WO2007110751A2

WO2007110751A2 - Mosaic panel with pre-mounted tesserae, device for the production of the mosaic panel with pre-mounted tesserae and method of production of the mosaic panel with pre-mounted tesserae.

Info

Publication number: WO2007110751A2
Application number: PCT/IB2007/000774
Authority: WO
Inventors: Ivan Ghirelli
Original assignee: Ghi.Tech S.R.L.
Priority date: 2006-03-27
Filing date: 2007-03-27
Publication date: 2007-10-04
Also published as: ITMO20060102A1; WO2007110751A3

Abstract

The mosaic panel with pre-mounted tesserae comprises a plurality of tesserae, making up the mosaic, and a device comprising a frame having a plurality of seats for the interlock housing of the tesserae.

Description

MOSAIC PANEL WITH PRE-MOUNTED TESSERAE, DEVICE FOR

THE PRODUCTION OF THE MOSAIC PANEL WITH PRE-MOUNTED

TESSERAE AND METHOD OF PRODUCTION OF THE MOSAIC

PANEL WITH PRE-MOUNTED TESSERAE. Technical Field

The present invention refers to a mosaic panel with pre-mounted tesserae, device for the production of the mosaic panel with pre-mounted tesserae and method of production of the mosaic panel with pre-mounted tesserae for the installation in constructions, generally buildings, of tesserae organized in mosaics or the like.

Background Art

Various systems are known for mounting mosaic tesserae distinguished by the different production method and the different materials used.

A common characteristic of these systems is that the tesserae making up the mosaic are fixed together using adhesive or with a support that can be of various kinds.

One of the most widespread types is the system in which the tesserae making up the mosaic are glued on the hidden surface to a support substantially with mesh structure, generally made of paper or glass fibre. For this type of products, vinyl adhesives are normally used or, alternatively, resins, resins with ultra-violet drying, silicone adhesives and the like.

A mosaic obtained using such system does however present a number of drawbacks.

The gluing of the tesserae making up the mosaic is often problematic if the tesserae are wet or dirty.

The drying of the adhesives results in losses of productivity of the lines and in a considerable expenditure of energy and is generally affected by the environmental conditions.

The quality of the adhesion of the tesserae to the supporting mesh depends on the type of material to be glued and it is also affected by the environmental conditions of the end-product storage, creating evident logistics problems and limitations. The free surface on the face of the tesserae to be definitively glued on the intended surface is generally below 80% creating a reduction of the adhesion of the mosaic definitively mounted on the surface to be covered.

A further problem of the pre-mounted mosaic where the tesserae are glued to a support with mesh structure concerns the difficulty or the impossibility of replacing the faulty tesserae or of even changing their position.

Another type of pre-mounted mosaic is that in which the tesserae making up the mosaic are glued on the visible surface to a generally semi-transparent adhesive film. Even a device for mounting mosaic tesserae obtained in this way does in any case have a number of drawbacks.

The drying of the adhesives is considerably affected by the environmental conditions.

The quality of the adhesion of the tesserae to the supporting film depends on the type of material to be glued and it is also affected by the environmental condition of the end-product storage, creating evident logistic problems and limitations. The mounting of tesserae on surfaces that are not substantially smooth is not possible.

In a further type of pre-mounted mosaic, the tesserae making up the mosaic are glued together on the hidden surface.

In this case as well the gluing of the tesserae making up the mosaic is often problematic if the tesserae are wet or dirty.

The drying of the adhesives is generally greatly affected by the environmental conditions both in terms of quality and of drying times.

The quality of the adhesion of the tesserae together depends on the type of material to be glued and is also affected by the environmental conditions of the end-product storage, creating evident logistic problems and limitations.

The free surface of the tesserae intended to be definitively glued on the intended surface is generally less than 95% creating a reduction in mechanical resistance. Replacing faulty tesserae making up the device for the mounting of mosaic tesserae or even just changing their position is very difficult or impossible. Object of the Invention

The main object of the present invention is a mosaic panel with pre-mounted tesserae, device for the production of the mosaic panel with pre-mounted tesserae and method of production of the mosaic panel with pre-mounted tesserae having characteristics such as to overcome, in a simple and inexpensive way, all the drawbacks mentioned with reference to the background art. The above-mentioned object is achieved by the present mosaic panel with pre- mounted tesserae comprising a plurality of tesserae making up the mosaic characterized in that it comprises a device comprising a frame having a plurality of seats for the interlock housing of said tesserae.

