A decoration method of a decorated ceramic tile and a ceramic tile obtainable by actuating the method

Abstract

A decoration method of a decorated ceramic tile is described, decorated by digital dye-sublimation and diffusion transfer printing, (also known as sublimation printing). The method enables obtaining a novel decorated ceramic tile (1) comprising: a body, in turn comprising: a first larger face (31), a second larger face (32), wherein the first larger face and the second larger face are substantially flat and substantially parallel to one another; and a perimeter surface which joins the first larger face and the second larger face to one another; and a first decoration (D1) arranged at the larger face (31) of the body of the decorated ceramic tile (1); The novel decorated ceramic tile (1) further comprises at least a first solid layer which is fixed to at least a transversal portion of the perimeter surface of the body of the decorated ceramic tile (1) which is transversal, with respect to the first larger face. The solid layer comprises: a transparent resin which is decoratable by dye sublimation and diffusion transfer printing; and a second decoration (D2) comprising, in turn, at least a colorant substance for liquid inks for dyesublimation and diffusion transfer printing, wherein the at least a colorant substance is in the solid state.

Description

[0001] A DECORATION METHOD OF A DECORATED CERAMIC TILE AND A CERAMIC TILE OBTAINABLE BY ACTUATING THE METHOD

[0002] FIELD OF THE INVENTION

[0003] The invention relates to the sector of ceramic tiles also known as “table tiles” or “pianella tiles” and to the relative methods of decoration.

[0004] DESCRIPTION OF THE PRIOR ART

[0005] It is known that ceramic tiles are at present produced in various sizes. With reference to figures 1-2 it is known that a ceramic tile (10) is slab-shaped, and that is has two larger faces (11, 12), substantially flat and being substantially parallel to one another and a perimeter surface that conjoins the two larger faces to one another and which is typically perpendicular thereto. A ceramic tile (10) usually has a body which has the shape of a parallelepiped with a rectangular base (see figures 1 and 2) or a square base having a small thickness and which has two larger faces (11 , 12) and four smaller faces (12, 13, 14, 15) which constitute the perimeter surface of the tile. Ceramic tiles are at present used as floors, wall coverings and, especially when made in larger sizes, are, over time, progressively growing in size, and are also being used in the construction of furniture. In fact, these are used for realising planes of articles of furniture such as, for example: work planes of an assemblable kitchen; support planes for bathroom furniture, in particular of an article comprising a wash basin; table tops, of which tiles constitute the support plane; or they are used for producing shelves, or shelving. Furniture planes are also known as “tops”.

[0006] The tiles are often decorated with a decoration which imitates marble or granite and, especially if sanded, are successful in presenting an aesthetic appearance that is comparable to marble and granite at a decidedly lower cost with respect thereto. Further, they are of a lighter weight with respect to a slab of marble or granite, which is necessarily thicker than a ceramic tile.

[0007] The production process of the body of the decorated ceramic tile (10) enables decorating only a first larger face (11) thereof which is destined to remain in view, once the ceramic tile has been installed. In a case in which the ceramic tile (10) is used as a wall covering or a floor the other larger face is destined to be fixed to a support surface by means of a suitable adhesive material, and can comprise a plurality of fixing projections, not illustrated, which project from the body of the ceramic tile at the second end of the second larger face.

[0008] With reference to figures 1 and 5-6, usually, for obtaining the ceramic tiles (10) decorated with the decoration that imitates the marble or granite, a file in electronic format is used, typically with the extensions: PSB” Photoshop or. “.TIFF” (Tagged Image File Format), which encodes an image. This image has a larger dimensionthan the first larger face to be decorated of a semi-finished ceramic object, such as, for example, a ceramic bisque. This, once decorated, must be subjected to a further firing. Therefore, typically, on the larger faces of various different semi-finished ceramic products different portions (18, 19) of the image (17) are randomly printed. Note that, following the further firing, the decorated ceramic tile (10) has smaller dimensions than the bisque used for producing it. Consequently, the dimensions of the decoration of the bisque are greater than those of the decorated ceramic tile (10) produced thereby.

[0009] When, however, the decorated ceramic tile (10) is used in the manufacture of furniture as indicated above, at least a relative smaller face (12, 13, 14, 15) will remain visible, being positioned perpendicularly to the plane of the item of furniture. Taking figure 2 into consideration, from the point of view of an observer arranged at point P, the smaller face (16) would remain visible. In tables, where the plane is constituted by a single ceramic tile having large dimensions, all four smaller faces (12, 13, 14, 15) of the tile would remain in view. The smaller face or faces of the decorated ceramic tile (10) which remains or remain in view are aesthetically unattractive and therefore it is necessary that they should not be in view, for example by covering them with another material, typically by using an aluminium profiled element. Unfortunately this is not possible with all types of furniture, for example classical-type furniture. The furniture industry, therefore, has created a method for decorating while preventing the smaller faces from being in view. With reference to figures 1-4, this method includes cutting at least two decorated ceramic tiles (10) with an oblique cut along an oblique plane (21), with respect to the larger face (11), decorated at typically 45°. In this way, two cut ceramic tiles (10’) are obtained each with a relative inclined fixing surface (22) with respect to the decorated larger face (11). One of the two ceramic tiles (10’) is further cut transversally with a further transversal cut along a transversal plane (23) (see figure 2), so as to obtain a further cut tile (10”) having small dimensions (visible in figure 3). The two fixing surfaces (23) of the cut tile (10’) and of the further cut tile (10”) are then fixed to one another, typically by means of an adhesive material, obtaining a manufactured product (24) in an L shape to realise a support plane for an article of furniture. This method involves manual operations. Further, the cutting of the tiles must be carried out by specialised staff. This implicates the use of machinery and / or the creation of ceramic dust with the consequent repercussions on safety and hygiene in the workplace as well as the obligation to use personal protection means. Obviously this method generates waste, for example of the unused part (25) (see figure 3) of the ceramic tile (10) which has been cut, possibly transversally, or possibly other tiles broken during the cutting step.

[0010] It is further evident that, in order to realise a support plane of a table, it is necessary to carry out this method on each perimeter side of the decorated ceramic tile (10) with a consequent increase in times and working costs.

