Patent Application
20250109597
The present disclosure generally relates to reinforced porcelain panel products, and systems and methods of manufacturing, forming, and installing such reinforced porcelain panel products. In particular, the present disclosure relates to embodiments of a reinforced porcelain panel products for use as flooring tiles, counters, for shower installations, and other types of installations and kits, which are configured to reduce risk of chips or cracks from handling, installing, cutting, or transporting of the reinforced porcelain panel products and increase speed of installations of such reinforced porcelain panel products.
Porcelain slabs have various uses within residential and commercial locations. In particular, bathrooms, common spaces, such as living rooms and kitchens, lobbies, and other similar occupied spaces, may benefit from the aesthetic design of porcelain slabs. Furthermore, porcelain can be crafted, or engineered, to display a variety of designs, such as, for example, a marble appearance, a metallic appearance, or other similar features. Therefore, porcelain installations have been increasing in frequency as their popularity grows, to beautify living spaces and to remove obstacles, such as, for example, a tub or other obstructions in a bathroom that may cause accidents. However, the use of porcelain products during renovations, in particular when using conventional porcelain installation techniques, can mandate a long installation time, and while porcelain has desirable aesthetic characteristics, among other benefits, it is a delicate and brittle material that is vulnerable to chips and cracks upon mishandling, such as during fabrication, shipping, and installation. Applicant has recognized that the implementation of proper handling training, tools, and techniques to move or install porcelain has not achieved a suitable protection from stress induced fractures of the porcelain from mishandling, transportation, and installation.
Applicant has recognized a need for enhanced protection of porcelain products from stress induced fractures that can be caused by mishandling of the porcelain products during installation, transport, handling, or cutting thereof, such as, for example, collisions of delicate porcelain slabs, and which lead to loss of material, non-aesthetic repairs, and increasing the cost of construction for bathroom installations. Various aspects of the present disclosure, are directed to reinforced porcelain products, including, but not limited to, porcelain panels, tiles (e.g., tiles for use in flooring installations/applications, ceiling tiles, among others), counter materials, slabs and other construction products, for use in a variety of construction applications, including for renovations or new construction such as in residential or commercial applications, as well as to systems, kits, and methods for the production and installation of such reinforced porcelain products, as will be understood by those skilled in the art.
For example, in embodiments, a reinforced porcelain product can be provided for use in various building applications, such as for flooring, ceiling materials, bathrooms (e.g., showers, floors, walls, among other applications), kitchens (e.g., for counters, backsplashes, walls, among other applications), and which can be used in renovations or new construction such as in residential or commercial applications as will be understood by those skilled in the art. In embodiments, the reinforced porcelain panel product can include a first layer or component, such as a porcelain slab or panel and a second layer or component that can includes a structural support, including structural core material, which, in embodiments, can be formed as a sheet or board.
In embodiments, the reinforced porcelain product can include a reinforced porcelain product having a first component or layer and a second component or layer. In embodiments, the first component or layer can include a porcelain material layer having a top surface with a first surface area and a bottom surface positioned opposite the top surface. For example, in embodiments, the first component can include a porcelain slab. The second component or layer can include a structural layer or component that, in some embodiments, can include a structural foam material. In some embodiments, the structural component can include a structural core board having a foam material, and which can have a second surface area greater than the first surface area of the porcelain slab. The structural core board also has a top surface and a bottom surface. In embodiment, the top surface of the structural core board can be positioned in abutting contact with the bottom surface of the porcelain slab with an adhesive material positioned in one or more regions therebetween or uniformly extending across a surface therebetween.
In addition, in some embodiments, the structural core board can include regions (e.g., along the top surface of the structural core board) that can extend beyond one or more peripheral side edges of the first surface area of the porcelain slab. In embodiments, the regions of the top surface of the structural core board extend beyond outer peripheries of the first surface area of the porcelain slab define a buffer region. The buffer region is visible when viewing the reinforced porcelain panel product from a front view of the top surface of the reinforced porcelain panel product, e.g., prior to installation or cutting, which can be configured and can extend for a selected length so as to enhance protection of the porcelain slab from cracking or chipping when the reinforced porcelain panel product is handled (e.g., transported, cut, positioned in place, or installed). The bottom surface of the structural core board further generally will be configured to be attached to a mounting surface when installed, for example.
According to an embodiment of the present disclosure, a tile in provided including at least one reinforced porcelain tile product having: a first component including porcelain material and having a top surface with a first surface area, a bottom surface opposite the top surface, and a plurality of peripheral side portions; and a second component including a structural material and having top surface, a bottom surface, and a plurality of peripheral side portions. The second component can include a structural foam material including: a breaking strength greater than a breaking strength of the porcelain material of the first component; a fracture toughness greater than a fracture toughness of the porcelain material of the first component; and a young's modulus value lower than a young's modulus value of the porcelain material of the first component. Also, the at least one reinforced porcelain tile product can be configured to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.
In embodiments, the tile can further comprise an adhesive material positioned between the top surface of the second component and the bottom surface of the first component and is configured to attach the first and second components together to form the at least one reinforced porcelain tile product.
In embodiments of the tile, the at least one reinforced porcelain tile product has an impact resistance of at least a 30% greater than a facture toughness of a porcelain slab having a thickness of 6 mm or higher without a structural backing, and a breaking strength of at least 40% greater than a porcelain slab having a thickness of at least 6 mm.
In embodiments of the tile, the first component includes a porcelain slab having a thickness of at least about 3 mm, and the second component includes a structural core board having a thickness that is greater than the thickness of the porcelain slab.
In embodiments of the tile, the structural core board has a fracture toughness greater than the porcelain slab, and wherein the young's modulus value of the structural core board includes about 2.0 GPa to about 14.6 GPa.
In embodiments of the tile, the top surface of the second component is attached to the bottom surface of the first component with one or more of the peripheral side portions of the second component projecting outwardly past one or more of the peripheral side portions of the second component so as to define one or more buffer regions configured to protect the first component from cracking or chipping when the at least one reinforced porcelain tile product is handled.
In embodiments of the tile, the one or more buffer regions comprise a first pair of opposing peripheral side edge portions extending substantially parallel to each other and a second pair of opposing peripheral side portions extending transversely with respect to the first pair of opposing peripheral side edge portions and extending substantially parallel to each other.
In embodiments of the tile, 8 the reinforced porcelain tile product further includes one or more scorelines positioned along the top surface of the first component, the one or more scorelines extending substantially parallel to the first pair of opposing peripheral side edge portions or the second pair of opposing peripheral side edge portions; wherein the one or more scorelines are configured to control separation of the porcelain material of the first component when a radial force is exerted on the porcelain material at or near the scoreline sufficient to divide the first component into one or more portion; and wherein a fracture toughness of the structural foam material of the second component is configured to resist fracture when the first component is divided.
In embodiments of the tile, two or more of the peripheral side portions of the second component include interlocking features configured to interlock with corresponding interlocking features of adjacent reinforced tile products to form a tile floor, wall, or ceiling; and wherein each of the two or more interlocking fingers comprise a finger joint, a shiplap joint, a dovetail joint or a combination thereof.
In embodiments of the tile, the structural foam material of the second component includes polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, acrylonitrile butadiene styrene, or combinations thereof; and wherein the young's modulus value of the structural foam material includes a range of about 2.0 GPa to about 14.6 GPa.
In embodiments, the tile is configured to withstand a weight of at least 200 lb. applied using a Robinson-type floor tester with hard rubber wheels.
According to another aspect, a porcelain tile flooring system is provided, comprising a substrate; and a plurality of reinforced porcelain tiles each having an exposed upper surface, a lower surface, and a plurality of peripheral edge portions; wherein the reinforced porcelain tiles each comprise: a porcelain material layer having a top surface with a first surface area and defining the exposed upper surface; and a structural support layer and having a top surface configured to attach to a bottom surface of the porcelain material layer, a bottom surface, and a plurality of peripheral side portions; wherein the porcelain material layer includes a thickness of at least about 3 mm and the structural support layer includes a thickness that is greater than the thickness of the porcelain material layer; wherein the structural support layer includes a breaking strength that is greater than a breaking strength of a porcelain slab alone; a fracture toughness greater than a fracture toughness of a porcelain slab alone; and a young's modulus value lower than a young's modulus value of a porcelain slab alone; and wherein the reinforced porcelain tiles are each configured withstand a weight of at least 200 lb. applied using a Robinson-type floor tester with hard rubber wheels so as to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.
In embodiments of the porcelain tile flooring system, the substrate includes wood, concrete, oriented strand board, concrete, cement, particle board, or combinations thereof.
In embodiments, the porcelain tile flooring system further includes a waterproofing layer, a pan, cement panel, vapor barrier, underlayment, cushion layer, or combinations thereof, positioned between the substrate and the reinforced porcelain tiles.
In embodiments of the porcelain tile flooring system, at least two of the peripheral side portions of the structural support layer are configured to overlap at least two corresponding peripheral side edge portions of the porcelain material layer to as to define a series of buffer regions along two or more sides of each reinforced porcelain tile; and wherein the buffer regions are configured to enhance an impact resistance of each reinforced porcelain tile product of at least a 30% greater than a porcelain slab alone having a thickness of at least about 6 mm.
