EP4667173A1

EP4667173A1 - Cutting device for cutting a strand of extruded material into extruded bricks or slips, method for producing them and extruded bricks or slips obtained thereby

Info

Publication number: EP4667173A1
Application number: EP24183396.1A
Authority: EP
Inventors: Andreas Bartel
Original assignee: Wienerberger GmbH
Current assignee: Wienerberger GmbH
Priority date: 2024-06-20
Filing date: 2024-06-20
Publication date: 2025-12-24

Abstract

The current invention relates to a cutting device (2) and related method for cutting an extruded strand (3) into parts (44) for forming bricks or slips (4). The strand (3) is cut in a direction (H) transverse to its longitudinal direction (L), whereby first (5) and second (6) cutting faces of the parts (44) are formed, in addition to the extruded faces (7-10). The cutting device (2) comprises a transverse cutting knife (11) with a blade (12), comprising a first partial blade (13) and a second partial blade (16) at an angle (α) to the first partial blade (13), for correspondingly providing a first said cutting face (5) with a first partial cutting face (15), at a first edge (15a) adjacent to a first said extruded face (7), and a second partial cutting face (18), at said angle (α) to the first partial cutting face (15) at a second edge (15b) of the first partial cutting face (15) away from the first edge (15a).

Description

The invention relates to a cutting device for cutting a strand of extruded material into parts for forming extruded bricks or slips, thereby cutting the strand in a first cutting direction transverse to the longitudinal direction of the strand, thereby forming cutting faces of the parts, the parts further comprising extruded faces, formed by extrusion of the strand. The invention further relates to a production facility for producing extruded bricks or slips, comprising a mouthpiece for extruding a strand, conveying means for conveying the strand and the aforementioned cutting device.
The invention also relates to a method for producing extruded bricks or slips.
To protect the outer walls of buildings and to provide insulation, facade cladding has been used for a long time, as can be seen in for example the cladding shown in WO8607402A1 . Such cladding bricks have an upper and bottom face, they have a front-facing and back-facing face, known as the stretcher faces and they have two side faces, known as the header faces. The faces are defined from the frontal perspective of a cladding, so that only the front-facing face is visible while looking at the cladding. In the frontal perspective the stretcher faces have a vertical direction, confined by the upper and bottom face, and a horizontal direction, confined by the header faces.
WO8607402A1 discloses cladding tiles for the external or internal cladding of a structure wherein the upper edge of the tiles have a stepped configuration to form a raised tongue with an inclined outer surface, delimiting a frontal groove and wherein the bottom edge of the tiles comprises a lower undercut groove, delimited by a hanging lip. The raised tongue can engage in the lower undercut groove of an adjacent identical tile, such that the hanging lip overlaps the raised tongue at least partially in the vertical direction, in order to form a cladding facade.
Such cladding slips or bricks are known to be preferably made of ceramic, although a wide variety of other suitable weather resistant substances such as injection mouldable plastics could be used as well. These slips or bricks are typically produced using the well-known extrusion process.
In such a process a strand of clay first passes through an extrusion die mouthpiece so that an extruded strand of clay is formed, with a particular cross section. This cross section is then identical along the extruded strand. Then the extruded strand of clay is conveyed by conveying means towards wire-cutting devices where the extruded strand of clay is cut, perpendicular to the longitudinal direction of the strand, into a row of parts for forming extruded bricks or slips. Thereafter these parts are fired so that they become ceramic. Alternatively other materials could be used, which may or may not need to be fired afterwards. By ensuring that the longitudinal direction of the strand is the same as the horizontal direction of the bricks, the tongues and lower grooves shown in WO8607402A1 can be fabricated simply by changing the design of the mouthpiece of the extrusion die.
These extrusion processes can be adapted to provide for twin extrusion, where two bricks or slips are produced from the same strand and the same wire-cutting device by adapting the extrusion die mouthpiece. The strand is cut by the cutting devices into a row of extruded parts for forming two bricks or slips. After firing, these parts are divided, seen in the length direction of the strand, in half, using a cracker, in order to separate the extruded double bricks into two extruded single bricks. Possible bridges between the double bricks or slips are thereby also removed. Usually, these extruded double bricks are formed mirror-symmetrically before separation, such that they are lined up with their back-facing faces adjacent to each other.
A well-known problem with the cladding bricks or tiles known from WO8607402A1 is that due to the way these bricks overlap each other water can penetrate the cladding. In the vertical direction the cladding tiles of WO8607402A1 are provided to overlap but in the horizontal direction there is no overlap and thus water can penetrate the cladding structure through these openings.
In GB1601381 it is therefore suggested in order to reduce water penetration in the horizontal direction, to provide facing panels with corresponding slanted header sides so that they overlap horizontally. DE3641747A1 shows a similar solution to the water issue: in this publication facing panels are extruded in a different direction so that the vertical direction of the facing panels becomes the longitudinal direction of the strand. Now the horizontal overlap is created due to the extrusion die mouthpiece while the overlap in the vertical direction is created by ensuring that there is a slant on the upper and bottom side of the tile. However, DE3641747A1 differs from GB1601381 in that in GB1601381 the entire sides were slanted while in DE3641747A1 only half of the upper and bottom sides are slanted while half is still straight, thus forming a triangular tongue and triangular groove.
The facing panels as described in GB1601381 and DE3641747A1 can be realised with the known extrusion process wherein the wire-cutting device now no longer cuts fully perpendicular to the conveying direction but instead cuts at least partially at a slight angle with respect to this perpendicular plane. This ensures that the facing panels have slanted header sides. This can be combined with the overlap created in the mouthpiece as in WO8607402A1 to ensure vertical, respectively horizontal overlap as well.
While such slanted sides reduce the water infiltration in the structure, it is still possible for the water to enter the slanted openings and thus penetrate the cladding so the weather-related problem is not completely solved.
With facade cladding using slips as illustrated in all of these publications it is very visible that a cladding structure is used instead of regular brickwork. Especially in GB1601381 and DE3641747A1 the slanted openings are aesthetically very noticeable.
An object of the present invention is to provide for cladding bricks or slips that have an increased protection against water infiltration while improving the aesthetic appeal so that the cladding bricks or slips aesthetically look as similar as possible to regular brickwork structures.
