Inkjet Printing Decorative Patterns on Engineered Stone
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Solution Overview
Problem
Existing methods for manufacturing engineered stone with decorative patterns lack reproducibility and precision, resulting in inconsistent veined effects and limited resolution.
Innovation Solution
A method involving the use of inkjet printing to apply a decorative pattern on the surface of an engineered stone substrate, which is made by compacting a mixture of inorganic filler and binder, and then curing it to achieve low porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coloring agent is loaded by means of appropriate nozzles to the surface of the mixture substantially in correspondence of the end of the belt so to fall into the mold together with the mixture in a non-controlled manner, then the manufacturing process is simple, but the decorative pattern is not reproducible and predefined
Solution Approach 1:
The coloring agent is applied to the mixture in advance, before the mixture is deposited in the mold. The coloring agent is applied to a temporary support in a predefined pattern, and then the mixture is deposited over it. This preliminary action allows the decorative pattern to be predetermined and reproducible while maintaining manufacturing simplicity.
Solution Approach 2:
A temporary support acts as an intermediary carrier for the coloring agent. The coloring agent is applied to this temporary support in a predefined pattern, and then the mixture is deposited over it. This intermediary allows precise control of the decorative pattern while keeping the overall process simple.
2Adaptability or versatility
If a robotic arm with nozzles is used to deliver coloring agent on the surface of mixture in a temporary support, then programmable chromatic effect can be created, but the machine work of the mixture is required and the décor imitated natural stone has low-quality resolution
Solution Approach 1:
Instead of using a complex robotic system to create chromatic effects, the patent uses a simpler approach where the coloring agent is applied in a predefined pattern on a temporary support, and then the mixture is deposited over it. This copying approach maintains adaptability while achieving high-quality resolution.
Solution Approach 2:
The coloring agent is applied in a predefined pattern on a temporary support before the mixture is deposited. This preliminary action eliminates the need for complex machine work on the mixture itself, achieving high-resolution decorative patterns without requiring sophisticated robotic manipulation.
3Productivity
If the mixture is carried by an endless belt above the mold and loaded into the mold by free falling from the end of the belt, then the manufacturing process is continuous, but the pigment particles distribute in the mixture in a non-controlled manner
Solution Approach 1:
The coloring agent is applied to the mixture on the endless belt in a predefined pattern before the mixture is deposited in the mold. This preliminary action allows continuous manufacturing while controlling the distribution of pigment particles in a reproducible manner.
Solution Approach 2:
The endless belt acts as an intermediary carrier that allows the coloring agent to be applied in a predefined pattern before the mixture is deposited in the mold. This intermediary enables continuous production with controlled pigment distribution.
4Reliability
If natural stone is extracted from mines and subsequently cut and polished to obtain slabs or boards, then high-quality natural stone can be obtained, but the cost is high and environmental impact is high
Solution Approach 1:
The patent changes the fundamental parameters of stone production by using engineered stone instead of natural stone. The engineered stone is made by combining inorganic filler with binder in a controlled manufacturing process, eliminating the need for mine extraction while maintaining quality through precise control of material composition and structure.
Solution Approach 2:
The patent uses composite materials (engineered stone made from inorganic filler and binder) to replace natural stone. This composite approach maintains the desired quality and aesthetic properties while eliminating the environmental harm associated with mine extraction and natural stone processing.
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 creation of engineered stone with high-resolution, reproducible decorative patterns that maintain the low porosity and durability of the substrate, enhancing both aesthetic quality and environmental sustainability.
Implementation Method 1
curing the binder to obtain the substrate
Implementation Method 2
inkjet printing a first decorative pattern on at least a top surface of the substrate
Data Source
AI summary
A method for manufacturing a decorative element comprising a substrate and a top layer wherein the substrate is made of an engineered stone and wherein the top layer comprises a decorative pattern, comprising the steps of: providing a mixture comprising at least an inorganic filler and a binder; compacting the mixture; and curing the binder to obtain the substrate; wherein the method comprises the step of inkjet printing a first decorative pattern on at least a top surface of the substrate, and wherein the method comprises the step of providing a protective coating above the printed pattern, wherein the protective coating comprises a base coat that is applied immediately on top of the printed pattern and a top-coat that is provided above the base coat, between the application of the base-coat and the application of the top coat the method comprises the step of sanding the base coat.