Ceramic Composite Panel with Bonded Reinforcing Layer
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Solution Overview
Problem
Ceramic tile elements typically have one decorative and one lesser-quality surface, limiting their applications, and existing solutions for enhancing their structural integrity for load transfer and insulation do not fully address the need for versatile, durable, and aesthetically consistent use.
Innovation Solution
A ceramic composite panel comprising two ceramic panel elements with a reinforcing layer between them, where both decorative surfaces are exposed and the reinforcing layer is bonded to each panel, providing enhanced structural integrity and allowing for free-standing use, with options for sealing to protect against environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ceramic plate elements are used with one decorative surface and one lesser-quality surface, then manufacturing cost and complexity are reduced, but application versatility and aesthetic consistency are limited
Solution Approach 1:
The panel is segmented into three distinct layers: a first ceramic plate element, a reinforcing layer, and a second ceramic plate element. This segmentation allows each layer to have optimized properties - the ceramic plates provide decorative surfaces while the reinforcing layer provides structural support, enabling versatile applications without increasing overall complexity
Solution Approach 2:
The invention creates a composite panel structure combining ceramic plate elements with a reinforcing layer. This composite approach allows the integration of materials with different properties - the aesthetic ceramic surfaces combined with the structurally superior reinforcing layer - thereby achieving both versatility and controlled complexity
2Strength
If a reinforcing layer is added between ceramic plate elements, then structural integrity and load transfer capability are improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The reinforcing layer is integrated as an essential component of the composite panel structure, bonded to both ceramic plate elements. This creates a unified structural system where the reinforcing layer's high strength properties enhance the overall panel integrity and load transfer capability, while the bonding integration maintains manufacturing feasibility
Solution Approach 2:
The reinforcing layer is positioned specifically between the ceramic plate elements where structural support is most needed. This localized placement of high-strength material optimizes structural integrity at critical locations without unnecessarily increasing complexity throughout the entire panel structure
3Adaptability or versatility
If both decorative surfaces are exposed on the outside, then aesthetic consistency and application versatility are improved, but susceptibility to breakage increases
Solution Approach 1:
The composite structure with the reinforcing layer bonded between both ceramic plate elements provides internal structural support that protects the decorative surfaces from breakage. This allows both surfaces to be exposed aesthetically while the reinforcing layer acts as a protective backbone, maintaining reliability
Solution Approach 2:
The reinforcing layer is positioned beforehand between the ceramic plate elements to provide structural support and cushioning. This pre-positioned reinforcement protects the decorative ceramic surfaces from impact and breakage before any damage can occur, enabling both surfaces to be safely exposed
4Stability of the object's composition
If the reinforcing layer is bonded to both ceramic plate elements, then load transfer capability and structural stability are improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into sequential steps: first bonding the reinforcing layer to one ceramic plate element, then bonding the second ceramic plate element to the other side of the reinforcing layer. This segmentation of the manufacturing process makes the dual-bonding operation more manageable and feasible, maintaining ease of manufacture while achieving structural stability
Solution Approach 2:
The reinforcing layer is preliminarily bonded to one ceramic plate element before the second ceramic plate element is added. This preliminary action creates a stable intermediate structure that simplifies the subsequent bonding operation, making the overall manufacturing process more manageable while ensuring structural stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables ceramic composite panels to be used as separating elements, retaining structural integrity and preventing moisture penetration, while maintaining aesthetic consistency and enhancing durability for various applications, including outdoor and indoor settings.
Implementation Method 1
the reinforcing layer is bonded to a main surface of each of the ceramic plate elements
Data Source
Figure 1
Figure 2
AI summary
Ceramic composite panel comprising two ceramic panel elements (2) and a reinforcing layer (3), wherein each ceramic panel element (2) comprises two opposing main surfaces (2a, 2b) and a panel plane (21); wherein the panel planes (21) of the two panel elements (2) are arranged parallel to each other and the space between the two panel elements (2) is filled by the reinforcing layer (3); and wherein the reinforcing layer (3) is bonded to each main surface (2a, 2b) of the ceramic panel elements (2).