COVERING ELEMENT, METHOD FOR DECORATING A COVERING ELEMENT, AND MACHINE FOR DECORATING A COVERING ELEMENT

Abstract

Set comprising a plurality of covering elements for floors and/or walls, wherein each covering element comprises an upper surface having a pattern and at least one distressed upper edge, wherein at least two covering elements of the set comprises substantially the same pattern, and wherein the shape of the distressed upper edge differs in each covering element of the set.

Claims

1.-17 (canceled)

18. A set comprising a plurality of covering elements for floors and/or walls, wherein each of the plurality of covering elements comprises an upper surface having a pattern and at least one distressed upper edge, wherein at least two covering elements of the set comprises substantially the same pattern, wherein the shape of the distressed upper edge differs in each covering element of the set.

19. The set according to claim 18, wherein each of the plurality of covering elements comprises a backing of ceramic material.

20. The set according to claim 18, wherein the at least one distressed upper edge of each of the plurality of covering elements of the set comprises the pattern.

21. The set according to claim 18, wherein at least two covering elements of the set comprise a relief structure on a central portion of the upper face, and wherein the shape of the relief structures of at least two covering elements of the set is substantially the same.

22. The set according to claim 21, wherein the relief structure has characteristics corresponding to characteristics of the pattern.

23. The set according to claim 18, characterized in that each of the plurality of covering elements of the set comprises at least one coating layer on the upper face.

24. The set according to claim 23, wherein the at least one coating layer comprises a base coat capable of receiving the pattern on itself.

25. The set according to claim 23, wherein the at least one coating layer comprises a protective coat placed on top of the pattern.

26. The set according to claim 23, wherein the at least one coating layer covers the at least one distressed upper edge of the covering elements.

27. The set according to claim 18, wherein each of the plurality of covering elements comprises a plurality of distressed upper edges.

28. The set according to claim 18, wherein all the distressed upper edges of the set are shaped differently from one another.

29. A method for decorating covering elements for floors and/or walls, comprising the steps of: providing a backing of green ceramic material for the covering element; distressing at least one upper edge of the backing; and firing the covering element after the distressing step.

30. The method according to claim 29, comprising the step of applying at least one coating layer on an upper surface of the backing after the distressing step.

31. The method according to claim 30, wherein the coating layer is applied on the distressed upper edge.

32. The method according to claim 29, comprising a step of the applying the pattern on an upper surface of the backing after the distressing step.

33. An apparatus for decorating covering elements for floors and/or cladding, the apparatus comprising: an element for supporting the covering element; at least one grinding wheel capable of distressing an upper edge of the covering element; and at least one drive device for driving the grinding wheel in rotation about its own axis.

34. The apparatus according to claim 33, wherein the drive device is configured to drive the grinding wheel in rotation at a variable rotation speed.

Description

[0034] Further characteristics and advantages of the invention will be apparent from a perusal of the following examples, provided solely by way of non-limiting example, with the support of the figures shown on the appended sheets.

[0035] FIG. 1 is a perspective view of a covering element according to the invention.

[0036] FIG. 2 is a cross section taken along the plane II of FIG. 1.

[0037] FIG. 3 is an enlargement of the detail III of FIG. 2.

[0038] FIG. 4 is an enlargement of the detail IV of FIG. 2.

[0039] FIG. 5 is a top view of a covering element during the distressing step.

[0040] FIG. 6 is a cross section taken along the plane VI of FIG. 5.

[0041] FIG. 7 shows some stages of the method according to the invention.

[0042] FIG. 8 is a schematic side view of a decorating apparatus according to the invention.

[0043] FIG. 9 is a top view of a set of covering elements according to the invention.

[0044] FIG. 1 shows a covering element 1, for floors or wall cladding for example, which comprises a backing 2. For example, the covering element is a ceramic tile or slab, that is to say one comprising a backing 2 of ceramic material, for example porcelain stoneware, single-fired ceramic material, white or red body ceramic material, majolica, terracotta, or other ceramic powders sintered at high temperatures, and is preferably of rectangular or square shape.

[0045] As shown in FIG. 1, the covering element 1 also comprises at least one distressed upper edge 3, or preferably a plurality of distressed upper edges 3; better still, all the upper edges 3 of the covering element 1 are distressed. The term distressed is taken to mean that the upper edge 3 has an artificially created shape and is such as to simulate the wear on the upper edge 3 due to time and use, such as chips, scratches, scrape marks and incisions. In other words, the surface of the upper edge 3 comprises a shape, for example a three-dimensional structure, formed by recesses and protrusions, having irregular characteristics, for example variations in depth, width and/or length, and arranged in a random and non-predetermined order. Thus the distressed upper edge 3 gives a general impression of distressing and wear of the covering element 1, thereby reducing the impression of its artificiality.