The above-mentioned object is also achieved by the present method for the production of a mosaic panel with pre-mounted tesserae characterized in that it comprises the following phases : arrangement of a plurality of tesserae making up a mosaic panel with pre- mounted tesserae; arrangement of a device comprising a frame having a plurality of seats for the support and interlock housing of said tesserae; interlock fixing of said tesserae in said seats.

Brief description of the drawings

Further characteristics and advantages of the present invention will appear even more evident from the detailed description of a preferred, but not exclusive, embodiment of a mosaic panel, illustrated indicatively by way of non limiting example, in the attached drawings wherein: figure 1 is a schematic plan view from above of a possible mosaic panel with pre-mounted tesserae; figure 2 is a schematic section view of the panel of figure 1; figure 3 is a schematic section view of the panel of figure 1 having a protective tesserae cover; figure 4 is a schematic section view of two panels of figure 1 positioned side by side to cover a surface; figure 5 is a schematic section view of the panel of figure 1 with covering of the visible surface of the device with prized material for the final installation; figure 6 is a schematic section view of an alternative embodiment of the panel according to the invention; figure 7 is a schematic section view of a further alternative embodiment of the panel according to the invention with application of an adhesive; figure 8 is a schematic section view of two panels according to the invention with superimposed perimeter edges; figures 9 and 10 represent further embodiments of the panel according to the invention; figures Ha₅ Hb₅ 12₅ 13 and 14 represent a panel according to the invention in which the device is made up of two elements that can be coupled together; figures 15, 16, 17, 18 and 19 schematically represent a panel according to the invention with particular embodiments of the mosaic tesserae; figure 20 represents a panel according to the invention in which the device has bodies sensitive to temperature; figure 21 is a schematic section view of the device of figure 20; figure 22 is a schematic section view of the device of figure 20 after the heat treatment; figure 23 is a schematic section view of the panel of figure 22 after the removal of the device; figure 24 is a schematic section view of the device of figure 20 with protective tesserae cover; figures 25, 26, 27 and 28 are schematic section views of the device with bodies sensitive to temperature and of a modelling apparatus.

Embodiments of the Invention

With special reference to figures 1 and 2, a mosaic panel 1 with pre-mounted tesserae 3 according to the present invention, is shown indicatively by way of non limiting example. The panel 1 involves a device 2 made up of a frame of substantially flat shape, having seats 2' in which the tesserae 3 can be inserted and housed and blocked by interlocking them mechanically. The frame 2 is obtainable by means of different forming methods such as, for example, thermoforming, die cutting, pressing, casting, melting, injection, blowing, extrusion and drawing.

The material making up the frame 2 can be either coloured or transparent. The frame 2 is essentially made up of a substantially rigid perimeter edge 5 and of semirigid intermediate segments 4 that define the seats 2' of the tesserae 3. At least one side of the tesserae 3 is in perimeter contact with at least one semirigid intermediate segment 4 so as to allow the mechanical interlocking by friction of the tessera 3 with the device 2. Advantageously, the width of the projection on the plane of the perimeter edge 5 is the same or less than the projection width on the plane of the semirigid intermediate segments 4 so as to allow the installation of the devices 2 maintaining substantially constant the space between all the tesserae covering the surface. Such feature permits installing said mosaic panels with pre-mounted tesserae with the perimeter edges 5 positioned side by side or superimposed. Once the mosaic has been installed on the surface to be covered, the device 2 can be integrated in the covered surface or totally removed or at least in part removed; this decision depends on the requirements of the user and/or on the construction shape of the device 2.

The figure 3 shows a schematic section view of the mosaic panel 1 with pre- mounted tesserae 3 of figure 1 in an embodiment with protective cover 6 of the tesserae 3.

The figure 4 shows a schematic section view of two mosaic panels 1 with pre- mounted tesserae 3 positioned side by side and definitively installed on the surface to be covered 7 by means of a layer of adhesive material 8. In this application the perimeter edges 5 of the devices 2 combine side by side to form the correct gap between the tesserae 3.

