EP2414306A1 - Carreau céramique et son procédé de fabrication - Google Patents

Carreau céramique et son procédé de fabrication

Info

Publication number
EP2414306A1
EP2414306A1 EP10720711A EP10720711A EP2414306A1 EP 2414306 A1 EP2414306 A1 EP 2414306A1 EP 10720711 A EP10720711 A EP 10720711A EP 10720711 A EP10720711 A EP 10720711A EP 2414306 A1 EP2414306 A1 EP 2414306A1
Authority
EP
European Patent Office
Prior art keywords
glaze
tile
ceramic tile
layer
ceramic
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Withdrawn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
EP10720711A
Other languages
German (de)
English (en)
Inventor
Ruslan Yun
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.)
Petraluxe GmbH
Original Assignee
Petraluxe GmbH
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 Petraluxe GmbH filed Critical Petraluxe GmbH
Publication of EP2414306A1 publication Critical patent/EP2414306A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5022—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with vitreous materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/86—Glazes; Cold glazes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility

Definitions

  • the present invention relates to a ceramic tile and more particularly to a porcelain stoneware tile having a glazed body (tile body).
  • Stoneware belongs to the dense silicate ceramic materials and has been known for centuries. It is characterized in that it has a water absorption capacity of less than 2 o wt .-%. Porcelain stoneware is a modern development of this material, from which mostly tiles with very low water absorption (less than 0.5 wt .-% or even less than 0.1 wt .-%) are produced. This very low water absorption makes porcelain stoneware extremely frost resistant. In addition, it has a very good abrasion resistance and high breaking strength, since it is a completely sintered through and very compact material.
  • the tile body has consistently the color o resulting from the base material and the addition of pigments in the shards, which are either uniformly or granulated (locally accumulated) distributed therein.
  • the appearance of the tile body can be adapted to the different natural stones.
  • press- and fire-related pore spaces are sanded and opened, in which then easily dirt can settle.
  • the surfaces are impregnated (eg silane, siloxane, polymer mixtures).
  • porcelain stoneware tiles can only be produced in formats of up to 90 x 120 cm and have thicknesses of less than 10 mm. They require when using as facade cladding relatively complex support and suspension structures for surface stabilization, which can be omitted in the paneling with large comparatively strong (from about 3 cm) natural stone slabs. Thus, despite their weight and cost disadvantages, natural stone panels are often preferred over porcelain stoneware tiles.
  • Depth effect (optical-prismatic effect), which is due to the fact that incident light is hardly scattered in such a glaze surface with a Refleerreterwert between 65 and 90 (at a measuring angle of 20 °), but almost undisturbed by the transparent Layer falls on the visible surface of the cullet, where it is reflected and scattered and passed back through the transparent glaze layer.
  • refraction effects occur, which bring about an optical depth effect, which works out the color and surface structure of the shard. If necessary, this effect can be influenced and controlled by transparent coloring of the glaze and by further surface treatment of the glaze surface.
  • the optical and prismatic effect can be further enhanced with the execution of the surface according to claim 2.
  • the glaze surface may further comprise at least portions according to claim 3, e.g. are processed mechanically, chemically or electrochemically. These may be in particular mechanical grinding or polishing operations, in which the natural glaze surface is further leveled, leveled and / or smoothed. Such treatments are suitable for improving the aspect properties of the visible tile surface on the decorative side.
  • the natural waviness of the glaze surface which may form during the formation and solidification of the glaze layer, is thus completely leveled or at least partially reduced.
  • the glaze layer is removed only so far that the shards or the decorative surface is not exposed.
  • Surface structures according to claim 4 and in particular according to claim 5 thereby ensure a completely blank surface to the naked eye and enhance the desired optical and prismatic properties.
  • the further developments according to claims 6 and 7 relate to features which make the ceramic product according to the invention a suitable and advantageous facade element, in which, on the one hand, a thickness exceeding 5 to 30 mm is provided (claim 6) and the dimensions are extended to surface dimensions of up to 1200 x 2400 mm (claim 7).
  • This dimensioning allows large-scale stable facade elements, which have sufficient intrinsic stability and can be hung without overly complex support structures, but nevertheless have weight advantages of more than 65% compared to natural stone slabs. Especially with tall buildings so the entire facade and / or even the building statics can be favorably influenced.
  • the developments according to the claims 8 and 9 relate to features that further increase the design variety.
  • a special decorative layer between the glaze layer and the broken pieces allows a virtually unlimited design variety of the decor side.
  • the decors can be applied in a wide variety of colors, patterns and representations, which are covered, protected and deep-set by the glaze layer. In this case, color decorative effects and relief effects can optionally be combined with each other according to claim 7.
  • Claim 10 relates to a ceramic product in which the glaze layer is formed from a glaze raw material.
  • glaze raw materials can be different transparent and / or colored glasses glass frits or glaze raw material components or even those with certain other defined properties (eg refraction, chemical resistance) which then alternatively or in addition to conventional glaze raw materials (in the form of slip, grits) on the ceramic fragments are applied and melted.