This object is firstly obtained by providing a cutting device for cutting a strand of extruded material into parts, for forming extruded bricks or slips, thereby cutting the strand in a first cutting direction transverse to the longitudinal direction of the strand, thereby forming cutting faces of the parts, the parts further comprising extruded faces, formed by extrusion of the strand, wherein the cutting device according to the present invention comprises a transverse cutting knife, which transverse cutting knife is provided with a blade, comprising a first partial blade with a cutting edge, and comprising a second partial blade with a cutting edge, wherein the second partial blade is positioned at a first angle, different from a multiple of 180° to the first partial blade, and which transverse cutting knife is provided for correspondingly providing a first said cutting face of a said part with a first partial cutting face, which is at a first edge positioned adjacent to a first said extruded face and for correspondingly providing the first said cutting face or a second said cutting face of the part, opposite to the first said cutting face, with a second partial cutting face, positioned at said first angle to the first partial cutting face at a second edge of the first partial cutting face away from the first edge.
By using said cutting device and thus providing the bricks or slips with said first partial cutting face and said second partial cutting face, it is possible to create bricks that have a more complex 3D structure than was previously possible.
In this way it is possible to create rectangular tongues with the cutting device with which an overlap can be realised which is much more resistant against water than for example with the triangular ones known as in DE3641747 .
Using said cutting device it is also possible to create bricks or slips with which the differently realised tongues and grooves are not noticeable aesthetically in a facade.
Such a cutting device can however also be used to make bricks or slips with a similar shape to the existing bricks in an alternative or even simpler way, this allowing other advantages, such as creating fake joints and/or - as explained further on - allowing excess material to be left on cut parts during drying and/or firing, in order to give different partial faces of the thereby formed bricks or slips an aesthetically different appearance.
The first cutting angle is preferably 90°. Alternatively the first cutting angle is preferably obtuse.
A second rectangular overlap can be realised as in WO8607402A1 by using the shape of the mouthpiece of the extrusion die or can alternatively be realised using additional knives or cutting devices. Since now two rectangular overlaps can be realised with the cladding bricks/slips, the cladding is much more water-resistant than using the known cladding slips.
The cutting device could preferably be provided to cut bricks that are extruded as in WO8607402A1 and GB1601381 so that the horizontal direction of the bricks corresponds to the longitudinal direction of the strand or it could alternatively be provided to cut bricks that are extruded as in DE3641747 so that the height direction of the brick corresponds to the longitudinal direction of the strand.
Preferentially, in embodiments wherein the second partial blade is provided for providing the first said cutting face with said second partial cutting face, the blade further comprises a third partial blade with a cutting edge, wherein the third partial blade is positioned at a second angle, different from a multiple of 180° to the second partial blade and wherein the transverse cutting knife is further provided for correspondingly providing the first said cutting face with a third partial cutting face positioned at said second angle to the second partial cutting face at an edge of the second partial cutting face away from the first partial cutting face and at a side of the second partial cutting face away from the first partial cutting face.
The second cutting angle is preferably 90° or alternatively the second cutting angle is preferably obtuse.
Preferentially, the first, the second and, if present, the third partial blade completely cut through the strand. Alternatively, it is possible for the cutting device to comprise one or more additional knives and/or a cutting wire with which the cut of the strand into bricks can be completed.
In a first direction, which is provided to extend in the first cutting direction when cutting, a partial blade preferentially comprises different dimensions and/or in a second direction, which is provided to extend in the longitudinal direction of the strand when cutting, a partial blade preferentially comprises different dimensions and/or in a third direction, which is provided to extend oblique to the first cutting direction and oblique to the longitudinal direction of the strand, a partial blade preferentially comprises different dimensions.
By adapting the heights and/or widths and/or lengths of a partial blade in function of the amount of material to be removed, it is possible to limit the deformation of the strand and thus make a smoother cut.
More specifically, in case there are three abovementioned partial blades, the third partial blade preferentially comprises different heights in the first said direction and/or different widths in the second said direction.
The cutting edge of the third partial blade preferably comprises a leading part, which seen in the first cutting direction, prior to cutting and ready for cutting, is, as a part of this third partial blade, positioned closest to the strand. Said leading part is preferentially tangent to the second partial blade and is preferably tangent to the cutting edge of this second partial blade. The cutting edge of the second partial blade also preferably comprises a leading part, which seen in the first cutting direction, prior to cutting and ready for cutting, is, as a part of this second partial blade, positioned closest to the strand.
The leading part of the third partial blade is preferably the part of the cutting blade positioned closest to the extruded strand, seen in the first cutting direction, prior to cutting and ready for cutting. In specific embodiments without third partial blade, the leading part of the second partial blade is preferably the part of the cutting blade positioned closest to the extruded strand, seen in the first cutting direction, prior to cutting and ready for cutting.
The third partial blade also preferably comprises a tailing part, which seen in the first cutting direction, prior to cutting and ready for cutting, is the part of the third partial blade which is provided furthest from the extruded strand as seen in the first cutting direction prior to cutting and ready for cutting. This tailing part of the cutting edge of the third partial blade is preferably the part of the cutting blade provided furthest from the extruded strand, seen in the first cutting direction, prior to cutting and ready for cutting.
The blade of embodiments wherein the second partial blade is provided for providing the first said cutting face with the second partial cutting face, further preferably comprises a fourth partial blade with a cutting edge, wherein the fourth partial blade is positioned at a third angle, different from a multiple of 180° to the first partial blade and extends on the opposite side of the first partial blade than the second partial blade in line with the second partial blade and wherein the fourth partial blade and the second partial blade of the transverse cutting knife are together provided for correspondingly providing the second said cutting face with a fourth partial cutting face.
Alternatively, it is also possible to realise such a fourth partial blade using an additional knife.
The cutting edge of the fourth partial blade preferably comprises a leading part, which seen in the first cutting direction, prior to cutting and ready for cutting, is, as a part of the fourth partial blade, provided closest to the extruded strand and comprises a tailing part, which seen in the first cutting direction, prior to cutting and ready for cutting, is as a part of the fourth partial blade provided furthest from the extruded strand and that the leading part is tangent to the first partial blade and the tailing part is furthest removed from the first partial blade.
The cutting edge of the first partial blade, as seen in the first cutting direction prior to cutting and ready for cutting, is preferably provided further from the extruded strand than the cutting edge of the second partial blade, and if the embodiment is provided with a fourth partial blade, then the cutting edge of the first partial blade is preferably provided further from the extruded strand than the cutting edge of the fourth partial blade.
