Ceramic Slab Decoration Inclination Control via Inversion
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Solution Overview
Problem
Existing methods for decorating ceramic slabs to replicate natural stone or wood patterns fail to maintain the veining effect throughout the thickness of the slabs, resulting in unnatural inclination of the decorations on lateral surfaces.
Innovation Solution
A method involving the application of a soft ceramic layer with a decoration that is transferred between multiple surfaces with controlled relative motion, allowing for the modification of the decoration's inclination by reversing the direction of the transfer, ensuring the veining effect remains vertical and consistent throughout the slab's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a decoration is applied to a soft ceramic layer and the layer is transferred between surfaces with relative motion, then the decoration can be applied throughout the thickness of the slab, but the relative motion produces an inclination of the decoration on vertical planes
Solution Approach 1:
The patent applies the inversion principle by reversing the direction of the deposition surface motion relative to the decoration source. When the deposition surface moves in the opposite direction to the soft layer transfer, it compensates for the inclination caused by the relative motion between the decoration source and the moving layer, thereby maintaining vertical alignment of the decoration on vertical planes.
Solution Approach 2:
The patent employs dynamics by making the deposition surface movable rather than stationary. The deposition surface can adjust its motion dynamically to match or counteract the relative motion between the decoration source and the soft ceramic layer, enabling real-time correction of decoration inclination during the transfer process.
2Manufacturing precision
If the soft layer is pressed to increase thickness and compact the material, then the decoration penetrates throughout the thickness, but the pressing process may distort the decoration orientation
Solution Approach 1:
The patent applies preliminary action by pre-aligning the decoration source perpendicular to the soft layer surface before pressing occurs. The decoration is applied in a controlled manner prior to the pressing operation, ensuring that the decorative elements are properly oriented before the compaction force is applied, thereby preventing distortion during pressing.
Solution Approach 2:
The pressing force is applied in a controlled manner that counteracts potential distortion forces. By distributing the pressing force uniformly and controlling the pressing speed, the system maintains decoration orientation while achieving the necessary compactness and thickness increase.
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 approach ensures that the veining effect is uniformly maintained across the ceramic slab's thickness, enhancing the aesthetic appeal of finished products like kitchen counters and bathroom surfaces by correcting the inclination of the decorations, resulting in a more natural and consistent appearance.
Implementation Method 1
The liquid decoration penetrates by diffusion or absorption throughout the whole thickness of the soft layer
Implementation Method 2
The liquid decoration penetrates by diffusion or absorption throughout the whole thickness of the soft layer
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A method for decorating in thickness a ceramic slab, comprising the following steps: preparing, on a decoration surface (10), a first soft decorated layer (L1) of ceramic material endowed with a decoration (V); progressively transferring, by deposition, the soft decorated layer (L1) from the decoration surface (10) to a first deposition surface (50), situated at a lower height than the decoration surface (10), thus progressively forming on the first deposition surface (50) a second soft decorated layer (L2) which has a head (H) and a tail (T); progressively transferring, by deposition, the second soft decorated layer (L2) from the first deposition surface (50) to a second deposition surface (83), situated at a lower height than the first deposition surface (50), starting from the tail (T) of the second soft decorated layer (L2), thus progressively forming on the second deposition surface (83) a third soft decorated layer (L3).