In embodiments, the porcelain tile flooring system, further includes a trim piece constructed from a reinforced porcelain panel product and positioned to cover an outer periphery of two or more adjacent reinforced porcelain tiles such that structural core boards are not visible when viewing the two or more adjacent reinforced porcelain tiles when installed.
In embodiments of the porcelain tile flooring system, each of the reinforced porcelain tiles further compromises an adhesive, resin, laminate, glue, mortar, or combinations thereof, configured to adhere the porcelain material layer to the structural support layer.
In embodiments, the porcelain tile flooring system further includes a tile mortar, vinyl flooring adhesive, or combinations thereof, applied between the substrate and the bottom surface of the structural support layer.
In embodiments of the porcelain tile flooring system, wherein each of the reinforced porcelain tiles include a unique identifier configured to identify a location for placement of the reinforced porcelain tiles to create a selected pattern of the reinforced porcelain tiles.
In embodiments of the porcelain tile flooring system, each of the reinforced porcelain tiles has an impact resistance of at least a 30% greater than a porcelain slab having a thickness of 6 mm or higher without a structural backing, and a breaking strength of at least 40% greater than a porcelain slab alone having a thickness of at least 6 mm.
In embodiments of the porcelain tile flooring system, the structural support layer has a fracture toughness of at least 10% greater than a facture toughness of the porcelain material layer, and wherein the young's modulus value of the structural support layer includes about 2.0 GPa to about 14.6 GPa.
In embodiments of the porcelain tile flooring system, the structural support layer includes a structural foam material; and wherein the structural foam material includes polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, acrylonitrile butadiene styrene, or combinations thereof; and wherein the young's modulus value of the structural foam material includes a range of about 2.0 GPa to about 14.6 GPa.
In embodiments of the porcelain tile flooring system, each of the reinforced porcelain tiles has a breaking strength of at least 40% greater than a porcelain slab having a thickness of at least 6 mm; and wherein the structural support layer is attached to the porcelain material layer with a silyl-terminated polyether base resin.
In embodiments of the porcelain tile flooring system, the structural support layer includes two or more interlocking backing segments configured to interlock with two or more adjacent interlocking backing segments, and wherein each of the two or more interlocking backing segments includes a finger joint, a shiplap joint, or a dovetail joint.
In embodiments of the porcelain tile flooring system, the reinforced porcelain tiles are installed as a floor in a shower enclosure.
According to other aspects, a reinforced porcelain tile product for renovations or new construction includes a first component including an exposed top surface and a bottom surface, the top surface opposite the bottom surface; and a second component including a top surface adhesively attached to the bottom surface of the first component, and a bottom surface; wherein the first component includes a porcelain material; wherein the second component includes a breaking strength greater than a breaking strength of the porcelain material of the first component; a fracture toughness greater than a fracture toughness of the porcelain material of the first component; and a young's modulus value lower than a young's modulus value of the porcelain material of the first component; and wherein the reinforced porcelain tile product is configured to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.
In embodiments, the reinforced porcelain tile product has an impact resistance of at least a 30% greater than a porcelain slab having a thickness of 6 mm or higher; and wherein the second component extends beyond outer peripheries of the first surface area of the porcelain slab by about 0.125 inch to about 0.750 inches.
In embodiments, the reinforced porcelain tile product has a breaking strength of at least 40% greater than porcelain having a thickness of at least 6 mm; and wherein the second component includes a structural core board having has a fracture toughness of at least 10% greater than a facture toughness of the porcelain material of the first component, and a young's modulus value of includes about 2.0 GPa to about 14.6 GPa.
In embodiments of the reinforced porcelain tile product, the first component includes a sheet of porcelain; wherein the sheet of porcelain has one or more scorelines positioned at one or more selected locations across the top surface of the first component; and wherein the scorelines are configured to facilitate controlled breaks along the sheet of porcelain so divide the sheet of porcelain into a selected pattern when a radial force is exerted along or near the one or more scorelines.
In embodiments of the reinforced porcelain tile product, the second component includes a structural foam material having a young's modulus value of the structural foam material includes a range of about 2.0 GPa to about 14.6 GPa.
In some embodiments of the reinforced porcelain tile product, the structural foam material includes polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, acrylonitrile butadiene styrene, or combinations thereof.
In some embodiments of the reinforced porcelain tile product, the structural foam material includes a thermoplastic or a thermoset polymer material.
In embodiments of the reinforced porcelain tile product, the second component includes two or more interlocking backing segments configured to interlock with adjacent interlocking backing segments; and wherein each of the two or more interlocking backing segments includes a finger joint, a shiplap joint, or a dovetail joint.
In embodiments of the reinforced porcelain tile product, the top surface of the first component has at least a portion of an artistic design displayed therealong.
In embodiments of the reinforced porcelain tile product, the reinforced porcelain tile product is configured to construct a wall, ceiling, or floor.
According to still other aspects, a kit for construction or reconstruction of a shower enclosure, includes a plurality of reinforced porcelain tile products; wherein each of the reinforced porcelain tile products includes a porcelain slab having a top surface and a bottom surface; and a structural core board having a top surface adhesively attached to the bottom surface of the porcelain slab, and a bottom surface; wherein the structural core board includes a breaking strength greater than a breaking strength of the porcelain slab; a fracture toughness greater than a fracture toughness of the porcelain slab; and a young's modulus value lower than a young's modulus value of the porcelain slab; and wherein the at least one reinforced porcelain tile product is configured to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.
In embodiments of the kit, the reinforced porcelain tile products include three or more reinforced porcelain tile products configured to form a floor for a selected shower enclosure size.
In embodiments of the kit, the selected shower enclosure size includes about 60 inches by about 74 inches, about 60 inches by about 96 inches, or about 60 inches by about 106 inches; and wherein at least one of the three or more reinforced porcelain tile products includes about 31 inches by about 74 inches, about 31 inches by about 96 inches, or about 31 inches by about 106 inches.
In embodiments of the kit, the structural core board includes a first pair of peripheral side portions positioned substantially parallel with each other and extending beyond a corresponding first pair of peripheral side edge of the porcelain slab so as to define a first pair of buffer regions, and a second pair of peripheral side portions opposite the first pair of peripheral side portions and positioned substantially parallel with each other and extending beyond a corresponding second pair of peripheral side edges of the porcelain slab so as to define a second pair of buffer regions.
In embodiments of the kit, buffer regions extend beyond first and second pairs of peripheral side edges of the porcelain slab by about 0.125 inches to about 0.750 inches.
In embodiments, the kit can further comprise a container within which the plurality of reinforced porcelain tile products is received for transport.
In some embodiments of the kit, the container can include one or more a supporting members configured to retain at least one reinforced porcelain tile product within the container.
In some embodiments, the container can comprise a box, a crate, a pallet, or an a-frame crate; and can further comprise one or more straps configured to restrain the at least one reinforced porcelain tile product against movement within the container during transport.
In embodiments of the kit, each reinforced porcelain tile product has an impact resistance of at least 30% greater than porcelain having a thickness of 6 mm or higher; wherein each reinforced porcelain tile product has a breaking strength of at least 50% greater than porcelain having a thickness of at least 6 mm; wherein the young's modulus value of the structural core board of each reinforced porcelain tile product has a range of about 2.0 GPa to about 14.6 GPa; and wherein the structural core board of one or more of the reinforced porcelain tile products extends beyond an outer periphery of the porcelain slab thereof by about 0.125 inches to about 0.750 inches.
In embodiments of the kit, the structural core board of each reinforced porcelain tile product includes one or more interlocking peripheral side edge portions configured to interlock with peripheral side edge portions of a structural core board of an adjacent reinforced porcelain tile product such that each reinforced porcelain tile product and its adjacent reinforced porcelain tile product are interlockable and positionable with one another.
In embodiments of the kit, the structural core board includes a thermoplastic or a thermoset foam material; and wherein the thermoplastic or thermoset foam material includes polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, or acrylonitrile butadiene styrene, wherein the structural core board has a young's modulus value lower than the porcelain slab; and wherein the young's modulus value of the structural core board is about 2.0 GPa to about 14.6 GPa.
In embodiments, the kit can further comprise a magnetic panel configured to be installed behind and adjacent to a bottom surface of the at least one reinforced porcelain tile product such that magnetic shower accessories are configured to magnetically attach on the top surface of the porcelain slab when positioned within an installed shower enclosure.
Another aspect of the present disclosure includes a kit with reinforced porcelain tile products such as for use as flooring; wherein the kit includes a container and one or more reinforced porcelain tile products received within the container and including a porcelain slab having a top surface with a first surface area positioned opposite a bottom surface, and a structural core board that can comprise a foam-core material and can have a top surface with a second surface area greater than the first surface area of the porcelain slab, and a bottom surface positioned opposite the top surface of the structural core board; wherein the top surface of the structural core board is positioned in abutting contact with the bottom surface of the porcelain slab with adhesive material therebetween such that regions of the top surface of the structural core board extend beyond outer peripheries of the first surface area of the porcelain slab to define a buffer region, thereby to allow the buffer region to be visible when viewing the reinforced porcelain tile product from a front view of the top surface of the reinforced porcelain tile product and to enhance protection from cracking or chipping when the reinforced porcelain tile product is handled and wherein the bottom surface of the structural core board can be attached to a mounting surface when installed, for example.
