Reinforced Porcelain Panel Buffer Zone for Crack Prevention

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Solution Overview

Problem

Porcelain slabs are prone to chips and cracks during handling, installation, transport, and cutting due to their brittle nature, leading to material loss, aesthetic issues, and increased construction costs.

Innovation Solution

A reinforced porcelain panel product is developed, comprising a porcelain slab bonded with a structural core board, which enhances impact resistance and breaking strength by at least 30% and 40% respectively, and features a buffer region to protect against fractures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

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

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidresistance to chips and cracks

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies composite materials by bonding a porcelain slab to a structural core board, creating a reinforced composite panel. The porcelain slab provides aesthetic appearance while the structural core board provides mechanical strength and impact resistance, resolving the contradiction between aesthetic appearance and resistance to chips and cracks.

Inventive Principle:

Principle #40Composite materials

2Shape

If porcelain slabs are used for construction, then aesthetic design benefits are improved, but material loss due to fractures increases

Engineering Contradiction:

Improveaesthetic designVSAvoidmaterial loss

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

By creating a composite structure with porcelain slab bonded to structural core board, the invention prevents stress-induced fractures during handling, transport, and installation. This reduces material loss while maintaining the aesthetic design benefits of porcelain.

Inventive Principle:

Principle #40Composite materials

3Shape

If porcelain slabs are used for construction, then aesthetic benefits are improved, but construction costs increase due to repairs and material replacement

Engineering Contradiction:

Improveaesthetic benefitsVSAvoidconstruction costs

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The reinforced composite panel structure prevents chips and cracks during construction activities, eliminating the need for expensive repairs and material replacements. The structural core board absorbs stresses that would otherwise damage the porcelain slab, reducing construction costs while maintaining aesthetic benefits.

Inventive Principle:

Principle #40Composite materials

4Ease of operation

If porcelain slabs are handled without reinforcement, then handling simplicity is improved, but stress-induced fractures increase

Engineering Contradiction:

Improvehandling simplicityVSAvoidprotection from stress-induced fractures

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The structural core board bonded to the porcelain slab provides protection from stress-induced fractures during handling, transport, and installation. The composite structure maintains handling simplicity while adding the necessary protection against damage.

Inventive Principle:

Principle #40Composite materials

5Productivity

If porcelain slabs are cut or installed without protective measures, then installation speed is improved, but chipping and cracking increase

Engineering Contradiction:

Improveinstallation speedVSAvoidprotection from chipping and cracking

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The reinforced composite panel structure protects the porcelain slab from chipping and cracking during cutting and installation operations. The structural core board absorbs stresses during these operations, enabling faster installation without compromising protection from damage.

Inventive Principle:

Principle #40Composite materials

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 porcelain panel product significantly reduces the risk of chips and cracks during handling and installation, offering enhanced structural protection and cost-effectiveness by minimizing material loss and repair costs.

Implementation Method 1

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

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20250109598A1Reinforced porcelain panel product for enhanced structural protection

Publication Date: 2025.04.03 MIGHTYSLAB DISTRIBUTION CO LLC

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.