Reinforced porcelain panel product fabrication methods for enhanced structural protection

A method to fabricate one or more reinforced porcelain panel products for renovations or new constructions, the method comprising:

• applying an adhesive material to a top surface of a structural core board, the structural core board including a foam-core material, a bottom surface opposite the top surface, a total surface area defined by summating surface areas from all surfaces of the structural core board, and having a thickness up to 10-millimeters;
• positioning the structural core board such that the top surface of the structural core board aligns with a preselected position of a bottom surface of a porcelain slab, the porcelain slab having a thickness within a range between, and including, about 3-millimeters to about 8-millimeters;
• contacting the top surface of the structural core board to the bottom surface of the porcelain slab with the adhesive material therebetween at the preselected position to produce a reinforced porcelain panel product, the structural core board having a thickness greater than 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 and a second surface area of the top surface of the structural core board substantially equal to a first surface area of the top surface of the porcelain slab such that outer peripheries of the structural core board substantially align with outer peripheries of the first surface area of the porcelain slab, thereby to enhance protection from cracking or chipping when the reinforced porcelain panel product is handled, the bottom surface of the structural core board (a) having a first surface plane substantially parallel to the top surface of the porcelain slab and (b) to be attached to a mounting surface when installed;
• and
• pressing the structural core board onto the porcelain slab to spread the adhesive material thereon so as to be substantially evenly distributed therebetween, thereby to reduce air between the structural core board onto the porcelain slab and to affix the structural core board onto the porcelain slab when in the adhesive material cures.

A method to fabricate one or more reinforced porcelain panel products for renovations or new constructions, the method comprising:

• forming a structural core board of a foam-core material, the forming including one or more steps of molding, pressing, or layering, the foam-core material having a Young's modulus value in a range between, and including, about 2.0 GPa to about 14.6 GPa, the structural core board having a bottom surface opposite a top surface, and a total surface area defined by summating surface areas from all surfaces of the structural core board;
• applying an adhesive material to a top surface of the structural core board;
• positioning the structural core board such that the top surface of the structural core board aligns with a preselected position of a bottom surface of a porcelain slab;
• abuttingly contacting the structural core board to the bottom surface of the porcelain slab with the adhesive material therebetween at the preselected position to produce a reinforced porcelain panel product, the structural core board having a thickness greater than 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, thereby to enhance protection from cracking or chipping when the reinforced porcelain panel product is handled, the bottom surface of the structural core board (a) having a first surface plane substantially parallel to a top surface of the porcelain slab and (b) to be attached to a mounting surface when installed;
• and
• pressing the structural core board onto the porcelain slab to spread the adhesive material thereon so as to be substantially evenly distributed therebetween, thereby to reduce air between the structural core board onto the porcelain slab and to affix the structural core board onto the porcelain slab when in the adhesive material cures.