Casting mould, method and plant for manufacturing ceramic sanitary ware

Abstract

A method for manufacturing ceramic sanitary ware (2) by means of pressure casting in a mould (4) comprising at least two mould parts (5A, 5B), the method comprising the following steps: - a mould treatment step, during which an application device (7) applies a first ceramic body comprising a ceramic suspension with a viscosity of 3,000-30,000 cPs on a surface of at least one of the mould parts (5A, 5B) to form a defined decoration (D) thereon; - a step of closing the mould (4), whereby a casting cavity (6) is formed; - a casting step during which a feeding system feeds a second ceramic body under pressure into the casting cavity (6); - a forming step, during which the liquid component of the second ceramic body flows through the walls of the mould parts (5A, 5B) and out of the casting cavity (6), while the solid component is deposited on said walls; and - a demoulding step, during which the finished ceramic sanitary ware (2), with the defined decoration (D) incorporated therein, is extracted from the mould (4).

Description

[0001] CASTING MOULD, METHOD AND PLANT FOR MANUFACTURING CERAMIC SANITARY WARE

[0002] Cross-Reference to Related Applications

[0003] This Patent Application claims priority from Italian Patent Application No . 102024000018043 filed on August 1 , 2024 , the entire disclosure of which is incorporated herein by reference .

[0004] Technical Field

[0005] The present invention concerns a method and a plant for manufacturing ceramic sanitary ware by pressure casting .

[0006] In particular, the present invention is advantageously but not exclusively applied in pressure casting for manufacturing ceramic sanitary ware ( such as wash basins , toilet cisterns , bidets , water closets , etc . ) , to which the following description will explicitly refer without loss of generality .

[0007] Background to the Invention

[0008] Ceramic items , in particular ceramic sanitary ware ( such as wash basins , toilet cisterns , bidets , water closets , etc . ) , are generally formed by casting slip inside hygroscopic permeable moulds , typically made of resin or plaster, to allow dehydration of the slip during the pressure casting, namely outflow of the water contained in the slip through the porous walls of the mould and therefore formation of the ceramic item .

[0009] Typically the pressure casting moulds are composed of two or more mould parts , according to the complexity of the item to be produced, configured to couple with one another in a closed configuration so as to define between them at least one casting cavity, into which, in use , the slip is introduced at high pressure so that following the above-mentioned dehydration, it penetrates into the walls of the mould parts and through them flows out of the mould, causing deposit of the solid part of the slip inside the walls of the mould parts and, therefore , formation of the ceramic item, which is then extracted from the moulds . The piece thus formed typically undergoes successive heat treatments and is coated with a white covering glaze .

[0010] In recent years , in the field of sanitary ware , there is an increasing demand for ceramic items of particular aesthetic value which have , on their exposed surfaces , both internal and external , decorations and / or graphics , for example to reproduce the appearance of natural stone .

[0011] At present , said decorations are generally created by skilled operators after the above casting step, with all the drawbacks in terms of costs , times and precision typical of manual work, or by the application of decals on greenware and glazed products .

[0012] Alternatively, when the type of decoration and structure of the sanitary ware permit , the decoration is printed by means of digital printers that operate directly on the ceramic sanitary ware already formed and glazed .

[0013] The obj ect of the present invention is to provide a method and a plant for manufacturing ceramic sanitary ware which overcome at least partly the drawbacks of the known art , allowing the production of sanitary ware made of ceramic material with particular aesthetic value having di f ferent types of decoration, in a simple inexpensive manner .

[0014] Summary

[0015] In accordance with the present invention, a method and a plant are proposed for manufacturing ceramic sanitary ware , as described in the attached independent claims and preferably in any one of the claims depending directly or indirectly on the mentioned independent claims .

[0016] The claims describe preferred embodiments of the present invention, forming an integral part of the present description .

[0017] Brief Description of the Drawings

[0018] The invention is described below with reference to the attached drawings , which illustrate some non-limiting embodiment examples thereof , in which :

[0019] - figure 1 is a perspective view of a plant for manufacturing ceramic sanitary ware which illustrates an apparatus for manufacturing ceramic sanitary ware consisting of a casting mould for the formation of a wash basin in an open configuration, and two application devices in accordance with an embodiment of the present invention;

[0020] - figure 2 is a perspective view which illustrates one of the two application devices of the plant for manufacturing ceramic sanitary ware of figure 1 during a first step of treatment of a first mould part of the above-mentioned casting mould;

[0021] - figure 3 is a perspective view which illustrates the other of the two application devices of the plant for manufacturing ceramic sanitary ware of figure 1 while the operation of treatment of a second mould part of the above-mentioned casting mould is about to begin; and

[0022] - figure 4 is an enlarged view of the second casting mould part once the treatment operation has been completed;

[0023] - figure 5 is a lateral view of the casting mould with the two mould parts already decorated in the closed configuration during the casting operations ; figure 6 is a perspective view of a wash basin obtained following the casting shown in figure 5 to better illustrate the type of decoration obtained;

[0024] - figure 7 is a perspective view of a further variation of an application device of the plant for manufacturing ceramic sanitary ware ; and

[0025] - figure 8 is a view from above of a ceramic sanitary ware produced by pressure casting with a casting mould treated by means of the application device illustrated in figure 7 . Detailed Disclosure

[0026] In the attached figures, the number 1 indicates overall a plant for manufacturing ceramic sanitary ware 2 by means of pressure casting.

