Wall and/or floor tile and method and apparatus for its production

Abstract

A wall and/or floor tile ( 10 ) comprises a container element ( 1 ) and a filling material ( 2 ) disposed inside the container element and constituted by a polymeric material having a Shore hardness of between 55 and 85, preferably 75, and a setting time, at ambient temperature, of between 5 and 15 minutes, preferably 10 minutes. The filling material ( 2 ) is produced from a multi-component material, preferably a two-component material. An apparatus ( 20 ) for the production of a wall and/or floor tile ( 10 ) comprises at least one supply head ( 22 ) provided with injector means ( 24 ) having separate supply circuits ( 26, 28 ) for each of the multiple components. The filling material ( 2 ) is supplied into the container element ( 1 ) in controlled manner by a single nozzle ( 30 ) for mixing the multiple components, in order to form the wall and/or floor tile ( 10 ).

1 . A wall and/or floor tile comprising a container element and a filling material disposed inside the container element, characterized in that the filling material is a polymeric material having a Shore D hardness greater than 50 and a setting time, at ambient temperature, of more than 3 minutes.  
   
   
       2 . A tile according to  claim 1  in which the filling material has a Shore D hardness of between 55 and 85 and a setting time, at ambient temperature, of between 5 and 15 minutes.  
   
   
       3 . A tile according to  claim 1  in which the filling material has a Shore D hardness of 75 and a setting time, at ambient temperature, of 10 minutes.  
   
   
       4 . A tile according to  claim 1  in which the filling material is produced from a multicomponent material, preferably a two-component material.  
   
   
       5 . A tile according to  claim 4  in which the two-component material is a polyurethane.  
   
   
       6 . A tile according to  claim 5  in which the polyurethane is produced by reaction of a polyol having a number of OH groups of between 80 and 500 mgKOH/g, and a viscosity of between 200 and 200,000 cps, with an isocyanate having an NCO content of between 5 and 31%.  
   
   
       7 . A tile according to  claim 6  in which the polyurethane is produced by reaction of a polyol having a number of OH groups of between 100 and 400 mgKOH/g, preferably 120 and 250 mgKOH/g, and a viscosity of between 2,000 and 10,000 cps, with an isocyanate having an NCO content of between 10 and 25%.  
   
   
       8 . A tile according to  claim 4  in which the two-component material is a polyurea.  
   
   
       9 . A tile according to  claim 8  in which the polyurea is produced by reaction of an amine having a number of OH groups of between 500 and 1000 mgKOH/g with an isocyanate having an NCO content of between 5 and 15% .  
   
   
       10 . A tile according to  claim 9  in which the polyurea is produced by reaction of an amine having a number of NH 2  groups of between 600 and 800 mgKOH/g with an isocyanate having an NCO content of between 7 and 10%.  
   
   
       11 . A tile according to  claim 1  in which the container element ( 1 ) is in view.  
   
   
       12 . A tile according to  claim 1  in which the container element completely filled with the filling material so that the tile has a flat surface of the filling material.  
   
   
       13 . A tile according to  claim 1  in which the container element is metallic.  
   
   
       14 . A tile according to  claim 13  in which the container element ( 1 ) is made of stainless steel.  
   
   
       15 . A method of producing a tile  4 , the method comprising the steps of: 
 a) introducing separately into an injector the components which are to form the filling material.    b) reacting the components of step a) only in the region of a mixer connected to the injector,    c) completely filling the container elements) with the mixture obtained in step b), and    d) causing the filling material  2 to set in situ inside the container elements.    
   
   
       16 . Apparatus for the production of a wall and/or floor tile the apparatus comprising at least one supply head suitable for depositing, in a container element of a tile a multi-component, polymeric, filling material which is capable of setting after a predetermined period of time, upon mixing of the multiple components, at ambient temperature, the supply head comprising injector means provided with separate supply circuits for each of the multiple components, and the separate supply circuits converging in a single nozzle for mixing the multiple components, from which nozzle the filling material is supplied into the container element.  
   
