NZ569196A - Apparatus for and method of manufacturing a laminated tile with tile cap adhered to wetted concrete mix with water pressed out - Google Patents
Apparatus for and method of manufacturing a laminated tile with tile cap adhered to wetted concrete mix with water pressed outInfo
- Publication number
- NZ569196A NZ569196A NZ569196A NZ56919606A NZ569196A NZ 569196 A NZ569196 A NZ 569196A NZ 569196 A NZ569196 A NZ 569196A NZ 56919606 A NZ56919606 A NZ 56919606A NZ 569196 A NZ569196 A NZ 569196A
- Authority
- NZ
- New Zealand
- Prior art keywords
- tile
- adhesive
- mix
- cap
- base
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000000203 mixture Substances 0.000 title claims description 39
- 239000004567 concrete Substances 0.000 title claims description 38
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims description 12
- 239000004570 mortar (masonry) Substances 0.000 claims abstract description 42
- 239000000853 adhesive Substances 0.000 claims abstract description 31
- 230000001070 adhesive effect Effects 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 24
- 230000013011 mating Effects 0.000 claims abstract description 15
- 239000012790 adhesive layer Substances 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 7
- 239000000843 powder Substances 0.000 claims description 5
- 239000002131 composite material Substances 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- 230000006835 compression Effects 0.000 claims description 2
- 238000007906 compression Methods 0.000 claims description 2
- 238000009826 distribution Methods 0.000 claims description 2
- 238000010924 continuous production Methods 0.000 claims 1
- 230000008569 process Effects 0.000 abstract description 10
- 239000010410 layer Substances 0.000 description 15
- 239000007921 spray Substances 0.000 description 12
- 238000007373 indentation Methods 0.000 description 6
- 238000013019 agitation Methods 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 4
- 230000032258 transport Effects 0.000 description 4
- 238000009736 wetting Methods 0.000 description 4
- 239000000080 wetting agent Substances 0.000 description 4
- 238000001723 curing Methods 0.000 description 3
- 239000003292 glue Substances 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000005304 joining Methods 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000012615 aggregate Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000001459 mortal effect Effects 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
- B28B5/06—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping in moulds on a turntable
- B28B5/08—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping in moulds on a turntable intermittently rotated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
- E04F13/142—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of ceramics or clays
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Architecture (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Dispersion Chemistry (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
Abstract
A method and equipment for forming a laminated tile includes a multi-stage process line adapted to combine a tile base and a tile surface. The tile forming equipment includes a production line with a number of operation stations where the tile base is formed in a mould (4) and compacted. Adhesive or mortar is applied to a mating surface of the tile base. A tile cap has its mating face wetted and/or supplied with a second adhesive and is then applied to the mating surface of the base and pressed to form a sound contact with the adhesive.
Description
WO 2007/070925 PCT/AU2006/001889
1
A Laminated Tile and Method of Manufacturing a Laminated Tile Field of the invention
[001] This invention relates to a laminated tile and a method of manufacturing such a tile. Background of the invention
[002] Tiles are commonly manufactured monolithically of a single material. Glazes and coatings are sometimes applied to one or more faces of the tiles.
[003] There is a demand for natural look tiles which are made of clays. However, the supply of some clays is limited.
Summary of the invention
[004] This invention proposes a laminated tile in which an upper layer of the tile is made of a first material or materials and the remainder is made of a different material or materials.
[005] The invention also provides a method of forming a laminated tile, including the steps of:
forming a tile cap;
forming a tile base;
applying a binding or adhesive layer to at least one of the mating faces of the base or the cap; bringing the mating faces of the base and the cap together.
Adhesive can be applied to both the mating surface of the tile cap and the base. Different adhesives or adhesive components can be used for the cap and the base. The first adhesive can be mortar.
A second adhesive can be a resinous adhesive.
The second adhesive can be PVA.
The base can include concrete.
The cap can include clay.
The cap can include ceramic material.1
[006]
[007]
[008]
[009]
[010]
[011]
[012]
[013]
WO 2007/070925 PCT/AU2006/001889
2
[014] According to a further embodiment of the invention, the method can include the steps of:
inserting a measured quantity of wetted tile base mixture into a tile mold;
distributing the mix within the mold;
compressing the mix;
applying an adhesive;
applying a tile cap.
[015] The method can include the step of compressing and de-watering the concrete mix.