[0046] As shown in FIG. 1, all the upper edges 3 of the covering element 1 are distressed. Preferably, the upper edges 3 are distressed along their whole length. It is also emphasized that each distressed upper edge 3 has a different shape from the other distressed upper edges 3 of the same covering element 1.

[0047] FIG. 1 also shows that the covering element 1 has an upper face 4 bearing a pattern 5 having various colours, designs or graphics. In particular, the pattern 5 is formed on at least a central portion 6 of the upper face 4 of the covering element 1. Evidently, the expression central portion 6 is taken to mean substantially the whole upper face 4, with the exception of the distressed upper edge 3, so that the distressed upper edge 3 substantially forms a frame around the pattern 5. However, in the preferred embodiment shown in FIG. 1, the pattern 5 is formed on the whole of the upper face 4 of the covering element 1. In other words, the distressed upper edge 3 is provided with the pattern 5.

[0048] FIGS. 2, 3 and 4 show that the covering element 1 may comprise coating layers capable of at least partially coating the upper face 4 of the covering element 1.

[0049] In particular, the covering element 1 comprises a base coat 7, for example a glaze or an engobe, configured to cover the upper surface of the backing 2 at least partially, or preferably entirely. In particular, according to the preferred embodiment, the base coat 7 is configured to cover the distressed upper edge 3 at least partially, or preferably entirely.

[0050] In this case, the shape of the distressed upper edge is apparent through the base coat 7.

[0051] The covering element 1 further comprises a protective coat 8, for example a transparent glaze or a grit, which covers the upper face 4 at least partially, or preferably entirely, and which can be placed on top of the pattern 5 so as to cover and protect it. According to the preferred embodiment, the protective coat 8 covers the distressed upper edge 3 at least partially, or preferably entirely, the shape of the distressed upper edge 3 being apparent through the protective coat 8. Advantageously, the protective coat 8 is transparent or translucent.

[0052] As shown in FIG. 4, the upper face 4 of the covering element 1 comprises a relief structure 9, for example comprising recesses and protrusions, preferably arranged in a predetermined order, but there is no reason why such recesses and protrusions should not be arranged in a random order. In particular, the relief structure 9 is arranged in the central portion 6 of the upper face 4. In particular, FIG. 4 shows an example of embodiment in which the relief structure 9 may comprise recesses and protrusions formed in the backing 2, which are apparent on the upper face 4 of the covering element 1 through the base coat 7 and the protective coat 8.

[0053] FIG. 9 shows a set 10 of covering elements 1, each having one or more of the characteristics described above, and in which the distressed upper edges 3 have a different shape in each covering element 1. In other words, all the distressed upper edges 3 of the set 10 are shaped differently from one another.

[0054] FIG. 9 shows an example of embodiment in which at least two covering elements 1 of the set 10 have substantially the same pattern 5. In particular, the pattern 5 is the same in the central portion 6 of the upper face 4 of said two covering elements 1. Additionally, according to this embodiment, at least two covering elements 1 of the set 10 have substantially the same relief structure 9. In particular, the relief structure 9 is the same in the central portion 6 of the upper face 4.

[0055] FIG. 7 shows schematically a preferred embodiment of a method for decorating and manufacturing the covering elements 1 described above.

[0056] The method shown in FIG. 7 comprises, in the first place, a step S1 of preparing the backing 2 of the covering element 1, for example a backing of ceramic material. According to this example, the preparation step S1 provides for the forming of the backing 1, by pressing for example. In practice, a body of wet ceramic raw materials is placed in a mould 11 of a press 12, and pressed to form the backing 2. During the pressing, the relief structure 9 may be formed on the upper surface of the backing 2, by means of a suitably shaped die, for example. Additionally, according to this example, the preparation step S1 comprises drying the newly formed backing 2 to remove the excess moisture from the body and give the backing sufficient mechanical strength for movement. The drying is preferably carried out in a dryer 13 at temperatures above 80 C., for example above 100 C.

[0057] After the preparation step S1, the backing is conveyed to a distressing station 14 to be subjected to a step of distressing S2, of the mechanical type for example, that is to say a step capable of causing the mechanical erosion or incision of the upper edge 3 of the backing 2. In the example illustrated in FIGS. 5, 6 and 7, the distressing station 14 comprises at least one distressing apparatus 15 having a shaped grinding wheel 16, that is to say one in which the active surface 17 of the grinding wheel 16 (in other words the active surface of the grinding wheel 16 adapted to come into contact with the upper edge 3 to be distressed) is not flat, but has protuberances and/or pits. The grinding wheel 16 is driven in rotation about its own axis A by a drive device 18, for example an electric motor. The grinding wheel 16 and the drive device 18 are supported by a frame 19 of the distressing apparatus 15. Additionally, according to the preferred embodiment, the grinding wheel 16 rotates about its own axis A at a variable rotation speed RS, for example with irregular and non-predetermined variations. For example, the grinding wheel 16 may rotate about its own axis A at a rotation speed RS of between 15 Hz and 70 Hz, or preferably between 20 Hz and 60 Hz.