   
       17 . Apparatus according to  claim 16  in which the at least one supply head is suitable for supplying filling material into a container element.  
   
   
       18 . Apparatus according to  claim 16  in which the mixing nozzle is housed in a protective tube comprising, at one end, an opening which cooperates with a supply opening ( 30 a) of the nozzle and, at the opposite end, a ring nut for fixing to the body of the injector means.  
   
   
       19 . Apparatus according to  claim 16  in which the mixing nozzle comprises a tubular body provided, at one end, with a supply opening and, at an opposite end, with a receptacle suitable for collecting the multiple components emerging from the injector means and conveying them into a mixing chamber.  
   
   
       20 . Apparatus according to  claim 19  in which the mixing chamber comprises obstacles for facilitating contact and mixing of the multiple components forming the filling material.  
   
   
       21 . Apparatus according to  claim 16  in which each of the separate supply circuits of the injector means is closed by valve means which bring about controlled opening and/or closure of the circuit.  
   
   
       22 . Apparatus according to  claim 21  in which the valve means comprise closure members which are constantly urged into abutment against valve seats to close flow apertures for the multiple components of the circuits.  
   
   
       23 . Apparatus according to  claim 22  in which the closure members are opened pneumatically, in controlled manner.  
   
   
       24 . Apparatus according to  claim 21  in which the injector means comprise an injection chamber suitable for connection to the single mixing nozzle, the separate supply circuits converging in the chamber.  
   
   
       25 . Apparatus according to  claim 24  in which at least one partition is provided in the injection chamber and is disposed between outlets of the separate supply circuits in a manner such that each component of the filling material comes into contact with another component only after reaching the nozzle.  
   
   
       26 . Apparatus according to  claim 24  or which anti-drip means are provided and comprise separate means for withdrawing, from the injection chamber, a predetermined quantity of each component which is not yet mixed, to prevent drips falling from the free opening of the nozzle.  
   
   
       27 . Apparatus according to  claim 26  in which each of the anti-drip means comprises a diaphragm which cooperates, in a leaktight manner, through a through-hole, with the injection chamber and, on the opposite side, with a suction duct suitable for creating a partial vacuum which, by deforming the diaphragm draws the predetermined quantity of component which is not yet mixed, from the injection chamber.  
   
   
       28 . Apparatus according to  claim 16  in which a plurality of supply heads is provided.  
   
   
       29 . Apparatus according to  claim 28  in which the plurality of supply heads is connected to supply manifolds suitable for causing each of the components for forming the filling material to flow separately to each head.  
   
   
       30 . Apparatus according to  claim 16  in which two pluralities of supply heads are provided and are arranged parallel to one another and a predetermined distance apart suitable for the deposition of the filling material in two rows of container elements.  
   
   
       31 . Apparatus according to  claim 16  in which the at least one supply head is operatively connected to a plurality of separate supply ducts for each of the components for forming the filling material.  
   
   
       32 . Apparatus according to  claim 31  in which each of the ducts is heated.  
   
   
       33 . Apparatus according to  claim 32  in which each of the ducts is heated to a temperature of between 20° C. and 40° C., preferably to 30° C.  
   
   
       34 . Apparatus according to  claim 16  in which each of the separate supply circuits is operatively connected to a pump which is controlled in a manner such as to supply the component which is to form the filling material to each supply head at a predetermined pressure.  
   
   
       35 . Apparatus according to  claim 34  in which each separate supply circuit is supplied at a predetermined pressure which is independent of the other pressures.  
   
   
       36 . Apparatus according to  claim 34  in which the supply circuit is supplied at a pressure of between 20 and 70 atmospheres, preferably between 30 and 50 atmospheres.  
   
   
       37 . Apparatus according to  claim 36 , in which one component is supplied at 30 atmospheres and a second component is supplied at 50 atmospheres.  
   
