EP3915803A1 - Mosaic segment, mosaic, method for printing a mosaic segment, method for producing a mosaic segment - Google Patents

Abstract

The invention relates to a mosaic segment (1) comprising a carrier plate (2) with a surface structure, the surface structure comprising a plurality of mosaic structure elements (3) which are grouped in such a way that they form a segment pattern (12) and between the mosaic structure elements (3) Joints (4) are formed, the structured carrier plate (2) being designed as a one-piece pressed ceramic part. The mosaic segment according to the invention makes it possible, in a time-saving and simple manner, to produce precise mosaics which have a large number of mosaic elements (mosaic structural elements).

Description

The invention relates to a mosaic segment comprising a carrier plate with a surface structure. The invention also relates to a mosaic comprising a plurality of mosaic segments joined together, a method for printing a mosaic segment and a method for producing a mosaic segment.

Background of the invention

Mosaics known from the prior art comprise a large number of small mosaic stones which are put together to form a pattern / picture. The assembly of the small mosaic stones is extremely complex and the mosaics are correspondingly expensive.

For the luxury sector, the tesserae are made of glass and colored with sand oxides [2].

In order to facilitate the joining of the mosaic stones at the installation site, it is common, especially in the sanitary area, to prefabricate 20-45cm ² large mosaic nets in which the mosaic stones are glued to a plastic net [1], which facilitates handling and further processing.

Since the effort to create a mosaic increases enormously the smaller the mosaic stones are, only approx. 4,300 mosaic stones (edge length approx. 1.5 cm) per square meter are used for normal mosaics. Detailed images can therefore only be insufficiently resolved.

Object of the invention

It is the object of the invention to provide mosaic segments with which precise mosaics can be produced in a time-saving and simple manner, which mosaics have a large number of mosaic elements (mosaic structural elements). In addition, it is the object of the invention to propose a method for producing such mosaic segments with which mosaic segments can be produced easily and inexpensively which have a high-quality, exclusive optical appearance.

Description of the invention

This object is achieved according to the invention by a mosaic segment according to claim 1, a mosaic according to claim 6, a method for printing a mosaic segment according to claim 9 and a method for producing a mosaic segment according to claim 14.

The mosaic segment according to the invention comprises a carrier plate with a surface structure, the surface structure comprising a plurality of mosaic structure elements which are grouped so that they form a segment pattern and joints are formed between the mosaic structure elements, the structured carrier plate being designed as a one-piece pressed ceramic part. A mosaic assembly can have mosaic structure elements of different sizes and shapes.

Pressed ceramic is understood to mean, for example, an injection-molded ceramic.

Compared to metal-cutting manufacturing processes, the injection molding of ceramic materials (Ceramic Injection Molding CIM) offers much greater freedom in the part geometry. In many cases, the material properties of the ceramics alone create a better solution from an economic and technical point of view than conventional materials or manufacturing methods. The freedom of design of the injection molding process can increase these advantages or enable completely new product ideas to be realized.

According to the invention, the elements of the mosaic to be produced are not produced as individual elements, but as structural elements of a carrier plate. A mosaic segment therefore takes on the function of a large number of conventional tesserae, wherein the tessellated segment can be handled like a single tesserae, since it is only a single part. Due to the planned joints between the mosaic structural elements, the impression of many mosaic stones can still be created.

The mosaic structural elements are grouped on the carrier plate, i.e. arranged in a predetermined order, and form the segment pattern (i.e. the pattern within a mosaic segment). The mosaic segment is also known as a "cluster".

In order to prevent a visible repeat of the individual clusters, the design of the mosaic elements shown is such that it can be laid homogeneously in all directions, ie the mosaics are visually arranged in new ways. As the clusters are later grouted, the beginnings and ends of the clusters are no longer visible. The mosaic structural elements form elevations. The space (joint) between the mosaic structural elements is limited by the carrier plate. The width (smallest dimension parallel to the plane of the carrier plate) of the mosaic structure elements is preferably less than 2 cm. The distance between adjacent mosaic structure elements is preferably smaller than the width of the mosaic structure elements, in particular less than 1/10 of the width of the mosaic structure elements.

