Reinforced porcelain panel assemblies, systems, and methods for surface installations

Abstract

The present disclosure provides embodiments of a tile 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. In embodiments, the second component comprises a structural foam material having 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. The at least one reinforced porcelain tile product may be configured to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.

What is claimed is: 
     
         1 . A tile comprising:
 at least one reinforced porcelain tile product comprising:
 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 comprising a structural material and having top surface, a bottom surface, and a plurality of peripheral side portions; 
 wherein the second component comprises 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; 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. 
   
     
     
         2 . The tile of  claim 1 , further comprising 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. 
     
     
         3 . The tile of  claim 1 , wherein 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. 
     
     
         4 . The tile of  claim 1 , wherein the first component comprises a porcelain slab having a thickness of at least about 3 mm, and the second component comprises a structural core board having a thickness that is greater than the thickness of the porcelain slab. 
     
     
         5 . The tile of  claim 4 , wherein 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 comprises about 2.0 GPa to about 14.6 GPa. 
     
     
         6 . The tile of  claim 1 , wherein 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. 
     
     
         7 . The tile of  claim 6 , wherein 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. 
     
     
         8 . The tile of  claim 7 , wherein 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. 
     
     
         9 . The tile of  claim 1 , wherein 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. 
     
     
         10 . The tile of  claim 1 , wherein the structural foam material of the second component comprises 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 comprises a range of about 2.0 GPa to about 14.6 GPa. 
     
     
         11 . The tile of  claim 1 , wherein the tile is configured to withstand a weight of at least 200 lb. applied using a Robinson-type floor tester with hard rubber wheels. 
     
     
         12 . A porcelain tile flooring system 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 comprises a thickness of at least about 3 mm and the structural support layer comprises a thickness that is greater than the thickness of the porcelain material layer; 
 wherein the structural support layer comprises:
 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. 
 
   
     
     
         13 . The porcelain tile flooring system of  claim 12 , wherein the substrate comprises wood, concrete, oriented strand board, concrete, cement, particle board, or combinations thereof. 
     
     
         14 . The porcelain tile flooring system of  claim 12 , further comprising a waterproofing layer, a pan, cement panel, vapor barrier, underlayment, cushion layer, or combinations thereof, positioned between the substrate and the reinforced porcelain tiles. 
     
     
         15 . The porcelain tile flooring system of  claim 12 , wherein 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. 
     
     
         16 . The porcelain tile flooring system of  claim 12 , further comprising 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. 
     
     
         17 . The porcelain tile flooring system of  claim 12 , wherein 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. 
     
     
         18 . The porcelain tile flooring system of  claim 12 , further comprising a tile mortar, vinyl flooring adhesive, or combinations thereof, applied between the substrate and the bottom surface of the structural support layer. 
     
     
         19 . The porcelain tile flooring system of  claim 12 , 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. 
     
     
         20 . The porcelain tile flooring system of  claim 12 , wherein 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. 
     
     
         21 . The porcelain tile flooring system of  claim 12 , wherein 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 comprises about 2.0 GPa to about 14.6 GPa. 
     
     
         22 . The porcelain tile flooring system of  claim 12 , wherein the structural support layer comprises a structural foam material; and wherein the structural foam material comprises 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 comprises a range of about 2.0 GPa to about 14.6 GPa. 
     
     
         23 . The porcelain flooring tile system of  claim 12 , wherein 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. 
     
     
         24 . The porcelain flooring tile system of  claim 12 , wherein the structural support layer comprises 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 comprises a finger joint, a shiplap joint, or a dovetail joint. 
     
     
         25 . The porcelain tile flooring system of  claim 12 , wherein the reinforced porcelain tiles are installed as a floor in a shower enclosure. 
     
     
         26 . A reinforced porcelain tile product for renovations or new construction, the reinforced porcelain tile product comprising:
 a first component including an exposed top surface a 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 comprises a porcelain material;   wherein the second component comprises:
 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.   
     
