EP3481790A1 - Procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince - Google Patents

Procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince

Info

Publication number
EP3481790A1
EP3481790A1 EP17746193.6A EP17746193A EP3481790A1 EP 3481790 A1 EP3481790 A1 EP 3481790A1 EP 17746193 A EP17746193 A EP 17746193A EP 3481790 A1 EP3481790 A1 EP 3481790A1
Authority
EP
European Patent Office
Prior art keywords
process according
glaze
support
temperature
decoration
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Withdrawn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
EP17746193.6A
Other languages
German (de)
English (en)
Inventor
Claudio Fossaluzza
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.)
Target - Srl
Target SRL
Original Assignee
Target - Srl
Target SRL
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 Target - Srl, Target SRL filed Critical Target - Srl
Publication of EP3481790A1 publication Critical patent/EP3481790A1/fr
Withdrawn legal-status Critical Current

Links

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
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
    • 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
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/044—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with glaze or engobe or enamel or varnish
    • 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
    • C04B41/45—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
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • 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
    • 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
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions

Definitions

  • the present invention relates to a process for obtaining glazed flat ceramic elements having large dimensions and reduced thickness, such as slabs suitable for being advantageously used both as they are and also suitable for being used to obtain tiles of smaller dimensions and different shapes, for cladding surfaces such as for example floorings and walls, both internal and external.
  • Said slabs can also have glazed surfaces, i.e. surface-decorated thanks to the application of special ceramic glazes, i.e. compositions suitable for developing, generally at heat, a glassy surface, obtaining desired colouring or aesthetic effects.
  • special ceramic glazes i.e. compositions suitable for developing, generally at heat, a glassy surface, obtaining desired colouring or aesthetic effects.
  • the traditional method for obtaining conventional glazed tiles thus having a thickness of greater than 6-7 mm and modest dimensions, i.e. substantially less than 3m 2 , known in the sector as "double-firing", consists in preparing a support made of a clayey material, subjecting it then to a first firing, at a temperature comprised between about 1050 - 1 100°C, so as to cause vitrification thereof, realising a vitrified ceramic product known as a "biscuit"; this product is then glazed using suitable ceramic glazes and then subjected to a further firing, at a temperature close to vitrification temperature, with the aim of obtaining the glazing of the surface glaze.
  • the ceramic glazes generally used have a glazing temperature of a little lower than the vitrification temperature of the clayey support.
  • the large-dimension slabs with reduced thickness at present available on the market are obtained with a process known as "single-firing", in which a single operation achieves both the firing of the preformed clayey mixture constituting the body of the slab and the surface glazing.
  • the slab of unfired clayey material is surface- decorated by application of suitable glazes, and thereafter fired in a single cycle, in which temperatures of about 1 150 - 1200°C are reached, so as to cause, at the same time, firing of the clayey mixture, i.e. the vitrification thereof, and the glazing of the surface glaze.
  • the ceramic glazes generally used have a glazing temperature that is substantially equal to the vitrification temperature of the clayey support.
  • the main task of the object of the present invention is to obviate the drawbacks in the prior art, by providing a process for obtaining slabs with glazed ceramic coatings having large dimensions and reduced thickness while enabling a planarity thereof to be maintained and preventing formation of fractures.
  • an aim of the present invention is to provide a process for realising ceramic cladding slabs which can be surface-decorated according to a user's requirements, possibly also realising "single-tone" colourings.
  • a further aim of the invention is to obtain a process that is simple to realise, versatile and reliable, and which does not require particular instrumentation or equipment, and is therefore easily industrialisable.
  • a process according to the present invention enables realising flat slabs made of surface-glazed vitrified ceramic material, i.e. surface areas of up to more than 3m 2 , with a reduced thickness, preferably comprised about between 3 and 6 mm and, more generally, between 3 and 1 1 mm, suitable for being used for cladding floors or walls, either with their original size or reduced to elements having smaller dimensions.
  • a process according to the present invention is particularly advantageous for obtaining glazed slabs with a single colouring, which is homogeneous over the whole extension of the slab and uniform for all the slabs obtained using the process.