In one embodiment, for example, the container has three reinforced porcelain tile products configured to accommodate standard shower enclosure sizes (e.g., generally standard sizes adapted to fit residential or commercial shower stalls or rooms). For example, the kit may include one of three reinforced porcelain tile products sized at about 60 inches by about 74 inches, 60 inches by about 96 inches, or 60 inches by about 106 inches. In another example, the kit may further include two of the three reinforced porcelain tile products sized at about 31 inches by about 74 inches, 31 inches by about 96 inches, or 31 inches by about 106 inches.
Features of the kit also can include the structural core board having a fracture toughness greater than the porcelain slab.
In addition, in embodiments, the buffer region can include a first pair of peripheral opposite side portions positioned substantially parallel with each other and a second pair of opposite side portions connected to and extending transverse to the first pair of peripheral opposite side portions also positioned substantially parallel to each other.
In some embodiments, the structural core board may have a young's modulus value lower than the porcelain slab. Furthermore, the young's modulus value of the structural core board has a range of about 2.0 GPa to about 14.6 GPa and the adhesive material contains a silyl-terminated polyether base resin. Additionally, in embodiments, the structural core board extends beyond outer peripheries of the first surface area of the porcelain slab by about 0.125 inches to about 0.750 inches.
In some embodiments, the structural core board can include one or more interlocking backing segments so that each of the one or more interlocking backing segments interlock to another of the one or more interlocking backing segments to construct a structural core board. Additionally, each of the one or more interlocking backing segments includes a finger joint, a shiplap joint, or a dovetail joint, each configured to adhesively interlock each of the one or more interlocking backing segments together.
In other embodiments, the container can include at least one supporting member configured to position and/or retain the positioned reinforced porcelain tile products within the container. In some embodiments, the container can comprise box, a crate, a pallet, or an a-frame crate, and further can include one or more straps configured to restrain each of the reinforced porcelain tile products to the container to reduce movement during transport.
In yet another embodiment, each of the reinforced porcelain tile products can an impact resistance of at least 30% greater than porcelain having a thickness of 6 mm or higher. Furthermore, each of the reinforced porcelain tile products can a breaking strength of at least 50% greater than porcelain having a thickness of at least 6 mm. In addition, in embodiments, the structural core board can have a young's modulus value lower than the porcelain slab wherein the young's modulus value of the structural core board has a range of about 2.0 GPa to about 14.6 GPa; and further can extend beyond outer peripheries of the first surface area of the porcelain slab by about 0.125 inches to about 0.750 inches.
In another embodiment, the kit may also include a magnetic metal tile configured to be installed behind and adjacent to bottom surface of the one or more reinforced porcelain tile products such that magnetic shower accessories are configured to magnetically attach on the top surface of the porcelain slab when positioned within an installed shower enclosure (e.g., a shower room, stall, or other enclosure).
In some embodiments, the foam-core material can comprise a thermoplastic or a thermoset material. Additionally, in embodiments, the foam-core material can comprise polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, or acrylonitrile butadiene styrene. Furthermore, in embodiments, the structural core board has a young's modulus value lower than the porcelain slab wherein the young's modulus value of the structural core board has a range of about 2.0 GPa to about 14.6 GPa.
In some embodiments, the adhesive material can comprise a silyl-terminated polyether base resin.
In still other embodiments, the reinforced porcelain panel products can have a width of about 31 inches or about 60 inches.
Various aspects and advantages of these exemplary embodiments and other examples of reinforced porcelain products, including panels, tiles, counters, seating, and other products, and systems, kits and methods of installation and formation thereof, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiment and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.
The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to illustrate embodiments of the disclosure more clearly.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated into other embodiments without further recitation.
The present disclosure describes various embodiments of reinforced porcelain panel products and associated methods for enhanced structural protection to reduce risk of chips or cracks from a handling of the reinforced porcelain panel products by protection of the porcelain slab with a structural core board. Porcelain slabs have various utility in the construction and decoration industry. Large porcelain slabs may be designed, textured, decorated, or engineered for specific aesthetic appealing walls. However, large porcelain slabs are challenging to transport, fabricate, and install as expert, or routine, handling methods may result in broken, fractured, chipped, or cracked porcelain slabs attributed to mishandling of the fragile porcelain slab. These mishandling failures necessitate repairs that increase cost of construction projects, repair solutions that may be undesirable to the purchaser, and/or lost productivity of fabrication and installation.
The below description may use the phrases “in certain embodiments,” “in various embodiments,” “in an embodiment,” “in one embodiment, or “in example,” which may each refer to one or more of the same or different embodiment. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. The term “plurality” as used herein refers to one or more items or components. The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting example, these terms are defined to be within 10 percent (%), preferably within 5%, more preferably within 1%, and most preferably within 0.5%.
The terms “removing,” “removed,” “reducing,” “reduced,” or any variation thereof, when used in the claims and/or the specification includes any measurable decrease of one or more components in a mixture to achieve a desired result. The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having,” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The terms “wt. %,” “vol. %,” or “mol. %” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a non-limiting example, 10 grams of a component in 100 grams of the material is 10 wt. % of the component.
Generally, fabricated porcelain material may include a ceramic made by heating porcelain-creating raw materials to temperatures commonly between about 1,200 degrees Celsius and about 1,400 degrees Celsius. Porcelain-creating raw materials may include kaolin, such as kaolinite, feldspar, ball clay, glass, bone ash, steatite, quartz, petuntse and alabaster. Porcelain may include natural patterning, such as veins, which offers a variety of decorative purposes, such as art displays. Further, porcelain may be manipulated to display a variety of finishes or designs, for example, polished, natural, honed, marble look, wood-look, metal-look, concrete-look, fabric-look and may possess grains therein to exhibit types of textures created by varied processes. Porcelain may also be etched, or engraved, to include descriptive text for signage or other functional uses. Therefore, porcelain is an attractive material for wall cladding, kitchen countertops, tabletops, fireplaces, shower walls, floors, pools, and/or other construction uses due to its ability to be manipulated with a variety of designs or textures.
Porcelain may be fabricated in sheets of porcelain referred herein as porcelain slabs. The porcelain slabs described herein can include various types of porcelain materials, types including sintered stone, such as neolith, or ultra compact porcelain, such as florim, having various grades and/or qualities. One use of porcelain includes fabricating porcelain large panels for use in occupied spaces, such as, for example, lodgings, hotels, houses, new space construction, and/or renovations of the former. However, as discussed above, porcelain slabs are large, thin, and delicate, and therefore, the panels are susceptible to chip or crack when used by fabricators, stone masons, or the like, as compared to other more tolerant materials, such as quartz, or granite, leading to a reduction of the use of porcelain slabs in construction projects to reduce risk of mishandling in the fabrication cutting and/or installation process.
The following disclosure is related to thin and large porcelain slabs, commonly referred to as “thin large format porcelain” amongst those skilled in the art. However, the solution provided to the challenges plaguing thin large format porcelain herein may be also provided for various sizes of porcelain slabs to reduce the risk of stress induced fractures from transportation and mishandling. Further, the following disclosure refers to “panel(s)” as sheets, or portions of slabs of porcelain material that are independent, or stand alone, and further refers to “board(s)” as integrated, or fabricated materials that are united to provide structure, such as a structural core board having an internal structural core. Furthermore, the following disclosure may refer to “assembly(ies),” as integrated materials that are adhesively united, such as a porcelain slab and a structural core board to define a reinforced porcelain panel product being produced under the trademark “MightySlab™.”
