Integrated Image Layer Construction for Tile Decoration
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Solution Overview
Problem
The traditional tile decoration processes, including screen printing and digital printing, rely on the kiln firing process, which is costly and inefficient, and existing non-firing methods like peel and stick tiles lack durability and authenticity compared to ceramic or porcelain tiles.
Innovation Solution
A method for creating an integrated image layer construction using a releasable carrier with an absorbable layer, printed with inkjet ink, followed by a penetrating resin and a hard top coat, allowing for a durable and resistant decoration that can be applied to tiles before, during, or after installation without kiln firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screen printing or digital printing is used for tile decoration, then the decoration can be applied to tiles, but the kiln firing process is required which increases production cost and time
Solution Approach 1:
The patent extracts the decoration application process from the traditional kiln firing sequence by introducing a post-installation application method. The decorative layer is applied to the tile surface after the tile has been manufactured, eliminating the requirement for kiln firing and thereby reducing production cycle time while maintaining decoration durability.
Solution Approach 2:
The patent prepares the decorative layer with adhesive properties in advance, allowing it to be applied directly to the tile surface without requiring subsequent high-temperature firing. This preliminary preparation of the decorative layer enables direct adhesion and eliminates the time-consuming kiln firing process.
2Reliability
If kiln firing is used to fuse decoration to tile surface, then decoration durability is improved, but production cost increases
Solution Approach 1:
The patent employs a disposable adhesive layer that provides sufficient bonding strength without requiring the expensive and energy-intensive kiln firing process. The adhesive layer is designed to be applied and cured at lower costs, eliminating the need for costly high-temperature firing while maintaining adequate decoration resistance.
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary between the decorative layer and the tile surface. This adhesive mediator provides the necessary bonding strength to secure the decoration without requiring kiln firing, thereby reducing production costs while maintaining decoration durability.
3Manufacturing precision
If digital printing is used to eliminate color matching issues, then manufacturing precision is improved, but the process still requires kiln firing which increases production time
Solution Approach 1:
The patent prepares the decorative layer with precise color matching through digital printing in advance, and simultaneously prepares it with adhesive properties. This dual preparation allows the decoration to be applied directly to the tile surface without requiring subsequent kiln firing, thereby maintaining color matching accuracy while eliminating the time-consuming firing process.
Solution Approach 2:
The patent changes the application parameters by transitioning from a high-temperature firing process to a lower-temperature adhesive curing process. This parameter change maintains the precision of digital printing for color matching while dramatically reducing the production cycle time by eliminating the lengthy kiln firing step.
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 provides a durable, resistant, and authentic decoration for ceramic or porcelain tiles that can be applied easily, eliminating the need for kiln firing and addressing the limitations of existing methods by creating a clear homogenous mix for a vibrant image on hard surfaces.
Implementation Method 1
coating a first releasable carrier with an absorbable layer, printing said layer with an absorbable ink
Implementation Method 2
applying a penetrating resin layer formulated to integrate the image layer into the absorbable layer
Implementation Method 3
coating a second releasable carrier with an adhesive layer, which layer may comprise a pressure sensitive
Data Source
AI summary
An integrated image layer construction and method of making same resulting in a homogenous mix which can be applied it to a target surface, such as a surface of a floor, wall tile or other hard surface, to yield a durable, resistant form of decoration.