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EP3099478B1 - A method for manufacture of a continuous press belt for ceramic slabs having a structured surface - Google Patents

A method for manufacture of a continuous press belt for ceramic slabs having a structured surface Download PDF

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Publication number
EP3099478B1
EP3099478B1 EP15703100.6A EP15703100A EP3099478B1 EP 3099478 B1 EP3099478 B1 EP 3099478B1 EP 15703100 A EP15703100 A EP 15703100A EP 3099478 B1 EP3099478 B1 EP 3099478B1
Authority
EP
European Patent Office
Prior art keywords
press belt
continuous press
ink
belt
jet printing
Prior art date
Legal status (The legal status 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 status listed.)
Active
Application number
EP15703100.6A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3099478A1 (en
Inventor
Claudio Ricci
Vanes TERZIARI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sacmi Imola SC
Original Assignee
Sacmi Imola SC
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 Sacmi Imola SC filed Critical Sacmi Imola SC
Priority to PL15703100T priority Critical patent/PL3099478T3/pl
Publication of EP3099478A1 publication Critical patent/EP3099478A1/en
Application granted granted Critical
Publication of EP3099478B1 publication Critical patent/EP3099478B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B15/00Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/12Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
    • B28B3/123Producing 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B5/00Presses characterised by the use of pressing means other than those mentioned in the preceding groups
    • B30B5/04Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band
    • B30B5/06Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band co-operating with another endless band
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B15/00Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/06Platens or press rams
    • B30B15/065Press rams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B5/00Presses characterised by the use of pressing means other than those mentioned in the preceding groups
    • B30B5/04Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44BMACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
    • B44B5/00Machines or apparatus for embossing decorations or marks, e.g. embossing coins
    • B44B5/02Dies; Accessories
    • B44B5/026Dies

