Description:FORM 2
THE PATENT ACT 1970
(39 of 1970) &
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
"Ultra White Tile and Process for Manufacturing the Same"
________________________________________
2. APPLICANT (S)
APPLICANT (S)
NAME NATIONALITY COUNTRY OF
RESIDENCE ADDRESS
Simpolo Vitrified Pvt. Ltd.
INDIA
INDIA Simpolo Vitrified Pvt. Ltd.
Old Ghuntu Road, Morbi-363642

PREMABLE TO THE DESCRIPTION
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

"Ultra White Tile and Process for Manufacturing the Same"

Field of the Invention
The present invention relates to the field of ceramic tile manufacturing, specifically to a novel composition and process for producing ultra-white vitrified tiles with significantly enhanced optical and thermal properties. More particularly, the invention pertains to the formulation of both the body and surface layer (special slurry) of the tile that results in:
• A Lightness (L) value of 94 or higher, indicating exceptional brightness and whiteness, and
• A Solar Reflective Index (SRI) of 107, which makes the tile highly reflective to solar radiation and suitable for energy-efficient roofing or exterior cladding applications.
This invention falls within the domain of building materials, ceramic engineering, and advanced surface coating technologies. It further incorporates functional additives such as silver ion-based antibacterial agents into the surface layer, thereby offering not only improved thermal performance and brightness but also hygienic properties for application in both commercial and residential environments.
The invention also addresses the technical challenges associated with achieving ultra-white finishes in fired ceramic bodies, including formulation of high-opacity top surface coatings, maintaining dimensional stability during firing, and ensuring compatibility between body and glaze layers under high-temperature kiln conditions.
The invention can be applied to floor tiles, wall tiles, facade panels, solar-reflective roofing tiles, and specialty architectural ceramics, particularly in applications where high albedo, energy efficiency, and aesthetic appearance are desired.

Background of the Invention
Ceramic tiles are one of the most widely used building materials in modern construction, valued for their durability, aesthetic appeal, water resistance, and ease of maintenance. Among the various types of tiles, white and ultra-white tiles are in particularly high demand due to their clean appearance, high reflectivity, and ability to visually expand interior and exterior spaces.
However, achieving consistent ultra-white shades in ceramic tiles remains a technical challenge for manufacturers. The whiteness of a tile is commonly measured using the Lightness (L) value on the CIELAB scale, where an L-value above 90 indicates high brightness. Yet, most commercially available white tiles fail to reach L-values of 94 or above, particularly after high-temperature firing in kilns. Factors such as the raw material composition, impurities in clays or fluxes, and inadequate surface coatings contribute to a drop in whiteness after vitrification.
In addition to color quality, solar reflectivity has become an increasingly important performance metric. Tiles with a high Solar Reflective Index (SRI) can reflect more sunlight and absorb less heat, contributing to cooler building surfaces. This is particularly critical in tropical or arid regions, where the urban heat island effect and energy consumption for cooling are major concerns. Traditional tiles often lack sufficient SRI, limiting their application on rooftops or exterior wall claddings where thermal insulation is vital.
Furthermore, the market is increasingly demanding value-added functionalities such as antibacterial surfaces, especially in public, healthcare, or hygienic environments. Conventional white tiles typically require post-manufacture coatings or treatments to gain these functionalities, which increases cost and reduces long-term durability.
While various attempts have been made to improve tile whiteness, surface hardness, and functional performance, existing solutions often compromise on one or more of these parameters. For example:
• Some manufacturers use high zircon content to increase opacity, but this significantly raises production cost.
• Others rely on thick glaze layers, which may cause delamination or cracking during firing.
• Silver ion coatings for antibacterial function are often applied as external treatments, which can wear off over time.
Therefore, there is a clear need for a tile that integrates:
• A body and top surface formulation that ensures high whiteness (L ≥ 94) after firing,
• A Solar Reflective Index of at least 107,
• Antibacterial functionality built directly into the tile matrix, and
• Compatibility with standard manufacturing processes including pressing, drying, firing, and polishing.
The present invention—ULTRA WHITE TILE1—addresses these longstanding industry problems by introducing a specialized combination of raw materials in the tile body and a scientifically engineered top surface slurry. This results in a tile with unmatched whiteness, thermal reflectivity, mechanical strength, and hygiene features, all manufactured within existing industrial lines.

