EP3862506B1

EP3862506B1 - Tile for covering a building wall

Info

Publication number: EP3862506B1
Application number: EP21156373.9A
Authority: EP
Inventors: Dealmo Incerti
Original assignee: IDeaRe Srl; Pugnaghi Claudio
Current assignee: Xtile Srl
Priority date: 2020-02-10
Filing date: 2021-02-10
Publication date: 2023-04-19
Anticipated expiration: 2041-02-10
Also published as: EP3862506A1; IT202000002557A1

Description

Field of application

The present invention refers to a tile for covering a building wall.
The present tile is generally inserted in the industrial field of production of tiles, in particular made of ceramic material, and in the field of systems for covering building walls so as to attain an insulation, e.g. thermal or acoustic.
The present tile is therefore inserted in the field of attaining machines for the construction and/or civil industry, in particular for producing covering tiles.

State of the art

In accordance with the prior art, the tiles are made by compacting clay powders or granules usually in atomized form (generically indicated with the term "earth" in the technical jargon of the field and hereinbelow with the term powders for the sake of simplicity) within a shaped chamber, which remains defined between two opposite molds of a press.
As is known, the tiles, in particular of ceramic material, have always been used historically for the purpose of covering a building surface, such as for example a floor or a wall of a home, so as to render the walling itself aesthetically pleasing. More in detail, the tiles normally have substantially parallelepiped shape and are provided with an extension along a main lying plane much greater than their thickness transverse to the plane itself.
The tiles of known type are, during use, normally fixed to the building wall to be covered, side-by-side with respect to each other, covering the desired area.
For such purpose, each tile is mainly extended on a main lying plane and comprises a visible portion, which is extended in a solid body between an external face, intended to be visible and normally colored and/or decorated with many different ornaments, and an internal face, intended to be fixed to the building wall.
In order to fix the internal face of the visible portion, in a per se known manner the tiles also comprise a fixing portion provided at the internal face of the visible portion.
Such fixing portion is normally known in the technical jargon of the field with the term "mark" since it is usually intended to house the trademark of the manufacturing company.
The mark of the tile usually comprises several projections which extend starting from the internal face of the visible portion, forming a pre-established design, such as for example checkerboard or grid design.
The projections of the fixing portion of the tiles of known type have height, starting from the internal face of the visible portion, smaller than about a quarter with respect to the thickness of the visible portion itself.
In this manner, the mark of the tile of known type allows lightening the tile itself, since several empty channels remain defined between the projections, allowing raw material savings during the formation thereof.
The tiles of known type are in practice used for covering building walls, for example in order to render aesthetically pleasing an internal or external dividing wall of a building or of a flooring.
In order to fix the known tiles to the building wall, usually a material layer is used that acts as glue, such as for example a smoothing material, in particular smoothing mortar, which is placed on the building wall and connects the tile to the latter.
Also known in the construction technical field is a process for covering a building wall, which provides for equipping the building walls with an insulation coat, for example a thermal or acoustic insulation, so as to thermally or acoustically insulate two different settings that are separated by the aforesaid building wall.
More in detail, the insulation coats for building walls of known type can be provided for on any surface of any building wall, both vertical walls and floors, and on internal and external surfaces and they are interposed between the building wall itself and the tiles, which serve only for aesthetic decoration purposes.
The insulation coats comprise a layer of adhesive mortar, applied directly on the building wall, to which an insulating panel is thus applied, in particular a thermal insulating panel. On the insulating panel, a layer of smoothing mortar, or another layer of skim finish material, is normally provided for.
Normally, moreover, on the layer of smoothing mortar, a reinforcing mesh is normally applied, in particular made of glass fiber, which confers mechanical strength to the insulation. Indeed, the reinforcing mesh has the object of absorbing and distributing, in a substantially uniform manner, possible stresses to which the insulation coat could be subjected and remedying the risk of forming cracks which are often created due to the multiplicity of different layers present. Therefore, the smoothing mortar, in addition to the object of skim finish of the surface, also has the object of acting as adhesive in order to retain in position the aforesaid reinforcing mesh.
Finally, on the reinforcing mesh, a further layer of smoothing material is superimposed, in particular smoothing mortar, in order to equip the wall with the skim finish necessary for fixing the tiles of known type. The tiles of known type are indeed glued on the latter layer of smoothing mortar so as to equip the building wall with a quality aesthetic finish.
In this situation, the tile for covering a building wall and the process for covering a building wall have in practice shown that they do not lack drawbacks.
The main drawback lies in the fact that the process for covering a building wall of known type provides for a long of succession of steps, in order to fix the aforesaid plurality of layers on the building wall, which involves considerable material and manpower costs.
In addition, the covering process of known type provides for a plurality of layers of materials that are very different from each other, which often detach from each other, causing cracks, breakage, and even structural yielding of the entire insulation.
A further drawback of the tile of known type lies in the fact that the latter requires aforesaid final layer of smoothing mortar so as to be constrained to the building wall, it only carries out a decorative function, in reality weighing down the insulation coat.
A further drawback lies in the fact that the process for covering a building wall of known type involves a thickening of the building wall itself due to the plurality of layers with high thickness, superimposed on each other, necessary for attaining the insulation.
In this situation, if the insulation coat is provided on an internal surface of the building wall, such coat reduces the habitable volume, for example of a room of a home.
Several examples of tiles of known type are described in the documents DE 2149123 A1 , EP 1020589 A2 , US 2,156,149 and US 3,873,402 .
In particular, the document DE 2149123 describes a tile in accordance with the preamble of claim 1 which is provided, on the side of the mark, with multiple rear ends within which the thermally insulating or sound-absorbent materials is inserted. The latter tiles of known type, however, have severe limits with regard to production quality, since the zones of the tile at the rear cavities are subjected to a stronger compaction than the other thicker zones of the tile, thus creating discontinuities of density in the tile itself which facilitate the formation of cracks or breakage between the zones with different density of the same.