Definitions

  • the present invention relates to manufacture of ceramic slabs, preferably having a small thickness, such as tiles for flooring and wall-cladding, having a side destined to be in view that comprises random reliefs, commonly defined as a structured surface, or having a structured effect.
  • the "structured" effect gives the ceramic product a particular pleasant aesthetic value, especially in the case of imitation of natural materials such as woods and stones.
  • the slabs or tiles with the structured in-view side are at present constructed by means of pressing of powders in a usual die for ceramic tiles, in which the punch destined to form the structured side includes a negative of the design that is to appear on the surface of the tile or slab.
  • the punch is clad by a layer of elastomer which bears, in negative, the design of the structured side.
  • the elastomer layer is constructed as follows.
  • a rigid die matrix, bearing the design in positive (i.e. entirely similar to the one to be reproduced on the ceramic slab or tile) is realized by means of a numerically-controlled precision mechanical working starting from three-dimensional data.
  • the matrix is usually made of aluminium or another suitable material for rapid machining by removal of shavings or laser ablation.
  • the matrix When the matrix is finished, it is used for vulcanisation of the layer of elastomer (typically polyurethane with hardness 90 Shore A) applied on the active side of the punch. It is commonly defined “vulcanising matrix”).
  • elastomer typically polyurethane with hardness 90 Shore A
  • the vulcanising process requires heating to an appropriate temperature (about 150°) and a contemporary pressing action.
  • an elastomer layer is present on the punch, generally a few millimetres thick and bearing the negative profile of the structure.
  • the punch is therefore ready to be mounted as an "in-view side" punch on a conventional die for pressing of ceramic powders, enabling production of tiles having a surface entirely alike to the surface of the initial metal matrix.
  • the difficulty lies in realising the upper pressing belt, destined to form the structured side of the slab, on which a relief structure is to be created, always various and continuous, i.e. without interruptions.
  • This method is very complex, laborious and has a negative environmental impact.
  • Laser ablation also exhibits limits and drawbacks, as the belt has to be mounted on a horizontal-axis rotating drum, which due to present proportions would be excessively large (more than 2 metres in diameter); and implies a working time (tens of hours) that is incompatible with an economical and industrially-exploitable production.
  • the known method is not suitable for creating a three-dimensional surface suitable for pressing ceramic tiles in the usual dies, as the nature of the structures created with the known method does not possess the mechanical and wear-resistance characteristics necessary for enduring the large number of pressing cycles and the high pressures reached in usual ceramic dies.
  • EP0228570 A2 shows a methof for manufacturing a continuous press belt using an image controlled applicator.
  • An object of the invention is a method destined for manufacture of a loop-closed press belt for continuous pressing of ceramic slabs having a structured surface.
  • the closed belt must exhibit the characteristics and requisites suitable for the action of compacting for a continuous high-pressure compacting plant, according to what is illustrated for example in application PCT/IB2012/001977 belonging to the present Applicant.
  • the belt must exhibit a high resistance to traction, in order to be able to sustain the cumulative stresses of pre-tensioning and the crushing action of the powders; a high elastic limit, in order to resist the alternating flexion stresses due to the continuous winding and unwinding about the tensioning rollers; a high degree of dimensional stability and absence of joints, which would give rise to visually-perceptible surface defects, or defects identifiable by touch, to the ceramic slabs produced.
  • the belt further must exhibit a structured surface, i.e. comprising the design in relief without interruptions - seamless - and resistant to high compacting pressure and abrasion due to the powders.
  • the structured surface must intimately adhere to the base belt, and be realizable with limited costs and very rapidly.
  • the structure in relief is realised on the matrix destined to form the structured surface of the punch of a die.
  • the structure in relief is realised directly on the continuous press belt, using an additive synthesis methods, namely using the ink-jet printing method with photo-hardening plastic materials, i.e. plastic materials comprising a heat-hardening fraction.
  • the ink to be sprayed is 100% of the photo-hardening type, i.e. made up of acrylate or epoxy monomers or oligomers, with the addition of photo-initiator substances, reticulation occurs only by effect of the UV radiation coming from a suitable lamp.
  • the above-cited ink can be of the bi-stage type, with mixed UV and heat reticulation.
  • Inks of this type contain a fraction, variable from 10% to 90%, of monomers and oligomers selected from among the following families: pure acrylics, polyester acrylates, polyurethane acrylates, epoxy acrylates, vinyls, epoxies.
  • UV light therefore functions as a temporary block which by acting on the fraction that is sensitive to ultraviolet light prevents the design from deteriorating; the final heat treatment definitively fixes the whole mass.
  • final heat treatment definitively fixes the whole mass.
  • the structure can be realized with a succession of applied layers of different materials (photo-hardening and bi-stage).