The figure 5 shows a section view of the mosaic panel 1 with pre-mounted tesserae 3 of figure 4 in an embodiment with covering of the visible surface of the device 2 with prized material 9 for the final installation without building joint. The figure 6 shows a particular alternative, but not limitative embodiment, of the panel 1 in which the semirigid intermediate segments 4 of the frame 2 are made with V-shaped section, of appropriate material, preferably plastic or paper, and which conveys in terms of shape the adequate elasticity to the semirigid intermediate segments 4.

The figure 7 shows a schematic section view of a mosaic panel 1 with pre- mounted tesserae 3 in a particular embodiment in which, after the interlock fitting of the tesserae 3, an adhesive 10 is applied to the device 2 suitable for ensuring a better fastening of the tesserae 3. The figure 8 shows a schematic section view of two panels 1 positioned side by side and definitively installed on the surface to be covered 7 by means of a layer of adhesive material 8.

In such application, the perimeter edges 5 of the devices 2 combine and superimpose to form the correct gap between the tesserae 3. The figure 9 shows a schematic view of the frame 2 of a panel 1 in a particular embodiment in which the seats 12 for housing the tesserae 3 have at least one substantially rigid border 13 to allow the alignment of the tesserae 3 and at least one substantially semirigid and deformable border 14 to allow the mechanical retention of the tesserae 3. In the embodiment shown the border 14 is made semirigid and deformable by a series of protrusions 15 suitable for being deformed in the assembly phase of the tesserae 3.

The substantially elastic deformation of such protrusions 15 permits the interlock fixing by friction of the tesserae 3 and, at the same time, the alignment of the same on the borders 13 of the seats 12.

The figure 10 shows a schematic view of the device 2 of a panel 1 in a further embodiment in which the tesserae 3 are kept fastened to the frame 2 thanks to the retention borders 16. The figures 11a and lib show a schematic view of a panel 1 in an embodiment in which the frame 2 comprises two elements that can be coupled together, one bottom 17 and the other top 19. In this embodiment, the tesserae 3 are housed in the bottom element 17, in seats 18 arranged according to a preset pattern.

Above the bottom element 17 the top element 19 can be applied, which has one or more fastening bodies suitable for fixing the tesserae 3.

The figures 12, 13 and 14 show the panel 1 in which the bottom element 17 and the top element 19 are hinged together in a perimeter area 20, permitting the folding closing of the device 2.

Usefully, in the perimeter area 20 cuts 21 are obtained suitable for allowing the removal of the top element 19 after the final installation on the surface to be covered. In figures 15, 16, 17, 18 and 19 a panel 1 is shown in which the frame 2 has a plurality of seats 2' with dimensions smaller than those of the tesserae 3.

The borders of the seats 2' have a series of cuts 22 that enable them to bend and couple with a series of fixing portions 3' obtained on the tesserae 2.

The figure 16 shows a section view of the device of figure 15 in which the fixing portions 3' are obtained by executing on the sides of the tesserae 3 a number of compartments 3" of rectangular section in which the borders of the seats 2' of the frame 2 can be inserted.

In figure 17, the fixing portions 3' are obtained by executing on the sides of the tesserae 3 a number of compartments 23 grooved to form a dove-tail profile. In figure 18, the fixing portions V are obtained by executing on the sides of the tesserae 3 a number of compartments 24 grooved with square section.

In figure 19, the fixing portions 3' are obtained by executing on the base of the tesserae 3 a number of grooved compartments 25 suitable for being fixed into the frame 2. For this purpose, the semirigid intermediate segments 4 of the device 2 have a substantially V-shaped section such as to give them the necessary deformability.

With reference to the figures 20, 21 and 22, the frame 2 of the panel 1 has a shape substantially developed on the plane and bodies sensitive to the temperature 26 are associated with it. After positioning the tesserae 3, the device 2 undergoes a heat treatment with consequent deformation of the bodies sensitive to the temperature 26 (figure

22). The bodies sensitive to the temperature 26, thus deformed, allow interlocking the tesserae 3.

The figure 23 shows a schematic section view of the panel 1 of figure 22 after the application of the heat treatment and after the removal of the frame 2. In such configuration, the tesserae 3 are kept mechanically fastened by the bodies sensitive to the temperature 26.

Advantageously, the bodies sensitive to the temperature 26 can be made up of adhesive substances.

The figure 24 shows a schematic section view of the panel 1 of figure 20 with protective cover 6 of the tesserae 3.

