EP3073025A2

EP3073025A2 - Ceramic covering system and method for covering a space

Info

Publication number: EP3073025A2
Application number: EP16382118.4A
Authority: EP
Inventors: Juli Febrero Llop
Original assignee: Tot Disset Construccio Sl
Current assignee: Tot Disset Construccio Sl
Priority date: 2015-03-25
Filing date: 2016-03-16
Publication date: 2016-09-28
Anticipated expiration: 2036-03-16
Also published as: ES2640286T3; ES2584457B1; EP3073025B1; ES2584457A1; EP3073025A3

Abstract

The present invention relates to a ceramic covering system and method for covering a space comprising a support structure defining an enclosure to be covered with ceramic pieces, said space being formed by one or more first areas formed by developable surfaces with isometry with respect to a plane, and said space being able to optionally include one or more second areas formed by surfaces curved along two axes, wherein the first areas are covered by means of a division of regular, rectangular, first metal support panels and where the second areas are covered with a division of irregular, second metal support panels, each adapted to its position, there being a regular first array of fixing points for fixing ceramic pieces on the first support panels, and an irregular second array of fixing points for fixing ceramic pieces on the second support panels, the irregularity of the second array being limited.

Description

Field of the Art

The present invention relates to a ceramic covering system and method for covering a space, envisaged particularly for covering the outside of buildings having a complex geometry, with developable surfaces with isometry with respect to a plane or two axes and non-developable, and optionally also including parts having planar surfaces.

State of the Art

Many patent documents describing how to fix ceramic pieces on a support, mainly for covering floors or walls in a simple and quick manner are known, many of the proposed solutions providing dry bonding. Examples of these patent documents are US2872804 , GB1113104 , FR2420621 , US4561232 , EP0629754 , but none of them allows covering spaces provided with complex geometries, their field of actuation being limited to planar elements.
Solutions which allow breaking down a three-dimensional surface into a set of regular planes, such as patent documents US5524396 and US2001020352 , are also known. Patent document MX2012007352 also describes a solution which allows generating a three-dimensional space from planar elements.
None of these background documents allows ceramic covering, nor envisages the use of curved panels which allow being adapted to certain geometries, allowing mass production of part of the covering.

Brief Description of the Invention

The present invention relates to a ceramic covering system and method for covering a space, and to a ceramic piece and a covering panel, envisaged for covering a space, particularly for covering the outside of a building by means of said panels and by means of said ceramic pieces, performing the functions of a façade and roof.
The proposed system for the ceramic covering for covering a space includes the following elements:

a plurality of rectangular first support panels having a predefined size, each provided with tongued and grooved configurations on two of its opposing sides, and with a plurality of fixing points distributed according to a pattern forming part of a first repetitive array of fixing points;
a plurality of covering ceramic pieces anchored to said fixing points of the first support panels by fixing means.

Each of said first support panels holds a plurality of ceramic pieces anchored at the fixing points defined in said first support panel by fixing means, the ceramic pieces therefore being distributed on each first support panel following the distribution pattern of the fixing points.
It will be understood that the mentioned fixing means can be any one of the following, as will be obvious for a person skilled in the art:

screw, rivet, bolt, nail, adhesive, bending, deep-drawing, magnetic force, flange configurations, harpoon configurations, thermal friction, threading by rolling, etc.