  • these glaze raw materials can be arranged in areas or layers with different properties.
  • the surface layer may be formed of a glaze raw material (for example glass frits) which results in a glaze layer of defined (e.g., very high) refractive power, while an underlying layer may be particularly colored.
  • a glaze raw material for example glass frits
  • an underlying layer may be particularly colored.
  • special color and / or surface effects can be achieved by matching the glaze or glaze raw material areas to a particular, underlying pattern or structure or even form a superimposed pattern.
  • Claim 12 relates to a tile arrangement with porcelain stoneware tiles, which are suitable for floor, ceiling, wall, facade and / or roof arrangements (panels, tiled surfaces, raised floors, etc.).
  • the claims 13 to 15 relate to methods for producing the ceramic tile according to the invention.
  • the basic method according to claim 13 comprises the steps Providing a vitrified ceramic mass as starting material for the cullet,
  • Claims 14 and 15 relate to process steps which further optimize the application of the glaze raw material, in which, according to claim 14, alternating glaze suspension and suitable grits or glazes (glaze raw materials and / or glaze raw material components) are applied to apply the requisite glaze raw material layer the desired transparency and surface properties during firing is formed. This can also include more
  • edge processing can be provided after firing to produce tiles with very high dimensional accuracy.
  • FIG. 1 is a schematic sectional view of a first embodiment of the present invention
  • FIG. 1 a shows an enlarged representation of the region a from FIG. 1
  • FIG. 2 shows a schematic sectional view of a second embodiment of the present invention
  • FIG. 3 shows a schematic representation of the method steps for producing the embodiment shown in FIG. 1
  • FIG. 4 shows a further schematic representation of a method sequence for the production of the embodiment shown in FIG. 2,
  • FIG. 5 shows a schematic representation of an exemplary method sequence for applying a glaze
  • Figure 6 is a schematic representation showing a process flow for further surface treatment of the glaze.
  • FIG. 1 shows a partial cross section through a porcelain stoneware tile 1, the tile body
  • the glaze layer 3 is transparent, preferably crystal-clear and has a low-insertion fit and has a transparent layer thickness d and is intimately connected to the broken piece 2.
  • the surface 4 is smooth and largely flat.
  • the glaze layer 3 thus forms an optically active body, which makes the surface 5 of the sherd 2 clear and with reinforcing depth effect by its optical properties.
  • the glaze layer 3 may have different optical properties in terms of area and layer. That it can be different in layers. o refraction properties, colors or even transparency properties are present. This is possible in particular if, for the construction of the glaze layer 3, glasses are used which have glaze raw materials or glaze raw material components with different properties. Such glasses can also be combined with other glaze raw materials. The glasses can also be provided as needed with additives 5, z. B. to the thermal expansion coefficient of the glasses (and thus the
  • Glaze on the ceramic shards tune.
  • FIG. 1a shows the region a in FIG. 1 enlarged and illustrates that the glaze surface 4 can be processed in regions.
  • the unprocessed glaze surface is denoted by 4a o and the machined areas 4b.
  • the glaze surface 4 is additionally smoothed and leveled, suitable mechanical methods are, for example, grinding and / or polishing.
  • suitable mechanical methods are, for example, grinding and / or polishing.
  • a transparent minimum layer thickness d is maintained in order to To ensure that the glaze layer 3 remains closed, so the surface 5 of the cullet 2 is not exposed and does not affect the optical effect, but is reinforced by the leveling of elevations of the natural glaze surface 4.
  • the grinding process detects the regions 4b, while the polishing covers all regions 4a, 4b, the transitions 4c are polished or polished and the glaze surface 4 as a whole is smoothed.
  • the thickness D of the tile body 2 is 5 to 30 mm, preferably 7.5 to 20 mm.
  • the tile body 2 itself is formed from a suitable porcelain stoneware mixture, which may be total or locally colored, in order to achieve irregular patterning and grain effects with a natural stone-like appearance over the entire fragmentary section.
  • the porcelain stoneware tile 1 has external dimensions of at least 900 x 1800 mm, preferably 1200 to 2400 mm. Porcelain stoneware tiles of this size are suitable for serving as large-area panel elements for facade cladding, which have a high breaking strength with the appropriate thickness D by the dense fragments 2 in conjunction with the glaze structure and can be provided as a replacement for corresponding natural stone slabs.
  • the glaze layer 3 has technical properties in order to achieve the corresponding optical depth effect. These include e.g. Refraction properties, coloring and transparency.
  • This optical depth effect is particularly related to the gloss values and the topography data of the porcelain stoneware tile 1 or the glaze surface.
  • Tables 1 and 2 give reflectometer values (gloss measurement) according to DIN 67530 or topography data for a tile according to the invention (Petraluxe) in comparison to conventional tiles (pattern 1, pattern 2), the inventive tile and the conventional tile being polished in conventional methods ,
  • FIG. 2 shows a second exemplary embodiment of a ceramic product according to the invention, namely a porcelain stoneware tile 10, which likewise has a tile body / shards 12 and a glaze layer 13.
  • a decorative layer 16 is additionally formed here between the glaze layer 13 and the broken piece 12. This decorative layer 16 is formed in the region A of a color layer 18 which is applied to the surface 15 of the cullet 12 5 and is completely covered by the glaze layer 13.
  • the decorative layer consists of a relief structure 20, which is embossed in the surface 15 of the cullet 12.