[0011] Further, this method does not enable obtaining a graphic continuity of the decoration between the decorated faces (26, 27) of the product (24), in particular when the decoration imitates marble or granite and, especially, when it imitates marble. In fact, with reference to figures 4-6, the two decorated ceramic tiles (10) used can have decorations that are different and that correspond to two different portions (18, 19) of the image (17) which are not consecutive to one another. In this case, the face (27) of the product (24) will have a decoration that corresponds to the part (20) of the portion (19) of the image (17) which will not match the decoration of the other decorated face of the product (24) as the decoration corresponds to the other first portion (18) of the image (17). This visually evidences the fact that the product (24) is not really made of a single body and, in particular, is not made of marble. Additionally, the joint obtained with the adhesive material is also visible. Further, this method does not enable obtaining furniture planes having a curved rest surface, for example in the case of a round or oval table or a rounded kitchen island. Note also that wall coverings can also terminate at a height at which the relative upper edge is visible to a person who is standing up, realising “boiseries”. In this case, in order to avoid that, at the edge of the boiseries, the smaller face, not decorated, of the terminal tile, is visible, terminal decorative elements have to be installed which will cover the smaller face.

[0012] Inks are known for dye-sublimation and diffusion transfer printing. These can be printed by means of inkjet printing and have been created for the textile industry for decorating textiles made of polyester, following printing on a paper sheet, by means of dye-sublimation and diffusion transfer printing, (also known as sublimation printing). These comprise at least a solvent and / or at least a colorant substance, typically organic, dissolved and / or dispersed in the solvent. These sublimated inks are for example produced and marketed by Epson Europe B.V. or Roland DG.

[0013] A multi-layer film is known that is utilisable for decorating, by means of dyesublimation and diffusion transfer printing, a composite object comprising about 70% in weight of marble powder and about 30% in weight of polyester resin (for example a shower base tray). The multi-layer film is a heat-formable multi-layer film for dye-sublimation and diffusion transfer printing and comprises: a first layer made of a heat-formable plastic material, typically of polyethylene terephthalate or PET; and a second layer made of a plastic material which is preferably a heat-curing resin and which is generally a polyester resin or a polyamide resin. The decoration to be transferred onto the object can be digitally printed on the second layer, using liquid inks by dyesublimation and diffusion transfer printing. Therefore, a decorated multi-layer film is obtained which comprises the multi-layer film and a decoration comprising at least an ink by dye-sublimation and diffusion transfer printing, which is dry i.e. solid.

[0014] A decoration method of the object made of a composite material is known, comprising following steps: - obtaining, on the object, a solid transparent decoratable layer: which comprises a plurality of pores; which is decoratable by dye-sublimation and diffusion transfer printing; which is solidly constrained to the surface of the object and which, typically, is made of a transparent acrylic polyol resin, obtaining an object at least partially covered by the solid transparent decoratable layer;

[0015] - positioning the decorated multi-layer film with the above-mentioned second decoration facing the solid transparent decoratable layer and fixing the positioned decorated multi-layer film to the covered object;

[0016] - eliminating the air present between the decorated multi-layer film and the object to be decorated in order to place the decoration and the solid transparent decoratable layer in direct contact, obtaining a covered ceramic tile / decorated multi-layer film group;

[0017] - heating the covered ceramic tile / decorated multi-layer film group to bring it to a temperature such as to heat-form the decorated multi-layer film; and so as to sublimate the decoration, and so as to open the pores of the plurality of pores of the solid transparent decoratable layer in order to transfer, by dyesublimation and diffusion transfer printing, the decoration from the decorated multi-layer film to the transparent solid decoratable layer, obtaining a covered ceramic object / heat-formed decorated multi-layer film group;

[0018] -removing the heat-formed multi-layer film from the covered ceramic object / heat-formed decorated multi-layer film group while the first layer of film made of a heat-formable thermoplastic material is softened, obtaining an object that is partially covered and decorated.

[0019] When the second layer of the decorated multi-layer film is made of a heatcuring resin, the temperature can also be such as to heat-cure it.

[0020] Typically the heating step takes place in an oven at a temperature of about 140-155°C, bringing the surface of the object made of composite material to a temperature of about 120-130 °C. An oven is used that is provided with aspiration means and an aspirated plane couplable to the aspiration means of the oven for carrying out the step of eliminating the air contemporaneously with the heating step. To facilitate the aspiration, the step of eliminating the air can comprise: the arrangement of the object on the perforated surface of the aspirated plane; the arrangement of the multi-layer film also on a portion of the aspirated plane contiguous to the object; and / or the arranging of a further plastic film on the multi-layer film, already positioned on the partially-covered object, on the portion of the aspirated plane contiguous to the object; and aspiration of the air present between the decorated multi-layer film and the object covered by the aspirated plane.

[0021] Owing to the nature of the composition of the object, the heating gradient of the heating step must be slow. This limits the productivity of the decoration method.

[0022] SUMMARY OF THE INVENTION

[0023] The main aim of the present invention is to obviate the drawbacks relating to known decorated ceramic tiles having a decoration only on the main face. A further aim of the invention is to provide a decorated ceramic tile on the relative first larger face and at least a second decoration on a portion of the relative perimeter surface. Further, an additional object consists in providing a decoration method of a decorated ceramic tile of known type which: does not involve design of specific equipment, does not implicate the use of dangerous materials or suction devices in the work environment and extensive use of manpower and creation of a large quantity of waste. An additional aim consists in providing a production method of the ceramic tile which is versatile and simple to industrialise.

[0024] The Applicant has established that the production method of the invention enables obtaining a novel decorated ceramic tile wherein there is no interruption between the first decoration and the second decoration. Advantageously, this makes the novel decorated ceramic tile, when decorated with decorations imitating marble or granite, easy confusable with marble or granite, indeed with a result that is aesthetically alike to a slab of marble or granite as the first and second decoration have a graphic continuity. Note further that the decoration method of the invention enables maintaining unaltered the first larger face of the decorated ceramic tile and thus leaving the relative characteristics unchanged, for example the properties of resistance to temperatures or wear. Further, by using circular or elliptical forming dies of the ceramic mix the invention enables easy decoration also of the perimeter surface of the oval or elliptical decorated ceramic tiles obtained from the dies, resulting in decorated ceramic tiles, according to the invention, which are circular, oval and elliptical, and which can even be of a large size. The latter are particularly advantageous for the making of round, oval or elliptical tables or small tables. Additionally, the production method is easy to industrialise and simply customisable and enables decorating tiles of different dimensions and shapes with various decorations without having to carry out size changes in the equipment used with the heating gradient of the heating step being greater with respect to the decoration method than the marble and polyester composite object. Further, it is possible to decorate one portion only of the perimeter surface of the decorated ceramic tile according to the invention, a plurality of portions of the perimeter surface or the entire perimeter surface according to the use intended for the decorated ceramic tile.