[0027] In particular, the present description will refer explicitly to the production of sanitary ware 2 made of ceramic material such as, for example, wash basins (as in the attached figures) , water closets, etc. without loss of generality. In other words, the ceramic items 2 produced by the manufacturing plant 1 are intended, after successive treatments, for example drying, glazing, firing etc., to form finished ceramic products, in particular ceramic sanitary ware 2; even more specifically, decorated ceramic sanitary ware 2.

[0028] It should be noted that in the present description the terms "upper", "lower", "lateral", "right", "left", "front", "rear", are used with reference to the plant 1 for manufacturing ceramic sanitary ware 2 arranged resting on a horizontal surface. Therefore, for example, the terms "at the top" or "at the bottom" indicate respectively "which is above" or "which is below" with respect to another component of the plant 1 for manufacturing ceramic sanitary ware 2. Furthermore, in the context of the present description, the term "second" does not necessarily imply the presence of a "first". Said terms are at times used as labels for greater clarity.

[0029] With particular reference to the attached figures (see in particular figures 1, 2, 3, 5 and 7) , the plant 1 for manufacturing ceramic sanitary ware 2 comprises at least one apparatus 3 for manufacturing ceramic sanitary ware 2 by means of pressure casting; in the case illustrated, an apparatus 3 for manufacturing a ceramic wash basin 2, known per se. Said apparatus 3 for manufacturing ceramic sanitary ware 2 comprises, in turn, at least one mould 4 (more advantageously but without limitation, a plurality of moulds 4 each) comprising (in particular, consisting of) at least two mould parts 5A, 5B, advantageously but without limitation complementary to each other, reciprocally movable between a closed configuration C, in which the mould parts 5A, 5B are coupled to each other to define between them a casting cavity 6, and an open configuration A, in which the mould parts 5A, 5B are uncoupled from each other.

[0030] In detail, advantageously but without limitation, the mould 4, namely the mould parts 5A, 5B comprise at least a portion (in particular are made) of permeable porous material; more advantageously of porous resin having a (total open) porosity of at least 10%, in particular up to 50% (more specifically, up to 28%) by volume, with respect to the volume of the portion of the mould parts 5A, 5B .

[0031] The porosity is measured by mercury porosimetry with a Pascal 140 / 240 porosimeter by Thermo Fisher Scientific (following the instructions enclosed therewith) . The principles and operation of mercury porosimetry are well known and are described, for example, in: Mercury Porosimetry: a General (Practical) Overview, Part. Part. Syst. Charact. 23 (2006) 1-11, Herbert Giesche, DOI: 10.1002 / ppsc .200601009; Characterization of Porous Solids and Powders: Surface Area, Pore Size and Density, S. Lowell, Joan E. Shields, Martin A. Thomas and Matthias Thommes, Kluwer Academic Publishers 2004, ISBN 1- 4020-2302-2 (HB) , ISBN 1-4020-2302-0 (e-book) . In particular, the porosity is measured according to the ISO 15901-1:2016 standard .

[0032] The total open porosity is the porosity measured considering the pores open (and not the pores closed) , namely the pores that can be accessed by a fluid (ISO 15901-1:2016) .

[0033] Advantageously but not necessarily, the mould 4 (in particular all the mould parts 5A, 5B; more in particular, the cited resin that forms it / them) has pores with a median diameter ranging from 0.5 (in particular, approximately 5 pm) to 80 pm (in particular, approximately 15 pm) .

[0034] Unless specified otherwise, in the present text, by diameter of a pore we mean the limiting diameter, namely the diameter of a circle having the same area as the smallest (cross) section of the pore.

[0035] The median diameter of the pores is measured by mercury porosimetry with a Pascal 140 / 240 porosimeter by Thermo Fisher Scientific (following the instructions enclosed therewith) . The principles and operation of mercury porosimetry are well known. In particular, the median diameter of the pores is measured as established by the ISO 15901-1:2016 standard.

[0036] It should be noted that by median diameter we mean the diameter that corresponds to the fiftieth percentile of the volume of the pores, namely the diameter for which half of the volume of the pores is in the larger pores and half of the volume of the pores is in the smaller pores (ISO 15901-1:2016, in particular paragraph 3.16) .

[0037] According to other advantageous but non-limiting embodiments, the mould 4, namely the mould parts 5A, 5B comprise at least one portion (in particular are made) of plaster.

[0038] Advantageously, the apparatus 3 for manufacturing ceramic sanitary ware 2 further comprises at least one feeding system (not shown in the attached figures) configured to feed a ceramic body, known as slip, comprising (in particular, consisting of) approximately 50% a 55% by weight of a plastic and semiplastic component which, in turn, comprises (in particular, consists of) clay and kaolin, approximately 45% a turn, comprises ( in particular, consists of ) feldspar minerals , quartz minerals and chamotte , and approximately 0 . 1 % a 15% of inorganic dyes ( or oxides ) under pressure in the casting cavity 6 to form the ceramic sanitary ware 2 , in the case illustrated the wash basin .

[0039] Advantageously but without limitation, the feeding system is configured to feed the above-mentioned ceramic body into the casting cavity 6 with a pressure above approximately 0 . 2 bar ; more advantageously, with a pressure ranging from 0 . 2 to 3 bar .

[0040] Alternatively or in combination, advantageously but without limitation, the apparatus 3 for manufacturing ceramic sanitary ware 2 also comprises a hydraulic system ( known per se and not detailed or illustrated here ) configured to feed a fluid comprising ( in particular consisting of ) air and / or water under pressure into the walls of the mould 4 ( in particular, each of the mould parts 5A, 5B as will be further explained below) during casting of the ceramic sanitary ware 2 to facilitate the formation and / or extraction of said ceramic sanitary ware 2 .

