WO2023126733A1 - Procédé, installation et machine de fabrication de dalles en céramique présentant un effet structuré, particulièrement en vue du revêtement de surface - Google Patents

Procédé, installation et machine de fabrication de dalles en céramique présentant un effet structuré, particulièrement en vue du revêtement de surface Download PDF

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Publication number
WO2023126733A1
WO2023126733A1 PCT/IB2022/062191 IB2022062191W WO2023126733A1 WO 2023126733 A1 WO2023126733 A1 WO 2023126733A1 IB 2022062191 W IB2022062191 W IB 2022062191W WO 2023126733 A1 WO2023126733 A1 WO 2023126733A1
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WO
WIPO (PCT)
Prior art keywords
fact
slab
plant
powder
phase
Prior art date
Application number
PCT/IB2022/062191
Other languages
English (en)
Inventor
Andrea Vaccari
Original Assignee
Graf Industries S.P.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Graf Industries S.P.A. filed Critical Graf Industries S.P.A.
Publication of WO2023126733A1 publication Critical patent/WO2023126733A1/fr

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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
    • 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
    • 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
    • B28B11/0863—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for profiling, e.g. making grooves
    • 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
    • B28B13/022—Feeding several successive layers, optionally of different materials
    • 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
    • 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
    • B28B5/02—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 on conveyors of the endless-belt or chain type
    • B28B5/021—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 on conveyors of the endless-belt or chain type the shaped articles being of definite length
    • 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
    • C04B41/53—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete
    • 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
    • C04B41/91—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics involving the removal of part of the materials of the treated articles, e.g. etching

Definitions

  • PROCESS PLANT AND MACHINE FOR THE MANUFACTURE OF CERAMIC SLABS WITH A TEXTURED EFFECT, PARTICULARLY FOR SURFACE COATING
  • the present invention relates to a process, plant and machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating.
  • Known plants involve the use of molds or forming jigs which are adapted to imprint a predefined imprint reproducing the desired decorative effect on the surface of a ceramic article made of a raw material, that is, not yet fired in a kiln.
  • This method requires the creation of special molds which, however, must be replaced whenever the desired decorative effect is to be changed and/or depending on the size of the ceramic slab.
  • the main aim of the present invention is to devise a process, plant and machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, which allow ceramic slabs provided with a textured effect to be made conveniently and easily.
  • Another object of the present invention is to devise a process, plant and machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, which allow reproducing the faithful and accurate three- dimensional effect drawings.
  • Still one object of the present invention is to devise a process, plant and machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, which allow customizing the decorative effect to be given to the ceramic slabs quickly and easily, depending on the needs of the individual customer.
  • Another object of the present invention is to devise a process, plant and machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, which will overcome the aforementioned drawbacks of the prior art within the framework of a simple, rational, easy and effective to use as well as affordable solution.
  • the aforementioned objects are further achieved by the present plant for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, having the characteristics of claim 8.
  • the aforementioned objects are further achieved by the present machine for the manufacture of ceramic slabs with a textured effect, particularly for surface coating, having the characteristics of claim 24.
  • Figure 1 is a schematic representation of the plant according to the invention, in accordance with a first embodiment
  • Figure 2 is an axonometric view of a ceramic slab obtained by means of the plant in Figure 1 ;
  • Figures 3-6 are schematic representations of the various phases of the process carried out by means of the plant in Figure 1 ;
  • Figure 7 is a sectional view along the VII- VII plane in Figure 6;
  • Figure 8 is a sectional view along the VIII- VIII plane in Figure 6;
  • Figure 9 is a schematic representation of the plant according to the invention, in accordance with a second embodiment.
  • Figure 10 is an axonometric view of a ceramic slab obtained by means of the plant in Figure 9;
  • FIGS 11-14 are schematic representations of the various phases of the process which are carried out by means of the plant in Figure 9;
  • Figure 15 is a sectional view along the XV-XV plane in Figure 14.
  • reference numeral 1 globally denotes a plant for the manufacture of ceramic slabs with a textured effect, particularly for surface coating.
