Method for making porcelain-based cabinets for household applications

Abstract

The present invention provides a method for constructing kitchen cabinets using exclusively porcelain stone, eliminating the need for wood or any wooden components. This innovative approach offers significant health, environmental, and structural advantages. The porcelain material is 100% termite-proof, formaldehyde-free, and resistant to bacteria and fungi, ensuring a healthier and safer living environment. Environmentally, it eliminates deforestation and reduces the carbon footprint by avoiding harmful mining practices. Structurally, porcelain provides superior strength, fire resistance, and long-lasting durability, with a lifespan exceeding 25 years. This invention offers a sustainable, hygienic, and durable alternative to traditional kitchen materials, promoting a safer and more reliable solution for modern kitchen designs.

Description

“METHOD FOR MAKING STONE BASED CABINETS FOR HOUSEHOLD APPLICATIONS”A) TECHNICAL FIELD OF INVENTION

[0001] The present invention generally relates to the field of kitchen construction. More specifically, the present invention relates to a kitchen cabinet and accessories constructed entirely from porcelain stone, reducing usage of any wood or wooden components.B) BACKGROUND OF INVENTION

[0002] The construction of kitchens has evolved over time with the use of a variety of materials, from natural stone to engineered materials like wood, plastic laminates, and metals. Traditionally, wooden kitchens have been the most common choice due to their affordability, ease of construction, and aesthetic appeal. However, wooden kitchens present a number of drawbacks, including susceptibility to termite infestations, wear and tear, and the emission of harmful chemicals such as formaldehyde. Furthermore, the use of wood in kitchen construction contributes to deforestation and environmental degradation, raising concerns about the sustainability of such materials in the long run.

[0003] In recent years, there has been a growing shift towards more sustainable building materials in the quest for eco-friendly alternatives. Natural stones, such as granite and marble, have been used for countertops and flooring; however, the mining of these stones has its own set of challenges, including significant environmental impact, energy-intensive processes, and the depletion of nonrenewable resources. Moreover, these materials do not provide the same level of durability or health benefits as other innovative solutions, leaving the need for a better, more sustainable option.

[0004] With increasing concerns about health and environmental sustainability, the need for an alternative that addresses both issues simultaneously has become more pressing. Traditional kitchen materials, whether wood or natural stone, are often linked to both health risks, such as chemical exposure or bacterial growth, and environmental harm, such as resource depletion and ecological disruption.2The solution lies in finding a material that is not only durable and aesthetically pleasing but also offers significant advantages in terms of both health and environmental impact.

[0005] Therefore, there is a need to provide a groundbreaking approach to these challenges. By completely eliminating the use of wood and replacing it with porcelain stone, the present invention proposes a new way to build kitchens that is not only environmentally sustainable but also healthier for homeowners. The absence of wood ensures that the kitchen is immune to termite infestations, a problem often encountered with traditional wooden kitchens. Moreover, the use of porcelain stone eliminates the emission of toxic substances like formaldehyde, which are common in conventional kitchen designs, ensuring a safer living environment for residents.C) OBJECT OF INVENTION

[0006] The primary object of the present invention is to introduce a novel approach to kitchen construction by using porcelain stone as the primary material, completely eliminating the need for wood or any wooden components. This aims to revolutionize traditional kitchen building practices, offering a more sustainable and healthier alternative.

[0007] It is another object of the present invention to reduce environmental impact by eliminating a need for wood, thus preventing deforestation and minimizing a carbon footprint associated with traditional kitchen materials. The use of porcelain stone also avoids the harmful ecological effects of mining natural stone, further contributing to environmental preservation.

[0008] It is yet another object of the present invention to provide a healthier living environment by eliminating the use of formaldehyde-emitting materials and reducing the risk of health hazards, such as bacteria and fungi growth, which are often associated with wooden kitchens. The non-porous, hygienic surface of porcelain stone contributes to better indoor air quality and overall health.

[0009] It is yet another object of the present invention to provide a kitchen solution with enhanced durability, superior strength, and long-term performance.3The engineered porcelain stone offers a robust and fire-resistant construction, ensuring that the kitchen will withstand wear and tear over time and provide a safer, more durable alternative to wooden kitchens.