In a preferred embodiment, the mosaic structure elements have rounded contours in plan view (view perpendicular to the plane of the carrier plate), for example round or elongated with rounded corners or organic shapes, for example pebble-like. The rounded contours enable serial, transparent glazing of the mosaic elements. Due to the rounded shape, the glaze can flow out completely around the mosaic structure elements. In addition, the rounded elements can later be grouted more precisely by the craftsmen. In principle, however, any shape can be implemented.

In a particularly preferred embodiment of the mosaic segment according to the invention, the carrier plate is made of oxide ceramic, in particular made of zirconium oxide ZrO2 or aluminum oxide Al2O3, or silicate ceramic. manufactured. Press ceramic parts of this type are used in dental technology for crowns and bridges [3] and can be manufactured with a high degree of precision as parts off the tool.

In order to reduce the weight of the mosaic segment, it is advantageous if the carrier plate is provided with bores between the mosaic structural elements. In addition, the boreholes offer the possibility of illuminating the mosaic segment from behind, which means that luminous mosaic images can be generated.

The mosaic structural elements of the mosaic segment according to the invention are preferably provided with a glaze, the glazed mosaic structural elements having a crown. The crowning is brought about by a special glaze technique, which is preferably applied by machine using stainless steel stencils, and is used to create a glossy / luminous effect, since light falling through the crowning falls through the surface to the pure white background of the mosaic structural elements and through the glaze is reflected back. Due to the small contact area, the camber also prevents profound and visible effects when it comes into contact with an object Scratch. The mosaic segment according to the invention therefore has a high level of scratch resistance.

The glaze is preferably an opaque, that is to say light-impermeable, glaze, in particular a white or black opaque glaze.

The mosaic according to the invention comprises a multiplicity of previously described mosaic segments joined together. The joints between the mosaic structural elements are at least partially filled with a joint compound. Both the joints between the mosaic structure elements within a mosaic segment and the joints between the mosaic structure elements of adjacent mosaic segments are grouted.

Since the elements of the mosaic according to the invention are not manufactured as individual elements, but rather as structural elements of a carrier plate which comprises a large number of structural elements, very small structural elements can be produced with comparatively little effort. The structural elements of the mosaic segment according to the invention are preferably smaller than 1 cm, in particular 0.5 cm or smaller. This makes it possible to create high-resolution mosaic images, for example of portraits, so that the personality traits of the person depicted are not lost.

In order to obtain a uniform overall pattern, in particular without a repeat, it is advantageous if adjacent mosaic segments are each arranged rotated with respect to one another with an edge rotation of 90 °. For this purpose, the mosaic segments are preferably square.

In a special embodiment of the mosaic according to the invention, the joints between the mosaic structural elements are at least partially filled with a self-illuminating joint compound. “Self-illuminating” is understood to mean, in particular, phosphorescent. In combination with a perforated carrier plate, the impression can be created that the mosaic structure elements are applied to a luminous surface.

The mosaic segments according to the invention are preferably used to cover an interior wall or a side wall of a ship, in particular a yacht. In addition, the mosaic segments according to the invention can be used to cover room walls, aircraft walls, furniture, etc.

1. a) Bereitstellung von abgespeicherten Farbverteilungen, wobei die Farbverteilungen erzeugt wurden durch:
   • a.a.i. Herstellen eines Mosaiksegment-Dummies, wobei der Mosaiksegment-Dummy eine Dummy-Trägerplatte mit Dummy-Mosaikstrukturelementen umfasst, wobei die Dummy-Mosaikstrukturelemente in demselben Segmentmuster angeordnet sind wie die Mosaikstrukturelemente des Mosaiksegments;
   • a.a.ii. Kolorieren der Mosaiksegment-Dummies, wobei jedes Dummy-Mosaikstrukturelement eine charakteristische Farbverteilung erhält;
   • a.a.iii. digitales Ablichten der kolorierten Mosaiksegment-Dummies, wobei jede Farbverteilung der Dummy-Mosaikstrukturelemente in einem Speicher abgelegt wird;
2. b) Erstellung eines Gesamtmusters durch virtuelles Zusammenfügen von einer vorgegebenen Anzahl an Segmentmustern mittels einer Software;
3. c) virtuelles Aufteilen des Zielmotivs in Mosaikstrukturelement-Bereiche durch Überlagerung des Zielmotivs mit dem Gesamtmuster, wobei jeder Mosaikstrukturelement-Bereich ein Mosaikstrukturelement des Mosaiksegments repräsentiert;
4. d) Zuweisen einer der abgespeicherten Farbverteilungen zu jeweils einem der Mosaikstrukturelement-Bereiche;
5. e) Farbauftrag auf die Mosaikstrukturelemente mit denjenigen Farbverteilungen, die den Mosaikstrukturelement-Bereichen zugeordnet wurden, welche die jeweiligen Mosaikstrukturelemente repräsentieren.

