WO2000003851A1

WO2000003851A1 - Covering process for terra cotta and ceramic tiles and tile obtained from the process

Info

Publication number: WO2000003851A1
Application number: PCT/IT1999/000186
Authority: WO
Inventors: Luciano Paci
Original assignee: Policurvo S.R.L.
Priority date: 1998-07-16
Filing date: 1999-06-24
Publication date: 2000-01-27
Also published as: AU4646699A; ITPS980013A1; IT1306420B1; ITPS980013A0

Abstract

A covering process for terra cotta or ceramic tiles, comprising phases of: spreading a layer of glue (2) over at least a portion of a face of a tile or brick support (1); application of a covering (3) on the support (1) which covering consists of a synthetic resin film (3) or a paper sheet; adhesion of the film or sheet (3) to the support (1) by heat polymerization or pressure; an optional plastering of the film or sheet; painting the film or sheet (3); and a drying and finishing process (9) in a kiln and a final optional finishing stage by glass-papering, brushing, or polishing. The invention also relates to the tiles produced using the process, comprising a layer of glue (2) over at least a portion of a face of the tile, a synthetic resin layer or sheet of paper, an optional layer of plaster and a coat of paint.

Description

Covering Process for Terra Cotta and Ceramic Tiles and Tile obtained from The Process

Technical Field

The invention relates to the field of production of flooring or wall-covering manufactures, especially for bathrooms or kitchens and in any case wherever decoration or decorative coordination is required. Background Art The prior art teaches products which are usually made of sheets or slabs of natural stones, especially marble and granite, or small wooden planks, or ceramic tiles and bricks decorated with usually expensive materials both because of the mtrinsic value of the materials used and of the production and working methods. There is also a very considerable expense due to waste of materials, either because of natural defects or due to problems during the processing phase.

The main aim of the present invention, therefore, is to provide flooring and wallcovering products and the like which can be manufactured at contained cost levels in comparison with natural stone, and in comparison to other materials used in flooring and wall-covering, and which can offer any decorative effect whatever, either natural or artificial, with a pleasing aesthetic result.

A further aim of the present invention is to achieve the above-mentioned aim by using materials which are not particularly subject to wear but which age in harmony with other materials used for similar purposes. A still further aim of the present invention is to achieve the above-mentioned aims by providing products which have no drawbacks in terms of hygiene, health or safety, and which are in conformity with the most rigid of construction standards in this sector.

A still further aim of the present invention is to achieve the above-described aims by providing products which need no particular special laying preparation with respect to the known construction and decorating practices in the furnishing industry.

A yet further aim of the present invention is that it attains the above-described aims while providing simple products which are also reliable, aesthetically pleasing and relatively economical taking into account the results obtained. Disclosure of Invention

These and other aims besides are all attained by the covering process for terra cotta or ceramic tiles according to the present invention, comprising the following phases: spreading a layer of glue (2) over at least a portion of one face of the tile or brick (1), application of a synthetic resin film (3) or a paper sheet, adhesion (5) of the film or sheet (3) by heat polymerization or pressure, plastering, if required, of the film or sheet (3), painting (7) the film or sheet (3) and if necessary drying in a kiln (8) and fmishing (9) by glasspapering and/or bmshing and/or polishing; as well as terra cotta or ceramic tiles obtained by the above-described process, comprising a layer of glue (2) on at least a portion of a face of the tile, a layer of film or synthetic resin or a sheet of paper (3), possibly a layer of plaster (6) and a coat of paint (7).

Further characteristics and advantages of the process and product of the present invention will better emerge from the detailed description that follows, of preferred but non-exclusive embodiments, represented in the form of non-limiting examples in the appended two drawings, in which: figure 1 shows the flow of the process of the invention, in a sort of staged diagram where each single operation on the production line is shown; figure 2 shows a section of the product realised by the process. With reference to the above figures, 1 denotes in its entirety a terra cotta tile of known type, for example a double- or single-fired tile, or a ceramic tile, constituting the support 1 for the process of the invention, which will now be described.

3 denotes in its entirety a thin layer of material in sheet form, made of a synthetic resin layer, or a paper sheet, which is the covering for the process of the invention.