   
       38 . Apparatus according to  claim 34  in which the separate supply circuits are supplied at respective pressures such that, if the various components are supplied for the same period of time, when mixed, they form the filling material which has a Shore D hardness greater than 50 and which sets at ambient temperature within a time longer than 3 minutes.  
   
   
       39 . Apparatus according to  claim 34  in which a reservoir suitable for holding each of the components of the filling material is operatively connected to each pump.  
   
   
       40 . Apparatus according to  claim 39  in which a stirring device is associated with each reservoir.  
   
   
       41 . Apparatus according to  claim 39  in which the reservoir is heated.  
   
   
       42 . Apparatus according to  claim 41  in which the reservoir is heated to a temperature of between 20° C. and 40° C. and preferably to 30° C.  
   
   
       43 . Apparatus according to  claim 16  in which a further store for each of the components for forming the filling material is provided, operatively connected to the respective separate supply circuit.  
   
   
       44 . Apparatus according to  claim 16  in which the at least one head is associated with a movement carriage for bringing about controlled movement thereof.  
   
   
       45 . Apparatus according to  claim 44  in which the carriage is moved in controlled manner, longitudinally relative to a conveyor line of the container elements, which are arranged in a manner suitable for receiving the filling material when it emerges from the nozzle.  
   
   
       46 . Apparatus according to  claim 44  in which the carriage is moved in controlled manner, transversely relative to a conveyor line of the container elements.  
   
   
       47 . Apparatus according to  claim 44  in which the carriage is associated with sliding guides, preferably ball or roller guides.  
   
   
       48 . Apparatus according to  claim 44  in which the carriage is operatively connected to actuators which are operated in controlled manner, preferably with position and/or velocity feedback.  
   
   
       49 . Apparatus according to  claim 16  in which each supply head is operatively connected to a control unit for bringing about controlled opening of the valve means.  
   
   
       50 . Apparatus according to  claim 49  in which the valve means are opened for a period of time of between 50 and 150 msec.  
   
   
       51 . Apparatus according to  claim 44  in which, in addition to working operations brought about in controlled manner, the carriage adopts at least one rest position.  
   
   
       52 . Apparatus according to  claim 51  in which an operative connection with a device for activating the discharge of material at predetermined time intervals is provided in the rest position of the carriage so as to prevent setting of the material which is present in the mixing nozzle.  
   
   
       53 . Apparatus according to  claim 44  in which the carriage has associated sensor means for identifying the position of the carriage relative to a grating for supporting and transporting at least one container element, the grating being disposed on a; conveyor line in a manner such that the nozzle is positioned so as to deposit the filling material in the at least one container element.  
   
   
       54 . Apparatus according to  claim 16  in which a conveyor line for at least one container element is provided and passes through an oven suitable for accelerating the setting of the filling material, in series with positions of cooperation with the at least one supply head.  
   
   
       55 . Apparatus according to  claim 16  in which a conveyor line for at least one container element is provided and passes through positions in which the at least one container element containing the filling material cooperates with a device for depositing binding and reinforcing fabric on the rear of each tile.  
   
   
       56 . Apparatus according to  claim 16  in which a conveyor line for at least one container element is provided and passes through positions in which it cooperates with a second oven for setting the filling material.  
   
   
       57 . Apparatus according to  claim 16  in which the at least one supply head comprises valve means having at least one piston the diameter of which varies along a longitudinal axis of the piston.  
   
   
       58 . Apparatus according to  claim 57  in which the at least one piston is operated for opening and closure in controlled manner by pneumatic means.  
   
   
       59 . Apparatus according to  claim 58  in which means are provided for adjusting the stroke of the at least one piston and can cause the stroke of the piston for closing a valve seat to continue in order to bring about withdrawal of material from an injection chamber.  
   
   
       60 . Apparatus according to  claim 16  in which means are provided for checking the wear of the sealing rings disposed along a sliding seat of valve means.