[0025] Specific embodiments of the invention will be described in the following part of the present description, according to what is set down in the claims and with the aid of the accompanying tables of drawings, in which figures 1-6 and 15- 17 relate to the prior art, and the remaining figures are relative to the invention.

[0026] BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a front schematic view from above of a known ceramic tile.

[0028] Figure 2 is a schematic lateral view of two known ceramic tiles.

[0029] Figure 3 is a schematic lateral view of two known ceramic tiles, cut, and a remaining unused part.

[0030] Figure 4 is a schematic lateral view of a known product.

[0031] Figure 5 is a front schematic view from above of an encoded image in an electronic file.

[0032] Figure 6 is a schematic side view of figure 5 in which some relative portions are evidenced.

[0033] Figure 7 is a schematic view from above of an aspirated plane. Figure 8 is a schematic lateral view of a ceramic tile / aspirated plane group.

[0034] - figure 9 is a schematic lateral view of the section of the aspirated plane of figure 7 along plane IX-IX of figure 7.

[0035] Figure 10 is a schematic lateral view in section of a ceramic tile / aspirated plane group.

[0036] Figure 11 is a schematic lateral view in section of a decorated ceramic tile / aspirated plane group.

[0037] Figure 12 is a schematic lateral view in section of a decorated ceramic tile / aspirated plane group / further film before the aspiration of the aspirated plane.

[0038] Figure 13 is a schematic lateral view in section of the group of figure 12 during the aspiration of the aspirated plane.

[0039] Figure 14 is a schematic lateral view of the aspiration plane and of a decorated ceramic tile according to the invention.

[0040] Figure 15 is a frontal schematic view from above of a known ceramic tile.

[0041] Figure 16 is a schematic lateral view of the known ceramic tile of figure 15.

[0042] Figure 17 is a schematic perspective view of the known ceramic tile of figure 15.

[0043] Figure 18 is a schematic view from above and in larger scale of the decorated ceramic tile of figure 14.

[0044] Figure 19 is a schematic lateral view in larger scale of the decorated ceramic tile of figure 14.

[0045] Figure 20 is a schematic perspective view of the decorated ceramic tile of figure 14.

[0046] Figures 21-24 are schematic views from above of a printable image in which the various relative portions are indicated.

[0047] Figures 25-26 are schematic views from above of a decorated multi-layer film utilisable for actuating the method of the invention. Note that in the figures the thicknesses of the decorated multi-layer film and the plastic film are not in scale in order that they can be illustrated in a more visible way.

[0048] DESCRIPTION OF PREFERRED EMBODIMENTS

[0049] With reference to the appended tables of drawings, generic reference numeral (1) relates to a decorated ceramic tile according to the invention obtainable by carrying out the relative decoration method according to the invention.

[0050] The decoration method of a decorated ceramic tile comprises following steps:

[0051] A) preparing a file in electronic format which encodes an image (17);

[0052] B) predisposing a decorated ceramic tile (10) comprising:

[0053] - a body, in turn comprising: a first larger face (11); a second larger face (12), both substantially flat and substantially parallel to one another; and a perimeter surface which joins the first larger face (11) and the second larger face (12) to one another; and

[0054] - a first decoration (D1): which corresponds to a first portion of the image (17); and which is arranged at the larger face (11) of the body of the decorated ceramic tile (10);

[0055] C) establishing a plurality of reference points (01 , P1, P2, P3) of the first decoration (D1);

[0056] D) obtaining a solid transparent decoratable layer: which comprises a plurality of pores; which is decoratable by dye-sublimation and diffusion transfer printing; which is in a transparent resin (and which is preferably an acrylic polyol resin or a polyester resin); which is solidly constrained to and arranged in at least a transversal portion of the perimeter surface; which originates at a first edge (B1) of the first decoration (D1); and which extends from the first larger face (11) to the second larger face (12), obtaining a covered ceramic tile (45) which is at least partially laterally covered by the solid transparent decoratable layer;

[0057] E) predisposing a multi-layer film which is a heat-formable multi-layer film for dye-sublimation and diffusion transfer printing, wherein the multi-layer film comprises: a first layer made of a heat-formable plastic material (which is preferably polyethylene terephthalate); and a second layer made of a plastic material which is preferably a heat-curing resin (and which more preferably is a polyester resin or a polyamide resin);

[0058] F) predisposing at least a liquid ink which is at least a liquid ink for dyesublimation and diffusion transfer printing, wherein the at least a liquid ink is usable to print digitally, using the file in electronic format, the image (17) on a physical substrate obtaining a printed image (17) corresponding to the image (17), wherein each liquid ink predisposed comprises at least a solvent and / or at least a colorant substance dissolved and / or dispersed in the solvent;

[0059] G) identifying in the image (17): the first portion (40) of the image (17) which corresponds to the first decoration (D1); and a plurality of reference points (02, P4, P5, P6) of the first portion (40) of the image which points correspond to the plurality of reference points (01 , P1, P2, P3) of the first decoration (D1);

[0060] H) dimensioning the image (17) of the file in electronic format in such a way that by printing the image, a printed image is obtained comprising a first portion which is perfectly superposable on the first decoration (D1) obtaining a file in electronic format which encodes a dimensioned image (41) comprising: a first portion (42) corresponding, including dimensionally, to the first decoration (D1); and a plurality of reference points (03, P7, P8, P9) of the first portion (42) of the dimensioned image (41) corresponding to the plurality of reference points (02, P4, P5, P6) of the first portion (40) of the image (17) and superposable on the plurality of reference points (01 , P1 , P2, P3) of the first decoration (D1);

