Angled Powder Distribution for Full-Body Textured Porcelain Stoneware Slabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ceramic tile production methods fail to achieve a full-body textured pattern effect with natural flowing textures, as they rely on micro-powders lacking fluidity and require multiple distribution steps, resulting in products with artificial traces and limited applicability in cutting, edging, and chamfering.
Innovation Solution
A distribution device comprising a powder-preforming box angled between 61° to 90° with a belt conveying assembly, allowing ceramic raw materials to accumulate and flow under their own weight, forming a fluid-like layout, and adjustable angles for straight or diagonal textures, combined with a feeding assembly for precise control of material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-powder is used for distribution, then a fine pattern effect can be achieved, but the micro-powder lacks fluidity and requires multiple distribution steps, resulting in artificial traces and limited applicability
Solution Approach 1:
The patent changes the particle size parameter from micro-powder (60-100 mesh) to coarse powder (3-5mm), which fundamentally alters the flow characteristics. The coarse powder maintains fluidity and can be distributed in a single step, eliminating the artificial traces caused by multiple distribution steps while still achieving fine pattern effects through controlled distribution mechanisms.
Solution Approach 2:
The patent extracts the fluidity problem from the distribution process by using coarse powder that naturally flows like a fluid. This allows the material to be distributed in a single continuous motion without requiring multiple steps, thereby eliminating the artificial traces and simplifying the operation while maintaining pattern precision.
2Manufacturing precision
If multiple distribution steps are used, then a fine pattern effect can be achieved, but the process becomes complex and creates artificial traces
Solution Approach 1:
The patent merges multiple distribution steps into a single continuous distribution process. By using coarse powder with natural fluidity, the system combines what would otherwise require separate distribution operations into one unified step, reducing process complexity while maintaining pattern precision through controlled single-pass distribution.
Solution Approach 2:
The patent implements continuous distribution in a single pass, eliminating the interruptions and complexity of multiple discrete steps. The coarse powder flows continuously and forms patterns in one uninterrupted motion, simplifying the device requirements while maintaining manufacturing precision through sustained controlled distribution.
3Shape
If ceramic powder accumulates with high and low heights alternately, then a texture can be formed, but the ceramic powder will not flow under gravity on a slope
Solution Approach 1:
The patent changes the particle size parameter to coarse powder (3-5mm) that maintains fluidity even on slopes. This allows the material to flow under gravity while still accumulating to form textures with high and low heights, resolving the contradiction between texture formation and gravitational flow by selecting particles that naturally flow like fluids.
Solution Approach 2:
The patent uses the natural fluidity of coarse powder to enable self-flow under gravity, eliminating the need for external forces to move the material. The coarse powder automatically flows and accumulates to form textures through its inherent properties, combining texture formation with gravitational flow in a self-service manner.
4Manufacturing precision
If inkjet-printed patterns are used, then a surface protective layer can be applied, but the wear resistance of a glazed surface is not as high as the wear resistance of a surface based on clay sands
Solution Approach 1:
The patent changes the material parameter from fine micro-powder to coarse powder (3-5mm), which fundamentally alters the surface structure after sintering. The coarse powder creates a porous, sand-like surface that inherently provides high wear resistance, eliminating the need for additional glazing layers while maintaining precise surface patterns through the controlled distribution of coarse particles.
Solution Approach 2:
The patent creates a composite surface structure where coarse powder particles are distributed throughout the ceramic matrix, forming a dual-layer effect: the base ceramic provides structural integrity while the coarse powder creates a wear-resistant, sand-like surface layer. This composite approach integrates pattern formation with enhanced wear resistance in a single material system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device produces full-body textured porcelain stoneware slabs with a natural flowing effect, overcoming limitations of previous methods by achieving consistent patterns from top to bottom, enhancing market demand for applications like paving, edging, and chamfering, while reducing dust pollution and environmental health risks.
Implementation Method 1
the powder-preforming box is arranged at an included angle α with a conveying plane of the belt conveying assembly, and 61°≤α≤90°, such that a ceramic raw material in the powder-preforming box can rely on its own weight to accumulate and flow in a preforming cavity
Data Source
AI summary
Disclosed is a distribution device and a manufacturing method for a full-body textured porcelain stoneware slab and relates to the field of construction ceramic tile production. The distribution device includes a feeding assembly, a powder-preforming box, and a belt conveying assembly, where the powder-preforming box is arranged at an included angle α with a conveying plane of the belt conveying assembly, and 61°≤α≤90°, and an intersecting line of a lower end of the powder-preforming box and the conveying plane of the belt conveying assembly is at an included angle β with a center line of the conveying plane of the belt conveying assembly, and 45°≤β≤90°. A process using the distribution device can produce a full-body textured porcelain stoneware slab of a natural flowing effect, and can form a straight or diagonal textured pattern effect as needed.