Presentation of the invention

In this situation, the problem underlying the present invention is therefore that of remedying the drawbacks manifested by the solutions of known type, by providing a tile for covering a building wall, which is simple and inexpensive to attain.
Further object of the present invention is to provide a tile for covering a building wall which is particularly solid and structurally strong.
Further object of the present invention is to provide a tile for covering a building wall, which also carries out a structural function.
Further object of the present invention is to provide a tile for covering a building wall, which is structurally entirely reliable.
A further object of the present invention is to provide a tile for covering a building wall, which does not reduce the habitable volume of a setting where it is applied.

Brief description of the drawings

The technical characteristics of the invention, according to the aforesaid objects, can be clearly seen in the contents of the below-reported claims and the advantages thereof will be more evident in the following detailed description, made with reference to the enclosed drawings, which represents a merely exemplifying and non-limiting embodiment of the invention in which:

figure 1 shows a schematic perspective view of a tile for covering a building wall, object of the present invention;
figure 1a shows a schematic plan view in which projections of a fixing portion of the tile, object of the present invention, define a honeycomb weave;
figure 2 shows a sectional view of the tile, object of the present invention, illustrated in figure 1 according to the trace II-II of figure 1 itself;
figure 3 shows a detail of the sectional view of figure 2, depicting a projection of the tile, object of the present invention;
figure 4 shows an exploded perspective view of a building wall covered by the tile, object of the present invention.

