Functional Image Tile Using Clay-Fiber Composite for Moisture-Resistant Printing
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Solution Overview
Problem
Conventional image tiles face issues with image peeling or spreading due to moisture, lack of heat resistance, strength, and moisture-adjusting capabilities, and require multiple processes and coatings, which hinder production efficiency and increase costs.
Innovation Solution
A functional image tile is manufactured by mixing red clay, basalt fiber, and mulberry fiber with a plaster-water mixture, allowing for ink absorption and eliminating the need for protective coatings, while incorporating Pelargonium graveolens extract and phytoncide for insect repellency and antibacterial properties, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional screen printing method is used for image tiles, then image colors can be reproduced, but production efficiency deteriorates due to multiple decomposition processes
Solution Approach 1:
The patent extracts and eliminates the color decomposition step from the conventional screen printing process. Instead of decomposing images into primary colors and printing separately, the invention uses direct full-color printing technology that reproduces original images in a single printing operation, thereby maintaining color accuracy while dramatically improving production efficiency
Solution Approach 2:
The invention skips the intermediate color decomposition and multiple printing steps by implementing direct full-color printing. This allows the printing process to rush through in a single operation rather than proceeding through multiple sequential steps, resolving the contradiction between color reproduction quality and production speed
2Temperature
If conventional clay-based tiles are used, then heat resistance is achieved, but weight increases and fragility occurs during transportation
Solution Approach 1:
The patent applies composite materials by combining clay with fibers (such as glass fibers, carbon fibers, or organic fibers) and other additives in specific proportions. This composite structure maintains the heat resistance of clay while the fibers provide tensile strength and reduce brittleness, resulting in tiles that are both heat-resistant and less fragile during transportation
Solution Approach 2:
The invention changes the compositional parameters of traditional clay tiles by introducing fiber content (1-20 wt%), water content (8-15%), and sintering temperature ranges (900-1200°C). These parameter adjustments optimize the balance between heat resistance, weight, and mechanical strength, producing tiles that meet both thermal and structural requirements
3Reliability
If protective coated layers are applied to image tiles, then image peeling is prevented, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements self-service by enabling the tile body itself to provide the protective function. Through compositional design (clay with fibers and additives) and surface treatment during sintering, the tile develops inherent properties that prevent image peeling and moisture damage without requiring separate protective coating layers, thus simplifying the manufacturing process
Solution Approach 2:
The invention extracts and eliminates the protective coated layer from the conventional tile structure. By incorporating protective functionalities directly into the tile body through material composition and processing, the separate coating step is removed, reducing manufacturing complexity while maintaining image adhesion reliability
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 resulting tile exhibits excellent heat resistance, strength, and moisture-adjusting capabilities, preventing image peeling and spreading, and offers enhanced durability and aesthetic benefits with simplified production processes and cost savings.
Implementation Method 1
capable of smoothly absorbing ink during image printing since the red clay and the plaster having excellent absorbency are mixed
Implementation Method 2
exhibits excellent heat resistance, strength, and moisture-adjusting capability since the basalt fiber and the mulberry fiber are mixed together
Implementation Method 3
enables the image printed on the surface thereof to be prevented from peeling off or spreading by moisture
Data Source
AI summary
Disclosed are a functional image tile and a manufacturing method therefor, the tile: being manufactured by printing a desired image on a surface of a tile manufactured through a mixture produced by mixing red clay, basalt fiber and mulberry fiber with a raw material formed by mixing plaster and water; being capable of smoothly absorbing ink during image printing since the red clay and the plaster having excellent absorbency are mixed; enabling the image printed on the surface thereof to be prevented from peeling off or spreading by moisture; and exhibiting excellent heat resistance, strength, and moisture-adjusting capability since the basalt fiber and the mulberry fiber are mixed together.