OBJECT OF THE INVENTION
The primary object of the present invention is to develop an ultra-white vitrified tile that exhibits:
• A Lightness (L) value of 94 or more, indicating superior brightness and whiteness, and
• A Solar Reflective Index (SRI) of 107, making the tile highly effective in reflecting solar radiation and minimizing heat absorption.
More specifically, the invention seeks to achieve the following key objectives:
1. To formulate an advanced tile body composition using a carefully selected blend of minerals and clays—such as feldspar, ball clay, kaolin, quartz, wollastonite, bentonite, frit, and corundum—optimized for high-temperature firing while preserving whiteness and dimensional stability.
2. To engineer a specialized surface slurry that can be applied over the dried tile body, which enhances whiteness, reflectivity, opacity, and functional properties of the final tile. The slurry includes ingredients like titanium dioxide (rutile), zircon, zinc oxide, frit (opaque), and silver ions for antibacterial effect.
3. To improve the solar reflectivity of the tile by incorporating highly reflective minerals and oxides in the surface layer so that the tile reflects a significant portion of incident sunlight, reducing heat gain in buildings and enabling energy savings.
4. To achieve integrated antibacterial properties in the tile without the need for external coatings, using silver ion-based additives in the surface slurry. This helps inhibit microbial growth on the tile surface, making it suitable for hygiene-sensitive applications.
5. To maintain compatibility with conventional tile production processes, such as ball milling, spray drying, pressing, drying, surface coating, high-temperature kiln firing (around 1200°C), polishing, and sizing—thereby ensuring scalability and ease of industrial adoption.
6. To offer a surface finish that is polishable, aesthetically appealing, and resistant to wear, ensuring that the tile retains its brightness and reflectivity even after prolonged use.
7. To provide a cost-effective alternative to existing white or reflective tiles, by optimizing the composition and reducing dependence on expensive whiteners like high-purity zircon or specialty coatings.
8. To produce tiles suitable for diverse applications, including interior flooring, wall cladding, exterior facades, rooftops, public infrastructure, and hygiene-critical environments such as hospitals, kitchens, and laboratories.
By achieving these objectives, the invention provides a technologically advanced, aesthetically superior, and functionally enriched tile product that meets modern architectural, environmental, and hygienic demands.

Statement of the Invention
The present invention discloses a novel composition and manufacturing process for producing ultra-white vitrified tiles, herein referred to as ULTRA WHITE TILE1, which possess a high degree of brightness with a Lightness (L) value of 94 or greater, and a Solar Reflective Index (SRI) of 107. These tiles are designed for both aesthetic excellence and high solar reflectivity, making them suitable for energy-efficient architectural applications.
The invention comprises two main components:

1. Tile Body Formulation:
A unique combination of raw materials is used to form the base tile body, which is ball-milled, spray-dried into granules, and pressed to form the tile base. The formulation includes:
• Feldspar: 47% to 50%
• Kaolin clay: 10% to 12%
• Ball clay: 25% to 30%
• Quartz: 4% to 5%
• Wollastonite: 4% to 5%
• Bentonite: 2% to 3%
• Frit (flux): 5% to 6%
• Corundum: 3% to 4%
This combination ensures proper vitrification, thermal strength, dimensional stability, and a light-colored body suitable for applying the special slurry.

2. Special Slurry Formulation for Top Surface Coating:
Before kiln firing, a surface coating layer (up to 1 mm thickness) is applied over the dried tile using a specially developed slurry containing high-opacity and high-reflectivity minerals. The special slurry comprises:
• Titanium Dioxide (Rutile): 1% to 2%
• Zinc Oxide: 4% to 6%
• Corundum: 10% to 12%
• Magnesium Oxide: 3% to 4%
• Zircon: 18% to 20%
• Nepheline: 8% to 10%
• Frit (opaque): 30% to 35%
• Quartz: 15% to 16%
• Kaolin Clay: 10% to 11%
• Anti-bacterial Agent (Silver Ion-based): 1% to 2%
This surface layer is critical to achieving the final tile's brightness (L-value), high SRI, surface hardness, polishability, and antibacterial properties.

