Reinforced Porcelain Panels With Buffer-Edge 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 comprising a porcelain slab and a structural core board, where the core board is made of a foam material with a larger surface area than the slab, providing a buffer region that enhances impact resistance and fracture toughness, and is attached with adhesive material to protect the slab from chipping and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If porcelain slabs are used for aesthetic construction, then aesthetic design quality is improved, but susceptibility to chips and cracks during handling increases
Solution Approach 1:
The patent applies composite materials by bonding a porcelain slab to a structural core board to create a reinforced panel product. The porcelain slab provides aesthetic design qualities while the structural core board provides mechanical strength and resistance to chips and cracks during handling and installation.
2Loss of substance
If standard porcelain slabs are used, then material cost is reduced, but risk of stress-induced fractures during handling increases
Solution Approach 1:
The patent applies beforehand cushioning by providing a buffer region of the structural core board that extends beyond the periphery of the porcelain slab. This buffer region absorbs impact forces before they can reach the porcelain slab, preventing stress-induced fractures and reducing material loss during handling and installation.
3Ease of operation
If porcelain slabs are handled without enhanced protection, then handling complexity is reduced, but frequency of stress-induced fractures increases
Solution Approach 1:
The reinforced panel product combines porcelain slab with structural core board to create a composite material that maintains the ease of handling a single panel while providing enhanced protection against stress-induced fractures through the buffer region and increased structural strength.
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, reducing the risk of fractures and chipping during handling and installation, thus minimizing material loss and construction costs.
Implementation Method 1
The structural core board also has a top surface and a bottom surface. The top 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 such as 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 porcelain slab includes a top surface with a first surface area. The structural core board includes a core material having a second 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 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 installed, handled, transported, or cut. The bottom surface of the structural core board is to be attach to a mounting surface when installed.