SELF-DRAINING PORCELAIN STONEWARE TILE

Abstract

The invention concerns the production of draining porcelain stoneware tiles and method of production thereof. The invention concerns a tile with rectangular quadrilateral shape and edges with thickness (S), with a planar outer surface on which a series of variable geometry grooves are provided according to a drainage direction on the outer surface. The geometry of said groove can be triangular, trapezoidal or elliptical section. The vertexes of these embodiments form the bottom of said groove with height h, and said height h increases according to said drainage direction generating an inclined drainage plane of said groove. The invention also concerns a method of manufacturing a tile according to the invention; by moulding during the pressing phase of the ceramic powders with the use of punch/pad preformed with pattern according to the required geometry of the water drain grooves; by mechanical action by incision of the green pressed ceramic powder slab, dried or not, and not yet fired; or by incision of the fired tile.

Claims

1. A draining porcelain stoneware unit, comprising: a tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile; wherein: each of the plurality of grooves has a triangular cross-section, a base of the triangular cross-section is placed at the substantially planar surface, and the vertex of the triangular cross-section forms a bottom of the groove, and a height h between the base and the vertex increases from a first end of the groove to a second end of the groove.

2. A draining porcelain stoneware unit, comprising: a tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile; wherein: each of the plurality of grooves has a trapezoidal section, the trapezoidal section has a major base disposed at the substantially planar surface and a minor base, smaller than the major base forming a bottom of said groove, and a height h between the major base and the minor base increases from a first end of the groove to a second end of the groove.

3. A draining porcelain stoneware unit, comprising: a tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile; wherein: each of the plurality of grooves has a semi-elliptical cross-section, a semi-axis of the semi-elliptical cross-section is disposed at said substantially planar surface, and an opposite vertex of the semi-elliptical cross-section forms a bottom of the groove, and a height h between said semi-axis and the bottom vertex increases from a first end of the groove to a second end of the groove.

4. The unit according to claim 1, wherein: a central axis of the tile extends between a first pair of parallel edges of the tile and drainage directions are defined as extending from the central axis toward a second pair of parallel edges of the tile, perpendicular to the first pair of parallel edges; each of the plurality of grooves extends from the first end to the second end in one of the drainage directions, parallel to the first pair of parallel edges.

5. The unit according to claim 1, wherein: a first diagonal axis extends diagonally across the tile between a first pair of corners of the tile, a second diagonal axis extends diagonally across the tile between a second pair of corners of the tile, such that the second diagonal axis is perpendicular to the first diagonal axis, and drainage directions are defined as extending from one of the first diagonal axis and the second diagonal axis toward an edge of tile, and each of the plurality of grooves extends from the first end to the second end thereof in one of the drainage directions.

6. The unit according to claim 1, wherein: a drain fulcrum is defined at a central point on the substantially planar surface of the file and drainage direction are defined as extending radially inward from edges of the tile toward the drain fulcrum, and each of the plurality of grooves extends from the first end to the second end thereof in one of the drainage directions.

7. The unit according to claim 2, wherein the bottom of each of the plurality of grooves has an inclination gradient of between 0.3% and 5.0% from the first end to the second end thereof.

8. The unit according to claim 7, wherein the trapezoidal cross-section is isosceles and a ratio between a length of the minor base and a length of the major base between 1:3 and 1:6; and an isosceles angle of the trapezoidal cross-section is between 70 and 15.

9. The unit according to claim 1, wherein the triangular cross-section is isosceles, an isosceles angle of the triangular cross-section is between 70 and 15 and the bottom of each of the plurality of grooves an inclination gradient of between 0.3% and 5.0% from the first end to the second end thereof.

10. The tile according to claim 3, wherein the bottom of each of the plurality of grooves has an inclination gradient between 0.3% and 5.0% from the first end to the second end thereof.

11. A method of manufacturing a draining porcelain stoneware tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile, wherein each of the plurality of grooves has a cross-section, wherein a depth of each of the plurality of grooves increases from a first end of the groove to a second end of the groove, the method comprising: molding the tile, the molding comprising pressing ceramic powders with one of a punch and a pad, wherein the one of the punch and the pad is preformed with a pattern configured to from the plurality of grooves.

12. A method of manufacturing a draining porcelain stoneware tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile, wherein each of the plurality of grooves has a cross-section, wherein a depth of each of the plurality of grooves increases from a first end of the groove to a second end of the groove, the method comprising: prior to firing, mechanically incising a green tile comprising a pressed ceramic powder slab, using a plurality of diamond wheels, thereby forming the plurality of grooves.

