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Title:
METHOD TO PRODUCE MANUFACTURES BY MOULDING, WHERE THE VISIBLE SURFACE OF THE INSERT ELEMENTS NEVER TOUCHES THE BINDING MATERIAL
Document Type and Number:
WIPO Patent Application WO/2005/080057
Kind Code:
A1
Abstract:
This invention consists of a method to produce finished manufactures so that the constructing material never comes into contact with the sight surface of the finishing elements. It comprises the arrangement of a mould inside which we insert rubber gaskets that support the finishing elements. In this way, a gap is created and later the constructing material is inserted and left into the mould until its total dryness. Afterwards, the finished product is extracted from the mould without any need of finishing operations.

Inventors:
PEDERSEN HANS FLEMMING (DK)
AZZI LAMBERTO (DK)
Application Number:
PCT/IT2004/000423
Publication Date:
September 01, 2005
Filing Date:
July 29, 2004
Export Citation:
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Assignee:
GLASFIBER HOLDING APS (DK)
PEDERSEN HANS FLEMMING (DK)
AZZI LAMBERTO (DK)
International Classes:
B28B19/00; B29C33/00; B29C33/18; B29C70/72; E04F13/08; (IPC1-7): B28B19/00; B29C33/18; B29C70/72
Foreign References:
US2855653A1958-10-14
DE2252408A11974-05-09
BE633738A
Attorney, Agent or Firm:
Turini, Laura (P.za S. Giovanni 8, Ponsacco, IT)
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Claims:
CLAIMS
1. Method to produce finished manufactures by moulding, characterized in that it comprises at least the following phases : arrangement of a mould having such a shape as the one set for the manufactures to realize; insertion into the mould of one or more rubber gaskets, or other elastic material, of such a size and shape so as to constitute a sufficient support for at least one side of the finishing material; support of the finishing elements over said gaskets, so that a gap (14) of changeable volume remains under them. exertion of a negative pressure that presses the finishing material above said gaskets; insertion of the material forming the body of the manufactures in plastic state; the manufactures so become hard and are extracted from the mould.
2. Method according to claim 1, characterized in that, in the portion of the mould where a gap (14) remains under the finishing material, some tubes (6) are applied, by means of which the gap is created and from which air comes out, in this way the finishing material perfectly adheres to the rubber gaskets, which form a packing along the entire surface in contact, thus avoiding that the material forming the manufactures comes into contact with the sight surface of the same gaskets.
3. Method according to claim 1, characterized in that the gaskets support the finishing elements (7), so that between them a gap (8) is created above the zone where the same gasket is placed.
4. Gaskets according to claim 1, characterized in that they must be as little as the distance necessary to cover the gap (8) remaining between the various finishing materials and the edges (13,13A) of two finishing elements.
5. Finishing material according to claim 1, characterized in that it is made of ceramic tiles, or elements in wood, stone, metal, glass, plastic.
6. Constructing material according to claim 1, characterized in that it is formed by reinforced plastic, cement, plastic substances such as the polyurethane, thermoplastic substances.
7. Method according to claim 1, characterized in that the negative pressure is exerted by means of a pump for gaps or a space generator connected to the equipment.
Description:
METHOD TO PRODUCE ARTICLES BY MOULDING, WHERE THE VISIBLE SURFACE OF THE INSERT ELEMENTS NEVER TOUCHES THE BINDING MATERIAL

Technical Field The present invention concerns the technical sector relating to the production of manufactures of any shape realized by moulding.'In particular, it relates to the production of manufactures taking in their complex the appearance of a tiled surface. The relative technical sector is the production of prefabricated bathrooms.

Background Art Nowadays, we know surfaces or manufactures realized by moulding that give the impression they have been realized"on the spot", e. g. applying directly the tiles on a surface. The advantage of realizing this kind of prefabricated surfaces consists in a saving of costs and, above all, a saving of the assembling time. At present, in order to perfectly build said manufactures, a support is firstly made, which can be also a slab of any material, above which tiles or other finishing elements are applied or pasted, after that, the surface is finished off by pointing the conjunction parts. These systems nowadays known, involve a. considerable cost of labour and materials, therefore the finished product is easy to install in the suitable place, but its production cost is very high.

Disclosure of invention The present invention principally aims at eliminating the above-mentioned and other drawbacks, supplying a method of construction to realize manufactures with any finishing material, where the material used for the realization of the manufactures never comes into contact with the sight surface of the finishing material, made by moulding and at competitive price.

The advantages resulting from the present invention essentially consist of the fact that it's possible to produce manufactures at a low cost; that they can be quickly mass- produced by moulding; that the aesthetic result is perfect, as the sight surface of the finishing material never comes into contact with the material forming the body of the manufactures; that once the manufactures have been completed, they do not need finishing off operations, such as the pointing of the joints between tiles.

Reduced to its essential structure and with reference to the figures of the enclosed drawings, a method for the construction of finished manufactures by moulding, according to the present invention, comprises at least the following phases: - arrangement of a mould having such a shape as the one set for the manufactures to realize; - insertion into the mould of one or more rubber gaskets, or other elastic material, of such a size and shape so as to

constitute a sufficient support for at least one side of the finishing material ; support of the finishing elements over said gaskets, so that a gap (14) of changeable volume remains under them. exertion of a negative pressure that presses the finishing material above said gaskets; -insertion of the material forming the body of the manufactures in plastic state; the manufactures so become hard and are extracted from the mould.

