WO2022123410A1 - Process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating - Google Patents
Process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating Download PDFInfo
- Publication number
- WO2022123410A1 WO2022123410A1 PCT/IB2021/061283 IB2021061283W WO2022123410A1 WO 2022123410 A1 WO2022123410 A1 WO 2022123410A1 IB 2021061283 W IB2021061283 W IB 2021061283W WO 2022123410 A1 WO2022123410 A1 WO 2022123410A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fact
- process according
- phase
- powder
- slab
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 50
- 230000008569 process Effects 0.000 title claims abstract description 47
- 239000000919 ceramic Substances 0.000 title claims abstract description 40
- 230000000694 effects Effects 0.000 title claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- 239000011248 coating agent Substances 0.000 title claims abstract description 14
- 238000000576 coating method Methods 0.000 title claims abstract description 14
- 239000000843 powder Substances 0.000 claims abstract description 54
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 21
- 238000009826 distribution Methods 0.000 claims abstract description 13
- 238000010304 firing Methods 0.000 claims abstract description 12
- 239000002245 particle Substances 0.000 claims description 28
- 230000006835 compression Effects 0.000 claims description 14
- 238000007906 compression Methods 0.000 claims description 14
- 238000003825 pressing Methods 0.000 claims description 7
- 239000000049 pigment Substances 0.000 claims description 6
- 230000003993 interaction Effects 0.000 claims description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 230000006870 function Effects 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- 239000011435 rock Substances 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 238000005411 Van der Waals force Methods 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 235000013980 iron oxide Nutrition 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000012255 powdered metal Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 230000001131 transforming effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/0036—Laser treatment
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
- B28B11/0872—Non-mechanical reshaping of the surface, e.g. by burning, acids, radiation energy, air flow, etc.
-
- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
-
- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0295—Treating the surface of the fed layer, e.g. removing material or equalization of the surface
-
- 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
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
- B28B3/123—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
Definitions
- the present invention relates to a process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating.
- this method requires the replacement of the mould every time the desired decorative effect and/or the size of the ceramic slab have to be changed. Furthermore, in order to respond adequately to customers’ requirements, it is necessary for companies to make one or more specific moulds for every customer.
- the main aim of the present invention is to devise a process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating, which enables ceramic slabs with a textured effect to be manufactured in a practical and easy manner.
- a further object of the present invention is to devise a process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating, which allows reproducing in a faithful and precise manner the three- dimensional effect typical of the surfaces of natural materials.
- Another object of the present invention is to devise a process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating, which allows the aforementioned drawbacks of the prior art to be overcome within a simple, rational, easy and effective to use as well as affordable solution.
- Figure 1 is a schematic representation of the process according to the invention, according to a first embodiment
- Figures 2 to 5 are schematic representations of the various phases of the process in Figure 1 ;
- Figure 6 is a schematic representation of the process according to the invention, according to a second embodiment
- Figures 7 to 10 are schematic representations of the various phases of the process in Figure 6.
- reference numeral 1 globally indicates a ceramic slab, particularly for surface coating.
- the process according to the invention comprises a phase of full-field distribution of at least one powder 5 comprising at least one raw ceramic material on a supporting surface 4 to obtain a slab-shaped article 2.
- raw ceramic material means a mixture of ceramic material, i.e. composed of a mixture comprising at least one of clays, feldspars, kaolin, silica sand, iron oxides, alumina, quartz, etc., not yet fired in a kiln.
- the expression “slab-shaped article” means a manufactured article with significantly greater width and length than its thickness, i.e. at least one order of magnitude greater (i.e. more than 10 times greater).
- the powder 5 may also comprise glaze.
- Glaze is glass powder, made up of e.g. silicon dioxide, boron trioxide, aluminum oxide.
- the supporting surface 4 is movable along a direction of forward movement D and is adapted to move the slab- shaped article 2 to implement the various phases of the process.
- the supporting surface 4 is defined on top of a movement line 3.
- the movement line 3 comprises a series of conveyor belts and roller conveyors arranged in sequence with each other along the direction of forward movement D. It is easy to appreciate, however, that alternative embodiments are possible wherein the movement line 3 consists of forward-moving systems other than those illustrated herein and intended, for example, to transfer the slab-shaped article 2 between different machining stations intended to implement the phases of the process according to the invention.
- the slab- shaped article 2 is provided with at least one work surface 2a.
- the slab- shaped article 2 is arranged on the movement line 3 with the work surface 2a facing upwards.
- the powder 5 comprises a plurality of powder particles 5a provided with a predefined particle size.
- the distribution phase allows obtaining one or more layers of powder particles 5a evenly arranged to coat the supporting surface 4 depending on the shape one wish to give to the slab-shaped article 2.
- the distribution phase is carried out by means of the distribution means 6.