The transverse cutting knife is preferably provided with means to cut extruded bricks or slips in a twin extrusion process. In this twin extrusion process a row of double bricks or slips are formed by the cutting device by cutting the extruded strand in parts. Afterwards a separate blade or cutting device can be provided to separate the row of double bricks or slips into two rows of single bricks or slips.
The transverse cutting knife is preferably mirror symmetrical with respect to a plane, which when cutting, extends along the first cutting direction and along the longitudinal direction of the strand.
By using a mirror symmetrical transverse cutting knife, where each mirror symmetrical side is provided with at least a first and second partial blade, it is possible to use a twin extrusion process where a row of rotation-symmetrical double bricks are formed by the cutting device, lined up with their back-facing faces adjacent to each other and one row being turned upside down with respect to the other row. The corresponding opening in the mouthpiece of the extrusion die is then mainly formed rotation-symmetrical.
Using said mirror symmetrical transverse cutting knife where the partial blades are provided in the same direction due to the mirror symmetry, for cutting the strand completely, avoids damage to the bricks/slips by the blade and increases the stability of the extruded bricks/slips.
If one or more additional knives and/or a cutting wire is used in addition to one or more above described cutting knives with at least a first said partial blade and a second said partial blade, it is possible to use a twin extrusion process wherein the rows of double bricks are lined up with their back-facing faces adjacent to each other, but both standing up in the same direction and the means of the cutting device for cutting the strand completely are positioned mainly rotation-symmetrical. The corresponding opening in the mouthpiece of the extrusion die is then mainly formed mirror-symmetrical.
The invention secondly provides a production facility for producing extruded bricks or slips, said production facility comprising a mouthpiece for extruding a strand, conveying means for conveying the strand and a cutting device for cutting the strand of extruded material into parts for forming extruded bricks or slips, thereby cutting the strand in a first cutting direction, transverse to the longitudinal direction of the strand, thereby forming cutting faces of the parts, the parts further comprising extruded faces, formed by extrusion of the strand, wherein the cutting device is a cutting device according to the invention.
The conveying means preferably comprise one or more transport bands, and also preferably comprise an opening in the transport band or between adjacent transport bands, such that the cutting knife can enter said opening for cutting the strand, which simplifies cutting entirely through the extruded strand.
The production facility further preferably comprises embossing means, which are provided to push the strand of extruded material inwards in a horizontal direction, transverse to the first cutting direction and transverse to the longitudinal direction of the strand, along the first edge of the first partial cutting face, prior to cutting the strand with the cutting knife. In a specific embodiment, these embossing means can be provided as part of the cutting device.
The embossing means preferentially comprise a roller. By using a roller prior to cutting the strand with the cutting device, the strand is pressed to avoid burrs on the cutting edge at the level of the cut yet to be formed. Bricks or slips are thus formed with smoother edges.
Preferably the production facility further comprises means to realise a fake joint in the extruded bricks or slips and/or to realise edges of bricks or slips with a different appearance.
Mortar joints in brickwork fill in the spaces between bricks and are critical to the structural integrity and stability of masonry structures. These mortar joints provide the characteristic brick wall aesthetic. Since cladding bricks/slips are merely connected to a backing structure they do not require such joints, but the addition of fake joints without structural function to these bricks/slips provides the typical characteristic brick wall aesthetic which is desired.
The production facility therefore preferably further comprises a supplemental transverse cutting device which is provided for partially cutting the strand of extruded material, for providing said second cutting face with a fifth partial cutting face, adjacent to said first extruded face, such that the second partial cutting face or the fourth partial cutting face and the fifth partial cutting face delimit first excess material of the strand and such that upon removal of the first excess material, the second partial cutting face or the fourth partial cutting face and the fifth partial cutting face are forming a groove in the part, which opens in said first extruded face and in said second cutting face.
The first excess material can be removed immediately but can alternatively be removed after a surface-treatment and/or after the firing of the parts, using for example a hammer, for forming the bricks or slips with corresponding partial faces with a different appearance than the first extruded face.
By removing the first excess material in embodiments where the cutting device comprises a said fourth partial blade and wherein the first partial cutting face, the fourth partial cutting face and the fifth partial cutting face form the first excess material, the groove on one side of the extruded brick/tile will be larger than the tongue on the other side so that it is possible to use this groove for both the overlap and for the creation of a fake joint.
The fifth partial cutting face preferably extends in the first cutting direction and in a second cutting direction, transverse to the first cutting direction and transverse to the longitudinal direction of the strand. The fifth partial cutting face could alternatively e.g. extend at an obtuse angle with respect to the first extruded face. Preferably, the fifth partial cutting face mainly extends parallel to the first partial cutting face, but could alternatively e.g. extend at an acute angle with respect to this first partial cutting face.
The supplemental transverse cutting device can be located in the production facility before the cutting device according to the invention, so that it cuts the extruded strand, but could also be located after this cutting device, so that it further cuts the already partially cut parts. It is most easily placed within the same opening in the transport band or between transport bands as the cutting device according to the invention, so that a cutting knife thereof can enter said opening at cutting of the strand. Alternatively, it could also e.g. be placed adjacent to the extrusion die mouthpiece.
Said supplemental transverse cutting device could comprise a flat sideways knife which is movable in this second cutting direction for cutting the strand or alternatively a circular spinning knife which is movable up and down in the first cutting direction.
In specific alternative embodiments the cutting device itself comprises an additional knife or cutting blade for realising said fifth partial cutting face such that the tongue formed by the first cutting face and the second partial cutting face can overlap the groove formed by the fourth partial cutting face and the fifth partial cutting face.
The production facility further preferably comprises rolling means, for straightening the first extruded face adjacent to the first edge of the first partial cutting face.
Thinly shaped tongues that would tend to warp can in this way easily be straightened, so that the tongues keep their sharp rectangular features.
The second overlap of the extruded bricks/slips can e.g. be realised as in WO8607402A1 by the shape of the mouthpiece of the extrusion die or can alternatively be realised using additional knives or cutting devices. If the second overlap is realised with additional knives or cutting devices, it can be provided with a similar appearance as the first overlap. The second fake joint can also be created in the groove that is created for the second overlap.
The production facility preferably further comprises:

first longitudinal cutting means, for partially cutting the strand of extruded material, providing a first cut in the first extruded face, the first cut extending in the longitudinal direction; and
second longitudinal cutting means, for partially cutting the strand of extruded material, providing a second cut in a second said extruded face, adjacent to the first extruded face, the second cut extending in the longitudinal direction;

The longitudinal cutting means preferably comprise cutting knives. By removing the second excess material a groove on one side of the extruded brick/tile can be made which is larger than a tongue on the other side so that it is possible to use this groove for both overlap with the tongue and for the creation of a fake joint.
The second excess material can be removed immediately but can alternatively be removed after a surface-treatment and/or even more preferably after the firing of the parts, using for example a hammer, for forming the bricks or slips with corresponding partial faces with a different appearance than the first extruded face.
The first longitudinal cutting means and the second longitudinal cutting means are in specific embodiments mounted in the mouthpiece. By integrating the cutting means into the mouthpiece there is no need to provide additional devices.
The invention also provides in a method for producing extruded bricks or slips, which comprises cutting a strand of extruded material into parts using a cutting device according to the invention.
More specifically this method comprises cutting a strand of extruded material into parts in a production facility according to the invention.
Even more specifically this method comprises cutting a strand of extruded material into parts in a production facility comprising a supplemental transverse cutting device and/or longitudinal cutting means according to the invention, thereby forming said first excess material and/or said second excess material, with the inclusion of the additional steps of:

treating the first extruded face with a surface treatment, before removal of said excess material;
firing the bricks or slips; and
after firing of the bricks or slips removing said excess material.

Preferably said surface treatment includes engobing, so that the first extruded face will be completely engobed with the exception of grooves that are created after the removal of said excess material. This makes it possible to colour front-facing faces of a brick or tile, with the exception of the grooves and thus accentuate the appearance of fake joints, to give the stereotypical brick structure aesthetic. It is also possible to colour the grooves separately. In the embodiments produced using this method, the first extruded face corresponds to the front-facing face of a brick.
Furthermore the invention provides in an extruded brick or tile obtainable by the method according to the invention.
Lastly, the invention also provides in a facade, erected with extruded bricks or slips according to the invention.
The present invention will now be explained in more detail by means of the following detailed description of cutting devices, production facilities, methods, extruded bricks or slips and facades according to the present invention. The sole aim of this description is to give explanatory examples and to indicate further advantages and particulars of the present invention, and can thus by no means be interpreted as a limitation of the area of application of the invention or of the patent rights defined in the claims.
In this detailed description, reference numerals are used to refer to the attached drawings, in which:

Fig. 1 illustrates a part of a facade in front view, erected using slips according to the invention;
Fig. 2 shows a tile, as used in the facade of fig. 1, in front view;
Fig. 3 illustrates the tile of fig. 2 in a cross section;
Fig. 4 illustrates an alternative tile, obtainable with a method according to the invention for erecting a facade;
Fig. 5 illustrates an extruded strand, for forming alternative slips according to the invention, in cross section;
Fig. 6 illustrates an intermediate product of the strand of fig. 5, which is cut transverse to the longitudinal direction, in perspective view, seen from the side of a first cutting face thereof;
Fig. 7 illustrates the intermediate product of fig. 6, in perspective view, seen from the side of a second cutting face;
Fig. 8 shows a mouthpiece for forming the strand of fig. 5, together with part of this strand, in perspective view;
Fig. 9 shows part of the strand of fig. 5 in top view, with the strand being cut transverse to the longitudinal direction, using a cutting device according to the invention;
Fig. 10 illustrates a cutting knife of a cutting device according to the invention for cutting the strand as in fig. 9 in perspective view;
Fig. 11 shows the cutting knife from fig. 10 in side view;
Fig. 12 shows the cutting knife from fig. 10 in top view;
Fig. 13 shows the cutting knife from fig. 10 in front view;
Fig. 14 illustrates part of a production facility according to the invention at the height of a cutting device according to the invention, which is provided with the cutting knife of fig. 10, in perspective view;
Fig. 15 illustrates part of the production facility of fig. 14 at the height of the cutting device in perspective view, showing further aspects of this production facility;
Fig. 16 illustrates part of the production facility of fig. 14 at the height of the cutting device in perspective view, showing further aspects of this production facility;
Fig. 17 schematically illustrates alternative cutting devices for cutting a strand in the first cutting direction using a cutting device according to the invention;
Fig. 18 schematically illustrates the cutting devices of the production facility of fig. 14-16 for cutting the strand of fig. 5 in the first cutting direction;
Fig. 19 schematically illustrates alternative cutting devices for cutting a strand in the first cutting direction using a cutting device according to the invention;
Fig. 20 schematically illustrates alternative cutting devices for cutting a strand in the first cutting direction using a cutting device according to the invention;
Fig. 21 schematically illustrates alternative cutting devices for cutting a strand in the first cutting direction using a cutting device according to the invention;
Fig. 22 illustrates part of an alternative production facility according to the invention at the height of a cutting device according to the invention, in perspective view.