  • a process according to the present invention it is possible also to obtain glazed slabs provided with surface decorations recreating complex figures, patterns or relief decorations.
  • a first step a) of the process according to the present invention consists in predisposing a vitrified slab support having desired dimensions and thickness.
  • This slab support is preferably obtained by pouring a suitable mixture formed by essentially clayey components internally of a suitable and conventional die, then subjecting the mixture to a pressing by action of suitable ceramic presses.
  • the unfired support is subjected to a first heat treatment, or first firing, at a temperature T1 that is substantially equal to the vitrification temperature TG of the clayey material which the support is formed in, essentially comprised between about 1 150°C and 1200°C for obtaining vitrification thereof.
  • the vitrified support is a semi-finished piece that can be stored and also transported for restricted distances, like any other ceramic product.
  • the vitrified support has in fact sufficient resistance to be sent, using conventional work lines, to the following operating steps, in particular to the following step b) of surface glazing.
  • the support can be subjected to a cutting step, in which it is appropriately cut, preferably by use of diamond cutting heads, following the most suitable geometries and dimensions on the basis of specific use requirements.
  • At least a surface portion of the vitrified flat support obtained during said step a) is subjected to a step b) of glazing, in which glazes, i.e. substances in liquid or paste or powder form, are used that have a composition such as to develop a glassy surface at a determined temperature.
  • glazes i.e. substances in liquid or paste or powder form
  • the glazes applied during the glazing step b) of a process according to the present invention are selected from among those having a fusible base and metal pigments having a glazing temperature TV that is lower than the vitrification TG temperature of the support, and preferably comprised between about 600°C and about 900°C and, still more in particular, between 600° C and 830° C.
  • step c) of heat treatment, or firing able to obtain the vitrification of the glaze placed on the surface thereof.
  • the firing temperature T2 reached in said step c) is essentially equal to, or at least close to, the above-mentioned glazing temperature TV of the glaze and this therefore preferably comprised between about 600°C and 900°C, on the basis of the dimensions of the support and the type of glaze used.
  • the temperature T2 is advantageously sufficient for obtaining the glazing of the applied glaze without however altering the support, as it is already vitrified, and in any case has a much high firing temperature. In this way, tensions are advantageously not created between the two materials, and consequently no fractures or deformations of the slab occur, which remains perfectly flat notwithstanding the significant dimensions thereof.
  • Step c) is preferably carried out using suitable single-layer roller kilns, taking care to maintain the temperature as constant as possible.
  • Said glazing step b) can be carried out with various techniques, known and conventional, selected on the basis of the type of decoration which is desired on the slab.
  • various techniques known and conventional, selected on the basis of the type of decoration which is desired on the slab.
  • the use of a screen printing method is particularly advantageous; in this case the glazes used will preferably be in paste form.
  • the screen printing method initially comprises preparation of a special screen comprised in a frame substantially formed by an external metal frame, on which screening mesh yarns are applied and stretched so as to form a large-mesh fabric.
  • This screen is then positioned at the portion of the surface of the vitrified support which is to be decorated, and is kept more or less raised with respect to the support on the basis of the quantity of colouring paste that is to be deposited.
  • the glaze in paste form is then poured onto the fabric of the screen frame and distributed with a doctor, on the portion of the surface of the slab which is to be decorated; by doing this it is possible to apply the glaze in paste form in a very uniform and precise way and in the right quantity on the surface that is to be glazed.
  • a water-soluble photo-emulsion is suitably applied, which is then dried; a film is then created for screening, bearing the positive of the final decoration on a substantially high-density black background, and is placed in close contact with said emulsion, at the side destined to go into contact with the surface of the slab to be decorated, thus exposing it to ultra-violet rays.
  • the rays cause the hardening of the underlying emulsion exclusively in the free areas defined by the film; the portions of film realised in high-density black, on the other hand, prevent passage of the ultraviolet rays, thus preventing the hardening of the underlying emulsion, which will therefore remain water-soluble.
  • a subsequent washing of the fabric has the effect of removing the non-hardened emulsion, revealing the open areas of the screen material, which thus allows passage of the glaze in paste form towards the underlying surface to be decorated.
