ITUB20155976A1 - TILE FOR FLOORING, PLANT AND PROCEDURE FOR THE REALIZATION OF THAT TILE - Google Patents

Description

"TILE FOR FLOORING, PLANT AND PROCEDURE FOR THE CONSTRUCTION OF THAT TILE"

FIELD OF APPLICATION

The present invention refers to a tile for flooring, for example, for the production of flooring mainly for outdoor use, such as streets, squares, sidewalks, cobblestones, paths, lanes, or similar structures or parts thereof, even if a possible use of tiles for the construction of indoor flooring.

Furthermore, the present invention relates to a plant and process for manufacturing flooring tiles.

STATE OF THE TECHNIQUE

It is now known, in the field of construction in general, that the technique of making self-locking tiles for flooring requires that they are produced with a single layer of concrete or a double layer of concrete with different colors and / or grain sizes.

In particular, the embodiment of a double-layer tile provides that a first layer, or base body, is made of a cement agglomerate and that a coating layer defined by an agglomerate of particles is deposited on at least one surface of the base body. minerals bonded together by a cement-based binder.

The current construction of the flooring tiles takes place manually and / or automatically using special systems.

The flooring tiles produced in this way have aesthetic limitations and drawbacks such as, by way of example, limits to coloring, as only certain types of colors are obtainable and these colors are dull and dull due to the cementitious materials that form their base, such as cementitious binders. , natural aggregates and limited spectrum dyes.

In addition, the paving tiles of the known art show the drawback of presenting a porous structure that favors the absorption of liquids and dirt.

Another problem related to the porosity of the known paving tiles is that of facilitating their getting dirty by means of mud, water, earth, rain, dust, salts, etc.

In addition to the ease with which the paving tiles get dirty and retain dirt, there is therefore to add up the difficulties and problems of carrying out their practical and effective cleaning.

In addition, the porosities favor the onset of cracks and / or fractures due to solidification and consequent expansion of the penetrating liquids. In the case of water, for example, forming ice.

The aforementioned difficulties in cleaning the floor tiles of the known art can lead, in relation to the place of installation, to slipping hazards for users both independently and on board means of transport.

In addition, in filtration of liquids and dirt in general, it favors the onset of molds, fungi and / or mosses that attack the flooring tiles, thus giving them an unattractive and even unhygienic appearance.

Another problem arises from the action of chemical agents on the flooring tiles, which are responsible for the onset of efflorescence due to saltpetre or other salts.

The aforementioned flooring tiles are mainly used outdoors, replacing stones, asphalt and / or various types of artefacts, accentuating the problems outlined above.

Sometimes, the aforementioned performance limits are mitigated by the use of surface protectors, but these have the drawback of having short and limited duration and effectiveness.

A further drawback is due to the premature degradation of the floor tiles of the known art, making it necessary to replace them prematurely.

There is therefore the need to make a tile for flooring by means of a relative process, and being able to provide a plant for its production, which allow at least one of the drawbacks of the known art to be overcome.

In particular, an object of the present invention is to provide a tile for flooring which is durable over time and guarantees the permanence of its initial conditions, in any place it is installed, for as long as possible.

Another object resides in the fact of obtaining a tile for flooring having a structure that avoids the absorption of liquids and dirt in general.

Therefore, it is also an object of the present invention to provide a tile for flooring that is simple and quick to clean.

A further purpose is to make a flooring tile that can resist chemical action and / or physical stresses, even if they are of high intensity or prolonged over time.

Another object is to obtain a tile for flooring which exhibits inertia to thermal expansion.

Another object of the present invention is to obtain a tile for flooring with which to realize a much wider range of aesthetic solutions, allowing to obtain geometries, colors, textures, chromatic effects and aesthetic devices equal to or superior to those obtainable in the state of the art.

Furthermore, an object is also that of realizing tiles for flooring of reduced thickness with respect to those of the state of the known art, while guaranteeing them to withstand greater or equal stresses.

A purpose linked to the previous one is to bring about a reduction in the weight of the flooring tiles, facilitating their transport and storage, as well as making the workings for the operators in the sector much lighter and simpler.