[0041] Furthermore , advantageously but without limitation, the apparatus 3 for manufacturing ceramic sanitary ware 2 also comprises an actuator system (not shown in the attached figures and known per se , therefore not described in detail ) configured to control the reciprocal movement of the mould parts 5A, 5B . In detail , according to some non-limiting embodiments , the actuator system moves the male mould part 5B by means of an actuator (not shown in the attached figures ) , which pushes the male mould part 5B against the female mould part 5A which is fixed . Alternatively, the actuator system moves the female mould part 5A against the male mould part 5B which is fixed . According to further non-limiting embodiments not illustrated, the actuator system comprises two actuators , each of which move a respective mould part 5A, 5B between the closed configuration C and the open configuration A and vice versa .

[0042] The plant 1 for manuf cturing ceramic sanitary ware 2 further comprises at least one application device 7, advantageously but without limitation arranged at a mould treatment station 8, and configured to apply, according to a defined pattern, a further ceramic body, comprising (in particular, consisting of) a ceramic suspension having a viscosity ranging from approximately 3000 CPS (namely 3 Pa.s) to approximately 30000 CPS (namely 30 Pa.s) ; more advantageously but without limitation, from approximately 10000 CPS (namely 10 Pa.s) to approximately 30000 CPS (namely 30 Pa.s) , on at least one surface of at least one of the above-mentioned mould parts 5A, 5B to form a defined decoration D which is configured to remain incorporated in the walls of the ceramic sanitary ware 2 when the liquid component of the above-mentioned ceramic body (in particular, of the above-mentioned slip) fed by the feeding system flows out of the casting cavity 6 through the walls of the mould parts 5A, 5B and the solid component is deposited on the internal part of said walls to form the ceramic sanitary ware 2; in other words, during the slip dehydration process via the mould parts 5A, 5B which results in formation of the ceramic sanitary ware 2.

[0043] Advantageously but without limitation, the ceramic suspension of the further ceramic body comprises: approximately 50% to approximately 55% by weight of a plastic and semiplastic component which, in turn, comprises (in particular, consists of) clay and kaolin, approximately 45% a 50% of a further nonplastic (or hard) component which, in turn, comprises (in particular, consists of) feldspar minerals, quartz minerals and chamotte; 0.1% to approximately 15% by weight of inorganic dyes (or oxides) ; and approximately 0.01% to 1% by weight of additives, for example organic flocculants and / or acetic acid, adapted to vary the viscosity of the ceramic body up to the above values (namely 3000 - 30000 CPS ; more in particular, 10000 - 30000 CPS ) . Said viscosity value advantageously guarantees that the defined decoration D maintains its form, thus guaranteeing the quality and the definition of the defined decoration D, which will then be incorporated in the walls of the ceramic sanitary ware 2 , as explained above , in addition to the stability and separability thereof .

[0044] Alternatively or additionally, advantageously but without limitation, the inorganic dyes comprised in said further ceramic body are , at least partially, di f ferent from the organic dyes present in the ceramic body ( slip ) which is fed by the above-mentioned feeding system for casting of the ceramic sanitary ware 2 so that the defined decoration D is di f ferent and distinguishable from the rest of the ceramic sanitary ware 2 .

[0045] According to some advantageous but non-limiting embodiments such as , for example , those illustrated in the attached figures , the plant 1 for manufacturing ceramic sanitary ware 2 comprises a plurality of application devices 7 for treating the ( or when the manufacturing apparatus 3 comprises several moulds 4 , each) mould 4 , for example a number of application devices 7 equal to the number of mould parts 5A, 5B that forms the ( or each) mould 4 .

[0046] More advantageously but without limitation, in this case , the various application devices 7 can all be the same as one another or di f ferent from one another .

[0047] According to some advantageous but non-limiting embodiments such as , for example , the one illustrated in figures 1 , 2 and 3 , the ( in particular, at least one ) application device 7 comprises ( in particular, consists of ) : a support structure 9 , advantageously but without limitation movable in space ; an application head 10 which is carried by the support structure 9 and which, in turn, comprises at least a delivery noz zle 11 configured to deliver a filament of the above-mentioned further ceramic body having a thickness ranging from approximately 1 mm to approximately 10 mm, and a controller (not shown in the attached figures ) to control the support structure 9 and the application head 10 so that the noz zle 11 applies the above-mentioned ceramic body filament on the surface to be treated of at least one ( in particular, of each) of the mould parts 5A, 5B forming a bead having a thickness ranging from approximately 1 mm to approximately 10 mm .

[0048] More advantageously but without limitation, the application head 10 comprises a plurality of noz zles 11 , each configured to deliver a certain type of ceramic body, di f ferent from the remaining types in terms of colour, viscosity, type of additives etc .

[0049] Even more advantageously but without limitation, the above- mentioned ( or each) noz zle 11 comprises a delivery outlet having a diameter of 0 . 5 a 5 mm .

[0050] According to some advantageous but non-limiting embodiments such as , for example , those illustrated in figures 1 and 2 , the support structure 9 comprises ( in particular consists of ) an anthropomorphic robot .

