Reinforced porcelain panel product fabrication methods for enhanced structural protection
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Solution Overview
Problem
Porcelain slabs are prone to stress-induced fractures during fabrication, handling, transportation, and installation due to their brittle nature, leading to material loss, aesthetic damage, and increased construction costs.
Innovation Solution
A reinforced porcelain panel product is fabricated by attaching a structural core board with a foam-core material to the porcelain slab, extending beyond its periphery to form a buffer region, using an adhesive material to enhance protection against cracking and chipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If porcelain slabs are used for aesthetic purposes, then design flexibility and appearance are improved, but vulnerability to chips and cracks during handling and installation increases
Solution Approach 1:
The patent applies composite materials by bonding a rigid backing board to the rear surface of the porcelain slab to create a sandwich structure. This composite construction combines the aesthetic and hardness properties of porcelain with the flexibility and impact resistance of the backing board, resolving the contradiction between design flexibility and vulnerability to damage.
Solution Approach 2:
The patent implements beforehand cushioning by pre-attaching a protective backing board to the porcelain slab before installation. This backing board acts as a cushion that absorbs impact forces and prevents stress-induced fractures during handling, transportation, and installation, thereby improving reliability without compromising the aesthetic design.
2Ease of manufacture
If porcelain slabs are used without reinforcement, then manufacturing simplicity is maintained, but stress-induced fractures during fabrication and installation occur
Solution Approach 1:
The patent uses composite materials by combining porcelain slab with a rigid backing board through adhesive bonding. This creates a reinforced sandwich structure that significantly improves strength and resistance to stress-induced fractures while maintaining relatively simple manufacturing processes through conventional bonding techniques.
3Ease of operation
If porcelain slabs are handled using standard methods, then handling procedures remain simple, but material loss due to mishandling increases
Solution Approach 1:
The patent implements beforehand cushioning by attaching a protective backing board to the porcelain slab before it enters the handling and installation process. This backing board cushions the porcelain against impacts and mishandling, reducing material loss while requiring only standard handling procedures, thus maintaining ease of operation.
4Device complexity
If porcelain slabs are installed without protective backing, then installation complexity is reduced, but structural integrity during installation deteriorates
Solution Approach 1:
The patent applies composite materials by bonding a rigid backing board to the porcelain slab, creating a reinforced sandwich structure. This composite construction improves structural integrity during installation without significantly increasing installation complexity, as the bonded structure acts as a single unit that is easier to handle and install.
Solution Approach 2:
The patent implements beforehand cushioning by pre-attaching a protective backing board that provides structural support during installation. This backing board prevents stress-induced fractures and improves structural integrity while requiring only standard installation procedures, thus maintaining low installation complexity.
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 method significantly reduces the risk of fractures by at least 30% compared to standard porcelain slabs, providing enhanced impact resistance and structural integrity during handling and installation.
Implementation Method 1
applying an adhesive material to a top surface of a structural core board... abuttingly contacting the structural core board to a bottom surface of a porcelain slab with the adhesive material therebetween
Data Source
AI summary
The present disclosure provides embodiments of a method a reinforced porcelain panel product for renovations or new constructions. In an embodiment, a method includes applying an adhesive to a top surface of a structural core board that includes a foam-core material. Further, the method continues with abuttingly contacting the structural core board to a bottom surface of a porcelain slab with the adhesive such that regions of the structural core board substantially extend beyond outer peripheries of the porcelain slab to define buffer regions, thereby to allow the buffer regions to be visible and to enhance protection from cracking when the reinforced porcelain panel product is handled. Additional features include the bottom surface of the structural core board having a second surface area larger than the first surface area of the porcelain slab and a fracture toughness greater than the porcelain slab.