# US 2014/0197577 A1 · Durable earthenware engraving process > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0197577 A1 - Document ID: US20140197577A1 - Status: Published application - Kind: A1 - Application number: 14/155,242 - Filed: 2014-01-14 - Published: 2014-07-17 - Earliest claimed: 2013-01-14 - Inventors: Geoffrey Gretton - Web page: https://patentgrep.com/patent/US20140197577A1 ## CPC - B28B 7/346: {Manufacture of moulds} - B28B 7/0064: {Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces (B28B7/36 takes precedence; producing decorative effects B44C; designs of stone surfaces B44F)} - B28B 7/348: {of plastic material or rubber} - B28B 11/001: {Applying decorations on shaped articles, e.g. by painting} - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) ## Abstract A method of forming a detailed image on a surface of an earthenware item is disclosed. The method comprises: (a) processing a digital image to produce an output image; (b) etching a burnable material to create peaks, valleys and indents corresponding to the output image to form a mold; (c) casting a flexible template against the mold to obtain a mirror image of the output image in the flexible template; (d) casting a surface of the earthenware in an unsintered state against the flexible template to record the output image by peaks and valleys in the surface of the earthenware item; (e) bisque firing the earthenware item in the unsintered state to render the output image permanent; and (f) applying stain to the surface of the bisque fired earthenware item and removing excess stain from of the surface of the earthenware item. ## Claims ### Claim 1 A method for durably engraving an earthenware item, said method comprising: (a) processing a digital image to produce an output image, wherein said output image comprises a plurality of pixels each having a gray level; (b) etching a burnable material to create peaks, valleys and indents corresponding to said output image to form a mold, wherein said burnable material comprises a surface roughness; (c) casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template; (d) casting a surface of the earthenware item in an unsintered state against said flexible template to record said output image by peaks and valleys in said surface of the earthenware item; (e) bisque firing the earthenware item in the unsintered state to render said output image permanent; and (f) applying a stain to said surface of the earthenware item in the sintered state and removing excess stain from said surface of the earthenware item. ### Claim 2 (depends on 1) The method of claim 1, wherein said etching step comprises ablating said burnable material by varying the power level of a laser ablation apparatus according to the gray level of said plurality of pixels. ### Claim 3 (depends on 1) The method of claim 1, wherein said earthenware is selected from a group consisting of ceramic, stoneware, bone china and porcelains. ### Claim 4 (depends on 1) The method of claim 1, wherein said stain is an oxide. ### Claim 5 (depends on 1) The method of claim 1, wherein said burnable material is selected from a group consisting of Medium Density Fiberboard (MDF), pressed paper fiberboard, Masonite, coated wall board and silicone rubber. ### Claim 6 (depends on 1) The method of claim 1, wherein said burnable material is a fine grain hardwood having a grain structure, wherein said etching step exposes said grain structure. ### Claim 7 (depends on 1) The method of claim 1, wherein said burnable material is a pressed paper fiberboard adapted to be bonded to a substrate, wherein said surface roughness of said pressed paper fiberboard corresponds to a grit number ranging from about 120 to about 150. ### Claim 8 (depends on 1) The method of claim 1, wherein said output image is selected from a group consisting of line art images, halftone images and depth maps. ### Claim 9 (depends on 1) The method of claim 1, wherein said flexible template is constructed from silicone rubber. ### Claim 10 A method for durably engraving an earthenware item, said method comprising: (a) processing a digital image to produce an output image, wherein said output image comprises a plurality of pixels; (b) etching a burnable material to create peaks, valleys and indents corresponding to said output image to form a mold, wherein said burnable material comprises a surface roughness; (c) casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template, wherein said flexible template is constructed from an incinerable material; (d) applying stain to said mirror image of said output image in said flexible template; (e) engaging said mirror image of said output image of said flexible template against a surface of the earthenware item in an unsintered state to record said output image by peaks and valleys in said surface of the earthenware item; and (f) bisque firing the earthenware item in the unsintered state to render a complementary image of said mirror image of said output image of said flexible template permanent. ### Claim 11 (depends on 10) The method of claim 10, wherein said burnable material is pressed paper fiberboard. ### Claim 12 A method for durably engraving an earthenware item, said method comprising: (a) processing a digital image to produce an output image, wherein said output image comprises a plurality of pixels; (b) etching a burnable material to create peaks, valleys and indents corresponding to said output image to form a mold; (c) applying colorant to said mold and removing excess colorant from said mold; (d) casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template, wherein said flexible template is constructed from an incinerable material; (e) engaging said mirror image of said output image of said flexible template against a surface of the earthenware item in an unsintered state to record said output image by peaks and valleys in said surface of the earthenware item; and (f) bisque firing the earthenware item in the unsintered state to render a complementary image of said mirror image of said output image of said flexible template permanent. ### Claim 13 (depends on 12) The method of claim 12, wherein said earthenware is selected from a group consisting of ceramic, stoneware, bone china and porcelains. ### Claim 14 (depends on 12) The method of claim 12, wherein said output image is selected from a group consisting of line art images, halftone images and depth maps. ### Claim 15 (depends on 12) The method of claim 12, wherein said flexible template comprises acrylic. ### Claim 16 (depends on 12) The method of claim 12, wherein said step of casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template comprises heating said flexible template. ### Claim 17 (depends on 12) The method of claim 12, wherein said step of casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template comprises a technique of applying a material to form said flexible template that is selected from a group consisting of painting the material on said mold with a brush and spraying the material on said mold. ### Claim 18 (depends on 12) The method of claim 12, wherein said step of casting a flexible template against said mold to obtain a mirror image of said output image in said flexible template comprises incorporating a carrier sheet to form said flexible template. ### Claim 19 (depends on 18) The method of claim 18, further comprising a step for perforating said flexible template such that perforations form through the thickness of said flexible template. ### Claim 20 (depends on 19) The method of claim 19, wherein said step of perforating said flexible template is performed by perforating said flexible template starting from the side of said flexible template opposingly disposed from said carrier sheet.