[0010] These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.D) SUMMARY OF INVENTION

[0011] The embodiments of the present invention provide a method for constructing a wellness kitchen cabinet. The method primarily uses the a selection of a plurality of porcelain stone panels as the sole material for kitchen components, excluding use of any wood or wooden components. The porcelain stone panels are then cut into specified dimensions and shapes using a waterjet or similar cutting tool or mechanism to meet the kitchen design requirements. Following this, a plurality of grooves or holes are drilled in the porcelain stone panels to enable assembly of fixture, accessories and other extension components. The grooving allows fixtures without usage of adhesives or other bonding agents. Finally, the porcelain stone panels are assembled using suitable hardware and / or screws or a fixture mechanism to form a cabinetry and other kitchen structures, resulting in a kitchen that is both environmentally sustainable and promotes human health by avoiding materials associated with environmental and health risks.

[0012] According to one embodiment of the present invention, the porcelain stone panels are treated with an antibacterial compound. This treatment results in a 5.76% reduction in the inoculation of Escherichia coli bacteria.

[0013] According to one embodiment of the present invention, the porcelain stone panels are treated with an antibacterial compound, which reduces the inoculation of Staphylococcus aureus bacteria by 5.65%.

[0014] According to an embodiment of the present invention, the assembled wellness kitchen cabinet contributes to a reduced carbon footprint by using only4porcelain stone, thereby reducing dependence on wood and natural stone, which are associated with deforestation and ecological damage from mining.

[0015] According to an embodiment of the present invention, the assembled wellness kitchen cabinet incorporates a modular design allowing for easy disassembly and reassembly, promoting long-term sustainability and reuse of porcelain panels.

[0016] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.E) BRIEF DESCRIPTION OF DRAWINGS

[0017] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

[0018] FIG. 1 illustrates a flowchart of a method for making porcelain cabinets for household applications, according to an embodiment of the present invention.

[0019] FIG. 2 illustrates the experimental details for antibacterial activity and efficacy against Escherichia coli, according to an embodiment of the present invention.

[0020] FIG. 3 illustrates the experimental details for antibacterial activity and efficacy against Staphylococcus aureus, according to an embodiment of the present invention.

[0021] FIG. 4 illustrates the experimental details for evaluating the antibacterial performance of the porcelain stone specimen (600 x 600 mm) against Pseudomonas aeruginosa, according to an embodiment of the present invention.5

[0022] FIG. 5 illustrates the experimental details for evaluating the surface burning characteristics of the porcelain stone, including the setup and dimensions of the test specimen, according to an embodiment of the present invention.

[0023] FIG. 6 illustrates the experimental details of the tests, including the setup and procedures for evaluating waterproofing and weatherproofing characteristics, according to an embodiment of the present invention.

[0024] FIG. 7 illustrates the experimental details for evaluating the durability and safety of the porcelain stone specimen, according to an embodiment of the present invention.F) DETAILED DESCRIPTION OF DRAWINGS

[0025] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical, electronic and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

[0026] Various features and embodiments of the present invention are explained in conjunction with the description of FIGURES (FIGs) 1 to 3.

[0027] FIG. 1 illustrates a flowchart of the method of making porcelain cabinets for household applications, according to an embodiment of the present invention. The method begins with selection of a plurality of porcelain stone panels from a quarry in a such a manner that each porcelain stone panel is treatable in nature (101). The selected panel is then treated with an antibacterial compound, which is chosen based on the intended application of the kitchen cabinet (e.g., dry area or wet area application) (102). Then, the porcelain panels are cut according to a design requirement using a waterjet machine (103). This cutting process ensures that the porcelain panels meet the precise size and shape specifications as dictated by the design, offering flexibility in terms of customization for different cabinet6designs. The use of a waterjet machine for cutting provides a high level of accuracy and precision, making it ideal for creating complex shapes and intricate details in porcelain materials.

[0028] After the porcelain panels are cut to the required dimensions, the next step involves drilling one or more grooves in the panels (104). These grooves are strategically placed to facilitate the subsequent assembly of the panels. The grooves are designed to allow for the smooth interlocking and alignment of adjacent porcelain panels, ensuring a stable structure during assembly. In one embodiment, the grooves also enable the sliding of one panel over another, which simplifies the assembly process by allowing the panels to fit together seamlessly.