Furthermore, an object of the present invention is to improve a tile for flooring having a greater surface adherence which reduces the possibility of slipping.

It is also an aim to obtain a tile for flooring, and a related procedure, through the possible use of existing systems as they are or with minimal modifications and / or precautions.

In order to obviate the drawbacks of the known art and to obtain these and further objects and advantages, the Applicant has studied, tested and implemented the present invention.

EXPOSURE OF THE FOUND

The present invention is expressed and characterized in the independent claims. The dependent claims disclose other features of the present invention or variants of the main solution idea.

In accordance with the aforementioned purposes, a tile for flooring according to the present invention comprises at least a base body and a covering layer associated with at least one surface of the base body.

In accordance with the present invention, the base body is made with a cement agglomerate, or alternatively with a resinous agglomerate, which defines most of the thickness of the flooring tile.

According to an aspect of the present invention, the coating layer is made with a resinous coating agglomerate.

This resinous agglomerate of coating allows to define a tile for flooring in which the surface, which usually faces Testerno in use, is covered by the layer of resin agglomerate of coating which can present the most varied colors depending on the specific needs and aesthetic and refinement requests. The presence of a resin agglomerate coating guarantees the structural absence of porosity, at least in the coating layer, preventing external elements from affecting them and giving them an intrinsic cleanliness.

In addition, it is possible to obtain flooring tiles that have an increased resistance to chemical and physical stresses, allowing them to be produced even with thicknesses lower than those of the prior art.

It is therefore possible to define a tile in which the base body can be made of an economical material, having a purely structural function, while the covering layer can also be made of a valuable material to obtain a desired aesthetic result. This also allows you to respect the cost-effectiveness of making the tiles.

Between the base body and the coating layer, a synergistic fixing is created due to a mechanical, as well as chemical bond, given by the wetting and anchoring properties of the resins on the base body.

In accordance with construction variants, a gripping layer is interposed between the base body and the coating layer, to increase adhesion between them.

In accordance with possible embodiments of the invention, the finishing resinous agglomerate can include pigments of various kinds allowing to obtain a range of aesthetic solutions, effects and aesthetic devices of the most disparate.

The present invention also relates to a process for manufacturing flooring tiles which comprises:

- the generation of a base agglomeration;

- the realization of a base body with said base agglomerate;

- the generation of a resinous finishing agglomerate;

- the application or deposition, on at least one surface of the base body, of a coating layer defined by the finishing resin agglomerate.

Embodiments of the present invention also refer to a plant for making flooring tiles as described above.

ILLUSTRATION DET DRAWINGS

These and other characteristics of the present invention will become clear from the following description of embodiments, provided by way of non-limiting example, with reference to the attached drawings in which:

- fig. 1 is a perspective view of a flooring tile according to embodiments described here;

- fig. 2 is a view of a possible variant of fig. 1;

- fig. 3 is a view of a further variant of fig. 1;

- fig. 4 is a schematic representation of a plant for making flooring tiles according to embodiments described here;

- fig. 5 is a sectional perspective view of a part of the plant for making flooring tiles in accordance with the embodiments described here;

- fig. 6 is a simplified perspective view of a further part of the system for making flooring tiles in accordance with the embodiments described here.

To facilitate understanding, identical reference numbers have been used wherever possible to identify identical common elements in the figures. It should be understood that elements and features of one embodiment can be conveniently incorporated into other embodiments without further specification.

DESCRIPTION OF EMBODIMENTS

The figs. 1-3 are used to describe exemplary embodiments of a tile for flooring 10 according to the present invention comprising at least one base body 12 and at least one covering layer 14.

The base body 12 can be made of lower quality materials than those of the covering layer 14 to reduce the costs of the flooring tile 10.

Preferably, the base body 12 occupies a volume between 60% and 99%, more preferably between Γ70% and 95%, even more preferably between 80% and 90% of the volume of the flooring tile 10.