[0051] According to some advantageous but non-limiting embodiments such as , for example , those illustrated in figures 1 and 3 , the support structure 9 comprises ( in particular , consists of ) a fixed frame arranged in the mould treatment station 8 which carries the above-mentioned appl ication head 10 . In this case , advantageously but without limitation, the plant 1 for manufacturing ceramic sanitary ware 2 comprises at least one retrieving device 12 configured to move at least one mould part 5A, 5B at a time until reaching the above-mentioned application head 10 . In particular, in the advantageous but non-limiting embodiment illustrated in figure 3 , said retrieving device 12 comprises ( in particular, consists of ) an anthropomorphic robot provided with a gripping head, for example vacuum-operated, to retrieve and move the mould parts 5A, 5B .

[0052] Alternatively or additionally, according to some advantageous but non-limiting embodiments such as , for example , those illustrated in figure 7 , the ( in particular, at least one ) application device 7 comprises a support structure 9 , advantageously but without limitation movable in space ; an application head 10 which is carried by the support structure 9 and which, in turn, comprises at least one printing pad 13 ( advantageously but without limitation a plurality of printing pads 13 as shown in figure 7 ) ; at least one tray (not visible in the attached figures ) configured to contain a matrix ( known per se and typically defined as a "cliche" ) having an image to be reproduced and a certain type of the further ceramic body as above to cover said matrix ; and a controller ( also not illustrated) configured to control the support structure 9 so as to move the application head 10 at least between a first position, in which the ( in particular, at least one ) printing pad 13 is placed in contact with the matrix immersed in the above-mentioned certain type of ceramic body, and a second position, in which the ( in particular, at least one ) printing pad 13 is brought into contact with the surface to be treated of the mould part 5A, 5B thus leaving a print of the printing pad 13 ( in particular, of said matrix ) on said surface and forming a treated mould part 5A, 5B ; more in particular, having a defined decoration D .

[0053] Advantageously but without limitation, the plant 1 for manufacturing ceramic sanitary ware 2 comprises a control unit CU, only schematically illustrated in figure 1 , configured to control the operation at least of the apparatus 3 for manufacturing ceramic sanitary ware 2 and of the , in particular of each, application device 7 .

[0054] Even more advantageously but without limitation, in this case , the control unit CU is configured (programmed) to operate the (namely each) application device 7 so that the latter applies the defined decoration D on the surface of at least one ( in particular of each) of the mould parts 5A, 5B, when the mould 4 is in the open configuration A, and to operate the apparatus 3 for manufacturing ceramic sanitary ware 2 ( in particular, the mould parts 5A, 5B and the feeding system) so that the above-mentioned further body is inj ected into the casting cavity 6 , once the mould parts 5A, 5B ( at least one of which bears the defined decoration D) are in the closed configuration C, and so that the feeding system inj ects the above-mentioned slip with a pressure and a feeding speed such as to guarantee that the defined decoration D remains incorporated in the walls of the ceramic sanitary ware 2 during the dehydration process .

[0055] According to some advantageous but non-limiting embodiments , the control unit CU is configured to operate the feeding system so that the above-mentioned further body is inj ected into the casting cavity 6 at a variable pressure ranging from approximately 0 . 2 to approximately 3 bar .

[0056] Advantageously but without limitation, the control unit CU is configured to control the application of the above-mentioned further body on the various mould parts 5A, 5B, thus , for example , creating specular defined decorations D on the mould parts 5A, 5B intended to form the internal and external walls of the ceramic sanitary ware 2 or in any case combining as required the various parts of the defined decoration D . In other words , the control unit CU coordinates the action of the various controllers of the various application devices , thus automatically carrying out a certain treatment on each mould part 5A, 5B to be treated .

[0057] Advantageously but without limitation, the above-mentioned controller of the ( in particular, of each) application device 7 communicates with a control unit CU, namely it is controlled by said control unit CU . Even more advantageously but without limitation, the above-mentioned controller of the ( in particular, of each) application device 7 is comprised in ( in particular, coincides with) the control unit CU .

[0058] According to some advantageous but non-limiting embodiments , the ( in particular, each) appl ication device 7 comprises a writable memory ( advantageously but without limitation comprised in the above-mentioned controller of the application device 7 ) configured to contain : a library of defined decorations D which associates with each of said defined decorations D the number of mould parts 5A, 5B to be treated, the type ( for example colour, thickness etc . ) of the further body with which to create the defined decoration D and the corresponding defined pattern along which said application device 7 must be moved; more advantageously, the application head 10 .

[0059] According to some advantageous but non-limiting embodiments , the apparatus 3 for manufacturing ceramic sanitary ware 2 comprises a hydraulic system (not visible in the attached figures and which advantageously coincides with the one described above ) which is configured to feed at least one fluid comprising ( in particular, consisting of ) air under pressure through the walls of each of the mould parts 5A, 5B and which can be selectively operated to deliver said fluid under pressure through the walls of the mould parts 5A, 5B to be treated, when the mould 4 is in the open configuration A, for a defined time ( in particular for the time necessary to guarantee the formation of a ceramic sanitary ware 2 which has walls with thickness ranging from 8 to 14 mm) thus stabili zing the defined decoration D before closing the mould 4 and carrying out the casting of the ceramic sanitary ware 2 . This ensures the stability of the defined decoration D before using the mould 4 to form the ceramic sanitary ware 2 . Said solution is particularly advantageous when the mould part 5A, 5B to be treated is oriented along an inclined plane with respect to the hori zontal ; in this way, in fact , it is possible to avert the risk of the ceramic body deposited by the application device 7 being deformed by the ef fect of gravity .

