Stone Slab Decoration via Dispersed Ink Diffusion
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Solution Overview
Problem
Existing methods for manufacturing slabs of stone or stone-like agglomerate material with decorations and chromatic effects face issues such as blurred and poorly defined decorations, removal of decorations during machining, and reduced resistance to wear and solvents.
Innovation Solution
A method involving machining of the slab surface, application of a dispersed ink, drying, and penetration of ink pigments into the slab by diffusion, followed by cooling and removal of excess ink, and finally applying a functional silazane compound to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dispersed ink is applied onto the slab surface to create decorations, then chromatic effects and decorations are formed, but the decorations become blurred and poorly defined
Solution Approach 1:
The slab surface is machined (sized, smoothed, polished) before ink application to create an optimal surface structure. This preliminary preparation ensures that when dispersed ink is applied, it penetrates uniformly and forms sharp, well-defined decorations rather than blurred patterns. The surface machining creates a controlled porosity and texture that guides ink penetration.
Solution Approach 2:
The physical and chemical parameters of the slab surface are modified through machining operations. The surface is transformed to have specific roughness, porosity, and texture characteristics that optimize ink absorption and penetration. This parameter change enables the dispersed ink to create sharp boundaries and clear decorations while maintaining ease of application.
2Shape
If machining operations are performed on the slab, then surface smoothness and finish are improved, but decorations previously applied are removed
Solution Approach 1:
The surface machining is performed before ink application rather than after. This preliminary action prepares the surface structure to optimize ink penetration while avoiding any subsequent machining that would remove or blur the decorations. The sequence is reversed from conventional methods to prevent decoration loss.
Solution Approach 2:
The conventional sequence of applying decoration then performing machining is inverted. Instead, the surface is machined first to create the optimal structure, then ink is applied. This inversion eliminates the problem where machining removes or blurs decorations, while still achieving the desired surface finish and decoration integrity.
3Manufacturing precision
If conventional ink application methods are used, then decorations can be applied to the slab, but resistance to wear and solvents is reduced
Solution Approach 1:
The physical parameters of the slab surface are changed through machining to create a surface with optimized porosity and texture. This modified surface structure enhances the penetration and bonding of dispersed ink, creating decorations that are deeply embedded in the surface rather than merely applied on top, thereby improving resistance to wear and solvents.
Solution Approach 2:
The combination of machined surface structure and dispersed ink creates a composite system where the ink-pigment mixture is integrated into the surface matrix. This composite structure provides both the decorative effect and enhanced durability, as the pigments are embedded within the modified surface material rather than being superficially applied.
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 method achieves clear, well-defined, and long-lasting decorations and chromatic effects on the slabs, while also improving their resistance to abrasion, solvents, and chemical agents, making them suitable for flooring and external cladding.
Implementation Method 1
the change in state favours the penetration, by means of diffusion, of the pigments into the surface layer of the slab
Implementation Method 2
an ink in which the pigments are intended to undergo a transition from the solid state to the liquid/gaseous state owing to the action of a heat source and/or application of a pressure
Implementation Method 3
applying a functional silazane compound to enhance durability
Data Source
AI summary
A method for manufacturing slabs made of stone or stone-like agglomerate material and having decorations and/or chromatic effects, including steps of machining at least one surface of the slab by means of sizing and/or polishing, applying a dispersed ink containing pigments on the at least one machined surface, drying the dispersed ink, penetration, by means of diffusion, of the pigments of the dispersed ink into the slab following a change in state of the pigments, to realize the decorations and/or the chromatic effects, cooling the slab, removing the excess or residual dispersed ink from the at least one surface of the slab, and applying a layer of functional compound on the at least one surface of the slab. Also relating to a slab of stone or stone-like agglomerate material including at least one surface with decorations and/or chromatic effects and a working intermediate for manufacture thereof.