The base body 12 is made of a base agglomerate having a load-bearing structural function for the tile for flooring 10. In accordance with the embodiment solutions illustrated in figs. 1 and 2, Γ base agglomerate can be defined as a cement agglomerate in which mineral parts are bound together by a cement-based binder. By way of example only, in the case of cement agglomerate it can include aggregates, such as quartz, crushed stone, sand, clay, expanded clay, and cementitious binders, such as gray cement and / or white cement, additives for concrete, structural fibers, similar elements and assimilable and water.

In accordance with a possible alternative embodiment, or in addition, the base agglomerate 11 can comprise a resinous-based material as shown in fig. 3.

According to possible embodiments, the resinous material includes polymeric materials, such as binders based on mixtures of resins, additives to increase the chemical attachment to the aggregate, similar and assimilable elements. In accordance with the present invention, the resinous material can comprise epoxy resins, acrylic resins, polyurethane resins, cementitious resins, polyvinyl chloride PVC, polyurethane PU, polycarbonate PC, polypropylene PP, polyphenyl ether PPE, polyamide PA, polystyrene PS, polymethyl methacrylate PMMA, acrylonitrile butadiene styrene ABS, plastics in general, their mixtures, derivatives and / or compounds, and similar and assimilable elements.

In accordance with the present invention, the coating layer 14 is made with a resinous coating material configured to define the attachment of the coating layer 14 to the base body 12, without the aid of suitable adhesives.

Between the base body 12 and the covering layer 14, in fact, there is an excellent coupling and interpenetration.

In accordance with a possible embodiment, the resinous agglomerate of coating comprises one or more inert materials, designed to give a particular aesthetic effect to the tile for flooring 10 and at least one polymer-based material mixed with said inert materials and acting as a binder. of the latter.

According to possible embodiments, the polymeric-based material can comprise the same materials with which the resinous agglomerate described above is made with reference to the base body 12 of Fig. 3.

According to a possible embodiment, the coating resinous agglomerate may also include pigments of natural and / or synthetic origin also, but not limited to, with a metallic, iridescent, mother-of-pearl, phosphorescent and / or photoluminescent effect, or others.

By means of the coating layer 14, which is obtained on the surface of the base body 12 which, in use, faces outwards, it is therefore possible to make the flooring tile 10 assume a virtually infinite color spectrum.

Additionally, at least the parts of the flooring tile 10 made of resin agglomerate coating, have self-cleaning properties and immunity to the action of external agents such as dirt, liquids, salts, etc.

In accordance with a possible embodiment, the polymer-based material can include at least one of mono and / or bicomponent synthetic resins, with or without insulating primers, and / or anchors on the base body 12.

In accordance with possible embodiment solutions, the inert materials can be of the synthetic or natural type.

By way of example only, inert materials can include at least one of glass, and stone and / or mineral materials such as natural stones, marble, quartz, granite and / or coated with synthetic materials colored or not, and similar and similar elements.

At least one of the base body 12 and the covering layer 14, or the agglomerates that define them, can comprise reinforcing components, such as fibers, binders, fabrics and / or crosslinks, or other elements used to increase the mechanical resistance capacity. This allows to obtain a reduction of the dimensions, at least in thickness, with respect to the tiles of the known art, guaranteeing in any case resistance to the stresses that respect the desired limits. Consequently, the flooring tiles 10 can be lighter, facilitating the handling of the operators.

In accordance with possible embodiments of the present invention, at least one of the external surfaces in use of the covering layer 14 can be provided with ennobling elements, such as designs and / or textures, to achieve customization effects and aesthetic devices on the flooring tiles. 10. These ennobling elements can be obtained by means of natural and / or synthetic aggregates in variable ratios and / or grain sizes, using for example glass, stone, marble, quartz and / or granite, natural and / or coated with synthetic and non-synthetic materials. , colored or not.

In accordance with variants made and not illustrated, surface irregularities such as knurls and / or grooves and / or knurls can be obtained on the surface of the coating layer 14 to increase the adhesion of the flooring tile 10.

In accordance with embodiment variants described using fig. 2, between the base body 12 and the covering layer 14 it is possible to provide a gripping layer 16 with an improved anchoring function and accentuated interpenetration between the base body 12 and the covering layer 14.

The gripping layer 16 can comprise, by way of example, a primer or fixative.