[0061] I) identifying in the dimensioned image (41) at least a second portion (43) of the dimensioned image (41), which second portion (43) of the dimensioned image (41): is contiguous to the first portion (42) of the dimensioned image (41); originates at the first portion (42) of the dimensioned image (41) at a first edge (B2) of the dimensioned image (41) which corresponds to the first edge (B1) of the first decoration (D1); J) using the at least a liquid ink, digitally printing on the second layer of the multi-layer film at least: the at least a second portion (43) of the dimensioned image (41); and the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41), obtaining, following evaporation of the solvent of the at least a liquid ink, a decorated multi-layer film (44) (see figures 25 and 26) comprising: the multi-layer film and at least: a second decoration (D2), corresponding to the second portion (43) of the dimensioned image (41), and a plurality of reference points (04, P10, P11 , P12) corresponding to the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41) and superposable on the plurality of reference points (01, P1, P2, P3) of the first decoration (D1), wherein the second decoration (D2) is sublimable and comprising at least the colorant substance in the solid state;

[0062] K) positioning the decorated multi-layer film (44) with the second decoration (D2) facing the solid transparent decoratable layer of the covered ceramic tile (45) of the covered ceramic tile (45) and with the plurality of reference points (04, P10, P11, P12) of the decorated multi-layer film (44) at the plurality of reference points (01, P1, P2, P3) of the first decoration (D1) and fixing the positioned decorated multi-layer film (44) to the covered ceramic tile (45);

[0063] L) eliminating the air present between the decorated multi-layer film (44) and the covered ceramic tile (45) in order to place the second decoration (D2) and the solid transparent decoratable layer in direct contact, obtaining a covered ceramic tile (45) / decorated multi-layer film (44) group.

[0064] M) heating the covered ceramic tile (45) / decorated multi-layer film (44) group to bring it to a temperature so as: to heat-form the decorated multi-layer film (44); to sublimate the second decoration (D2); and so as to open the pores of the plurality of pores of the solid transparent decoratable layer in order to transfer, by dye-sublimation and diffusion transfer printing, the second decoration (D2) from the decorated multi-layer film (44) to the solid transparent decoratable layer of the covered ceramic tile (45), obtaining a laterally-decorated covered ceramic tile / heat-formed multi-layer film group (the temperature is preferably comprised between 118°C and 135°C); N) removing the heat-formed multi-layer film from the laterally-decorated covered ceramic tile / heat-formed multi-layer film group (preferably when the first layer of the heat-formed multi-layer film has softened), obtaining a decorated ceramic tile (1) which is at least partially laterally covered and at least partially laterally decorated, the decorated ceramic tile comprising;

[0065] - a body comprising, in turn, a first larger face (31), a second larger face (32), wherein the first larger face (31) and the second larger face (32) are substantially flat and substantially parallel to one another; and a perimeter surface which joins the first larger face (31) and the second larger face (32) to one another;

[0066] - a first decoration (D1) arranged at the larger face (31) of the body of the decorated ceramic tile (1); and

[0067] - a solid layer: which is fixed to at least a transversal portion of the perimeter surface of the body of the decorated ceramic tile (1); which is transversal, with respect to the first larger face (31), wherein the solid layer comprises a transparent resin which is decoratable by dye-sublimation and diffusion transfer printing (and which is preferably an acrylic polyol resin or a polyester resin); and a second decoration (D2) arranged at the transversal portion of the perimeter surface and comprising, in turn, at least a colorant substance for liquid inks for dye-sublimation and diffusion transfer printing, wherein the at least a colorant substance is in the solid state;

[0068] O) optionally obtaining a further layer; which is a protective layer; which is transparent; which adheres and is solidly constrained to the solid layer; and which comprises a transparent resin (and which is preferably an acrylic polyol resin or a polyester) and, optionally, at least a UV filter.

[0069] Note that the further transparent solid layer enables protecting the second decoration (D2) both from wear and, when the UV filter is present, also from ultraviolet rays.

[0070] Step J) of digital printing can advantageously include printing only a second portion (43) of the dimensioned image (41) and the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41) in order to save the at least a liquid ink, but it is equally possible to print also the first portion of the image (17) or indeed all of the dimensioned image (41). In this way, in fact, it is possible to obtain a greater precision of step K) of positioning the decorated multi-layer film (44).

[0071] The positioning is preferably manual, but can also be automatic.

[0072] The solid transparent decoratable layer and the further transparent solid layer can advantageously be made of an acrylic polyol resin or a polyester resin, optionally comprising at least a UV filter, and / or can be obtained by painting, using a transparent paint, preferably having a binder, respectively, of the acrylic polyol resin type or the polyester type.

[0073] The solvent of the at least a liquid ink is preferably water or a watery solvent (for example a mixture of water and glycols or water, glycols and triethanolamine), as this makes the decoration method more ecological and secure.

[0074] The second layer of the film predisposed in step E) can advantageously be made of a heat-curing plastic material, i.e. a heat-curing resin which is preferably a polyester resin or a polyamide resin). In this case, the step (M) of heating includes taking the covered ceramic tile (45) / decorated multi-layer film (44) group to a temperature also such as to heat-cure the second layer of the decorated multi-layer film (44). This facilitates step N) of removing the heat- formed multi-layer film from the laterally-decorated covered ceramic tile / heat- formed multi-layer film group.

[0075] To obtain more complex second decorations the at least a liquid ink is preferably a plurality of inks for dye-sublimation and diffusion transfer printing, in particular when it enables carrying out a three-colour or four-colour digital print.

[0076] With the decoration method it is possible easily to obtain the decorated ceramic tile (1) according to the invention (see figures 18-20) with the production of ceramic waste. The decorated ceramic tile (1) according to the invention comprises: a body, in turn comprising: a first larger face (31), a second larger face (32), wherein the first larger face (31) and the second larger face (32) are substantially flat and substantially parallel to one another and a perimeter surface which joins the first larger face (31) and the second larger face (32) to one another; and a first decoration (D1) arranged at the larger face (31) of the body of the decorated ceramic tile (1); at least a first solid layer. The first solid layer is fixed to at least a transversal portion of the perimeter surface of the body of the decorated ceramic tile (1), which is transversal, with respect to the first larger face (31). The solid layer comprises: a transparent resin which is decoratable by dye-sublimation and diffusion transfer printing (and which is preferably an acrylic polyol resin or a polyester resin); and a second decoration (D2) arranged at the transversal portion of the perimeter surface and comprising, in turn, at least a colorant substance for liquid inks for dye-sublimation and diffusion transfer printing, wherein the at least a colorant substance is in the solid state. The decorated ceramic tile (1) of the invention preferably has a vitrified stoneware body.