When the covering 3 is a synthetic resin film 3, it can be made of any known-type polymer, for example polyvinyl chloride (PVC), polyester (PET), polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) and the like, and can be obtained in known ways, such as by glazing, lamination or the like, and can have any appearance - surface decoration, for example with a false woodgrain pattern, or a design, colour, picture of any type or combination of types, or it can have a raised or rough surface, or be characterised by a bas-relief pattern.

An especially interesting film for applications of the described process is one obtained by slicing a mass of polyvinyl chloride (PVC) polymerized in blocks of multi-coloured semi-opaque mixtures, which give the film 3 an aspect of depth of colour, with combinations of opacity and transparency producing an overall marble-type effect.

Especially useful is preapplication on the bottom surface of a film made as described above of an opaque bottom sheet 4 made of any suitable material and having an appropriate colour for the final chromatic effect sought. When the film 3 is made of a paper sheet 3, it can be made of any impregnated paper of known type, but is usually of the type made for covering poor-quality wood in the furniture industry. The process of the invention comprises, after a suitable preliminary cleaning stage by brushing or glass-papering on the basic support 1, a spreading of a layer of glue 2 over at least a portion of a face of the tile or brick 1. The glue 2 can be any adhesive suitable for the purpose, fof example a heat-polymerizing polyurethane or cold polymerizers, bi-component heat-adhesive water-based glues, and so on, applied in any normal way considered to be suitable, by spraying or rolling done by a device which in figure 1 is represented schematically by 2, which also indicates the relative stage of production. After waiting the correct time for the type of glue used, a synthetic resin film 3 is applied. The number 3 denotes also the relative stage in the manufacturing process.

If the synthetic resin film 3 is transparent, a background bottom sheet 4 can be applied on the back of the film 3 itself, and can be coloured to suit the purposes of the final desired effect. When the support 1 is a ceramic tile, the surface colour thereof can be used as the background colour of the transparent film 3.

The film is thus stuck to the support 1 according to the type of glue 2 used, either by heat polymerization or pressure, using any suitable device of known type, such as kilns, rollers or presses; the device is indicated in figure 1 by the number 5, which also refers to the film application stage of "the process. The surface covering as obtained according to the above description can be further processed, for aesthetic reasons or for reasons connected with the nature of the film 3, by plastering to remedy, the porosity of the surface, using appropriate materials such as polyesters, to be applied in any known way suitable for the purpose, for example by spreading machines equipped with a "Meyer bar", schematically illustrated by 6, which number refers also to this stage of the process and indeed the layer of plaster. The film can now be painted using any known-type product, for example polyesters, and using any suitable device of known type, for example spray units or coating machines, schematically illustrated and identified by 7, which also refers to this stage of the process and the layer of paint.

The painting phase can also be omitted, especially when the film 3 used has a woodgrain pattern.

Where needed the paint can be dried in an air or ultraviolet kiln of known types and schematically represented in the figure by number 8, which refers also to the relative stage. Finally the finished products are subjected to a last stage 9 comprising finishing operations, usually glass-papering and/or brushing and/or polishing.

When the film 3 is made from an impregnated paper sheet, the process phases are the same as described above, with use of suitable glues and resins. The products obtained using the process described above are constituted by terra cotta or ceramic tiles or bricks 1, comprising a layer of glue 2 over at least a portion of a face of the tile or brick, a synthetic resin film 3 or a sheet of paper 3, if necessary a layer 6 of plaster and a coat 7 of paint.

The products can be laid following normal procedures to become floors or wallcoverings. Obviously further or alternative embodiments of the invention or process which enter into the general scope of the illustrated process and product are possible, as are technically equivalent elements, as are added particulars, as are all the compositions and conformations of the constituent parts and substances. In particular the layer of covering can be used on edges or not, the latter alternative leaving the perimeter edges uncovered and accentuating the inter-lines of the tiles when laid, in some cases a desirable flooring effect.

It is therefore evident from the detailed description above of a preferred embodiment of the process and several possible variants thereof, the process and product of the invention offer those advantages set out in the aims, and more besides; they enable flooring and wall-covering products to be made which are functional and versatile, which are economical or at least competitively-priced, can achieve practically any desired natural or artificial decorative effect, do not wear any more quickly than other materials, or in any case age accordingly with other materials in the contexts in which they will be used; incur no hygienic risks, nor health, nor safety risks; need no special laying provisions, nor require any modifications of any sort with respect to known construction techniques and building finishing techniques. The whole process can be performed using known- type devices.

Claims

Qaims.

