramic pigments or flakes could be applied as needed.
  • the process may be performed while the green tile or slab still contains high moisture content so as to ease the process and reduce damages.
  • the products then are then dried and fired according to the standard developed to suit the property of the green tiles or slabs produced according to the invention.
  • the pattern of the ceramic according to the principle of the present invention is formed from the differential in quantity, types, colors, lines, and streaks of the slurry which will integrate to form a desired pattern.
  • the tile or slab is formed from the slurry of consistent quality and with the aid of the elements of the apparatus and while the method of forming the pattern when forming the tile or slab necessary precaution measures are taken.
  • measures are such as the consistency of the pore size on the filter sheet as well as on flat surface of the upper punch (505) and lower punch (510) and the gradually increase of the pressure being applied by the filter press unit (500) so that water and particles will evenly escape so that the achieved green tile will have even thickness and moisture content. Consequently, the obtained tiles or slabs not only have the pattern extend to the entire thickness, the tiles or slabs also have consistent thickness and strength as well.

Landscapes

  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Decoration By Transfer Pictures (AREA)
  • Filtering Materials (AREA)
EP07116535.1A 2006-09-22 2007-09-17 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness Not-in-force EP2036694B1 (en)

Priority Applications (15)

Application Number Priority Date Filing Date Title
PT71165351T PT2036694E (pt) 2007-09-17 2007-09-17 Aparelho e método para formar um padrão em azulejo ou ladrilho de cerâmica com espessura especificada
ES07116535.1T ES2470140T3 (es) 2007-09-17 2007-09-17 Aparato y procedimiento para formar un motivo en una baldosa o loseta cerámica con un espesor predeterminado
PL07116535T PL2036694T3 (pl) 2007-09-17 2007-09-17 Urządzenie i sposób tworzenia wzoru na płytce lub tafli ceramicznej o zadanej grubości
EP07116535.1A EP2036694B1 (en) 2007-09-17 2007-09-17 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness
MX2007011554A MX2007011554A (es) 2006-09-22 2007-09-19 Aparato y metodo para formar un patron en azulejo o losa de ceramica con un grosor prescrito.
JP2007243497A JP5435851B2 (ja) 2006-09-22 2007-09-20 所定の厚さを有するセラミックのタイルまたは平板のパターンを形成する装置および方法
MYPI20071579A MY154412A (en) 2006-09-22 2007-09-20 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness
CA002603282A CA2603282A1 (en) 2006-09-22 2007-09-20 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness
TW096135120A TWI401146B (zh) 2006-09-22 2007-09-20 形成圖案於具有指定厚度之磁磚或厚板的裝置和方法
AU2007216889A AU2007216889A1 (en) 2006-09-22 2007-09-20 Apparatus and Method for Forming a Pattern in Ceramic Tile or Slab with Prescribed Thickness
CN2007103051147A CN101186080B (zh) 2006-09-22 2007-09-20 在规定厚度的瓷砖或板坯中成形图案的装置和方法
BRPI0705308-8A BRPI0705308B1 (pt) 2006-09-22 2007-09-20 Aparelho para formar uma estampa em azulejo ou ladrilho de cerâmica com espessura especificada
RU2007135042/03A RU2443551C2 (ru) 2007-09-17 2007-09-20 Способ и устройство формирования рисунка на керамической плитке или плите с заданной толщиной
KR1020070096056A KR20080027449A (ko) 2006-09-22 2007-09-20 규정 두께를 갖는 세라믹 타일 또는 슬라브의 패턴을형성하기 위한 장치 및 방법
US11/859,684 US8333916B2 (en) 2006-09-22 2007-09-21 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP07116535.1A EP2036694B1 (en) 2007-09-17 2007-09-17 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness

Publications (2)

Publication Number Publication Date
EP2036694A1 EP2036694A1 (en) 2009-03-18
EP2036694B1 true EP2036694B1 (en) 2014-03-05

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EP07116535.1A Not-in-force EP2036694B1 (en) 2006-09-22 2007-09-17 Apparatus and method for forming a pattern in ceramic tile or slab with prescribed thickness

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EP (1) EP2036694B1 (pl)
ES (1) ES2470140T3 (pl)
PL (1) PL2036694T3 (pl)
PT (1) PT2036694E (pl)
RU (1) RU2443551C2 (pl)

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CN106696068B (zh) * 2015-07-23 2019-01-04 佛山市东鹏陶瓷有限公司 一种具有围边结构陶瓷砖的布料系统及其布料方法
CN108214851B (zh) * 2017-12-28 2020-10-02 广东博晖机电有限公司 一种适用于陶瓷砖制备的多级阵列式的布料方法
CN108297261B (zh) * 2018-03-23 2023-11-10 莎丽科技股份有限公司 一种防水型grc底盆生产线及其生产方法
CN113012245B (zh) * 2021-03-30 2022-10-04 清远市简一陶瓷有限公司 一种确定通体瓷砖各颜色用料比例配方的方法、装置

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RU2007135042A (ru) 2009-03-27
EP2036694A1 (en) 2009-03-18
PL2036694T3 (pl) 2014-08-29
PT2036694E (pt) 2014-06-12
ES2470140T3 (es) 2014-06-23
RU2443551C2 (ru) 2012-02-27

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