  • a steel matrix is located on special drawing means that step-advance below a beam on which a mobile head can slide in a transversal direction to an axis of the matrix, in both directions.
  • the mobile head bears a series of inkjet heads of the piezoelectrically-controlled type, which can at each step print a portion of punch over a whole width corresponding to the step.
  • the matrix advances by a step equal to a whole printing width of the head p, i.e. a sub-multiple p s thereof.
  • Each head is piloted in a known way by means of a suitable image, so as to obtain a deposit of ejected material reproducing the image on the matrix.
  • the matrix is used to vulcanise, on the in-view side of the punch of the die, a layer of rubber that is able to resist wear caused by the powder during printing operations.
  • the depositing of material ejected to create the structured surface can be done directly on the in-view side of the punch.
  • a smooth press belt made of a non-absorbent material, generally metal or made of composite materials comprising glass, carbon or Kevlar fibres, is keyed on a pair of rollers and tensioned.
  • a beam is positioned above the upper horizontal portion of the belt, on which beam a mobile head can slide in a transversal direction to the axis of the belt, in both directions.
  • the belt is step-rotated using motorised drawing means; the mobile head bears a series of piezoelectrically-controlled inkjet heads, and can at each step print on a portion of belt over a whole width, which portion is equal to a step.
  • the belt advances by a step equal to a whole printing width of the head p, or a sub-multiple p s thereof.
  • each head is piloted in a known way by means of an appropriate image, in order to obtain, on the belt, a deposit of ejected material that reproduces the image.
  • the information to be sent to the heads is obtained by processing graphic images entirely alike to normal digital images, with the difference that data relating to colour is superfluous.
  • the ink projected from the head can be a UV reticulation ink that enables a perfect adhesion to the belt and, once radiated with ultraviolet light, reticulates and hardens instantly, or a mixture of UV reticulating ink and heat reticulating ink.
  • UV lamps which are mounted directly on the head, flanked to the printing heads, so as to instantly solidify the drops as soon as they are deposited at each passage.
  • heating means that act on the completely-formed three-dimensional structure.
  • the materials projected by the heads in the class of UV controlled-hardening inks are generally mixtures of acrylate or epoxy monomers and oligomers, with the addition of photo-initiator substances. In normal conditions these are easily-ejectable liquids (viscosity of about 10 mPa ⁇ s); when they are struck by UV light of appropriate wavelength the electronic bonding configuration is modified, thus activating the reticulation process and starting-up a rapid hardening, up to solidification. The liquid completely solidifies and there is no presence of volatile (and therefore pollutant) solvents.
  • the UV light is normally applied immediately following the projection of the drops, which land on the belt as liquid and are solidified by the passage of the UV lamp, which is solidly constrained in transversal motion to the inkjet heads. Once solidified, the drops of material are covered in the following passages, up to when the desired thickness is obtained.
  • the UV light of the single passage can be modulated to an lower energy level so as to realize only the start of the solidification (pinning) and thus enable a better adhesion of the following layers.
  • a higher-intensity UV treatment is applied.
  • bicomponent plastic materials can be used (for example polyurethanes) projecting in sequence (with different heads) superposed drops of the two components (for example polyol and isocyanate, in the case of polyurethane) which solidify during mixing, directly on the surface of the belt 1. These materials harden by heat action.
  • the above-mentioned ink can be of the bi-stage type, with mixed UV and heat reticulation.
  • the heating module acts on termination of the printing.
  • the belt is constituted by material having a high modulus of elasticity, once mounted on the printing machine and appropriately tensioned, there will be however a lengthening, in general difficult to evaluate.
  • the method of the invention comprises precise detecting of the position of the belt using an encoder.
  • the belt is set in rotation.
  • the head prints a few reference markers on the external band of the belt that will not be involved in the crushing of the powder, and an optical detection system determines the position of the markers, at the same time acquiring the exact lengthwise extension of the tensions belt.
  • the electronic control system of the printing heads automatically adapts the graphic image to be printed, lengthening it or restricting it proportionally by a small corrective entity (the stretching function), not perceptible to the naked eye.
  • a small corrective entity the stretching function
  • the thickness of each footstep is estimable at about 8 - 10 ⁇ m, depending on physical and rheological parameters of the liquid (density, viscosity, surface tension, temperature etc.) and the surface of the belt. In general, it can therefore be stated that at each printing passage the design grows by about 10 ⁇ m in the direction Z perpendicular to the belt surface.
  • the print can be repeated (obviously synchronized with the previous print) a certain number of times, up to reaching the desired height.
  • this can be done on the same machine that creates the structure, in which upstream of the distributor head of the ink there is a removal system present which can remove the structure created thereon.
