EP2085248A1

EP2085248A1 - A process for producing a matrix for realising a tile

Info

Publication number: EP2085248A1
Application number: EP08425063A
Authority: EP
Inventors: Stefano Rosi; Mattia Alberto Foracchia; Ivan Gibertini
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-02-04
Filing date: 2008-02-04
Publication date: 2009-08-05

Abstract

A process for realising a matrix for realising a tile, comprising the stages of: forming a base structure (15) exhibiting an in-view surface (17); forming, at the in-view surface (17), a plurality of projecting reliefs (18), each exhibiting a respective crest (18a) being substantially equidistanced from the base structure (15) in order to define a single treading plane. The forming of the reliefs (18) comprises the stages of: forming a first zone having substantially parallel and equidistant reliefs (18); and forming a second zone having reliefs (18) orientated transversally with respect to the reliefs (18) of the first zone. The reliefs (18) of the second zone are distanced to a different amount than a distance between the reliefs (18) of the first zone.

Description

The invention relates to a process for realising a matrix for realising a tile.
A further object of the present invention is a tile, or more in general a cladding element, obtained with the above-mentioned matrix.
The matrix and the realisation process therefor enable a tile to be obtained which can be used in any dwelling and/or public or private infrastructure, such as for example health care structures, commercial, industrial structures, transport structures and the like. In particular the present invention is applicable to the building sector and can also be used in the realisation of places requiring special and/or characteristic aesthetic improvement or effects.
As is known, the prior art comprises tiles having an in-view surface which is provided with a plurality of reliefs that define a single treading plane. The reliefs each exhibit a crest from which inclined flanks extend which define, in pairs, an alternated series of reliefs adjacent to respective gullies. The gulleys are intercalated with reliefs such as to exhibit, in transversal section, a sawtooth profile developing along the in-view surface of the tile.
The inclined flanks of the reliefs exhibit concavities or jags which produce and define two difference images or figures which are selectively perceived according to a point of observation of the tile.
Although the above-mentioned double-effect tiles enable two images or figures to be seen according to the observational point of view thereof, the Applicant has noted that they are not without drawbacks, especially in relation to the jags of the treading plane, as well as the definition of the figures and/or the ornamentations afforded on the tiles.
In particular, the Applicant has found that in order to obtain figures and ornamentations of a sufficient sharpness, the crests of the above-mentioned reliefs have to be especially distanced, delimiting there-between corresponding gulleys of considerable width and/or particularly deep. Obviously on increasing the width and depth of the gulleys between the reliefs, the degree of jaggedness of the treading surface defined by the tile also increases, which transmits sensations similar to those of an uneven treading plane.
The alternating of deep or wide gulleys tends to weaken the tiles from a point of view of mechanical resistance to flexion.
A force applied on the in-view surface of the tile, generated for example during the laying operations, might cause breakage thereof with the breakage starting from the gully end.
In the preliminary tile storage stage, the bottom tiles in a stack can break for the same reasons as above.
Finally, in the specific field of application of the tiles, floor-located signals, the Applicant has found the complete perception of a figure, for example an indication of an emergency exit, possible only in a case in which the observer is positioned such that his or her point of observation is substantially perpendicular to a series of inclined flanks on which the image is reproduced.
In this situation, the technical task at the base of the present invention is to provide a process for realising a tile which can substantially obviate the cited drawbacks.
In the ambit of the technical objective, an important aim of the invention is to provide a process for realising a tile which defines a uniform treading plane despite the presence of reciprocally-intercalated reliefs and gulleys.
A further aim of the present invention is to provide a process with reliefs and gulleys which do not seriously weaken the mechanical resistance of the tile to flexion stress.
A further aim of the present invention is to originate a process which grants the tiles a double-face aesthetic effect, which is effective even at different angles of viewing thereof.
Finally, a further aim of the invention is to provide a process by means of which it is possible to give the tiles ornamentations and/or illustrations which can transmit a three-dimensional effect which is variable according to the point of observation thereof.
The set technical task and the specified aim are substantially attained by a process for realising a tile as described in the appended claims.
By way of non-limiting example, a description will now be made of a process for realising a tile according to the invention, the stages of which are described with the aid of the accompanying figures of the drawings, in which:

figure 1 is a perspective of a three-dimensional starting model, in agreement with the present invention;
figure 2 is a perspective of the model of the preceding figure, partially sub-divided according to a plurality of predetermined planes;
figure 3 is a perspective representation of a workpiece plane on which the profiles of the crests of the three-dimensions model of figure 2 are projected, tilted according to a predetermined rotation angle;
figure 4 is a perspective representation of the workpiece plane of figure 3 with the profiles of crests designed to be thicker;
figure 5 is a detail illustrating an extrusion of the projected profiles on the workpiece plane defining a plurality of reliefs;
figure 6 is a detail of a deformation of the flanks of the reliefs of figure 5 with the aim of obtaining the definitive three-dimensional model;
figure 7 is a perspective representation of a matrix exhibiting an in-view surface corresponding to the definitive three-dimensional model;
figure 8 is a perspective of an alternative three-dimensional starting model, already partially sub-divided into a plurality of predetermined planes;
figure 9 is a plan view of a workpiece plane on which the profiles of the crests of the portions of three-dimensional model of figure 8 are projected, lowered according to a predetermined angle of rotation;
figure 10 is a perspective representation of a matrix exhibiting an in-view surface corresponding to the definitive three-dimensional model.