  • the screen printing method further enables obtaining glazed decorations in relief, without however requiring the realisation of reliefs or incisions obtainable with dies in the material forming the support; in fact, by acting on the quantity of emulsion applied on the fabric and on the distance between the frame and surface to be decorated, it is possible to define areas in which a greater quantity of glaze in paste form can be applied with respect to surrounding areas, thus creating decorations in relief with respect to the bottom.
  • Step b) of glazing can advantageously also be carried out by spray- printing; in this case, the glaze will preferably be in the form of liquid ink, or alternatively dry-printing with powder glazes.
  • the glazes might possibly also be applied on the surface of the vitrified support by using one or more methods among which those described in the foregoing, on the basis of the specific effect that is to be obtained.
  • the glazes used can be added-to by a determined quantity of powders of specific materials, suitable for giving the glazed surface of the slab a strong resistance to wear.
  • the process of the invention can be configured in a plurality of embodiments, in which not only can the glazing be realised according to the various above-described ways, but it can also be combined in multiple ways with various decoration methods, including known ways, with the aim of obtaining special effects on the product.
  • the invention can also include, in combination with one or more of the different glazing modalities, decoration using digital inkjet printing and/or depositing of grits.
  • first a glazing of the support can be done, then to proceed with a decoration using digital printing.
  • a single-tone glaze coating can be realised and then, before or following the glaze hardening process, digital decoration can be carried out, creating a nuanced effect, or designs or different effects, proceeding with a re-firing at a temperature comprised between 600°C and 900°C.
  • the invention therefore enables, in a surprising way with respect to the present knowledge and practice in the sector, realising a completely new product that is not at present obtainable.
  • the glaze in another embodiment of the process of the invention, by way of non-limiting example, can be spread in such a way as to define a "structure", then, before or after the glaze hardening process, to proceed to a digital decoration using digital inkjet printing, with a re-firing at a temperature comprised between 600°C and 900°C.
  • structure is meant, in the present context, a decoration using reliefs and recesses, which implies the use of a significant quantity of material for this type of application, which cannot be obtained using digital printing.
  • the reliefs can be realised by spreading coats of glaze using a spatula, for obtaining very natural effects, or by using print screens, for obtaining special patterns or special textures.
  • Digital decoration also contributes to the finished product because of its great precision and the chromatic variety of the decorations.
  • the glazing is done before net screens are used to apply grits and create a decoration in relief.
  • glazing is done first, before application of glass flakes.
  • the process of the invention can enable glazing only in one or more portions of the support, then decorating the other portions with different methods, for example by digital printing; consider for example an affixing of gold or other metals using digital printing methods flanked by glazed portions, for enriching the decoration.
  • a process for obtaining a glazed cladding slab having large dimensions and reduced thickness, suitable for surface cladding for floorings or walls comprises following steps:
  • step b) subjecting the product obtained at step b) to a heat treatment, conducted at a firing temperature (T2) substantially equal to or essentially proximal to the glazing temperature (TV) of said glaze, and therefore preferably comprised between 600°C and 900°C, for obtaining a glazed ceramic slab.
  • T2 firing temperature substantially equal to or essentially proximal to the glazing temperature (TV) of said glaze, and therefore preferably comprised between 600°C and 900°C, for obtaining a glazed ceramic slab.
  • step b) of the process can advantageously be carried out using a screen printing method, and/or possibly with spray-printing.
  • the present invention achieves the set task and attains the set aims.
  • a process has been invented for obtaining ceramic and glazed cladding slabs, having large dimensions and reduced thickness which, thanks to the application of a suitable type of glaze, in particular, having a glazing temperature comprised between 600 and 900°C, and to the subsequent firing at a much lower temperature than the vitrification temperature of the material forming the support and essentially equal to the glazing temperature of the applied glaze, enables maintaining the planarity of the slabs, also preventing the formation of fractures which would compromise use thereof.
  • a process according to the present invention advantageously enables obtaining glazed and surface-decorated ceramic cladding slabs according to the requests of the user, possibly also simply realising any "single-tone" colouring in a perfectly uniform and homogeneous way.