In such embodiment the device 2 is made of thermoforming material and can undergo a heat treatment that allows its deformation and consequent interlock fixing of the tesserae 3 inserted in the seats 2\

The heat treatment which permits the deformation of the bodies sensitive to the temperature 26 and/or of the frame 2 in thermoforming material can be either by conduction, convection or irradiation.

The figures 25, 26, 27 and 28, for example, show a succession of schematic section views of the panel 1 and a modelling apparatus 27 suitable for modelling the bodies sensitive to the temperature 26. The figure 25 represents the initial configuration with the device 2 undergoing heat treatment.

The figure 26 shows the modelling apparatus 27 the instant it comes into contact with the bodies sensitive to the temperature 26.

In figure 27 the bodies sensitive to the temperature 26 have been modelled by the modelling apparatus 27.

The figure 28 shows the release of the mosaic panel 1 with the tesserae 3 fastened to the frame 2.

Advantageously, the production of the mosaic panel 1 with pre-mounted tesserae 3 can envisage continuous modelling apparatus 27 with cylindrical shape or the like (benders or the like).

Furthermore, it cannot be ruled out that with the frame 1 can be associated bodies sensitive to electromagnetic radiations which, if these undergo adequate radiations, permit interlocking the tesserae 3 in the seats 2' in the same way as the bodies sensitive to the temperature 26.

The method for the production of the panel 1 comprises the following phases: arrangement of a plurality of tesserae 3; arrangement of a frame 2 having a number of seats 2', 12, 18 for the support and interlock housing of the tesserae

3; interlock fixing of the tesserae 3 in the seats 2', 12, 18.

In the case of the embodiment of figure 7, the method also includes a gluing phase of the tesserae 3 to the device 2 by means of the application of the adhesive 10. With reference to the embodiments shown in the figures from 15 to 19, on the other hand, the method envisages an additional phase that consists in obtaining on the tesserae 3 the fixing portions 3' suitable for allowing the interlock coupling of the tesserae 3 to the edge of the seats 2' of the frame 2.

In relation to the embodiment of the invention shown in the figures from 20 to 23, a further phase is envisaged that consists in associating the bodies sensitive to the temperature 26 with the device 2 and, therefore, submitting these to the action of the modelling apparatus 27 suitable for ensuring the interlock fastening of the tesserae 3.

In the event of the device 2 being made of thermoforming material (figure 24), a heat treatment phase is envisaged of the frame 2 suitable for deforming the seats

2', 12, 18 and ensuring the interlock fastening of the tesserae 3.

Such heat treatment phase, for example, can consist in heating the frame 2 after the tesserae 3 have been inserted in the seats 2', 12, 18.

Alternatively, the heat treatment phase can consist in thermoforming a laminate in thermoforming material in such a way as to define the frame 2, the tesserae 3 being insertable in the seats 2', 12, 18 during such thermoforming phase.

The invention thus conceived is susceptible of numerous modifications and variations, all of which falling within the scope of the inventive concept.

Furthermore, all the details may be replaced by other elements which are technically equivalent.

In practice, the materials used, as well as the contingent shapes and dimensions, may be any according to requirements without because of this moving outside the protection scope of the following claims.

Claims

I) Mosaic panel with pre-mounted tesserae comprising a plurality of tesserae making up the mosaic, characterized in that it comprises a device comprising a frame having a plurality of seats for the interlock housing of said tesserae. 2) Panel according to claim 1, characterized in that said tesserae are mechanically interlocked in said seats of said frame by means of a plurality of semirigid deformable segments.

3) Panel according to one or more of the preceding claims, characterized in that said device has at least one protective cover of said tesserae. 4) Panel according to one or more of the preceding claims, characterized in that said device comprises at least two elements which can be coupled together. 5) Panel according to one or more of the preceding claims, characterized in that said elements which can be coupled together are connected in a perimeter area and suitable for permitting a folding closing. 6) Panel according to one or more of the preceding claims, characterized in that, in said perimeter area, it comprises a plurality of cuts suitable for allowing the reciprocal separation of said elements which can be coupled together once the installation is completed.

7) Panel according to one or more of the preceding claims, characterized in that on said tesserae are obtained fixing portions suitable for being mechanically interlocked with said device.

8) Panel according to one or more of the preceding claims, characterized in that the surface of said seats has dimensions smaller than that of said tesserae.