Detailed description of a preferred embodiment

In accordance with the figures of the enclosed drawings, reference number 1 overall indicates a tile for covering a building wall, object of the present invention.
Such tile 1 is intended to be operatively and mechanically associated with a building wall 100 in order to cover it, so to render it aesthetically appealing.
Advantageously, the present tile 1 is adapted to be applied on any type of building wall 100, in particular both on vertical walls, and on horizontal walls (such as floors, ceilings, attics, etc.). In addition, the present tile 1 is intended both for internal applications (for example in order to internally coat the walls or the floor of a room), and for outside applications (for example in order to attain pavement on terraces).
The tile 1 is extended, in a manner per se known to the man skilled in the art, along a main lying plane X, it is made of ceramic material and comprises at least one visible portion 2 and an opposite fixing portion 5.
The visible portion 2 of the tile 1 is extended between an external face 3 substantially parallel to the main lying plane X and intended, during use, to be visible, and an internal face 4, it too substantially parallel to the main lying plane X and spaced with respect to the internal face 4 by a first thickness D1 orthogonal to the main lying plane X.
The fixing portion 5 is extended, with particular reference to the embodiment of the enclosed figures, from the internal face 4 of the visible portion 2 and comprises a plurality of projections 6 which are extended, starting from the internal face 4 of the visible portion 2, transverse to the main lying plane X for a second thickness D2.
With the term "internal face" 4, it must be intended hereinbelow any one face, of any shape and size, substantially opposite the external face 3 and from which at least one projection 6 is extended, along a direction substantially orthogonal to the lying plane X.
For example, during use, with the tile 1 placed to cover a vertical building wall 100, the lying plane is substantially parallel to the building wall itself (i.e. in particular it too substantially vertical) while the orthogonal extension direction of the projections 6 will be orthogonal to the extension plane X and to the building wall 100, i.e. in particular substantially orthogonal.
Advantageously, the ceramic material, with which the tile 1 according to the invention is attained, can be porcelain stoneware, and/or single-fire material (i.e. tiles made of enameled ceramic material, formed via pressing, subjected to a single-firing process), and/or monoporous (i.e. a single-fire material, in which the attainment process provides for a water absorption, so as to render the ceramic material more easily workable), and/or double-fired material (i.e. tiles made of enameled ceramic material, formed via pressing, subjected to a double firing process), and/or refractory material.
In particular, the present tile 1 is obtained by means of pressing of powders or granules of material (e.g. clay) usually in atomized form, in particular cold, within a shaped chamber which remains defined between two opposite molds of a press. Advantageously, the powders subjected to the pressing have a moisture percentage between 3% and 8% (e.g. 4-5%).
Preferably, the tile 1 according to the invention has substantially parallelepiped shape, i.e. prismatic with polygonal base and advantageously it is intended to face other tiles 1 that are congruent with each other so as to cover the building wall 100.
The external face 3 of the visible portion 2 of the tile 1 is advantageously provided with at least one surface finish, such as for example a coloring, in particular so as to render the building wall 100 aesthetically pleasing.
According to the invention, the height D2 of the plurality of projections 6 of the fixing portion 5 is greater than or equal to half the first thickness D1 of the visible portion 2.
In other words, the height D2 of the plurality of projections 6 of the fixing portion 5 is greater than or equal to a third of the total thickness (transverse to the lying plane X) of the tile 1.
In addition, each projection 6 of the plurality of projections 6 delimits, with at least one adjacent projection 6 thereof, a containment volume 7 susceptible of containing at least one dose of filling material 8 different from the aforesaid ceramic material.
In this manner, the tile 1, object of the present invention, allows attaining, at the fixing portion 5, a layer of filling material 8, which is susceptible of making a cover, in particular insulating, of a building wall 100.
In addition, the tile 1 according to the invention allows attaining a ceramic coat that is inexpensive, light, easy to apply and quite durable over time. Advantageously, the tile 1 according to the invention is on its own capable of forming a cover of a building wall 100, avoiding the need to equip such building wall 100 with further material layers.
Preferably, the filling material 8 is selected from the group comprising a thermal-insulating material, and/or a sound-absorbent material, and/or a dehumidifying material, and/or a refractory material.
Of course, it will be possible to arrange within the containment volume 7 of the tile 1 also other types of material that is capable of insulating the building wall 100, without departing from the protective scope of the present patent.
The filling material 8 can for example be in liquid form, or in gel form susceptible of solidifying following an introduction thereof within the containment volume 7.