  • ceramic slabs refers both to largesized slabs, i.e., provided with a length and/or width of more than one meter, and to tiles and surface covering tops, i.e., small-sized slabs ready for installation.
  • the plant 1 comprises at least one supporting surface 2 and distribution means 3 adapted to distribute a powder 5 comprising at least one raw ceramic material on the supporting surface 2 to obtain a slab- shaped article 6.
  • raw ceramic material means a paste of ceramic material, i.e., composed of a mixture comprising at least one of clays, feldspars, kaolin, silica sand, iron oxides, alumina, quartz, etc., which has not yet been fired in a kiln.
  • the expression “slab-shaped article” means an article with width and length dimensions which are significantly greater than thickness, i.e., at least one order of magnitude greater (i.e., more than 10 times greater).
  • the powder 5 is full-field distributed over the supporting surface 2 depending on the conformation which is intended to give to the slab- shaped article 6.
  • the supporting surface 2 is movable along a direction of forward movement D.
  • the supporting surface 2 is adapted to move the slab- shaped article 6 between the various stations of the plant 1.
  • the plant 1 comprises at least one line of movement 4 movable along the direction of forward movement D and defining, above it, the supporting surface 2.
  • the line of movement 4 comprises a series of conveyor belts and roller conveyors arranged in sequence with each other along the direction of forward movement D.
  • the line of movement 4 consists of systems of forward movement different from those illustrated and intended, e.g., to transfer the slab-shaped article 6 between different working stations designed to implement the various working phases.
  • the supporting surface 2 is intended to receive the powder 5 directly.
  • the distribution of the powder 5, in fact, is carried out directly on the supporting surface 2.
  • the slab-shaped article 6 is, therefore, formed by the full-field distributed powder 5 alone.
  • the slab- shaped article 6 so obtained is provided with at least one work surface 6a.
  • the slab- shaped article 6 is placed on the supporting surface 2 with the work surface 6a facing upwards.
  • the powder 5 comprises a plurality of powder particles 5a provided with a predefined particle size.
  • the distribution means 3 are adapted to distribute the powder particles 5a in one or more layers arranged on top of each other to cover at least part of the supporting surface 2, depending on the shape to be given to the slab- shaped article 6.
  • the distribution means 3 comprise at least one hopper adapted to release the powder 5 onto the supporting surface 2 as a result of its movement along the direction of forward movement D.
  • the plant 1 also comprises a machine 23 provided with modeling means 7 adapted to machine the work surface 6a according to at least one predefined pattern and at least one predefined depth to obtain a structured surface.
  • structured surface refers to a surface provided with reliefs and depressions that give a three-dimensional finish to the surface of the slab-shaped article.
  • the machine 23 will be described in more detail later in this disclosure.
  • the plant 1 comprises firing means 8 adapted to fire the slab- shaped article 6 to obtain a ceramic slab 9 provided with a textured effect.
  • the expression “textured effect” means that the surface of the ceramic slab 9 has a three-dimensional decorative effect such as, e.g., and without any limitation, the aesthetic effect typical of the surfaces of natural materials, such as wood, marble, rocks or the like.
  • the firing means 8 are of the type of a ceramic kiln and are configured to subject the slab- shaped article 6 to very high temperatures.
  • the function of firing is to chemically/physically transform the ceramic components of the powder 5 in order to give the finished ceramic slab 9 a mechanically resistant structure.
  • the powder particles 5a firmly unite with each other and stabilize the textured decorative effect defined on the surface of the slab- shaped article 6 ( Figure 2).
  • the machine 23 there may be further working/finishing stations between the machine 23 and the firing means 8 such as, e.g., an engobe application station, a decorating station, a glazing station and so on.
  • the powder 5 may also comprise glaze.
  • the glaze is glass powder composed of, e.g., silicon dioxide, boron trioxide and aluminum oxide.
  • the function of the glaze is to help keep the powder particles 5 a cohesive following firing and defines a surface coating for the ceramic slab 9.
  • the powder 5 may also comprise enamels/glazes and other solid finishing elements.
  • the powder 5 can be mixed with additives, such as e.g. resin-type bonding materials, which help promote cohesion between the powder particles 5 following firing, thus increasing the mechanical strength of the ceramic slab 9 and reducing the porosity thereof.
