Ceramic Tile Relief Structure for Natural Patterned Surfaces
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Solution Overview
Problem
Existing ceramic tiles with printed patterns often exhibit monotonous surfaces and artificial relief, leading to noticeable height differences when installed, especially in offset relationships, and reflect light in a mirror-like manner, detracting from a natural appearance.
Innovation Solution
Ceramic tiles with a relief structure that corresponds to the printed pattern, featuring irregular or random relief features to diffuse light reflection and minimize height differences, using a combination of digital printing and structured press elements or matrices to create a more natural appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a printed pattern is applied to the ceramic tile surface, then the aesthetic appearance is improved, but the surface becomes monotonous and artificial
Solution Approach 1:
The patent applies different relief structures to different areas of the tile surface corresponding to different printed pattern features. The relief structure includes valleys and ridges that are locally adapted to enhance specific elements of the printed pattern, creating a more natural and varied appearance while maintaining the overall aesthetic design.
Solution Approach 2:
The relief structure is designed with asymmetric features including irregular valleys and ridges that do not follow uniform patterns. This asymmetry breaks the monotony of the printed surface by introducing natural variations in height and texture that mimic organic materials like wood grain or stone, thereby enhancing the aesthetic appearance.
2Device complexity
If a relief structure is added to the ceramic tile surface, then the natural appearance is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines the printed pattern application and relief structure formation into a single integrated manufacturing process. The relief structure is formed during the same manufacturing step as the printed pattern, rather than as a separate subsequent operation, thereby reducing overall manufacturing complexity while achieving the desired natural appearance.
Solution Approach 2:
The relief structure serves multiple functions simultaneously: it enhances the natural appearance of the tile, provides tactile feedback, and works in conjunction with the printed pattern to create a unified aesthetic effect. This multi-functionality justifies the added manufacturing complexity by delivering multiple benefits from a single structural feature.
3Object-affected harmful factors
If the tile surface is made smooth with glaze, then the light reflection is reduced, but the height differences become noticeable when installed
Solution Approach 1:
The relief structure is incorporated into the tile during the manufacturing process, before installation. This preliminary formation of the relief ensures that the height variations are built-in and consistent across all tiles, allowing for better control of installation flatness. The relief structure is pre-coordinated with the printed pattern to ensure proper alignment and reduce noticeable height differences during installation.
4Adaptability or versatility
If offset installation is used for rectangular tiles, then the installation flexibility is improved, but the height differences and light reflection become more noticeable
Solution Approach 1:
The relief structure is locally adapted to the offset installation pattern, with valleys and ridges positioned to accommodate the staggered arrangement of tiles. This local adaptation ensures that the relief features of adjacent tiles align or complement each other in offset installations, reducing the visibility of height differences while maintaining installation flexibility.
Data Source
AI summary
Ceramic tile having a ceramic base layer and a cover glaze layer including a printed pattern, where the surface of the ceramic tile has a relief having structural features corresponding to the printed pattern. The relief being basically formed as a plurality of excavations present in the generally plane upper surface of the ceramic tile and the structural features have a depth such that they are completely situated above the ceramic base layer.