1). A covering process comprising phases of: spreading a layer of glue (2) over at least a portion of a face of a tile or brick support (1) made of terra cotta or a ceramic material; application of a covering (3) on said support (1) which covering consists of a synthetic resin film (3) or a paper sheet, adhesion of the film or sheet (3) to said support (1); an optional plastering of the film or sheet, painting the film or sheet (3); and a drying and finishing process (9).

2). The process of claim 1, wherein the phase of spreading a layer of glue (2) over at least a portion of a face of the tile (1) employs a glue (2) constituted by a suitable adhesive for the purpose, from a range including heat-polymerizing polyurethanes, cold polymerizing polyurethanes, heat- welding dual-component water-based glues.

3). The process of claim 1, wherein the phase of spreading a layer of glue (2) over at least a portion of a face of the tile (1) employs a technique which is suitable for the purpose, for example spraying or rolling. 4). The process of claim 1, wherein the phase of spreading a layer of glue (2) over at least a portion of a face of the tile (1) employs any technique which is suitable for the purpose and any spreading device which is suitable for the purpose. 5). The process of claim 1, wherein the synthetic resin film (3) is constituted by any known-type polymer suitable for the purpose, for example polyvinyl chloride (PVC), polyester (PET), polyethylene (PE), polypropylene (PP), acrylonitrile- butadiene-styrene (ABS).

6) The process of claim 1, wherein the synthetic resin film (3) is obtained in any known way suitable for the purpose, such as glazing or lamination. 7). The process of claim 1, wherein the synthetic resin film (3) has any appearance and surface decoration, for example a woodgrain pattern, or colours, or designs of any combination, smooth, rough or with bas-reliefs. 8). The process of claim 1, where f the synthetic resin film (3) is obtained by slicing a mass of polyvinyl chloride (PVC) polymerized in mixed-colour semi- opaque blocks exhibiting characteristics combining transparency and opacity giving an overall effect similar to marble.

9). The process of cfaim 1, wherein an opaque sheet of any suitable material of any desired colour is applied to a back side of the synthetic resin film (3). 10). The process of claim 1, wherein the synthetic resin film (3) is such that a natural colour of the underlying tile is visible.

11). The process of claim 1, wherein the paper used as covering is made of any impregnated paper suitable for the purpose. 12). The process of claim 1, wherein the paper used as covering is made of any impregnated paper which has been pre-impregnated so as to be usable for covering wooden surfaces, especially where a quality of the wood is poor, in the furniture industry.

13). The process of claim 1, wherein the phase of application of the covering to the support (1) is carried out in any way suitable for the purpose with any type of appropriate device.

14). The process of claim 1, wherein the phase of adhesion of the covering (3) to the support (1) is done is any appropriate way with reference to the characteristics of the glue (2) used, for example by heat polymerization or pressure. 15). The process of claim 1, wherein the phase of adhesion of the covering to the support (1) is carried out in any way suitable for the purpose with any type of appropriate device. 16). The process of claim 1, wherein the optional phase of plastering (6) of the covering (3) is done using any material suitable for the purpose.

17). The process of claim 1, wherein the optional phase of plastering (6) of the covering (3) is done using any technique and device suitable for the purpose.

18). The process of claim 1, wherein the phase of painting (7) of the covering (3) is done using any product suitable for the purpose.

19). The process of claim 1, wherein the optional phase of painting (7) of the covering (3) is done using any technique and device suitable for the purpose.

20). The process of claim 1, wherein the optional phase of drying (8) is performed using hot-air or ultraviolet ray kilns. 21). The process of claim 1, wherein the optional phase of drying (8) is done using any technique and device suitable for the purpose.

22). The process of claim 1, wherein the optional phase of finishing (9) is done using any technique and device suitable for the purpose.

23). Terra cotta or ceramic tiles or bricks (1) comprising a layer of glue (2) over at least a portion of a face (3) of the tile support (1), a synthetic resin film (3) or a sheet of paper (3), an optional layer of plaster (6) and a coat of paint (7).

24). Terra cotta or ceramic tiles or bricks (1), made according to the process of the first claim.

25). Terra cotta or ceramic tiles or bricks (1), made according to the process of claims 1 to 22.

26). Terra cotta or ceramic tiles or bricks (1) wherein a covering (3) is applied to one or more faces thereof or is limited to a portion of a face thereof.