Embodiments of the present invention also refer to a plant 20, illustrated by way of example in figs. 4-6, for making floor tiles 10 as described above. The plant 20 in accordance with the present invention comprises at least a first generation unit 21 configured to generate the aforementioned base agglomerate and at least a second generation unit 22 configured to generate the resinous coating agglomerate.

The first generation unit 2 1 and the second generation unit 22 can be configured to receive in predetermined doses the components necessary for the definition of the respective agglomerates, and to mix them together in order to obtain uniform mixtures.

In accordance with solutions of the present invention, the first generation unit 21 and the second generation unit 22 can comprise at least one of a mixer, a concrete mixer, one or more containers for supplying the components, conveyor belts, means for supplying aqueous solutions. .

In accordance with the embodiment illustrated in fig. 4, the first generation unit 21 and the second generation unit 22 each comprise at least one silo 23 in which one or more components defining the aforementioned base agglomerate and resinous coating agglomerate are stored.

The first generation unit 2 1 and the second generation unit 22 may also comprise a mixing apparatus 24 in which the components of the base agglomerate and the resinous coating agglomerate are mixed together to define a homogeneous mixture.

For this purpose, the mixing apparatuses 24 are connected with pipes to the respective silos 23 for supplying the components to be mixed.

The coating agglomerate 13 advantageously has the consistency of moist earth, so as not to dirty the components of the system 20.

The mixing apparatuses 24 are configured to mix the aforementioned components until the base agglomerate and the resinous coating agglomerate are brought to a consistency not to dirty the subsequent components of the plant 20 which are placed downstream, as will be described in continue.

By way of example only, it can be envisaged that the agglomerates leaving the mixing apparatuses 24 have a consistency of moist earth, that is, they are sufficiently consistent to be self-sustaining in the event that they are compacted, not to be destroyed due to a too liquid consistency, and not dirty the system components 20.

For example, the base agglomerate may contain substances with mixture ratios that depend on and vary according to the production area and available raw materials.

The plant 10 also comprises a forming unit 25, or block-making unit, in which the base agglomerate and the resinous coating agglomerate are deposited, in a programmed sequence, to obtain at least one flooring tile 10, advantageously a plurality of flooring tiles 10. The forming unit 25 can be equipped with one or more molds 26 reproducing the shape and dimensions of the flooring tiles 10 and in which the aforementioned base agglomerate and coating agglomerate are arranged.

The molds 26 can be divided into a plurality of sectors 27, each of which reproducing the shape of one of the covering tiles 10. These sectors 27 can have the same or different shape.

In accordance with a possible embodiment, the mold 26 is provided with a fixed part 28, in which the aforesaid base and resinous coating agglomerates are usually arranged, and with a movable part 29 which is placed to close the fixed part 28 and allows to give the agglomerates the desired shape.

The fixed part 28 can optionally be provided with the aforesaid sectors 27 as described above.

At least the movable part 29 of the mold 26 can be connected to a press 30 configured to move the movable part 29 approaching away from the fixed part 28. The press 30 allows to compact the base and resinous agglomerates of coating one face that have been introduced in the mold 26.

In accordance with possible embodiments, the mold 26, or at least one of the fixed part 28 and the mobile part 29, are associated with vibration members 3 1 configured to induce vibrations in the base and resinous agglomerates of the coating suitable for increasing their compactness and prevent the formation of bubbles inside the flooring tile 10 which compromise its mechanical properties. In accordance with possible embodiments, the forming unit 25 can be served by a first distributing unit 32 and by a second distributing unit 33 configured to distribute the base agglomerate and the resinous coating agglomerate inside the mold 26 for the generation of the paving tile 10.

According to a possible embodiment, the first distributing unit 32 and the second distributing unit 33 can each comprise at least one container 34 into which the base agglomerate and the resinous coating agglomerate are poured respectively, and a distributor member 35 configured to pour the latter in the mold 26.

By way of example, the containers 34 can have a holding capacity, of base agglomerate or coating resin agglomerate, to fill about one or two molds 26.

The distributor member 35 can be provided with a blade 36 which, by sliding on the mold 26 releases and levels a quantity of base agglomerate, or resin agglomerate of coating suitable for the realization of the base body 12.