[016] The method can include the step of distributing the concrete mix by vibration.
[017] Preferably, the vibration is not done during tile cap application.
[018] The invention also provides laminated tile manufacturing equipment including:
one or more tile molds adapted to receive a predetermined quantity of concrete tile base mix; a plurality of manufacturing operation stations;
the stations including:
a mold filling station at which a wetted concrete tile base mix is inserted into a mould; a distribution station;
a compression station to compress the mix in the mold;
a first adhesive application station adapted to apply a first adhesive layer to a mating surface of the concrete base mix; and a tile cap application station adapted to apply a tile cap to the first adhesive layer.
[019] The equipment can include a second adhesive application station adapted to apply a second adhesive layer to a mating surface of the tile cap.
[020] The equipment can include a robot arm with a gripper capable of picking up the vibrating head as well as a tile cap independently.
[021] The gripper can include a vacuum pad to pick up a tile cap for placement on the substrate.
WO 2007/070925 PCT/AU2006/001889
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Brief description of the drawings
[022] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[023] Figure 1 is a schematic view of a multi-station carousel implementing a process embodying the invention from a first perspective;
[024] Figure 2 is a schematic view of the carousel of Figure 1 from a second perspective;
[025] Figure 3 is a schematic view of a mold filling station ;
[026] Figure 4 is a schematic view of an agitation station;
[027] Figure 5 is a schematic view of a pressing station;
[028] Figure 6 is a schematic view of a mortar application station;
[029] Figure 7 illustrates aspects of the tile delivery and attachment process; and
[030] Figure 8 illustrates an unloading press.
[031] Figure 9 illustrates a laminated tile 1200 made according to an embodiment of the invention.
[032] Figure 10 shows a first embodiment of the pressed concrete base.
[033] Figure 11 shows a second embodiment of the pressed concrete base.
[034] Figure 12 is a schematic representation of a method of forming a continuous tile/base composite.
[035] Figure 13 illustrates a production line adapted to use pre-formed base and cap layers.
Detailed description of the embodiment or embodiments
[036] Figures 1 & 2 illustrate different views of an embodiment of tile manufacturing equipment. The ingredients for making a concrete tile base, such as cement, sand, aggregate and additives, are stored in bins and hoppers (not shown). The various ingredients of the concrete are measured into the required proportions, for example, by weight or by quantity, using the appropriate weighing or measuring equipment (not shown) and conveyed to mixer 2. The mixer 2 mixes and blends the ingredients and water is added at this stage.
WO 2007/070925 PCT/AU2006/001889
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[037] The mixer provides a preset measured amount of concrete mix equivalent to one concrete tile base to a delivery system such as a screw feed 5, which transports the mix. to a mold 4 on a carousel table 3 which carries molds 4 through a sequence of stations where the stages of the manufacturing process are performed. The operation of the carousel table 3 can be synchronized to the slowest operation in the process.
[038] The molds are preferably steel plates with a cavity of the shape of the tile. To facilitate the removal of the assembled paver from the cavity, the cavity can be a through-hole. Usually the cavity will be square, but other shapes are within the scope of the invention.
[039] The various elements of Figures 1 and 2 include:
2 tile base mixer
3 carousel
4 tile mold
screw feeder
6 agitator station
7 press station
8 mortar application station
281 mortar hopper
282 mortar feeder
283 mortar spray
284 mortar spillage shield
9 cap delivery station
291 robot arm
292 tile caps
293 glue spray
294 gripping head
unloading station
WO 2007/070925 PCT/AU2006/001889
[040] Figure 3 illustrates details of a mould filling station. The mixer 2 delivers a measured quantity of concrete mix to the mould charging device which can be a screw conveyor or chute 5 which feeds the mix into the mold 4. The mold 4 is mounted on the carousel table 3.
[041 ] When the concrete base mix has been delivered to the tile cavity in mold 4 and the compaction process has been completed, and all other stages have been completed on the other molds on the carousel, the carousel 3 indexes to the next stage which is agitator station 6. At agitator station 6, the concrete mix in the mould 4 is shaken and vibrated to spread the mix evenly and condense the mix within the cavity of the mould.
[042] Details of the agitation station 6 are shown in Figure 4. The mold 4 is mounted on an agitation platen which is adapted to agitate the mix in at least one direction. Preferably the agitation station produces agitation in 2 or 3 dimensions. This assists in distributing the mix in the mold cavity.