- the distribution means 6 are of the type of a hopper adapted to release the powder 5 onto the supporting surface 4 as a result of the movement along the direction of forward movement D.
- the process also comprises a phase of at least partial removal of the powder 5 from the work surface 2a according to at least one predefined pattern and at least one predefined depth, by means of radiation-emitting removal means 9.
- the process also comprises a phase of compression of the powder 5 on the supporting surface 4.
- the compression phase has the function of providing greater compactness to the powder 5 and contributes to giving high strength and surface mechanical resistance to the finished ceramic slab 1.
- the compression phase is carried out prior to the removal phase.
- the compression phase may be carried out subsequently to the removal phase.
- the compression phase is carried out by means of the compression means 7.
- the compression means 7 are of the type of a shifting belt arranged on top of the movement line 3 and adapted to operate in conjunction with the latter to compact the deposited powder 5, as a result of the forward movement of the slab- shaped article 2.
- the process comprises a firing phase of the slab-shaped article 2 in a kiln to obtain a ceramic slab 1 provided with a textured effect.
- the expression “textured effect” means that the surface of the ceramic slab 1 has a series of reliefs and depressions typical of natural surfaces, such as wood, marble, rocks or the like.
- the firing phase is carried out at very high temperatures (greater than 1100 °C) using firing means 14.
- the firing means 14 are of the type of a ceramic kiln.
- the firing phase has the function of transforming the ceramic material mixture by supplying the finished ceramic slab 1 with a mechanically resistant structure.
- the powder particles 5a firmly unite with each other, by stabilizing the textural decorative effect defined on the surface of the ceramic slab 1 ( Figure 5).
- the powder 5 comprising also the glaze, mixed together with the ceramic material, it is possible to avoid the ancillary glazing/coating phases of the ceramic slab 1.
- the glaze in fact, melts during firing and allows forming a protective coating for the surface of the ceramic slab 1.
- the process comprises a phase of at least partial removal of the powder 5 from the work surface 2a according to at least one predefined pattern and at least one predefined depth.
- the removal phase is carried out so as to make one or more grooves 8 in the powder 5 in order to give a three-dimensional effect to the work surface 2a.
- the removal phase comprises a phase of moving at least one powder particle 5a away from the adjacent powder particles 5a.
- the process provides for the repetition of the moving away phase so as to remove a plurality of powder particles 5a and to form a groove 8.
- the removal means 9 comprise at least one laser device 10 adapted to emit a laser beam 11 towards the work surface 2a.
- the removal means 9 also comprise reflecting means 12 adapted to receive the laser beam 11 from the laser device 10 and to reflect it towards the work surface 2a.
- the laser device 10 is of the pulsed type.
- the laser device 10 emits short pulses of high-intensity radiations so as to move the powder particles 5a away from the adjacent powder particles 5a while preserving the chemical and physical properties of the ceramic material.
- the moving away phase is carried out by interaction between the laser beam 11 and the powder particles 5a.
- the laser beam 11 is adapted to break the cohesion forces between the powder particles 5a.
- cohesion forces are forces of attraction which are created among the molecules of the same substance and which help to keep them united together, opposing any external forces which tend, instead, to separate them.
- the cohesion forces are the forces of attraction among the powder particles.
- Cohesion forces are a set of bonds of attraction, comprising van der Waals forces, the force of gravity, any compressive forces applied to the powder 5, etc.
- the laser device 10 is therefore suitably configured to emit the laser beam 11 at an intensity such that it can break such cohesion forces and move the predefined powder particles 5a away while at the same time keep the remaining powder particles 5a in place.
- the moving away phase comprises a movement phase of the laser beam 11 relative to the work surface 2a depending on the predefined pattern and the predefined depth.
- the movement of the laser beam 11 is carried out by means of the reflecting means 12 which are able to direct the laser beam 11 towards any powder particle 5a as a result of the movement of the slab-shaped article 2 along the direction of forward movement D.
- each groove 8 can be made according to different depths in order to reproduce in an extremely faithful manner the most complex natural materials, such as e.g. wood.
- the removal means 9 comprise at least one electronic unit comprising at least one memory unit adapted to store at least one of either the predefined pattern or the predefined depth.
- the electronic unit is operatively connected to the reflecting means 12 and is configured to operate the latter to move the laser beam 11 according to the predefined pattern and/or the predefined depth.
- the laser beam 11 by interacting with the powder particles 5a, breaks the cohesion forces and helps to push the powder particles themselves away.
- the removal phase comprises a suctioning phase of the at least one powder particle 5a moved away.
- the suctioning phase occurs substantially at the same time as the removal phase so that the powder particle 5a moved away does not fall back by gravity on the underlying powder particles 5a.
- the removal means 9 also comprise suctioning means 13 adapted to remove the powder particle 5a moved away by means of vacuum application.
- the process may also comprise an application phase of decorative pigments onto the powder 5.