In various example embodiments in accordance with the principles of the present disclosure, such as illustrated in
The structural core board 130 has a top surface 134 and a bottom surface 136 positioned opposite of the top surface 134. In one embodiment, top surface 134 and a bottom surface 136 each have a plane that are substantially parallel to each other. The top surface 134 has a surface area 138. In one embodiment, the bottom surface 136 has a surface area that substantially matches the surface area 138 of the top surface 134. In one embodiment, the structural core board 130 is rectangular, although various shapes are contemplated as discussed below. The structural core board 130 may be constructed from a foam-core material such as a variety of structural foams, foams, or other foam-core materials with similar foam strength, weight, and/or structural characteristics. In some examples, the foam-core material may be formed by techniques using molding, pressing, layering, or the like, as would be understood by one skilled in the art. In one embodiment, the structural core board 130 includes polyethylene terephthalate (“PET”) foam. In some embodiments, the PET foam may be mixed with glass fibers or carbon fiber. In one embodiment, the bottom surface 136 of the structural core board 130, may be laminated, thereby to have a smooth surface for use on air suction tables for positioning, for example, a CNC table, as would be understood by those skilled in the art. In one embodiment, the PET foam is closed-cell PET foam formulated to provide enhanced mechanical properties from, for example, recyclable material such as plastic bottles. Furthermore, PET foam mechanical properties have exhibited significant structural resilience in other industry uses such as, the wind industry on turbine blades, the marine industry on decks and hulls of vessels, the railroad industry on train body sidewalls and flooring supports, and the aerospace industry on plane structural periphery supports. PET foam is temperature tolerant up to about 150 degrees Celsius. In some embodiments, PET foam has a young's modulus of about 2.0 GPa to about 14.6 GPa and a fracture toughness ranging from about 3 MPa-m1/2 to about 9.5 MPa-m1/2. In comparison, porcelain has a young's modulus of about 67 GPa to about 150 GPa and a fracture toughness of about 2.0 MPa-m1/2. Therefore, PET foam is less brittle and more fracture resistant as compared to the mechanical properties of porcelain. Furthermore, the structural core board 130 may weigh approximately 0.018 pounds per square foot. For example, suitable commercially available PET foams include recyclable polymer foams, such as AIREX® T92. Conventionally, alternate 0.375 inches thick (or about 10-millimeter) support products for stone structural support, such as honeycomb plates, is about 3.5 to about 4 times the weight per square foot as compared to the structural core board 130 embodiment disclosed herein. As an example of the total weight of the reinforced porcelain panel product 100, including the structural core board 130, a 6-millimeter-thick reinforced porcelain panel product 100 may weigh about 150 pounds as compared to a similarly sized 2-centimeter thick quartz panel which may weigh about 800 pounds. Therefore, weight reduction may be advantageous in weight sensitive applications, such as, for example, yachts or other weight sensitive construction.
The adhesive material 250 unites the bottom surface 106 of the porcelain slab 102 to the top surface 134 of the structural core board 130 such that the porcelain slab 102 and the structural core board 130 are abutting connected and physically contacting. In one embodiment, the adhesive material 250 permanently bonds the porcelain slab 102 and the structural core board 130 together. In one embodiment, the adhesive material 250 is evenly spread across the top surface 134 of the structural core board 130 to promote an even spread of adhesive material 250 across the bottom surface 106 of the porcelain slab 102 when installed, as shown in
Furthermore,
In one embodiment, for example, the length overhang 246 may be about 0.313+/−0.001 inch and the width overhang 248 may be about 0.313+/−0.001 inch. In another embodiment, for example, the length overhang 246 and the width overhang 248 are substantially equivalent having an overhang of about 0.125 inch to about 0.750 inch, such as about 0.175 inch to about 0.500 inch, such as about 0.200 inch to about 0.430 inch, such as about 0.250 inch to about 0.380 inch, such as about 0.300 inch to about 0.330 inch, such as about 0.313+/−0.001 inch, or such as less than about 0.750+/−0.001 inches, such as less than about 0.500 inches, such as less than about 0.43 inches, such as less than about 0.380 inches, or such as less than about 0.330 inches. Stated differently, the structural core board may extend an equidistant distance beyond all outer peripheries of the porcelain slab. In some embodiments, the structural core board 130 may be trimmed, after positioning onto the porcelain slab 102, to possess the aforementioned length overhang 246 and the width overhang 248 distances.
The length overhang 246 and the width overhang 248 of the structural core board 130 are particularly advantageous as the defined buffer region 260 has been empirically found to protect the porcelain slab 102 from chips, cracks, fractures, or the like, as will be understood by those skilled in the art, from mishandling of the reinforced porcelain panel product 100 during transport or installation. For example, the porcelain slab 102, as discussed above, is large, thin, and fragile such that bumps or an unassisted lift may cause stresses, such as shear, bend, torsion, torque, and the like, which may lead to a failure of the porcelain slab to remain intact, undamaged, or not chipped. However, the length overhang 246 and the width overhang 248 have empirically been found to significantly reduce the likelihood of fractures, and the like, from inadvertent drops, such as falls directly onto the bottom surface 136 of the structural core board 130 drops, corner bumps, or other similar collisions with another hard surface, such as a floor, crate, another panel, or other construction hazards that commonly occur with transportation and installation process of the porcelain slabs. Furthermore, the inventors discovered that overhangs exceeding the above disclosure are prone to failure by breaking off the porcelain slab 102 and thereby to expose the porcelain slab 102 to risk of stress induced damage. Similarly, the inventors discovered that overhangs not exceeding the lower values of the above disclosure are likely to expose the porcelain slab 102 to stress induced damage by not providing adequate protection against inadvertent drops, bumps, or other similar collisions on the sides. Therefore, the length overhang 246 and the width overhang 248 of the structural core board 130 are critical to the protection of the porcelain slab 102 to stress induced damage related to inadvertent drops, bumps, or other similar collisions with another hard surface that commonly occurs with transportation and installation process of the porcelain slabs.
The embodiment of
Foams commonly used for the structural core board 130 may be recycled polymeric foams, but others could be used as well. Structural foams commonly include a thermoplastic or a thermoset. In one embodiment, a commonly used thermoplastic includes, for example but not limited to, polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, and acrylonitrile butadiene styrene, although other materials are contemplated. In one embodiment, a chemical blowing agent may be used to promote foam expansion. In one embodiment, the foam may be a rigid polymeric foam including polyethylene terephthalate. The foam may exhibit desired mechanical properties including increased strength and/or low-weight characteristics, as discussed above. In some embodiments, the structural core board 130 may be chemically stable, exhibit good adhesion and fatigue strength, significantly low water absorption, among other features rendering the structural core board 130 desirable for the reinforced porcelain panel product.
Each of the interlocking backing segments 430a-430c may have one or more ends 432 for each of the interlocking backing segments 430a-430c. Each of the one or more ends 432 have an interlocking configuration to connect the interlocking backing segments 430a-430c to each other, as desired. In one embodiment, a method to fabricate the interlocking backing segments 430a-430c may include fabricating the interlocking configurations onto the interlocking backing segments 430a-430c, as discussed below, for protective use on the reinforced porcelain panel product 400. As illustrated, the one or more ends 432 each have a shelf 435 configured to receive the opposite shelf 435 such that the shelf 435 is positioned on the opposite shelf 435 and joined to marry at least two of the interlocking backing segments 430a-430c. In one embodiment, the one or more ends 432, or interlocking configuration, may be an overlay joint, such as a finger, shiplap, or a dovetail joint, among other types of overlay joints, configured to join or fasten the interlocking backing segments 430a-430c together. In one embodiment, adhesives may be used to join and secure one or more ends 432 together. In one embodiment, the interlocking backing segments 430a-430c may be fabricated with adhesive tape positioned on mating surfaces of the one or more ends 432, for example on the shelf 435, to bond the shelf 435 of one backing segment to the opposite shelf 435 of another backing segment. In one embodiment, the adhesive tape may be covered with a peelable cover to expose the tape. In one embodiment, the interlocking backing segments 430a-430c may be fabricated with porcelain-compliant adhesive tape positioned on the bottom surface 434 of each of the interlocking backing segments 430a-430c to adhere to the bottom surface 106 of the porcelain slab 102, thereby to construct the reinforced porcelain panel product 400. Further, some of the interlocking backing segments, such as interlocking backing segments 430a and 430c may have termination ends 440 that are not configured to interlock with another backing segment but rather are configured to provide the appropriate overhang, as discussed above.
In another embodiment, an interlocking configuration may be placed on the periphery edges of the reinforced porcelain panel product such that the structural core board includes one or more interlocking edges configured to interlock with a structural core board of another reinforced porcelain panel product such that two or more reinforced porcelain panel products are interlockable and positionable adjacent each other. Stated differently, the peripheral outer edges of the structural core board may possess interlocking configurations that may be utilized to connect two or more reinforced porcelain panel products together when being installed. This feature is advantageous to reduce the amount of waste or structural core board cut by a worker when installing adjacent reinforced porcelain panel products. Further the interlocking configurations on the periphery edges of the reinforced porcelain panel product may provide adequate spacing for some installation embodiments.
Similarly, as shown in
Each of the movements of the reinforced porcelain panel products 100 is an added risk to mishandling leading to loss of product. Hazards during operations at fabrication or distribution sites 620 may include dropping of the reinforced porcelain panel product 100, 400 onto a hard surface, colliding the reinforced porcelain panel product 100, 400 with a hard surface, or bending the reinforced porcelain panel product 100, 400 from improper use of the rail 624 and suction cup 626 tool. Similarly, each of these stresses on the porcelain slab 102 has previously challenged industrial usage of large size panels as the porcelain slab 102 is often broken, chipped, or fractured, prior to installation. However, the structural core board 130 integrated onto the porcelain slab 102 has provided a layer of protection against these likely stresses from handling during installation reducing product loss and construction cost by for example, enabling the structural core board 130 to deform to absorb the contact or weight of stacked, or layered reinforced porcelain panel products 100 that advantageously reduce the breakage, chipping, and/or cracking of the porcelain slab 102.