The proposed system includes, in a novel manner, a support structure made up of a plurality of support profiles arranged equidistant from one another and formed in curved segments and optionally also straight segments, together defining an enclosure for the space to be covered.
The geometry of said enclosure includes one or more first areas formed by developable surfaces with isometry with respect to a plane, optionally also including planar surfaces.
A plurality of both concave- and convex-curved first support panels, and optionally also a plurality of straight first support panels, are fixed on a plurality of support profiles covering one or more first areas being adapted to the geometry thereof.
Said plurality of first support panels are laterally attached to one another by means of said tongued and grooved configurations provided on their sides, such that said first array of fixing points has continuity between the laterally adjacent first support panels, each of said first support panels being fixed on at least two of said support profiles arranged equidistant from one another and contiguous.
The lateral attachment between support panels also allows the inclusion of expansion joints allowing independent movement of contiguous support plates.
Said plurality of ceramic pieces is anchored at the anchoring points distributed throughout the first areas according to the first array.
Therefore, the system will include a support structure defining the geometry of the space to be covered, and that geometry will comprise one or more first areas that are defined as those areas of the space including developable surfaces with isometry with respect to a plane, and optionally also including planar regions.
A developable surface with isometry with respect to a plane is mathematically defined as a surface with a Gaussian curvature equal to zero. It is a surface with three-dimensional volumetry that can expand, by means of deformations which do not alter the distances between its points, until it becomes a plane. In contrast, a plane can deform until it becomes said developable surface with three-dimensional volumetry.
This geometric property allows covering said developable surface by means of planar panels having a predefined size and shape arranged laterally adjacent to one another by means of a simple curvature along an axis of said planar panels, and also covering, if said planar panels can cover a planar surface completely by fitting with one another laterally, said developable surface without requiring the planar panels being cut or deformed beyond said curvature along an axis. In layman's term, it could be said that a developable surface is a surface that can be covered with a paper without the need to crease or cut the paper.
Said geometric property of the first areas allows defining the first array of fixing points on a plane, and which is perfected adapted on said developable surface without altering the distance between the points thereof.
Therefore, the first areas of the support structure can be completely covered with the first support panels having the ceramic pieces, said first support panels being able to be regular and therefore prefabricated with a geometry which allows them to fit with one another laterally to cover a plane. Examples of that geometry of the first support panels are a square, a rectangle, a triangle and a hexagon, and therefore the first support panels preferably adopt one of said geometries in order to allow completely covering the first area.
This allow the first support panels, the fixing points and the ceramic pieces covering the first areas to be regular and prefabricated, despite covering a surface having a complex geometry. Repetition of first support panels, arranged laterally adjacent and laterally attached to one another by means of tongued and grooved configurations, each with one and the same pattern of fixing points, gives rise to the first array of fixing points which can completely cover the first area.
Non-limiting examples of that developable surface can be simple geometric figures such as a cylinder or a cone, or complex surfaces such as a Möbius strip, or other examples of ruled surfaces.
According to another optional embodiment, the geometry defined by the support structure also includes one or more second areas integrating surfaces curved along two axes, bordering the first areas.
Said second areas are covered by means of trapezoidal second support panels having a width equal to that of the first support panels and tongued and grooved configurations on two of their opposing sides equal to those of the first support panels.
Said second support panels are each fixed between at least two support profiles and are individually sized for together completely covering each at least one second area, being adapted to the complex geometry thereof.
The second support panels are laterally attached by means of the tongued and grooved configurations to the other second support panels and to the bordering first support panels of the second area.
Furthermore, it is envisaged that each second support panel is provided with a plurality of fixing points distributed according to a pattern forming part of a second array of fixing points completely covering said second area in continuity with the first array of the first area, such that the bordering fixing points between each first area and the second area are shared between the first and second arrays.
In other words, the support structure also includes second areas with a curvature along two axes, i.e., forming a non-developable surface which is mathematically defined as surfaces with a positive or negative Gaussian curvature other than zero. Therefore, said second areas cannot be covered with panels having a regular and standard size and shape. Again using layman's term, they are those surfaces that cannot be covered with a sheet of paper without creasing or cutting the paper. Non-limiting examples of such surfaces are a sphere, a hyperbolic paraboloid, or a hyperboloid of revolution, or other rounded amorphous shapes.
Therefore, the first support panels cannot be used in the second areas because when they are curved to adapt to the geometry of the support structure, they would not fit laterally with one another, therefore resulting in the impossibility of completely covering said second areas and furthermore causing the array of fixing points to not have continuity.
For this reason, these second areas require second support panels having an individually defined shape and size to allow, together, covering said second areas in continuity, fitting at the same time with the bordering first support panels of the bordering first areas.
If the first array follows a regular pattern and visual continuity is required between the first and second arrays, the second array must reproduce the pattern of the first array introducing a limited irregularity. Said limited irregularity allows being adapted to the surfaces curved along two axes, since it is not possible to apply the regular first array on the second area without causing its deformation.
In order to maintain an appearance of regularity between the first array and the second array, said irregularity is limited within a narrow range that can allow an appearance of regularity. Said limitation is controlled by one of the following parameters:

the distance separating the anchoring points of the second array is at most 15% greater or smaller or 10% greater or smaller or 5% greater or smaller than the distance separating the anchoring points of the first array.

