Laser-Fixed Ceramic Edge Decoration for Single-Firing Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for decorating the edges of ceramic slabs or tiles are costly, prone to faults, and limited in achieving desired aesthetic effects, especially for oversize products, as they require separate firing processes that increase production costs and environmental emissions, and often result in non-harmonious edge decorations.
Innovation Solution
A process using ceramic inks deposited on edges followed by localized physical-chemical fixing with a laser beam, allowing for precise energy application to achieve the same aesthetic effects as the main surface without altering mechanical and chemical resistance, reducing energy consumption and material costs, and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional decoration systems or digital printers are used to decorate ceramic edges, then decoration can be applied, but production cost increases and faults occur due to stresses from separate firing processes
Solution Approach 1:
The patent combines the decoration application and firing processes into a single integrated operation. The digital printer deposits ceramic ink directly on the edge, and the entire piece is fired once in the kiln, merging what were previously separate decoration and firing steps. This eliminates the stress from multiple heating cycles while maintaining decoration quality.
Solution Approach 2:
The decoration is applied in advance during the initial manufacturing process before the final firing. The ceramic ink is deposited on the edge surface prior to the single firing cycle, allowing the decoration to be permanently integrated into the ceramic matrix during the primary firing process, avoiding later stress-induced faults.
2Manufacturing precision
If separate firing processes are used for edge decoration, then decoration can be permanently fixed, but energy consumption and environmental emissions increase
Solution Approach 1:
The patent merges the edge decoration firing with the main body firing process. Instead of firing the edge separately after decoration, the entire ceramic piece including the decorated edge is fired in a single kiln cycle, eliminating redundant energy consumption while ensuring permanent fixation of the decoration.
Solution Approach 2:
The patent applies decoration only to the specific edge portions that require it, rather than firing or decorating the entire surface. This partial action approach reduces the overall energy requirement while still achieving permanent fixation through the single firing process.
3Reliability
If full refiring is performed for edge decoration, then decoration adheres permanently, but production time and costs increase
Solution Approach 1:
The patent combines multiple operations into a single production cycle. The edge decoration is applied and permanently fixed during the same firing process used for the main ceramic body, eliminating the need for a separate refiring step and thereby reducing production time while maintaining strong adhesion.
Solution Approach 2:
The decoration is applied in advance before the final firing process. By depositing the ceramic ink on the edge prior to the single firing cycle, the decoration becomes permanently integrated during the primary firing, avoiding the need for time-consuming subsequent refiring operations.
4Ease of manufacture
If conventional decoration methods are used on cut edges, then decoration can be applied, but the edge decoration does not harmonise aesthetically with the main surface
Solution Approach 1:
The patent applies different decoration characteristics to different parts of the ceramic piece. The digital printer can deposit varying patterns, colors, and textures on the edge that are specifically tailored to match or complement the main surface decoration, achieving aesthetic harmony through localized customization rather than uniform decoration.
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
This method enables harmonious edge decoration with reduced production costs, lower energy use, and minimized emissions, while maintaining the mechanical and chemical resistance of ceramic products, allowing for a wide range of aesthetic effects without the need for full refiring.
Implementation Method 1
through the localised action of at least one laser beam aimed at the portion of the surface of edges in question
Implementation Method 2
the physical-chemical fixing or firing of the materials deposited onto the said portions of surface through the action of at least one laser beam
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a process for decorating portions of the surface of objects (2) which comprises, in order: - the deposition of decorating materials or other semi-finished materials used for decorating objects (2) onto individual portions of surface; - the physical-chemical fixing or firing of the materials deposited onto the said portions of the surface through the action of at least one laser beam (3) aimed at the individual portion of surface in question.