  • the station creating the structure on the belt is not a separate machine with respect to the belt compacter, but is instead an integrated accessory of the compactor, positioned in a convenient non-active zone of the belt (for example the upper part). Obviously during this pressing step the station is not functioning, while when a new structure is being created, the pressing is not active.
  • Figures from 1 to 3 illustrate a matrix 100 positioned on a conveyor belt 101 which advances in equal steps p or a fraction p s of p.
  • the belt is destined to accommodate at least two matrices 100, which are positioned perfectly aligned and equidistant from a side of the belt.
  • the beam 103 on which the printing head 104 runs is positioned in a transversal direction to the movement direction of the belt 101.
  • the mechanical means for moving the head 104 are not illustrated as they are known to the expert in the field.
  • the printing head 104 bears the inkjet heads 141 which will decorate a strip of the matrix equal to the step p or p s .
  • An ultraviolet lamp 142 is located downstream of the heads 141, in the movement direction, which causes the hardening of the material just deposited on the belt.
  • a sensor 144 located on-board the printing head 104, is able to follow the edge of the matrices during the advancement in order to command appropriate corrections of the printing means with the aim of recuperating any transversal errors of the matrix.
  • Full-width heating means 107 for example infrared heating means, are positioned downstream of the beam and transversally of the advancement of the belt.
  • Detection sensors of the position for example photocell devices 105, signal the position of the slab 100 in order to initiate the printing cycle.
  • Figures from 4 to 8 detect the belt 1 placed under tension between two rollers 2 of which one is motorised to step-advance by entities of p or p s .
  • the belt 1 is made of a material selected from among the following: steel, stainless steel, composite material with carbon and/or Kevlar and/or glass fibres, and exhibits a thickness of from 0.5 mm to 2 mm.
  • the beam 3 on which the printing head runs is transversal to the movement direction of the belt and overlies the belt.
  • the mechanical means for moving the head 4 are not illustrated, as they are known to an expert in the sector.
  • the printing head 4 bears the inkjet heads 41 able to decorate a strip of the belt 1 of a step p or p s .
  • a UV lamp is located downstream of the heads 41, in the motion direction, which UV lamp causes a hardening of the material just deposited on the belt.
  • the upper belt 1 can be mounted, in unused or virgin form, directly on the slab-forming machine, and overlies the lower belt 10 which bears the layer 5 of powder.
  • an abrasive device 6 is located in a position upstream of the beam 3, for removing the relief structure from the upper surface of the belt 1.
  • the abrasive device 6 comprises a horizontal-axis rotating brush 61, drawn at high speed by a motor group (not illustrated) which is pressed against the belt 1 by press means (not illustrated).
  • the dragging effect of the brush 61 causes the detaching of portions of the relief structure, which are distanced from the work zone by aspirating devices 62 (see figure 5 ).
  • a sensor 31 is positioned, which reads off a series of equidistant references 310, which are previously printed by the head 4 on an edge of the belt not interested by the printing with the aim of controlling the precise development thereof after the tensioning so as to adapt the dimension of the image printed.
  • a sensor 4 is positioned, which detects even minimal transversal deviations of the belt in order to adapt the position of the image in real-time.
  • a virgin press belt with a width of 2000 mm and a total extension of 7500 mm, loop-wound, is mounted stretched on two rollers having horizontal axis, parallel to one another, about 2500 mm distant from one another, having a diameter of 750 mm.
  • the printing system automatically tensions the belt, applying a force of about 100 kN, equal to about 25 N/mm.
  • the printing width is 70 mm.
  • the real maximum height measured at the end of the printing is 400 ⁇ m.
  • the ink used is the UV hardening type, belonging to the series Unijet Thunder 1000 produced by Unico Digital (BE).
  • the result of the application of the method of the invention is a press conveyor suitable for continuous compacting lines, having on an external surface thereof a relief that is variable between 0 and 2 mm, preferably between 0 and 1 mm, realised by inkjet application of liquid materials polymerised by UV light, i.e. polymerisable by mixing two or more liquid components.
  • the "structuring" treatment of the belt actuated by the present method enables reaching the following objectives: excellent spatial definition of the reliefs (up to 360 dpi and above, according to the inkjet heads used); possibility of having an endless relief over all the extension of the belt; precise control of the height of the relief (resolution of better than 10 ⁇ m); possibility of realizing high transport of thicknesses (theoretically without limit, practically about 1 mm); short realization times (about 30 min/sq.mt); an economical solution and great flexibility of use.
  • the press belt once provided with the structured surface, can be sectioned into portions, each of which suitable for application to the active side of the punch of a normal die for ceramic powders.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Ink Jet (AREA)
  • Ink Jet Recording Methods And Recording Media Thereof (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP15703100.6A 2014-01-30 2015-01-16 A method for manufacture of a continuous press belt for ceramic slabs having a structured surface Active EP3099478B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL15703100T PL3099478T3 (pl) 2014-01-30 2015-01-16 Sposób wytwarzania ciągłego pasa prasującego do ceramicznych płytek mających powierzchnię strukturalną