According to another complementary embodiment, at the fixing points of the second area there is fixed a plurality of models of ceramic pieces, all the models of ceramic pieces having the same geometry and differing in size, the difference in size of each model of ceramic pieces being at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller than the size of the ceramic pieces covering the first areas.
Therefore, the size of the ceramic pieces can also be adapted to the variations in the distance between the fixing points of the second array, thus allowing a limited number of model of ceramic pieces to also be adapted, by means of a limited size irregularity, to the limited irregularity of the second array, thereby maintaining the appearance of regularity.
Furthermore, according to another embodiment it is proposed that the each ceramic piece includes a threaded metal rod protruding from the rear face thereof, partially inserted into the body of the ceramic piece and attached thereto by means of adhesives or resins, and that said metal threaded rod can be fixed to a complementary anchoring point formed by a hole envisaged in a first support panel and/or in a second support panel provided with a screw thread, the screw thread of the hole being provided by a nut, or by a screw thread machined on the inner walls of the hole, or by a circular deformation protruding from the support plate, in the inner walls of which the screw thread has been defined.
This last embodiment consists of a perforation of the first support plate or of the second support plate, producing holes and deformation on the wall surrounding said hole. This allows obtaining from a thin plate a hole with a sufficient wall for arranging a screw thread therein, without having to use nuts, and allows screwing the ceramic panels only having access to the outer face thereof. The use of adhesives or resins or retaining washers is optionally furthermore proposed to prevent said ceramic pieces screwed on the support plates or transition plates from accidentally becoming unscrewed.
According to a preferred embodiment, the ceramic pieces are circular and dished and there are interstitial gaps between them, being fixed on the panels.
Additionally it is proposed that the support panels are extruded metal sheets having a thickness less than 6 mm with parallel reinforcement ribs protruding from the rear face thereof. This construction allows the quick and economical production of thin plates, with little material consumption, but with high rigidity in one direction as a result of said parallel ribs. Preferably, the support plates are fixed between pairs of support profiles orienting said ribs perpendicular to said support profiles.
Furthermore, it is also envisaged that the first array arranges the fixing points following a square, rectangular, triangular or equilateral triangle pattern. In other words, the lines joining the adjacent fixing points to one another form a square, a rectangular or triangular figures, particularly equilateral triangle figures.
The proposed invention also includes the ceramic covering method for covering a space by means of the following elements:

In a novel manner it is proposed that the system includes a support structure on which to anchor the mentioned plurality of first support panels in laterally adjacent position, said support structure defining a complex geometry (either including developable surfaces or non-developable surfaces), said method including the following steps:

a) defining the size and shape of the ceramic pieces;
b) defining the size and shape of the first support panels;
c) defining the pattern of fixing points on the first support panels such that, by arranging them laterally adjacent to one another, they form a first array of fixing points with continuity;
d) analyzing the geometry defined by the support structure and demarcating one or more first areas formed by developable surfaces with isometry with respect to a plane, optionally also including planar surfaces;
e) subdividing said first areas into uniform segments having a developed geometry and surface coinciding with those of the defined first support panels, assigning a precise position to each first support panel within said first areas;
f) manufacturing a plurality of first support panels having the defined size and shape, and with the support points also located in their defined position;
g) installing said first support panels on the support structure in the assigned precise positions, curving them, and installing the ceramic pieces at the anchoring points obtaining a ceramic covering of the first area according to the pre-established first array.

It will be understood that the definition of the developable surface mentioned in the method is the same as that used in the description of the system.
The proposed method optionally also includes the following steps:

h) analyzing the geometry defined by the support structure and demarcating one or more second areas formed by surfaces curved along two axes;
i) defining the pattern of fixing points on the second areas such that they form a second array of fixing points with continuity with respect to the bordering first array;
j) subdividing said second areas into bands having a width equal to the width of the first support panels, and subdividing said bands establishing a plurality of precise laterally adjacent positions in which to fix a plurality of trapezoidal second support panels having a width equal to that of the first support panels and tongued and grooved configurations on two of their opposing sides equal to those of the first support panels;
k) installing said second support panels on the support structure in the assigned precise positions, being adapted to the curvature of the second area to be covered;
l) distributing said second array on said plurality of second support panels, determining the precise position of each support point on each individual second support panel;
m) manufacturing each individual second support panel having the size and shape adapted to its precise position, and with the support points also located in their precise position on said second support panel;
n) installing each second support panel in its precise position, the second support panels being laterally connected to other laterally adjacent first and/or second support panels by means of their respective tongued and grooved configurations;
o) installing the ceramic pieces at the anchoring points, obtaining a ceramic covering of the second area according to the pre-established second array.

Since the second support panels have a width equal to that of the first support panels, and therefore certainly having two parallel sides, their manufacture can be standardized, differing only in their length and/or in the angle formed by the other two sides with respect to the two parallel sides.
According to a preferred embodiment, the support panels are manufactured by means of extrusion, so for the production of the first and of each of the second support panels, only the cut made on the continuous extruded panel is modified.
According to another embodiment of the proposed method, the first array is regular and step l) described above additionally includes the following steps:

p) determining the position of all the anchoring points of the first areas bordering the second areas;
q) calculating, by means of calculation tools and based on the position of said peripheral points and the geometry of the second area to be covered, the second array of anchoring points so that it covers the second areas being adapted to the geometry thereof in continuity with the bordering first array, the second array defining a pattern similar to that of the first array introducing a limited irregularity, the irregularity of the second array being limited such that the distance between the anchoring points of the second array is at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller than the distance separating the anchoring points of the first array, said limited irregularity of said second array allowing the adaption of the pattern of the first array on surfaces curved along two axes, maintaining an appearance of regularity and continuity with respect to the first array.

