Ceramic Tile Dry Particle Decoration Method
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Solution Overview
Problem
Current ceramic inkjet technology for producing three-dimensional patterns on ceramic tiles faces issues such as blurred patterns, dust generation, nozzle damage, ash contamination, and reduced three-dimensional effects due to inefficient dry particle application and glazing processes.
Innovation Solution
A method involving glazing a green body with a ground coat, maintaining temperature, decorating a pattern, drying, spreading dry particles directly on the surface, spraying a protective glaze, and firing to produce ceramic tiles with clear patterns, strong three-dimensional effects, and stable physical and chemical properties, while minimizing dust and ash contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If dry particles are applied after inkjet pattern decoration with glue, then three-dimensional pattern is formed, but pattern becomes blurred when product color is dark and requires large amount of inkjet ink
Solution Approach 1:
The patent applies the preliminary action principle by conducting the inkjet pattern decoration before applying the ground coat and dry particles. This sequence ensures that the pattern is established on the green body surface before subsequent layers are applied, preventing pattern blur while maintaining three-dimensional effects. The ground coat is applied after pattern decoration but before dry particle application, creating a stable base that prevents pattern distortion.
2Shape
If dry particles are applied with glue and excess particles are removed by suction, then three-dimensional effect is achieved, but large amount of dust is generated affecting nozzle operation and reducing equipment service life
Solution Approach 1:
The patent extracts and eliminates the harmful dust generation step by replacing the traditional glue application method with direct dry particle application. Instead of applying glue and then removing excess particles through suction (which generates dust), the patent applies dry particles directly to the green body surface after pattern decoration, eliminating the intermediate glue layer and subsequent removal process that causes dust contamination of equipment.
3Quantity of substance
If kiln suction is used to remove dry particles not held by glue, then particle distribution is improved, but ash contamination and defects occur on glaze surfaces
Solution Approach 1:
The patent converts the previously harmful suction process into a beneficial direct application process. Instead of using kiln suction to remove excess particles (which causes ash contamination and glaze defects), the patent applies dry particles directly to the green body surface where they remain as part of the final glaze structure. This eliminates the harmful suction operation entirely while achieving proper particle distribution through the direct application method.
4Quantity of substance
If glue is applied before dry particle application, then particles are held on surface, but glue does not completely volatilize and solidify before firing causing particle loss
Solution Approach 1:
The patent extracts and eliminates the glue application step from the process sequence. By applying dry particles directly to the green body surface after pattern decoration and before glazing, the patent removes the intermediate glue layer that caused incomplete volatilization and particle loss. The dry particles are applied in a state where they can be directly retained on the surface without requiring glue binding, eliminating the reliability issue associated with glue curing.
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 achieves high production efficiency, low costs, and improved surface quality with distinct layers, non-slip effects, and rich colors, suitable for industrial-scale production.
Implementation Method 1
glazing a surface of a green body with a ground coat
Implementation Method 2
spraying a protective glaze on the surface of the green body
Implementation Method 3
maintaining a temperature of the green body at 40-60° C. after the green body is glazed with the ground coat
Implementation Method 4
drying the green body after the green body is decorated with the pattern
Implementation Method 5
firing the green body after the green body is sprayed with the protective glaze to produce the ceramic tile
Data Source
AI summary
The present disclosure relates to a ceramic tile decorated with dry particles to give a three-dimensional pattern and a manufacturing method thereof. The manufacturing method comprises the steps of A: glazing a surface of a green body with a ground coat; B: decorating a surface of the ground coat of the green body to form a pattern; C: drying the green body; D: embellishing the green body with dry particles; E: spraying a protective glaze on the surface of the green body; and F: firing the green body after the green body is sprayed with the protective glaze of step E to produce the ceramic tile decorated with dry particles. The manufacturing method can make the ceramic tile produced have a clear pattern, distinct layers, low glaze glossiness, a good non-slip effect, an obvious sense of dry particles, a strong three-dimensional effect, rich colors, and stable properties.