The invention also relates to a method for printing a mosaic segment with a target motif, the mosaic segment comprising a carrier plate and a plurality of mosaic structure elements arranged in a segment pattern, the carrier plate and mosaic structure elements being designed as a one-piece pressed ceramic part. The method according to the invention for printing a mosaic segment comprises the following method steps:

1. a) Provision of stored color distributions, whereby the color distributions were generated by:
   • aai producing a mosaic segment dummy, the mosaic segment dummy comprising a dummy carrier plate with dummy mosaic structure elements, the dummy mosaic structure elements being arranged in the same segment pattern as the mosaic structure elements of the mosaic segment;
   • aaii. Coloring the mosaic segment dummies, each dummy mosaic structure element being given a characteristic color distribution;
   • aaiii. digital imaging of the colored mosaic segment dummies, each color distribution of the dummy mosaic structure elements being stored in a memory;
2. b) Creation of an overall pattern by virtually assembling a predetermined number of segment patterns by means of software;
3. c) virtually dividing the target motif into mosaic structure element areas by superimposing the target motif with the overall pattern, each mosaic structure element area representing a mosaic structure element of the mosaic segment;
4. d) assigning one of the stored color distributions to one of the mosaic structure element areas;
5. e) Applying paint to the mosaic structural elements with those color distributions which were assigned to the mosaic structural element areas which represent the respective mosaic structural elements.

The dummy mosaic structure elements of the mosaic segment dummy produced in step a) are arranged in the same segment pattern as the mosaic structure elements of the mosaic segment, ie the geometric arrangement (alignment of the elements to one another) and the proportions (length / width / spacing) of the dummy mosaic structure elements correspond the geometric arrangement and proportions of the corresponding mosaic structural elements of the mosaic segment. However, the size of the mosaic structure elements may differ from that of the dummy mosaic structure elements. This allows flexibility in the choice of material to be used for the mosaic segment dummies. For example, a material with a higher or lower material shrinkage can be used for the mosaic segment dummy than for the mosaic segment. The height of the dummy mosaic structure elements is preferably smaller than the height of the mosaic structure elements of the mosaic segment. This enables easy coloring. The height of the dummy mosaic structure elements is preferably equal to the height difference between the mosaic structure elements and the joint compound in a fully grouted mosaic segment.

The coloring in step b) is preferably carried out by applying a glaze, in particular a ceramic glaze. When coloring, the dummy mosaic structure elements are given an individual color distribution. Each dummy mosaic structure element is preferably colored in a specific color shade or with a combination of similar color shades, preferably by hand.

As a result, craftsmanship comes to the fore. Therefore, brightness and color saturation in particular can change within a dummy mosaic structure element.

The digital imaging in step c) can take place by photographing or scanning. Each color distribution stored in step c) preferably receives an individual color code which can be assigned to the respective mosaic structure element areas. The corresponding color codes are then transmitted to a printer system together with information that identifies the respective mosaic structure element.

The creation of the overall pattern in step d) can take place by means of a 2-dimensional arrangement of segment patterns each rotated by 90 ° in relation to one another. The size of the overall pattern corresponds to the size of the target motif.

In step e) the target motif is divided according to the mosaic segments of the overall pattern, so that a mosaic structure element area of the target motif is assigned to each mosaic structure element of the overall pattern.

The colorations present in the mosaic structure element areas are assigned in step f) to those stored color distributions which come closest to the real colorations of the corresponding mosaic structure element areas of the target motif.

The application of paint to the mosaic structural elements in step g) is preferably carried out by means of brushes or airbrushes.