The mentioned irregularity limitation allows the first and second arrays to maintain a regular appearance, which allows adapting the first array on the second areas giving the feeling of continuity and regularity, when the first and second arrays must be different in reality due to geometry problems.
Furthermore, calculation by means of calculation tools allows creating result simulations, being able to perform different tests and allowing corrections before the production thereof. This method also allows specialized computer-controlled manufacturing tools to produce each of the necessary parts with the precise geometry determined by the calculation tools, such that the placement thereof is simplified, on-site adaptation being unnecessary.
According to another embodiment, the ceramic pieces of the first area have a uniform size and shape and the ceramic pieces of the second area reproduce the shape of the ceramic pieces of the first area, but their size is adapted, for introducing a limited irregularity which allows adapting the size of each ceramic piece anchored at each fixing point of the second area to the irregularity of the second array at that point, the irregularity of the size of the ceramic pieces being limited such that the size of each ceramic piece is at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller than the size of the ceramic pieces covering the first areas.
This limited irregularity in the size of the ceramic pieces of the second area allows adapting said ceramic pieces to the irregularities of the second array with respect to the first array, since by not modifying the size of the ceramic pieces, said limited irregularity of the second array would be much more apparent when a greater or smaller separation is produced between the ceramic pieces covering the second areas than the separation existing between the ceramic pieces covering the first area. This contributes to maintaining said appearance of regularity, since the proportion of the distances between ceramic pieces with respect to the size of said pieces is visually much more apparent than the size ratio existing between different ceramic pieces spaced from one another, so the irregularity in size is much less perceptible than an irregularity in the separation distance between contiguous ceramic pieces.
Optionally, it is proposed that the number of models of ceramic pieces having a different size is equal to or less than five models, few different molds being necessary for the production thereof.
Additionally, it is proposed that some or all of the first support panels and/or the second support panels are manufactured with a specific curvature adapted to their assembly position. This allows said panels to be perfectly adapted to the curvature of the area to be covered. Said curvature can be obtained by means of bending the panels or for example during extrusion.
The curvatures of the panels are simplified to a limited number of angles of curvature, which allows reducing the number of models of curved panels to be produced. Therefore, the complex geometries to be covered are simplified to a limited number of angles of curvature, for example, five different angles of curvature which the panels can adopt.
Therefore, combining said angles of curvature with said first and second support panels and said first and second array, a complex geometry can be covered with panels manufactured in a standardized manner, only introducing variations in a percentage of the produced panels, the number of possible variations being limited.
Other features of the invention are described in the following detailed description of an embodiment.

Brief Description of the Drawings

The foregoing and other advantages and features will be better understood based on the following detailed description of an embodiment in reference to the attached drawings which must be interpreted in an illustrative and non-limiting manner, in which:

Figure 1 shows a space covered with a plurality of support panels lacking ceramic pieces, said space being formed by a first central area of developable surface with isometry with respect to a plane curved along a single axis, which is covered by a plurality of rows and columns of laterally adjacent first support panels, said first area being flanked at the top and bottom by respective second areas curved along two axes and covered by a plurality of rows and columns of laterally adjacent second support panels;
Figure 2 shows the same space shown in Figure 1, in which the first area has been separated from the second areas in order to show them clearly;
Figure 3 shows a plan view of a first support panel provided with fixing points distributed according to a pattern followed by the first array of fixing points;
Figure 4 shows a cross-section view of the first support panel, shown in Figure 3, on which an also sectioned ceramic panel is shown in an uncoupled position with respect to the first support panel;
Figure 5 shows the same first support panel shown in Figure 3 covered with a plurality of ceramic pieces anchored by fixing means;
Figure 6 shows the same cross-section view shown in Figure 4, with a plurality of ceramic pieces anchored to the first support panel by means of screwing the threaded rod to the protruding perforation provided with a screw thread forming the fixing points in this embodiment;
Figure 7 shows a plan view of a second support panel covered with a plurality of ceramic pieces of three different models of ceramic pieces, said ceramic pieces being anchored at the fixing points which are distributed according to a pattern followed by the second array of fixing points;
Figure 8 shows a cross-section view of the second support panel shown in Figure 7, which is curved according to a radius coinciding with the curvature of the support profile on which it is fixed.

