Ceramic Tile Dry Particle Ink Manufacturing Method
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Solution Overview
Problem
Current ceramic inkjet technology faces issues such as blurred patterns, dust contamination, ash contamination, and reduced three-dimensional effects in ceramic tiles due to integrated inkjet and dry particle application processes, leading to low production efficiency and quality.
Innovation Solution
A method involving glazing a green body with a ground coat, maintaining temperature, decorating a pattern, performing multiple drying steps, and spraying dry particle ink followed by a protective glaze, then firing to produce ceramic tiles with clear patterns and strong three-dimensional effects, while reducing production complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If inkjet pattern decoration and glueing are integrated with glue applied after inkjet, then the process is simplified, but the pattern becomes blurred when color is dark and requires large amount of inkjet ink
Solution Approach 1:
The process is divided into separate stages: first inkjet the pattern, then apply glue only where needed, then apply dry particles. This segmentation prevents pattern blurring by avoiding the need to apply glue over freshly inkjetted dark patterns, while maintaining process efficiency through automated positioning systems.
2Device complexity
If inkjet pattern decoration, glueing and dry particle distribution are integrated, then the process is streamlined, but large amount of dust is generated affecting nozzle operation and reducing equipment service life
Solution Approach 1:
The process separates inkjet decoration, glue application, and dry particle application into distinct stages. Dry particles are applied after glueing in a controlled environment, preventing dust generation during the inkjet phase and protecting equipment from particle contamination while maintaining process integration through automated coordination.
Solution Approach 2:
Glue is applied to the ceramic surface before dry particles are introduced. This preliminary action creates a bonding layer that prevents dry particles from becoming airborne dust during subsequent handling, while the automated system coordinates the timing to minimize overall dust generation.
3Productivity
If kiln is used to suction away dry particles not held by glue with negative pressure from rotating fan, then dry particles are removed, but they adhere to wall and roof causing ash contamination and requiring manual cleaning
Solution Approach 1:
Instead of using strong negative pressure that causes dust and ash contamination, the process uses a gentle air flow system that selectively removes excess dry particles without creating harmful dust clouds. The controlled air flow prevents particle adhesion to kiln surfaces, converting the removal function into a clean process that eliminates the need for manual cleaning.
4Loss of time
If green body with dry particles is fired in kiln with fan suction, then drying is achieved, but dry particles are blown away or suctioned away reducing amount on glaze and making three-dimensional effect inapparent
Solution Approach 1:
Glue is applied to the ceramic surface before dry particles are introduced and before firing. This preliminary bonding action ensures dry particles are securely attached to the glaze layer, preventing them from being blown away or suctioned away during the firing process, while still allowing efficient moisture evaporation through controlled air flow.
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 results in ceramic tiles with clear patterns, distinct layers, low glaze glossiness, good non-slip effects, rich colors, and stable physical and chemical properties, suitable for industrialized large-scale production, while minimizing dust and ash contamination.
Implementation Method 1
glazing a surface of a green body with a ground coat
Implementation Method 2
performing a second drying
Implementation Method 3
spraying a protective glaze on the surface of the green body
Implementation Method 4
firing the green body after the green body was sprayed with the protective glaze
Data Source
AI summary
The present disclosure relates to the field of ceramic tiles, in particular, to a ceramic tile decorated with a dry particle ink and a manufacturing method thereof. The manufacturing method comprises the steps of A: decorating a ground coat; B: decorating to form a pattern; C: drying firstly; D: embellishing with dry particles; E: spraying a protective glaze; and F: firing. The manufacturing method has simple operation steps and convenient control, simplifies the process flow, improves production efficiency, and reduces production difficulty and production cost. By spraying with the dry particle ink, jet printing is carried out on a designated position on the surface of a green body, so that the texture sprayed can accurately correspond to the pattern-decorated texture, and the uniformity and adhesion of the dry particle distribution on the surface of the green body can be improved.