13. A method of manufacturing a draining porcelain stoneware tile having a rectangular shape and a substantially planar outer surface with a plurality of grooves formed therein, parallel to edges of the tile, wherein each of the plurality of grooves has a cross-section, wherein a depth of each of the plurality of grooves increases from a first end of the groove to a second end of the groove, the method comprising: tile according to claim 1, wherein the method provides for formation of the grooves by incision of the mechanically incising a fired tile biscuit using a plurality of diamond wheels, thereby forming the plurality of grooves.

14. The unit according to claim 4, wherein: the plurality of grooves are a first plurality of grooves, and the tile further comprises a second plurality of grooves, each of the second plurality of grooves extending in a diagonal direction with respect to the drainage direction from a second end of one of the first plurality of grooves to a first end of another one of the first plurality of grooves.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0022] To better understand the characteristics and advantages, a preferred embodiment is described below, solely by way of non-limiting example, with reference to the accompanying drawings in which:

[0023] FIG. 1Draining porcelain stoneware tile according to a first embodiment of the invention in which the drainage direction runs from the central axis of said planar surface towards the opposite edges of said tile with grooves which develop by parallel lines perpendicular to the respective edges.

[0024] FIG. 2Draining porcelain stoneware tile according to a second embodiment of the invention in which the drainage direction runs from the diagonal axes of said planar surface towards the opposite edges of said tile, in which the grooves develop by parallel lines perpendicular to the respective edges.

[0025] FIG. 3Draining porcelain stoneware tile according to a third embodiment of the invention in which the tile has a drain fulcrum located on the planar surface and the drainage direction develops radially from the edges of said tile towards said drain fulcrum.

[0026] FIG. 4Draining porcelain stoneware tile according to the invention in which the drainage direction runs from the central axis of said planar surface towards the opposite edges of said tile with grooves that develop by a combination of parallel and diagonal lines communicating with one another.

[0027] FIG. 5Draining porcelain stoneware tile according to the invention in which the axis A-A and the axis B-B of the views of subsequent figures are indicated for the embodiment of FIG. 1.

[0028] FIG. 6Detail view according to axis B-B of the inclined grooves with triangular geometry.

[0029] FIG. 7Detail view according to axis B-B of the inclined grooves with trapezoidal geometry.

[0030] FIG. 8Detail view according to axis B-B of the inclined grooves with elliptical geometry.

[0031] FIG. 9Detail view according to axis A-A of the inclined grooves according to the invention.

DISCLOSURE OF PREFERENTIAL EMBODIMENTS

[0032] The preferential embodiments will be first described with reference to the geometry of creation of the drainage grooves on the surface of the porcelain stoneware tile.

[0033] FIG. 1 shows a draining porcelain stoneware tile (1) according to the invention. The draining porcelain stoneware tile (1) comprises a tile (1) having rectangular quadrilateral shape and edges with thickness (S), with a planar outer surface (2) of said tile, and a series of grooves (3) with variable geometry according to a drainage direction (5) provided on said outer surface (2). In the embodiment of FIG. 1, the drainage direction (5) runs from the central axis (4) of said planar surface towards the opposite edges (10,10) of said tile with grooves (3) that develop by parallel lines perpendicular to the respective edges (10,10) and to the central axis (4).

[0034] FIG. 2 shows a further embodiment of the grooves (3) for producing a draining porcelain stoneware tile (1) according to the invention in which the drainage direction (5, 5) runs from the diagonal axes of said planar surface (2) towards the opposite edges of said tile (10,10), in which the grooves develop by parallel lines perpendicular to the respective edges (10,10). According to this pattern, drainage of the water towards the edges of the tile is significantly improved since the mean distance to the edge of the tile is shorter, with the dimensions thereof remaining equal.

[0035] FIG. 3 shows a further embodiment of the grooves (53) for producing a draining porcelain stoneware tile (1) according to the invention in which the tile has a drain fulcrum (50) located on the planar surface and the drainage direction (53) develops radially from the edges of said tile towards said drain fulcrum. The drainage towards a drain point which is central or in an asymmetrical position allows the technology according to the invention to be applied to shower trays, in which it is important to rapidly discharge the water that accumulates in the shower tray during use.

[0036] FIG. (4) shows a further embodiment of the grooves (41,42) for producing a draining porcelain stoneware tile (1) according to the invention in which the drainage direction runs from the central axis of said planar surface towards the opposite edges of said tile with grooves which develop by combination of parallel lines (41) and diagonal lines (42) communicating with one another. The combination of parallel and diagonal lines improves the drainage with respect to the geometry of FIG. 1. The water is intercepted more easily by the oblique lines and conveyed towards the edge by the grooves perpendicular to the edge of the tile.

[0037] FIGS. 6, 7 and 8 refer to the lateral view detail along the plane B-B of a tile according to the invention shown in FIG. 5.

