Reinforced Porcelain Panel Buffer Structure for Crack Protection
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Solution Overview
Problem
Porcelain slabs are prone to stress-induced fractures during handling, transport, and installation due to their brittle nature, leading to increased construction costs and material loss.
Innovation Solution
A reinforced porcelain panel product is designed with a structural core board made of foam-core material, such as PET foam, which has a larger surface area than the porcelain slab and extends beyond its perimeter to create a buffer region, enhancing impact resistance and fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If porcelain slabs are used for aesthetic construction purposes, then aesthetic design quality is improved, but vulnerability to chips and cracks during handling increases
Solution Approach 1:
The patent combines porcelain slab with a structural core board made of foam-core material to create a composite panel system. The porcelain slab provides aesthetic design qualities while the foam core provides structural support and impact resistance, resolving the contradiction between aesthetic quality and vulnerability to damage during handling
Solution Approach 2:
The panel system is divided into two functional segments: a porcelain slab layer for aesthetic purposes and a separate foam-core structural board for mechanical strength. This segmentation allows each material to perform its optimal function without compromising the other
2Productivity
If porcelain slabs are handled and transported, then installation progress is improved, but stress-induced fractures occur leading to material loss
Solution Approach 1:
The foam-core structural board is attached to the back of the porcelain slab before handling and transport operations. This pre-applied cushioning layer absorbs impacts and reduces stress on the porcelain during movement, preventing fractures and material loss while enabling continued installation progress
3Reliability
If structural core board extends beyond porcelain perimeter to create buffer region, then impact resistance is improved, but visible buffer region increases apparent size
Solution Approach 1:
The foam-core structural board is designed with varying dimensions relative to the porcelain slab, extending beyond the perimeter in specific regions to create buffer zones where impact protection is most needed, while maintaining a compact overall profile to minimize visible area increase
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 reinforced panel product offers at least 30% greater impact resistance and 40% greater breaking strength than standard porcelain, significantly reducing the risk of chipping and cracking during handling and installation.
Implementation Method 1
The structural core board has an upper surface and a lower surface. The upper surface of the structural core board is positioned in abutting contact with the bottom surface of the porcelain slab with an adhesive material therebetween
Data Source
AI summary
The present disclosure provides embodiments of a reinforced porcelain panel product for renovations or new construction in buildings. In an embodiment, a reinforced porcelain panel product includes a porcelain slab and a structural core board. The structural core board includes a foam-core material having a surface area and a thickness larger than the porcelain slab. An upper surface of the structural core board is positioned in contact with a bottom surface of the porcelain slab with an adhesive material. A buffer region is defined by regions of the structural core board extending beyond outer peripheries of the porcelain slab. The buffer region enhances protection from cracking when the reinforced porcelain panel product is handled. The lower surface of the structural core board has a first surface plane parallel to a top surface of the porcelain slab and a lower surface positioned to attach to a mounting surface.