Inkjet process for three-dimensional relief on tiles
A technique is described for the application of three-dimensional (3D) relief to a substrate such as a ceramic tile using digital inkjet technology. In an example embodiment, the introduced technique includes application of binder ink to a portion of the surface of a substrate using a digital inkjet process. This binder ink forms a barrier layer which protects the portion of the surface of the substrate. Next, a brushing process is applied to remove unprotected portions of the substrate, thereby forming the 3D relief in the substrate.
1. A system for forming a three-dimensional (3D) relief in a substrate, the system comprising:
a digital inkjet printer configured to:
apply binder ink to a first region of a surface of the substrate to form a protective barrier over the first region of the surface of the substrate based on a relief pattern; and
apply solvent ink to the substrate to cause at least some of the binder ink to sink into the substrate such that the protective barrier is at a gradient depth relative to the surface of the substrate; and
a mechanical brusher configured to:
brush the substrate to remove material from an unprotected second region of the substrate to form the 3D relief.
2. The system of claim 1 , wherein the input includes a digital image of the relief pattern and wherein the digital inkjet printer is configured to apply the binder ink by:
processing the received digital image to determine the first region of the surface of the substrate; and
propelling droplets of the binder ink at the first region of the surface of the substrate to recreate the relief pattern.
3. The system of claim 1 , wherein the binder ink includes a resin solution.
4. The system of claim 1 , wherein the substrate is a double charged ceramic tile including a top layer of absorbent material upon which ink can be applied using digital inkjet printing.
5. The system of claim 1 , further comprising:
a glazing apparatus configured to apply a glaze to the surface of the substrate after the 3D relief has been formed.
6. The system of claim 1 , wherein the digital inkjet printer is further configured to:
apply color ink to the surface of the substrate after the 3D relief has been formed.
7. The system of claim 1 , further comprising:
an automated kiln configured to fire the substrate after the 3D relief has been formed to produce a ceramic tile.
8. A method for operating a system for forming a three-dimensional (3D) relief in a substrate, the method comprising:
applying, by a digital inkjet printer of the system, binder ink to a first region of a surface of the substrate to form a protective barrier over the first region of the surface of the substrate based on a relief pattern;
applying, by the digital inkjet printer, solvent ink to the substrate to cause at least some of the binder ink to sink into the substrate such that the protective barrier is at a gradient depth relative to the surface of the substrate; and
brushing, by a mechanical brusher of the system, the substrate to remove material from an unprotected second region of the substrate to form the 3D relief.
9. The method of claim 8 , wherein the input includes a digital image of the relief pattern and wherein the digital inkjet printer applies the binder ink by:
processing the received digital image to determine the first region of the surface of the substrate; and
propelling droplets of the binder ink at the first region of the surface of the substrate to recreate the relief pattern.
10. The method of claim 8 , wherein the binder ink includes a resin solution.
11. The method of claim 8 , wherein the substrate is a double charged ceramic tile including a top layer of absorbent material upon which ink can be applied using digital inkjet printing.
12. The method of claim 8 , comprising:
applying, by a glazing apparatus of the system, a glaze to the surface of the substrate after the 3D relief has been formed.
13. The method of claim 8 , comprising:
applying, by the digital inkjet printer, color ink to the surface of the substrate after the 3D relief has been formed.
14. The method of claim 8 , comprising:
firing, by an automated kiln of the system, the substrate after the 3D relief has been formed to produce a ceramic tile.