SYNTHETIC MOLDED SLABS, AND SYSTEMS AND METHODS RELATED THERETO

• US 20160221215A1
• Filed: 02/16/2016
• Published: 08/04/2016
• Est. Priority Date: 01/30/2015
• Status: Active Grant

• Current Assignee: Cambria Company LLC
• Original Assignee: Cambria Company LLC
• Inventors: Grzeskowiak, Jon Louis II, Davis, Martin E.
• Granted Patent: US 10,252,440 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 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 process of forming a synthetic molded slab from different particulate mineral mixes, comprising,

sequentially dispensing at least first and second pigmented particulate mineral mixes comprising predominantly a quartz material into a single slab mold using at least first and second distributors, wherein the first distributor outputs the first pigmented particulate mineral mix through a first stencil positioned over the slab mold and into the slab mold according to a first stencil pattern, and the second distributor subsequently outputs the second pigmented particulate mineral mix through a second stencil positioned over the slab mold and into the slab mold according to a second stencil pattern such that the second pigmented particulate mineral mix is deposited in regions of the slab mold that are unoccupied by the first pigmented particulate mineral mix;

contemporaneously vibrating and compacting the pigmented particulate mineral mixes arranged in the slab mold so as to form a synthetic molded slab that is generally rectangular and has major surface with a width or at least 3 feet and a length of at least 6 feet.

2. The process of claim 1, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes comprises dispensing at least two differently colored mineral mixes that each include the quartz material, one or more pigments, and at least one binder.

3. The process of claim 1, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes comprises dispensing a first mix of the differently colored mineral mixes distributed according to a first predefined pattern, and dispensing a second mix of the differently colored mineral mixes distributed according to a second predefined pattern.

4. The process of claim 3, wherein the first predefined pattern defines a first pigmented vein and the second predefined pattern defines a second pigmented vein of the slab.

5. The process of claim 4, wherein at least a portion of the first pigmented vein at least partly surrounds at least a portion of the second pigmented vein.

6. The process of claim 3, further comprising polishing the major surface of the slab.

7. The process of claim 6, wherein the slab emulates the appearance of a quarried stone slab due at least in part to the two differently colored mineral mixes distributed according to the first predefined pattern and the second predefined pattern.

8. The process of claim 1, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes comprises depositing the plurality of different particulate mineral mixes into the slab mold according to a predefined and repeatable pattern so as to define complementary regions of multiple different particulate mineral mixes.

9. The process of claim 8, wherein the first stencil pattern is an inverse of the second stencil pattern.

10. The process of claim 3, wherein the first pigmented particulate mineral mix occupies an entire slab thickness extending perpendicularly to the major surface at a set of first regions that collectively provide the first pigmented vein pattern and the second pigmented particulate mineral mix occupies the entire slab thickness at a set of second regions that collectively provide the second pigmented vein pattern.

11. The process of claim 10, comprising sequentially dispensing at least the first and second pigmented particulate mineral mixes into each slab mold in a series of slab molds according to a predefined and repeated pattern for each mold in the series of molds so as to define complementary regions of multiple different particulate mixes have generally the same appearance in each mold in the series of molds.

12. The process of claim 8, further comprising dispensing a third pigmented particulate mineral mix comprising predominantly a quartz material.

13. The process of claim 12, wherein the third particulate mineral mix is dispensed through a third stencil positioned over the slab mold and into the slab mold according to a third stencil pattern such that the third pigmented particulate mineral mix is deposited in a set of third regions of the slab mold that are unoccupied by the first and second pigmented particulate mineral mixes.

14. The process of claim 13, wherein the third pigmented particulate mineral mix occupies the entire slab thickness at the set of third regions that collectively provide a third pigmented vein pattern.

15. The process of claim 12, wherein the third particulate mineral mix comprises a vein that does not extend through the entire thickness of the synthetic molded slab.

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

sequentially dispensing at least first and second pigmented particulate mineral mixes into a single slab mold using at least first and second distributors, wherein the first distributor outputs the first pigmented particulate mineral mix through a first stencil positioned over the slab mold and into the slab mold according to a first stencil pattern, and the second distributor subsequently outputs the second pigmented particulate mineral mix through a second stencil positioned over the slab mold and into the slab mold according to a second stencil pattern such that the second pigmented particulate mineral mix is deposited in regions of the slab mold that are unoccupied by the first pigmented particulate mineral mix;

contemporaneously vibrating and compacting the pigmented particulate mineral mixes arranged in the slab mold so as to form a synthetic molded slab that is generally rectangular and has a major surface with a width of at least 3 feet and a length of at least 6 feet.

17. The process of claim 16, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes comprises dispensing at least two differently colored mineral mixes that each include a quartz material, one or more pigments, and at least one binder.

18. The process of claim 17, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes further comprises dispensing a first mix of the differently colored mineral mixes distributed according to a first predefined pattern, and dispensing a second mix of the differently colored mineral mixes distributed according to a second predefined pattern, wherein the first predefined pattern defines a first pigmented vein and the second predefined pattern defines a second pigmented vein of the slab.

19. The process of claim 18, wherein sequentially dispensing at least first and second pigmented particulate mineral mixes comprises depositing the plurality of different particulate mineral mixes into the slab mold according to a predefined and repeatable pattern so as to define complementary regions of multiple different particulate mineral mixes.

20. The process of claim 18, comprising sequentially dispensing at least the first and second pigmented particulate mineral mixes into each slab mold in a series of slab molds according to a predefined and repeated pattern for each mold in the series of molds so as to define complementary regions of multiple different particulate mixes have generally the same appearance in each mold in the series of molds.