WO2007070925A1 - A laminated tile and method of manufacturing a laminated tile - Google Patents
A laminated tile and method of manufacturing a laminated tile Download PDFInfo
- Publication number
- WO2007070925A1 WO2007070925A1 PCT/AU2006/001889 AU2006001889W WO2007070925A1 WO 2007070925 A1 WO2007070925 A1 WO 2007070925A1 AU 2006001889 W AU2006001889 W AU 2006001889W WO 2007070925 A1 WO2007070925 A1 WO 2007070925A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- tile
- adhesive
- base
- cap
- concrete
- Prior art date
Links
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
Definitions
- This invention relates to a laminated tile and a method of manufacturing such a tile. Background of the invention
- Tiles are commonly manufactured monolithically of a single material. Glazes and coatings are sometimes applied to one or more faces of the tiles.
- 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.
- 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.
- 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.
- 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.
- the method can include the step of compressing and de-watering the concrete mix.
- the method can include the step of distributing the concrete mix by vibration.
- the vibration is not done during tile cap application.
- 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.
- the equipment can include a second adhesive application station adapted to apply a second adhesive layer to a mating surface of the tile cap.
- the equipment can include a robot arm with a gripper capable of picking up the vibrating head as well as a tile cap independently.
- the gripper can include a vacuum pad to pick up a tile cap for placement on the substrate.
- Figure 1 is a schematic view of a multi-station carousel implementing a process embodying the invention from a first perspective;
- Figure 2 is a schematic view of the carousel of Figure 1 from a second perspective
- Figure 3 is a schematic view of a mold filling station ;
- Figure 4 is a schematic view of an agitation station
- Figure 5 is a schematic view of a pressing station
- Figure 6 is a schematic view of a mortar application station
- Figure 7 illustrates aspects of the tile delivery and attachment process
- Figure 8 illustrates an unloading press.
- Figure 9 illustrates a laminated tile 1200 made according to an embodiment of the invention.
- Figure 10 shows a first embodiment of the pressed concrete base.
- Figure 11 shows a second embodiment of the pressed concrete base.
- Figure 12 is a schematic representation of a method of forming a continuous tile/base composite.
- Figure 13 illustrates a production line adapted to use pre-formed base and cap layers.
- 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.
- 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.
- the molds are preferably steel plates with a cavity of the shape of the tile.
- the cavity can be a through-hole.
- the cavity will be square, but other shapes are within the scope of the invention.
- 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.
- FIG. 4 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.
- the agitation station produces agitation in 2 or 3 dimensions. This assists in distributing the mix in the mold cavity.
- 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.
- 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.
- FIG. 5 illustrates details of the pressing station.
- An hydraulic press has a plate
- 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.
- 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.
- 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.
- FIG. 11 An alternative tile base 1102 is shown in Figure 11.
- the indentations are replaced by raised grid 1104 which functions in a similar manner to the rims of the 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.
- 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.
- FIG. 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.
- 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.
- FIG. 7 Details of the tile cap delivery process are illustrated in Figure 7.
- a supply of tile caps 742 is provided by conveyor 744.
- 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.
- 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.
- 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.
- the robot/gripper takes a dry tile and places it over the sprays or dips it in a water tub and leaves it there.
- 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.
- 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.
- 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.
- FIG. 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.
- 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.
- 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.
- 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.
- a second pair of rollers 1210, 1212 can be used to apply a keying surface to the mating surface of the upper extrudate.
- 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.
- 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.
- 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.
- Figure 13 shows a production line adapted for assembling pre-made bases and caps to make a composite paver.
- 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.
- a dedicated machine can be used to place the caps and bases on their respective conveyors.
- the caps and bases can be loaded manually.
- 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.
- 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.