The mosaic segment dummies are preferably colored by hand in step b). By applying the color by hand, there is a unique color distribution for each mosaic structure element. With the method according to the invention, on the one hand, printing can be done by machine, and on the other hand, a color distribution is realized that corresponds to that of hand painting. In this way, high-quality mosaics with individual characteristics can be produced in a comparatively inexpensive manner.

Different materials can be used to produce the mosaic segment dummies and the mosaic segments. While pressed ceramic is preferably used for the mosaic segments that are used for the mosaic to be created in order to minimize shrinkage after firing, a more easily processable material can be used for the mosaic segment dummies, since here it only depends on the proportions of the mosaic structural elements to each other.

The mosaic segment dummies are preferably made of pourable or paste-like porcelain (because of the impossibility of demolding as a whole cluster, the joints are filled here). Porcelain is ideal as a material for the mosaic element dummies, as it is available as a casting compound and has the perfect consistency for glazing by hand. The dummies made of castable porcelain have all the properties of the classic "crockery porcelain". In traditional hand painting, this affects the way the glazes are absorbed into the surface - work can be done much more precisely and therefore authentically.

• Herstellung einer einteiligen strukturierten Trägerplatte mit einer Oberflächenstruktur, die eine Vielzahl an Mosaikstrukturelementen umfasst, die so gruppiert sind, dass zwischen den Mosaikstrukturelementen Fugen ausgebildet sind, mittels eines Keramik-Presswerkzeugs;
• Glasieren der Mosaikstrukturelemente, wobei eine Bombierung der Mosaikstrukturelemente erzeugt wird;
• Bedrucken der Mosaikstrukturelemente.

The invention also relates to a method for producing a mosaic segment described above with the following method steps:

• Production of a one-piece structured carrier plate with a surface structure comprising a plurality of mosaic structure elements which are grouped in such a way that joints are formed between the mosaic structure elements by means of a ceramic pressing tool;
• Glazing the mosaic structural elements, a crowning of the mosaic structural elements being produced;
• Printing of the mosaic structural elements.

The carrier plates are preferably manufactured using a method similar to injection molding, in particular using ceramic injection molding [4]. The tool structure is significantly simplified here; the use of standard parts is dispensed with. Of the Ceramic injection molding enables a great variety of shapes with high material quality.

When the carrier plates are pressed, a certain amount of a polymer material is added to the liquid mass of the carrier plate material (e.g. aluminum oxide) and then "baked" under high pressure in the tool (almost free of shrinkage).

In order to increase the roughness of the surface if necessary, the surfaces of the mosaic structure elements can be ground flat before glazing. If the process is optimized accordingly, surface grinding can be dispensed with.

The method described above for printing a mosaic segment is preferably used for printing the mosaic structural elements.

In a special variant of the method according to the invention, a muffle glaze method is used for printing. Muffle glazes can be burned in perfectly and are therefore particularly hard. The muffle glaze gives the mosaics a special brilliance in the surface, as the prefabricated elements are delivered with a transparent glaze.

Further advantages of the invention emerge from the description and the drawing. The features mentioned above and below can also be used according to the invention individually or collectively in any combination. The embodiments shown and described are not to be understood as an exhaustive list, but rather have an exemplary character for describing the invention.

Detailed description of the invention and drawing

Fig. 1

shows a three-dimensional representation of a mosaic segment according to the invention with round and elongated mosaic structural elements.

Fig. 2

shows a plan view of the mosaic segment Figure 1 .

Fig. 3

FIG. 14 shows a side view of the mosaic segment from FIG Figure 1 .

Fig. 4

shows a detail of a plan view of a mosaic segment according to the invention with bores through the carrier plate.

Fig. 5

shows the overall pattern of a mosaic according to the invention from 4 mutually rotated mosaic segments.

Fig. 6

shows the overall pattern Fig. 5 , a target subject and the superposition of the target subject with the overall pattern.

Fig. 7

shows mosaic segments with pebble-shaped mosaic structure elements shifted against each other in rows

Fig. 8

shows that from the arrangement of Fig. 7 resulting overall pattern.

Fig. 9

shows the method steps for a method according to the invention for printing a mosaic segment.

Fig. 10

shows a three-dimensional representation of a mosaic segment dummy.