Otherwise, moreover, the filling material 8 can have solid form, e.g. glass fiber for the thermal insulation or a sound-absorbent material, e.g. a sound-absorbent sponge in order to allow the tile 1 according to the invention to acoustically insulate at least two settings with respect to each other.
With particular reference to the example of the enclosed figure 2, each projection 6 is extended transversely to the main lying plane X between a base 9 at the internal face 4 of the visible portion 2 provided with a first width A, parallel to the main lying plane X, comprised between 2mm and 40mm and preferably comprised between 5mm and 20mm and in particular comprised between 6mm and 9mm, and an end 10 opposite the base 9 provided with a second width B comprised between 0.4mm and 30mm and preferably comprised between 2mm and 6mm and in particular comprised between 3mm and 4mm. According to the invention, the first width A of the base 9 is greater than the second width B of the end 10.
In accordance with a preferred embodiment illustrated in the enclosed figure 1a, the projections 6 of the fixing portion 5 define a substantially honeycomb weave. Advantageously, the plurality of projections 6 defines the aforesaid honeycomb weave, in particular with hexagonal sectors, in which each containment volume 7 has substantially hexagonal shape.
Otherwise, in accordance with further embodiments not illustrated in the enclosed figures, the honeycomb weave can be of any desired shape, such as for example polygonal, in particular square, rectangular, rhomboid, or otherwise it can be circular, in particular a circle or ellipse.
In this situation, each projection 6 defines a wall and is connected at a connection end thereof to two contiguous projections 6 that are tilted with respect to each other by about 120° with respect to a direction orthogonal to the lying plane X. Advantageously, the intermediate walls which connect the projections 6 also have height D2.
Each projection 6 is extended with tapered form from the base 9 towards the end 10, with the first width A of the base 9 greater than the second width B of the end 10. In particular, the projection 6 is thinned in a substantially gradual manner from the base 9 towards the end 10.
In accordance with the particular embodiment illustrated in the enclosed figure 1, each projection 6 is provided with substantially conical form and is extended starting from the base 9, being tapered up to the end 10.
Each projection 6 comprises a lateral wall 12 with substantially frustoconical shape which joins the base 9 to the corresponding tip 10. Such lateral wall 12 externally delimits the aforesaid containment volume 7 in order to house the corresponding dose of filling material 8.
Advantageously, the end 10 of at least one projection 6 of the plurality of projections 6 has substantially rounded shape with curvature radius comprised between 0.2mm and 15mm and preferably comprised between 1mm and 3mm. In this manner, the rounded shape of the ends 10 of the projections 6 of the fixing portion 5 of the tile 1 allows a facilitated fixing to the building wall 100 during the application of the tile 1 itself to cover the wall.
The fixing portion 5 comprises a plurality of bottom sections 11, in which each bottom section 11 is placed to connect between the bases 9 of the contiguous projections 6 of the plurality of projections 6 and delimits, together with the contiguous projections 6, the containment volume 7.
More in detail, each bottom section 11 delimits, together with the lateral walls 12 of at least two contiguous projections 6, a corresponding containment volume 7 for the dose of filling material.
According to the idea underlying the present invention, each bottom section 11 of the fixing portion 5 is concave with curvature radius comprised between 15mm and 50mm.
In this manner, the concave shape of the bottom section 11 of the fixing portion 5 allows easily containing the dose of filling material 8.
In addition, the concave shape of the bottom section 11 (and preferably also the rounded shape of the ends 10) allows an optimal forming of the tile 10.
Indeed, as is known, the tile 1 is attained by compacting powders or granules of material (e.g. clay), usually in atomized form (generically indicated with the term "earth" in the technical jargon of the field and hereinbelow with the term powders for the sake of simplicity), cold, within a shape chamber that remains defined between two opposite molds of a press.
The height D2, in particular equal to at least half of the thickness of the visible portion 2, of the projections 6 tends to compact the powders more at the bottom sections 11, and otherwise obtain a reduced compaction and hence smaller density at the ends 10 of the projections 6 themselves.
In this situation, the concave shape of the bottom section 11 (and preferably also the rounded shape of the ends 10) allows obtaining a tile 1 provided in each point with the same density and compaction of the powders, in particular by distributing the powders along the aforesaid frustoconical shape of the projections 6 in order to increase the compaction and hence the density both at the lateral walls 12 and at the ends 10, since the latter can be moved along the aforesaid concave shape while the molds of the press cold-crush the powders. Therefore, the concave shape of the bottom section 11 of the fixing portion 5 allows more uniformly distributing the powders in the zones of the bottom sections 11 and of the projections 6 of the tile 1 during the pressing operations, thus obtaining a uniform compaction of the powders themselves within the tile 1 which ensures good solidity for the latter, since significant density differences between the different zones of the tile 1 - which could facilitate the formation of cracks or breakage - are avoided.
