Ceramic Slab Decoration Alignment via Optical Mark Compensation

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Solution Overview

Problem

Existing methods for producing ceramic slabs with thickness decoration face issues of misalignment between surface and thickness decorations due to deformation during the pressing process, leading to imperfect superposition.

Innovation Solution

A method involving the application of an identification mark on the soft layer before pressing, allowing for optical detection and correction of deformations, enabling precise alignment and modification of both surface and thickness decorations through control modules and deformation compensation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If high pressure is applied during pressing to compact the ceramic layer, then the compacting effect is improved, but the thickness decoration undergoes deformation leading to misalignment with surface decoration

Engineering Contradiction:

Improvealignment precision between surface and thickness decorationsVSAvoiddeformation of thickness decoration during pressing

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies identification marks to the thickness decoration before the pressing operation. These marks serve as reference points that allow the control system to detect and calculate deformations that occur during pressing, enabling subsequent correction of the surface decoration to match the deformed thickness decoration pattern.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses optical detection to capture the position of identification marks on the thickness decoration before and after pressing. The control module compares these positions to calculate deformation vectors and uses this feedback information to adjust the surface decoration pattern, ensuring precise alignment despite pressing-induced deformations.

Inventive Principle:

Principle #23Feedback

2Ease of manufacture

If the surface decoration is applied after pressing, then the decoration process is simplified, but misalignment occurs due to deformation of the thickness decoration

Engineering Contradiction:

Improvedecoration process simplicityVSAvoidalignment between surface and thickness decorations

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The control module detects the position of identification marks on the thickness decoration after pressing and uses this feedback to calculate the deformation that occurred. This information is then used to modify the surface decoration pattern digitally before application, ensuring that the surface decoration aligns perfectly with the deformed thickness decoration even though the surface decoration is applied after pressing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system modifies the parameters of the surface decoration pattern (position, orientation, scale) based on the detected deformation of the thickness decoration. The control module transforms the decoration coordinates to compensate for pressing-induced deformations, allowing the surface decoration to match the thickness decoration despite the time sequence of application.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If identification marks are applied and deformation detection is implemented, then alignment precision is improved, but the device complexity increases

Engineering Contradiction:

Improvealignment precision of decorationsVSAvoidcomplexity of detection and control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent introduces identification marks as intermediary elements that mediate between the thickness decoration and the detection system. These simple visual markers serve as reference points that the optical detection system can easily track, enabling complex deformation measurement without requiring complex sensing technology. The marks act as a bridge between the physical deformation and the digital correction process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures precise alignment and correction of decorations by detecting and compensating for deformations, ensuring perfect correspondence between surface and thickness decorations post-pressing.

Implementation Method 1

detecting, by optical means, a position of the mark (M) on the compacted layer (CL)

Methodology Applied

Scientific EffectOptical detection: Reflection

Data Source

PatentUS12564983B2Method for realising ceramic slabs or tiles

Publication Date: 2026.03.03 SYSTEM CERAMICS SPA

AI summary

A method for realising ceramic slabs or tiles, comprising the following steps: laying a soft layer (SL) of granular or powder ceramic material on a support plane (P); pressing the soft layer (SL) in order to obtain a compacted layer (CL); firing the compacted layer (CL); prior to the pressing, applying an identification mark (M) onto the soft layer (SL), the identification mark (M) having an optical contrast with respect to the soft layer (SL), so as to enable an optical detection of the mark (M); subsequently to the pressing, acquiring an image of the mark (M); processing the image of the mark (M) detected so as to control one or more operating steps subsequent to the pressing.