In accordance with a possible embodiment, transfer units 37 configured to transfer from the first generation unit 21 and from the second generation unit are interposed between the first generation unit 21, the second generation unit 22 and the forming unit 25 22 respectively the base agglomerate and the resinous coating agglomerate towards the forming unit 25, or, if present, towards the first distributing unit 32 and the second distributing unit 33. The transfer units 37 can comprise a conveyor belt 38 , as illustrated in FIG. 5, intended to receive the base agglomerate, or the resinous coating agglomerate, and bring it to the forming unit 25.

In accordance with a variant embodiment illustrated in fig. 4, the transfer units 37 can comprise a transfer path 39 on which one or more trolleys, or in general containers 40, are installed, configured to contain and transfer the agglomerates along the transfer path 39.

The transfer paths 39 are configured to bring the containers 40 into a first operating position suitable for receiving one of the agglomerates from the first generation unit 21 or from the second generation unit 22, and a second operating condition suitable for discharging one of the agglomerates towards the forming unit 25 or, possibly, if present, towards the first distributing unit 32 or the second distributing unit 33.

The plant 20 may comprise a transfer unit 41 associated downstream of the forming unit 25 and configured to transfer the tiles for flooring 10 to a temporary storage station.

In accordance with embodiments not illustrated, regret 20 can comprise heating means configured to heat and dry the tiles for flooring 10.

Furthermore, the plant 20 can comprise suction means configured to stabilize the base body 12 and / or the coating layer 14 under vacuum.

The present invention also relates to a process for manufacturing a tile for flooring 10, as described above, which provides for at least the generation of the aforementioned base agglomerate, the manufacture of at least one base body 12 with the base agglomerate, the generation of the aforesaid coating resin agglomerate, and the production of a coating layer 14 with the finishing resin agglomerate.

The aforementioned operations can be carried out manually or automatically, for example by using the system 20 described above.

In particular, the method can provide for the realization first of the base body 12 and then of the covering layer 14 which is placed to cover at least part of a surface of the base body 12. This allows to realize a base body 12 with function self-supporting, capable of also supporting the covering layer 14 which is subsequently placed on top.

However, the production of the coating layer 14 and then of the base body 12 is not excluded.

The process can provide for the compaction of the base body 12, in order to make it self-supporting, and the subsequent deposition on at least one surface of the latter of the coating layer 14. The first compaction of the base body 12 prevents the resin agglomerate for coating 14 there is an interpenetration and mixing thereof with the base agglomerate 12. This ensures the obtainment of a tile with also desired aesthetic properties.

In accordance with a possible embodiment, it can be foreseen that, after the realization of the base body 12 and of the covering layer 14, there is also an overall compaction of the base body 12 and of the covering layer 14 in order to give the flooring tile 10 a self-supporting structure even before drying.

If the base agglomerate is of the "cementitious" type, the flooring tile 10 can be self-supporting after laying the base body 12 and the covering layer 14, thus allowing the extraction of the flooring tile 10 from the relative mold 26 and the consequent storage and maturation operations in a specific structure.

In the event that the base agglomerate is of the "resinous" type, as a result of forming it can flake off if removed immediately from the mold. For this purpose, a suitable container may be necessary in which the flooring tiles 10 are kept even after their generation. In this case, the tile for flooring 10 must remain in the appropriate container until at least partial drying. Said container can be a disposable container, such as, for example, a shape or envelope made of polystyrene or similar material, which is introduced directly into the mold even before the deposition of the agglomerates, acting itself at least partially as a mold.

Alternatively, the container can be of the reusable type, such as a container made of aluminum, stainless steel, plexiglass or other suitable material.

In accordance with a possible embodiment of the invention, the operation of the plant 20 is described below.

The components necessary for the preparation of the base agglomerate and the resinous coating agglomerate are inserted into the mixing apparatus 24.

In these mixing apparatuses 24 the components are mixed together until they are obtained in the desired consistency. Subsequently these agglomerates are transferred through the transfer units 37 to the forming unit 25.

In particular with reference to fig. 4, the agglomerates are transferred by means of the containers 40 into the first distributing unit 32 and into the second distributing unit 33.

