SYNTHETIC MOLDED SLABS, AND SYSTEMS AND METHODS RELATED THERETO

• US 20160052333A1
• Filed: 10/08/2015
• Published: 02/25/2016
• Est. Priority Date: 08/19/2014
• Status: Active Grant

• Current Assignee: Cambria Company LLC
• Original Assignee: Cambria Company LLC
• Inventors: Grzeskowiak, Jon Louis II, Davis, Martin E.
• Granted Patent: US 9,718,303 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 13/022 Feeding several successive layers, optionally of different materials
• CPC Class Codes: B28B 13/0245 Rotatable feed frames, e.g. horizontally rotated over 90 degrees
• CPC Class Codes: B29C 31/10 of several materials
• CPC Class Codes: B29C 67/244 by vibrating the composition before or during moulding
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29D 99/0039 Producing countertops
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 5/14 characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B44F 9/04 of stone surfaces, e.g. marble
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

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

Claims

1. (canceled)

2. A synthetic molded slab, comprising:

a major surface at least 2 feet wide by at least 6 feet long and extending perpendicularly to a slab thickness, the major surface having at least a first pigmented vein extending generally lengthwise from edge-to-edge that separates at least second and third pigmented veins extending generally lengthwise and positioned on opposing sides of the first pigmented vein, wherein the first pigmented vein is defined by a first particulate mineral mix and at least the first particulate mineral mix is separated from and forms a substantially unmixed layer with respect to a second particulate mineral mix defining the second pigmented vein according to a predefined layer pattern such that each of the first and second pigmented veins has a vein thickness equal to and parallel to the slab thickness, the second particulate mineral mix being different than the first particulate mineral mix.

3. The synthetic molded slab of claim 2, wherein the third pigmented vein is defined by the second particulate mineral mix.

4. The synthetic molded slab of claim 2, wherein the third pigmented vein is defined by a third particulate mineral mix, and at least the first particulate mineral mix is separated from and forms a substantially unmixed layer with respect to the third particulate mineral mix according to the predefined layer pattern.

5. The synthetic molded slab of claim 4, comprising a fourth pigmented vein, wherein the fourth pigmented vein is defined by a fourth particulate mineral mix, and at least the first particulate mineral mix is separated from and forms a substantially unmixed layer with respect to the fourth particulate mineral mix according to the predefined layer pattern.

6. The synthetic molded slab of claim 2, further comprising a plurality of transverse pigmented veins extending transversely to and intersecting the first pigmented vein, the transverse pigmented veins having a different color than the first pigmented vein.

7. The synthetic molded slab of claim 6, wherein at least one of the transverse pigmented veins extends generally widthwise from edge-to-edge.

8. The synthetic molded slab of claim 6, wherein the transverse pigmented veins are thinner than the first pigmented vein.

9. The synthetic molded slab of claim 2, wherein each of the particulate mineral mixes includes a quartz material and at least one binder.

10. The synthetic molded slab of claim 2, wherein the slab comprises at least four differently colored particulate mineral mixes distributed in a series of successive unmixed layers according to the predefined pattern.

11. The synthetic molded slab of claim 2, wherein the second and third pigmented veins extend generally lengthwise from edge-to-edge of the slab.

12. The synthetic molded slab of claim 2, wherein each of the first, second, and third pigmented veins has a vein thickness equal to and parallel to the slab thickness.

13. The synthetic molded slab of claim 12, further comprising a plurality of transverse pigmented veins extending transversely to and intersecting the first pigmented vein, the transverse pigmented veins having a different color than the first, second, and third pigmented veins, wherein at least one of the transverse pigmented veins extends generally widthwise from edge-to-edge, and wherein the transverse pigmented veins have a vein thickness less than the slab thickness.

14. The synthetic molded slab of claim 2, wherein the major surface of the slab is polished and emulates the appearance of a quarried stone slab due at least in part to the first and second particulate mineral mixes distributed according to the predefined pattern.

15. A set of separately molded synthetic slabs, each respective slab of the set comprising a major surface at least 2 feet wide by at least 6 feet long and extending perpendicularly to a slab thickness, the major surface having at least a first pigmented vein extending generally lengthwise that separates at least second and third pigmented veins extending generally lengthwise and positioned on opposing sides of the first pigmented vein, wherein the first pigmented vein is defined by a first particulate mineral mix and at least the first particulate mineral mix is separated from and forms a substantially unmixed layer with respect to a second particulate mineral mix defining the second pigmented vein according to a predefined layer pattern such that each of the first and second pigmented veins has a vein thickness equal to and parallel to the slab thickness, the second particulate mineral mix being different than the first particulate mineral mix, and wherein the first, second and third pigmented veins extend substantially lengthwise on each respective slab such that the major surface of each respective slab in the set has similarly positioned and colored substantially lengthwise veins.

16. The set of separately molded synthetic slabs of claim 15, wherein at least one of the lengthwise extending pigmented veins of each respective slab extends fully lengthwise from edge-to-edge of the respective slab.

17. The set of separately molded synthetic slabs of claim 15, wherein the major surface of each respective slab of the set further comprises a plurality of transverse pigmented veins extending transversely to and intersecting the substantially lengthwise veins, the transverse pigmented veins having a different color than the substantially lengthwise veins.

18. The set of separately molded synthetic slabs of claim 17, wherein the transverse pigmented veins of each respective slab are thinner than the substantially lengthwise veins of the respective slab.

19. The set of separately molded synthetic slabs of claim 15, wherein each of the first, second, and third pigmented veins has a vein thickness equal to and parallel to the slab thickness.

20. The set of separately molded synthetic slabs of claim 15, wherein the third pigmented vein is defined by the second particulate mineral mix.

21. The set of separately molded synthetic slabs of claim 15, wherein the third pigmented vein is defined by a third particulate mineral mix, and at least the first particulate mineral mix is separated from and forms a substantially unmixed layer with respect to the third particulate mineral mix according to the predefined layer pattern, and wherein each of the first, second, and third pigmented veins has a vein thickness equal to and parallel to the slab thickness.