The cutting of the reinforced porcelain panel product 100, as described, is advantageous as the speed of cutting a porcelain slab is significantly increased. The reinforced porcelain panel product 100 may also be cut by use of conventional cutting tools, such as a bridge-saw using a diamond blade, a water jet, an edging machine used to grind panel edges, a CNC router, or the like, as would be understood by one skilled in the art. Conventionally, cutting techniques using saws for porcelain slabs 102, for example, necessitate the tuning of the cutting speed and water cooling to reduce the damage to porcelain slabs. For example, a stone mason 702 may have to adjust the cutting wheel and the cooling water flow of the cutting tool to a slow speed/high flow to reduce the chipping effect resulting from high-speed, or high heat, of cutting porcelain. In comparison, the stone mason 702 may not be required to slow the cutting speed of the cutting tool, and/or adjust the cooling water flow, for other stone materials, such as a quartz or granite panel. Based on results of experimentation of the disclosed reinforced porcelain panel product 100, it was found that the reinforced porcelain panel product 100 may be cut about four to five times faster than a quartz or granite panel in manner described above. In one embodiment, a fabricator may cut the reinforced porcelain panel product 100 using a diamond bladed bridge-saw at a speed of up to 30 feet per minute (“fpm”), such as about 3 fpm to about 30 fpm, such as about 15 fpm to about 27 fpm, such as about 20 fpm to about 25 fpm, thereby improving upon traditional porcelain cutting times. Therefore, the added stability from the structural core board 130, or interlocking backing segments 430a-c, enables a stone mason 702 to portion, or cut, the reinforced porcelain panel product 100 with a cutting technique discussed above, thereby to significantly reduce cutting times and save overall water usage.
In another embodiment, as illustrated in
In one embodiment, the reinforced porcelain panel product 100 may be directly attached to the wall 902, or the wall 904, with adhesive. In one embodiment, the reinforced porcelain panel product 100 may abut a water proofing barrier (not shown), such as Redguard® or waterstop as would understood by one skilled in the art, positioned on a floor 920 and between the reinforced porcelain panel product 100, the stud wall 902, and the gypsum paneled wall 904 when installed. In one embodiment, the structural core board 130 of the reinforced porcelain panel product 100 may be coated with a waterproof coating to create a watertight enclosure when the reinforced porcelain panel product 100 is installed onto the wall 902, or wall 904. In one embodiment, the waterproof coating may be rolled, sprayed, or placed on the structural core board 130 with a large format roll of tape, or the like, as will be understood by those skilled in the art. In yet another embodiment, the waterproof coating may be rolled, sprayed, or placed on the wall 902 such that the reinforced porcelain panel product 100 is installed onto the wall 902 with the waterproof coating.
Generally, large panels of material are desired in bathroom settings as more wall coverage is available with the large panels. Therefore, thin large format porcelain is desirable for such applications due to a reduction of necessary grout, or caulking, compared to conventional tiling of the same walls and also due to the ability of porcelain to withstand wear and tear of showers when installed. For example, a finished shower room 901 using the thin large format porcelain, as shown in
Previously, thin large format porcelain was limited to smaller panel sizes and unable to provide full coverage for shower walls as the thin large format porcelain was fragile to handle in large sizes. However, the implementation of the structural core board 130 onto the porcelain slab 102 has enabled the size of the reinforced porcelain panel product 100 to increase to provide larger panels previously unattainable by porcelain slabs 102 alone. Therefore, installation of the reinforced porcelain panel product 100, or 400, may be easier and quicker to install as larger panels provide greater coverage as compared to prior porcelain slabs, alternative stone, or tile solutions. For example, an installation may be increased by a reduction of preparation time, such as squaring off walls, and shimming the reinforced porcelain panel product 100 thereby to stabilize the material resulting in less damage to the porcelain, as would be understood by one skilled in the art.
Furthermore, fewer materials may be required for installation further increasing the ease and speed of installation. For example, in one embodiment, the wall 902 may be finished with only the reinforced porcelain panel product 100 compared to the conventional method of installation that requires tiles attached, via thinset mortar, to a gypsum panel that is fastened to the wall and a waterproof barrier, or coating, positioned between the tile and the gypsum panel. Thus, the speed of installation of the reinforced porcelain panel product 100, as discussed, increases project completion efficiency, and also provides the owner less maintenance as less grout is used. In one example, the installation of a shower room 901 may be performed in less than about 24 hours, such as less than about 20 hours, such as less than about 15 hours, such as less than about 10 hours, such as less than about 5 hours, such as less than about 3 hours, such as about 3 hours.
In one embodiment, the magnetic shower accessories 961 can further include a magnet configured to be attracted to the metal panel 960. In another embodiment, the magnetic shower accessories 962 possess a magnetic material to attract to a magnet positioned behind the porcelain slab 102. In one embodiment, the metal panel 960 is a small panel positioned and installed in desired areas behind the installed reinforced porcelain panel product 100 and adhesively connected to the wall 902. In one embodiment, the metal panel 960 is thin and does not add a significant difference in thickness to the wall 902 during construction. It is also contemplated that a non-metallic sheet, equal in thickness to the metal panel 960, may be installed around the metal panel 960 such that the wall 902 is level. Fasteners, such as screws, clips, or the like, as will be understood by those skilled in the art, and adhesives, as discussed above, are contemplated methods of securing the metal panel 960 to the wall 902.
In one embodiment, the metal panel 960 is large such that a significant portion of the wall 902 is magnetic, thereby to provide a large surface area to adjust the magnetic shower accessories 962 about the wall 902 and into a desired position to fit an individual's need, which may be due to height, weight, temporary disability, permanent disability, aesthetic preference, or other functional preference. The magnetic shower accessory 962 may be a shelf, a shower caddy, a footrest, a towel rack, a shower arm for a handheld shower hose, or the like shower accessories, as will be understood by those skilled in the art. In one embodiment, the porcelain slab 102, or the reinforced porcelain panel product 100, are attached to the metal panel 960 with adhesive, such as construction grade adhesive.
The magnetic shower attachments advantageously hide the metal panel 961 behind the porcelain slab 102 to discreetly provide functionality to the positioning of the magnetic shower accessories 962 while reducing the use of grout, or caulking, that challenges shower installations. While the magnetic shower attachments are illustrated connected and installed in a wall, other surfaces walls are contemplated, such as a ceiling or the floor 920. Therefore, it may be understood an assembly for positioning a movable magnetic accessory may include a magnetic panel affixed to a mounting surface and the reinforced porcelain panel product positioned to conceal the magnetic panel and having thickness less than the magnetic attractive force configured between a magnetic accessory attachment positioned on a top surface of the porcelain slab and the magnetic panel.
It is to be understood that the disclosure of the magnetic shower attachments as discussed in
The reinforced porcelain tile products also can be used in various other flooring applications as will be understood by those skilled in the art. For example, in embodiments, the reinforced tile product can be used in various residential and light commercial ceramic tile flooring applications as a substitute for ceramic tiles or planks and/or luxury vinyl tile or plank products.
In embodiments, reinforced porcelain tile product(s) (e.g., flooring tiles, ceiling panels, counters, seating, etc.) can be installed over a supporting substrate material 921 (
In one example embodiment of a flooring application, the reinforced porcelain tile product(s) 920 can be used as the shower enclosure or room 901 can include a substrate 921, which, in embodiment, can comprise a subfloor 952 comprising a material such as wood (e.g., plywood sheeting positioned on joints), a concrete slab, cement, OSB, or other subfloor material. In some embodiments, an additional layer can be positioned between the subfloor 952 and the reinforced porcelain tile product 100. For example, in some embodiments, a shower pan or a waterproof membrane material 954 can be applied over an upper surface of the substrate and can be attached to the subfloor with an adhesive material.
In addition, in embodiments where the installation is for a floor of a shower enclosure such as indicated in
In embodiments where the reinforced porcelain tile product 920 includes a larger sheet or tile having a size that substantially matches the size of the floor area of the shower enclosure, as shown in
To install the reinforced porcelain tile product 920, as shown in
Traditionally, conventional tiles (not shown) are installed onto cement, concrete, or the like hard surfaces, as will be understood by those skilled in the art, with an adhesive mortar, such as a thinset mortar. Thinset mortar, commonly referred to as thinset cement, dryset mortar, or drybond mortar by those skilled in the art, is an adhesive mortar made of cement, fine sand, and a water-retaining agent such as an alkyl derivative of cellulose to bond two hard surfaces together, such as a ceramic tile to a hard surfaced wall. The installation of conventional tiles (not shown) is directed by policies set forth by the Tile Council of North America (TCNA), a trade organization, which requires the use of thinset mortar for installation of tile, including conventional porcelain. The use of thinset mortar may be problematic as voids, or cavities, between the installed material and the wall may be prone to breaking as the void is unsupported by the thinset mortar leading to future repairs. However, the use of the reinforced porcelain panel product 100 may not require the use of thinset mortar as the structural core board 130 is the adhesive surface, rather than the porcelain slab 102 which required thinset mortar. Therefore, as the reinforced porcelain panel products 100 are lighter than other stone alternatives and cause less stress, and/or damage, to the mounting wall, an adhesive, such as a construction grade adhesive, may be used to secure the tiled art piece 1202 onto the display wall 1204, thereby to reduce the amount of clean up from thinset derived dust or splatter, offsetting any additional costs of materials, such as the cost of thinset mortar and adhesive, and increase the speed of installation to thereby increase project efficiency.