9) Panel according to one or more of the preceding claims, characterized in that said device is made of mermoforming material, the deformation of said frame being suitable for interlocking said tesserae in said seats.

10) Panel according to one or more of the preceding claims, characterized in that bodies sensitive to the temperature can be associated with said device.

I I) Panel according to one or more of the preceding claims, characterized in that said bodies sensitive to the temperature are made up of solid adhesive substances.

12) Panel according to one or more of the preceding claims, characterized in that said bodies sensitive to the temperature are coated with adhesive substances.

13) Panel according to one or more of the preceding claims, characterized in that said bodies sensitive to the temperature are deformable mechanically by a modelling apparatus or the like.

14) Panel according to one or more of the preceding claims, characterized in that said frame is made up of substantially transparent material.

15) Panel according to one or more of the preceding claims, characterized in that said frame is obtainable by means of a forming technique selected from the list comprising: memioforming, die cutting, pressing, casting, melting, injection, blowing, extrusion and drawing.

16) Panel according to one or more of the preceding claims, characterized in that said tesserae are glued to said device.

17) Device for the production of a mosaic panel with pre-mounted tesserae characterized in that it comprises a frame having a plurality of seats for the interlock housing of respective tesserae for mosaic.

18) Device according to claim 17, characterized in that it comprises a plurality of substantially semirigid and deformable segments suitable for interlocking said tesserae in said seats. 19) Device according to claim 17, characterized in that it comprises at least one protective cover of said seats for the protection of said tesserae.

20) Device according to claim 17, characterized in that said device comprises at least two elements which can be coupled together.

21) Device according to claim 20, characterized in that said elements which can be coupled together are connected in a perimeter area and suitable for permitting a folding closing.

22) Device according to claim 21, characterized in that, in said perimeter area, it comprises a plurality of cuts suitable for allowing the reciprocal separation of said elements which can be coupled together once the installation is completed. 23) Device according to claim 17, characterized in that the surface of said seats has dimensions smaller than that of said tesserae. 24) Device according to claim 17, characterized in that said frame is made of iheπnoforming material, the deformation of said frame being suitable for interlocking said tesserae in said seats.

25) Device according to claim 17, characterized in that bodies sensitive to the temperature can be associated with said frame. 26) Device according to claim 25, characterized in that said bodies sensitive to the temperature are made up of solid adhesive substances.

27) Device according to claim 25, characterized in that said bodies sensitive to the temperature are coated with adhesive substances.

28) Device according to claim 25, characterized in that said bodies sensitive to the temperature are deformable mechanically by a modelling apparatus or the like.

29) Device according to claim 17, characterized in that bodies sensitive to electromagnetic radiations can be associated with said frame.

30) Device according to claim 17, characterized in that said frame is coated on its surface.

31) Device according to claim 17, characterized in that said frame is made up of substantially transparent material.

32) Device according to claim 17, characterized in that said frame is obtainable by means of a forming technique selected from the list comprising: thermoforming, die cutting, pressing, casting, melting, injection, blowing, extrusion and drawing.

33) Method for the production of a mosaic panel with pre-mounted tesserae characterized in that it comprises the following phases: arrangement of a plurality of tesserae making up a mosaic panel with pre- mounted tesserae; arrangement of a device comprising a frame having a plurality of seats for the support and interlock housing of said tesserae; interlock fixing of said tesserae in said seats.

34) Method according to claim 33, characterized in that it comprises the phase of obtaining on these tesserae a plurality of fixing portions suitable for allowing the interlock coupling of said tesserae with said device.

35) Method according to claim 33, characterized in that it comprises a phase of gluing said tesserae to said device.

36) Method according to claim 33, characterized in that it comprises the phase of associating a plurality of bodies sensitive to the temperature with said device and submitting these to the action of a modelling apparatus suitable for ensuring the interlock fastening of said tesserae.

37) Method according to claim 33, characterized in that it comprises at least one phase of heat treatment of said device suitable for deforming said seats and ensuring the interlock fastening of said tesserae, said device being made of thermoforming material. 38) Method according to claim 33, characterized in that it comprises a phase of thermoforming of a laminate in thermoforming material suitable for defining said device, said tesserae being insertable in said seats during said thermoforming phase. 39) Mosaic tessera for the embodiment of the method according to one or more of the claims from 33 to 38, characterized in that it comprises at least one fixing portion suitable for being interlocked with said device.