[0038] FIG. 6 shows the view detail according to axis B-B of the inclined grooves with triangular geometry. The porcelain stoneware tile with thickness S has a series of grooves with triangular section geometry which develop in the drainage direction. The triangular section has a base (16) and a vertex (17), the base is located on the planar surface (2) of the tile, the vertex (17) forms the bottom of said groove, oblique sides (18, 18) connecting base and vertex which form angles () and () with respect to the base (16) and a height h between base and vertex of the triangle. The height of the triangular section of the groove h increases according to said drainage direction generating a groove with vertex that forms an inclined drainage plane of said groove. The triangular section grooves of this embodiment of the invention are preferably isosceles. The discharge of liquids depends heavily on the opening angle of the triangular section. Preferably for isosceles angle sections, this angle ranges from 70 to 15.

[0039] Analogously, FIG. 7 shows a view detail according to axis B-B of the inclined grooves with trapezoidal geometry. The trapezoidal section has a major base (6) located on the planar surface (2), a minor base (7) which forms the bottom of said groove, oblique sides (8, 8) connecting said major and minor bases with angles () and () relative to said major base (6) and a height h between the major and minor bases. The height h of the trapezoidal section increases according to said drainage direction generating an inclined drainage plane in said groove. The trapezoidal section can be isosceles and the ratio between the dimensions of said minor and major bases ranges from 1:3 to 1:6; preferably said isosceles angle ranges from 70 to 15, and said ratio between the dimensions of said minor and major bases ranges from 1:4 to 1:5.

[0040] FIG. 8 shows the view detail according to axis B-B of the inclined grooves with semi-elliptical geometry. By geometry of the groove with semi-elliptical section (22) we mean a section limited to a semi-axis (26), preferably the minor semi-axis. The semi-elliptical section has its semi-axis (26) located on the planar surface (2), an opposite vertex (27) that forms the bottom of the groove, and a height h between the semi-axis (26) and the vertex forming the bottom of the groove; the height h increases according to the drainage direction generating an inclined drainage plane in said groove.

[0041] FIG. 9 shows a view detail according to the axis A-A of the inclined grooves according to the invention. In particular it shows evolution of the depth of the groove in the scheduled discharge direction.

[0042] In the case of both the triangular, trapezoidal and elliptical section, their respective development according to the drainage direction generates a groove with vertex with an inclination according to said drainage direction having a gradient ranging from 0.3% to 5.0%; preferably from 0.5% to 3.0%; more preferably from 1.0% % to 3.0%. Considering that the linear dimensions of a porcelain stoneware tile can reach 1000 mm, with gradient limit of 0.3%, grooves with maximum depth of approximately 1.5 mm can be achieved. The maximum gradient must be chosen according to the quadrilateral dimensions of the tile and the thickness of the latter.

[0043] The geometry of the channels moulded and/or incised on the porcelain stoneware for discharge of the water can vary according to aesthetic-functional requirements, while observing specific inclination values ranging from 0.3% (3 mm difference in level every 1000 mm longitude) up to a maximum of 5% (50 mm difference in level every 1000 mm longitude). Values below 0.3% do not guarantee good discharge of the water whereas values above 5% can not only be difficult to produce when the porcelain stoneware is fine in terms of thickness in relation to the format (dimension), but can also reduce the mechanical strength of the porcelain stoneware.

[0044] The invention also concerns the process of manufacturing draining porcelain stoneware tiles with a series of variable geometry grooves made on the outer surface according to a drainage direction. The method comprises a moulding phase during the phase of pressing the ceramic powders which form said ceramic piece with the use of punch/pad preformed with pattern according to the required geometry of the water drainage grooves.

[0045] According to a further embodiment the method comprises formation of the incision grooves in the green tile in which the pressed ceramic powder slab, dried or not, and not yet fired, is subjected to mechanical incision of the planar outer surface of said slab by means of diamond wheels, to create incisions according to the required geometry.

[0046] The method can comprise formation of the grooves by incision of the fired tile in which the slab is subjected to mechanical incision of the planar outer surface thereof with diamond wheels, to create incisions according to the required geometry.

[0047] From the above, the functional characteristics and advantages that can be obtained with draining porcelain stoneware tiles featuring a series of variable geometry grooves according to a drainage direction provided on the planar outer surface of a tile having rectangular quadrilateral shape and edges (10) with thickness (S) are evident. The discharge of liquids, mainly water, through grooves with widths, geometries and arrangements as claimed is considerably improved.

[0048] Different variations can be made to the subject of the present invention without departing from the ambit of what is described and claimed below with reference to the accompanying drawings and therefore from the protective scope of the present industrial property right.