[0029] Following the preparation of the panels, the final step in the method involves assembling the porcelain panels using hardware and / or screws (105). The assembly process includes aligning the grooves in adjacent panels, inserting screws or other hardware through the aligned grooves, and securing the panels together to form a stable, durable porcelain cabinet. The use of hardware and screws ensures that the panels are securely fastened without the need for adhesives or bonding agents, which may introduce environmental or health risks. This step results in the formation of a strong and durable cabinet structure, suitable for various household applications, including but not limited to kitchen cabinets.

[0030] In an alternative embodiment, the method may include additional steps to customize the appearance of the porcelain panels, such as surface treatments or decorative finishes, thereby enhancing the aesthetic appeal of the porcelain cabinet. The modular design of the cabinet also allows for easy disassembly and reassembly, offering flexibility for future modifications or repairs. Furthermore, the method promotes sustainability by using only porcelain, a material that is durable, environmentally friendly, and free from harmful chemicals found in some other construction materials.

[0031] The present invention provides an efficient, precise, and sustainable method for making porcelain cabinets, particularly for household applications. By utilizing waterjet cutting and hardware assembly, the method ensures that the7cabinets are not only durable and functional but also contribute to a healthier environment by eliminating the use of wood, adhesives, or other materials associated with environmental and health concerns.EXPERIMENTAL DETAILS

[0032] In one embodiment, the antibacterial activity and efficacy of porcelain used in the kitchen construction was evaluated according to the protocol outlined in JIS-Z2801-2010, a standard for measuring antibacterial properties of antimicrobial-treated products. The test involved assessing the porcelain material's ability to inhibit the growth of bacteria, specifically Escherichia coli and Staphylococcus aureus, which are commonly used as test organisms due to their significant presence in foodborne illnesses and their ability to represent a broad spectrum of bacterial activity.

[0033] A sample of porcelain panels with dimensions 50 mm x 50 mm was tested for its antibacterial activity. The results were recorded for both Escherichia coli as shown in the FIG. 2 and Staphylococcus aureus as shown in the FIG. 3. The porcelain material demonstrated significant antibacterial efficacy, with a measured antibacterial activity value of 5.76 against Escherichia coli and 5.65 against Staphylococcus aureus.

[0034] These values exceed the threshold of 2.0, as stipulated by the JIS-Z2801- 2010 standard, which indicates a product that is effective in inhibiting bacterial growth. Consequently, the porcelain material used in the present invention passes the antibacterial test, demonstrating its effectiveness in providing a hygienic surface. This result underscores the material's suitability for use in kitchen environments, where hygiene is of paramount importance.

[0035] FIG. 4 illustrates the experimental details for evaluating the antibacterial performance of the porcelain stone specimen (600 x 600 mm). The testing was conducted using the ASTM E-2180 method to determine the reduction in bacterial colonies over 24 hours. The test utilized Pseudomonas aeruginosa (ATCC- 15442) with an initial bacterial concentration of 4.6 x 106CFU / ml. The results indicated a >99.99% reduction in bacterial colonies, with no observable growth on thespecimen surface after 24 hours. This data demonstrates the superior antibacterial properties of the tested material.

[0036] The high antibacterial efficacy of the porcelain material signifies that it is highly resistant to bacterial colonization, contributing to a cleaner, safer environment. This is particularly advantageous in kitchen settings, where surfaces are regularly exposed to foodborne pathogens. The material’s resistance to bacterial growth not only ensures better hygiene but also reduces the likelihood of contamination, thus enhancing the health and safety of users.

[0037] Further, the test specimen, made of porcelain stone with dimensions of 600 mm x 600 mm, underwent a fire rating test in accordance with ASTM E 84- 2018 standards (UL-273). The results demonstrated compliance with NFPA 90A, 90B, and the Life Safety Code NFPA 101. The material exhibited a Flame Spread Index (FSI) of 5 and a Smoke Developed Index (SDI) of 12, achieving a Class A classification under the specified requirements (FSI: 0-25; SDI: 0-450). During testing, the specimen ignited approximately 24 seconds after exposure to the test flame, with partial delamination observed. FIG. 5 illustrates the experimental details for evaluating the surface burning characteristics of the porcelain stone, including the setup and dimensions of the test specimen. These results validate the material's suitability for applications requiring stringent fire safety standards.

