Ceramic Tile Relief Structure Production via Digital Erosion
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Solution Overview
Problem
The existing methods for producing ceramic tiles with relief structures are limited by the need for preformed negatives, which wear quickly and restrict design variability, and the use of sinking agents only allows for shallow relief on glazed tiles.
Innovation Solution
A method that forms relief structures on ceramic tiles by erosion or deposition after the tile body has been formed, using digital or contactless methods to increase design variability and depth, and includes the use of abrasive particles and controlled fluid spraying to create detailed patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If preformed negatives are used for pressing relief structures, then relief structures can be produced, but the negatives are subject to wear and restrict design variability
Solution Approach 1:
The patent replaces the mechanical pressing system with preformed negatives with a digital printing system that applies sinking agents. This substitution eliminates the wear problem of mechanical negatives and enables unlimited design variability through digital control, while still producing relief structures on ceramic tiles.
Solution Approach 2:
The patent changes the approach from mechanical deformation to chemical modification by using sinking agents that alter the glaze properties during firing. This allows the same pressing mechanism to produce varied relief structures by changing the chemical composition and application parameters of the sinking agent rather than changing physical negatives.
2Adaptability or versatility
If sinking agents are applied to create relief structures, then design variability is increased, but the relief depth is limited to glaze thickness
Solution Approach 1:
The patent applies the sinking agent to the green body (unfired tile) before the glazing and firing processes. This preliminary action allows the sinking agent to create deeper impressions in the softer green body material, and these impressions are then preserved and enhanced during subsequent glazing and firing, resulting in deeper final relief structures than would be possible by applying sinking agents after glazing.
3Productivity
If preformed negatives are used for compacting belts, then production can continue, but regeneration or replacement increases costs
Solution Approach 1:
The patent replaces the mechanical compacting belt with preformed negatives with a digital printing system that applies sinking agents directly to the green body. This eliminates the physical wear of compacting belt negatives while maintaining continuous production capability, as the digital system requires no physical contact with the tile surface and thus no regeneration or replacement.
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 method allows for the production of ceramic tiles with complex and varied relief structures of greater depth and detail, reducing production costs and increasing output by eliminating the need for preformed negatives and enhancing design flexibility.
Implementation Method 1
said structure is produced by erosion of the upper surface (7) of the green tile body (2)
Implementation Method 2
said structure is produced by deposition of material on to the upper surface (7) of the green tile body (2)
Data Source
AI summary
A method for producing ceramic tiles, comprising the steps of providing a ceramic mixture, forming a raw tile with a body having an upper surface based on said mixture, and firing said raw tile to produce said ceramic tile, wherein the method comprises a step of producing a relief structure on said upper surface and wherein said structure is produced after said forming step and before said firing step.