Manufacturing Process Steps:
1. Raw materials for the tile body are mixed, ball-milled into a slurry, and then spray-dried into granules.
2. The granulated powder is pressed into tile shape using continua + Technology” press or conventional hydraulic press machine.
3. The pressed green tile is dried in a dryer.
4. The special slurry is applied on the top surface of the dried tile to a thickness of up to 1 mm.
5. The coated tile is fired in a kiln at approximately 1200°C, ensuring vitrification and bonding of surface and body.
6. The tile undergoes polishing, sizing, sorting, and packing.

Performance Characteristics of the Finished Tile:
• Lightness (L) Value: 94 or higher
• Solar Reflective Index (SRI): 107
• Antibacterial surface due to embedded silver ion agents
• High mechanical strength and abrasion resistance
• Environmentally sustainable due to reduced heat gain on building surfaces

The invention provides a technologically superior, environmentally friendly, and commercially viable tile solution that addresses the limitations of conventional white tiles in terms of brightness, solar reflectivity, hygiene, and longevity.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments.

Detailed description of the invention
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

The present invention relates to a novel formulation and manufacturing method for producing ultra-white vitrified tiles—referred to as ULTRA WHITE TILE1—with exceptional surface brightness (Lightness L ≥ 94), a Solar Reflective Index (SRI) of 107, antibacterial properties, and high surface strength. The invention specifically describes the raw material formulations, processing steps, firing profile, and post-processing that result in superior tile performance for both interior and exterior architectural applications.

1. Tile Body Powder Formulation
The base body of the tile is engineered using a specific combination of ceramic raw materials, designed to ensure high whiteness, dimensional stability, vitrification, and surface polishability after high-temperature firing.
Body Composition (in weight percentage):
• Feldspar: 47% to 50%
• Kaolin Clay: 10% to 12%
• Ball Clay: 25% to 30%
• Quartz: 4% to 5%8
• Wollastonite: 4% to 5%
• Bentonite: 2% to 3%
• Frit (Flux): 5% to 6%
• Corundum: 3% to 4%
These materials are mixed with water and subjected to ball milling to achieve a fine slurry with appropriate particle size distribution. The slurry is then spray dried to form free-flowing granules suitable for dry pressing.

2. Tile Forming and Drying
• The spray-dried powder is filled into molds and compressed using hydraulic or isostatic pressing machines to form green tiles of standard size and thickness.
• The pressed tiles are then dried in a controlled dryer to remove residual moisture, preparing them for surface coating.

3. Application of SPECIAL SLURRY Layer
To achieve superior whiteness, reflectivity, and antibacterial function, a top surface coating slurry is applied over the dried tile using flat coaters or spray systems.
Special Slurry Formulation (in weight percentage):
• Titanium Dioxide (Rutile): 1% to 2%
• Zinc Oxide: 4% to 6%
• Corundum: 10% to 12%
• Magnesium Oxide: 3% to 4%
• Zircon: 18% to 20%
• Nepheline: 8% to 10%
• Frit (Opaque): 30% to 35%
• Quartz: 15% to 16%
• Kaolin Clay: 10% to 11%
• Anti-bacterial Agent (Silver Ion-based): 1% to 2%
The slurry is applied to a uniform thickness of up to 1 mm. The inclusion of zircon, TiO₂, and frit ensures opacity and brightness; corundum and MgO provide hardness; while silver ions provide embedded antibacterial properties.

4. Firing Process
The slurry-coated tiles are fed into a roller kiln and fired at approximately 1200°C. This temperature is carefully controlled to allow:
• Vitrification of the body,
• Sintering of the surface slurry into a uniform glassy layer,
• Integration of antibacterial agents,
• Retention of whiteness without deformation or surface defects.
The resulting fired tile shows strong adhesion between the body and surface layer with high mechanical integrity.

5. Post-Firing Processing
After firing, the tiles undergo:
• Polishing – using diamond abrasives to achieve a smooth and reflective surface;
• Sizing – to ensure dimensional accuracy;
• Sorting and Grading – based on optical and mechanical quality;
• Packing – for commercial distribution.