The bottom section 11 has curved shape, preferably rounded, and it is connected to the lateral walls 12 of the corresponding containment volume 7 by means of respective rounded connector sections.
Preferably, in order to define the aforesaid at least one containment volume 7 with a volume suitable for containing the dose of filling material 8, the height D2 of the plurality of projections 6 of the fixing portion 5 is about equal to the first thickness D1 of the visible portion 2.
In this manner, half of the total thickness of the tile 1, object of the present invention, is substantially defined by the fixing portion 5, in which the at least one containment volume 7 is susceptible of being filled by a corresponding dose of filling material 8.
A process for covering at least one building wall is defined hereinbelow, in particular actuatable by means of at least one tile 1 of the type described above and regarding which, for description simplicity, the same reference numbers will be maintained.
Such process comprises a succession of operating steps, described in detail hereinbelow.
First, the process provides for at least one step of arranging at least one tile 1, made of ceramic material, and preferably a plurality of tiles 1 that are congruent with each other.
Advantageously, the process also provides for a step of skim finish, in which at least one layer of smoothing material 200 is applied on at least one surface 101 of the building wall 100.
Advantageously, the smoothing material 200 comprises at least one smoothing mortar.
With the term "skim finish" it must be intended hereinbelow the application of a layer of material, e.g. plaster, or the aforesaid smoothing mortar (also known as fine mortar or plaster finish, also known as civil plaster).
Such smoothing mortar advantageously comprises slaked lime and fine sand in order to make the surface smooth and uniform.
Of course, the step of skim finish can be executed before, after or simultaneously with the aforesaid arranging step without departing from the protective scope of the present patent.
The process then provides for a step of fixing the at least one tile 1 on the building wall 100.
Advantageously, the fixing step provides for fixing a plurality of the aforesaid tiles 1 side-by-side each other on the smoothing material 200, in order to cover the desired area of the building wall 100.
Advantageously, in order to fix the tile 1 to the building wall 100, and in particular to the smoothing material 200, the process according to the invention also comprises a gluing step, in which at least one glue layer (not illustrated in the enclosed figures and per se well-known to the man skilled in the art) is interposed between the fixing portion 5 of the tile 1 and the building wall 100, and in particular the layer of smoothing material 200, before the aforesaid fixing step.
The process also comprises at least one step for filling the containment volume 7 of the fixing portion 5 of the tile 1 with at least one dose of at least one filling material 8.
In this manner, the process, object of the present invention, allows attaining a coat of a building wall 100 that is inexpensive and easy to make, since it is sufficient to fix the aforesaid tiles 1, object of the present invention, avoiding the need to superimpose a plurality of different-material layers.
Advantageously, the filling step provides for filling a plurality of containment volumes 7 with a corresponding plurality of doses of filling material 8.
The filling material 8 of the filling step is selected from the group comprising a thermal-insulating material, and/or a sound-absorbent material, and/or a transmitting material, and/or a dehumidifying material, and/or a refractory material.
Advantageously, the glue layer of the gluing step comprises the filling material 8 of the filling step and in particular, preferably, consists of the same filling material 8.
In accordance with the preferred embodiment illustrated in the enclosed figures, the filling step provides for filling a plurality of containment volumes 7 with a corresponding plurality of doses of filling material 8 in a substantially honeycomb weave defined by the plurality of projections 6.
For example, the filling step can provide for filling the containment volumes 7 of the honeycomb weave of the preferred embodiment illustrated in the enclosed figure 1a with corresponding sound-absorbent portions in order to acoustically insulate two settings that are separated by the building wall 100.
The invention thus conceived therefore achieves the pre-established objects.
In particular, the tile 1 and the process according to the present invention allow attaining a simple, quick and inexpensive insulation coat, with high durability and mechanical stability, due to the provision that the height D2 of the plurality of projections 6 of the fixing portion 5 of the tile 1 is greater than or equal to half of the first thickness D1 of the visible portion 2 and that each projection 6 of the plurality of projections 6 delimits, with at least one adjacent projection 6 thereof, a containment volume 7 susceptible of containing at least one dose of filling material 8.