     
         27 . The reinforced porcelain tile product of  claim 26 , wherein 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 porcelain slab by about 0.125 inch to about 0.750 inches. 
     
     
         28 . The reinforced porcelain tile product of  claim 26 , wherein 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 comprises 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 comprises about 2.0 GPa to about 14.6 GPa. 
     
     
         29 . The reinforced porcelain tile product of  claim 26 , wherein the first component comprises 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. 
     
     
         30 . The reinforced porcelain tile product of  claim 26 , wherein the second component comprises a structural foam material having a young's modulus value of the structural foam material comprises a range of about 2.0 GPa to about 14.6 GPa. 
     
     
         31 . The reinforced porcelain tile products of  claim 30 , wherein the structural foam material comprises polyurethane, polycarbonate, polyphenylene oxide, polybutylene terephthalate, polyethylene terephthalate, acrylonitrile butadiene styrene, or combinations thereof. 
     
     
         32 . The reinforced porcelain tile product of  claim 30 , wherein the structural foam material comprises a thermoplastic or a thermoset polymer material. 
     
     
         33 . The reinforced porcelain tile product of  claim 26 , wherein the second component comprises 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 comprises a finger joint, a shiplap joint, or a dovetail joint. 
     
     
         34 . The reinforced porcelain tile product of  claim 33 , wherein the top surface of the first component has at least a portion of an artistic design displayed therealong. 
     
     
         35 . The reinforced porcelain tile product of  claim 26 , wherein the reinforced porcelain tile product is configured to construct a wall, ceiling, or floor. 
     
     
         36 . A kit for construction or reconstruction of a shower enclosure, the kit comprising:
 a plurality of reinforced porcelain tile products;   wherein each reinforced porcelain tile product 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 comprises:
 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 each of reinforced porcelain tile products is configured to meet or exceed the standard for Residential and Light Commercial Use Ceramic Floor Tile as measured according to ASTM C627-18.   
     
     
         37 . The kit of  claim 36 , wherein the plurality of reinforced porcelain tile products comprises three or more reinforced porcelain tile products configured to form a floor for a selected shower enclosure size. 
     
     
         38 . The kit of  claim 37 , wherein the selected shower enclosure size comprises 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 comprises about 31 inches by about 74 inches, about 31 inches by about 96 inches, or about 31 inches by about 106 inches. 
     
     
         39 . The kit of  claim 36 , wherein 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. 
     
     
         40 . The kit of  claim 39 , wherein 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. 
     
     
         41 . The kit of  claim 36 , further comprising a container within which the plurality of reinforced porcelain tile products is received for transport. 
     
     
         42 . The kit of  claim 41 , wherein the container includes a supporting member configured to position and retain at least one reinforced porcelain tile product within the container. 
     
     
         43 . The kit of  claim 41 , wherein the container comprises a box, a crate, a pallet, or an a-frame crate; and wherein the container further includes one or more straps restrain the reinforced porcelain tile products within the container so as to reduce movement thereof during transport. 
     
     
         44 . The kit of  claim 36 , wherein the reinforced porcelain tile products each have an impact resistance of at least 30% greater than porcelain having a thickness of 6 mm or higher; wherein the reinforced porcelain tile products each have 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 is about 2.0 GPa to about 14.6 GPa; and wherein the structural core board extends beyond an outer periphery of the porcelain slab by about 0.125 inches to about 0.750 inches. 
     
     
         45 . The kit of  claim 36 , wherein 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 the adjacent reinforced porcelain tile product are interlockable and positionable with one another. 
     
     
         46 . The kit of  claim 36 , wherein the structural core board comprises a thermoplastic or a thermoset foam material; and wherein the thermoplastic or thermoset foam material comprises 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. 
     
     
         47 . The kit of  claim 36 , further comprising a magnetic panel configured to be installed behind and adjacent to a bottom surface of 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 of the at least one reinforced porcelain tile product when positioned within an installed shower enclosure.