[0038] In addition to fire rating tests, the porcelain stone was subjected to rigorous waterproofing and weatherproofing evaluations. The waterproofing test, conducted in accordance with BS EN 12390 Part 8:2000, confirmed the material's impermeability, with no water permeability or penetration observed under 5 -bar pressure. Furthermore, the weekly rate of water penetration was recorded as 2 mm, ensuring the material's suitability for moisture-prone environments. The weatherproofing test, performed as per BIS 1125-1974, demonstrated the material's resilience under cyclic conditions. After 30 cycles, no changes were observed in the absorption or volume of the test specimens. FIG. 6 illustrates the experimental details for these tests, including the setup and procedures for evaluating waterproofing and weatherproofing characteristics. These results underscore the porcelain stone's robustness and its ability to withstand harsh9environmental conditions, making it ideal for both indoor and outdoor applications.

[0039] FIG. 7 illustrates the experimental details for evaluating the durability and safety of the porcelain stone specimen. The tests include scratch resistance, where the material exhibited no scratches based on the Mohs hardness scale (EN101- 1991), and stain resistance testing (EN 122, ISO 10545-14), which classified the material as Class I. Additionally, the material demonstrated excellent thermal shock resistance (ISO-10545-11) over 10 cycles between 15°C and 145°C. The impact resistance test recorded a coefficient of restitution of 0.95, highlighting the material's robustness against mechanical impacts. Zero formaldehyde emissions were confirmed through ISO- 16000-3 testing, and the specimen passed antitermite testing, ensuring it meets environmental and safety standards. These results collectively affirm the material's reliability and versatility in demanding applications.

[0040] Overall, these experimental results highlight the superior antibacterial properties of porcelain, reaffirming its suitability as a material for kitchen construction in the present invention. In addition to its antibacterial efficacy, the material has demonstrated exceptional performance across a range of critical evaluations. The Scratch Resistance Test (Mohs Hardness) confirms its durability against abrasion, while the Stain Resistance Test showcases its ability to maintain surface cleanliness. The material also passed the Heat Resistance Test, including thermal shock resistance from 15°C to 145°C over 10 cycles, and exhibited resilience in the Impact Resistance Test, with a high coefficient of restitution. Furthermore, the Zero Formaldehyde Test ensures the material is free from harmful emissions, and the Anti-termite Test confirms its resistance to pest infestation. These comprehensive results, along with its compliance with fire rating, waterproofing, and weatherproofing standards, solidify porcelain as a superior choice for kitchen environments, offering unparalleled health, safety, and durability.G) ADVANTAGES OF INVENTION10

[0041] The present invention relates to an innovative kitchen design and construction method, which uses exclusively porcelain stone, eliminating the need for wood or any wooden components. This approach provides significant health, environmental, and structural advantages compared to traditional kitchen designs.Health Benefits:

[0042] The complete absence of wood in the kitchen design makes the structure 100% termite-proof. Wood-based kitchens are commonly subject to termite infestations, which can damage the structure and require costly treatments. By eliminating wood, the kitchen construction ensures greater longevity and reduces maintenance costs over time. Furthermore, unlike traditional wooden kitchens, which may emit formaldehyde - recognized as a carcinogen by health authorities - this invention offers a formaldehyde-free environment. This significantly reduces the risk of cancer and other health issues associated with formaldehyde exposure, making it a safer and healthier option for homeowners.