[0077] With the aim of simplifying the dimensioning of the dimensioned image (41), a preferable actuation of the decoration method according to the invention is one in which step C) (in which the plurality of reference points (01 , P1, P2, P3) of the first decoration (D1) is established) includes establishing a reference point of origin (D1) of the first decoration (D1) and establishing at least a distance reference point (P1 , P2, P3) of the first decoration (D1) and wherein step G) of identification includes identifying as a plurality of reference points 02, P4, P5, P6 of the first portion (40) of the image (17): a reference point of origin (02) of the first portion (40) of the image (17), corresponding to a reference point of origin (01) of the first decoration (D1); and an at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17), corresponding to the at least a distance reference point (P1, P2, P3) of the first decoration (D1); and wherein step H) of dimensioning comprises following substeps:

[0078] H1) measuring: a first distance parameter (XP1, DP1) of the at least a distance reference point (P1, P2, P3) of the first decoration (D1) from the reference point of origin (01) of the first decoration (D1); and a second distance parameter (YP1, G) of the at least a distance reference point (P1, P2, P3) of the first decoration (D1) from the reference point of origin (01) of the first decoration (D1);

[0079] H2) measuring: a third distance parameter (XP5, DP5) of the at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17) from the reference point of origin (02) of the first portion (40) of the image (17); and a fourth distance parameter (YP5, O’) of the at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17) from the reference point of origin (02) of the first portion (40) of the image (17);

[0080] H3) dimensioning the image (17) of the file in electronic format so that: the value of the third distance parameter (XP5, DP5) is identical to the value of the first distance parameter (XP1 , DP1) and so that the value of the fourth distance parameter (YP5, O’) is identical to the value of the second distance parameter (YP1 , O), obtaining a dimensioned image (41) comprising at least a distance reference point (P7, P8, P9) corresponding to the at least a distance reference point (P4, P5, P6) of the image (17).

[0081] When a Cartesian system is used, having the origin of the reference point of origin (01) of the first decoration (D1) and of the first portion of the image (17) the first distance parameter (XP1, DP1) and the third distance parameter (XP5, DP5) can be an X-axis (XP1 , XP5) while the second distance parameter ((YP1 , O) and the fourth distance parameter (YP5,0’) can be a Y-axis (YP1, YP5).

[0082] Alternatively, the first distance parameter (XP1, DP1) and the third distance parameter (XP5, DP5) can be a distances (DP1, DP5), while the second distance parameter (YP1, O) and the fourth distance parameter (YP5, O’) can be an angle (0,0’) comprised between the segment conjoining the points to be measured to the relative reference point of origin (01, 02) and: the axis of the X-axis or the axis of the ordinates of a reference system having origin in the relative reference point of origin (01, 02); or a side of the decoration and a corresponding side of the first portion of the image (17).

[0083] Should the mix of the known decorated ceramic tile (10) to be decorated be too dark and the second decoration (D2) to be obtained is light, a decoration method is preferable according to the invention, in which, before step D) of obtaining the solid transparent decoratable layer, obtaining a solid coloured layer, preferably white, is included (or in any case a light colour): which is made of a resin (preferably an acrylic polyol resin or a polyester resin); and which is arranged in and solidly constrained to the at least a transversal portion of the perimeter surface and wherein the step D) of obtaining the solid transparent decoratable layer includes arranging the solid transparent decoratable layer on the solid coloured layer. In this way, a second decoration (D2) can be obtained of any type, including on tiles obtained starting from dark ceramic mixes.

[0084] In this case, the decorated ceramic tile (1) according to the invention will advantageously also comprise a second solid layer (not illustrated); which is coloured (and is preferably white); which is made of a resin (preferably an acrylic polyol resin or a polyester resin); and which is arranged between the at least a transversal portion of the perimeter surface and the first solid layer.

[0085] In a relative preferred actuation of the decoration method of the invention, the body of the decorated ceramic tile (10) predisposed in step B) of predisposing has a parallelepiped shape with a rectangular or square base and further comprises a first smaller face (33), a second smaller face (34), a third smaller face (35), a fourth smaller face (36), which together constitute the perimeter surface of the decorated ceramic tile (10) and wherein the at least a transversal portion of the perimeter surface comprises one from among: the first smaller face (13), the second smaller face (14), the third smaller face (15) and the fourth smaller face (16). This enables obtaining a decorated ceramic tile (1) according to the invention, that is usable for the production of support planes of “TOP” for furniture, wherein the body of the decorated ceramic tile: has a parallelepiped shape with a rectangular or square base and further comprises a first smaller face (33), a second smaller face (34), a third smaller face (35), a fourth smaller face (36), which together constitute the perimeter surface of the decorated ceramic tile (1) according to the invention and wherein the at least a transversal portion of the perimeter surface comprises one from among: the first smaller face (33), the second smaller face (34), the third smaller face (35) and the fourth smaller face (36), preferably at least two smaller faces (opposite and contiguous, in the case of a use for a support plane for a corner article of furniture) and, more preferably, at least the smaller faces (in the case of a use for a support plane for an island or a plane of a bathroom item of furniture) and more advantageously all four smaller faces (in a case of use for a support plane for rectangular or square tables). This is obviously also valid for the decoration method of the invention.

[0086] In an alternative and advantageous embodiment of the decoration method of the invention, the body of the decorated ceramic tile (10) predisposed in step B) has a shape selected from between: the shape of a transversal section of a circular cylinder or of a cone wherein the first larger face (11) and the second larger face (12) are round and the perimeter surface of the body of the ceramic tile has the shape of a transversal section of the lateral surface, respectively of the cylinder or the cone; and the shape of a transversal section of an elliptical cylinder wherein the first larger face (11) and the second larger face (12) are elliptical and the perimeter surface of the body of the ceramic tile has a shape of a transversal section of the lateral surface of the elliptical cylinder. In this case, the at least a transversal portion of the perimeter surface coincides with the whole perimeter surface. This enables obtaining a decorated ceramic tile (1) according to the invention utilisable as a support plane for round or elliptical tables, wherein the body of the ceramic tile has a shape chosen from: the shape of a transversal section of a circular cylinder or of a cone wherein the first larger face (31) and the second larger face (32) are round and the perimeter surface of the body of the ceramic tile has the shape of a transversal section of the lateral surface, respectively of the cylinder or the cone; and the shape of a transversal section of an elliptical cylinder wherein the first larger face (31) and the second larger face (32) are elliptical and the perimeter surface of the body of the ceramic tile has a shape of a transversal section of the lateral surface of the elliptical cylinder. In these cases, the at least a transversal portion of the perimeter surface coincides with the whole perimeter surface. Figure 24 also illustrates a first portion (42) of dimensioned image (41) and a second portion (42) of dimensioned image (41) which are elliptical and utilisable in a case in which the body has the shape of a transversal section of an elliptical cylinder.