The illustrated cutting devices (2) and production facilities (1) according to the invention are provided for cutting a strand (3) of extruded material into parts (44), in a first cutting direction (H) transverse to the longitudinal direction (L) of the strand (3).
Such a strand (3) is obtained by extruding e.g. clay or any other suitable mouldable material, such as e.g. metal or concrete, through a die mouthpiece (25) of the production facility (1) as e.g. illustrated in fig. 8. This extruded strand (3) is then conveyed by conveying means (26) and guiding means (38) along its length direction (L) as illustrated in fig. 14-15. Examples of such conveying means (26) and guiding means (38) are well-known in the art. A cutting device (2) cuts the strand (3) transverse to the longitudinal direction in several parts (44) for forming corresponding bricks or slips or twin-bricks (double bricks) or twin-slips (double slips). At cutting of the strand (3), a gap is created between the cut (double) bricks or (double) slips (44) with means (39), examples of which are well-known in the art, e.g. with a mechanical spring system. Creating such a gap allows cutting means (11) of the cutting devices (2) - after being moved down in order to cut the strand (3) - again to move up between the cut parts (44) for cutting further parts (44).
When the mouthpiece (25) is provided for twin extrusion as in fig. 8, the cross-section of the strand (3) is provided for forming two bricks or slips at a time as illustrated in fig. 5-9 and 14-16. Such bricks or slips (4) are in the strand (3) interconnected with bridges (37), which are removed after curing and/or firing the double bricks or double slips (44). Examples of how these bridges (37) are removed are well-known in the art. At extrusion of the strand (3), extruded faces (7, 8, 9, 10) are formed, extending in the longitudinal direction (L) of the strand (3). By cutting the strand (3) in the first cutting direction (H), using cutting devices (2) according to the invention, cutting faces (5, 6) are at least partially formed.
The cutting devices (2) according to the invention to this end comprise a cutting knife (11), which is provided with a blade (12) comprising a first partial blade (13) with a cutting edge (14) and a second partial blade (16) with a cutting edge (17). The second partial blade (16) is positioned at a first angle (α) (shown in figure 12) with respect to the first partial blade (16). In the illustrated embodiment, this first angle (α) is about 90°. In alternative embodiments, this angle (α) could e.g. be an obtuse angle. still allowing cut parts (44) to be separated from each other, creating said gap.
The cutting knife (11) is in all embodiments provided for correspondingly providing a first said cutting face (5) of a said part (44) with a first partial cutting face (15), which is at a first edge (15) positioned adjacent to a first said extruded face (7) and for correspondingly providing this first cutting face (5) (fig. 10-21) or a second said cutting face (6) opposite to the first said cutting face (5) (fig. 22) with a second partial cutting face (18) positioned at said first angle (α) to the first partial cutting face (15) at a second edge (15) of the first partial cutting face (15) away from the first edge (15a).
In the first illustrated embodiment of a cutting device (2) according to the invention, as illustrated in fig. 10-16 and 18, the blade (12) further comprises a third partial blade (19) with a cutting edge (20), which third partial blade (19) is positioned at a second angle (β), different from a multiple of 180° to the second partial blade (16). At cutting of the strand (3), this third partial blade (19) correspondingly provides the first said cutting face (5) with a third partial cutting face (21) positioned at said second angle (β) to the second partial cutting face (18) at an edge (18a) of the second partial cutting face (18) away from the first partial cutting face (15) and at a side of the second partial cutting face (18) away from the first partial cutting face (15). Said third partial cutting face (21) is preferably provided to extend essentially parallel to said first partial cutting face (21), as illustrated, but could also e.g. be provided at an acute angle with respect to the first partial cutting face (21).
The blade (12) of this first embodiment furthermore comprises a fourth partial blade (22) with a cutting edge (23), which fourth partial blade (22) is positioned at a third angle (γ), different from a multiple of 180° to the first partial blade (13) and which fourth partial blade (22) extends on the opposite side of the first partial blade (13) than the second partial blade (16) in line with the second partial blade (16). At cutting of the strand (3), this fourth partial blade (22), together with the third partial blade (19) correspondingly provides a second said cutting face (6), opposite to the first cutting face (5) with a fourth partial cutting face (24).
In alternative embodiments, such fourth partial blade (22) could e.g. be provided at a distance from the second partial blade (16), parallel to this second partial blade (16) or at an angle different from a multiple of 180° with respect to this second partial blade (16).
The blade (12) of the illustrated first embodiment is furthermore mirror symmetrical with respect to a symmetry plane (S) which when cutting, extends along the first cutting direction (H) and along the longitudinal direction (L) of the strand (3).
In this first illustrated embodiment, a supplemental transverse cutting device (29) is provided. This supplemental transverse cutting device (29) is provided with cutting blades (28) for partially cutting the strand (3), in a transverse direction (T), transverse to the first cutting direction (H) and transverse to the longitudinal direction (L) of the strand (3), for providing the second cutting face (6) with a fifth partial cutting face (30) adjacent to said first extruded face (7), such that the fourth partial cutting face (24) and the fifth partial cutting face (30) delimit first excess material (31) of the strand (3). Upon removal of the first excess material (31), the fourth partial cutting face (24) and the fifth partial cutting face (30) are forming a groove (46) in the brick or tile (4), which opens in said first extruded face (7) and in said second cutting face (6). Alternatively, instead of such transverse cutting device (29), e.g. circular spinning knife could be provided, which is movable up and down in the first cutting direction, in order to provide such a fifth partial cutting face (30).
Alternatively, in other embodiments of cutting devices (2) according to the invention, the blade (12) is not always provided with all mentioned partial blades (13, 16, 19, 22) and/or could be provided with further not yet mentioned partial cutting blades.
In the embodiment as schematically illustrated in fig. 17, the blade (12) comprises a said first partial cutting blade (13), a said second partial cutting blade (16), a said third partial cutting blade (19) and a said fourth partial cutting blade (22). Similarly as how twin-strands (3) for forming double bricks or slips (44) can be cut using the first illustrated embodiment, single strands (3) for forming single bricks or slips (4) can be cut in the first cutting direction (H) using a cutting knife (11) with such a blade (12) as illustrated in fig. 17 and a similar supplemental transverse cutting device (29) with a cutting blade (28) for partially cutting the strand (3).