  • the glaze layer 13 completely fills the relief recesses 21 and is formed over the relief protrusions 22 with the desired minimum layer thickness d.
  • the relief structure 20 is combined with a color layer 18.
  • a color layer 18 In region B, the relief structure 20 is combined with a color layer 18.
  • a correspondingly applied decorative layer 16 Variant A, B or C
  • the dimensions correspond to the areas indicated in connection with the first exemplary embodiment.
  • FIG. 3 shows the basic sequence of the method:
  • the vitrified ceramic mass is molded by means of an extruder whose mouthpiece width is tuned to the raw plate width of up to 1400 mm. o
  • the distance of the mouthpiece to the end of the extruder screws is coordinated so that a steady error-free chansamer extrusion strand is discharged from the mouthpiece. Possibly. adjustable or exchangeable mouthpieces should be provided for different strand widths and thicknesses.
  • the outer edges can be increased 5 to be formed during firing, the melting of the glaze layers in the
  • the plastic (still plastic) strand is cut to the desired roughness (e.g., width 1400 mm, length 2700 mm). 0
  • the glaze material is applied to the plate blanks.
  • wet processes can be used in which glaze suspensions are sprayed onto the ceramic surface (eg by compressed air or by airless spraying using suitable spray guns or nozzles).
  • the suspension contains glaze particles in suitable grain bands as solid phase (here further details if necessary).
  • the desired glaze thickness is achieved by applying several layers one above the other, possibly with different grain bands.
  • the cavities between the individual glaze particles are closed during the fire by the glaze particles melting and melting together. Emerged bubbles ideally emanate at the glaze surface. 0
  • the tile blank passes through a "waterfall" of glaze slurry produced by means of a glaze bell, which allows for a very smooth and uniform glaze surface, and drying steps can be provided between the individual application steps.
  • the glaze material can also be applied by dry process. These are grits with glaze constituents (frit, matting agent and color body) for producing a low-bleach transparency or glaze These grits are mixed in different grain bands, so that the raw glaze in the required thickness and sufficient density (packing density of each Glaze granules) is set low in cavities.
  • glasses instead of the classical glaze suspensions (glaze slip), which are applied in the wet process, and the so-called grits, which are applied by dry process, glasses (glaze raw materials or glaze raw material components, especially also so-called glass frits) can be applied in similar processes.
  • FIG. 5 schematically shows such a sequence in which glaze suspension (slip) is first applied and then grits are applied or spread in a dry process. 5 This is followed by a drying step. The cycle can be repeated several times.
  • the glaze is applied only after drying (5) of the raw tiles and a possibly applied in a wet process Rohglasur with several provided in the production line Gritaufgabe- 5 devices, each order strengths possibly with different grain bands between 0.2 and 2 mm can be realized.
  • the usual grain sizes are between 0.1 and 1 mm. Grains below 0.1 mm are called glass powders. By suitable o mixture and alternate application of different grain sizes can
  • the raw tiles with the glaze material are fired in roller kilns designed for the corresponding large formats in a single firing (about 1100 - 1300 ° C for 1 hour).
  • the tile blank sinters to the tile body / shards (2; 12) and the glaze raw material melts bubbles and waves with high gloss to the glaze layer (3; 13) and combines with the shards (2; 12).
  • a further surface treatment takes place, which according to FIG. 6 comprises at least one polish (optionally in regions) of the glaze surface.
  • the polish may also precede a leveling grinding process.
  • appropriate roughness should be achieved after polishing.
  • further surface finishing techniques may be used after the polishing to achieve particular optical surface effects, or may also be applied, e.g. to increase the skid resistance of such tiles (1; 10).
  • Other mechanical processing methods e.g., sandblasting
  • chemical methods etching
  • process steps can be edge processing to improve the dimensional accuracy (accurate cutting) or to improve processability (chamfering).
  • FIG. 4 shows that a decorative layer can be applied or formed between the cutting of the tile blanks (3) and the application of the glaze material (4).
  • decoration allows the exact representation of rock structures and color patterns on the surface of the cullet (cf., FIG. 2), which in combination with the glaze described above comes into its own in a very high brilliance.
  • the decoration like the glaze before drying (5), can be applied to the leather-hard ceramic shears and / or on the dried shards immediately before the
  • natural stone decors are realized according to the "Rotocolor” process, whereby the selected rock patterns are scanned and “baked” in the "Rotocolor” rolls o made of synthetic material.
  • the decorative colors (a mixture of ceramic colors) are then applied over several rolls in series 2), which is then subsequently covered by the glaze raw material Color of the desired colors to end decoration, which remains visible under the transparent glaze layer.
  • mixtures of ceramic colors and thermoplastics can also be applied by rotary screen printing.
  • the decor pattern is defined by sieves, by means of which a warmed and thus processable screen printing ink is pressed onto the tile surface with a squeegee. This method makes it possible to print up to eight colors one behind the other extremely precisely.
  • other suitable ceramic decoration methods can also be used.
  • relief pattern (20) can be embossed in the still soft or leather-hard tile body and that via suitable die 5 or rollers whose embossing reliefs either directly from corresponding Molded surfaces or indirectly produced by suitable scanning and processing methods.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Finishing Walls (AREA)

