Three-Dimensional Tile Coating With Powder-First Adhesive Application
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Solution Overview
Problem
Existing methods for creating three-dimensional structures on ceramic tiles are limited by the thickness of the structure that can be achieved, require multiple pads or glues, and are prone to defects such as bubble formation and contamination, leading to complex and costly processes.
Innovation Solution
A process involving applying a fixing agent in a given pattern, depositing a solid powder material, removing unfixed material by suction, and subjecting the product to firing, which allows for greater thickness and precision in the three-dimensional coating, reducing defects and enabling diverse visual effects.
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 the maximum thickness of the structure is limited to 0.4-0.5 mm, but the process complexity and cost increase due to the need for precise particle-size classification and multiple solids management
Solution Approach 1:
The patent changes the particle size parameter of the solid ceramic material from the traditional fine grit (requiring precise classification) to coarser particles. This parameter change allows achieving greater structure thickness (over 0.5 mm) while simplifying the classification process and reducing the need for multiple solids, thereby decreasing process complexity
Solution Approach 2:
Instead of applying glue first and then adding solid material (traditional glue-grit method), the patent inverts the sequence by first depositing the solid ceramic material and then applying the adhesive. This inversion allows the use of coarser particles that can form thicker structures while being easily retained by the adhesive, simplifying the overall process
2Manufacturing precision
If multiple solids with different chemical and mineralogical compositions are used to obtain surface variations, then the aesthetic quality improves, but the process complexity increases due to the need to manage multiple solids and prevent contamination
Solution Approach 1:
The patent segments the surface appearance variation achievement into two independent parts: (1) using a single solid material deposited in a uniform layer, and (2) creating variations through the adhesive application pattern and digital printing. This segmentation eliminates the need to manage multiple solids while still achieving diverse aesthetic effects
Solution Approach 2:
The patent introduces the adhesive as an intermediary that enables surface appearance variations without requiring multiple solids. The adhesive is applied in specific patterns to create visual effects, and it mediates between the single solid material and the final aesthetic result, eliminating contamination risks associated with multiple solids
3Manufacturing precision
If fine solid materials are used with the glue-grit method, then the aesthetic result improves, but bubble defects occur due to degassing problems as the glue must pass through the solid layer to volatilize
Solution Approach 1:
The patent inverts the traditional sequence by first depositing the solid material and then applying the adhesive. This inversion eliminates the degassing problem because the adhesive is applied on top of the solid layer rather than needing to pass through it. The adhesive can volatilize freely without trapping air bubbles, eliminating bubble defects while maintaining aesthetic quality
4Reliability
If the adhesive is applied too early before solid material deposition, then the adhesive is absorbed by the support and becomes partially unavailable for adhesion, but waiting too long reduces the quantity of solid material that will adhere
Solution Approach 1:
The patent inverts the traditional sequence by first depositing the solid material and then applying the adhesive. This inversion eliminates the timing problem entirely because the adhesive is always applied after the solid material is in place. The adhesive never gets absorbed by the support before bonding to solids, ensuring maximum adhesive availability and consistent adhesion quality
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 graphic contours, reduces defects, and allows for varied visual effects without compromising the aesthetic quality, using less fixing agent and simplifying the production process.
Implementation Method 1
removing unfixed solid powder material, preferably by means of suction
Implementation Method 2
subjecting the product obtained in step e) or f) to firing
Data Source
Figure 1
Figure 2a~2d
AI summary
The present invention relates to a process for producing a three-dimensional tile, a three-dimensional tile obtained by said process and an article comprising said tile.