Fig. 11

shows the method steps for a method according to the invention for producing a mosaic segment.

Figures 1 to 3 show a mosaic segment 1 according to the invention. The mosaic element 1 has a carrier plate 2 with a multiplicity of mosaic structure elements 3 which form a segment pattern 12 . There are joints 4 between the mosaic structural elements 3 Figure 3 the joints 4 are filled with a joint compound 5 up to a certain height. The joints 4 can be filled with the joint compound 5 before and / or after several mosaic segments 1 have been joined together to form a mosaic 7 (see FIG. Figure 5 ) take place. The mosaic structure elements 3 have a curved surface (crown 6 ) and can be designed in different shapes (here three different shapes).

In the area of the joints 4, holes 8 can be provided in the carrier plate 2 in order to enable background lighting, as in FIG Figure 4 shown.

Figure 5 shows a plan view of a mosaic 7 according to the invention. The mosaic structure elements 3 of all mosaic segments 1 form an overall pattern 9. The in Figure 5 The mosaic 7 shown comprises, by way of example, four mosaic segments 1 which are each rotated by 90 ° with respect to one another so that a uniform, repeat-free overall pattern is formed. In order to illustrate the rotation of the individual mosaic segments 1, the same mosaic structure element 3 was marked with hatching in each mosaic segment 1. The edges of the individual mosaic segments 3 are shown in dashed lines.

Another possibility to create a repeat-free overall pattern is to move the mosaic segments of different rows against each other, as in the Figures 7 and 8th shown by way of example for mosaic segments with pebble-shaped mosaic structural elements.

Figure 6 shows on the right a target motif 10, which is based on a mosaic with the in Figure 6 Overall pattern 9 shown on the left is to be shown.

The individual process steps for printing the corresponding mosaic segments 1 are shown in Figure 9 shown: First of all, the overall pattern 9 is created from individual segment patterns 12 with the aid of software. The number of segment patterns 12 depends on the size and desired resolution of the mosaic to be generated. In Figure 6 Below is shown how the target motif 10 is superimposed with the overall pattern 9 in order to divide the target motif 10 into mosaic structure element areas 11 which correspond to the mosaic structure elements of the mosaic to be produced. The colors (shown here as hatching) within each mosaic structure element area 11 are analyzed and each mosaic structure element area 11 is assigned a previously provided (stored) color distribution, such that the assigned color distribution corresponds as closely as possible to the colors of the corresponding mosaic structure element area 11. In this way, the colors contained in the target motif are replaced in certain areas by the color distributions provided. The mosaic structure elements 3 of the mosaic segments 1 are then printed in accordance with the assigned color distributions.

This allows the character of the target motif to be changed, for example by creating the color distributions provided by hand painting.

To provide color distributions, at least one mosaic segment dummy 13 is first produced which has dummy mosaic structure elements 14 which form the same segment pattern 12 as the mosaic structure element 1 to be printed, as in FIG Figure 10 shown. The mosaic segment dummy 13 usually consists of a different (easy to process material) than the mosaic segment 1 and is preferably painted by hand. In order to facilitate the coloring of the dummy mosaic structure elements 14, the dummy mosaic structure elements 14 of the mosaic segment dummy 13 are less raised than the mosaic structure elements 3 of the mosaic segment 1. When the mosaic segment dummy 13 is colored, the target motif 10 is not painted on, but each dummy - Mosaic structure element 14 is provided with a certain color or a combination of similar color shades, whereby the hand-painting means that the dummy mosaic structure elements 14 are not monochrome, but rather have a certain color distribution within the specified color / color combination. The mosaic segment dummy 13, which has been colored in such a very complex manner, is then digitally photographed and the color distribution of each dummy mosaic structure element 14 is stored. The color distributions stored in this way can be used for a large number of target motifs, so that the method steps described so far relating to the production and coloring of the mosaic segment dummies 13 do not have to be carried out again for each printing process.

The mosaic segments 1 printed with the method described above are produced by first producing the structured carrier plate 2 with the mosaic structure elements 3 and the joints 4 between them as a pressed ceramic workpiece. The mosaic structural elements are then provided with a crown with a glaze and can then be printed using the method described above ( Figure 11 ).