Claims

Tile (1) for covering a building wall, which is extended along a main lying plane (X), is made at least of a ceramic material and comprises:
- a visible portion (2), which is extended between an external face (3) substantially parallel to said main lying plane (X) and intended, during use, to be visible and an internal face (4) substantially parallel to said main lying plane (X) and spaced with respect to the internal face (4) by a first thickness (D1) orthogonal to said main lying plane (X);

- a fixing portion (5) extended from the internal face (4) of said visible portion (2) and comprising a plurality of projections (6) which are extended, starting from the internal face (4) of said visible portion (2), transverse to said main lying plane (X) for a second thickness (D2);

wherein the height (D2) of the plurality of projections (6) of said fixing portion (5) is greater than or equal to half the first thickness (D1) of said visible portion (2);

wherein each projection (6) of said plurality of projections (6) delimits, with at least one adjacent said projection (6) thereof, a containment volume (7) susceptible of containing at least one dose of filling material (8) different from the ceramic material of said tile (1);

wherein each projection (6) is extended transverse to said main lying plane (X) between a base (9) at the internal face (4) of said visible portion (2) provided with a first width (A), parallel to said main lying plane (X), and an end (10) opposite said base (9) provided with a second width (B);

wherein said fixing portion (5) comprises a plurality of bottom sections (11),

wherein each said bottom section (11) is placed to connect between the bases (9) of contiguous projections (6) of said plurality of projections (6) and delimits, together with said contiguous projections (6), said containment volume (7); wherein each said projection (6) comprises a lateral wall (12) which joins said base (9) to the corresponding said end (10), and said lateral wall (12) externally delimits said containment volume (7) in order to house the corresponding dose of filling material (8);

said tile (1) being characterized in that said first width (A) is comprised between 2mm and 40mm, and said second width (B) is comprised between 0.4mm and 30mm;

and in that

each bottom section (11) of said fixing portion (5) is concave with curvature radius comprised between 15mm and 50mm;

wherein said bottom section (11) has curved and rounded shape and is connected to the lateral walls (12) of the corresponding containment volume (7) by means of respective rounded connector sections;

wherein each projection (6) is extended with tapered form from said base (9) towards said end (10), with the first width (A) of said base (9) greater than the second width (B) of said end (10).
Tile (1) for covering a building wall according to claim 1, comprising said filling material (8) contained within said containment volumes (7); wherein said filling material (8) is selected from the group comprising a thermal-insulating material, and/or a sound-absorbent material, and/or a dehumidifying material, and/or a refractory material.
Tile (1) for covering a building wall according to claim 1 or 2, wherein said first width (A) is comprised between 5mm and 20mm.
Tile (1) for covering a building wall according to any one of the preceding claims, wherein said second width (B) is comprised between 2mm and 6mm.
Tile (1) for covering a building wall according to any one of the preceding claims, wherein the end (10) of at least one projection (6) of said plurality of projections (6) has substantially rounded shape with curvature radius comprised between 0.2mm and 15mm and preferably comprised between 1mm and 3mm.
Tile (1) for covering a building wall according to any one of the preceding claims, wherein the height (D2) of the plurality of projections (6) of said fixing portion (5) is about equal to the first thickness (D1) of said visible portion (2).
Tile (1) for covering a building wall according to any one of the preceding claims, wherein said projections (6) of said fixing portion (5) define a substantially honeycomb weave.