EP2314432A1 - Verfahren zur Herstellung von Bodenfliesen - Google Patents

Verfahren zur Herstellung von Bodenfliesen Download PDF

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Publication number
EP2314432A1
EP2314432A1 EP10188532A EP10188532A EP2314432A1 EP 2314432 A1 EP2314432 A1 EP 2314432A1 EP 10188532 A EP10188532 A EP 10188532A EP 10188532 A EP10188532 A EP 10188532A EP 2314432 A1 EP2314432 A1 EP 2314432A1
Authority
EP
European Patent Office
Prior art keywords
concrete layer
floor tiles
concrete
forming
layer
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.)
Withdrawn
Application number
EP10188532A
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English (en)
French (fr)
Inventor
Brecht Soenen
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.)
Soenen bvba
Original Assignee
Soenen bvba
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 Soenen bvba filed Critical Soenen bvba
Publication of EP2314432A1 publication Critical patent/EP2314432A1/de
Withdrawn legal-status Critical Current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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0845—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for smoothing
    • 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
    • B28B1/29—Producing shaped prefabricated articles from the material by profiling or strickling the material in open moulds or on moulding surfaces
    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/14—Apparatus or processes for treating or working the shaped or preshaped articles for dividing shaped articles by cutting
    • 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

Definitions

  • the present invention relates on the one hand to a method for forming tile elements.
  • the present invention relates to a device for forming separate floor tiles.
  • the present invention relates in particular to a method for forming a series of separate floor tiles.
  • Floor tiles are a popular form of floor covering.
  • floor tiles there are three kinds of tiles, i.e. natural stone tiles, ceramic tiles and cement or concrete tiles. They each have their own character with specific advantages and disadvantages.
  • Natural stone tiles have a unique and lively appearance. They are formed from large blocks which are quarried in quarries and subsequently sawn to form plates or tiles.
  • Ceramic tiles are relatively thin slices of ceramic material in various forms, dimensions and thicknesses. They are hard, strong, hygienic, easy to clean and are used for covering both floors and walls.
  • Ceramic floor tiles are made from a mixture of clay and sand, if desired combined with several different natural substances, each of which may have their own effect.
  • the mixtures are ground to the required size, dried to a specific degree of moisture, formed into the desired shape and then fired at a temperature of 1000 to 1250 degrees, depending on the desired type of tile.
  • Ceramic floor tiles are formed by drawing or pressing. Pressed tiles are manufactured by moistening a pulverulent mixture and pressing this mixture into a mould under high pressure. Drawn tiles are formed by drawing the clay mixture in paste form through special injection nozzles.
  • concrete or cement tiles are mainly suitable for outdoor use. Such tiles are produced by pouring concrete or cement into pre-formed moulds and then allowing these to harden.
  • the object of the invention is achieved by providing a method for forming a series of separate floor tiles comprising the following steps:
  • the above-described method according to the present invention has the advantage that the method can be controlled much more, resulting in end products of a higher quality.
  • the method it is moreover possible to produce perfectly flat floor tiles which can be used to make a floor without scratches and the like.
  • the method does not depend on weather conditions.
  • the resultant separate floor tiles are taken away and stacked.
  • the first polishing treatment is carried out using a polishing device provided with solid plates which carry out a rotary movement
  • the second polishing treatment is carried out using a polishing device provided with blades (fine blades) which also carry out a rotary movement.
  • the first polishing treatment should be regarded as the rough treatment
  • the second polishing treatment should be regarded as the fine treatment.
  • the formed top layer is subjected to a third polishing treatment, following the second polishing treatment.
  • the "fine" blades of the polishing device which are used to carry out the polishing treatment are provided with protective elements which prevent them from damaging the top surface of the concrete layer.
  • This third polishing treatment is carried out until the top surface of the concrete layer is smooth and shiny so that this top surface is given a mirror effect.
  • the poured concrete layer is compacted, after levelling, by means of vibrating beams.
  • Compacting of the concrete layer is carried out in order to remove air bubbles from the mixture.
  • use is preferably made of special high-frequency vibrating beams.
  • the separate floor tiles are formed on a shuttering table.
  • the shuttering table is in particular provided with a shuttering edge so that the poured concrete layer does not run off the table.
  • said concrete layer comprises a reinforcement, preferably a reinforcement mesh.
  • a reinforcement mesh preferably a reinforcement mesh.
  • the reinforcement produces a stronger floor tile, as a result of which it can be more readily handled without the risk of breaking.
  • the reinforcement prevents cracks and splits in the floor tile formed.
  • the layer thickness of the concrete layer is between 2 and 12 cm.
  • the layer thickness of the concrete layer is preferably between 2 and 8 cm, more particularly between 2 and 4 cm, and most particularly 3 cm.
  • the surface area of the concrete layer is between 150 and 450 m 2 .
  • the surface area of the concrete layer is preferably between 150 and 350 m 2 and more particularly between 150 and 300 m 2 .
  • said mixture comprises colour pigments.
  • colour pigments In this way, it is possible to give the floor tiles a coloured appearance.
  • Another subject of the present invention relates to a device for forming a series of separate floor tiles, the device comprising:
  • the abovementioned device may furthermore be provided with means which are suitable for treating, preferably polishing, the concrete layer formed on the shuttering table, such as for example one or more polishing devices.