6. Performance Results of the Finished Tile
The final tile manufactured using this process exhibits the following key performance metrics:
• Lightness (L) Value: ≥ 94 (as measured by spectrophotometry)
• Solar Reflective Index (SRI): 107
• Surface Hardness: ≥ 7 on Mohs scale
• Abrasion Resistance: Meets ISO/EN standards for vitrified tiles
• Antibacterial Effectiveness: >99% inhibition of bacterial growth on tile surface (tested as per ISO 22196)

Applications of the Invention
The ULTRA WHITE TILE1 is ideally suited for:
• Outdoor open to sky holy places like temples , mosques etc, where direct sunlight is falling and devotees walk with open feet on that floor , this ultra white tiles gives cooler effect and support the devotee’s faith toward supreme lord.
• Exterior walls and rooftops in tropical or warm climates to reduce building heat absorption;
• Interior spaces where high brightness and clean aesthetics are desired;
• Public and commercial areas such as hospitals, schools, kitchens, labs, and washrooms where hygienic surfaces are essential;
• Green building and sustainable construction projects, contributing to energy efficiency and LEED rating.

, Claims:I claim
1. A vitrified tile composition comprising a unique body formulation for the base tile and a specially designed surface slurry layer, wherein said tile exhibits a Lightness (L) value of 94 or greater and a Solar Reflective Index (SRI) of 107, the said composition of tile body powder comprising:
• Feldspar: 47% to 50%
• Kaolin clay: 10% to 12%
• Ball clay: 25% to 30%
• Quartz: 4% to 5%
• Wollastonite: 4% to 5%
• Bentonite: 2% to 3%
• Frit (flux): 5% to 6%
• Corundum: 3% to 4%
wherein the tile body mixture is milled, spray dried, pressed, and dried to form a green tile body.

2. The tile as claimed in claim 1, wherein the top surface of the dried tile is coated with a special slurry layer having a thickness up to 1 mm, the slurry comprising:
• Titanium Dioxide (Rutile): 1% to 2%
• Zinc oxide: 4% to 6%
• Corundum: 10% to 12%
• Magnesium oxide: 3% to 4%
• Zircon: 18% to 20%
• Nepheline: 8% to 10%
• Frit (opaque): 30% to 35%
• Quartz: 15% to 16%
• Kaolin clay: 10% to 11%
• Anti-bacterial agent (silver ion based): 1% to 2%

3. The tile as claimed in claims 1 and 2, wherein the coated tile is fired in a kiln at approximately 1200°C, resulting in a vitrified tile with a sintered, highly reflective, ultra-white surface layer.

4. The tile as claimed in any of the preceding claims, wherein the finished tile is subjected to polishing, sizing, sorting, and packing to yield a product having:
• Surface Lightness (L) value ≥ 94 (as per CIELAB scale),
• Solar Reflective Index (SRI) of 107,
• Surface hardness ≥ 7 on Mohs scale,
• Antibacterial properties providing ≥99% bacterial inhibition on surface.

5. The tile as claimed in any of the preceding claims, wherein the antibacterial property is achieved by the incorporation of silver ion-based agents in the surface slurry layer.

6. The tile as claimed in any of the preceding claims, wherein the said tile is suitable for use in external building cladding, rooftops, hospitals, kitchens, clean rooms, or energy-efficient construction projects due to its high SRI and hygienic properties.
7. A method for manufacturing an ultra-white tile, comprising the steps of:
• Mixing and ball milling the tile body components to form a slurry,
• Spray drying the slurry to obtain powder,
• Pressing the powder into tiles,
• Drying the tiles,
• Applying the special slurry to the top surface of the dried tiles up to 1 mm thickness,
• Firing the tiles in a kiln at around 1200°C,
• Polishing and sizing the tiles,
• Sorting and packing to obtain ULTRA WHITE TILE1.

8. The method as claimed in claim 7, wherein the fired tile displays improved thermal reflectivity, brightness, scratch resistance, and antibacterial functionality.

For,
Simpolo Vitrified Pvt. Ltd.

Jitendra T Aghara
Applicant