  • additives such as e.g. resin-type bonding materials, which help promote cohesion between the powder particles 5 following firing, thus increasing the mechanical strength of the ceramic slab 9 and reducing the porosity thereof.
  • the plant 1 may also comprise means for laying a bonding material on the work surface 6a, arranged upstream of the firing means 8, not shown in detail in the figures.
  • the textured effect is achieved by means of the machine 23 provided with the modeling means 7.
  • the machine 23 is adapted to make one or more recesses 12 in the powder 5 so as to give the work surface 6a its three-dimensional finish.
  • the machine 23 comprises at least one electronic unit provided with at least one memory unit adapted to store at least one image defining at least one of either the predefined pattern or the predefined depth.
  • the image is made up of a plurality of pixels arranged in a grid pattern to each other according to a plurality of columns and a plurality of lines, wherein each pixel corresponds to a relevant work point 14 of the work surface 6a.
  • the work points 14 are, therefore, also arranged according to a plurality of columns and a plurality of lines, wherein the columns are substantially parallel to the direction of forward movement D and the lines are substantially parallel to a transverse direction T, substantially perpendicular to the direction of forward movement D (Figure 8).
  • the arrangement and intensity of pixels define the predefined pattern and the predefined depth, respectively.
  • the expression “intensity of pixels” means the gradation of each pixel in the image, with reference to every possible value of between black and white.
  • the depth of the recesses 12 is substantially proportional to the color gradation of the various pixels in the image.
  • the modeling means 7 comprise at least one blowing device 10 adapted to emit a jet of air 11 concentrated on the work surface 6a so as to remove part of the powder 5.
  • the term “jet of air” refers to a jet of compressed air. Embodiments cannot, however, be ruled out wherein gases of different types, such as inert gases and/or moisture-controlled gases, are used. Specifically, the blowing device 10 is operable to emit the jet of air 11 towards a specific work point 14 according to the predefined pattern and/or the predefined depth ( Figure 7).
  • the electronic unit is operationally connected to the blowing device 10 and is configured to operate the latter according to the predefined pattern and/or the predefined depth.
  • the machine 23 also comprises at least one suction unit 13 adapted to suck in the powder 5 which has been removed by means of the blowing device 10.
  • the blowing of the jet of air 11 causes the affected powder particles 5a to be lifted off the work surface 6a and the suction unit 13 is adapted to suck them in before they can redeposit by gravity back onto the work surface itself.
  • the machine 23 is able to achieve an extremely precise and defined decorative effect.
  • the blowing device 10 comprises a delivery port 17 connected to a compressed gas pumping system.
  • the delivery port 17 has a cross-sectional area of characteristic size between 10 pm and 1000 pm, preferably between 50 pm and 300 pm, even more preferably 250 pm. More in detail, considering a cross-sectional area of circular conformation, the characteristic size corresponds to the diameter of the circle, on the other hand, in case the cross-sectional area is of polygonal conformation, the characteristic size corresponds to the equivalent diameter.
  • the blowing device 10 is configured to emit the jet of air 11 at a pressure of between 0.1 mbar and 10 bar.
  • the pressure of the jet of air 11 is selected according to the degree of compaction of the powder particles 5a.
  • the blowing device 10 is configured to emit the jet of air 11 discontinuously.
  • the blowing device 10 is configured to emit the jet of air 11 for a predetermined dispensing time and according to a frequency of up to even 2,000 Hz with variable duty cycle.
  • the dispensing time of the jet of air 11 determines the degree of depth of the recess 12. As the dispensing time increases, in fact, the jet of air 11 is able to hit the same point for a longer time, so that the powder particles 5a of underlying layers are also removed.
  • the pressure of the jet of air 11 is also selected according to the dispensing time of the jet of air itself.
  • the modeling means 7 comprise at least one supporting crossbar 16 extending transversely to the direction of forward movement D, superiorly to the supporting surface 2 and supporting the blowing device 10.
  • the supporting crossbar 16 is substantially parallel to the transverse direction T.
  • the supporting crossbar 16 extends for at least the full width of the supporting surface 2.