[0087] With the aim of facilitating the elimination of the air present between the multilayer film and the covered ceramic tile (45), the decoration method of the invention of any aforementioned description is advantageous, as it further comprises the arrangement of the covered ceramic tile (45) on a perforated surface (50) of an aspirated plane (51) (see figures 7-10) wherein the step (L) of eliminating the air further comprises the arranging of the decorated multilayer film (44) also on a portion of the aspirated plane (51) contiguous to the covered ceramic tile (45) and / or the arranging of a further plastic film (46) on the decorated multi-layer film (44) positioned on the portion of the aspirated plane (51) contiguous to the covered ceramic tile (45); and the aspiration of the air present between the decorated multi-layer film (44) and the covered ceramic tile (45) through the aspirated plane (51).

[0088] When the producer of the known decorated ceramic tile (10) to be decorated further provides the file in original electronic format used for obtaining, the first decoration (D1) by digital printing, the file in electronic format predisposed in the step A) of predisposing is that original file in electronic format. Alternatively, when the original file is not available, an embodiment of the decoration method of the invention is especially preferred in which the step A) of predisposing the file in a format that encodes an image (17) comprises following substeps:

[0089] A1) photographing a decorated ceramic tile (10) (which can coincide with the one predisposed in step B) of predisposing) having a body, in turn having: a first larger face (11); a second larger face, both being substantially flat and being substantially parallel to one another; and a perimeter surface which joins the first larger face (11) and the second larger face (12) to one another, wherein the first larger face (11) is decorated with a first decoration (D1), obtaining a further file in electronic format which encodes a further image (17) corresponding to the first decoration (D1); and

[0090] A2) modifying the further image (17) by cloning portions thereof and gluing the portions at the at least an edge of the further image (17) translating and / or mirroring the portions, with respect to at least an edge of the further image (17), so as to obtain the image (17) and the file in electronic format which encodes the image (17).

[0091] The watery solvent preferably comprises water, glycerols (CAS no. 56-81-5) triethanolamine (CAS no. 102-71-6) and, optionally, 1,2-Benzisothiazol-3(2H)- one (CAS no. 2634-33-5)

[0092] Further, particularly advantageous, in particular in terms of precision of the second decoration (D2), is an actuation of the decoration method of the invention wherein the transparent resin is an acrylic polyol resin, wherein step D) of obtaining the solid transparent decoratable layer comprises painting the at least a transversal portion of the perimeter surface with a transparent acrylic polyol paint (preferably watery, also termed as “water-based”); wherein the multi-layer film predisposed in step E) of predisposing comprises a first layer made of polyethylene terephthalate (PET) and a second layer made of a polyester resin (preferably heat-curing) or of a polyamide resin (preferably heat-curing); wherein step J) of digitally printing preferably includes digital printing, by inkjet printing, on the second layer of the multi-layer film, also the first portion (42) of the dimensioned image (41) adjacent to the second portion (43) of the dimensioned image (41) and the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41); wherein the step M) of heating comprises use of an oven (not illustrated) having an internal temperature comprised between 140-180°C (preferably between 160 and 178 °C) to take the covered ceramic tile group (42) / decorated multi-layer film (44) group to a temperature (which is preferably measured on the surface of the decorated ceramic tile (10) and which is preferably comprised between 105°C and 140°C, between 110 and 135 °C, and between 120 and 130°C) higher than the sublimation temperature of the at least a colorant substance and lower than the temperature of decomposition of the at least a colorant substance; and wherein the solvent of the liquid ink is watery or is water and the at least a colorant substance is an organic colorant.

[0093] The oven is provided with aspiration means and the aspirated plane is provided with coupling means (60) couplable to the aspiration means of the oven for carrying out the step of eliminating the air through the aspirated plane contemporaneously with the heating step.

[0094] A non-limiting example of an organic colorant is 5-nitro-2-(2-methyl-4- (dimethylamino) phenyl azo)thiazole also known as “Dispersed blue 360” having number EC 435-600-5.

[0095] Articles of furniture comprising a decorated ceramic tile (1) fall within the ambit of the invention according to the invention, among which square tables, rectangular tables, round and oval tables, furniture for bathrooms having a support plane, a base for an assemblable kitchen, and, obviously, also wall coverings which comprise a decorated ceramic tile (1) according to the invention.

