Processed slabs, and systems and methods related thereto

• US 10,773,418 B2
• Filed: 03/21/2019
• Issued: 09/15/2020
• Est. Priority Date: 01/30/2015
• Status: Active Grant

• Current Assignee: Cambria Company LLC
• Original Assignee: Cambria Company LLC
• Inventors: Grzeskowiak, II, Jon Louis, Davis, Martin E.
• Primary Examiner(s): Polley, Christopher M
• Application Number:
  US16/360,628
• Publication Number:
  US 20190283270A1
• Time in Patent Office: 544 Days
• Field of Search: None
• CPC Class Codes: B28B 1/005 Devices or processes for obtaining articles having a marble appearance producing decorative effects B44C; design of stone surfaces, e.g. marble, B44F9/04
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B28B 13/022 Feeding several successive layers, optionally of different materials
• CPC Class Codes: B28B 13/0225 Feeding specific quantities of material at specific locations in the mould
• CPC Class Codes: B28B 3/022 combined with vibrating or jolting
• CPC Class Codes: B28B 5/022 the moulds or the moulding surfaces being individual independant units and being discontinuously fed feeding B28B13/0215 and sub-groups
• CPC Class Codes: B28B 7/007 with moulding surfaces simulating natural effets, e.g. wood or stone
• CPC Class Codes: B29C 39/12 Making multilayered or multicoloured articles B29C39/021 takes precedence
• CPC Class Codes: B29C 39/24 Feeding the material into the mould
• CPC Class Codes: B29C 39/26 Moulds or cores
• CPC Class Codes: B29C 67/243 for making articles of definite length
• CPC Class Codes: B29C 67/244 by vibrating the composition before or during moulding
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2509/00 Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
• CPC Class Codes: B29K 2995/0021 Multi-coloured
• CPC Class Codes: B29L 2007/00 Flat articles, e.g. films or sheets B29L2024/00 takes precedence
• CPC Class Codes: B29L 2031/10 Building elements, e.g. bricks, blocks, tiles, panels, posts, beams frameless domes B29L2025/00, doors B29L2031/724
• CPC Class Codes: B29L 2031/441 Countertops
• CPC Class Codes: B29L 2031/722 Decorative or ornamental articles
• CPC Class Codes: B29L 2031/732 : Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: B44C 5/0453 : produced by processes involving moulding
• CPC Class Codes: B44C 5/06 : Natural ornaments; Imitations thereof artificial flowers, fruit, leaves A41G1/00; artificial feathers A41G11/00
• CPC Class Codes: B44F 9/04 : of stone surfaces, e.g. marble
• CPC Class Codes: C04B 14/06 : Quartz; Sand
• CPC Class Codes: C04B 14/34 : Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 2103/54 : Pigments; Dyes
• CPC Class Codes: C04B 2103/67 : Biocides
• CPC Class Codes: C04B 2111/54 : Substitutes for natural stone, artistic materials or the like
• CPC Class Codes: C04B 26/02 : Macromolecular compounds
• CPC Class Codes: C04B 26/32 : containing silicon
• CPC Class Codes: C04B 32/00 : Artificial stone not provided for in other groups of this subclass
• CPC Class Codes: C04B 40/02 : Selection of the hardening environment
• CPC Class Codes: C04B 41/60 : of only artificial stone

Abstract

This document describes systems and processes for forming synthetic molded slabs, which may be suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

Claims

1. A processed slab formed from a plurality of particulate mineral mixes deposited into a mold, comprising:

a slab width that is at least 2 feet, a slab length that extends perpendicular to the slab width and that is at least 6 feet, and a slab thickness that extends perpendicular to the slab width and the slab length, the slab length greater than the slab width, the slab width greater than the slab thickness;

a first predetermined pattern defined by a first particulate mineral mix and comprising a set of slab veins exposed along a major surface of the slab, the set of slab veins comprising;

a first vein in a generally lengthwise direction along the major surface, the first vein having a first vein thickness defined by the first particulate mineral mix that is equal and parallel to the slab thickness,

a second vein in a generally widthwise direction along the major surface, the second vein having a second vein thickness defined by the first particulate mineral mix that is equal and parallel to the slab thickness,

wherein the first vein in the generally lengthwise direction intersects the second vein in the generally widthwise direction; and

a second predetermined pattern defined by a second particulate mineral mix that occupies the entire slab thickness;

wherein the first and second mineral mixes are different and each comprise quartz and one or more binders, the first particulate mineral mix absent from the second predetermined pattern and the second particulate mineral mix absent from the first predetermined pattern.

