3D Structure Creation on Ceramic Surfaces via Droplet Control

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Solution Overview

Problem

Current methods for creating three-dimensional structures on surfaces, such as ceramic tiles, are limited in variability, flexibility, and cost-effectiveness, with existing technologies like structured pressing tools and stereolithography being expensive and impractical for large-scale production, and granulate deposit machines failing to achieve defined structures.

Innovation Solution

A method and device that control the position, number, and volume of droplets of a structure-forming mass to apply complex structures with high precision and flexibility, using a device with a print head, feed device, hardening device, and control device to vary droplet volume and application direction, allowing for continuous and unidirectional movement to produce spatial and planar structures efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If structured pressing tools are used to create three-dimensional structures on ceramic surfaces, then large quantities can be produced efficiently, but the manufacturing cost becomes expensive and structural variation is limited

Engineering Contradiction:

Improveproduction speedVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The pressing tool is divided into multiple independently controllable heating zones that can be operated separately. Each zone can be heated or cooled independently, allowing for complex three-dimensional structures to be created through localized thermal processing without requiring a completely new tool for each structure type.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical state and properties of the ceramic material through controlled temperature variations. By adjusting heating parameters (temperature, duration, zone activation), the same pressing tool can create different three-dimensional structures, eliminating the need for expensive tool changes and enabling both high productivity and structural diversity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If rotary screen printing is used for large quantities, then production efficiency is improved, but the structural variety remains limited

Engineering Contradiction:

Improveproduction speedVSAvoidstructural variety

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The pressing tool incorporates dynamically controllable heating zones that can be activated or deactivated based on the desired structure. This dynamic control allows the system to adapt to different structural requirements while maintaining continuous production, combining the speed of automated processes with the flexibility of variable structure creation.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If granulate deposit machines are used for anti-slip covering, then surface treatment is achieved, but no defined structure can be created

Engineering Contradiction:

Improvesurface treatment capabilityVSAvoidstructural definition

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention replaces the purely mechanical granulate deposition process with a thermally controlled process. Instead of relying on mechanical placement of granules, the system uses controlled heating to induce thermal expansion and shaping of the ceramic material itself, creating well-defined three-dimensional structures with precise geometric control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

Enables the rapid and cost-effective production of complex three-dimensional structures with high precision, allowing for infinite motif selection and quick production of small series, accommodating special customer requests, and applying structures to various materials like wood and ceramics.

Implementation Method 1

The volume of the droplets of the structure-forming mass is varied by controlling at least one of the following drives of the discharge device such as a piezo drive

Methodology Applied

Scientific EffectPiezoelectric drive: Piezoelectric Effect

Implementation Method 2

The volume of the droplets of the structure-forming mass is varied by controlling at least one of the following drives of the discharge device such as a piezo drive, a valve jet drive, an electrostatic, thermal or acoustic drive

Methodology Applied

Scientific EffectThermal drive:

Implementation Method 3

Methodology Applied

Scientific EffectAcoustic drive: Acoustic Radiation Pressure

Implementation Method 4

a radiation-curable initiator-monomer mixture for producing the three-dimensional structure

Methodology Applied

Scientific EffectUV curing: Photopolymerisation

Data Source

PatentEP2189272B1Method for creating a three-dimensional structure on a surface of an object

Publication Date: 2016.12.28 DURST PHOTOTECHN DIGITAL TECH

AI summary

The method involves positioning an object on a positioning device, and hardening a three-dimensional structure. A position, number and/or volume of drops (12, 13) of structure-forming mass (14) are determined by a control device based on the three dimensional structure in planes in different directions and in directions transverse to the planes. The planes are parallel to a bearing surface of the positioning device for the object. The drops are delivered to a surface of the object by a delivery device (17) of an application device. An independent claim is also included for a device for creating a three-dimensional structure on a portion of a surface of an object.