  • the blowing device 10 is attached to the supporting crossbar 16.
  • the blowing device 10 is configured to emit the jet of air 11 only towards a specific column of work points 14 as the slab- shaped article 6 moves forward along the direction of forward movement D.
  • the modeling means 7 comprise a plurality of blowing devices 10.
  • blowing devices 10 are equal in number to the number of columns of work points 14 and are arranged so as to cover the entire modeling field of the work surface 6a.
  • modeling field means the area of the work surface 6a on which modeling can be carried out as the slab-shaped article 6 moves forward along the direction of forward movement D.
  • the modeling field corresponds to the width of the work surface 6a, i.e., its horizontal extension perpendicular to the direction of forward movement D.
  • the blowing devices 10 are arranged side by side and staggered from each other so that each of them can emit the jet of air 11 towards a work point 14 of a respective column. As the slab- shaped article 6 moves forward along the direction of forward movement D, the blowing devices 10 are, therefore, able to emit the jets of air simultaneously so as to hit multiple work points 14 at the same time.
  • the modeling means 7 comprise a single blowing device 10, which is associated with the supporting crossbar 16 in a movable manner and is movable with respect thereto depending on the predefined pattern.
  • the blowing device 10 is movable similarly to a printing plotter to emit the jet of air 11 at a specific work point 14 as the slab- shaped article 6 moves forward along the direction of forward movement D.
  • modeling means 7 comprise a single blowing device 10 which is attached to the supporting crossbar 16 and wherein the supporting surface 2 is freely movable in its lying plane to position the single work points 14 to be hit where the jet of air 11 is located.
  • the supporting crossbar 16 is further adapted to support the suction unit 13 as well.
  • the suction unit 13 may comprise, e.g., a blade vacuum unit, which extends across the entire width of the supporting surface 2.
  • the suction unit 13 may comprise a suction device which is movable with respect to the supporting crossbar 16 to position itself where the work points 14 affected by the jet of air 11 are located.
  • the suction unit 13 may comprise a plurality of suction devices, one for each column of the work points 14. Also, there are embodiments wherein the suction device is arranged to surround a respective blowing device 10 so as to suck air in where the blowing device itself is located.
  • the plant 1 also comprises compaction means 18, which are arranged upstream of the machine 23 with respect to the direction of forward movement D and adapted to compact the slab- shaped article 6.
  • the compaction means 18 have the function of providing greater compactness to the powder 5 and contribute to impart high strength and surface mechanical resistance to the finished ceramic slab 9.
  • the compaction means 18 are of the type of a belt compactor.
  • the compaction means 18 are of a different type, e.g. of the type of an alternating press.
  • belt compactors allow for continuous compaction of the materials, i.e., without the need to stop moving the material itself along a line of forward movement. It cannot, however, be ruled out that the compaction means may be of a different type.
  • the compaction means 18 comprise a belt 19 closed on itself around a series of motorized rollers 20 that cause the movement thereof.
  • the compaction means 18 also comprise at least one pressing body 21 movable towards the supporting surface 2 and adapted to exert a pressing force on the deposited powder 5.
  • the pressing body 21 exerts pressure on the powder 5 through the belt 19.
  • the compaction means 18 also comprise at least one shockabsorbing body 22 placed between the pressing body 21 and the supporting surface 2.
  • shock-absorbing body 22 is placed between the pressing body 21 and the belt 19.
  • the shock-absorbing body 22 is adapted to cushion the pressing force exerted by the pressing body 21 on the powder 5 and to even out the degree of compaction thereof.
  • shock-absorbing body 22 allows evening out the compaction of the powder particles 5a so that, during modeling, the same amount of powder particles 5a is always removed, the pressure of the jet of air 11 being equal during modeling.
  • the pressing body 21 is made of a hard material, such as of metal material
  • the shock-absorbing body 22 is made of a soft material, such as e.g. rubber or the like.
  • the shock-absorbing body 22 can be made of a material having a hardness value of between 10 Shore A and 40 Shore A.
  • the plant 1 may also comprise means for leveling the work surface 6a, not shown in detail in the figures, arranged upstream of the compaction means 18.
