Ceramic Decorating Tubular Film Belt Flatness Control
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Solution Overview
Problem
Existing decorating machines for ceramic products face issues with maintaining the flatness and correct advancement of thin, transfer belts during decoration, leading to problems with the deposition of granular or powdered materials, such as folding, overlapping, and irregular image transfer.
Innovation Solution
A decorating machine utilizing a tubular film belt anchored by elastic flat belts on rotating rollers with a differential system for synchronized tensioning and stabilization, ensuring a rigid and flat state for precise decoration, combined with a vibration mechanism for effective material transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a very thin belt is used for vibration, then effective vibration is achieved, but the belt folds and overlaps due to inability to resist lateral compression
Solution Approach 1:
The belt is segmented into multiple layers: a thin flexible inner layer for vibration transmission and outer protective layers for structural stability. This segmentation allows each layer to perform its specific function - the inner layer provides vibration effectiveness while the outer layers prevent folding and maintain flatness during lateral compression.
Solution Approach 2:
The belt uses composite material construction combining different material properties - a flexible polymer base layer for vibration capability with reinforcing outer layers that provide lateral compression resistance. This composite structure resolves the contradiction by integrating both vibration effectiveness and shape stability in a single belt system.
2Ease of operation
If holes are provided in the belt for engagement with rollers, then conveyance is enabled, but the laminate cannot be tensioned much to avoid tearing
Solution Approach 1:
The belt structure is segmented with reinforced zones around the engagement holes. These reinforced segments distribute the mechanical stress around the holes, preventing tear propagation while maintaining the necessary engagement functionality with roller pegs. The segmentation allows localized strengthening without compromising overall belt flexibility.
Solution Approach 2:
The belt design incorporates pre-reinforced areas around the holes before engagement occurs. This beforehand cushioning in the form of strengthened material zones prevents tearing by distributing tensile stresses that would otherwise concentrate at the hole edges during tensioning and conveyance operations.
3Ease of operation
If engagement systems between belt and rollers are used, then conveyance is achieved, but irregular advancement occurs which damages image quality
Solution Approach 1:
The engagement system uses dynamic elements such as elastic deformable zones around the holes that adapt during roller engagement. This dynamic behavior allows smooth passage over rollers while maintaining consistent belt tension and position, preventing irregular advancements that would compromise image transfer precision.
Solution Approach 2:
The belt design incorporates parameter changes in material properties around the engagement holes - varying thickness, elasticity, or hardness in specific zones to optimize both engagement functionality and advancement regularity. These parameter changes enable the belt to maintain consistent positioning during conveyance, ensuring high-quality image transfer.
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 solution provides stable and precise decoration by maintaining the flatness and correct direction of the belt, ensuring consistent and high-quality image transfer onto ceramic products while preventing material detachment issues.
Implementation Method 1
forming an image constituted by liquid ejected from inkjet apparatuses, having the decorating material in powdered or granular form (hence the name 'dry' decorating) adhere to this image
Implementation Method 2
a rotor with slight interference on the film and it is coated with a layer of granular decorating material, which adheres to the film at the point of the image
Implementation Method 3
an actuator brings about vibration on the relative section of film, forcing the decorating material to detach from the film and deposit on the receiving surface
Implementation Method 4
these flat belts are elastically elongated in the operating stage so that a given load and good contact on the surface of the rolls is ensured at all times
Data Source
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AI summary
A decorating machine particularly for the decoration of ceramic products, and a method for realising a belt for decorating said ceramic products, wherein the machine comprises: a closed loop belt (3) for the transfer of a decoration (9) on a receiving surface (11) of a ceramic product; a plurality of conveyor rollers (2) about which said belt (3) is wound and moved in rotation; at least one of said conveyor rollers (2) comprises a central portion (12) and two end portions (14) opposite one another, at least one of said end portions (14) being free in rotation with respect to the other said portions (12, 14).