Detailed Description of an Embodiment

An embodiment shown in the attached drawings is described below in an illustrative and non-limiting manner.
According to the present embodiment, the invention relates to a ceramic covering system for covering a space having a complex geometry, combining planar surfaces, surfaces curved along a single axis, and surfaces curved along two axes arranged in continuity, enclosing a space.
The ceramic covering is fixed on support panels 10 or 20 which are in turn fixed on a support structure defining the geometry of the space to be enclosed.
Said support structure is made up of a plurality of support profiles 3 arranged equidistant from one another and made up of curved segments and optionally also straight segments, said support profiles 3 serving as anchoring points of the support panels 10 or 20 covering said space, and on which the covering ceramic pieces 30 are fixed.
It is proposed that each of said support panels 10 or 20 shown in Figures 4 to 8 consists of a thin aluminum sheet of between 3 and 4 mm thick, provided with parallel reinforcement ribs 12 arranged on the rear face thereof, conferring rigidity to the support panel 10 or 20, and the panel being provided with tongued and grooved configurations 11 on two of its parallel opposing sides, which allows laterally attaching different support panels 10 or 20, these panels being flush with one another.
As mentioned above, the space to be covered consists of planar surfaces, surfaces curved along one axis and along two axes. Both the planar surface and the surface curved along a single axis are developable surfaces with isometry with respect to a plane the Gaussian curve of which is equal to zero. This means that both surfaces can be covered using regular planar panels laterally attached to one another. The areas of the space to be covered of this type will be referred to hereinafter as first areas 1.
In contrast, the surface curved along two axes is a positive Gaussian curvature that cannot be covered using regular planar panels laterally attached to one another, panels having different shapes are required so that they fit with one another laterally forming said surface with a double curvature. The areas of the space to be covered of this type will be referred to hereinafter as second areas 2.
Both the first areas 1 and the second areas 2 are shown in Figures 1 and 2.
For this reason, the system proposes demarcating the first areas 1 and the second areas 2, which allows performing a regular division of the first areas 1, suitable for being covered by means of a plurality of regular first support panels 10, all of which are equal to one another. In contrast, the second areas 2 require a division according to size and shape adapted to said geometry curved along two axes, giving rise to a plurality of second support panels 20 having a size and shape adapted to a precise position within the second area 2 to be covered, such that they can be laterally attached to one another covering said second area.
Therefore, in order to cover the space shown in Figure 1, the first support panels 10, all of which are equal to one another, are used for covering the first areas 1, fixing each first support panel 10 on the support profiles 3 by means of screws, for example, all the first support panels 10 being laterally connected to one another by means of the tongued and grooved configurations 11 of their sides, providing a continuous covering of the first areas.
To obtain the covering of the second areas 2, the contour of the first support panels 10 demarcating the second areas 2, and also the geometry of said second areas 2, must be known. With this information, and with the help of calculation programs implementing algorithms, the size, shape and precise position of each of the second support panels 20 can be calculated individually and with precision, which allows completely covering the second areas 2 with said second support panels 20, these panels being laterally attached to one another and to the bordering first support panels 10 by means of the tongued and grooved configurations 11.
In order to simplify manufacture and increase system standardization, said second support panels 20 are calculated imposing as a limitation that their width will be regular and equal to the width of the first support panels 10, only their length or the angle formed by their two sides that do not define the width of the panel being modified.
Extrusion is proposed as a method for manufacturing the first and second support panels 10 and 20, which method allows obtaining a constant section having a constant width, provided with ribs 12 and tongued and grooved configurations 11 on the sides thereof, and adapting the length of the manufactured panels by simply modifying the cutting line. Furthermore, the panels allow introducing small curvatures of the extruded panels in a simple manner, thereby making it easier for the panels to be manufactured already having a certain curvature adapted to their position in the covering.
By means of this system and the method implementing it, a metal covering of a complex surface is obtained, but the specification has yet to describe the integration of the ceramic pieces 30 in this system, which is provided below.
As mentioned above, a plurality of ceramic pieces 30 is fixed on said first and second support panels 10 and 20. In the present embodiment, each ceramic piece 30 is circular, bulging in the center and planar on the rear face. In the center of its rear face there has been envisaged an opening in which a threaded rod 41 attached to the ceramic piece 30 by means of adhesive or epoxy resin is partially inserted, part of said threaded rod 41 protruding from the rear face of the ceramic piece 30. Said rod 41 serves as a fixing means 40 for fixing the ceramic piece 30 with the first support panel 10 or second support panel 20, together with a hole made on said support panel 10 or 20, determining a fixing point 42.