In figures 19-21 other possible embodiments for cutting single strands (3) for forming single bricks or slips (4) are illustrated. In the embodiment as schematically illustrated in fig. 19, two blades (12) are provided, each comprising a said first partial cutting blade (13) and a said second partial cutting blade (16), together with a said supplemental transverse cutting device (29). In the embodiment as schematically illustrated in fig. 20, a first blade (12) is provided, comprising a first partial cutting blade (13) and a second partial cutting blade (16) and a second blade (12) is provided, comprising a first partial cutting blade (13), a second partial cutting blade (16) and a third partial cutting blade (19). In the embodiment as schematically illustrated in fig. 21, a blade (12) is provided, comprising a said first partial cutting blade (13), a said second partial cutting blade (16) and a said fourth partial cutting blade (22) and a first supplemental cutting device (29). In this embodiment, also a further supplemental cutting device is provided with a further cutting blade (54) for partially cutting the strand (3), for providing the first cutting face (5) with a third partial cutting face (21), similarly as how this is done using the third partial blade (19) in the embodiments of figures 10-18 and 20.
Embodiments as illustrated in figures 19 and 20 could also be made mirror symmetrical in order to cut double bricks or slips (44). Using such mirror symmetrical knives, wherein each mirror symmetrical side is provided with at least a first and second partial blade, it is possible to use a twin extrusion process where rows of rotation-symmetrical double bricks are formed by the cutting device, rotated about a horizontal axis, such that the rows are lined up with their back-facing faces (60) adjacent to each other and one row being turned upside down with respect to the other row. The corresponding opening in the mouthpiece (25) of the extrusion die is then mainly formed rotation-symmetrical, as is the case in fig. 8.
Furthermore, in order to cut a strand (3) in the first cutting direction (H), a cutting device (2) according to the invention can also be provided both with one or more of said cutting blades (12), together with a cutting wire (55), such as e.g. illustrated in fig. 22.
The means (12, 55) of the cutting device (2) for cutting the strand (3) completely, are thus positioned mainly rotation-symmetrical. The corresponding opening in the mouthpiece of the extrusion die is then mainly formed mirror-symmetrical. A row of rotation-symmetrical double bricks (4) is thus formed by the cutting device (2), rotated about a vertical axis, such that the rows are lined up with their back-facing faces (60) adjacent to each other and both rows standing up in the same direction.
In the illustrated embodiments, the partial cutting blades (13, 16, 19, 22) of the cutting knives (12) of the cutting devices (2) are essentially planar, but in alternative embodiments of cutting devices (2) according to the invention, such partial cutting blades could alternatively e.g. be curved. The partial cutting blades (13, 16, 19, 22) in the illustrated embodiments are also interconnect with a minimal bend, but in alternative embodiments, they could connect with a more pronounced bend, for example.
Some partial cutting blades (19, 22) comprise in the first embodiment different first dimension (h₁, h₂, h₃, h₄) in a first direction (H), which is provided to extend in the first cutting direction (H) when cutting, in order to limit deformation of the strand (3) at cutting (see fig. 11 and 13).
Similarly it is possible in alternative embodiments, to provide partial blades with different second dimensions in a second direction (L) and/or with different third dimensions in a third direction (T), which is provided to extend oblique to the first cutting direction (H) and oblique to the longitudinal direction (L) of the strand (3) when cutting.
The third partial blade (19) of the first embodiment furthermore comprises a leading part (20a), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is, as a part of this third partial blade (19), positioned closest to the strand (3). Said leading part (20a) is tangent to the second partial blade (16) and is tangent to the cutting edge (17) of this second partial blade (16).
The leading part (20a) of the third partial blade (19) is also the part of the cutting blade (12) positioned closest to the extruded strand (3), seen in the first cutting direction (H), prior to cutting and ready for cutting. In specific embodiments without third partial blade (19), the leading part of a second partial blade is preferably the part of the cutting blade (12) positioned closest to the extruded strand (3), seen in the first cutting direction (H), prior to cutting and ready for cutting.
The third partial blade (19) in the first embodiment also comprises a tailing part (20b), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is the part of the third partial blade (19) which is provided furthest from the extruded strand (3) as seen in the first cutting direction (H) prior to cutting and ready for cutting. This tailing part (20b) of the cutting edge (20) of the third partial blade (19) is also the part of the cutting blade (12) provided furthest from the extruded strand (3), seen in the first cutting direction (H), prior to cutting and ready for cutting.
In the first embodiment, the cutting edge (23) of the fourth partial blade (22) furthermore comprises a leading part (23a), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is, as a part of the fourth partial blade (22), provided closest to the extruded strand (3) and comprises a tailing part (23b), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is as a part of the fourth partial blade (22) provided furthest from the extruded strand (3). The leading part (23b) of this fourth partial blade (22à is tangent to the first partial blade (13) and the tailing part (23b) is furthest removed from the first partial blade (13).
The cutting edge (14) of the first partial blade (13), as seen in the first cutting direction (H) prior to cutting and ready for cutting, is furthermore provided further from the extruded strand (3) than the cutting edge (17) of the second partial blade (16). This cutting edge (14) of the first partial blade (13) is also provided further from the extruded strand (3) than the cutting edge (23) of the fourth partial blade (22) seen in the first cutting direction (H) prior to cutting and ready for cutting.
The illustrated cutting blades (12) can be made using 3D metal-forming, but it could alternatively be possible to make such cutting blades (12) with other types of forming, such as e.g. sheet metal forming, sheet metal bending, milling with a CNC milling machine, lasing and edging and/or from different materials, such as e.g. a suitable plastic, such as e.g. polyoxymethylene.
In order to cut the strand (3), a transverse cutting knife (11) can be displaced with similar driving means as used at the state of the art for displacing a cutting wire in order to cut a strand into parts for producing bricks or slips.
The illustrated cutting devices (2) are furthermore provided with rollers (27), which are provided to push the strand (3) of extruded material inwards in a horizontal direction (T), transverse to the first cutting direction (H) and transverse to the longitudinal direction (L) of the strand (3), along the first edge (15a) of the first partial cutting face (15), prior to cutting the strand (3) with the transverse cutting knife (11), this in order to avoid burrs on the cutting edge at the level of the cut yet to be formed. Such rollers or other embossing means (27) could alternatively be provided separate from the cutting device (2).
Furthermore, rolling means can be provided in the production facility for straightening the first extruded face (7) adjacent to the first edge (15a) of the first partial cutting face (15), after the cut has been formed.
The illustrated mouthpiece (25) is furthermore provided with:

first longitudinal cutting knives (32), for partially cutting the strand (3) of extruded material, providing a first cut (33) in the first extruded face (7), the first cut (33) extending in the longitudinal direction (L); and
second longitudinal cutting kives (34), for partially cutting the strand (3) of extruded material, providing a second cut (35) in a second said extruded face (8), adjacent to the first extruded face (7), the second cut (35) extending in the longitudinal direction (L).

A first cut (33) and a second cut (35) thus formed, delimit second excess material (36) of the strand (3). Upon removal of the second excess material (36), the first cut (33) and the second cut (34) are forming a groove (41) in the brick or tile (4), which opens in said first extruded face (7) and in said second extruded face (8).
Alternatively, instead of one or more of said first longitudinal cutting knives (32) and one or more of said second longitudinal cutting knives (34) being provided in the mouthpiece (25), such cutting knives (32) could also be provided at a distance from the mouthpiece (25) in the production facility. Instead of providing fixedly positioned cutting knives (32) , e.g. one or more circular spinning knives could be provided in this respect.
In alternative embodiments, without first longitudinal cutting knives (32) and second longitudinal cutting knives (34), a similar groove, opening in said first extruded face and in said second extruded face can be realised similarly as with the prior art as e.g. disclosed in WO8607402A1 , this then without the advantages of providing said second excess material (36).
Both above described first excess material (31) as this second excess material (36) can either be removed immediately or can alternatively be removed after a surface-treatment and/or after firing of the parts (44), using for example a hammer, for forming the bricks or slips(4) with corresponding partial faces with a different appearance than the first extruded face (7).
With a suitable design of the cutting device (2) according to the invention and/or the mouthpiece (2), it is thus possible to provide cuts, delimiting said first excess material (31) and/or said second excess material (36), which can be provided for e.g. forming fake joints (51) in a facade (50).
It is also possible in this way not only to provide bricks or slips (4) with a top frontal groove (41), a corresponding top raised tongue (40) delimiting this top frontal groove (41) and an undercut groove (42), delimited by a hanging lip (43), extending in the longitudinal direction of the brick or tile (4) as in the prior art, for forming a horizontal overlap (52) when the top raised tongue (40) of a lower brick or tile (4) engages the undercut groove (42) of a brick or tile (4) placed thereon, but also to provide such bricks or slips (4) with a side raised tongue (45), a corresponding side frontal groove (46) and a side undercut groove (47) delimited by a side lip (48), for forming a vertical overlap (53), when the side raised tongue (45) engages the side undercut groove (47) of an adjacent brick or tile (4) as illustrated in fig. 1, or vice versa.
Besides the said tongues (40, 45), lips (43, 48) and grooves (41, 42, 46, 47), ribs (56) and grooves (57) can be provided at the back-facing sides (60) of such bricks or slips (4) and/or at the upper face (8) and/or and the bottom face (10), as illustrated in fig. 3-4, e.g. in a similar way as with the prior art, for attachment of these bricks or slips (4) to a support. These ribs (56) and grooves (57) can be provided in many different forms, adapted for interconnection with different types of support.