Reference list

1

Mosaic segment

2

Carrier plate

3

Mosaic structure elements

4th

Put

5

Grout

6th

Crowning

7th

mosaic

8th

Holes in the carrier plate

9

Overall pattern

10

Target motive

11

Mosaic structure element areas

12th

Segment pattern

13th

Mosaic segment dummy

14th

Dummy mosaic structure elements

Reading list

1. [1] https://cerasell.de/index.php/mosaike
2. [2] https://de.wikipedia.org/wiki/Bisazza
3. [3] http://www.bolkart-dental.de/RBDT/zahntechnik.html
4. [4] https://www.keramik Spritzguss.eu/

Claims (14)

Mosaic segment (1) comprising a carrier plate (2) with a surface structure, the surface structure comprising a plurality of mosaic structure elements (3) which are grouped so that they form a segment pattern (12) and joints (4) between the mosaic structure elements (3) are formed, wherein the structured carrier plate (2) is designed as a one-piece pressed ceramic part. Mosaic segment (1) according to Claim 1, characterized in that the carrier plate (2) is made from oxide ceramic, in particular from zirconium oxide ZrO2 or aluminum oxide Al2O3, or silicate ceramic, in particular porcelain. Mosaic segment (1) according to one of the preceding claims, characterized in that the carrier plate (2) is provided with bores (8) between the mosaic structural elements. Mosaic segment (1) according to one of the preceding claims, wherein the mosaic structural elements (3) are provided with a glaze, and wherein the glazed mosaic structural elements (3) have a crown (6). A mosaic (7) comprising a plurality of joined together mosaic segments (1) according to claim 4. Mosaic (7) according to Claim 5, characterized in that the joints (4) between the mosaic structural elements (3) are at least partially filled with a self-illuminating joint compound. Use of mosaic segments (1) according to one of Claims 1 to 4 for cladding an interior wall or a side wall of a ship, in particular a yacht. A method for printing a mosaic segment (1) with a target motif (10), comprising a carrier plate (2) and a plurality of mosaic structure elements (3) arranged in a segment pattern, the carrier plate (2) and mosaic structure elements (3) being designed as a one-piece pressed ceramic part, including the following process steps: b) Provision of stored color distributions, the color distributions being generated by: i. Production of a mosaic segment dummy, the mosaic segment dummy comprising a dummy carrier plate with dummy mosaic structure elements, the dummy mosaic structure elements being arranged in the same segment pattern (12) as the mosaic structure elements (3) of the mosaic segment (1); ii. Coloring the mosaic segment dummies, each dummy mosaic structure element being given a characteristic color distribution; iii. digital imaging of the colored mosaic segment dummies, each color distribution of the dummy mosaic structure elements being stored in a memory; c) creating an overall pattern (9) by virtually assembling a predetermined number of segment patterns (12) by means of software; d) virtually dividing the target motif (10) into mosaic structure element areas (11) by superimposing the target motif (10) with the overall pattern (9), each mosaic structure element area (11) representing a mosaic structure element (3) of the mosaic segment (1); e) assigning one of the stored color distributions to a respective mosaic structure element area (11); f) application of paint to the mosaic structure elements (3) with those color distributions which were assigned to the mosaic structure element areas (11) which represent the respective mosaic structure elements (3). Method according to Claim 8, characterized in that in step b) the mosaic segment dummies are colored by hand. Method according to one of Claims 8 to 9, characterized in that different materials are used to produce the mosaic segment dummies and the mosaic segments (1). Method according to Claim 10, characterized in that the mosaic segment dummies are cast from porcelain. Method for producing a mosaic segment according to one of Claims 1 to 4, comprising the following method steps: • Production of a one-piece structured carrier plate (2) with a surface structure which comprises a plurality of mosaic structure elements (3) which are grouped in such a way that joints (4) are formed between the mosaic structure elements (3) by means of a ceramic pressing tool; • Glazing the mosaic structural elements (3), a crown (6) of the mosaic structural elements (3) being produced; • Printing of the mosaic structural elements. Method according to claim 12, characterized in that a method according to one of claims 8 to 11 is used for printing the mosaic structure elements (3). Process according to one of Claims 12 to 13, characterized in that a muffle glaze process is used for printing.

Images