Ceramic Tile Asymmetric Relief and Dimensional Control

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Solution Overview

Problem

Ceramic tiles produced using traditional methods have limited variability in relief structures, resulting in an artificial appearance due to high repetition rates and require costly rectification to achieve uniform dimensions, which increases waste and abrasive consumption.

Innovation Solution

The method involves producing ceramic tiles with a lower face and upper face of differing shapes and dimensions, where the lower face has square edges and the upper face has edges out of square, allowing for reduced joint installation and eliminating the need for rectification, using a ceramic body with a surface coating and relief structures created through digital printing and firing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional pressing methods with dies are used to produce relief structures, then manufacturing precision is maintained, but the product appears artificial due to high repetition rates and limited variability

Engineering Contradiction:
Improvevariability of relief structuresVSAvoidregularity of relief patterns
Core Design Contradiction:
Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies asymmetry by intentionally creating irregular relief structures that deviate from perfect geometric regularity. The relief patterns incorporate random variations in size, shape, and positioning, mimicking natural stone or wood grain patterns rather than repeating mechanical impressions. This asymmetric approach eliminates the artificial appearance caused by uniform die pressing while maintaining manufacturing control through digital design parameters.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent implements dynamics by transitioning from static, fixed die patterns to dynamically generated relief structures. Digital models generate unique, non-repeating relief patterns for each tile or even within single tiles, creating visual variety without requiring multiple physical dies. This dynamic approach allows the relief structures to adapt and vary while maintaining production efficiency through digital fabrication processes.

Inventive Principle:
Principle #15Dynamics

2Manufacturing precision

If rectification is performed after firing to achieve uniform dimensions, then manufacturing precision is improved, but production cost increases due to waste material and abrasive consumption

Engineering Contradiction:
Improvedimensional uniformityVSAvoidwaste material from rectification
Core Design Contradiction:
Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by achieving the desired dimensional characteristics and relief structure during the forming stage itself, rather than correcting them after firing. The green state tiles are shaped with precise control over thickness and surface geometry before drying and firing, eliminating the need for subsequent rectification operations. This preliminary shaping prevents dimensional deviations rather than correcting them, avoiding waste generation.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the potential harm of dimensional variation into a beneficial aesthetic feature. Instead of viewing slight thickness variations as defects requiring rectification, the design embraces controlled irregularities as part of the natural, hand-crafted appearance. The relief structures and surface variations are intentionally designed to create visual interest while maintaining functional tolerances, turning what would normally require correction into a selling point.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If rectification operations are performed to enable reduced joint laying, then ease of operation is improved, but production cost and time increase

Engineering Contradiction:
Improveinstallation simplicityVSAvoidrectification processing time
Core Design Contradiction:
Ease of operationVSLoss of time

Solution Approach 1:

The patent applies parameter changes by designing tiles with non-standard dimensions and irregular shapes that are intentionally produced without rectification. Rather than forcing all tiles to conform to uniform rectangular dimensions through machining, the design accepts and incorporates dimensional variations as part of the aesthetic concept. This parameter flexibility allows tiles to be installed with minimal preparation, as the variations are designed to work together in random or varied patterns.

Inventive Principle:
Principle #35Parameter changes

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 enhances the natural appearance of ceramic tiles by reducing artificial patterns, simplifies installation by eliminating the need for cross spacers, and imparts a hand-made quality to the tiled surface while reducing production costs and waste.

Implementation Method 1

the powders forming the ceramic mixture are placed in a mould and pressed with a die

Methodology Applied
Scientific EffectCompression: Compression

Implementation Method 2

firing said raw tile to produce the ceramic tile

Methodology Applied
Scientific EffectSintering: Sintering

Data Source

PatentUS20240384542A1Ceramic tile and method for producing ceramic tiles
Publication Date: 2024.11.21 MARAZZI GRP SPA
  • US20240384542A1 patent drawing
  • US20240384542A1 patent drawing

AI summary

Method for making a ceramic tile, comprising the steps of providing a raw tile having a body with an upper surface, said body being formed from a ceramic mixture; providing a surface coating on said upper surface of the body, said surface coating comprising refractory particles; firing said raw tile to produce a ceramic tile. The method also comprises a step of brushing the upper surface of the ceramic tile.