WO2007069872A1

WO2007069872A1 - Refreshed image tile

Info

Publication number: WO2007069872A1
Application number: PCT/KR2006/005506
Authority: WO
Inventors: Bu Sik Kim
Original assignee: Bu Sik Kim
Priority date: 2005-12-15
Filing date: 2006-12-15
Publication date: 2007-06-21

Abstract

Provided an image tile which is manufactured by refreshing a defective tile generated in a baking process or an overproduced tile. In the image tile, the surface thereof is processed by a sandblast process, a picture or photograph is printed on the processed surface, and the printed image layer is coated, thereby forming a picture or photograph image.

Description

REFRESHED IMAGE TILE

Technical Field

[1] The present invention relates to an image tile which is manufactured by refreshing a defective tile generated in a baking process or an overproduced tile. In the image tile, the surface thereof is processed by a sandblast process, a picture or photograph is printed on the processed surface, and the printed image layer is coated, thereby forming a picture or photograph image.

Background Art

[2] In general, tiles are used as internal and external finishing materials for construction. [3] Such a tile is manufactured by baking clay in a cake shape. After glaze is applied on the surface of the tile, the tile is again baked. [4] Typically, a tile producer receives an order from customers so as to produce tiles. In a process where tiles are manufactured, a large number of defective tiles are generated.

Therefore, a larger number of tiles are inevitably produced than the number of tiles ordered by customers. [5] In such defective tiles, abnormalities are not found in a clay layer. However, cracks occurring in the baking process are found, because the thickness of applied glaze is not uniform. Further, bubbles are formed on the surface of the glaze layer. The proportion defective of tiles generated in a tile manufacturing process is unexpectedly high. [6] Conventionally, such defective tiles have been discarded because they have no commodity value. In this case, it costs a lot of money to discard defective tiles.

Further, when defective tiles are discarded, an environmental consideration should be made. [7] Further, most of outdated tiles have been discarded because they also have no commodity value. The discarding of a large number of defective tiles and outdated tiles having no commodity means that resources are wasted. [8] Accordingly, a technique has been proposed in which an image (picture or photograph) is printed on the tiles, which are not reused even though they can be reused, so as to manufacture image tiles. [9] In such image tiles, ink sprayed in a printing process is not permeated into the tiles and hardens on the surface thereof so as to form an image layer. In this case, however, the resolution of the image layer is considerably low, and the image layer is easily damaged by external causes such as scratching and the like. [10] Further, the image layer is easily decolored and is wiped by a volatile material. Further, cracks can occur on the image layer. Such defects significantly reduce a quality of the image tile. [H]

Disclosure of Invention

Technical Problem

[12] An advantage of the present invention is that it provides a refreshed image tile which is manufactured by refreshing a defective tile generated in a baking process, an overproduced tile, an outdated tile and the like. In the refreshing of the tiles, the surface of the tile is processed by a sandblast process, and a picture or photograph is printed on the processed surface. Further, the printed image layer is coated so as to provide a refreshed image tile on which a picture or photograph is printed.

[13] Another advantage of the invention is that it provides a refreshed image tile in which an image is formed to be permeated into the surface of the tile such that the resolution of the image increases and the image is not easily damaged by an external cause such as scratching.

[14] A further advantage of the invention is that it provides a refreshed image tile on which a partial image is printed like a portion of mosaic. When a plurality of image tiles having a partial image are arranged like a checkerboard, partial images are combined so as to represent an entire image. Such image tiles can be attched on the inner and outer walls of a building. Technical Solution

[15] According to an aspect of the invention, a refreshed image tile is manufactured by the steps of: peeling off a glaze layer from the surface of a tile which is mainly formed of clay and is subjected to a baking process; applying primer on the surface on which the glaze layer is removed; and sublimation-transferring an image onto the surface on which the primer is applied. In the peeling off of the glaze layer, minute grooves are formed on the surface of the tile by a sandblast process, and ink is permeated into the minute grooves so as to form an image.

[16] Further, the minute grooves are formed to have a depth of 0.15mm to 0.2mm.

Advantageous Effects

[17] According to the present invention, the minute grooves are formed at a predetermined depth on defective tiles, outdated tiles, or overproduced tiles by a sandblast process. The ink forming an image is permeated into the minute grooves such that a high-resolution and high-quality image can be realized. Therefore, the commodity value of the tile can be increased, and new goods can be produced.

[18] On the walls of a subway station, an overpass, an entrance of parking lot, a kindergarten and the like, on which people's eyes are turned, the image tiles can be used as finishing materials. Therefore, it is possible to create a more agreeable environment.

[19] Further, a plurality of partial images are separately manufactured by using the refreshed image tiles and are continuously arranged like a checkerboard such that a large-sized image can be represented.

[20] Further, tiles to be discarded can be refreshed so as to be used. Therefore, a cost of discarding the tile can be saved, and environmental pollution can be prevented. Brief Description of the Drawings

[21] Fig. 1 schematically shows a refreshing process of a refreshed image tile according to the invention.

[22] Fig. 2 is a diagram exemplifying the refreshing process of the refreshed image tile according to the invention.

