Digital Ceramic Slip Printing for 3D Relief Structures
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Solution Overview
Problem
The existing methods for manufacturing ceramic tiles and slabs, which use digital glazing to create three-dimensional structures, result in a fragile product due to the chemical and physical discrepancies between the glaze and the ceramic powder, leading to structural weaknesses and increased production costs.
Innovation Solution
A process involving the differential application of a ceramic slip, composed of the same raw materials as the ceramic powder, to create relief structures on the substrate before firing, using digital printing technology to apply the slip in a controlled and precise manner, allowing for complex and varied designs without the need for complicated equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital glazing is used to create three-dimensional structures, then design flexibility and surface texture diversity are improved, but product strength and structural integrity deteriorate due to chemical and physical discrepancies between glaze and ceramic powder
Solution Approach 1:
The patent applies homogeneity by using ceramic slip with the same chemical composition as the ceramic powder substrate. This ensures that the relief structures and printed graphics are made from material that is chemically and physically compatible with the base ceramic, eliminating the adhesion problems and structural weaknesses that occur when using conventional glazes with different compositions.
Solution Approach 2:
The patent creates a composite structure where the ceramic slip forms a relief layer that is chemically integrated with the ceramic powder substrate. This composite approach allows different regions of the ceramic product to have different functions (relief areas, printed areas, plain areas) while maintaining overall structural integrity through chemical compatibility.
2Adaptability or versatility
If conventional glazes are used for digital application, then three-dimensional structures can be created, but production costs increase due to the need for scrupulous parameter control and specialized frit composition
Solution Approach 1:
The patent changes the material parameters by using ceramic slip instead of conventional glaze frits. This substitution eliminates the need for complex parameter control of viscosity, surface tension, and density that is required for digital glazing, thereby reducing production costs while maintaining the ability to create three-dimensional structures.
3Adaptability or versatility
If multiple pads are mounted in the press to diversify surface structures, then relief structures can be created, but device complexity and the number of components increase
Solution Approach 1:
The patent replaces the mechanical system of multiple physical pads with a digital printing system that applies ceramic slip selectively. This substitution eliminates the need for mounting, storing, and managing multiple heavy pads while providing unlimited surface structure diversification through digital design files.
Solution Approach 2:
The ceramic slip application system serves multiple functions: it creates relief structures, provides surface texture, and acts as a substrate for subsequent digital printing of graphics. This multi-functional approach replaces what would otherwise require separate pads for each function.
4Shape
If ceramic glaze is applied in preset areas to create reliefs, then three-dimensional effects are improved, but material homogeneity and structural integration deteriorate due to the different composition of glaze versus ceramic powder
Solution Approach 1:
The patent ensures material homogeneity by using ceramic slip with the same composition as the ceramic powder. This allows the relief structures to be chemically integrated with the substrate, creating a uniform material composition throughout the entire ceramic product rather than having distinct glaze and body layers.
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 ensures a perfectly adhered structure after firing, reduces production costs, and allows for the creation of realistic, durable ceramic products that mimic natural materials like wood, stone, and marble with enhanced flexibility and precision.
Implementation Method 1
using digital printing technology to apply the slip in a controlled and precise manner
Implementation Method 2
firing the substrate, after applying the slip
Data Source
Figure 1
Figure 2a~2d
Figure 2e~2h
AI summary
A process and a plant for manufacturing ceramic products, for example ceramic slabs and tiles are described, wherein the process comprising the steps of: preparing a soft layer (100) of ceramic powder, pressing said soft layer (100) to obtain a substrate (105) of compacted ceramic powder, applying a ceramic slip (115) differentially to at least one surface (110) of said substrate (105) by digital printing, and firing the substrate (105), for example inside a ceramic kiln (230), after the application of the slip (115).