Landscapes

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

Abstract

Le procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince comprend les étapes consistant à : prédisposer un support plat en matériau céramique vitrifié présentant des dimensions et une épaisseur souhaitées, appliquer, sur au moins une partie de la surface dudit support, un émail présentant une base fusible et des pigments métalliques présentant une température d'émaillage (TV) inférieure à une température de vitrification (TG) dudit support, soumettre le produit obtenu à un traitement thermique, réalisé à une température de cuisson (T2) égale à la température d'émaillage (TV) dudit émail.
EP17746193.6A 2016-07-07 2017-07-06 Procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince Withdrawn EP3481790A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102016000071139A IT201600071139A1 (it) 2016-07-07 2016-07-07 Procedimento per l’ottenimento di lastre ceramiche smaltate di rivestimento aventi grandi dimensioni e ridotto spessore
PCT/IB2017/054076 WO2018007972A1 (fr) 2016-07-07 2017-07-06 Procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince

Publications (1)

Publication Number Publication Date
EP3481790A1 true EP3481790A1 (fr) 2019-05-15

Family

ID=57610039

Family Applications (1)

Application Number Title Priority Date Filing Date
EP17746193.6A Withdrawn EP3481790A1 (fr) 2016-07-07 2017-07-06 Procédé d'obtention de dalles en céramique glacée de grand format et d'épaisseur mince

Country Status (4)

Country Link
EP (1) EP3481790A1 (fr)
CN (1) CN109476559A (fr)
IT (1) IT201600071139A1 (fr)
WO (1) WO2018007972A1 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201800006122A1 (it) * 2018-06-07 2019-12-07 Procedimento di trattamento di grandi lastre ceramiche
CN111004038B (zh) * 2020-01-02 2022-05-03 杭州诺贝尔陶瓷有限公司 一种具有电热功能的超大规格薄型瓷质板材及其生产方法
EP3888588A1 (fr) * 2020-03-30 2021-10-06 Institut Straumann AG Procédé de fabrication d'une prothèse dentaire émaillée
CN115490539A (zh) * 2021-06-18 2022-12-20 北京小米移动软件有限公司 制作陶瓷壳体的方法、陶瓷壳体及电子设备
ES2940532A1 (es) * 2021-11-04 2023-05-08 Asitec Ceram S L Procedimiento e instalación correspondiente para la fabricación de losetas cerámicas

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1183389B (it) * 1985-02-21 1987-10-22 Marazzi Ceramica Procedimento e immpianto per la produzione di piastrelle ceramiche smaltate, e piastrelle cosi'ottenute
JPS61286283A (ja) * 1985-06-13 1986-12-16 メルク・パテント・ゲゼルシヤフト・ミツト・ベシユレンクテル・ハフツング 真珠顔料被覆粘土素地製品
US5693395A (en) * 1995-03-30 1997-12-02 Imagine Tile, Inc. Glazed ceramic floor tile having high-resolution image
EP2679566A1 (fr) * 2012-06-28 2014-01-01 Colorobbia España, S.A. Procédé permettant d'obtenir des effets d'interférence optique au moyen d'une technique par jet d'encre numérique

Also Published As

Publication number Publication date
IT201600071139A1 (it) 2018-01-07
WO2018007972A1 (fr) 2018-01-11
CN109476559A (zh) 2019-03-15

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