Conveniently, in the portion of the mould where a gap (14) remains under the finishing material, some tubes are applied, by means of which the gap is created and from which air comes out, in this way the finishing material perfectly adheres to the rubber gaskets.

Conveniently, the gaskets support the finishing elements (7), so that between them a gap (8) is created above the zone where the same gasket is placed.

The gaskets adhere to the finishing material forming a packing along the entire surface in contact, thus avoiding that the material forming the manufactures comes into contact with the sight surface of the same gaskets.

Conveniently, if the chosen finishing material is fragile, it's possible to insert, in the space between the mould and the same material, a shim that guarantees the hold of the

gasket avoiding excessive squeeze and bending of the finishing material.

Said gaskets must be as little as the distance necessary to cover the gap (8) remaining between the various finishing materials and the edges (13) of two finishing elements, since, exception made for the gaskets at the ends of the mould, every gasket supports two edges (13,13A) of two adjacent finishing elements divided by a gap (8).

They can also be larger and cover a greater portion of the sight surface of the finishing material, but however such as to leave under the finishing material a gap (14) connected to a discharging pipe (6) so as to create the negative pressure.

The gaskets must be placed on the mould in the portions where the conjunctions between the various finishing elements can be seen. They can be parallel each other, partly parallel and partly perpendicular or even take any other shape according to the shape of the finishing material of which they roughly follow the perimeter reproducing the, outline.

The gaskets have a thickness proportional to the type of the finishing element and constructing material used for the realization of the manufactures.

Conveniently, the finishing material is made of ceramic tiles, or elements in wood, stone, metal, glass, plastic or other materials chosen to form the finish of the manufactures.

Conveniently, the constructing material, which is inserted during moulding, is formed by reinforced plastic, cement,

plastic substances such as the polyurethane, thermoplastic substances or any other material suitable to be used inside a mould.

Conveniently, the negative pressure is exerted by means of a pump for gaps or a space generator connected to the equipment.

In practice, this system comprises the following phases.

Inside an open or closed mould (Fig. 1), having such a shape necessary to realize the manufactures, a pattern in synthetic rubber is realized following the outline of the finishing material to use (Fig. 2). Said rubber pattern (full or extensive) has a suitable largeness, thickness, hardness and material according to the type of materials used for the realization of the manufactures and the finishing.

The finishing material is placed into the mould in the selected position and in contact with the rubber pattern (Fig.

3).

At this point, we exert a negative pressure (partial gap) in the space between the mould and the finishing material, which is pressed against the rubber pattern by the external pressure (Fig. 4).

The rubber pattern adheres to the finishing material forming a packing along the entire surface in contact.

If the chosen finishing material is fragile, it's possible to insert, in the space between the mould and the same material, a shim that guarantees the hold of the gasket avoiding excessive squeeze and bending of the finishing material.

Subsequently, we insert in the mould the material (Fig. 5) forming the principal body of the manufactures (cement, <BR> <BR> synthetic resins, thermoplastic resins, etc. ) that comes into contact with the finishing material, fixing to it, so creating the finished manufactures (Fig. 6).

In a practical example, imagine to build a prefabricated wall with a series of tiles applied on it. We create a rectangular mould with side walls (3,3A) holding the material forming the body of the manufactures. On the base of the mould, the rubber gaskets are placed perpendicularly each other, so as to create the typical grid of the walls where ceramic tiles are applied.

In this case, the finishing material is constituted by tiles (7), which are applied over the rubber gaskets, so as to adhere with a part of the edge (13) over the same gaskets, leaving however a gap (8) later filled with the material (11).

At this point, we exert a negative pressure so that the tiles perfectly adhere to the gaskets, avoiding any infiltration of material that might dirty their sight surface. Once the tiles have been arranged over the gaskets inside the mould, we proceed inserting the constructing material that fills the gaps (8) forming a single block with the tiles. The finished product is a prefabricated wall with the tiles perfectly integrated into the body of the manufactures. There is no need to point or otherwise finish the product in the sight surface as it is already finished, once hard.

Brief description of drawings The attached drawings are given as practical examples of the invention, but are not to be considered restrictive.

- Fig. 1 shows an axonometric projection of a generic mould (1) formed by sides walls (3,3A) and a base (2), where a series of rubber gaskets (4,5) are perpendicularly applied or however arranged in different way according to the final impression of the finished product.

- Fig. 2 shows the section of the mould, with the tubes (6) for the exertion of the negative pressure.

- Fig. 3 shows the same mould as Fig. 2, with the finishing material (7) applied over the rubber gaskets, so that between the various finishing materials a gap (8) remains to be filled with the material forming the body of the manufactures.

- Fig. 4 shows the same mould as Fig. 2, highlighting the phase of the exertion of the negative pressure pressing the finishing material (7) over the rubber gaskets (4), thanks to the external pressure (9).

- Fig. 5 shows the phase of the insertion of the material forming the body of the manufactures (11), highlighting the finishing elements (7), the edges (13,13A), the gap (8) and another gap (14) created under the sight surface.

- Fig. 6 finally shows the finished product, where the material (11) constitutes the body of the manufactures penetrating also in the gaps deliberately created between the various finishing materials, whose sight surface (12) is never touched by the material (11).