SAME

BACKGROUND

A. Technical Field

[0001] The present subject matter relates generally to tiles and more particularly to ceramic tiles.

B. Background of the Invention

[0002] Tiles have been used since ages to cover interior walls, ceilings and facade of buildings etc. They may be applied on products on flat, angled and curved walls. The type and production method of tiles have undergone major changes with advancement of technology and change in tastes of the customers. [0003] A typical manufacturing process consists of various steps that may be classified into: preparing the raw materials, pressing, glazing, firing, sorting and finally packaging. The manufacturing process starts with the selection of the raw materials that make up the ceramic tile, essentially clays, feldspars, sand, carbonates and kaolins. As the raw materials are normally used exactly as they are extracted from the mines or quarries, it is essential to begin by ensuring that they are homogenised, in order to guarantee that their characteristics are consistent. [0004] They are therefore ground in order to disperse and reduce the particles. This grinding process may be wet or dry. Wet grinding is the most common method, whereby the clays are dissolved in water in a ball mill. The resulting suspension is known as 'slip'. Spray-drying is used to reduce its water content for the later compacting and drying processes.

[0005] The slip is pumped, sprayed and dried by a stream of hot gases inside the spray-dryer. A spray-dried powder is produced, made up of spherical granules that are uniform in shape and hollow inside, allowing for a fine loose powder which makes the mould-filling and pressing processes easier.

[0006] Dry pressing is the most common moulding method. The tiles produced usually have a moisture content of between 5 and 7 per cent, which is usually dried to reduce it to between 0.2 and 0.5 per cent in order to ensure successful firing, and, where appropriate, glazing. An excessively high water content may cause the tiles to crack or break.

[0007] In the case of unglazed products, after drying, the next phase is firing. If the tiles are to be glazed, then they must first be covered with one or more layers of glaze. This gives the tiles a series of technical and aesthetic features including colour, gloss and surface texture. Glazed tiles are also impermeable and easy to clean, and are chemically and mechanically resistant. Ceramic tiles are line-glazed and the most common techniques are waterfall glazing, spraying, dry glazing or decorating.

[0008] Firing is one of the most important stages in the manufacturing of ceramic tiles. During this process, a series of reactions take place that change the microstmcture of the tile, creating the required final properties such as mechanical strength, size stability, resistance to chemical agents and fire and easy cleaning. During the firing stage, the key variables in the thermal cycle are the firing time and temperature and the kiln atmosphere, which depend on the composition of the raw materials and the type of product required.

[0009] Today, fast firing is the most common method used in the production of ceramic tiles. Single layer roller kilns are now generally used, which have in many cases drastically reduced the firing cycle times to less than 40 minutes (thanks to the improved heat-transfer coefficients, as well as their uniform nature and flexibility). During this process, the heat is usually transmitted by convection and radiation.

[0010] A tile made of one of the above mentioned process is as shown in FIG. 1. It may be used as a decorative wall tile or glass brick strong cases, including the molten glass was poured into a mold comprising ceramic biscuit 101. The ceramic biscuit 101 is laminated and then coating done by pro coating method. The pre- coating method comprises step of engobing 103 and glazing 105 of the ceramic biscuit 101. Further a digital printing 107 is done on the ceramic biscuit with ultra- printing process.

[0011] However in conventional firing process is achieved by placing liquid glaze material on the ceramic biscuit and then heat it up at 1200 Degree Celsius, when material is melted and it forms a gloss layer on the ceramic biscuit and then both (glaze and ceramic biscuit) sealed with each other but because of baking the tile, many colors are evaporated and affect the color shade of printed color. [0012] There is therefore a need for tiles that provide for improved aesthetics including luster, durability with limited degradation in aesthetics and durability.

Summary of the Invention

[0013] A multilayered ceramic tile, a method and apparatus for making same are described. In one embodiment, the multilayered ceramic tile comprises of ceramic biscuit configured to engage with a float glass through binder. In between ceramic biscuit and float glass, there is a digital print and metallic coating. The ceramic biscuit and glass is compressed to form fused tile.

[0014] In one embodiment the method comprises the steps of applying a pre- digital printing coating on a first side of a glass, printing of primary colors at a set of angles defined by the nature of the design on the first side of the glass and applying a metallic coating on the first side of the glass. In some embodiments these may be preempted by the steps of laminating the glass on a second side prior to application of the pre-digital printing coating on the first side of the glass.

[0015] Further, the method may comprise the steps of applying a binder on a ceramic biscuit, pressing the glass on the first side and the ceramic biscuit together.

[0016] Since the top surface of the tile is glass (except a thin lamination on the top) the reflection of metallic coatings and the digital printing provides a magnificent three-dimensional visual effect, thereby providing a highly ornamental, decorative tile. The tiles are strong as well owing to the binding agent and the lamination used. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Reference will be made to embodiments of the invention, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

[0018] Fig. 1 illustrates a schematic of a conventional tile and layers thereof.

[0019] Fig. 2 illustrates a schematic of a multilayered tile and layers thereof as per an embodiment herein.