[0060] Alternatively or additionally, advantageously but without limitation, in this case , the control unit CU is configured to operate the retrieving device 12 so that , once the mould part 5A, 5B to be treated ( therefore intended to receive the defined decoration D) has been retrieved, it orients it according to a first defined orientation, with the surface intended to receive the defined decoration D arranged substantially hori zontally (namely lying / extending on a substantially hori zontal plane ) and facing upwards .

[0061] According to some advantageous but non-limiting embodiments , the plant 1 for manufacturing ceramic sanitary ware 2 comprises a glazing device , known per se and not described in detail here , for example of the spray type , configured to apply a layer of transparent covering material , comprising ( in particular, consisting of ) transparent glaze on the finished ceramic sanitary ware 2 prior to the subsequent steps of heat treatment of the ceramic sanitary ware 2 , thus coating the finished ceramic sanitary ware 2 without covering the defined decoration D .

[0062] According to a further aspect of the present invention, a manufacturing method of ceramic sanitary ware 2 is proposed which, advantageously but without limitation, is implemented by a plant 1 for manufacturing ceramic sanitary ware 2 of the type described above .

[0063] Advantageously, the method of manufacturing ceramic sanitary ware 2 provides for the use of an apparatus 3 for manufacturing ceramic sanitary ware 2 advantageously of the type described above comprising a mould 4 which, in turn, comprises at least two mould parts 5A, 5B (more advantageously but without limitation, a plurality of mould parts 5A, 5B ) , each having at least one portion made of porous and permeable material , more advantageously made of a porous resin such as the one described above , and reciprocally movable between a closed configuration C, in which they are coupled to each other to define between them a casting cavity 6 , and an open configuration A, in which they are uncoupled from each other .

[0064] The method of manufacturing ceramic sanitary ware comprises the following steps : a mould treatment step, during which the mould parts 5A, 5B are in the open configuration A, thus being accessible from the outside , and at least one application device 7 , advantageously but without limitation made according to one of the embodiments described above , which applies a first ceramic body, comprising ( in particular, consisting of ) a ceramic suspension having a viscosity ranging from approximately 3000 CPS (namely 3 Pa . s ) to approximately 30000 CPS (namely 30 Pa . s ) ; more advantageously but without limitation, from approximately 10000 CPS (namely 10 Pa . s ) to approximately 30000 CPS (namely 30 Pa . s ) , as already explained above , according to a pattern defined on at least one surface of at least one ( in particular, of each) mould part 5A, 5B to form a defined decoration D on said surface .

[0065] Even more advantageously but without limitation, as already explained in relation to the plant 1 for manufacturing ceramic sanitary ware 2 as above , the ceramic suspension of the ceramic body applied during said mould treatment step comprises : approximately 50% to approximately 55% by weight of a plastic and semiplastic component which, in turn, comprises ( in particular, consists of ) clay and kaolin, approximately 45% a 50% of a further non-plastic ( or hard) component which, in turn, comprises ( in particular, consists o f ) feldspar minerals , quartz minerals and chamotte ; 0 . 1 % to approximately 15% by weight of inorganic dyes ( or oxides ) , more advantageously di fferent from those contained in the body that forms the ceramic sanitary ware 2 ; and approximately 0 . 01 % to 1 % by weight of additives , for example organic flocculants and / or acetic acid, adapted to vary the viscosity of the ceramic body up to the above values (namely 3000 - 30000 CPS ; more advantageously but without limitation, 10000 - 30000 CPS ) , thus guaranteeing the quality, definition, separability and stability of the defined decoration D .

[0066] The manufacturing method of ceramic sanitary ware 2 further comprises : a closing step, subsequent to the mould treatment step, during which the above-mentioned mould parts 5A, 5B ( at least one of which comprising the defined decoration D) , are moved from the open configuration A to the closed configuration C, advantageously by means of an actuator system of the type described above ; a casting step, subsequent to the closing step, during which a feeding system, advantageously but without limitation of the type described above , feeds a second ceramic body, the slip, advantageously of the same type as described above, comprising ( in particular, consisting of ) approximately 50% a 55% by weight of a plastic and semiplastic component which, in turn, comprises ( in particular, consists of ) clay and kaolin, and approximately 45-50% of a further non-plastic ( or hard) component which, in turn, comprises ( in particular, consists of ) feldspar minerals , quartz minerals and chamotte , and approximately 0 . 1 % a 15% of inorganic dyes ( or oxides ) under pressure into the casting cavity 6 ; and a formation step, during which the liquid component of the above-mentioned slip flows out of the casting cavity 6 via the mould parts 5A, 5B and the solid component is deposited on the walls of said mould parts 5A, 5B incorporating the above- mentioned defined decoration D .

[0067] More advantageously but without limitation, it is highlighted ( as will be further explained below) , that , in use , as the ceramic sanitary ware 2 is being formed, namely as the liquid component of the ceramic body flows out of the mould 4 , defining the di f ferent walls of the ceramic sanitary ware 2 , the defined decoration D created in the mould treatment step is incorporated in the walls of the ceramic sanitary ware 2 thus detaching from the above-mentioned mould part 5A, 5B when the ceramic sanitary ware 2 is demoulded and forming a ceramic sanitary ware 2 bearing the above-mentioned defined decoration D .

[0068] Advantageously but without limitation, during the casting step the above-mentioned slip is fed into the casting cavity 6 with a pressure higher than approximately 0 . 2 bar ; more advantageously between 0 . 2 and 3 bar .