The object of the present invention relates to a model for realising one or more tiles (not illustrated).
In particular, the process described and illustrated with the aid of the figures is directed to realising dies for obtaining the desired tiles.
With reference to the figures of the drawings, the process which is object of the present invention first includes a three-dimensional model stage of the tile to be produced.
The design of the tiles to be produced is advantageously actuated by means of an electronic device for three-dimensional design (not shown in the figures).
In particular, with reference to figure 1, the model comprises realisation of a starting three-dimensional model 1, provided with a substantially plate-shaped base 2 exhibiting a main surface 3 from which at least a geometric solid 4 develops. Preferably, from the base 2 a plurality of solids 4 are realised which project from the main surface 3.
In the illustrated embodiment of figure 1, the solid 4 developing from the base 2 is an arrow which can be subdivided into a first portion 4a, defined by a parallelepiped, i.e. the leg of an arrow, and a second portion 4b, defined by a triangular-base prism.
It is understood that without forsaking the ambit of protection of the present invention, any regular or irregular solid can be reproduced on the main surface 3, as well as writings, motifs and any kind of decoration.
Once the starting three-dimensional model 1 has been realised, it is sub-divided according to a plurality of pre-defined sub-division planes 5 (figures 1 and 2), such as to give rise to a plurality of sections 6, each different to another. In particular, the sub-division planes 5 are preferably substantially parallel, so that the above-mentioned sections 6 exhibit respectively parallel surfaces. The sub-division planes 5 are advantageously substantially perpendicular to the main surface 3 of the base 2, so that the surfaces of the sections 6 extend substantially vertically.
Still with reference to figures 1 and 2, the sub-division planes 5 are preferably equidistant in order to give the sections 6 a same thickness.
When the sub-division of the starting three-dimensional model is complete, an image 7 of the starting three-dimensional model 1 is projected onto a workpiece plane 8 (figure 3). The image 7 is advantageously obtained by tilting each section 6 of the starting three-dimensional model 1 to a predefined angle which is such as to ensure that each section 6 rests on the workpiece plane and thereafter by tracing a line 9 on the workpiece plane 8, which line 9 corresponds to the profile of the respective crest 6a of the tilted section.
Each section 6 is preferably tilted by means of a rotation to an angle of about 90° about a respective rotation axis arranged on an opposite side with respect to the crest 6a.
In an intermediate stage, shown in figure 4, the lines 9 are thickened to an amount pre-defined by the designer.
Once the image 7 of the starting three-dimensional model 1 has been realised on the workpiece plane 8, for each of the lines 9 present on the plane a respective relief 10 is extruded, which relief 10 extends from the workpiece plane 8 (figure 5 and 6), preferably perpendicular thereto and with a predefined thickness. The reliefs 10 are advantageously extruded such as to exhibit thicknesses which are equal, with respective crests 10a preferably equidistanced from the workpiece plane 8.
In the embodiment of figure 5, the reliefs are extruded such as to be raised above the workpiece plane 8 by about 1 mm.
Thereafter, a deformation of the reliefs 10 previously extruded from the workpiece plane 8 is performed (figure 5). During this stage, the flank 10b of each relief 10 is inclined with respect to the workpiece plane 8 in order to define respective gullies 11, having a V-shape and being intercalated with the reliefs 10. The inclination of each flank 10b of each relief 10 preferably defines, together with the workpiece plane 8, at least an angle comprised between 1° and 89°, preferably 45°.
When the deformation has been completed, there follows a stage of lowering the crests 10a of the reliefs 10 extruded from the workpiece plane 8 (figure 6). In particular, the lowering is performed by intersecting the reliefs 10 with a cutting plane, preferably parallel to the workpiece plane 8, and interposed between the workpiece plane 8 and the crests 10a.
Thereafter the portions cut away by the cutting plane are eliminated such as to give a definitive three-dimensional model.
A matrix 14 (figure 7) is then formed, which faithfully reproduces the definitive three-dimensional model. The formation of the matrix 14 is advantageously realised on a block of raw material, preferably metal, by removal of matter. In particular, based on the form of the definitive three-dimensional model, the block of raw material is suitably worked by one or more shaving machines which recreate the shape of the definitive three-dimensional model.