  • the leveling means may comprise a trowel or roller placed in rotation, or a system for sucking in the exceeding powder 5.
  • a second embodiment is shown, which differs from the above by the fact that the plant 1 also comprises forming means, not shown in detail in the figures, arranged upstream of the distribution means 3 with respect to the direction of forward movement D and adapted to form at least one slab- shaped body 15 made of a further raw ceramic material on the supporting surface 2.
  • the distribution of the powder 5 is, therefore, carried out above the slab-shaped body 15.
  • 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 composition, color or grain size.
  • the slab-shaped article 6 obtained as a result of the deposition of the powder 5 is, therefore, composed of the slab-shaped body 15 and of the layer of powder 5 deposited thereon.
  • the powder 5 can be deposited full-field or only at certain parts of the surface of the slab- shaped body 15.
  • the plant 1 may also comprise means for spreading a bonding material arranged upstream of the distribution means 3 and, in such a case, the slab-shaped article 6 also comprises one layer of bonding material located between the slab- shaped body 15 and the layer of powder 5.
  • the forming means are of a type known to the technician in the field and comprise deposition means, such as e.g. a hopper, adapted to deposit the further raw ceramic material on the supporting surface itself.
  • the forming means also comprise pressing means adapted to press the further ceramic material to obtain the slab- shaped body 15.
  • the distribution means 3 are adapted to distribute the powder 5 on the slab- shaped body 15.
  • the ceramic slab 9 is, therefore, composed of a base layer, defined by the slabshaped body 15 and an exposed layer, defined by the molded powder 5.
  • the slab-shaped body 15 makes it possible to impart greater strength to the ceramic slab 9 than powder 5 alone, and its use is advantageous especially in applications wherein the ceramic slab 9 is subjected to high mechanical stress.
  • the second ceramic material is pressed at a higher pressure value than the compaction pressure of the powder 5.
  • pressing is carried out at a pressure of between 100 bar and 400 bar.
  • Compaction is carried out at a pressure of between 0.1 bar and 100 bar.
  • the values of pressure given refer to an over-pressure with respect to the atmospheric pressure.
  • the first ceramic material and the second ceramic material intimately join together, providing the finished ceramic slab 9 with a structure that is extremely resistant to mechanical stresses.
  • the operation of this plant 1 in the execution of the process according to the invention is as follows.
  • the process according to the invention first comprises a phase of providing at least one powder 5 comprising at least one raw ceramic material.
  • the process then comprises the phases of: distributing the powder 5 onto at least one supporting surface 2 to obtain a slab- shaped article 6 provided with a work surface 6a; modeling the work surface 6a according to at least one predefined pattern and at least one predefined depth to obtain a structured surface; and firing the slab- shaped article 6 in a kiln to obtain a ceramic slab 9 provided with a textured effect.
  • the phase of modeling comprises at least one sub-phase of blowing a jet of air 11 concentrated on the work surface 6a so as to remove part of the powder 5.
  • the phase of modeling also comprises at least one sub-phase of suctioning the powder 5 removed during the sub-phase of blowing.
  • Modeling is carried out by the machine 23, specifically, blowing is carried out by means of the modeling means 7 and suction is carried out by means of the suction unit 13.
  • the sub-phase of blowing is carried out by means of discontinuous emission of the jet of air 11.
  • the jet of air 11 is emitted for a predefined dispensing time and only at the time when it is necessary to hit specific work points 14 of the work surface 6a depending on the predefined pattern and on the predefined depth. Blowing is also carried out by emitting the jet of air 11 at a predefined pressure. In more detail, the pressure of the jet of air 11 is selected depending on the degree of compaction of the powder 5 and/or on the set dispensing time.
  • the process comprises a phase of compacting the slab-shaped article 6 on the supporting surface 2.
  • the phase of compacting is carried out by means of the compaction means 18 and gives a specific degree of compaction to the powder 5.
  • phase of compacting is carried out so as to give a substantially uniform degree of compaction to the powder 5.
  • the slabshaped article 6 is fired by means of the firing means 8 so as to give the ceramic slab 9 high mechanical strength.