[23] Fig. 3 is a sectional view illustrating the refreshed image tile according to the invention.

[24] Fig. 4 is a diagram showing an example where the refreshed image tile according to the invention is attached.

[25]

Best Mode for Carrying Out the Invention

[26] Hereinafter, the present invention will be described in detail.

[27] Fig. 1 schematically shows a refreshing process of a refreshed image tile according to the invention. Fig. 2 is a diagram exemplifying the refreshing process of the refreshed image tile according to the invention. Fig. 3 is a sectional view illustrating the refreshed image tile according to the invention. Fig. 4 is a diagram showing an example where the refreshed image tiles according to the invention are attached.

[28] First, a tile is manufactured by a typical tile manufacturing method. The manufacturing process thereof will be simply described as follows.

[29] Clay is baked in a cake shape, and glaze is then applied on the clay baked in a cake shape. The baking is performed at temperature of more than 1000 C.

[30] The tile 1 manufactured by the above-described manufacturing method is refreshed into a refreshed image tile by the process described in Fig. 1. Referring to Fig. 1, the respective steps of the process will be described.

[31] (1) Pearskin Finishing of Tile Surface (SlOO)

[32] The glaze layer on the surface of the set tile is peeled off by a physical method. In the invention, the glaze layer is peeled off by a sandblast process.

[33] In this case, an abrasive is jetted on the surface of the tile, which is referred to pearskin finishing. The abrasive is jetted from a nozzle at a right angle with respect to the surface. Here, the abrasive is jetted at a right angle, in order to prevent capillary- shaped portions from being generated on the surface of the tile. Then, a microvoid- shaped abraded surface with high precision can be formed on the pearskin-finished surface of the tile. The abraded surface formed in such a manner has grooves with a predetermined depth D.

[34] When printing is performed, the best image can be provided by the grooves formed in such a manner.

[35] Preferably, the minute grooves are formed to have a depth D of 0.15mm to 0.2 mm.

When the depth is larger than 0.2 mm, the tile itself becomes fragile, and an image formed thereon becomes coarse. On the contrary, when the depth is smaller than 0.15mm, ink is not sufficiently permeated. In this case, when a formed image is scratched, it is easily peeled off.

[36]

[37] (2) Primer Processing (S200)

[38] In order to provide an affinitive adhesive strength on the surface of the inorganic tile, organic synthetic resin and primer are applied on the pearskin finished surface of the tile.

[39]

[40] (3) Object Formation and Transfer Paper Manufacturing (S300)

[41] An image desired by a client is prepared. Particularly, when an image such as a large-sized wall painting is desired to be represented, a partial image suitable for the size of the tile is selected.

[42] High-resolution transfer paper is printed and manufactured by using disperse dye such as offset ink (for printing), printer ink (for cartridge jetting), or ink used in a gravure printing mechanism such that a transfer-printed image 2 is prepared.

[43]

[44] (4) Image Reception Layer Formation

[45] An object of a typical printed matter is heated at 180 to 220 C for one to two minutes such that an image reception layer is formed.

[46]

[47] (5) Completion

[48] The transfer paper image 2 is closely attached on the layer having disperse dye design formed thereon and is then pressed at the temperature of 180 to 220 C through hot pressing. Then, dyeing is completed.

[49]

[50] In the image tile according to the invention, when transfer printing is performed, the disperse dye is transferred and dyed onto an object through heating sublimation. Particularly, the disperse dye is permeated into the minute grooves which are formed on the surface of the tile at a predetermined depth by a sandblast process. As a result, an image is smoothly formed so that a high-resolution and high-quality image is realized.

[51] In the primer processing step, resin is applied and attached on the grooves of the tile. In other words, the resin is inserted into the grooves such that the tile and the resin layer of primer are prevented from being easily separated. Therefore, the durability is strengthened.

[52] Although the surface of the tile having an image formed thereon is scratched by a sharp body, the image is not easily damaged, because the ink forming the image is permeated into the minute grooves. Therefore, it is possible to maintain the original image.

[53] Meanwhile, a photocatalytic agent is applied and baked at high temperature or low temperature such that a coating layer 3 can be formed on the surface of the tile. Therefore, dust or the like is not easily adhered on the surface of the tile.

[54] Further, as described above, an image desired by a customer is formed on the tile 1 such that the commodity value thereof increases. Further, partial images are manufactured and continuously arranged like a checkerboard so that a large-sized image can be represented as shown in Fig. 4.

[55] While the present invention has been described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes and modifications in form and detail may be made therein without departing from the scope of the present invention as defined by the following claims.

Claims

[1] A refreshed image tile manufactured by the steps of: peeling off a glaze layer from the surface of a tile which is mainly formed of clay and is subjected to a baking process; applying primer on the surface on which the glaze layer is removed; and sublimation-transferring an image onto the surface on which the primer is applied, wherein, in the peeling off of the glaze layer, minute grooves are formed on the surface of the tile by a sandblast process, and ink is permeated into the minute grooves so as to form an image. [2] The refreshed image tile according to claim 1, wherein the minute grooves are formed to have a depth of 0.15mm to 0.2mm.