The first distributing unit 32 deposits in the mold 26 a first layer of base agglomerate to define therein at least one, in this case a plurality of base bodies 12. The base agglomerate can be distributed in the fixed part 28 of the mold 26 up to fill it. Furthermore, to facilitate the extraction of the flooring tiles 10 from the relative mold 26, before the distribution of the agglomerates in the mold 26, the use of disarming materials that facilitate the decoupling between the contact surfaces can be envisaged.

In particular, it is possible to provide for the actuation of the press 20 and / or of the vibrating members 31 to compact the base body 12. This compaction allows to generate in the fixed part 28 of the mold 26 a sufficient space for the deposition of the resin agglomerate of coating. 14.

The deposition, with the second distributing unit 33, of the resinous coating layer 14 in the fixed part 28 of the mold 26 is then provided.

The coating layer 14 is placed to fill the remaining space left free by the compaction of the base bodies 12.

According to a possible embodiment, before the deposition of the coating layer 14, the deposition of the aforementioned gripping layer 16 is provided.

The gripping layer 16 can be spread by means of "airless" techniques or other methods of application of resinous compounds in a liquid consistency, for example, of mono and bicomponent non-yellowing synthetic resins, insulators and / or anchors with direct coupling on the base body 12 allowing to to further improve and increase the coupling between the base body 12 and the coating layer 14.

A subsequent compaction of the paving tile 10 is envisaged to compact both the base bodies 12 and the covering layer 14 together.

A subsequent extraction of the flooring tiles 10, still in the undried condition, from the forming unit 25 is then envisaged for the start of a subsequent phase of construction of other flooring tiles 10.

It is clear that modifications and / or additions of parts can be made to the flooring tile 10, to the related plant 20 and manufacturing process described up to now, without thereby departing from the scope of the present invention.

It is also clear that, although the present invention has been described with reference to some specific examples, a person skilled in the art will undoubtedly be able to realize many other equivalent forms of paving tile 10, relative plant 20 and manufacturing process having the characteristics expressed in the claims and therefore all falling within the scope of protection defined by them.

Claims (10)

CLAIMS 1. Floor tile comprising a base body (12) and a covering layer (14) associated with at least one surface of said base body, characterized in that said covering layer (14) is made with a resinous agglomerate of coating configured to define the attachment of said coating layer to said base body (12). 2. Tile as in claim 1, characterized in that said resinous coating agglomerate comprises one or more inert materials, and at least one polymeric-based material mixed with said inert materials and acting as a binder for the latter. 3. Tile as in claim 2, characterized in that said inert materials comprise at least one of glass and / or stone and / or mineral materials. 4. Tile as in any one of the preceding claims, characterized in that said base body (12) is made of a cement agglomerate in which mineral parts are linked together by a cement-based binder. 5. Tile as in any one of the preceding claims, characterized in that said base agglomerate comprises a resin-based material. 6. Tile as in any one of the preceding claims, characterized in that said base body (12) occupies a volume comprised between 60% and 99%, more preferably between Γ70% and 95%, even more preferably between 1 80% and 90% of the volume of the flooring tile (10). 7. Plant for making a tile for flooring which comprises a first generation unit (21) configured to generate a base agglomerate and a second generation unit (22), characterized in that said second generation unit (22) is configured to generate a resinous coating agglomerate, and which comprises a forming unit (25) connected to said first generation unit (21) and to said second generation unit (22) and configured to receive, in programmed sequence, said base agglomerate and said resinous coating agglomerate for obtaining at least one flooring tile (10). 8. Process for making flooring tiles (10) comprising the generation of a base agglomerate and the construction of a base body (12) with said base agglomerate, characterized in that it comprises the generation of a finishing resin agglomerate and the application, on at least one surface of said base body (12), of a coating layer (14) defined by said finishing resin agglomerate. 9. Process as in claim 8, characterized in that it comprises manufacturing first the base body (12) and then the coating layer (14). 10. Process as in claim 9, characterized in that it comprises the compacting of said base body (12) to make it self-supporting, and the subsequent deposition / application of said coating layer (14).