- 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 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.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2006326914A AU2006326914B2 (en) | 2005-12-20 | 2006-12-13 | A laminated tile and method of manufacturing a laminated tile |
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 |
US12/158,154 US20090049793A1 (en) | 2005-12-20 | 2006-12-13 | Laminated tile and method of manufacturing a laminated tile |
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 | |
AU2005907220 | 2005-12-20 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2007070925A1 true WO2007070925A1 (en) | 2007-06-28 |
Family
ID=38188134
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2006/001889 WO2007070925A1 (en) | 2005-12-20 | 2006-12-13 | A laminated tile and method of manufacturing a laminated tile |
Country Status (4)
Country | Link |
---|---|
US (1) | US20090049793A1 (en) |
AU (1) | AU2006326914B2 (en) |
NZ (1) | NZ569196A (en) |
WO (1) | WO2007070925A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110273517A (en) * | 2019-06-17 | 2019-09-24 | 徐州工业职业技术学院 | A kind of heat-insulating decorative composite board automatic production line |
CN111516130A (en) * | 2020-05-11 | 2020-08-11 | 廊坊海斯建材机械有限公司 | Wet forming machine |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN106239698B (en) * | 2016-07-29 | 2018-08-24 | 山东建筑大学 | Multistation forming machine for concrete building unit |
DE102017123155A1 (en) * | 2017-10-05 | 2019-04-11 | Feiner Betonwerk GmbH und Co. KG | Composite panel and its manufacture |
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 |
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 |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
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 | Tile slab |
DE20202065U1 (en) * | 2002-02-12 | 2002-06-06 | Karl Heinz | 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 |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
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 |
-
2006
- 2006-12-13 NZ NZ569196A patent/NZ569196A/en not_active IP Right Cessation
- 2006-12-13 WO PCT/AU2006/001889 patent/WO2007070925A1/en active Application Filing
- 2006-12-13 AU AU2006326914A patent/AU2006326914B2/en not_active Ceased
- 2006-12-13 US US12/158,154 patent/US20090049793A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
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 | Tile slab |
DE20202065U1 (en) * | 2002-02-12 | 2002-06-06 | Karl Heinz | 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 |
Non-Patent Citations (3)
Title |
---|
"Kirk-Othmer Encyclopedia of Chemical Technology", 2000, JOHN WILEY & SONS, INC., article MICHELSEN T.: "Building Materials, Survey", pages: 16 - 17 * |
DATABASE WPI Week 199901, Derwent World Patents Index; Class Q45, AN 1999-000849 * |
DATABASE WPI Week 200250, Derwent World Patents Index; Class Q41, AN 2002-46641 * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110273517A (en) * | 2019-06-17 | 2019-09-24 | 徐州工业职业技术学院 | A kind of heat-insulating decorative composite board automatic production line |
CN111516130A (en) * | 2020-05-11 | 2020-08-11 | 廊坊海斯建材机械有限公司 | Wet forming machine |
CN111516130B (en) * | 2020-05-11 | 2021-08-10 | 廊坊海斯建材机械有限公司 | Wet forming machine |
Also Published As
Publication number | Publication date |
---|---|
NZ569196A (en) | 2011-07-29 |
US20090049793A1 (en) | 2009-02-26 |
AU2006326914A1 (en) | 2007-06-28 |
AU2006326914B2 (en) | 2011-08-25 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
AU2006326914B2 (en) | A laminated tile and method of manufacturing a laminated tile | |
RU2603146C2 (en) | Device, system and method of compacted articles and pressed articles made by pressing with the help of these devices and methods | |
US5415821A (en) | Method of manufacturing fiber reinforced inorganic hardened body | |
JPS58201936A (en) | Method and apparatus for forming cake | |
CN105599112B (en) | A method of preparing artificial stone plate | |
KR101872954B1 (en) | The multi layer forming sidewalk, its apparatus and method for manufacturing | |
BG100080A (en) | Mprovements in a machine for making roof tiles | |
CN104002373B (en) | Compression molding continuous production device | |
CA2010721C (en) | System for making composite blocks | |
US4098563A (en) | Concrete product manufacturing system | |
EP1097911A2 (en) | Decorated ceramic tiles, apparatus and method for decorating the same | |
EP1879728B1 (en) | A process for die filling supply, in forming of tiles or like products | |
JP3076857U (en) | Apparatus for bringing resist and wafer into close contact with substrate | |
JP2527294B2 (en) | Equipment for manufacturing composite blocks | |
CN104175384A (en) | Fiber board preparation equipment provided with leveling device | |
KR100527266B1 (en) | Method and apparatus for forming a concrete block | |
US3231438A (en) | Method of and apparatus for producing laminated elements | |
EP0752040B1 (en) | Tiles, a method and device for fitting said tiles with spacers, and a production facility | |
KR20060041035A (en) | Manufacturing method of tile block | |
JPH0622805B2 (en) | Equipment for manufacturing composite concrete products | |
JPH02261605A (en) | Apparatus for manufacture of composite block | |
JPS589730B2 (en) | Method for manufacturing tiles with draining ridges and device for forming the draining ridges | |
CN114434870A (en) | Automatic packaging equipment for integrated packaging products | |
DE2901025A1 (en) | Concrete slab prodn. system - has sets of moulds in frames filled simultaneously by metering machine | |
JPH0478503A (en) | Production of concrete block with outer board and producing equipment |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
WWE | Wipo information: entry into national phase |
Ref document number: 2006326914 Country of ref document: AU |
|
WWE | Wipo information: entry into national phase |
Ref document number: 569196 Country of ref document: NZ |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
ENP | Entry into the national phase |
Ref document number: 2006326914 Country of ref document: AU Date of ref document: 20061213 Kind code of ref document: A |
|
WWP | Wipo information: published in national office |
Ref document number: 2006326914 Country of ref document: AU |
|
WWE | Wipo information: entry into national phase |
Ref document number: 12158154 Country of ref document: US |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 06817615 Country of ref document: EP Kind code of ref document: A1 |