[043] At the succeeding press station 7, Figure 5, the concrete mix is pressed to further compress the mix and to form it into a stiff but uncured solid base. The press station 7 includes means for removing excess water. In one embodiment, the water can be removed using a vacuum. The use of a vacuum enables control of the surface moisture of the interface to optimise the wetting of the dry adhesive. This can be done by controlling the vacuum level during the pressing phase.
[044] Figure 5 illustrates details of the pressing station. An hydraulic press has a plate 52 adapted to fit closely within the mold cavity to compress the concrete mix. Water which is squeezed from the mix is collected in a gutter 517.
[045] Optionally, the press can impress a keying pattern on the upper surface of the compressed concrete base, such as those shown in Figures 10 or 11.
[046] Figure 10 illustrates an embodiment of a concrete tile base 1002 after the pressing operation. An array of indentations 1004 are formed in the upper surface of the concrete base. The mortar powder is applied to cover the rims of the indentations. Mortar powder will also fall into the indentations. Preferably the peripheral rims of the concrete base do not have mortar applied to them so that the mortar will not be forced out from between the concrete base and the tile cap when the tile cap is applied. The indentations permit the mortar to be displaced during the tile capping process described below with reference to Figure 7.
[047] An alternative tile base 1102 is shown in Figure 11. In this base, the indentations are replaced by raised grid 1104 which functions in a similar manner to the rims of the
WO 2007/070925 PCT/AU2006/001889
6
indentations 1004 of Figure 10. The walls of the grid 1104 can be of the order of 1 mm wide. The mortar powder applicator is designed so that little or no mortar powder is deposited on the peripheral area 1106. This reduces the possibility of the mortar being squeezed out from between the concrete base and the tile cap.
[048] When the pressing operation is complete, the carousel indexes to the next station 8, which is a mortar application station. Mortar is fed from a hopper 281 containing a pre-blended mix of dry polymer mortar via a feeder 282 which lays an even depth of mortar on the wet uncured concrete paver base. The feeder 282 can be a traversing vibrating feeder. The deposited layer of mortar is wetted by a spray 283. A shield 284 is provided to reduce spillage from the mortar application station.
[049] Figure 6 illustrates a mortar application station. A hopper 662 is mounted on a transport system shown illustratively as rails 663 and wheels 665. A vibrating feeder 668 receives mortar from the hopper 662 and delivers it evenly on top of the compressed concrete mix in the mold cavity of mold 604 mounted on conveyor 603. A surface spray 668 prepares the mortar for use in attaching a tile cap to the concrete tile base. A shield 666 can be provided to reduce spillage.
[050] On completion of the mortar application process, the carousel 3 indexes to a tile delivery station 9. The delivery station includes a robot arm 291 adapted to transfer a tile cap from a stack of tile caps 292 and apply it to the pre-mortared concrete tile base after an adhesive, for example, a PVA solution, has been applied to its underside by spray 293 to aid adhesion between the tile cap and the mortar. The robot arm has a head 294 which is adapted to grip each tile cap and lift it from the stack 292, transport it via the PVA wetting station 293 and embed the tile cap on the layer of mortar on the concrete paver base. The assembled tile is then delivered to the tile unloading station 10, where it can be placed on a conveyor for delivery to further processing such as drying.
[051] Details of the tile cap delivery process are illustrated in Figure 7. A supply of tile caps 742 is provided by conveyor 744. At Stage A, the robot arm 709 removes individual tile caps from the stack and, at Stage B, conveys them through the PVA solution spray 793 and thence, at Stage C, to the mold where the robot arm presses the tile cap into the mortar on the concrete base.
WO 2007/070925 PCT/AU2006/001889
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[052] The robot arm has a gripper capable of picking up the vibrating head as well as a tile independently, combined with a vacuum pad underneath the vibrating head to pick up a tile for placement on the substrate.
[053] At tile capping station 772, the vibrating head settles the tile cap into the mortar to ensure sound contact between the tile cap and the mortal'. A lateral vibration combined with a compressive force serve to form a sound contact. While the vibrating head settles a tile on to the base during a carousel-stationary period, the robot/gripper takes a dry tile and places it over the sprays or dips it in a water tub and leaves it there. When vibrating has finished it collects the vibrating head and uses it to pick up the tile with the now-wet underside, placing both on top of the mortar layer in the current mold.
