Three-Dimensional Ceramic Tile Coating Using Coarse Powder
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Solution Overview
Problem
Existing methods for creating three-dimensional structures on ceramic tiles are limited by the maximum thickness of the structure, require precise sifting and classification of ceramic materials, are costly, and prone to defects due to adhesive degassing and contamination, with limited versatility and aesthetic control.
Innovation Solution
A process involving applying a fixing agent in liquid form to a ceramic tile, depositing a solid powder material, and removing unfixed material by suction, followed by firing, which allows for greater thickness and precision in the three-dimensional coating, reducing adhesive usage and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the glue-grit method is used with digital printers to create three-dimensional structures on ceramic tiles, then aesthetic control and precision are improved, but the maximum thickness of the structure is limited to 0.4-0.5 mm
Solution Approach 1:
The patent changes the particle size parameter of the solid ceramic material from fine (0.4-0.5 mm limit) to coarse (0.6-1.0 mm or larger), which enables greater structure thickness while maintaining aesthetic control through digital printing of the adhesive
Solution Approach 2:
Instead of using fine particles that require thin layers for proper adhesion, the patent inverts the approach by using coarse particles that can support thicker structures, reversing the conventional wisdom that fine materials are always superior for digital printing applications
2Manufacturing precision
If fine solid ceramic materials are used to achieve desired aesthetic results, then surface appearance quality is improved, but adhesive degassing problems increase creating bubble defects
Solution Approach 1:
The patent changes the particle size parameter from fine to coarse materials, which fundamentally alters the adhesive's behavior during application. Coarse particles create larger void spaces that facilitate gas escape, eliminating bubble defects while maintaining aesthetic quality through controlled adhesive deposition
3Adaptability or versatility
If multiple solid ceramic materials are used to create surface variations, then aesthetic diversity is improved, but contamination between materials increases causing defects
Solution Approach 1:
The patent applies different solid ceramic materials to different local areas of the tile surface based on the desired aesthetic effect. Each area receives a specifically selected material type, and the digital printing technology ensures precise spatial control, preventing cross-contamination between different material zones
Solution Approach 2:
Instead of physically handling and transferring multiple material types which risks contamination, the patent uses digital printing to create a precise map of adhesive deposition patterns that guides where each material type should be applied, effectively copying the desired final pattern before material application
4Productivity
If structured press pads are used to create three-dimensional structures on large-sized tiles, then production efficiency is improved, but versatility decreases requiring numerous pads for different structures
Solution Approach 1:
The patent creates a universal system where a single digital printing device can produce any desired three-dimensional structure pattern by programmatically controlling adhesive deposition. This multi-functional approach replaces the need for multiple specialized press pads, maintaining high production efficiency while enabling unlimited structure variety
Solution Approach 2:
The patent replaces the mechanical press pad system with a digital printing system that uses controlled adhesive deposition followed by material application. This substitution eliminates the need for physical contact between the patterning tool and the tile surface, enabling versatile pattern creation without mechanical tool changes
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 process achieves thicker and more defined three-dimensional coatings with improved aesthetic control, reduced adhesive usage, and minimized defects, enabling varied graphic and color effects without contamination.
Implementation Method 1
a fixing agent, in liquid form... depositing a solid powder material... making these materials adhere to the surface using glue
Implementation Method 2
removing unfixed solid powder material, preferably by means of suction... The suction can be regulated in terms of both height and power to ensure an efficient and precise suction of the non-fixed material
Implementation Method 3
The tile thus prepared is then subjected to high-temperature firing and the finished product is obtained by sintering
Data Source
AI summary
A process for producing a three-dimensional tile, a three-dimensional tile obtained by the process and an article comprising the tile, the process including providing a support having a surface, depositing a solid powder material on the surface to form a uniform layer, printing at least one fixing agent in liquid form according to a pattern, removing the unfixed solid powder material, and subjecting the product to firing.