According to the proposed embodiment shown in the attached drawings, said fixing points 42 are formed by a perforation of the first or second support panel 10 or 20 causing a deformation of the material surrounding said hole protruding towards the front face of said panel, creating an annular wall around the hole. A screw thread complementary to the threading of the rod 41, allowing them to be coupled to one another by screwing, is proposed on the inner face of said annular wall.
The limited thickness of the panel does not allow making a sufficient screw thread on the inner wall of said hole if said protruding deformation were not made.
A type of retaining system preventing the ceramic pieces 30 from becoming accidentally unscrewed, such as for example, a type of adhesive or resin or a retaining washer, is also proposed.
Just as the first support panels 10 covering the first area 1 can be regular as a result of the first area 1 being a developable surface with isotropy with a plane, the arrangement of the fixing points 42 on said first support panels 10 can also follow a regular pattern, such that the grouping of first support panels 10 provides a regular first array 50 of fixing points 42 extending throughout the entire first area 1, which allows fixing the ceramic pieces 30 covering the first area 1 following the regular first array 50. In the preferred solution, the pattern of fixing points 42 of all the first support panels 10 are identical, making prefabrication and installation easier.
In this example, the first array 50 is formed by equilateral triangles, at the vertices of which the fixing points 42 where the ceramic pieces 30 are anchored are located. If the ceramic pieces 30 are rounded, there will be interstitial gaps between said ceramic pieces leaving the first support panel 10 uncovered.
The regular first array 50 of equilateral triangles cannot be used to cover the second area 2 since the geometry of the second area 2 is made up of curvatures along two axes, and as it is therefore not a developable surface, an irregular second array 51 adapting to said surface is required, but this would cause the pattern followed by the ceramic pieces 30 of the first area 1 and of the second area 2 to be different and lack unity.
To provide apparent unity to the arrangement of the ceramic pieces 30 located on the first area 1 and on the second area 2, a second array 51 is used which reproduces the same pattern as the first array 50, but modified by introducing limited irregularities that allow adapting said second array 51 on the geometry of the second area 2, but without greatly differing from the pattern reproduced by the first array 50.
It is proposed that said limitation to irregularity is such that the distance separating two fixing points 42 of the second array 51 is at most 15% greater or smaller than the distance between two fixing points 42 of the first array 50.
Any irregularity which is below that percentage will be hard to see at a glance and will therefore provide a feeling of regularity to the ceramic covering.
Additionally, in order to prevent the separation between the ceramic pieces 30 of the second area 2 from being obviously different from the separation existing between the ceramic pieces 30 of the first area 1, the use of several models of ceramic pieces 30 in the manner shown in Figure 7 is proposed, all the models having the same shape, but differing in size, that irregularity in the size of the ceramic pieces 30 of the second area 2 preferably being limited to 15% greater or smaller than the size of the ceramic pieces 30 covering the first area 1.
In the present example, the use of five models of ceramic pieces 30 is proposed, the models having the largest size being the one used for covering the first area 1, and a first model being between 2% and 4% smaller, a second model being between 4% and 8% smaller, a third model being between 8% and 11% smaller and a fourth model being between 11% and 15% smaller, always in reference to the model used for covering the first area 1.
According to another suggested embodiment, the model covering the first area 1 is a model having an intermediate size, a first model being between 5% and 10% greater, a second model being between 10% and 15% greater, a third model being between 5% and 10% smaller and a fourth model being between 10% and 15% smaller than the ceramic piece 30 used in the first area 1.
Regardless of the size ratio between the different models of ceramic pieces 30, they will be distributed avoiding the placement of adjacent ceramic pieces 30 with a significant size difference, in an attempt to create transitions between the ceramic pieces having a smaller size and those having a greater size, thereby preventing making said size difference obvious.
Therefore, at those points of the second area 2 in which the distance between the fixing points 42 is greater than normal, ceramic pieces 30 also having a size greater than normal can also be placed, thereby making it less apparent that there is an irregularity. Similarly, smaller ceramic pieces 30 will be used in areas in which the fixing points 42 are closer together.
The second array 51 must be calculated by means of calculation tools, such as specialized computer programs, for example, so that in the bordering areas between the first area 1 and the second area 2, the first and second arrays 50 and 51 have continuity, and in order to achieve the most regular possible distribution of the fixing points 42 on the second area 2, introducing minimal irregularity, making the transition between the first area 1 and the second area 2 unnoticeable.
After the calculation of the second array 51 and of the size, shape and position of the second support panels 20, the superposition of said second array 51 on the division of said second support panels 20 of the second area 2 will provide the exact pattern of fixing points 42 existing on each individual second support panel 20.
Said information will be transferred to the panel manufacturing machines so that they precisely manufacture each of the calculated panels, and it will also be transferred to the creation of all the fixing points 42 of each support plate 10 or 20 in their calculated precise position.