Claims

CLAIMS1. A decoration method of a decorated ceramic tile (10), comprising following steps:A) preparing a file in electronic format which encodes an image (17);B) predisposing a decorated ceramic tile (10) comprising:- a body, in turn comprising: a first larger face (11); a second larger face (12), both substantially flat and substantially parallel to one another; and a perimeter surface which joins the first larger face (11) and the second larger face (12) to one another; and- a first decoration (D1): which corresponds to a first portion of the image (17); and which is arranged at the larger face (11) of the body of the decorated ceramic tile (10);C) establishing a plurality of reference points (01 , P1, P2, P3) of the first decoration (D1);D) obtaining a solid transparent decoratable layer: which comprises a plurality of pores; which is decoratable by dye-sublimation and diffusion transfer printing; which is in a transparent resin that: is solidly constrained to and arranged in at least a transversal portion of the perimeter surface; which originates at a first edge (B1) of the first decoration (D1); and which extends from the first larger face (11) to the second larger face (12), obtaining a covered ceramic tile (45) which is at least partially laterally covered by the solid transparent decoratable layer;E) predisposing a multi-layer film which is a heat-formable multi-layer film for dye-sublimation and diffusion transfer printing, wherein the multi-layer film comprises: a first layer made of a heat-formable plastic material; and a second layer made of a plastic material;F) predisposing at least a liquid ink which is at least a liquid ink for dyesublimation and diffusion transfer printing, wherein the at least a liquid ink is usable to print digitally, using the file in electronic format, the image (17) on a physical substrate obtaining a printed image (17) corresponding to the image (17), wherein each liquid ink predisposed comprises at least a solvent and / or at least a colorant substance dissolved and / or dispersed in the solvent;G) identifying in the image (17): the first portion (40) of the image (17) which corresponds to the first decoration (D1); and a plurality of reference points (02, P4, P5, P6) of the first portion (40) of the image which points correspond to the plurality of reference points (01 , P1, P2, P3) of the first decoration (D1);H) dimensioning the image (17) of the file in electronic format in such a way that by printing the image, a printed image is obtained comprising a first portion which is perfectly superposable on the first decoration (D1) obtaining a file in electronic format which encodes a dimensioned image (41) comprising: a first portion (42) corresponding, including dimensionally, to the first decoration (D1); and a plurality of reference points (03, P7, P8, P9) of the first portion (42) of the dimensioned image (41) corresponding to the plurality of reference points (02, P4, P5, P6) of the first portion (40) of the image (17) and superposable on the plurality of reference points (01 , P1 , P2, P3) of the first decoration (D1);I) identifying in the dimensioned image (41) at least a second portion (43) of the dimensioned image (41), which second portion (43) of the dimensioned image (41): is contiguous to the first portion (42) of the dimensioned image (41); originates at the first portion (42) of the dimensioned image (41) at a first edge (B2) of the dimensioned image (41) which corresponds to the first edge (B1) of the first decoration (D1);J) using the at least a liquid ink, digitally printing on the second layer of the multi-layer film at least: the at least a second portion (43) of the dimensioned image (41); and the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41), obtaining, following evaporation of the solvent of the at least a liquid ink, a decorated multi-layer film (44) comprising: the multilayer film and at least: a second decoration (D2), corresponding to the second portion (43) of the dimensioned image (41), and a plurality of reference points (04, P10, P11 , P12) corresponding to the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41) and superposable on the plurality of reference points (01, P1 , P2, P3) of the first decoration (D1), wherein the second decoration (D2) is sublimable and comprising at least the colorant substance in the solid state;K) positioning the decorated multi-layer film (44) with the second decoration (D2) facing the solid transparent decoratable layer of the covered ceramic tile (45) of the covered ceramic tile (45) and with the plurality of reference points (04, P10, P11, P12) of the decorated multi-layer film (44) at the plurality of reference points (01, P1, P2, P3) of the first decoration (D1) and fixing the positioned decorated multi-layer film (44) to the covered ceramic tile (45);L) eliminating the air present between the decorated multi-layer film (44) and the covered ceramic tile (45) in order to place the second decoration (D2) and the solid transparent decoratable layer in direct contact, obtaining a covered ceramic tile (45) / decorated multi-layer film (44) group.M) heating the covered ceramic tile (45) / decorated multi-layer film (44) group to bring it to a temperature so as: to heat-form the decorated multi-layer film (44); to sublimate the second decoration (D2); and so as to open the pores of the plurality of pores of the solid transparent decoratable layer in order to transfer, by dye-sublimation and diffusion transfer printing, the second decoration (D2) from the decorated multi-layer film (44) to the solid transparent decoratable layer of the covered ceramic tile (45), obtaining a laterally-decorated covered ceramic tile / heat-formed multi-layer film group ;N) removing the heat-formed multi-layer film from the laterally-decorated covered ceramic tile / heat-formed multi-layer film group , obtaining a decorated ceramic tile (1) which is at least partially laterally covered and at least partially laterally decorated, the decorated ceramic tile (1) comprising:- a body comprising, in turn, a first larger face (31), a second larger face (32), wherein the first larger face (31) and the second larger face (32) are substantially flat and substantially parallel to one another; and a perimeter surface which joins the first larger face (31) and the second larger face (32) to one another;- a first decoration (D1) arranged at the larger face (31) of the body of the decorated ceramic tile (1); and- a solid layer: which is fixed to at least a transversal portion of the perimeter surface of the body of the decorated ceramic tile (1); which is transversal, with respect to the first larger face (31), wherein the solid layer comprises a transparent resin which is decoratable by dye-sublimation and diffusiontransfer printing; and a second decoration (D2) arranged at the transversal portion of the perimeter surface and comprising, in turn, at least a colorant substance for liquid inks for dye-sublimation and diffusion transfer printing, wherein the at least a colorant substance is in the solid state;O) optionally obtaining a further layer; which is a protective layer; which is transparent; which adheres and is solidly constrained to the solid layer; and which comprises a transparent resin and, optionally, at least a UV filter.

2. The decoration method of the preceding claim, wherein the second layer of the film predisposed in step E) is made of a heat-curing resin, which is preferably a polyester resin or a polyamide resin, and the step M) of heating includes taking the covered ceramic tile (45) / multi-layer decorated film (44) group to a temperature that is also such as to heat-cure the second layer of the decorated multi-layer film (44).

3. The decoration method of any one preceding claim, wherein step C) in which the plurality of reference points (01, P1 , P2, P3) of the first decoration (D1) is established includes establishing a reference point of origin (01) of the first decoration (D1) and establishing at least a distance reference point (P1, P2, P3) of the first decoration (D1) and wherein step G) of identification includes identifying as a plurality of reference points (02, P4, P5, P6) of the first portion (40) of the image (17): a reference point of origin (02) of the first portion (40) of the image (17), corresponding to a reference point of origin (01) of the first decoration (D1); and an at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17), corresponding to the at least a distance reference point (P1, P2, P3) of the first decoration (D1); and wherein step H) of dimensioning comprises following substeps:H1) measuring: a first distance parameter (XP1, DP1) of the at least a distance reference point (P1, P2, P3) of the first decoration (D1) from the reference point of origin (01) of the first decoration (D1); and a second distance parameter (YP1, G) of the at least a distance reference point (P1, P2, P3) of the first decoration (D1) from the reference point of origin (01) of the first decoration (D1);H2) measuring: a third distance parameter (XP5, DP5) of the at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17) from the reference point of origin (02) of the first portion (40) of the image (17); and a fourth distance parameter (YP5, O’) of the at least a distance reference point (P4, P5, P6) of the first portion (40) of the image (17) from the reference point of origin (02) of the first portion (40) of the image (17);H3) dimensioning the image (17) of the file in electronic format so that: the value of the third distance parameter (XP5, DP5) is identical to the value of the first distance parameter (XP1 , DP1) and so that the value of the fourth distance parameter (YP5, O’) is identical to the value of the second distance parameter (YP1 , O), obtaining a dimensioned image (41) comprising at least a distance reference point (P7, P8, P9) corresponding to the at least a distance reference point (P4, P5, P6) of the image (17).