- the decorative pigments are selected from ceramic pigments, powdered metals, glaze or a combination thereof.
- the application phase allows the textured effect defined by the grooves 8 to be finished by means of the distribution of the colored decorative pigments, so as to visually emphasize the three-dimensional effect of the ceramic slab 1.
- the application phase is preferably carried out prior to firing so that the decorative pigments can be firmly attached to the ceramic materials.
- the application phase is carried out using techniques known to the technician in the sector, e.g. digital printing.
- Figures 6 to 10 show a second embodiment of the present process which differs from the first embodiment in the following aspect.
- the process according to the second embodiment comprises, prior to the distribution phase, at least one phase of providing at least one slab- shaped body 15 made of an additional raw ceramic material.
- the slab- shaped body 15 is made of a first ceramic material and the powder 5 is made of a second ceramic material.
- the second ceramic material differs from the first ceramic material in at least one of its composition, color or grain size.
- the slab-shaped body 15 defines the supporting surface 4.
- the slab-shaped body 15 is arranged to rest on the movement line 3 with the supporting surface 4 facing upwards.
- the process Prior to the providing phase, the process comprises a phase of pressing the first ceramic material to obtain the slab- shaped body 15.
- the pressing phase has the function of providing greater compactness to the mixture and contributes to giving high strength and mechanical resistance to the finished ceramic slab 1 as a result of firing at high temperatures.
- the pressing phase is carried out by means of pressing means, not shown in the figures, of a type known to the technician in the field.
- the ceramic slab 1 is, therefore, composed of a base layer, defined by the slabshaped body 15 and a visible layer, defined by the powder 5.
- the slab-shaped body 15 makes the ceramic slab 1 stronger than powder 5 only and its use is especially advantageous in applications where the ceramic slab 1 is subjected to high mechanical stress.
- Pressing is carried out at a first pressure value.
- the compression phase is carried out at a second pressure value wherein the second pressure value is lower than the first pressure value.
- the subsequent distribution phase is, therefore, carried out on the slab-shaped body 15.
- the resulting slab-shaped article 2 is, therefore, defined by the slab-shaped body 15 and by the layers of powder particles 5a distributed thereon.
- the slab- shaped article 2 is subjected to the firing phase wherein the first ceramic material and the second ceramic material join intimately together, providing the finished ceramic slab 1 with a mechanically resistant structure.
- the described invention achieves the intended objects, and in particular the fact is emphasized that the process according to the present invention allows manufacturing, in a practical and easy manner, ceramic slabs provided with a textured effect, and in particular, it allows reproducing, in a faithful and precise manner, the three-dimensional effect typical of the surfaces of natural materials.
- this process allows customizing the decorative effect to be given to the ceramic slabs in a quick and easy manner, according to the requirements of the individual customer.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21830775.9A EP4259402A1 (en) | 2020-12-09 | 2021-12-03 | Process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating |
CN202180082151.4A CN116568471A (en) | 2020-12-09 | 2021-12-03 | Process for manufacturing ceramic plates with grain effect, in particular for surface coating |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IT102020000030146A IT202000030146A1 (en) | 2020-12-09 | 2020-12-09 | PROCESS FOR THE MANUFACTURE OF CERAMIC SLABS WITH A MATERIAL EFFECT, PARTICULARLY FOR COATING SURFACES |
IT102020000030146 | 2020-12-09 | ||
IT102021000001298A IT202100001298A1 (en) | 2021-01-25 | 2021-01-25 | PROCESS FOR THE MANUFACTURING OF CERAMIC SLABS WITH A MATERIAL EFFECT, PARTICULARLY FOR COATING SURFACES |
IT102021000001298 | 2021-01-25 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2022123410A1 true WO2022123410A1 (en) | 2022-06-16 |
Family
ID=79021905
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB2021/061283 WO2022123410A1 (en) | 2020-12-09 | 2021-12-03 | Process for the manufacturing of ceramic slabs with a textured effect, particularly for surface coating |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP4259402A1 (en) |
WO (1) | WO2022123410A1 (en) |
-
2021
- 2021-12-03 WO PCT/IB2021/061283 patent/WO2022123410A1/en active Application Filing
- 2021-12-03 EP EP21830775.9A patent/EP4259402A1/en active Pending
Non-Patent Citations (1)
Title |
---|
A. PASCUAL ET AL: "CERAMIC TILE DECORATION BY LASER TECHNOLOGY", CFI CERAMIC FORUM INTERNATIONAL 82, 1 January 2005 (2005-01-01), pages 3 - 17, XP055826592, Retrieved from the Internet <URL:https://www.qualicer.org/recopilatorio/ponencias/pdfs/0413011e.pdf> [retrieved on 20210721] * |
Also Published As
Publication number | Publication date |
---|---|
EP4259402A1 (en) | 2023-10-18 |
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