[0058] As indicated in FIG. 5, the axis A of the grinding wheel is incident on the upper edge 3 to be distressed, that is to say on an imaginary straight line parallel to said upper edge 3, so that an angle of incidence IA of between 90 and 180, for example between 120 and 180, is formed between them. Additionally, as shown in FIG. 6, the axis A of the grinding wheel 16 is incident on the plane in which the backing 2 lies, on a horizontal plane for example, so that a working angle EA of between 0 and 90, for example between 45 and 90, is formed between said axis A and the plane in which the backing 2 lies.

[0059] Additionally, as shown by FIGS. 5, 6 and 7, during the distressing step S2 the backing 2 is moved along a direction of advance D, preferably parallel to the upper edge 3 to be distressed. In practice, the distressing station 14 comprises a conveyor 20, preferably of the band or belt type, and the grinding wheel 16 is positioned at the side of said conveyor 20. Preferably, the distressing apparatus comprises a plurality of grinding wheels 16, for example a pair of grinding wheels 16 positioned on opposite sides of the conveyor 20 to act on opposite parallel upper edges 3 of the backing 2. The frame 19 of the distressing apparatus 15 may be connected, by fixing for example, to the conveyor 20, which then acts as a supporting device for the backing 2 during the distressing. In the preferred example of embodiment shown in FIG. 7, the distressing station 14 comprises two distressing apparatuses 15, each having two grinding wheels 16 positioned on opposite sides of the conveyor 20 to act on opposite parallel upper edges 3 of the backing 2, and comprises a swivel device 21 positioned between the apparatuses 15 and capable of modifying the position of the backing 2 relative to the direction of advance D, or of modifying the direction of advance D. Thus the second apparatus 15 is enabled to distress the upper edges 3 of the backing 2 that have not been distressed by the first apparatus 15, in order to distress all the upper edges 3 of the backing. For example, the swivel device 21 may be a device that rotates the backing 2 through 90 relative to an axis orthogonal to the plane in which the backing 2 lies, for example a vertical axis, or may be a device that modifies the direction of advance D by 90.

[0060] The apparatus 15 also comprises retaining elements 21, configured to keep the covering element 1, that is to say the backing 2 of the covering element 1, in a substantially fixed position relative to the conveyor 20. In practice, the retaining elements 22 are configured to limit, or preferably prevent, movements of the covering element 1 relative to the conveyor 20 in the plane parallel to the direction of advance D, and to limit, or preferably prevent, movements of the covering element 1 in a direction orthogonal to the plane in which the element lies, that is to say in a substantially vertical direction. According to the preferred embodiment shown in FIG. 8, the retaining elements 22 comprise a horizontal border 23 capable of pressing on the upper surface of the backing 2. In greater detail, in the preferred embodiment, the horizontal border 23 comprises a band or belts driven around rollers or pulleys, so that the portion of the horizontal border 23, which presses on the upper surface of the backing 2, moves along the direction of advance D, for example at the same speed of advance as the covering element 1.

[0061] After the distressing S2, the backing 2 undergoes a step of applying a base coat S3 on the upper surface of the backing 2. For example, the backing 2 is conveyed to a coating station, for example a glazing station 24, where the coating layer is applied, preferably in the wet state, by spraying or in a film for example, to provide uniform coverage of the upper surface of the backing 2, including the distressed edges 3.

[0062] Following the application of the base coat S3, the decoration S4 of the upper face 4 of the covering element 1 is carried out. In practice, the backing 2 is conveyed to a decoration station 25 having a digital inkjet printer 26 or other decoration devices. Inkjet printing, and contactless printing methods in general, are preferred because they enable the pattern 5 to be applied on the distressed edges 3 of the covering element 1.

[0063] After the distressing S4, the backing 2 undergoes a step of applying a protective coat S5 on the upper surface of the backing. For example, the backing 2 is conveyed to a covering station 27 having a grit application device, a spray gun or other device capable of applying the protective coat 8.

[0064] The decorated and coated backing 2 is then subjected to a step S6 of high-temperature firing, in a roller kiln 28 for example, in which the sintering of the backing 2 and the fixing of the pattern 5 and the coating layers 7, 8 to the backing take place. For example, the firing S6 is carried out at a temperature T of more than 900 C., or preferably more than 1000 C., for example about 1200 C.

[0065] The present invention is not limited in any way to the embodiments described above, but said covering elements and systems may be produced according to different variants without thereby departing from the scope of the present invention.