SYNTHETIC MOLDED SLABS, AND SYSTEMS AND METHODS RELATED THERETO

• US 20160052334A1
• Filed: 10/09/2015
• 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 9,993,942 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. A process of forming a synthetic molded slab from different particulate mineral mixes, comprising:

positioning a slab mold in a substantially vertical orientation;

dispensing multiple different particulate mineral mixes into the substantially vertically oriented mold so as to fill a mold space that is at least 6 feet long by at least 2 feet wide, the multiple different particulate mineral mixes being differently pigmented;

adjusting the mold to a substantially horizontal orientation while the different particulate mineral mixes are positioned in the mold; and

contemporaneously vibrating and compacting the particulate mineral mixes arranged in the mold while the mold is in the substantially horizontal orientation.

2. The process of claim 1, wherein said dispensing comprises substantially vertically depositing the multiple different particulate mineral mixes into the mold according to a predefined and repeatable pattern so as to define successive layers of multiple different particulate mineral mixes.

3. The process of claim 1, wherein at least some of the successive layers of multiple different particulate mineral mixes provide lengthwise veins of the synthetic molded slab.

4. The process of claim 1, wherein said dispensing multiple different particulate mineral mixes comprises pouring multiple differently pigmented particulate quartz mixes into the substantially vertically oriented mold according to a predetermined pattern.

5. The process of claim 4, wherein the substantially vertically oriented mold defines a mold space having a first edge thickness that is smaller than and parallel to a second edge thickness proximate to an upwardly facing opening of the mold.

6. The process of claim 5, wherein said contemporaneously vibrating and compacting provides a rectangular molded slab having a thickness that is generally constant at its four edges.

7. The process of claim 4, wherein said pouring according to the predetermined pattern provides successive layers of differently pigmented particulate quartz mixes, wherein at least some of the successive layers of differently pigmented particulate quartz mixes provide lengthwise veins of the synthetic molded slab.

8. The process of claim 7, wherein the successive layers of differently pigmented particulate quartz mixes provide at least a first pigmented vein extending generally lengthwise from edge-to-edge that is separated from and substantially unmixed with respect to at least second and third pigmented veins extending generally lengthwise and positioned on opposing sides of the first pigmented vein.

9. The process of claim 8, wherein the first pigmented vein is defined by a first particulate quartz mix, the second vein is defined by a second particulate quartz mix, and the third vein is defined by a third particulate quartz mix.

10. The process of claim 8, wherein the first pigmented vein is defined by a first particulate quartz mix, and the second and third veins are defined by a second particulate quartz mix.

11. The process of claim 8, comprising dispensing a different particulate mineral mix widthwise such that the different particulate mineral mix defines a transverse pigmented vein.

12. The process of claim 11, wherein dispensing a different particulate mineral mix widthwise occurs after adjusting the mold to a substantially horizontal position.

13. The process of claim 3, wherein at least two of the lengthwise veins each have a vein thickness equal to and parallel to the slab thickness.

14. The process of claim 8, wherein said dispensing comprises substantially vertically depositing the multiple different particulate mineral mixes into an open end of the mold.

15. The process of claim 8, comprising adjusting a mold end cap from an open position to a closed position before adjusting the mold to a substantially horizontal orientation.

16. A process of forming a synthetic molded slab from different particulate mineral mixes, comprising:

positioning a slab mold in a substantially vertical orientation;

dispensing at least first and second particulate mineral mixes into the substantially vertically oriented mold so as to fill a mold space that is at least 6 feet long by at least 2 feet wide; and

adjusting the mold to a substantially horizontal orientation while the different particulate mineral mixes are positioned in the mold;

wherein the first and second particulate mineral mixes are dispensed according to a predefined pattern to provide at least a first pigmented vein extending generally lengthwise from edge-to-edge defined by the first particulate mineral mix and that is separate and substantially unmixed with respect to at least a second pigmented vein defined by the second particulate mineral mix.

17. The process of claim 16, comprising dispensing a third particulate mineral mix into the substantially vertically oriented mold, wherein the third pigmented vein is dispensed according to the predefined pattern such that at least the first pigmented vein is separate and substantially unmixed with respect to a third pigmented vein defined by the third particulate mineral mix.

18. The process of claim 16, comprising contemporaneously vibrating and compacting the particulate mineral mixes arranged in the mold while the mold is in the substantially horizontal orientation.

19. The process of claim 16, wherein each of the first and second pigmented veins has a vein thickness equal to and parallel to the slab thickness.

20. The process of claim 16, wherein the first and second particulate mineral mixes each comprise predominantly a quartz material.