Claims

Cutting device (2) for cutting a strand (3) of extruded material into parts (44) for forming extruded bricks or slips (4), thereby cutting the strand (3) in a first cutting direction (H) transverse to the longitudinal direction (L) of the strand (3), thereby forming cutting faces (5-6) of the parts (44), the parts (44) further comprising extruded faces (7-10), formed by extrusion of the strand (3), characterised in that the cutting device (2) comprises a transverse cutting knife (11), which transverse cutting knife (11) is provided with a blade (12), comprising a first partial blade (13) with a cutting edge (14), and comprising a second partial blade (16) with a cutting edge (17), wherein the second partial blade (16) is positioned at a first angle (α), different from a multiple of 180° to the first partial blade (13), and which transverse cutting knife (11) is provided for correspondingly providing a first said cutting face (5) of a said part (44) with a first partial cutting face (15), which is at a first edge (15a) positioned adjacent to a first said extruded face (7) and for correspondingly providing the first said cutting face (5) or a second said cutting face (6) of the part (44) opposite to the first said cutting face (5) with a second partial cutting face (18), positioned at said first angle (α) to the first partial cutting face (15) at a second edge (15b) of the first partial cutting face (15) away from the first edge (15a).
Cutting device (2) according to claim 1, characterised in that the second partial blade (16) is provided for providing the first said cutting face (5) with the second partial cutting face (18) and that the blade (12) further comprises a third partial blade (19) with a cutting edge (20), wherein the third partial blade (19) is positioned at a second angle (β), different from a multiple of 180° to the second partial blade (16) and that the transverse cutting knife (11) is further provided for correspondingly providing the first said cutting face (5) with a third partial cutting face (21) positioned at said second angle (β) to the second partial cutting face (18) at an edge (18a) of the second partial cutting face (18) away from the first partial cutting face (15) and at a side of the second partial cutting face (18) away from the first partial cutting face (15).
Cutting device (2) according to one of the previous claims, characterised in that in a first direction (H), which is provided to extend in the first cutting direction (H) when cutting, a partial blade (19, 22) comprises different first dimensions (h₁, h₂, h₃, h₄) and/or that in a second direction (L), which is provided to extend in the longitudinal direction (L) of the strand (3) when cutting, a partial blade comprises different second dimensions and/or that in a third direction (T), which is provided to extend oblique to the first cutting direction (H) and oblique to the longitudinal direction (L) of the strand (3) when cutting, a partial blade comprises different third dimensions.
Cutting device (2) according to any of the preceding claims, characterised in that the second partial blade (16) is provided for providing the first said cutting face (5) with the second partial cutting face (18) and that the blade (12) further comprises a fourth partial blade (22) with a cutting edge (23), wherein the fourth partial blade (22) is positioned at a third angle (γ), different from a multiple of 180° to the first partial blade (13) and extends on the opposite side of the first partial blade (13) than the second partial blade (16) in line with the second partial blade (16) and that the fourth partial blade (22) and the second partial blade (16) of the transverse cutting knife (11) are together provided for correspondingly providing the second said cutting face (6) with a fourth partial cutting face (24).
Cutting device (2) according to claim 4, characterised in that the cutting edge (23) of the fourth partial blade (22) comprises a leading part (23a), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is, as a part of the fourth partial blade (22), provided closest to the extruded strand (3) and comprises a tailing part (23b), which seen in the first cutting direction (H), prior to cutting and ready for cutting, is as a part of the fourth partial blade (22) provided furthest from the extruded strand (3) and that the leading part (23b) is tangent to the first partial blade (13) and the tailing part (23b) is furthest removed from the first partial blade (13).
Cutting device (2) according to any of the preceding claims, characterised in that the transverse cutting knife (11) is mirror symmetrical with respect to a plane (P), which when cutting, extends along the first cutting direction (H) and along the longitudinal direction (L) of the strand (3).
Production facility (1) for producing extruded bricks or slips (4), comprising a mouthpiece (25) for extruding a strand (3), conveying means (26) for conveying the strand (3) and a cutting device (2) for cutting the strand of extruded material (3) into parts (44) for forming the extruded bricks or slips (4), thereby cutting the strand (3) in a first cutting direction (H), transverse to the longitudinal direction (L) of the strand (3), thereby forming cutting faces (5-6) of the parts (44), the parts (44) further comprising extruded faces (7-10), formed by extrusion of the strand (3), characterised in that the cutting device (2) is a cutting device (2) according to any of claims 1-6.
Production facility (1) according to claim 7, characterised in that the production facility (1) further comprises embossing means (27), which are provided to push the strand (3) of extruded material inwards in a horizontal direction (T), transverse to the first cutting direction (H) and transverse to the longitudinal direction (L) of the strand (3), along the first edge (15a) of the first partial cutting face (15), prior to cutting the strand (3) with the cutting knife (11).
Production facility (1) according to claim 7 or 8, characterised in that the production facility (1) further comprises a supplemental transverse cutting device (29) which is provided for partially cutting the strand (3) of extruded material, for providing said second cutting face (6) with a fifth partial cutting face (30), adjacent to said first extruded face (7), such that the second partial cutting face (18) or the fourth partial cutting face (24) and the fifth partial cutting face (30) delimit first excess material (31) of the strand (3) and such that upon removal of the first excess material (31), the second partial cutting face (18) or the fourth partial cutting face (24) and the fifth partial cutting face (30) are forming a groove (46) in the part (44), which opens in said first extruded face (7) and in said second cutting face (6).
Production facility (1) according to any of claims 7 to 9, characterised in that the production facility (1) further comprises:
- first longitudinal cutting means (32), for partially cutting the strand (3) of extruded material, providing a first cut (33) in the first extruded face (7), the first cut (33) extending in the longitudinal direction (L); and

- second longitudinal cutting means (34), for partially cutting the strand (3) of extruded material, providing a second cut (35) in a second said extruded face (8), adjacent to the first extruded face (7), the second cut (35) extending in the longitudinal direction (L);
such that the first cut (33) and the second cut (35) delimit second excess material (36) of the strand (3) and such that upon removal of the second excess material (36), the first cut (33) and the second cut (34) are forming a groove (41) in the part (44), which opens in said first extruded face (7) and in said second extruded face (8).
Production facility (1) according to the claim 10, characterised in that the first longitudinal cutting means (32) and the second longitudinal cutting means (34) are mounted in the mouthpiece (25).
Method for producing extruded bricks or slips (4), characterised in that this method comprises cutting a strand (3) of extruded material into parts (44) using a cutting device (2) according to any of claims 1 to 6.
Method according to claim 12, characterised in that the strand (3) of extruded material is cut into parts (44) in a production facility (1) according to any of the claims 9 to 11, thereby forming said first excess material (31) and/or said second excess material (36), that the method includes the additional steps of:
- treating the first extruded face (7) with a surface treatment, before removal of said excess material (31,36);

- firing the parts (44); and

- after firing of the parts (44) removing said excess material (31,36) in order to form extruded bricks or slips (4).
Extruded brick or tile (4) obtainable by the method according to claims 12-13.
Facade, erected with extruded bricks or slips (4) according to claim 14.