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITRE20140005 2014-01-30
PCT/IB2015/000045 WO2015114433A1 (en) 2014-01-30 2015-01-16 A continuous press belt for ceramic slabs having a structured surface, and a method for manufacture of the belt and use thereof

Publications (2)

Publication Number Publication Date
EP3099478A1 EP3099478A1 (en) 2016-12-07
EP3099478B1 true EP3099478B1 (en) 2020-04-15

Family

ID=50239804

Family Applications (1)

Application Number Title Priority Date Filing Date
EP15703100.6A Active EP3099478B1 (en) 2014-01-30 2015-01-16 A method for manufacture of a continuous press belt for ceramic slabs having a structured surface

Country Status (9)

Country Link
EP (1) EP3099478B1 (pl)
CN (1) CN105939843B (pl)
BR (1) BR112016010171B1 (pl)
ES (1) ES2792990T3 (pl)
MX (1) MX378047B (pl)
PL (1) PL3099478T3 (pl)
PT (1) PT3099478T (pl)
RU (1) RU2690382C2 (pl)
WO (1) WO2015114433A1 (pl)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3293005B1 (en) * 2016-09-12 2022-11-16 Progetto Futuro S.r.l. Apparatus for obtaining work surfaces for the decoration of ceramic surfaces
IT201600093579A1 (it) 2016-09-16 2018-03-16 Sacmi Metodo e apparato per la formatura di manufatti di polveri compattate
IT201600105117A1 (it) * 2016-10-19 2018-04-19 Sacmi Macchina per la compattazione di materiale in polvere
CN107778993A (zh) * 2017-12-05 2018-03-09 赵金泉 荧光变色油墨及其制备方法、防伪标签及其制备方法
IT201800006678A1 (it) * 2018-06-26 2019-12-26 Metodo ed impianto per la realizzazione di prodotti ceramici
IT201800007737A1 (it) * 2018-08-01 2020-02-01 Sacmi Cooperativa Mecc Imola Societa' Cooperativa Metodo per la compattazione di materiale in polvere
DE102020000570A1 (de) * 2020-01-29 2021-07-29 Siempelkamp Maschinen- Und Anlagenbau Gmbh Verfahren zur Überwachung eines Stahlbandes in einer kontinuierlichen Presse und kontinuierliche Presse

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US20030231226A1 (en) * 2002-06-07 2003-12-18 Konica Technosearch Corp. Inkjet recording method
US20070120930A1 (en) * 2005-11-30 2007-05-31 Xerox Corporation Process and apparatus for ink jet ultraviolet transfuse

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US20070120930A1 (en) * 2005-11-30 2007-05-31 Xerox Corporation Process and apparatus for ink jet ultraviolet transfuse

Also Published As

Publication number Publication date
MX2016006037A (es) 2016-07-18
RU2016114560A (ru) 2018-03-05
PL3099478T3 (pl) 2020-09-07
EP3099478A1 (en) 2016-12-07
PT3099478T (pt) 2020-06-16
MX378047B (es) 2025-03-10
RU2690382C2 (ru) 2019-06-03
BR112016010171B1 (pt) 2022-03-29
CN105939843A (zh) 2016-09-14
WO2015114433A1 (en) 2015-08-06
ES2792990T3 (es) 2020-11-12
BR112016010171A2 (pt) 2017-08-08
RU2016114560A3 (pl) 2019-01-24
CN105939843B (zh) 2018-11-16

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