[054] After the tile cap has been applied to the concrete base, the carousel indexes to the unloading station 10, where the tile is pressed from the underside of the mould plate onto a tray on a conveyor to transport the paver for further processing. The paver can be transferred to a drying/curing rack (not shown) which can be transported to a drying/curing area by suitable means such as a conveyor or forklift.
[055] Figure 8 illustrates details of the unloading press. An hydraulic press 810 pushes the paver out of the mold 804 onto a conveyor platen or tray 880 so that it is available for further processing.
[056] While the process has been described in relation to a carousel table, the process could also be implemented using a sequential line to implement the process steps. For example, a shuttle press can be used to implement the invention.
[057] Figure 9 illustrates a tile 900 made in accordance with an embodiment of the invention. The tile cap 902 is affixed to the concrete base 904 along the plane of the join 906. The thickness 908 of the concrete base 904 can be greater than the thickness 910 of the tile cap 902.
[058] The tile 900 includes an upper layer 902, and a lower layer 904. The layers 902 and layer 904 interface along the planes of line 906. The interface can be a suitable adhesive or mortar.
[059] The lower layer has a first thickness 908, and the upper layer has a second thickness 910, which may be the same as or different from the thickness 908. Preferably the thickness of the upper layer is less than the thickness of the lower layer.
WO 2007/070925 PCT/AU2006/001889
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[060] In Figure 12, the upper tile layer is extruded through first extrusion head 1202, and the base is extruded through second extrusion head 1204. The upper extrudate 1206 and the base extrudate 1208 are pressed together by a first pair of rollers 1222,1224. An adhesive and/or mortar can be applied to the mating faces of the upper and base layers from adhesive vessel 1262 before they are pressed together.
[061] Optionally a second pair of rollers 1210,1212canbe used to apply a keying surface to the mating surface of the upper extrudate. Similarly a third pair of rollers 1214,1216 can apply a keying surface or roughening to the mating surface of the base extrudate before they are pressed together by the first pair of rollers. The rollers 1214,1216 can also act as a de-watering press.
[062] A surface texturing roller 1226 can be used to apply a pattern or texture 1228 to the surface of the tile. This roller 1226 can be used in place of roller 1222.
[063] A flying cutter, such as described in Australian patent application AU2004906979 can be used to dissect the combined extrudate into individual tiles for downstream drying and processing in a manner similar to that disclosed in the above referenced Australian patent application.
[064] Figure 13 shows a production line adapted for assembling pre-made bases and caps to make a composite paver.
[065] A supply of pre-made paver bases 1340 and a supply of pre-made caps 1342 are fed to an assembly station via conveyors 1354, 1344 respectively. Robot arm 1343 having a gripping or vacuum head 1308 can be used to transfer the bases and caps to their conveyors. Alternatively, a dedicated machine can be used to place the caps and bases on their respective conveyors. Alternatively,, the caps and bases can be loaded manually.
[066] The base passes through adhesive station where a predetermined amount of mortar or glue is applied to the mating face of the base from adhesive vessel 1362 and spread evenly by vibration, raking or other suitable spreading means. The adhesive station can include a squaring and locating device 1353 to align the base for processing.
[067] At wetting station 1348, the cap is placed on an array of pegs to enable the underside to be wetted by a spray from underneath. The wetting agent can be water or a mixture of water and PVA, or other suitable wetting agent. A collecting trough is provided to collect the excess wetting agent. Instead of a spray, the cap interface surface can be wetted by dipping into a bath of wetting agent. Precise alignment means, such as squaring and location device 1351
WO 2007/070925 PCT/AU2006/001889
9
accurately aligns the cap for precision placement on the tile base at combining station 1350 after the base has also been accurately aligned by locating/squaring device 1352. The robot arm can provide the required amount of pressure and vibration to ensure proper adhesion. The robot arm 1309 then places the assembled tile on the unloading conveyor 1356 or transferred for drying, curing, packaging, etc. Again, the transfer of the assembled tile to the unloading conveyor can be done manually or by a dedicated machine.
[068] The Component Table below lists elements of the embodiments of the invention.