Method 1300 begins with optional block 1302 by, for example, interlocking two or more interlocking backing segments to construct a structural core board. As discussed above in
Method 1300 continues to block 1304 by applying an adhesive material 250 to foam-core backing material, such as structural core board 130. The adhesive material 250 may be applied by use of an aerosol adhesive tool, a roller, an applicator, and spread using a spreading tool, or the like, as would be understood by one skilled in the art.
At block 1306, a worker may continue method 1300 by applying the structural core board 130 to a bottom surface 106 of a porcelain slab 102 with an adhesive material 250 therebetween such that regions of the top surface 134 of the structural core board 130 substantially extend beyond outer peripheries of a first surface area 108 of the porcelain slab 102 to define buffer regions 260 so that a combination of the porcelain slab 102 and the structural core board 130 define the reinforced porcelain panel product 100, thereby to allow the buffer regions 260 to be visible when viewing the reinforced porcelain panel product 100 from a front view of a top surface 104 of the reinforced porcelain panel product 100, as shown in
Method 1300 may continue at optional block 1308 where the bottom surface 136 of the reinforced porcelain panel product 100 may be coated such that the bottom surface 136 is substantially non-permeable to air and thereby to allow the use of a vacuum lifting tool to move the reinforced porcelain panel product 100. In one embodiment, the structural core board 130 has a coating that is substantially waterproof. The waterproof coating is advantageous in embodiments that are installed in wet areas, such as shower enclosure floor where waterproofing is a desirable characteristic to reduce water damage from lack of water containment, as would be understood by one skilled in the art. The vacuum lifting tool may be an air-driven table, or “air table,” able to sufficiently lift the weight of the reinforced porcelain panel product 100 to aid a worker in the movement and/or positioning of the reinforced porcelain panel product 100. In another embodiment, the vacuum lifting tool may a vacuum table that provides suction configured to restrain the reinforced porcelain panel product 100 from movement and/or positioning of the reinforced porcelain panel product 100 while the reinforced porcelain panel product 100 is being processed, such as decorated, scored, or cut.
The method 1300 may pursue various pathways, such as pathways 1350, 1352, and/or 1354. For example, pathway 1350 may be utilized for shower enclosures as discussed above in
At block 1310, a worker, or stone mason, may score the reinforced porcelain panel product 100 such as, in one embodiment, scoring the top surface 104 of the porcelain slab 102 with one or more scorelines 706 positioned along one or more selected locations across the top surface 104. The scorelines 706 provide guided and controlled breaks to snap 720 the porcelain slab 102 into a selected pattern when a radial force is exerted on or near the scoreline 706.
At block 1312, a worker, or stone mason, may cut the reinforced porcelain panel product 100 configured to fit kitchen fixtures therein such that the reinforced porcelain panel product 100 is laid on a kitchen counter support structure to be used as a kitchen counter as discussed in
At block 1314, a worker, or stone mason, may cut the reinforced porcelain panel product 100 by using, for example, cutting techniques described in
At block 1316, the cut tiles from the reinforced porcelain panel product 100 may be positioned in a selected, or desired, orientation such that the reinforced porcelain panel product 100 may be reassembled in the selected orientation desired pattern at a second location for installation as discussed above in
The various embodiments of method 1300 may conclude at block 1318 where the bottom surface 136 of, for example, the kitchen counter, the trim pieces or tiles, or the shower enclosure panels using reinforced porcelain panel product 100 containing an embodiment of the structural core board 130, are adhesively mounted to the commercial or residential surface, such as display wall 1204 shown in
Method 1400 begins at block 1402 by positioning a reinforced porcelain panel product 100, defined above, onto a transport device, such as, but not limited to, a pallet 602, a freight shipping 610, a crate 630, a forklift, or an a-frame crate, as shown and discussed in
The method 1400 may continue at block 1404 with stacking two or more reinforced porcelain panel products 100 such that each of the structural core boards 130 deform to protect the porcelain slab 102 from chipping or cracking from a force exerted onto the reinforced porcelain panel product 100 by a ground or a weight of from another reinforced porcelain panel product 100 stacked thereon. As discussed in
The method 1400 continues to a remote location, such as a second location different than the first location, at block 1406, by transporting the reinforced porcelain panel product 100 to a recipient at a remote location such that the recipient receives the reinforced porcelain panel product 100 void, or absent, of breaks on the porcelain slab 102. In one embodiment, the fabricated reinforced porcelain panel product 100 may be in one or more reinforced porcelain panel product sections, such discussed in the cutting embodiment of the reinforced porcelain panel product 100 above.
Method 1500 begins at block 1502 by positioning a reinforced porcelain panel product 100, discussed above, within an interstitial space 550 of the lifting clamp 502 configured to open or close the interstitial space 550 by actuation of the lifting clamp 502. As discussed above in
The method 1500 may continue at block 1504 with contacting the reinforced porcelain panel product 100 with the lifting clamp 502 such that the porcelain slab 102 and the structural core board 130 each contact the movable jaws 552 of the lifting clamp 502. The movable jaws 552 of the lifting clamp may be actuated to close the interstitial space 550, thereby to contact the reinforced porcelain panel product 100 via the porcelain slab 102 and the structural core board 130, respectively.
The method 1500 continues at block 1506 by compressing the reinforced porcelain panel product 100 such that the structural core board 130 deforms to protect the porcelain slab 102 from chipping or cracking caused by the compression of the movable jaws 552 of the lifting clamp 502. In one embodiment, the compression of the movable jaws 552 of the lifting clamp 502 may exert a force that would fracture or crush conventional unsupported porcelain. In examples where the conventional unsupported porcelain was able to withstand the compression of the lifting clamp 502, the porcelain often broke upon a lifting of the lifting clamp 502 with the porcelain held within. However, the structural core board 130 of the present disclosure advantageously provides protection against breakage, chipping, and/or cracking of the porcelain slab 102 when using a lifting clamp 502. As illustrated in
The method 1500 continues at block 1508 by lifting the reinforced porcelain panel product using the lifting clamp to elevate the reinforced porcelain panel product 100 from, for example, the ground, or crate, as discussed in
The method 1500 may conclude at block 1510 by moving the reinforced porcelain panel product 100 to a location different than the location of the lifting of the reinforced porcelain panel product 100 without breakage, chipping, and/or cracking of the porcelain slab 102.
The following examples reveal the durability of the reinforced porcelain panel product 100 discussed above as will be understood by those skilled in the art. The reinforced porcelain panel product 100 was experimentally evaluated to exhibit strength and resilience as compared to conventional porcelain option available for construction purchase. Below are the findings of tested examples for breaking strength, impact resistance, and adhesive resilience as will be understood by those skilled in the art.
Example 1: In a first example, a breaking strength of the reinforced porcelain panel product 100 was experimentally determined under International Organization for Standardization (“ISO”) test number 10545-4, as will be understood by those skilled in the art. The breaking strength of the reinforced porcelain panel product 100 was determined to yield increased strength with a conventional 6-millimeter neolith porcelain. The below table illustrates the specific ISO test findings.
Table 1 illustrates the breaking strength increase of about 180% by using a structural core board, such as structural core board 130 discussed above on a conventional 6-millimeter neolith porcelain slab as compared to the conventional 6-millimeter neolith porcelain slab without the structural core board. Therefore, the results support a finding of at least 180% breaking strength increase, such as at least about 175% breaking strength increase, such as at least about 170% breaking strength increase, such as at least about 160% breaking strength increase, such as at least about 150% breaking strength increase, such as at least about 140% breaking strength increase, such as at least about 130% breaking strength increase, such as at least about 120% breaking strength increase, such as at least about 110% breaking strength increase, such as at least about 100% breaking strength increase, such as at least about 90% breaking strength increase, such as at least about 80% breaking strength increase, such as at least about 70% breaking strength increase, such as at least about 60% breaking strength increase, such as at least about 50% breaking strength increase, such as at least about 40% breaking strength increase, such as at least about 30% breaking strength increase, such as at least about 20% breaking strength increase, such as at least about 10% breaking strength increase, by using a structural core board, such as structural core board 130 discussed above on a conventional 6-millimeter neolith porcelain slab as compared to the conventional 6-millimeter neolith porcelain slab without the structural core board.
Example 2: In a second example, an impact resistance of the reinforced porcelain panel product 100 was experimentally determined under European Standard (“EN”) test number 14617-9, as will be understood by those skilled in the art. The impact resistance of the reinforced porcelain panel product 100 was determined to yield increased resistance as compared with a conventional 6-millimeter florim porcelain without a structural backing. The below table illustrates the specific EN test findings.