[0020] Fig. 3 illustrates a method a multilayered tile as per an embodiment herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] A multilayered ceramic tile and a method for making same are described. In one embodiment, the multilayered ceramic tile comprises of ceramic biscuit configured to engage with a float glass through binder. In between ceramic biscuit and float glass, there is a digital print and metallic coating. The ceramic biscuit and glass is compressed to form fused tile.

[0022] In the following description, for purpose of explanation, specific details are set forth in order to provide an understanding of the invention. It will be apparent, however, to one skilled in the art that the invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of different tile making systems, methods and devices. The embodiments of the present invention may be present in hardware, software or firmware. Structures and devices shown below in block diagram are illustrative of exemplary embodiments of the invention and are meant to avoid obscuring the invention. Furthermore, connections between components within the figures are not intended to be limited to direct connections. Rather, data between these components may be modified, re-formatted or otherwise changed by intermediary components.

[0023] Reference in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment. The headings and subheadings used in the document are not intended to limit the content therein to respective heading or subheading. Rather, they are used to help reader navigate and prevent obscuring the invention.

A. Overview

[0024] Fig. 2 discloses a schematic diagram of a fused tile 200 of the present subject matter. The tile may comprise of ceramic biscuit 201 made up of for example, kaolin ballclay, chinaclay, feldspar, ukrain. The ceramic biscuit 201 may engage with glass 207 through binder 203. In between ceramic biscuit and float glass, there may be a digital print 205a and metallic coat 205b.

B. Method of Construction

[0025] A method of making a multilayered fused tile as per an embodiment herein is shown in Fig. 3.

[0026] The method may comprise of forming ceramic biscuit. This might be made up of various materials used to form tile biscuits such as, for example, kaolin ballclay, chinaclay, feldspar, ukrain In parallel to the above step of forming ceramic biscuit or irrespective thereof the following steps of preparing the glass may be performed. Laminating 301 a glass. In one exemplary embodiment, the glass may be a float glass. The thickness of glass may vary and in an exemplary embodiment may be 1.5 mm. The lamination may be done on one side of the glass. Further, a pre-digital printing coating 302 of the glass may be performed in preparation for digital printing. Since digital printing may use UV-curing such coating are preferred. This may be done on the other side of the glass. For example, on the opposite side of the side used for lamination. In one exemplary embodiment, a product called Ultra glass UVGO provided by Marabu GmbH & Co. KG may be used for coating.

[0027] Then, Digital printing 303 may be performed on the other side of the glass by using for example the color model CMYK (Cyan, Magnata, Yellow and key/black). The colors file of the design to be printed may be processed and computer may instruct the printing machine to print at primary colors at different angles. For example CMYK colors may be incident on the glass at a defined set of angles. In one exemplary embodiment Cyan may be incident at 45 degrees, magenta at 30 degrees, yellow at 0 degrees and Key/black at 60 degrees. The angle chosen for printing of the inks of primary colors may depend on the design desired. Printing 303 of primary colors at a set of angles defined by the nature of the design may be performed. For example, for a design 1, they CMYK printing angles may be 30,45,0,60, while for a design 2, may be 0,30,45,60. Further, a metallic coating may be provided 304. In one exemplary embodiment spray coating may be performed. Various metallic colors such as for example, silver, copper, golden may be used.

[0028] The multilayered coloring provides combined effect of multiple colors at different angles giving rise to aesthetically pleasing product. A second set of angles may be defined for other designs. Further, post coating is done on glass.

[0029] A binder glue such as for example epoxy binder may be used for fusing 304 the printed glass on the tile biscuit formed in step 301. This glue does not chemically react with the print and settling time of this glue in exemplary embodiments may be about 8-10 hours. After that glass is properly sealed with the tile the glue may be transparent therefore having little to no effect on the color/s of the finished tile. Softness of glue is maintained according to glass and tile's hardness.

[0030] Glue (epoxy) may be mixed with hardener in a definite ratio to adjust the fusion time and by changing the ratio of glue (epoxy) and hardener, the fusion time may increase or decrease.

[0031] The step of fusing ceramic biscuit and glass with each other may be done by using cold process. In cold process glass and ceramic biscuit are prepare at their respective temperature separately and then fusion is achieved by sealing glass and ceramic biscuit using mixture of glue (epoxy) and hardener in the definite ratio.

[0032] The fused tile's strength enough, it can tile or wall as a ground to use, practical, wide application, laying floor tiles or wall stickers set also has a decorative effect, beautiful and practical.

[0033] Further, since the top surface of the tile is glass (except a thin lamination on the top) the reflection of metallic coatings and the digital printing provides a magnificent three-dimensional visual effect, thereby providing a highly ornamental, decorative tile. The tiles are strong as well owing to the binding agent and the lamination used.

[0034] While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by the way of figures/ examples in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject, some features may be omitted. In some other cases, some features may be emphasized while other are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternately, the methods may be performed in manner or order different than what is explained without departing from the spirit, meets and bounds of the present subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as described above.