[0069] According to some advantageous but non-limiting embodiments , the manufacturing method of the ceramic sanitary ware 2 comprises a demoulding step, during which the mould parts 5A, 5B are moved from the closed configuration C to the open configuration A and the finished ceramic sanitary ware 2 , with the defined decoration D incorporated therein, is extracted from the mould 4 .

[0070] In detail , when the application device 7 comprises ( in particular, consists of ) : a support structure 9 , advantageously but without limitation movable in space ; an application head 10 which is carried by the support structure 9 and which, in turn, comprises at least a delivery noz zle 11 (more advantageously, a plurality of delivery noz zles 11 , each) configured to deliver a filament of the above-mentioned further ceramic body, as explained more clearly above in relation to the plant 1 for manufacturing ceramic sanitary ware 2 , the mould treatment step comprises : a first sub-step, during which at least a certain type of the first body is fed to the application head 10 , and a second sub-step, ( at least partially) subsequent to the first sub-step, during which the controller of the application device 7 ( in particular, the control unit CU) controls the support structure 9 to move with respect to the surface of the ( in particular, of each) mould part 5A, 5B to be treated according to a defined pattern while the application head 10 is operated to deliver the filament , thus producing at least a bead having a thickness ranging from approximately 1 mm to approximately 10 mm of said first type of the first body on the surface of the ( in particular, of each) mould part 5A, 5B thus forming said defined decoration D .

[0071] Alternatively or additionally, when the application device 7 comprises ( in particular, consists of ) : a support structure 9 , an application head 10 which is carried by the support structure 9 and in turn comprises at least one printing pad 13 , as explained more clearly above in relation to the plant 1 for manufacturing ceramic sanitary ware 2 , the mould treatment step comprises at least a first sub-step, during which the controller of the application device 7 ( in particular, the control unit CU) operates the support structure 9 to move at least one printing pad 13 until immersing it in the above- mentioned tray in contact with the above-mentioned matrix ; and a second sub-step, during which the controller of the application device 7 ( in particular, the control unit CU) controls the support structure 9 to bring the printing pad 13 soaked in the above-mentioned body in contact with the surface of at least one ( in particular, of each) mould part 5A, 5B thus leaving a print of the printing pad 13 ( in particular, of the matrix ) on the ( in particular, on each) mould part 5A, 5B and forming the defined decoration D . Advantageously but without limitation, the method of manufacturing the ceramic sanitary ware 2 comprises a consolidation step which is ( at least partially) prior to the mould closing step and ( at least partially) subsequent to the mould treatment step, during which a hydraulic system, advantageously but without limitation of the type described above , feeds a fluid comprising ( in particular, consisting of ) air under pressure through ( in particular, each of ) the mould parts 5A, 5B bearing the defined decoration D to stabili ze it before said casting step .

[0072] This advantageously allows the defined decoration D to be stabili zed, namely obtain a def ined decoration D having an adequate strength / humidity percentage , as mentioned above , in less time and / or also in more disadvantageous conditions , for example when the body that forms the defined decoration D is applied on mould parts 5A, 5B inclined with respect to the hori zontal .

[0073] According to some advantageous but non-limiting embodiments , the method of manufacturing ceramic sanitary ware 2 comprises a coating step, during which a glazing device applies a layer of transparent covering material , comprising ( in particular consisting of ) transparent glaze on said finished ceramic sanitary ware .

[0074] According to some advantageous but non-limiting embodiments , the method of manufacturing ceramic sanitary ware 2 comprises an orientation step ( at least partially) preceding the mould treatment step, during which the ( in particular, each) mould part 5A, 5B intended to receive the defined decoration D is oriented according to a first defined orientation, in which the surface intended to receive the defined decoration D lies on a substantially hori zontal plane and faces upwards .

[0075] According to a further aspect of the present invention, a casting mould 4 is proposed for manufacturing ceramic sanitary ware 2 advantageously obtained via a treatment process according to the mould treatment step of the method for manufacturing ceramic sanitary ware 2 as above .

[0076] In detail , advantageously, the casting mould 4 comprises at least two mould parts 5A, 5B complementary and reciprocally movable between a closed configuration C, in which they are coupled to one other to define between them a casting cavity 6 , and an open configuration A, in which they are uncoupled from one another .

[0077] In detail , the mould 4 has on at least one surface of at least one of the mould parts 5A, 5B ( in particular, each of the mould parts 5A, 5B ) a defined decoration D which is created with a ceramic body comprising a ceramic suspension having a viscosity between approximately 3000 CPS and approximately 30000 CPS and protrudes from the surface for a stretch of at least approximately 1 mm ( in particular 1 mm to 10 mm) . As explained above , said defined decoration D is created so as to be incorporated in the walls of the ceramic sanitary ware 2 , when the casting mould 4 is used ( in a per se known manner ) for the pressure casting of ceramic sanitary ware 2 . Even more advantageously but without limitation, said defined decoration D is applied on one or more of the mould parts 5A, 5B by means of an application device 7 of the type described above .

[0078] Advantageously but without limitation, the mould 4 ( in particular, each mould part 5A, 5B ) comprises ( in particular, is made of ) porous and permeable material ; even more advantageously of porous resin such as the one described above or, alternatively, plaster .

[0079] Thanks to the plant 1 and method for manufacturing ceramic sanitary ware 2 and the casting mould 4 as above , advantageously it is possible to manufacture ceramic sanitary ware 2 decorated as needed in a simple and totally automatic manner and without requiring decoration steps subsequent to the casting, thus improving the ef ficiency of the method and the plant 1 for manufacturing ceramic sanitary ware 2 .