Table 2 illustrates the impact resistance increase of at least about 50% by using a structural core board, such as structural core board 130 discussed above on a conventional 6-millimeter florim porcelain slab as compared to the conventional 6-millimeter florim porcelain slab alone and without the structural core board. Therefore, the results support a finding of at least 50% impact resistance increase, such as at least about 45% impact resistance increase, such as at least about 40% impact resistance increase, such as at least about 35% impact resistance increase, such as at least about 30% impact resistance increase, such as at least about 25% impact resistance increase, such as at least about 20% impact resistance increase, such as at least about 15% impact resistance increase, such as at least about 10% impact resistance increase, such as at least about 5% impact resistance increase, by using a structural core board, such as structural core board 130 discussed above on a conventional 6-millimeter florim porcelain slab as compared to the conventional 6-millimeter florim porcelain slab alone, and without the structural core board.
Example 3: In a third example, an impact resistance of the reinforced porcelain panel product 100 was experimentally determined under European Standard (“EN”) test number 14617-9. The impact resistance of the reinforced porcelain panel product 100 was determined to yield increased resistance with a conventional 12-millimeter florim porcelain. The below table illustrates the specific EN test findings. Unless otherwise notated, the unit “J” refers to Joules, as would be understood by one skilled in the art.
Table 3 illustrates the impact resistance increase of at least about 57% by using a structural core board, such as structural core board 130 discussed above on a conventional 12-millimeter florim porcelain slab as compared to the conventional 12-millimeter florim porcelain slab without the structural core board. Therefore, the results support a finding of at least 57% impact resistance increase, such as at least about 55% impact resistance increase, such as at least about 45% impact resistance increase, such as at least about 40% impact resistance increase, such as at least about 35% impact resistance increase, such as at least about 30% impact resistance increase, such as at least about 25% impact resistance increase, such as at least about 20% impact resistance increase, such as at least about 15% impact resistance increase, such as at least about 10% impact resistance increase, such as at least about 5% impact resistance increase, by using a structural core board, such as structural core board 130 discussed above on a conventional 12-millimeter florim porcelain slab as compared to the conventional 12-millimeter florim porcelain slab without the structural core board.
It is important to note the testing results from Example 2 and Example 3 support a finding of at least 50% impact resistance increase, by using a structural core board on either a conventional 6-millimeter florim porcelain slab or a conventional 12-millimeter florim porcelain slab. Therefore, it may be understood the impact resistance is advantageously increased by at least 50% and other common values mentioned above.
Example 4: In a fourth example, an adhesive bonding test was performed using three types of KANEKA MS Polymer adhesives, referred to as 1) TAW, 2) SKIF-28, and 3) SWC-008. The three adhesives were tested for tensile strength, such as a pulling test, under the International Standard Organization (ISO) standard ISO13007-2 covering ceramic tiles including grouts and adhesives, which evaluates short term results, such as cohesive failure (CF) between ceramic surfaces using grouts and adhesives, as would be understood by one skilled in the art. Each adhesive was applied to a separate mortar substrate and adhered to green foam, as would be understood by one skilled in the art. The bond was tested after 4 days. The force to separate the bond was measured for each of the adhesives is shown in the below table.
Table 4 illustrates the tensile strength of each of the adhesives. The pressure, in megapascal (MPa), for TAW was 0.34 to achieve CF. The pressure for SKIF-28 was 0.49 MPa to achieve CF. The pressure for SWC-008B was 0.35 MPa to achieve cohesive failure. SKIF-28 was observed to tolerate the highest pressure on the tensile test.
Example 5: In a fifth example, a fast grab test was performed using two of the KANEKA MS Polymer™ adhesives in Example 4. The adhesives include 1) TAW and 2) SKIF-28. The two adhesives were tested for an evaluation of how much weight can be held by the substrate just after applying adhesive. One skilled in the art may refer to this test as a “non-sag” test. The force to move the substrate was evaluated against ANSI 118.4. The results of the fast grab test are shown in the below table.
Table 5 illustrates the results of the fast grab test in which both TAW and SKIF-28 adhesives exceed the requirements of the ANSI 118.4 standard. For example, ANSI 118.4 criteria requires more than 3.97 lb/ft2 and TAW exhibited a 14.68 lb/ft2 fast grab results. Similarly, SKIF-28 exceeded the 3.97 lb/ft2 ANSI 118.4 criteria at 13.10 lb/ft2. Porcelain tile weight may be about 2.9 lb/ft2, therefore TAW adhesive may require only about 20% coverage to hold tile or composite tile.
Example 6: In a sixth example, SWC-008 adhesive, as discussed in Example 4, was tested for satisfactory bonding of the porcelain to a foam panel. The SWC-008 adhesive was tested as an offset of GLAX, as SWC-008 is a 1-part, lower viscosity, rollable, and quick drying, as compared to the mixing requirement of a 2 part system. Dry time was observed to be less than 3.5 hours. The lower viscosity of SWC-008 enables bonding to bond porcelain tile to foam panels without gaps. Adhesion strength was empirically found to be satisfactory. In a subsequent tensile test, the foam panel was deformed before the SWC-008 adhesive was peeled off. Thus, SWC-008 has be found to have sufficient and satisfactory adhesion to bond porcelain and a foam panel, as disclosed above.
Example 7: In a seventh example, the compatibility of the KANEKA MS Polymer adhesives, referred to as 1) TAW, 2) SKIF-28, and 3) SWC-008, with waterproofing products, such as Redguard®, or waterstop, was tested. Each of the adhesives was applied to a wall coated with a waterproofing product. No damage or degradation of the waterproofing membrane, or wall coating, was observed.
Example 8: In an eighth example, a ceiling tile test was performed. At the time of filing this application, a ceiling tile test is planned by first bonding porcelain and a foam panel, as discussed above, by SWC-008 and then using the composite to test durability of the adhesive in a simulated downward facing orientation to perform as a ceiling tile would be positioned, as would be understood by one skilled in the art.
Example 9: In a ninth example, a flooring tile test in accordance with ASTM standard C627-18: “A Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems Using the Robinson-Type Floor Tester,” was performed using a reinforced porcelain tile product such as indicated at 100 and as discussed above and as will be understood by those skilled in the art for evaluating the performance of the reinforced porcelain tile product under dynamic loads. A test installation was constructed including 28 inch by 32 inch plywood sheets joined along a tongue and groove seam to form a subfloor, and which was nailed to joists with 2″ ring shank nails inserted at 6″ inch centers along perimeter joints and at 12″ centers on intermediate joists. A ¼″ bead of a construction adhesive was applied prior to nailing the subfloor to the joists. A Luxury Vinyl Tile & Plank Flooring Adhesive (in particular, a Henry® 647 Luxury Vinyl Tile & Plank Flooring Adhesive) was applied to the subfloor, after which a 48″×48″ reinforced porcelain tile product formed in accordance with the principles of the present disclosure and having a 6″×6″ hole in its center was applied over the subfloor and pressed into contact with the adhesive. The test installation was allowed to cure for approximately 24 hours. After curing, the test installation was subjected to a series of test cycles using a Robinson-type floor tester including a carriage with a series of spaced caster wheels. Different test cycles were conducted using wheels of different materials (e.g., soft rubber and hard rubber) and with different weights applied to simulate different conditions as shown in table 6 below.
As shown in the above table, during testing, minimal deflection of the tile was observed, ranging from 0.017″ to 0.034″ for the heaviest weight applied using the tester having hard rubber wheels, and only 1 broken tile was observed after 7 test cycles, with this one instance of damage occurring during the last cycle with a 300 lb. weight applied by a Robinson type tester having hard rubber wheels. Per the ASTM C627 standards, the reinforced porcelain tile product formed in accordance with the principles of the present disclosure meets the standard for residential and light commercial uses for ceramic floor tiles.
Example 10: In a tenth example, the above described flooring tile test of Example 9 conducted in accordance with ASTM standard C627-18: “A Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems Using the Robinson-Type Floor Tester,” was repeated using a reinforced porcelain tile product such as indicated at 100 and as discussed above and as will be understood by those skilled in the art. In this example test, the test installation was substantially the same as used for the test of the ninth Example, but a thin set adhesive material (in particular, a Laticrete LHT™ tile mortar for use with large and heavy tiles, was used in pace of the Luxury Vinyl Tile & Plank Flooring Adhesive. The results of this testing are shown in Table 7 below.
As shown in the above table, during testing, minimal deflection of the tile was observed, ranging from 0.017″ to 0.034″ for the heaviest weight applied using the tester having hard rubber wheels, and only 1 broken tile was observed after 7 test cycles, with this one instance of damage occurring during the last cycle with a 300 lb. weight applied by a Robinson type tester having hard rubber wheels. Per the ASTM C627 standards, the reinforced porcelain tile product formed in accordance with the principles of the present disclosure meets the standard for residential and light commercial uses for ceramic floor tiles.
Example 11: In an eleventh example, a further flooring tile test conducted in accordance with ASTM standard C627-18: “A Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems Using the Robinson-Type Floor Tester,” was performed using a reinforced porcelain panel product such as indicated at 100 and as discussed above installed on a concrete subfloor. For this example, a test installation was constructed including a 48″×48″ concrete base cured for a minimum of 28 days prior to use. A Luxury Vinyl Tile & Plank Flooring Adhesive (in particular, a Henry® 647 Luxury Vinyl Tile & Plank Flooring Adhesive) was applied to the concrete base, after which a 48″×48″ reinforced porcelain tile product formed in accordance with the principles of the present disclosure and having a 6″×6″ hole in its center was applied over the subfloor and pressed into contact with the adhesive. The test installation was allowed to cure for approximately 24 hours. After curing, the test installation was subjected to a series of test cycles using a Robinson-type floor tester using wheels of different materials (e.g., soft rubber and hard rubber) and with different weights applied to simulate different conditions as shown in table 8 below.
