Glass/Quartz Composite Slab for Thin-Format Strength and Translucency
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Solution Overview
Problem
Conventional quartz surfacing lacks the strength for thin format slabs and translucency for premium natural marble and quartzite aesthetics, leading to material inefficiencies and increased costs due to the need for foreign raw materials.
Innovation Solution
A glass/quartz composite structure comprising glass grit, quartz powder, a custom binding resin, and silane coupling agent, which allows for a stronger and more translucent material that can be used in thinner formats, incorporating specific mineral components for desired aesthetics and enhanced bonding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional quartz surfacing is used, then material strength is sufficient for standard thickness, but translucency and aesthetic quality are insufficient
Solution Approach 1:
The patent applies composite materials by combining glass aggregates with quartz powder and resin binder to create a new material system. The glass component provides translucency and aesthetic quality, while the quartz provides structural strength, and the resin binds them together. This composite approach resolves the contradiction by allowing both translucency and strength to coexist in the thin-format countertop material.
2Strength
If thicker slab format is used, then structural strength is sufficient, but material consumption and handling burden increase
Solution Approach 1:
The patent changes the physical and chemical parameters of the material composition by incorporating glass aggregates with specific size distributions (ranging from fine powder to larger chips) and optimizing the resin binder formulation. These parameter changes enable the material to achieve sufficient structural strength at reduced thickness, thereby reducing material consumption while maintaining required performance.
3Quantity of substance
If thinner format is used, then material consumption and handling costs are reduced, but structural strength becomes insufficient
Solution Approach 1:
The composite material system with glass aggregates, quartz powder, and resin binder provides enhanced strength-to-weight ratio and structural performance that enables thin-format applications. The interlocking structure of glass chips and quartz particles within the resin matrix creates a mechanically robust material that maintains structural strength even at reduced thickness, resolving the contradiction between thin format and structural adequacy.
4Illumination intensity
If foreign quartz raw materials are used, then premium natural white marble and quartzite aesthetics are achieved, but production costs and supply volatility increase
Solution Approach 1:
The patent replaces expensive imported quartz raw materials with domestically available glass aggregates and resin components. The glass aggregates can be sourced locally and processed into the required size distributions, eliminating dependence on foreign quartz supplies. This substitution maintains the desired aesthetic qualities through proper formulation while significantly reducing material costs and supply chain vulnerability.
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 glass/quartz composite structure provides the necessary strength and translucency for thin format applications, reducing material consumption and costs while mimicking premium natural stone aesthetics, with improved handling and installation safety.
Implementation Method 1
a silane coupling agent, the binding resin may be in an amount of 10-14 percent by weight of the composite structure
Data Source
AI summary
A glass/quartz composite structure comprises quartz grit, quartz powder and glass grit wherein the glass grit is in an amount greater than any other single material by weight of the composite structure (e.g. a combined weight of the quartz grit, quartz powder, glass grit, resin, and coupling agent). Natural stone components, which may include the quartz grit and quartz powder, may be in an amount greater than 30% by weight of the composite structure. The structure may be formed into a 1.2-1.5 cm thick slab for countertops using standard cabinet perimeter support. The slab may be made by mixing the quartz grit, quartz powder, glass grit, and binding resin, pouring the mixture in a mold, and compacting the mixture in the mold. Specific natural mineral components, decorative chips, and/or wet mixture pieces may be added to the composite structure to provide aesthetics of specific natural stones.