Reinforced Porcelain Panel With Foam-Core Buffer Regions

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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 chipping and cracking, which increases 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, that exceeds the dimensions of the porcelain slab, creating a buffer region to enhance protection against fractures and chips, with adhesive bonding and optional magnetic attachment for additional support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If porcelain slabs are used for aesthetic construction, then aesthetic design quality is improved, but vulnerability to chips and cracks during handling increases

Engineering Contradiction:

Improveaesthetic design qualityVSAvoidresistance to chips and cracks

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent combines porcelain slab with a structural core board made of foam-core material to create a composite panel product. The porcelain layer provides aesthetic design quality while the foam core provides structural support and impact resistance, resolving the contradiction between aesthetic quality and vulnerability to damage.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The structural core board with buffer regions extends beyond the porcelain slab peripheries to provide preemptive protection. This cushioning structure is designed in advance to absorb impacts and prevent stress-induced fractures during handling, shipping, and installation before damage can occur to the porcelain.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If standard porcelain slabs are handled during transport and installation, then construction progress is maintained, but stress-induced fractures occur leading to material loss

Engineering Contradiction:

Improveconstruction progressVSAvoidmaterial loss from fractures

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The buffer regions of the structural core board extend beyond the porcelain slab edges to provide protective cushioning during handling, transport, and installation. This preemptive protection reduces stress-induced fractures and material loss while maintaining construction productivity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The foam-core structural core board acts as an intermediary between the porcelain slab and external forces during handling. It absorbs and distributes stresses, protecting the porcelain from direct impact and reducing material loss while enabling continued construction progress.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Weight of moving object

If porcelain slabs are made thinner to reduce weight, then ease of handling is improved, but fracture resistance deteriorates

Engineering Contradiction:

Improveweight of porcelain panelVSAvoidfracture resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent creates a composite structure where a thin porcelain slab is bonded to a foam-core structural core board. This allows the porcelain to remain thin and lightweight while the foam core provides the necessary structural support and fracture resistance, resolving the contradiction between weight reduction and strength maintenance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The panel is segmented into two functional layers: a thin aesthetic porcelain layer and a thick structural foam core layer. This segmentation allows each layer to perform its optimized function - the thin porcelain provides aesthetics and weight reduction while the thick foam provides strength and fracture resistance.

Inventive Principle:

Principle #1Segmentation

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 enhanced impact resistance and fracture toughness, reducing the risk of chipping and cracking by at least 30% compared to standard porcelain, and allows for easier handling and installation with reduced material loss.

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

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12435521B2Reinforced porcelain panel product and associated methods for enhanced structural protection

Publication Date: 2025.10.07 MIGHTYSLAB DISTRIBUTION CO LLC

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.