As shown in the above table, only 1 broken tile was observed after 7 test cycles, with this one instance of damage occurring during the last cycle with a 300 lb. weight applied by a Robinson type tester having hard rubber wheels. Per the ASTM C627 standards, the reinforced porcelain tile product formed in accordance with the principles of the present disclosure meets the standard for residential and light commercial uses for ceramic floor tiles.
Example 12: In a twelfth example, the above described flooring tile test of Example 11 conducted in accordance with ASTM standard C627-18: “A Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems Using the Robinson-Type Floor Tester,” was repeated using a reinforced porcelain tile product such as indicated at 100 and as discussed above and as will be understood by those skilled in the art. In this example, the test installation was substantially the same as used for the test of the ninth Example, but a thin set adhesive material (in particular, a Laticrete LHT™ tile mortar for use with large and heavy tiles, was used in pace of the Luxury Vinyl Tile & Plank Flooring Adhesive. The results of this testing are shown in Table 9 below.
As shown in the above table, only 1 broken tile was observed after 7 test cycles, with this one instance of damage occurring during the last cycle with a 300 lb. weight applied by a Robinson type tester having hard rubber wheels. Per the ASTM C627 standards, the reinforced porcelain tile product formed in accordance with the principles of the present disclosure meets the standard for residential and light commercial use for ceramic floor tiles.
This application is a continuation-in-part of U.S. application Ser. No. 18/902,190, filed Sep. 30, 2024, titled REINFORCED PORCELAIN PANEL PRODUCT KIT FOR SHOWER INSTALLATION, which is a continuation-in-part of U.S. application Ser. No. 18/821,454, filed Aug. 30, 2024, titled “REINFORCED PORCELAIN PANEL SYSTEM AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” which claims priority to and the benefit of U.S. Provisional Application No. 63/676,400, filed Jul. 28, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/651,803, filed May 24, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/643,778, filed May 7, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/551,903, filed Feb. 9, 2024, titled “MAGNETIC SHOWER WALL ACCESSORIES,” U.S. Provisional Application No. 63/549,820, filed Feb. 5, 2024, titled “PORCELAIN BOARD TILES,” U.S. Provisional Application No. 63/549,704, filed Feb. 5, 2024, titled “PORCELAIN BOARD FOR FABRICATORS OR DISTRIBUTORS,” and U.S. Provisional Application No. 63/541,981, filed Oct. 2, 2023, titled “SYSTEMS AND METHODS FOR PORCELAIN BOARD,” the disclosures of all of which are incorporated herein by reference in their entireties. U.S. application Ser. No. 18/902,190 is also a continuation-in-part of U.S. application Ser. No. 18/821,478, filed Aug. 30, 2024, tided “REINFORCED PORCELAIN PANEL SYSTEM AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” which claims priority to and the benefit of U.S. Provisional Application No. 63/676,400, filed Jul. 28, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/651,803, filed May 24, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/643,778, filed May 7, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/551,903, filed Feb. 9, 2024, titled “MAGNETIC SHOWER WALL ACCESSORIES,” U.S. Provisional Application No. 63/549,820, filed Feb. 5, 2024, titled “PORCELAIN BOARD TILES,” U.S. Provisional Application No. 63/549,704, filed Feb. 5, 2024, titled “PORCELAIN BOARD FOR FABRICATORS OR DISTRIBUTORS,” and U.S. Provisional Application No. 63/541,981, filed Oct. 2, 2023, titled “SYSTEMS AND METHODS FOR PORCELAIN BOARD,” the disclosures of all of which are incorporated herein by reference in their entireties.
The present application further incorporates the disclosures of U.S. application Ser. No. 18/902,163, filed Sep. 30, 2024 and titled PORCELAIN BOARD TILE ASSEMBLIES, SYSTEMS, AND METHODS FOR SURFACE INSTALLATIONS, U.S. application Ser. No. 18/902,140, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL MAGNETIC ASSEMBLIES, SYSTEMS, AND METHODS FOR SHOWER INSTALLATIONS, U.S. application Ser. No. 18/902,121, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL PRODUCT FABRICATION METHODS FOR ENHANCED STRUCTURAL PROTECTION, and U.S. application Ser. No. 18/902,097, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL PRODUCT FOR ENHANCED STRUCTURAL PROTECTION, by reference in their entireties
Other objects, features, and advantages of the disclosure will become apparent from the foregoing figures, detailed description, and embodiments. It should be understood, however, that the figures, detailed description, and embodiments, while indicating specific embodiments of the disclosure, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from the detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiment. In further examples, additional features may be added to the specific embodiment described herein.
This application is a continuation-in-part of U.S. application Ser. No. 18/902,190, filed Sep. 30, 2024, titled REINFORCED PORCELAIN PANEL PRODUCT KIT FOR SHOWER INSTALLATION, which is a continuation-in-part of U.S. application Ser. No. 18/821,454, filed Aug. 30, 2024, titled “REINFORCED PORCELAIN PANEL SYSTEM AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” which claims priority to and the benefit of U.S. Provisional Application No. 63/676,400, filed Jul. 28, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/651,803, filed May 24, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/643,778, filed May 7, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/551,903, filed Feb. 9, 2024, titled “MAGNETIC SHOWER WALL ACCESSORIES,” U.S. Provisional Application No. 63/549,820, filed Feb. 5, 2024, tided “PORCELAIN BOARD TILES,” U.S. Provisional Application No. 63/549,704, filed Feb. 5, 2024, titled “PORCELAIN BOARD FOR FABRICATORS OR DISTRIBUTORS,” and U.S. Provisional Application No. 63/541,981, filed Oct. 2, 2023, titled “SYSTEMS AND METHODS FOR PORCELAIN BOARD,” the disclosures of all of which are incorporated herein by reference in their entireties. U.S. application Ser. No. 18/902,190 is also a continuation-in-part of U.S. application Ser. No. 18/821,478, filed Aug. 30, 2024, titled “REINFORCED PORCELAIN PANEL SYSTEM AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” which claims priority to and the benefit of U.S. Provisional Application No. 63/676,400, filed Jul. 28, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/651,803, filed May 24, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/643,778, filed May 7, 2024, titled “REINFORCED PORCELAIN PANEL PRODUCT AND ASSOCIATED METHODS FOR ENHANCED STRUCTURAL PROTECTION,” U.S. Provisional Application No. 63/551,903, filed Feb. 9, 2024, titled “MAGNETIC SHOWER WALL ACCESSORIES,” U.S. Provisional Application No. 63/549,820, filed Feb. 5, 2024, tided “PORCELAIN BOARD TILES,” U.S. Provisional Application No. 63/549,704, filed Feb. 5, 2024, titled “PORCELAIN BOARD FOR FABRICATORS OR DISTRIBUTORS,” and U.S. Provisional Application No. 63/541,981, filed Oct. 2, 2023, titled “SYSTEMS AND METHODS FOR PORCELAIN BOARD,” the disclosures of all of which are incorporated herein by reference in their entireties. The present application further incorporates the disclosures of U.S. application Ser. No. 18/902,163, filed Sep. 30, 2024 and titled PORCELAIN BOARD TILE ASSEMBLIES, SYSTEMS, AND METHODS FOR SURFACE INSTALLATIONS, U.S. application Ser. No. 18/902,140, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL MAGNETIC ASSEMBLIES, SYSTEMS, AND METHODS FOR SHOWER INSTALLATIONS, U.S. application Ser. No. 18/902,121, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL PRODUCT FABRICATION METHODS FOR ENHANCED STRUCTURAL PROTECTION, and U.S. application Ser. No. 18/902,097, filed Sep. 30, 2024 and titled REINFORCED PORCELAIN PANEL PRODUCT FOR ENHANCED STRUCTURAL PROTECTION, by reference in their entireties.
| Number | Date | Country | |
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| 63676400 | Jul 2024 | US | |
| 63651803 | May 2024 | US | |
| 63643778 | May 2024 | US | |
| 63551903 | Feb 2024 | US | |
| 63549820 | Feb 2024 | US | |
| 63549704 | Feb 2024 | US | |
| 63541981 | Oct 2023 | US | |
| 63676400 | Jul 2024 | US | |
| 63651803 | May 2024 | US | |
| 63643778 | May 2024 | US | |
| 63551903 | Feb 2024 | US | |
| 63549820 | Feb 2024 | US | |
| 63549704 | Feb 2024 | US | |
| 63541981 | Oct 2023 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18902190 | Sep 2024 | US |
| Child | 18977398 | US | |
| Parent | 18821454 | Aug 2024 | US |
| Child | 18902190 | US | |
| Parent | 18821478 | Aug 2024 | US |
| Child | 18902190 | US |