TABLE 1 - DRAWING CONCORDANCE
FIGURES
ITEM
1/2
3
4
6
7
8
9
11
12
13
2
302
tile base mixer
3
303
403
503
603
carousel
4
304
404
504
604
704
804
tile mold
305
screw feeder
6
agitator station
7
press station
517
gutter
8
mortar application station
281
mortar hopper
282
mortar feeder
283
mortar spray
284
mortar spillage shield
9
cap delivery station
291
robot arm
292
tile caps
293
793
glue spray
294
gripping head
unloading station
11
662
mortar hopper
663
hopper rails
664
surface spray
665
•
hopper wheels
66 6
shield
668
vibrating feeder
742
tile cap supply
772
tile capping station
810
hydraulic press
880
unloading platen
900
assembled tile
902
cap
TABLE 1 - DRAWING CONCORDANCE
FIGURES
ITEM
1/2
3
4
6
7
8
9
11
12
13
904
base
906
cap/base interface
908
•
base thickness
910
cap thickness
1000
pitted tile base
1002
toile base
1004
pits
1100
profiled tile base
1102
tile base
1104
raised profile
1106
tile interface surface
1202
cap extrusion head
1204
base extrusion head
1206
upper extrudate
1208
base extrudate
1210
support roller
1212
keying roller
1214
keying roller
1216
support roller
1218
feed roller
1220
feed roller
-
1222
joining roller
1224
joining roller
1226
pattern roller
1228
surface pattern
1262
adhesive application station
1309
robot grip head
1340
base supply
1342
cap supply
1344
cap conveyor
1346
cap
1348
cap wetting station
1350
cap/base combining station
1351/ 2/3
locating/squaring register device
1354
base conveyor
1356
unloading conveyor
1362
mortar vessel
WO 2007/070925 PCT/AU2006/001889
11
[069] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of'. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.
[070] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.
[071 ] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The invention covers various combinations of the features and functions of the different embodiments which would be apparent to a person skilled in the art. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.
Received by IPONZ 9 June 2011
12
Claims (14)
1. A method of forming a laminated tile in a continuous process, the method including the steps of: (a) inserting a measured quantity of wetted concrete tile base mixture into a tile mold; distributing the mix within the mold; (c) pressing the mix; (d) removing at least part of the water pressed from the mix at step (c); (e) applying an adhesive; (f) applying a tile cap.
2. A method as claimed in claim 1, wherein the adhesive is applied in step (e) as a dry powder, and wherein sufficient water is left after step (d) to wet the adhesive.
3. A method as claimed in claim 1 or claim 2, wherein the step of distributing the concrete mix in the mould is performed by vibration.
4. A method as claimed in any one of claims 1 to 3, wherein the step of removing at least part of the water is done by vacuum.
5. A method as claimed in any one of claims 1 to 4, wherein a keying surface is applied to the mating surface of the tile base before pressing them together.
6. A multi-station tile manufacturing equipment adapted to manufacture laminated tiles using one or more tile molds, the equipment, including: a mold filling station at which a wetted concrete tile base mix is inserted into a mould; a vibration distribution station to distribute the mix in the mould; a compression station to compress the mix in the mold and remove water pressed from the mix; a first adhesive application station adapted to apply a first adhesive layer to a mating surface of the concrete base mix; and a tile cap application station adapted to apply a tile cap to the first adhesive layer. Received by IPONZ 9 June 2011 13
7. Equipment as claimed in claim 6, including a second adhesive application station adapted to apply a second adhesive layer to a mating surface of the tile cap.
8. Equipment as claimed in claim 6 or claim 7, wherein the first adhesive is mortar.
9. Equipment as claimed in claims 6 or claim 7, wherein the second adhesive is resinous adhesive.
10. Equipment as claimed in any one of claims 6 to 8, wherein the second adhesive is PVA.
11. Equipment as claimed in any one of claims 6 to 10, including a robot arm with a gripper capable of picking up a vibrating head as well as a tile cap independently,
12. Equipment as claimed in claim 10, wherein the gripper includes a vacuum pad to pick up a tile cap for placement on the substrate.
13. Equipment as claimed in any one of claims 6 to 12, including one or more molds adapted to receive a predetermined quantity of concrete tile base mix.