[0080] Furthermore , the present invention, in which the defined decoration D is created with a ceramic body substantially of the same type as the one that forms the walls of the ceramic sanitary ware 2 , and above all in which said defined decoration D remains incorporated in the walls of the ceramic sanitary ware 2 during the casting step, guarantees full adhesion of the defined decoration D to the ceramic sanitary ware 2 .

Claims

CLAIMS1. A method for manufacturing ceramic sanitary ware (2) by means of an apparatus for manufacturing ceramic sanitary ware comprising a mould (4) , which, in turn, comprises at least two mould parts (5A, 5B) mutually movable between a closed configuration (C) , in which they are coupled to one another to define, between them, a casting cavity (6) , and an open configuration (A) , in which they are uncoupled from one another; the method for manufacturing ceramic sanitary ware (2) comprises the following steps: a mould treatment step, during which said at least two mould parts (5A, 5B) are in the open configuration (A) and at least one application device (7) applies a first ceramic body, comprising (in particular, consisting of) a ceramic suspension, having a viscosity ranging from approximately 3000 CPS to approximately 30000 CPS, according to a pattern defined on at least one surface of at least one of said at least two mould parts (5A, 5B) in order to form a defined decoration (D) on said surface of said at least one mould part (5A, 5B) ; a closing step, which is subsequent to said mould treatment step and during which said at least two mould parts (5A, 5B) , at least one of them comprising said defined decoration (D) , are moved from said open configuration (A) to said closed configuration (C) ; a casting step, which is subsequent to said closing step and during which a feeding system feeds a second ceramic body, comprising a water suspension of ceramic material, which, in turn, comprises (in particular, consists of) approximately 50% a 55% by weight of a plastic and semi-plastic component, approximately 45 a 50% of a further non-plastic component and approximately 0.1% a 15% of inorganic dyes, under pressure into said casting cavity (6) ; a forming step, during which the liquid component of said at least one second ceramic body flows out of said casting cavity (6) through said at least two mould parts (5A, 5B) and thesolid component is deposited on the walls of said at least two mould parts (5A, 5B) incorporating said defined decoration (D) ; and a demoulding step, during which said at least two mould parts (5A, 5B) are moved from the closed configuration (C) to the open configuration (A) and said finished ceramic sanitary ware (2) , with the defined decoration (D) incorporated therein, is extracted from said mould (4) .

2. The method for manufacturing ceramic sanitary ware (2) according to claim 1, comprising a consolidation step, which is at least partially prior to said closing step and at least partially subsequent to said mould treatment step and during which a hydraulic system, which is comprised in said apparatus (3) for manufacturing ceramic sanitary ware (2) , feeds a fluid comprising (in particular, consisting of) air through said at least one of said at least two mould parts (5A, 5B) bearing said defined decoration (D) to stabilize said defined decoration (D) prior to said casting step.

3. The method for manufacturing ceramic sanitary ware (2) according to claim 1 or 2, wherein: said application device (7) comprises a support structure (9) movable in space, an application head (10) , which is carried by said support structure (9) and, in turn, comprises at least one nozzle (11) configured to deliver a filament of said first ceramic body, having a thickness ranging from approximately 1 mm to approximately 10 mm, and a controller for controlling said support structure (9) and said application head (10) ; said mould treatment step comprises, in turn: a first substep, during which at least a certain type of said first body is fed to said application head (10) , and a second sub-step, which is at least partially subsequent to said first sub-step and during which said controller controls said support structure (9) so that it moves relative to said at least one (in particular, each) of said mould parts (5A, 5B) to betreated according to a defined pattern, while said application head (10) is operated to deliver said filament so as to create at least one bead having a thickness ranging from approximately 1 mm to approximately 10 mm of said first type of said first body on said surface of said at least one of said mould parts (5A, 5B) so as to form said defined decoration (D) .

4. The method for manufacturing ceramic sanitary ware (2) according to claim 1 or 2, wherein: said application device (7) comprises: a support structure (9) , an application head (10) , which is carried by said support structure (9) and, in turn, comprises at least one printing pad (14) , at least one tray containing a matrix having an image to be reproduced and a certain type of said first body, which covers said matrix, and a controller for controlling said support structure (9) and said application head (10) ; said mould treatment step comprises at least a first sub-step, during which said controller operates said support structure (9) so as to move said at least one printing pad (14) until it is immersed in said tray in contact with said matrix; and a second sub-step, during which said controller controls said support structure (9) so as to bring said at least one printing pad (14) , soaked in said type of said first body, into contact with said at least one surface of at least one of said mould parts (5A, 5B) so as to leave a print of said printing pad (14) on said at least one of said two mould parts (5A, 5B) and form said defined decoration (D) .

5. The method for manufacturing ceramic sanitary ware (2) according to any one of the preceding claims, comprising an orientation step, which is at least partially prior to said mould treatment step and during which at least said (in particular, each) mould part (5A, 5B) intended to receive said defined decoration (D) is oriented according to a firstdefined orientation, in which the surface of said at least one mould part (5A, 5B) intended to receive said defined decoration (D) lies on a substantially horizontal plane and faces upwards.

6. The method for manufacturing ceramic sanitary ware (2) according to any one of the preceding claims, comprising a coating step, during which a glazing device applies a layer of transparent covering material, comprising (in particular, consisting of) a transparent glaze, on said finished ceramic sanitary ware (2) .