Claims

A ceramic covering system for covering a space including the following elements:
• a plurality of rectangular first support panels (10) having a predefined size, each provided with tongued and grooved configurations (11) on two of its opposing sides, and provided with a plurality of fixing points (42) distributed according to a pattern forming part of a first repetitive array (50) of fixing points (42);

• a plurality of covering ceramic pieces (30) anchored to said fixing points (42) of the first support panels (10) by fixing means (40);
characterized in that the system includes:
a support structure made up of a plurality of support profiles (3) formed in curved segments, and optionally also straight segments, together defining an enclosure for the space to be covered, the geometry of said enclosure including one or more first areas (1) formed by developable surfaces with isometry with respect to a plane, optionally also including planar surfaces;

a plurality of curved first support panels (10), and optionally also planar first support panels (10) being fixed on a plurality of support profiles (3) covering one or more first areas (1) being adapted to the geometry thereof and said plurality of first support panels (10) being laterally attached to one another by means of said tongued and grooved configurations (11) provided on their sides and said first array (50) of fixing points (42) having continuity between the laterally adjacent first support panels (10), each of said first support panels (10) being fixed on at least two of said support profiles (3) which are contiguous; and

said plurality of ceramic pieces (30) being anchored at the anchoring points (42) distributed throughout the first areas according to the first array (50).
The system according to claim 1, characterized in that
the geometry of the enclosure to be covered further includes one or more second areas (2) integrating surfaces curved along two axes, bordering the first areas (1);
and in that the system includes
trapezoidal second support panels (20) having a width equal to that of the first support panels (10) and tongued and grooved configurations (11) on two of their opposing sides equal to those of the first support panels (10), said second support panels (20) each being fixed between two support profiles (3) and being individually sized for together completely covering each at least one second area (2), being adapted to the geometry thereof, the second support panels (20) being laterally attached by means of the tongued and grooved configurations (11) to the other second support panels (20) and to the bordering first support panels (10) of the second area (2);
each second support panel (20) being provided with a plurality of fixing points (42) for fixing ceramic pieces (30) distributed according to a pattern forming part of a second array (51) of fixing points (42) completely covering said second area (2) in continuity with the first array (50) of the first area (1).
The system according to claim 2, characterized in that the first array (50) is regular, and the second array (51) reproduces the pattern of the first array (50) introducing a limited irregularity which allows being adapted to the surfaces curved along two axes, said irregularity being limited such that the distance separating the fixing points (42) of the second array (51) is at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller, than the distance separating the fixing points (42) of the first array (50);
said limited irregularity of said second array (51) allowing the adaptation of the pattern of the first array (50) on surfaces curved along two axes, maintaining an appearance of regularity and continuity with respect to the first array (50).
The system according to claim 2 or 3, characterized in that at the fixing points (42) said one or more second areas (2) have fixed therein a plurality of models of ceramic pieces (30), all the models of ceramic pieces (30) having the same geometry and differing in size, the size of each model of ceramic pieces (30) being at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller, than the size of the ceramic pieces (30) covering the first areas (1).
The system according to any one of the preceding claims, characterized in that it includes at least a plurality of ceramic pieces (30) each provided with a metal rod (41) protruding from the rear face thereof, partially inserted into the body of the ceramic piece (30) and attached thereto by means of adhesives or resins, and in that said metal rod (41) can be fixed to a complementary fixing point (42) formed by a hole envisaged in a first support panel (10) and/or a second support panel (20), providing its retention.
The system according to claim 5, characterized in that the rod (41) is threaded and the complementary hole is provided with a screw thread provided by a nut or by a screw thread machined on the inner walls of the hole, or by a circular deformation protruding from the support plate, in the inner walls of which the screw thread has been defined.
The system according to claim 5 or 6, characterized in that the ceramic pieces (30) are circular and convex and there being interstitial gaps between the ceramic pieces placed in the fixing positions on the panels.
The system according to any one of the preceding claims, characterized in that the support panels (10, 20) are extruded metal sheets having a thickness less than 6 mm with parallel reinforcement ribs (12) protruding from the rear face thereof.
The system according to any one of the preceding claims, characterized in that the first array (50) arranges fixing points (42) following a square, rectangular, triangular or equilateral triangle pattern.
A ceramic covering method for covering a space including the following elements:
• a plurality of rectangular first support panels (10) having a predefined size, each provided with tongued and grooved configurations (11) on two of its opposing sides, and with a plurality of fixing points (42) distributed according to a pattern forming part of a first repetitive array (50) of fixing points (42);