Once the matrix 14 has been made, the shape of the in-view surface thereof is advantageously modelled in negative by using a counter-shaping material (not illustrated as of known type).
The counter-shaping material thus exhibiting the negative representation of the image of the in-view surface of the matrix 14 is then fixed on at least a press die for forming the in-view surfaces of the tiles to be produced.
Alternatively the negative image of the definitive three-dimensional model can be realised directly on the press die by means of one or more material-removing operations.
The three-dimensional model could also be realised by dropping, extrusion or pressing. Dropping involves predisposing a special two-face die, upper and lower faces, which is provided with a hole for dropping the forming mixture.
Extrusion involves extruding the base shape of the tile through the extrusion matrix and cutting the base shape when the desired length has been attained.
Pressing can be done using two different methods, dry pressing or damp pressing.
The formation of the matrix 14 or the press die is done by forming a base structure 15 which develops substantially on a preferential lie plane such that the base structure 15 is provided with a bottom surface 16 and an in-view surface 17 arranged on the opposite side to the bottom surface 16.
The above-mentioned stage of matrix formation comprises the formation, at the in-view surface 17, of a plurality of reliefs 18, each projecting from the base structure 15 to a predetermined amount and exhibiting a respective crest 18a facing opposite to the bottom surface 16. In conformity with the defined three-dimensional model 13 (figure 7), the crests 18a of the reliefs 18 are substantially equidistanced from the base structure 15 of the matrix 14, so that the tiles made by the use thereof exhibit a single treading plane.
Going into more detail, and in reference to figures from 8 to 11, the formation of the reliefs 18 comprises the formation of at least a first zone 19 having substantially parallel and equidistant reliefs 18, and the formation of a second zone 20 having reliefs 18 orientated transversally with respect to the reliefs 18 of the first zone19.
The formation of the reliefs is preferably done by realising a plurality of first zones 19 with reliefs 18 that are substantially parallel and equidistanced, and a plurality of second zones 20 having reliefs 18 orientated transversally with respect to the reliefs of the first zones 19.
The reliefs 18 of the second zones 20 can advantageously be distanced to a different amount with respect to the distance running between the reliefs 18 of the first zones 19. The reliefs of the second zones 20 can either develop along substantially straight directions or along curved trajectories, thus defining arched profiles. The reliefs 18 of the second zones 20 can develop substantially parallel or in reciprocally inclined directions. It is further possible that the reliefs 18 of the second zones 20 might exhibit at least a first tract that is substantially parallel to a respective first tract of a relief 18 of the respective second zone 20 adjacent thereto, and at least a second tract which is inclined with respect to the adjacent relief 18. The reliefs 18 of the second zones 20 can advantageously be equidistanced or can exhibit differentiated distances.
Naturally the formation of the matrix 14, the in-view surface 17 and the reliefs 18 of the first and second zones 19 and 20 are realised in a predetermined order.
Obviously the use of the above-described matrix 14 enables realisation of a press die exhibiting a negative impression of the design of the in-view surface 17 of the design, so that the tiles obtained by means of the die are provided with in-view surfaces which are identical to the surface of the matrix 17, i.e. provided with first and second zones 19, 20 having different reliefs 18.
The present invention solves the problems encountered in the prior art and achieves the set aims.
Firstly, the proposed process enables tiles to be realised which exhibit a single treading plane which transmits the sensation of a continuous plane without jags.
Also to be considered is the fact that the tiles obtained using the process of the invention exhibit ornamentations and/or graphic representations which change and which are however visible whatever the point of observation.
Also, the tiles obtained by the above-described process exhibit ornamentations or graphic representations which give a three-dimensional effect to the in-view surface.