  • the device according to the present invention is in particular suitable for carrying out the above-described method.
  • tile elements (1) preferably floor tiles (1), are formed by subjecting a poured concrete layer (3) having a well-defined layer thickness, to certain machine and manual treatments, as a result of which the appearance of the surface will become very smooth, flat and shiny.
  • the chosen layer thickness of the concrete layer (3) determines the thickness of the floor tiles (1).
  • the thickness of the concrete layer is between 2 and 12 cm.
  • a concrete layer of 2 to 4 cm, preferably 3 cm will be poured.
  • concrete layers having a larger (up to 12 cm) or smaller (1 cm) layer thickness will be poured.
  • the choice is made to pour the concrete layer (3) on a surface area of between 150 and 450 m 2 .
  • surface areas which are greater or smaller than these values are also covered by the scope of protection of the present invention.
  • the different floor tiles (1) are formed on a shuttering table (5) which has standard dimensions of 10.5 x 30 m.
  • the concrete used has a fixed composition and is produced by mixing water with a binder (such as cement) and granulate (sand and gravel), fillers and, if desired, aggregates (e.g. silicon powder).
  • a binder such as cement
  • granulate sand and gravel
  • fillers e.g. silicon powder
  • aggregates e.g. silicon powder
  • various additives can be used, such as for example:
  • the poured concrete layer (3) comprises a reinforcement.
  • the concrete preferably from a concrete mixer (6), is poured onto the shuttering table (5) which is provided on its outer periphery with (e.g. steel) edge profiles which form the shuttering edge and on which the reinforcement (e.g. a steel mesh) is already provided.
  • steel fibre-reinforced concrete can be used which is made by adding approximately 0.3 to 1 volume percent steel fibres to the concrete mixture.
  • the steel fibres ensure that the concrete can absorb tensile forces and can withstand heavy loads so that the formation of cracks is limited.
  • a screed (7) can be arranged so as to be displaceable in a profiled-section rail which extends along the length of the shuttering table (5).
  • the levelled and, if desired, compacted concrete layer (3) is then left to rest for a while until the poured concrete layer can be walked on, but is still sufficiently mouldable on its top surface (top side), this is also referred to as the semi-plastic phase.
  • this phase water may be present on the concrete layer, which water first has to be removed before the next steps can be carried out.
  • a cement-rich mass is situated on the upper side of the concrete layer (3) and is subsequently subjected to various treatments in order to give the individual floor tiles (1) their smooth appearance.
  • the upper side of the concrete layer (3) in particular the cement-rich mass, is first subjected several times to a first polishing treatment (rotary movement) (see Fig. 3 ).
  • the upper side of the concrete layer is treated using a polishing device(s) with a solid plate (such a plate has a thickness of approximately 5 mm and a diameter of approximately 90 cm.
  • this operation is referred to as "power-troweling".
  • a "squashy mass" is obtained which is evenly spread and on which no water is present anymore.
  • the next step is then to fill in the concrete layer (3) with a mixture of quartz and cement and then to mix the infill mixture with the concrete layer (3), thus forming a top layer (4).
  • said mixture may furthermore comprise colour pigments.
  • Said mixture is dry and is preferably scattered across the concrete layer manually while it is still wet.
  • the mixture is mixed with the concrete layer (3) by "rotating" the polishing device again until the top layer (4) has been mixed with the squashy layer which is present. In this way, a perfect bonding of the infill top layer (4) and the concrete layer (3) is achieved.
  • the "rotation” is preferably carried out using a polishing device with flat plates and is known as "floating", during which the top side of the concrete layer (3) is made flatter and flatter by rotation, and the traces from earlier treatments are gradually erased. This process is repeated until the concrete layer is sufficiently hard and hardly any footprints or significant uneven structures remain visible.
  • a polishing device with fine blades (the fine blades have a thickness of 3 mm and are 15 cm wide and approximately 45 cm long and are attached to the arms of the polishing device by means of a bolt connection) is placed on the concrete layer and the latter is subjected to a second polishing treatment (see Fig. 3 ).
  • a second polishing treatment see Fig. 3 .
  • the concrete layer is subjected to a third polishing treatment in which the fine blades of the polishing device are provided with protective elements, preferably made from plastic, e.g. nylon, in order to prevent damage due to the polishing action of the blades.
  • This step is repeated until a perfect shiny surface is obtained.
  • the object of the third polishing treatment is to perfect the top surface and to significantly reduce the risk of damage by fitting the protective elements. In addition, a more attractive and even colour can be obtained.
  • this concrete layer (3) is cut (see Fig. 4 ) to the desired tile format, for example by means of an automatic computer-controlled concrete saw (8).
  • the following tile formats will be sawn: 15 x 15 cm, 20 x 20 cm, 25 x 25 cm, 30 x 30 cm, 40 x 40 cm, 50 x 50 cm, 60 x 60 cm, 70 x 70 cm, 80 x 80 cm, 90 x 90 cm, 1 x 1 m, etc.
  • the separate floor tiles (1) are taken from the shuttering table (5) one by one by means of a removal device (9) and stacked on top of one another, as can be seen in Fig. 5 .
  • the concrete saw (8) is intended to run in the same rail as the one in which the above-described screed (7) is displaceably arranged.
  • the device for forming floor tiles (1) will essentially comprise the following parts: a shuttering table (5), if desired provided with a shuttering edge, means for supplying poured concrete (2) so that a concrete layer (3) is formed on the shuttering table (5), a screed (7) and a cutting device (8) for cutting up the treated concrete layer (3).
  • the screed and cutting device are displaceably arranged in a profiled-section rail which extends along the length of the shuttering table (5). After it has been poured, the concrete layer (3) is treated by means of polishing devices.
  • the formed floor tiles (1) or other covering elements also have the following advantages:

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Floor Finish (AREA)
EP10188532A 2009-10-22 2010-10-22 Verfahren zur Herstellung von Bodenfliesen Withdrawn EP2314432A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
BE2009/0650A BE1018975A5 (nl) 2009-10-22 2009-10-22 Werkwijze voor het vormen van vloertegels.

Publications (1)

Publication Number Publication Date
EP2314432A1 true EP2314432A1 (de) 2011-04-27

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP10188532A Withdrawn EP2314432A1 (de) 2009-10-22 2010-10-22 Verfahren zur Herstellung von Bodenfliesen

Country Status (2)

Country Link
EP (1) EP2314432A1 (de)
BE (1) BE1018975A5 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015190277A (ja) * 2014-03-28 2015-11-02 新日鐵住金株式会社 大型人工石材の製造方法
EP2747995A4 (de) * 2011-07-27 2016-03-16 Abbey And Pride Ip Pty Ltd Schichtprodukt und seine herstellung durch anbringen einer schicht auf einer halbgehärteten basisschicht

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0441204A (ja) * 1990-06-07 1992-02-12 Daiyu Kogyo Kk プレキャストコンクリート板の仕上げ方法
US5441677A (en) * 1993-09-01 1995-08-15 Hi-Tech Floors, Inc. Method of making high gloss, hardened concrete floors
DE19905770A1 (de) * 1999-02-12 2000-08-17 Bernhard Godelmann Verfahren zum Herstellen von Bodenplatten
EP1266734A2 (de) * 2001-06-11 2002-12-18 Venix S.r.l. Verfahren und Vorrichtung zum Herstellen von Fliesen, insbesondere von venezianischen Bodenfliesen und dergleichen
US20070187873A1 (en) * 2006-02-16 2007-08-16 Bailey Wayne E Cement-based, mesh reinforced concrete tiles with integral color and design

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0441204A (ja) * 1990-06-07 1992-02-12 Daiyu Kogyo Kk プレキャストコンクリート板の仕上げ方法
US5441677A (en) * 1993-09-01 1995-08-15 Hi-Tech Floors, Inc. Method of making high gloss, hardened concrete floors
DE19905770A1 (de) * 1999-02-12 2000-08-17 Bernhard Godelmann Verfahren zum Herstellen von Bodenplatten
EP1266734A2 (de) * 2001-06-11 2002-12-18 Venix S.r.l. Verfahren und Vorrichtung zum Herstellen von Fliesen, insbesondere von venezianischen Bodenfliesen und dergleichen
US20070187873A1 (en) * 2006-02-16 2007-08-16 Bailey Wayne E Cement-based, mesh reinforced concrete tiles with integral color and design

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2747995A4 (de) * 2011-07-27 2016-03-16 Abbey And Pride Ip Pty Ltd Schichtprodukt und seine herstellung durch anbringen einer schicht auf einer halbgehärteten basisschicht
JP2015190277A (ja) * 2014-03-28 2015-11-02 新日鐵住金株式会社 大型人工石材の製造方法

Also Published As

Publication number Publication date
BE1018975A5 (nl) 2011-12-06

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