14. A composite tile made by the method of any one of claims 1 to 5.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2005907220A AU2005907220A0 (en) | 2005-12-20 | A Laminated Tile and Method of Manufacturing a Laminated Tile | |
PCT/AU2006/001889 WO2007070925A1 (en) | 2005-12-20 | 2006-12-13 | A laminated tile and method of manufacturing a laminated tile |
Publications (1)
Publication Number | Publication Date |
---|---|
NZ569196A true NZ569196A (en) | 2011-07-29 |
Family
ID=38188134
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
NZ569196A NZ569196A (en) | 2005-12-20 | 2006-12-13 | Apparatus for and method of manufacturing a laminated tile with tile cap adhered to wetted concrete mix with water pressed out |
Country Status (4)
Country | Link |
---|---|
US (1) | US20090049793A1 (en) |
AU (1) | AU2006326914B2 (en) |
NZ (1) | NZ569196A (en) |
WO (1) | WO2007070925A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN106239698A (en) * | 2016-07-29 | 2016-12-21 | 山东建筑大学 | Multistation forming machine for concrete building unit |
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DE102017123155A1 (en) * | 2017-10-05 | 2019-04-11 | Feiner Betonwerk GmbH und Co. KG | Composite panel and its manufacture |
CN110273517B (en) * | 2019-06-17 | 2020-07-21 | 徐州工业职业技术学院 | Automatic production line for heat-insulating decorative composite board |
CN111376384B (en) * | 2020-03-20 | 2021-08-03 | 龙泉市建春青瓷厂 | Automatic production line for celadon blank |
NL2025389B1 (en) * | 2020-04-21 | 2021-10-27 | Excluton B V | Method for manufacturing a paving element |
CN111516130B (en) * | 2020-05-11 | 2021-08-10 | 廊坊海斯建材机械有限公司 | Wet forming machine |
CN113103427A (en) * | 2021-04-06 | 2021-07-13 | 甘肃安居建设工程集团有限公司 | Prefabricated assembled concrete exterior wall cladding and decorative layer mixed-striking method thereof |
DE102022127331A1 (en) * | 2022-10-18 | 2024-04-18 | Baustoffwerke Gebhart & Söhne GmbH & Co. KG | Method and device for producing a composite body |
Family Cites Families (10)
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US1431364A (en) * | 1921-10-31 | 1922-10-10 | Anchor Concrete Machinery Co | Tamping maghine |
US1989409A (en) * | 1932-05-24 | 1935-01-29 | Viber Company Ltd | Method and apparatus for compacting and dewatering cementitious materials |
NL47515C (en) * | 1935-10-05 | |||
US2558615A (en) * | 1947-11-26 | 1951-06-26 | Emil J Johnson | Mold for concrete steps |
NZ225374A (en) * | 1987-07-14 | 1991-01-29 | Chichibu Cement Kk | Paving block: topping layer on concrete base |
US4889330A (en) * | 1988-01-25 | 1989-12-26 | Mcswain Gregory D | Trowel vise |
US5062913A (en) * | 1988-04-05 | 1991-11-05 | Charles R. Owens | Laminated tile product and method for producing the same |
DE29810311U1 (en) * | 1998-06-09 | 1998-11-19 | Gilne GmbH, 49497 Mettingen | Tile slab |
DE20202065U1 (en) * | 2002-02-12 | 2002-06-06 | Karl, Heinz, Dipl.-Ing. (FH), 92637 Weiden | Cast stone |
JP2004243714A (en) * | 2003-02-17 | 2004-09-02 | Kurokawa Yasuhiro | Manufacturing method of board such as laminated tile, brick, tile and board such as laminated tile, brick, tile |
-
2006
- 2006-12-13 NZ NZ569196A patent/NZ569196A/en not_active IP Right Cessation
- 2006-12-13 AU AU2006326914A patent/AU2006326914B2/en not_active Ceased
- 2006-12-13 WO PCT/AU2006/001889 patent/WO2007070925A1/en active Application Filing
- 2006-12-13 US US12/158,154 patent/US20090049793A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN106239698A (en) * | 2016-07-29 | 2016-12-21 | 山东建筑大学 | Multistation forming machine for concrete building unit |
CN106239698B (en) * | 2016-07-29 | 2018-08-24 | 山东建筑大学 | Multistation forming machine for concrete building unit |
Also Published As
Publication number | Publication date |
---|---|
AU2006326914A1 (en) | 2007-06-28 |
US20090049793A1 (en) | 2009-02-26 |
AU2006326914B2 (en) | 2011-08-25 |
WO2007070925A1 (en) | 2007-06-28 |
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