Method of producing ceramic article with relief decoration

Details Method of producing ceramic article with relief decoration Method of producing ceramic article with relief decoration

1999-05-05

2001-06-05

Loney, Donald J. (Department: 1772)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C156S089240, C156S230000, C156S240000, C156S250000

Reexamination Certificate

active

06241837

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates to a method of producing ceramic articles with relief decoration.
One of the known techniques for relief or three-dimensional decoration of ceramic articles such as porcelains, earthenware and the like involves applying a planar or two-dimensional transfer decal to a relief image on a ceramic article, and then firing the ceramic article with the transfer decal thereon in a kiln at high temperature such that the decorative ceramic inks of the transfer decal is permanently fused onto the surface of the relief image of the ceramic article. The transfer decal has desired image corresponding to the relief image on the ceramic article and typically comprises a backing paper, a water-soluble film of glue on the backing paper, a decorative ceramic ink layer printed on the glue film, and a cover coat layer on the decorative ceramic ink layer. The transfer decal is soaked in the water to separate the decorative ceramic ink layer covered by the cover coat from the backing paper before application to the ceramic article. The ceramic article with relief image on its surface may be obtained by impressing technique or molding which is of known technique.
While it is easy to obtain a transfer decal having aesthetic, colorful, printed title such as scenery, characters, and people, etc., and a ceramic article with a relief image having raised and recessed portions, it is difficult to have the transfer decal adhered to and completely conformed to the ceramic article without any cavities or blisters between the transfer decal and the raised and recessed surfaces of the relief image of the ceramic article. It is known that such cavities or blisters may cause cleavages or shrinkage in the transfer decal when firing the ceramic article.
FIG. 1
shows a ceramic article
10
such as a mug having a relief design
14
covered by a transfer decal
16
. It can be seen that some spaces or cavities
18
exist between the transfer decal
16
and raised and recessed sections of the relief design
14
standing out from the curved outer surface
12
of the ceramic article
10
. In the prior art, it requires many laborious and costly manual operations to eliminate those spaces or cavities.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method for producing ceramic articles with relief decoration, ensuring that cavities or blisters that could possibill exist in between a relief image of a ceramic article and a transfer decal covered on the relief image can be significantly reduced and eliminated in a cost-effective manner.
A method of producing ceramic articles with relief decoration in accordance with the present invention comprises the steps of providing a ceramic article formed with a relief image thereon, providing a transfer decal having image corresponding to the relief image, perforating the transfer decal to form a plurality of perforations through the transfer decal, applying the perforated transfer decal to the ceramic article, and firing the ceramic article with the perforated transfer article in a kiln. A pin tool comprising an array of pins is used to perforating the transfer decal.
The relief image of the ceramic article can be formed in a mold or by an impressing roll wherein internal angle formed by each element of the relief image with respect to a surface of the ceramic article is less than 50 degree, preferably less than 45 degree, in order to facilitate conforming the perforated transfer decal to the ceramic article. The internal angle is formed at the junction where an edge of each element of the relief image and the surface of the ceramic article meet.
Upon applying the perforated transfer decal to the ceramic article, the perforations in the perforated transfer decal allow air captured therebetween to escape rapidly and thoroughly. Pressure is further applied to the perforated transfer decal against the surface of the relief image of the ceramic article manually or mechanically in order to avoid the development of cavities or blisters.
Other features and advantages of the present invention should be apparent from the following description of the preferred embodiment, which illustrates, by way of example, the principles of the invention.


REFERENCES:
patent: 3994727 (1976-11-01), Polichette et al.
patent: 5196248 (1993-03-01), Danico et al.
patent: 5362575 (1994-11-01), Trimble
patent: 5840418 (1998-11-01), Makita

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