Ceramic Slab Layer Transfer for Natural Veining Stability
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Solution Overview
Problem
Existing methods for producing ceramic slabs with natural veining effects result in unnatural inclinations of decoration, low productivity, and instability during the production process, leading to potential breakage and loss of geometric features.
Innovation Solution
A method involving controlled deposition and transfer of a decorated ceramic layer between two planes, adjusting the inclination angles of the decoration to 40°-80°, preferably 60°-80°, to achieve a natural appearance and increased stability during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the decoration is laid with a relative motion between the decorating device and deposition plane, then the decoration can be applied efficiently, but the veining becomes inclined at unnatural angles (15°-20°) when viewed on side surfaces
Solution Approach 1:
The patent inverts the conventional approach by not directly laying the decorated layer at the desired final inclination, but rather laying it at a different inclination (15°-20°) and then using a transfer process to reorient it to the natural appearance range (40°-80°). This indirect approach resolves the contradiction between efficient application and natural appearance.
Solution Approach 2:
The patent introduces a second deposition plane as an intermediary between the decorating device and the final product. The decorated layer is first laid on the first deposition plane, then transferred to the second deposition plane where the inclination is adjusted to the natural range. This intermediary transfer process enables both efficient application and natural appearance.
2Shape
If the decoration is deposited using a pen-like device moving along Cartesian axes, then vertical veining can be achieved, but productivity becomes rather low
Solution Approach 1:
The patent uses a decorated layer as a copy or template that is laid down in one pass and then transferred. Instead of depositing material point-by-point like a pen, the entire decorated pattern is copied onto the layer in bulk, then reoriented through the transfer process. This maintains vertical veining appearance while dramatically improving productivity.
3Device complexity
If the decoration is laid with conventional methods, then the process is simple, but the soft layer becomes unstable during displacement and pressing, causing breakage and loss of geometric features
Solution Approach 1:
The patent performs the inclination adjustment in advance during the transfer process, before the pressing and final displacement operations. By pre-establishing the correct 40°-80° inclination, the decoration is in its stable configuration before subsequent handling, preventing breakage and geometric feature loss during pressing and transport.
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
The method ensures a natural veining effect and enhanced structural stability of the decoration, maintaining geometric features and preventing breakage during transport and pressing, resulting in finished products resembling natural stones or wood.
Implementation Method 1
gradually depositing the decorated soft layer from a head to a tail
Implementation Method 2
gradually transferring the soft layer by deposition from the first deposition plane to a second deposition plane
Data Source
Figure 1
Figure 2
Figure 2a
AI summary
A method for realising a ceramic slab, comprising the following steps: arranging on a first deposition plane (50) a decorated layer (L2) provided with a decoration (200), gradually depositing the decorated soft layer (L2) from a head (H) to a tail (T); gradually transferring the soft layer (L2) by deposition from the first deposition plane (50) to a second deposition plane (83), placed at a lower height than the first deposition plane (50), starting from the tail (T) of the second soft layer (L2), gradually realising a second layer (L3) on the second deposition plane (83).