Porcelain Board Tile Assemblies With Foam-Core Crack Protection
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Solution Overview
Problem
Porcelain slabs are fragile and prone to chips and cracks during handling, transport, and installation due to mishandling, leading to increased construction costs and material loss.
Innovation Solution
A reinforced porcelain panel product comprising a porcelain slab bonded to a structural core board with a foam-core material, where the core board extends beyond the slab's perimeter to form a buffer region, enhancing impact resistance and fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional porcelain slabs are used for surface installations, then aesthetic design and material properties are achieved, but the porcelain is vulnerable to chips and cracks during handling, transport, and installation
Solution Approach 1:
The patent applies composite materials by bonding a porcelain slab to a structural core board with foam-core material. This creates a composite structure where the rigid porcelain provides aesthetic and surface properties while the flexible foam core provides impact absorption and fracture resistance, resolving the contradiction between achieving desired material properties and vulnerability to damage.
Solution Approach 2:
The patent implements beforehand cushioning by pre-attaching a foam-core structural core board to the back of the porcelain slab before installation. This buffer region extends beyond the porcelain perimeter and provides pre-positioned impact absorption and stress distribution, protecting the porcelain from chips and cracks during handling, transport, and installation.
2Reliability
If porcelain slabs are handled and installed using conventional methods, then installation is performed, but mishandling leads to stress induced fractures, material loss, and increased construction costs
Solution Approach 1:
The foam-core structural core board is attached beforehand to the porcelain slab, creating a buffer region that extends beyond the porcelain perimeter. This pre-positioned cushioning protects the porcelain from stress-induced fractures during handling and installation, reducing material loss and the need for costly repairs or replacements.
Solution Approach 2:
The structural core board with foam-core material acts as an intermediary between external forces and the porcelain slab. It absorbs and distributes impact forces, preventing direct transmission of stress to the fragile porcelain, thereby reducing fractures and material loss during installation activities.
3Strength
If a structural core board with foam-core material is attached to the porcelain slab, then impact resistance and breaking strength are enhanced, but the assembly complexity increases
Solution Approach 1:
The patent merges the porcelain slab with the structural core board into a single integrated assembly. The foam-core structural core board is bonded to the back of the porcelain slab, combining the aesthetic and functional properties of porcelain with the structural support and impact absorption of the foam core, achieving enhanced breaking strength while maintaining a unified structure.
Solution Approach 2:
By creating a composite assembly of porcelain slab bonded to foam-core structural core board, the patent achieves enhanced breaking strength and impact resistance. The composite structure distributes stresses across both materials, with the foam core absorbing impact energy and preventing propagation of fractures through the porcelain.
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 provides at least 30% greater impact resistance and 40% greater breaking strength than standard porcelain, reducing the risk of cracking and chipping during handling and installation.
Implementation Method 1
positioned in abutting contact with the bottom surface of the porcelain slab with adhesive material therebetween
Data Source
AI summary
The present disclosure provides embodiments of a porcelain board tile assembly. In an embodiment, assembly includes two or more porcelain board tiles cut from a reinforced porcelain panel product. A bottom surface of each porcelain board tiles to be adhesively affixed to a mounting wall when installed. Each 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 greater than the porcelain slab. A top surface of the structural core board is positioned in contact with a bottom surface of the porcelain slab with an adhesive. A buffer region, defined by regions of the structural core board extending beyond outer peripheries of the porcelain slab, enhances protection from cracking when the reinforced porcelain panel product is handled. The structural core board is configured to attach to the mounting wall.