Abstract

La présente invention porte sur un carreau céramique (1; 10), comportant une pâte de grès cérame fin (2; 12) (corps de carreau) et une couche de glaçure transparente (3;13), agissant comme un prisme optique, qui présente une épaisseur de couche (a) et une surface plane et lisse (4; 14), la surface (4; 14) de la couche de glaçure étant conçue de façon à présenter, pour un angle de mesure de 20°, une valeur au réflectomètre comprise entre 65 et 90, la couche de glaçure déployant ainsi un effet de prisme optique. L'invention porte en outre sur un procédé de fabrication d'un tel carreau céramique.
EP10720711A 2009-03-31 2010-03-31 Carreau céramique et son procédé de fabrication Withdrawn EP2414306A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102009015765 2009-03-31
DE102009023091 2009-05-28
PCT/EP2010/002101 WO2010112228A1 (fr) 2009-03-31 2010-03-31 Carreau céramique et son procédé de fabrication

Publications (1)

Publication Number Publication Date
EP2414306A1 true EP2414306A1 (fr) 2012-02-08

Family

ID=42272577

Family Applications (1)

Application Number Title Priority Date Filing Date
EP10720711A Withdrawn EP2414306A1 (fr) 2009-03-31 2010-03-31 Carreau céramique et son procédé de fabrication

Country Status (3)

Country Link
EP (1) EP2414306A1 (fr)
DE (1) DE102010013524A1 (fr)
WO (1) WO2010112228A1 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10316518B2 (en) * 2016-01-29 2019-06-11 Daltile Corporation Glazed porcelain roof tile
EP3339271B1 (fr) * 2016-12-22 2019-03-06 Toto Ltd. Objet mat antisalissure
CN109553299B (zh) * 2018-11-02 2021-06-29 广东萨米特陶瓷有限公司 一种结合喷墨效果的通体瓷质砖及其制备方法
CN109574711A (zh) * 2019-01-23 2019-04-05 信益陶瓷(中国)有限公司 一种表面具精细凹凸纹理的瓷质砖及其制造方法
CN114163261B (zh) * 2021-11-29 2023-01-06 佛山欧神诺陶瓷有限公司 一种具有木质温触感的仿木纹陶瓷砖及其制备方法

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19859547C2 (de) * 1998-12-22 2003-04-10 Steuler Fliesen Gmbh Verbundplatte und Verfahren zu ihrer Herstellung

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2010112228A1 *

Also Published As

Publication number Publication date
DE102010013524A1 (de) 2010-10-07
WO2010112228A1 (fr) 2010-10-07

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