7. A plant (1) for manufacturing ceramic sanitary ware (2) through pressure casting comprising: at least one apparatus (3) for manufacturing ceramic sanitary ware, which in turn comprises: at least one mould (4) comprising (in particular, consisting of) at least two mould parts (5A, 5B) mutually movable between a closed configuration (C) , in which said at least two mould parts (5A, 5B) are coupled to one another to define, between them, a casting cavity (6) , and an open configuration, in which said at least two mould parts (5A, 5B) are uncoupled from one another, a feeding system configured to feed a ceramic body comprising (in particular, consisting of) approximately 50% a 55% by weight of a plastic and semi-plastic component, approximately 45-50% of a further non-plastic component, approximately 0.1% a 15% of inorganic dyes under pressure into said casting cavity (6) to form at least one ceramic sanitary ware (2) ; at least one application device (7) configured to apply, according to a defined pattern, a further ceramic body, comprising (in particular, consisting of) a ceramic suspension having a viscosity ranging from approximately 3000 CPS to approximately 30000 CPS, on at least one surface of at least one of said at least two mould parts (5A, 5B) to form a defined decoration (D) , which is configured to remain incorporated in the walls of said ceramic sanitary ware (2) ,when the liquid component of said ceramic body fed by the feeding system flows out of said casting cavity (6) through said at least two mould parts (5A, 5B) and the solid component is deposited on the walls of said at least two mould parts (5A, 5B) to form the ceramic sanitary ware.

8. The plant (1) for manuf cturing ceramic sanitary ware (2) according to claim 7, wherein said at least one application device (7) comprises a writable storage memory configured to contain: a library of defined decorations (D) , which associates with each of said defined decorations (D) the number of mould parts (5A, 5B) to be treated, the type of said further body with which to create the defined decoration (D) , and the corresponding defined pattern, along which said application device (7) must be moved.

9. The plant (1) for manufacturing ceramic sanitary ware (2) according to claim 7 or 8, wherein said at least one application device (7) comprises, in turn, a support structure (9) , an application head (10) , which is carried by said support structure (9) and, in turn, comprises at least one delivery nozzle (11) (in particular, a plurality of delivery nozzles (11) , each) configured to deliver a filament of said further ceramic body having a thickness ranging from approximately 1 mm to approximately 10 mm, and a controller for controlling said support structure (9) and said application head (10) so that said at least one nozzle (11) applies said filament on said at least one surface of at least one (in particular, each) of said at least two mould parts (5A, 5B) , forming a bead having a thickness ranging from approximately 1 mm to approximately 10 mm; said at least one nozzle (11) (in particular, each nozzle (11) ) comprising a delivery outlet having a diameter of approximately 0.5mm a 5 mm.

10. The plant (1) for manufacturing ceramic sanitary ware (2)according to claim 7 or 8, wherein said at least one application device (7) comprises: a support structure (9) ; at least one tray to contain a matrix having an image to be reproduced and a certain type of said further body to cover said matrix; an application head (10) , which is carried by said support structure (9) and, in turn, comprises at least one printing pad ( 14 ) ; and a controller configured to control said support structure (9) so as to move said application head (10) at least between a first position, in which said printing pad (14) is in contact with said matrix immersed in said certain type of said further body, and a second position, in which said at least one printing pad (14) is brought into contact with said at least one surface of at least one of said two mould parts (5A, 5B) so as to leave a print of said printing pad (in particular, said matrix) on said at least one surface of said (in particular, of each) mould part (5A, 5B) .

11. The plant (1) for manuf cturing ceramic sanitary ware (2) according to any one of the claims from 7 to 10, wherein said at least one apparatus (3) for manufacturing ceramic sanitary ware (2) comprises a hydraulic system configured to feed at least one fluid comprising (in particular, consisting of) air under pressure through the walls of each of said at least two mould parts (5A, 5B) ; said hydraulic system being selectively operable to deliver said first fluid under pressure through said walls of said mould parts (5A, 5B) for a defined time so as to stabilize said defined decoration (D) .

12. The plant (1) for manufacturing ceramic sanitary ware (2) according to any one of the claims from 7 to 11, comprising at least one retrieving device (13) configured to retrieve said at least one of said at least two mould parts (5A, 5B) and move it towards a treatment station (8) ;in particular, said retrieving device (13) is configured to orient said mould part (5A, 5B) intended to receive said defined decoration (D) according to a first defined orientation, in which the surface intended to receive said defined decoration (D) lies on a substantially horizontal plane and faces upwards.

13. The plant (1) for manufacturing ceramic sanitary ware (2) according to any one of the claims from 7 to 12, comprising a glazing device configured to apply a layer of transparent covering material, comprising (in particular, consisting of) a transparent glaze, on said finished ceramic sanitary ware (2) .

14. A casting mould (4) for manufacturing ceramic sanitary ware (2) comprising at least two complementary mould parts (5A, 5B) mutually movable between a closed configuration (C) , in which they are coupled to one another to define, between them, a casting cavity (6) , and an open configuration (A) , in which they are uncoupled from one another; at least one of said mould parts (5A, 5B) (in particular, each of said mould parts (5A, 5B) ) comprising at least one defined decoration (D) , which is made of a ceramic body comprising (in particular, consisting of) a ceramic suspension having a viscosity ranging from approximately 3000 CPS to approximately 30000 CPS and protrudes from said at least one surface for a stretch of at least approximately 1 mm (in particular, from 1 mm to 10 mm) .

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