Porcelain board tile assemblies, systems, and methods for surface installations

A porcelain board tile assembly, the assembly comprising:

• two or more porcelain board tiles cut from a reinforced porcelain panel product, each of the two or more porcelain board tiles having a top surface opposite a bottom surface and outer peripheries extending between and connected to the top surface and the bottom surface, the bottom surface to be affixed to a mounting wall when installed, the reinforced porcelain panel product defined by:
• (a) a porcelain slab having a top surface with a first surface area opposite a bottom surface, and
• (b) a structural core board including a foam-core material and having a top surface and a bottom surface, the top surface of the structural core board having a second surface area greater than the first surface area of the porcelain slab and positioned in abutting contact with the bottom surface of the porcelain slab with adhesive therebetween and 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 panel product from a front view of the top surface of the reinforced porcelain panel product and to enhance protection from cracking or chipping when the reinforced porcelain panel product is handled,
• the reinforced porcelain panel product also including one or more scorelines positioned on the top surface of the reinforced porcelain panel product, the one or more scorelines extending substantially parallel to one of a first pair of peripheral opposite side portions or a second pair of peripheral opposite side portions of the buffer region of the top surface of an associated structural core board, such that a pattern of two or more porcelain board tiles occurs after controlled breaks, thereby to cut porcelain board tiles from the reinforced porcelain panel product when a radial force is exerted on or near the scoreline.

A porcelain board tile system, mounted to a mounting surface, the system comprising:

• the mounting surface;
• and
• two or more porcelain board tiles cut from a reinforced porcelain panel product, each of the two or more porcelain board tiles having a top surface opposite a bottom surface and outer peripheries extending between and connected to the top surface and the bottom surface, the bottom surface affixed to a mounting surface, the reinforced porcelain panel product defined by:
• (a) a porcelain slab having a top surface with a first surface area opposite a bottom surface, and
• (b) a structural core board having a thickness greater than the porcelain slab, a Young's modulus value lower than a Young's modulus value of the porcelain slab, and a top surface opposite a bottom surface, the top surface of the structural core board having a second surface area greater than the first surface area of the porcelain slab and positioned in abutting contact with the bottom surface of the porcelain slab with adhesive 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, so as to define a buffer region, thereby to allow the buffer region to be visible when viewing the reinforced porcelain panel product from a front view of the reinforced porcelain panel product and to have an impact resistance of at least 30% greater than an impact resistance of porcelain having a thickness of 6 mm or greater from cracking or chipping when the reinforced porcelain panel product is handled, the buffer region including a first pair of peripheral opposite side portions positioned substantially parallel with each other and a second pair of opposite side portions positioned substantially parallel to each other and connected to and extending transverse to the first pair of peripheral opposite side portions, each of the two or more porcelain board tiles including a unique identifier configured to identify and aid arrangement of the two or more porcelain board tiles to create an art piece when installed, at least two of the two or more porcelain board tiles arranged, so as to display the top surface having a pattern thereon, thereby to define the art piece, and at least two of the two or more porcelain board tiles in abutting contact, such that outer peripheries of a first porcelain board tile contact outer peripheries of a second porcelain board tile.

A porcelain board tile assembly, the assembly comprising:

• two or more porcelain board tiles derived from a reinforced porcelain panel product, each of the two or more porcelain board tiles having a top surface opposite a bottom surface and outer peripheries extending between and connected to the top surface and the bottom surface, the bottom surface to be affixed to a mounting surface when installed, the reinforced porcelain panel product defined by:
• (a) a porcelain slab having a top surface with a surface area opposite a bottom surface, the porcelain slab having:
• a total surface area defined by summating surface areas from all surfaces of the porcelain slab,
• a thickness ranging from about 3 millimeters (mm) to about 8 mm,
• an impact resistance of at least 30% greater than an impact resistance of porcelain having a thickness of at least 6 mm, and
• a breaking strength at least 40% greater than a breaking strength of porcelain having a thickness of at least 6 mm, and
• (b) a structural core board including a foam-core material, the structural core board having:
• a top surface opposite a bottom surface,
• a total surface area defined by summating surface areas from all surfaces of the structural core board,
• a thickness up to about 10 mm and greater than the thickness of the porcelain slab, such that the total surface area of the structural core board is greater than the total surface area of the porcelain slab, the top surface of the structural core board positioned in abutting contact with the bottom surface of the porcelain slab with adhesive therebetween, thereby to enhance protection from cracking or chipping when the reinforced porcelain panel product is handled, the bottom surface of the structural core board having a surface plane substantially parallel to the top surface of the porcelain slab,
• a fracture toughness greater than a fracture toughness of an associated porcelain slab, and
• a Young's modulus value lower than a Young's modulus value of the associated porcelain slab, the Young's modulus value of each structural core board ranging from about 2.0 GPa to about 14.6 GPa,
• at least two of the two or more porcelain board tiles configured to be positioned in abutting contact, such that outer peripheries of a first porcelain board tile contact outer peripheries of a second porcelain board tile when installed.

A method for installation of a display with porcelain board, the method comprising:

• scoring a top surface of a reinforced porcelain panel product to produce one or more scorelines positioned along one or more selected locations across the top surface of the reinforced porcelain panel product, thereby to define a preselected pattern, thereby to one or more of:
• (a) guide controlled breaks to cut the reinforced porcelain panel product into two or more porcelain board tiles when a radial force is exerted on or near the one or more scorelines or
• (b) guide a cutting tool to cut along the one or more scorelines;
• cutting the reinforced porcelain panel product along the preselected pattern on the top surface of the reinforced porcelain panel product to produce two or more porcelain board tiles, the reinforced porcelain panel product defined by:
• (a) a porcelain slab having a top surface with a surface area opposite a bottom surface, the porcelain slab having a total surface area defined by summating surface areas from all surfaces of the porcelain slab, and
• (b) a structural core board including a foam-core material, the structural core board having:
• (1) a top surface opposite a bottom surface,
• (2) a total surface area defined by summating surface areas from all surfaces of the structural core board, and
• (3) a thickness up to about 10 millimeters (mm), the thickness greater than a thickness of the porcelain slab, such that the total surface area of the structural core board is greater than the total surface area of the porcelain slab, the top surface of the structural core board positioned in abutting contact with the bottom surface of the porcelain slab with adhesive therebetween, thereby to enhance protection from cracking or chipping when the reinforced porcelain panel product is handled, the bottom surface of the structural core board having a surface plane substantially parallel to the top surface of the porcelain slab;
• aligning a first porcelain board tile of the two or more porcelain board tiles to a preselected position on a mounting surface, such that the bottom surface of the first porcelain board tile abuttingly contacts the mounting surface at the preselected position when installed;
• and
• attaching the first porcelain board tile to the preselected position, thereby to affix the first porcelain board tile to the mounting surface to display the top surface of the porcelain board tile.