Claims

A process for realising a matrix for realising a tile, comprising stages of:
forming a base structure (15) developing substantially on a preferential lie plane such as to exhibit a bottom surface (16) and an in-view surface (17) arranged on an opposite side of the basic structure (15) to the bottom surface (16);

forming, at the in-view surface (17), a plurality of reliefs (18), each projecting from the base structure (15) to a predetermined extent and each exhibiting a respective crest (18a) facing in an opposite direction to the bottom surface (16), the crests (18a) of the reliefs (18) being substantially equidistanced from the base structure (15) in order to define a single treading plane,

characterised in that formation of the reliefs (18) comprises stages of:
forming a first zone (19) having substantially parallel and equidistant reliefs (18);

forming a second zone (20) having reliefs (18) orientated transversally with respect to the reliefs (18) of the first zone (19), the reliefs (18) of the second zone (20) being distanced by a different amount than a distance between the reliefs (18) of the first zone (19).
The process of claim 1, wherein the forming of the reliefs (18) of the second zone (20) comprises realising equidistant reliefs (18).
The process of claim 1 or 2, wherein the forming of the reliefs (18) of the second zone (20) comprises realising reliefs (28) having differentiated distances.
The process of any one of the preceding claims, wherein the forming of the reliefs (18) of the first zone (19) and the second zone (19, 20) is preceded by a three-dimensional design stage of the matrix (14) of the tile, the design being done by means of an electronic three-dimensional modelling device.
The process of claim 4, wherein the design stage comprises realising a starting three-dimensional model (1) provided with a substantially-plate-shaped base (2) exhibiting a main surface (3) from which at least a solid (4) develops.
The process of claim 5, wherein realising the starting three-dimensional model (1) comprises forming a plurality of solids (4) extending from the main surface (3) of the base (2).
The process of claim 4 or 5, comprising a stage of sub-dividing the starting three-dimension model (1) into a predefined plurality of sub-division planes (5), producing a plurality of sections (6) of the first starting three-dimensional model (1).
The process of claim 7, in which the sub-dividing of the starting three-dimensional model (1) is done according to a substantially-parallel plurality of planes of sub-division, the sub-division producing a plurality of substantially parallel sections (6).
The process of claim 6 or 7, wherein the sub-dividing of the starting three-dimensional model (1) is performed in a plurality of planes of sub-division (5) which are substantially perpendicular with respect to the main surface (3) of the base (2).
The process of any one of claims from 6 to 9, wherein the sub-dividing of the starting three-dimensional model (1) is done according to a plurality of equidistant planes of sub-division (5), the sub-division producing a plurality of sections (6) having substantially a same thickness.
The process of any one of claims from 6 to 10, comprising a stage of projection of an image (7) of the starting three-dimensional model (1) on a workpiece plane (8), projection of the image (7) being achieved according to stages as follow:
tilting each section (6) of the starting three-dimensional model (1) to a predefined angle such that the section (6) is resting on the workpiece plane (8);

for each tilted section (6), tracing a line (9) corresponding to a profile of the crest (6a) of the section (6) on each workpiece plane (8).
The process of claim 11, wherein each section (6) is tilted to an angle of substantially 90° about a respective rotation axis arranged on an opposite side to the respective crest (6a).
The process of claim 11 or 12, further comprising a stage of extrusion of the lines (9) of the workpiece plane (8) in a predetermined direction and at a same distance each thereof from the workpiece plane (8).
The process of claim 13, comprising a stage of deforming the reliefs (10) extruded from the workpiece plane (8), the stage of deforming comprising an inclining of the flanks (10b) of each relief (10) extruded from the workpiece plane (8) in order to define gulleys (11) intercalated between the reliefs (10).
The process of claim 14, comprising a stage of lowering the crests (10a) of the reliefs (10) extruded from the workpiece plane (8), the lowering being realised by means of sub-stages as follow:
intersecting the reliefs (10) extruded from the workpiece planes (8) with a plane (12) interposed between the crests (10a) and the workpiece plane (8);

eliminating the portions of the reliefs (10) comprised between the crests (10a) and the intersection plane (12) for defining a definitive three-dimensional model (13).
The process of claim 15, wherein forming of the matrix (14) is realised on a block of raw material, preferably a metal, by removal of material based on the form of the definitive three-dimensional model (13).
The process of claim 16, further comprising a stage of forming a negative of the in-view surface (17) of the matrix (14) using a counter-shaping material.
The process of claim 17, comprising a stage of application of the counter-shaping material bearing the negative image of the in-view surface (17) of the matrix (1) on at least a press die.
The process of claim 18, comprising a stage of forming a die plate, preferably realised by removal starting from a raw block of metal material exhibiting a negative image of the definitive three-dimensional model (13).
A tile comprising a base structure (15) developing substantially on a preferential lie plane, the base structure (15) being provided with a bottom surface (16) and an in-view surface (17) arranged on an opposite side to the bottom surface (16); the in-view surface (17) exhibiting a plurality of reliefs (18), crests of which are equidistant from the base structure (15), defining a single treading plane, characterised in that the in-view surface exhibits:
a first zone (19) having reliefs (18) which are substantially parallel and reciprocally equidistant; a second zone (20) having reliefs (18) oriented transversally with respect to the reliefs (18) of the first zone (19), the reliefs (18) of the second zone (20) being distanced by a different amount than a distance between the reliefs (18) of the first zone (19).
The tile of claim 20, wherein the reliefs (18) of the second zone (20) are equidistant.
The tile of claim 20, wherein the reliefs (18) of the second zone (20) are distanced from one another at variable distances.
The tile of any one of claims from 20 to 22, wherein the tile is made by a process as in any one of claims from 1 to 19.