Ceramic Tile Edge Decor Matching via Image-Derived Printing
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Solution Overview
Problem
Existing methods for providing decor on the sides or edges of ceramic units, such as slabs or tiles, are inefficient, costly, and fail to match the main surface decor, often resulting in unsuitable finishes or unnatural appearances.
Innovation Solution
A method involving acquiring an image of the main surface decor, deriving side decor using machine-learning models or correction factors, and applying curable inks to match the main surface design, ensuring high-quality continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If decor is applied to the side or edge using ceramic inks or colorants with a glaze, then the side decor can be fixed and solidified, but the process becomes complex and expensive requiring a second firing treatment
Solution Approach 1:
The patent combines the main surface decor application and side decor application into a single continuous printing operation. The printing system applies decor to both the main surface and sides simultaneously in one pass, eliminating the need for separate firing operations and reducing process complexity while maintaining reliable decor fixation through the single high-temperature firing of the ceramic body
Solution Approach 2:
The patent uses digital imaging and replication techniques to capture the main surface decor pattern and reproduce it on the sides. A scanner or camera captures the main surface decor, and software processes this image to generate side decor patterns that are then printed using digital printing systems, allowing accurate replication without manual intervention
2Ease of manufacture
If spray painting is used to provide decor on the side or edge, then the process is simpler, but it cannot accurately replicate the main surface decor and only produces solid color or dotted patterns
Solution Approach 1:
The patent replaces traditional mechanical spray painting systems with a digital printing system. Instead of using spray guns that apply paint mechanically, the system uses digital imaging to capture the main surface decor and digital printing technology to reproduce it on the sides with high precision, maintaining both ease of operation and manufacturing accuracy
Solution Approach 2:
The patent changes the fundamental parameters of the decor application process by transitioning from analog spray painting to digital printing. This involves converting the decor design into digital image data, processing it through software algorithms, and applying it through precisely controlled digital print heads that can reproduce complex patterns with high resolution and accuracy
3Manufacturing precision
If multiple layers of paint are applied to the side or edge, then more detailed decor can be achieved, but each layer requires prolonged drying time generating substantial VOCs
Solution Approach 1:
The patent eliminates the prolonged air-drying phase transition that occurs with traditional paint application. Instead, the curable composition is applied and then cured through UV irradiation or other energy input, causing a rapid phase transition from liquid to solid state in seconds rather than requiring hours of evaporation-based drying, dramatically reducing both time and VOC emissions
Solution Approach 2:
The patent replaces the multi-step paint application and air-drying process with a single digital printing step followed by immediate UV curing. This substitution eliminates the need for multiple coating passes and prolonged drying chambers, reducing the process to one quick application and one rapid curing step that occurs in-place without requiring large drying facilities
4Manufacturing precision
If decor is formed extending through the body of the ceramic material, then the side decor matches the main surface decor, but the process requires specialized equipment and adds complexity and expense
Solution Approach 1:
The patent applies the side decor to the ceramic piece while it is still in its green state or immediately after forming, before the final firing. By printing the curable composition on the sides at this early stage and then curing it during or after the main surface decor application, the system ensures decor continuity without requiring complex equipment to embed decor within the body during the forming process itself
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
Achieves high-quality, cost-effective, and efficient decor on ceramic unit sides that accurately replicate the main surface design, eliminating the need for additional firing and reducing environmental impact.
Implementation Method 1
The curable ink is cured, for example, by UV irradiation
Data Source
AI summary
A method for providing one or more sides or edges of a ceramic unit with decor may include the step of providing the ceramic unit. The ceramic unit may be made of a ceramic material and may include decor disposed on a main surface of the ceramic unit. The method may also include the step of acquiring an image of at least a portion of the decor disposed on the main surface of the ceramic unit. The method may also include the step of deriving decor for a side of the ceramic unit from the image. The method may also include the step of providing the decor on the side of the ceramic unit.