2. The processed slab of claim 1, wherein the set of slab veins further comprises a third vein in a generally lengthwise direction along the major surface, the third vein having a third vein thickness that is equal and parallel to the slab thickness, the third vein thickness defined by the first particulate mineral mix.

3. The processed slab of claim 2, wherein the third vein in the generally lengthwise direction intersects the second vein in the generally lengthwise direction.

4. The processed slab of claim 2, wherein the first vein is spaced from the third vein and separated by at least a portion of the second predetermined pattern defined by the second particulate mineral mix.

5. The processed slab of claim 2, wherein the second particulate mineral mix occupies the entire slab thickness adjacent to the first vein and the second vein on opposite sides of each of the first vein and the second vein.

6. The processed slab of claim 1, wherein the first vein and the second vein are visible on both a front major surface and a rear major surface of the processed slab.

7. The processed slab of claim 6, wherein the first predetermined pattern is an inverse of the second predetermined pattern.

8. The processed slab of claim 1, further comprising a third particulate mineral mix that is different than the first and second particulate mineral mixes.

9. The processed slab of claim 8, wherein the third particulate mineral mix is differently pigmented than the first and second particulate mineral mixes.

10. The processed slab of claim 8, wherein the third particulate mineral mix forms a third predetermined pattern that does not extend through the entire slab thickness.

11. The processed slab of claim 1, wherein the major surface comprises a third predetermined pattern defined by a third particulate mineral mix, the third particulate mineral mix extending through the slab thickness.

12. The processed slab of claim 11, wherein the first predetermined pattern, the second predetermined pattern, and the third predetermined pattern do not overlap.

13. The processed slab of claim 1, wherein the first vein extends across the entire slab length.

14. The processed slab of claim 1, wherein the second vein extends across the entire slab width.

15. A processed slab formed from a plurality of particulate mineral mixes deposited into a mold, comprising:

a slab width that is at least 2 feet, a slab length that extends perpendicular to the slab width and that is at least 6 feet, and a slab thickness that extends perpendicular to the slab width and the slab length, the slab length greater than the slab width, the slab width greater than the slab thickness;

a first predetermined pattern defined by a first particulate mineral mix and comprising a set of slab veins exposed along a major surface of the slab, the set of slab veins comprising;

a first vein having a generally lengthwise segment along the major surface, the first vein having a first vein thickness defined by the first particulate mineral mix that is equal and parallel to the slab thickness,

a second vein having a generally widthwise segment along the major surface, the second vein having a second vein thickness defined by the first particulate mineral mix that is equal and parallel to the slab thickness; and

a second predetermined pattern defined by a second particulate mineral mix that occupies the entire slab thickness adjacent to opposite sides of each of the first vein and the second vein;

wherein the first and second mineral mixes are different and each comprise quartz and one or more binders, the first particulate mineral mix absent from the second predetermined pattern and the second particulate mineral mix absent from the first predetermined pattern.

16. The processed slab of claim 15, wherein the first vein having the generally lengthwise segment intersects the second vein having the generally widthwise segment.

17. The processed slab of claim 16, wherein the set of slab veins further comprises a third vein in a generally lengthwise direction along the major surface, the third vein having a third vein thickness that is equal and parallel to the slab thickness, the third vein thickness defined by the first particulate mineral mix.

18. The processed slab of claim 17, wherein the third vein in the generally lengthwise direction intersects the second vein having the generally widthwise segment.

19. The processed slab of claim 18, wherein the first vein is spaced from the third vein and separated by at least a portion of the second predetermined pattern defined by the second particulate mineral mix.

20. The processed slab of claim 19, wherein the first vein extends across the entire slab length.

21. The processed slab of claim 15, wherein the first predetermined pattern corresponds to a first stencil pattern.

22. The processed slab of claim 21, wherein the second predetermined pattern is a negative of the first predetermined pattern.

23. The processed slab of claim 15, wherein the second predetermined pattern corresponds to a second stencil pattern.