  • the process may comprise a phase of applying decorative pigments to the work surface 6a.
  • the process further comprises a phase of forming at least one slab- shaped body 15 made of a further raw ceramic material on the supporting surface 2.
  • the next phase of powder distribution is, therefore, carried out on the slabshaped body 15.
  • the phase of forming is carried out by means of the forming means.
  • the phase of forming comprises a sub-phase of deposition of the further ceramic material on the supporting surface 2, carried out by means of the deposition means.
  • the phase of forming also comprises a sub-phase of pressing the further ceramic material to obtain the slab-shaped body 15, which is carried out by means of the pressing means.
  • the phase of pressing is carried out at a higher pressure value than the phase of compacting.
  • the present invention refers to a machine 23 for the manufacture of ceramic slabs with a textured effect, particularly for surface coating.
  • the machine 23 comprises modeling means 7 adapted to machine the work surface 6a of the slab- shaped article 6 according to at least one predefined pattern and at least one predefined depth to obtain a structured surface.
  • the slab- shaped article 6 is made up of at least the powder 5 comprising at least one raw ceramic material distributed on the supporting surface 2.
  • the modeling means comprise at least one blowing device 10 adapted to emit the jet of air 11 concentrated on the work surface 6a so as to remove part of the powder 5.
  • the slab-shaped article 6 is arranged with the work surface 6a facing upwards and the jet of air 11 is emitted downwards.
  • the slab-shaped article 6 can be arranged differently.
  • the slab-shaped article 6 can be arranged with the work surface 6a facing downwards.
  • the slabshaped article 6 can be attached to the supporting surface 2, such as by means of glues, so that it is upside down.
  • the jet of air is emitted upwards.
  • the present process, plant and machine make it possible to customize the decorative effect to be given to the ceramic slabs quickly and easily, depending on the needs 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)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
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Abstract

Le procédé de fabrication de dalles en céramique présentant un effet structuré, particulièrement en vue du revêtement de surface, comprend au moins les phases suivantes : - fournir au moins une poudre (5) comprenant au moins une matière première en céramique; - distribuer la poudre (5) sur au moins une surface de support (2) pour obtenir un article en forme de dalle (6) pourvu d'une surface de travail (6a); - modeler la surface de travail (6a) en fonction d'au moins un motif prédéfini et d'au moins une profondeur prédéfinie pour obtenir une surface structurée, la phase de modelage comprenant au moins une sous-phase de soufflage d'un jet d'air (11) concentré sur la surface de travail (6a) afin de retirer une partie de la poudre (5) et de former des renfoncements (12); - calciner l'article en forme de dalle (6) dans un four (8) pour obtenir une dalle en céramique (9) pourvue d'un effet structuré.
PCT/IB2022/062191 2021-12-28 2022-12-14 Procédé, installation et machine de fabrication de dalles en céramique présentant un effet structuré, particulièrement en vue du revêtement de surface WO2023126733A1 (fr)

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IT102021000032780A IT202100032780A1 (it) 2021-12-28 2021-12-28 Procedimento, impianto e macchina per la fabbricazione di lastre ceramiche ad effetto materico, particolarmente per il rivestimento di superfici

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0659526A1 (fr) * 1993-12-21 1995-06-28 Cca Inc. Procédé de fabrication d'un élément moulé comportant un motif
US20020011680A1 (en) * 2000-07-31 2002-01-31 L.B. - Officine Meccaniche - S.P.A. Unit and method for loading the mould cavity with powder or granular material, in ceramic tile manufacture
WO2022113005A1 (fr) * 2020-11-30 2022-06-02 Marazzi Group Srl Procédé de production de carreaux en céramique

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0659526A1 (fr) * 1993-12-21 1995-06-28 Cca Inc. Procédé de fabrication d'un élément moulé comportant un motif
US20020011680A1 (en) * 2000-07-31 2002-01-31 L.B. - Officine Meccaniche - S.P.A. Unit and method for loading the mould cavity with powder or granular material, in ceramic tile manufacture
WO2022113005A1 (fr) * 2020-11-30 2022-06-02 Marazzi Group Srl Procédé de production de carreaux en céramique

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