[0043] Additionally, the engineered porcelain stone used in this kitchen design provides a non-porous surface that is resistant to the growth of bacteria and fungi. This property contributes to a hygienic kitchen environment, minimizing the risk of foodborne illnesses and promoting overall health by reducing the potential for bacterial and fungal contamination.Environmental Benefits:

[0044] A key environmental advantage of this invention is its contribution to zero deforestation. By eliminating the use of wood, the design reduces the reliance on wood-based materials and helps preserve forests and biodiversity. This sustainable approach significantly diminishes the negative ecological impact typically associated with the harvesting of timber. Moreover, the use of engineered porcelain stone ensures that no harmful mining practices are involved. This avoids the energy-intensive processes usually associated with mining and processing natural stone, thereby further reducing the carbon footprint of the kitchen construction.Structural and Durability Advantages:11

[0045] The engineered porcelain stone used in the kitchen design offers superior strength compared to traditional wooden kitchens. The stone’s robustness makes the structure resistant to physical wear and tear, ensuring long-lasting durability. Additionally, the material is inherently fire-resistant, providing an added layer of safety. The fireproof properties of porcelain stone reduce the risk of fire damage in the kitchen, offering peace of mind to homeowners.

[0046] Finally, the durability of the engineered porcelain stone ensures that the kitchen will have an extended lifespan of 25 years or more, which significantly surpasses the longevity of traditional wooden kitchens. This makes the kitchen a long-term investment, providing a durable and reliable solution that outperforms conventional materials in both functionality and lifespan.

[0047] In brief, this invention offers a sustainable, health-conscious, and structurally superior kitchen design. By utilizing only porcelain stone, it not only improves the environmental footprint but also promotes a safer and more durable living environment for homeowners.

[0048] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims presented in the complete specification or non-provisional application.12

Claims

CLAIMS:

1. A method for making porcelain cabinets, comprises the steps of: cutting porcelain panels according to design requirements using a waterjet machine, wherein the size and shape of the porcelain panels are defined by the design requirements; drilling one or more grooves in the porcelain panels to facilitate subsequent assembly; and assembling the porcelain panels using hardware and / or screws to form the porcelain cabinet.

2. The method of claim 1, wherein the grooves facilitate the sliding of one porcelain panel over another during assembly.

3. The method of claim 1, wherein the assembling step further comprises: aligning the grooves in adjacent porcelain panels; inserting screws and / or hardware through the aligned grooves; and securing the screws and / or hardware to form a stable structure or a durable cabinet.

4. The method of claim 1, wherein the porcelain cabinets are configured for household applications, including but not limited to use as kitchen cabinets.

5. A method for making porcelain cabinets for household applications, comprises the steps of: cutting porcelain panels according to design requirements using a waterjet machine, wherein the size and shape of the porcelain panels are specified by the design requirements; drilling one or more grooves in the porcelain panels to facilitate subsequent assembly, wherein the grooves enable sliding engagement of one porcelain panel with another; andassembling the porcelain panels by: aligning the grooves in adjacent porcelain panels, inserting screws and / or hardware through the aligned grooves, and securing the screws and / or hardware to form a stable cabinet structure, wherein the porcelain cabinet is configured for household use, including kitchen applications.

6. A method for constructing a wellness kitchen cabinet, comprises the steps of: selecting a plurality of porcelain stone panels as the sole material for kitchen components, excluding the use of any wood or wooden components; treating the porcelain stone panels with an anti-bacterial compound; cutting the porcelain stone panels to specified dimensions and shapes using a waterjet or similar cutting tool to meet the kitchen design requirements; drilling grooves or holes in the porcelain stone panels to enable assembly without adhesives or other bonding agents; and assembling the porcelain stone panels using hardware and / or screws to form cabinetry and other kitchen structures, resulting in a kitchen that is both environmentally sustainable and promotes human health by avoiding materials associated with environmental and health risks.

7. The method of claim 6, wherein the assembled wellness kitchen cabinet contributes to a reduced carbon footprint by using only porcelain stone, thereby reducing dependence on wood and natural stone, which are associated with deforestation and ecological damage from mining.

8. The method of claim 6, wherein the assembled wellness kitchen cabinet incorporates a modular design allowing for easy disassembly and reassembly, promoting long-term sustainability and reuse of porcelain panels.

9. The method as claimed in claim 6, wherein the porcelain stone panels are treated with an anti-bacterial compound, wherein the treatment of porcelain stone panels reduces an inoculation of Escherichia coli bacterium by 5.76%.

10. The method as claimed in claim 6, wherein the porcelain stone panels are treated with an anti-bacterial compound, wherein the treatment of porcelain stone panels reduces an inoculation of Staphylococcus aureus bacterium by 5.65%.

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