4. The decoration method of any one preceding claim, wherein before step D) of obtaining the solid transparent decoratable layer, obtaining a solid coloured layer, preferably white, is included: which is in a resin; and which is arranged in and solidly constrained to the at least a transversal portion of the perimeter surface and wherein step D) of obtaining the solid transparent decoratable layer includes arranging the solid transparent decoratable layer on the solid coloured layer.

5. The decoration method of any one preceding claim, wherein the body of the decorated ceramic tile (10) predisposed in step B) of predisposing has a parallelepiped shape with a rectangular or square base and further comprises a first smaller face (13), a second smaller face (14), a third smaller face (15), a fourth smaller face (6), which together constitute the perimeter surface of the decorated ceramic tile (10) and wherein the at least a transversal portion of the perimeter surface comprises one from among: the first smaller face (13), the second smaller face (14), the third smaller face (15) and the fourth smaller face (16).

6. The decoration method according to any one of preceding claims 1-4, wherein the body of the decorated ceramic tile (10) predisposed in step B) has a shape selected from between:- a shape of a transversal section of a circular cylinder or of a cone wherein the first larger face (11) and the second larger face (12) are round and the perimeter surface of the body of the ceramic tile has the shape of a transversal section of the lateral surface, respectively of the cylinder or the cone; and- the shape of a transversal section of an elliptical cylinder wherein the first larger face (11) and the second larger face (12) are elliptical and the perimeter surface of the body of the ceramic tile has a shape of a transversal section of the lateral surface of the elliptical cylinder; wherein the at least a transversal portion of the perimeter surface coincides with the whole perimeter surface.

7. The decoration method of any one preceding claim, wherein step A) of preparing the file in electronic format that encodes an image (17) comprises following substeps:A1) photographing a decorated ceramic tile (10) having a body, in turn, having: a first larger face (11); a second larger face, both being substantially flat and being substantially parallel to one another; and a perimeter surface which joins the first larger face (11) and the second larger face (12) to one another, wherein the first larger face (11) is decorated with a first decoration (D1), obtaining a further file in electronic format which encodes a further image (17) corresponding to the first decoration (D1); andA2) modifying the further image (17) by cloning portions thereof and gluing the portions at the at least an edge of the further image (17) translating and / or mirroring the portions, with respect to at least an edge of the further image (17), so as to obtain the image (17) and the file in electronic format which encodes the image (17).

8. The decoration method of any one preceding claim, wherein the transparent resin is an acrylic polyol resin, wherein step D) of obtaining the solid transparent decoratable layer comprises painting the at least a transversal portion of the perimeter surface with a transparent acrylic polyol paint; wherein the multi-layer film predisposed in step E) of predisposing comprises a first layer made of polyethylene terephthalate (PET) and a second layer made of a polyester resin or a polyamide resin; wherein step J) of digital printing includesdigitally printing, on the second layer of the multi-layer film, also the first portion (42) of the dimensioned image (41) adjacent to the second portion (43) of the dimensioned image (41) and the plurality of reference points (03, P7, P8, P9) of the dimensioned image (41); wherein the step M) of heating comprises use of a oven having an internal temperature comprised between 140-180°C so as to bring the covered ceramic tile (42) / decorated multi-layer film (44) group to a temperature greater than the sublimation temperature of the at least a colorant substance and lower than the temperature of decomposition of the at least a colorant substance; and wherein the solvent of the liquid ink is watery or is water and the at least a colorant substance is an organic colorant.

9. A decorated ceramic tile (1), obtainable by actuating a decoration method according to the preceding claims, comprising: a body, in turn comprising a first larger face (31), a second larger face (32), wherein the first larger face (31) and the second larger face (32) are substantially flat and substantially parallel to one another and a perimeter surface which joins the first larger face (31) and the second larger face (32) to one another; and a first decoration (D1) arranged at the larger face (31) of the body of the decorated ceramic tile (1); characterised in that it further comprises at least a first solid layer: which is fixed to at least a transversal portion of the perimeter surface of the body of the decorated ceramic tile (1) which is transversal, with respect to the first larger face (31), wherein the solid layer comprises: a transparent resin which is decoratable by dye-sublimation and diffusion transfer printing; and a second decoration (D2) comprising, in turn, at least a colorant substance for inks for dye-sublimation and diffusion transfer printing, wherein the at least a colorant substance is in the solid state.

10. The decorated ceramic tile (1) of the preceding claim, wherein the body of the decorated ceramic tile is selected from between:- the shape of a parallelepiped with a rectangular or square base; and further comprises a first smaller face (33), a second smaller face (34), a third smaller face (35), a fourth smaller face (36), which together constitute the perimeter surface of the decorated ceramic tile (1), in which case the at least atransversal portion of the perimeter surface comprises one from among: the first smaller face (33), the second smaller face (34), the third smaller face (35) and the fourth smaller face (36);- the shape of a transversal section of a circular cylinder or a cone wherein the first larger face (31) and the second larger face (32) are round and the perimeter surface of the body of the ceramic tile has a shape of a transversal section of the lateral surface, respectively of the cylinder or the cone and, in which case, the at least a transversal portion of the perimeter surface coincides with the entire perimeter surface; and- a shape of a transversal section of an elliptical cylinder wherein the first larger face (31) and the second larger face (32) are elliptical and the perimeter surface of the body of the ceramic tile has a shape of a transversal section of the lateral surface of the elliptical cylinder and, in which case, the at least a transversal portion of the perimeter surface coincides with the entire perimeter surface.

11. The decorated ceramic tile (1) of any one of claims 8-9, further comprising a second solid layer; which is coloured and, preferably, is white; which is in a resin; and which is arranged between the at least a transversal portion of the perimeter surface and the first solid layer.

Images