• a plurality of covering ceramic pieces (30) that can be anchored to said fixing points (42) of the first support panels (10) by fixing means (42);
characterized in that the method includes a support structure formed by a plurality of support profiles (3) on which to anchor the mentioned plurality of first support panels (10) in a laterally adjacent position, said support structure defining a complex geometry;
said method including the following steps:
a) defining the size and shape of the ceramic pieces (30);

b) defining the size and shape of the first support panels (10);

c) defining the pattern of fixing points (42) on the first support panels (10) such that, by arranging said panels laterally adjacent to one another, they form a first array (50) of fixing points (42) with continuity;

d) analyzing the geometry defined by the support structure and demarcating one or more first areas (1) formed by developable surfaces with isometry with respect to a plane, optionally also including planar surfaces;

e) subdividing said first areas (1) into uniform segments having a developed geometry and surface coinciding with those of the defined first support panels (10), assigning a precise position to each first support panel (10) within said first areas (1);

f) manufacturing a plurality of first support panels (10) having the defined size and shape, and with the fixing points (42) also located in their defined position;

g) installing said first support panels (10) on the support structure in the assigned precise positions, being adapted to the curvature of the first area (1) to be covered, and installing the ceramic pieces (30) at the anchoring points (42) obtaining a ceramic covering (30) of the first area (1) according to the pre-established first array (50).
The method according to claim 10, characterized in that it further includes the following steps:
h) analyzing the geometry defined by the support structure and further demarcating one or more second areas (2) formed by surfaces curved along two axes;

i) defining the pattern of fixing points (42) on the second areas (2) such that they form a second array (51) of fixing points (42) with continuity with respect to the bordering first array (50);

j) subdividing said second areas (2) into bands having a width equal to the width of the first support panels (10), and subdividing said bands establishing a plurality of precise laterally adjacent positions in which to fix a plurality of trapezoidal second support panels (20) having a width equal to that of the first support panels (10) and tongued and grooved configurations (11) on two of their opposing sides equal to those of the first support panels (10);

k) installing said second support panels (20) on the support structure in the assigned precise positions, being adapted to the curvature of the second area to be covered;

l) distributing said second array (51) on said plurality of second support panels (20), determining the precise position of each fixing point (42) on each individual second support panel (20);

m) manufacturing each individual second support panel (20) having the size and shape adapted to its precise position, and with the fixing points (42) also located in their precise position on said second support panels (20);

n) installing each second support panel (20) in its precise position on the support structure, the second support panels (20) being laterally connected to other laterally adjacent first and/or second support panels (10, 20) by means of their respective tongued and grooved configurations (11);

o) installing the ceramic pieces (30) at the fixing points (42) obtaining a ceramic covering of the second area (2) according to the pre-established second array (51).
The method according to claim 11, characterized in that the first array (50) is regular, and in that step l) additionally includes the following steps:
p) determining the position of all the fixing points (42) of the first areas (1) bordering the second areas (2);

q) calculating, by means of calculation tools and based on the position of said peripheral points and the geometry of the second area (2) to be covered, the second array (51) of fixing points (42) so that it covers the second areas (2) being adapted to the geometry thereof in continuity with the bordering first array (1), the second array (51) defining a pattern similar to that of the first array (50) introducing a limited irregularity, the irregularity of the second array (51) being limited such that the distance between the fixing points (42) of the second array (51) is at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller than the distance separating the fixing points (42) of the first array (1), said limited irregularity of said second array (51) allowing the adaptation of the pattern of the first array (50) on surfaces curved along two axes of the second areas (2), maintaining an appearance of regularity and continuity with respect to the first array (50) covering the first areas (1).
The system according to claim 10, 11 or 12, characterized in that the ceramic pieces (30) of the first area (1) have a uniform size and shape and the ceramic pieces (30) of the second area (2) reproduce the shape of the ceramic pieces (30) of the first area (1), but their size is adapted, for introducing a limited irregularity which allows adapting the size of each ceramic piece (30) anchored at each fixing point (42) of the second area (2) to the irregularity of the second array (51) at that point, the irregularity of the size of the ceramic pieces (30) being limited such that the size of each ceramic piece (30) is at most 15% greater or smaller, or 10% greater or smaller, or 5% greater or smaller than the size of the ceramic pieces (30) covering the first areas (1).
The method according to claim 13, characterized in that the number of models of ceramic pieces (30) having a different size is limited to six or less, a limited number of models of ceramic pieces (30) having a different size being produced.
The method according to any one of preceding claims 10 to 14, characterized in that some or all of the first support panels (10) and/or the second support panels (20) are manufactured with a specific curvature adapted to their assembly position, or the panels are produced using a limited number of angles of curvature, which allows reducing the number of models of curved panels.