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EP-3250395-B1 - SYSTEM AND METHOD RELATED TO SYNTHETIC MOLDED SLABS

EP3250395B1EP 3250395 B1EP3250395 B1EP 3250395B1EP-3250395-B1

Inventors

  • GRZESKOWIAK, JON LOUIS, II
  • DAVIS, MARTIN E.

Dates

Publication Date
20260513
Application Date
20160129

Claims (15)

  1. A process of forming a synthetic molded slab (50, 600) from different particulate mineral mixes, the method comprising: sequentially dispensing at least first and second differently pigmented particulate mineral mixes comprising predominantly a quartz material into a single slab mold (130) using at least first and second distributors (406a, 406b), wherein the first distributor (406a) outputs the first pigmented particulate mineral mix through a first stencil (200) positioned over the slab mold (130) and into the slab mold (130) according to a first stencil (200) pattern, wherein the first stencil (200) includes a collection of horizontally oriented occluded regions (204) that extend vertically substantially through the thickness of the slab mold (130) providing a vein pattern, and the second distributor (406b) subsequently outputs the second pigmented particulate mineral mix through a second stencil (300) positioned over the slab mold (130) and into the slab mold (130) according to a second stencil (300) pattern such that the second pigmented particulate mineral mix is deposited in regions (306) of the slab mold (130) that are unoccupied by the first pigmented particulate mineral mix; contemporaneously vibrating and compacting the pigmented particulate mineral mixes arranged in the slab mold (130) so as to form a synthetic molded slab (50, 600) that is generally rectangular and has a major surface (612) with a width of at least 0.91 meters (3 feet) and a length of at least 1.8 meters (6 feet).
  2. The process of claim 1, wherein sequentially dispensing at least first and second differently 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 differently pigmented particulate mineral mixes comprises dispensing a first mix of differently colored mineral mixes distributed according to a first predefined pattern, and dispensing a second mix of 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 (51) and the second predefined pattern defines a second pigmented vein (52) of the slab.
  5. The process of claim 4, wherein at least a portion of the first pigmented vein (51) at least partly surrounds at least a portion of the second pigmented vein (52).
  6. The process of claim 1, further comprising polishing the major surface (612) of the compacted 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 multiple different particulate mineral mixes into the slab mold (130) according to a predefined and repeatable pattern so as to define complementary regions of the multiple different particulate mineral mixes.
  9. A system for forming a synthetic molded slab (50) using a combination of different particulate mineral mixes, comprising: at least a first and a second particulate mineral mixes; a slab mold (130) defining a mold space that is at least 1.8 meters (6 feet) long by at least 0.91 meters (3 feet) wide; two or more stencils (200, 300) defining complementary patterns of open spaces (206, 306) and occluded spaces (204, 304), the cumulative areas of the open spaces of the stencils corresponding to substantially the mold space, wherein the occluded spaces (204, 304) are horizontally oriented occluded regions that extend vertically substantially through the thickness of the slab mold (130) providing a vein pattern; and two or more mineral aggregate distributors (406a, 406b) that are each configured to dispense a corresponding particulate mineral mix into the slab mold (130) through a corresponding one of the stencils (200, 300), each stencil (200, 300) preventing a mix in the distributor (406a, 406b) from accessing selected areas of each slab mold (130) in a series of slab molds (130).
  10. The system of claim 9, wherein the two or more stencils comprise a first stencil (200) defining a first pattern of open spaces (206) and a first pattern of occluded spaces (204), and a second stencil (300) defining a second pattern of open spaces (306) corresponding to the first pattern of occluded spaces (204) and a second pattern of occluded spaces (304) corresponding to the first pattern of open spaces (206).
  11. The system of claim 9, wherein the two or more mineral aggregate distributors (406a, 406b) comprise at least a first mineral aggregate distributor (406a) configured to dispense a first particulate mineral mix and a second mineral aggregate distributor (406b) configured to dispense a second particulate mineral mix, wherein the first particulate mineral mix and the second particulate mineral mix comprise two differently colored mineral mixes that each include the quartz material, one or more pigments, and at least one binder.
  12. The system of claim 9, wherein the two or more stencils (200, 300) provide at least a first predefined pattern of open spaces (206) and occluded spaces (204) and a second predefined pattern of open spaces (306) and occluded spaces (304).
  13. The system of claim 12, wherein the first predefined pattern defines a first pigmented vein (51) and the second predefined pattern defines a second pigmented vein (52) of a slab (50, 600) that emulates the appearance of a quarried stone slab due at least in part to two differently colored mineral mixes distributed by the two or more mineral aggregate distributors (406a, 406b) according to the first predefined pattern and the second predefined pattern.
  14. The system of claim 13, wherein at least a portion of the first pigmented vein (51) at least partly surrounds at least a portion of the second pigmented vein (52).
  15. The system of claim 9, wherein the two or more stencils (200, 300) and the two or more mineral aggregate distributors (406a, 406b) are configured to sequentially dispense at least two differently colored particulate mineral mixes into the slab mold (130) according to a predefined and repeatable pattern so as to define complementary regions of multiple different particulate mineral mixes.

Description

TECHNICAL FIELD This document describes systems and processes for forming synthetic mold slab products, for example, a synthetic mold slab that is thermoformed or otherwise compacted to a selected slab shape from a mixture including particulate mineral material, resin binder, and pigments so that the synthetic molded slab is suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like). BACKGROUND Quarried stone slabs are a commonly used building material. Granite, marble, soapstone, and other quarried stones are often selected for use as countertops due to their aesthetic properties. Despite the visual appeal of quarried stone, quarried stones can be quite expensive to obtain and are generally limited to naturally occurring color schemes. Engineered stone slabs may be formed from a man-made combination of materials that can provide improved stain-resistant or heat-resistant properties compared to quarried stone. Engineered stone is typically a combination of particulate mineral material and binder, such as a polymer resin or cement. Some engineered stones partly emulate some aesthetic properties of quarried stone, but still fall noticeably short of the complicated look and texture of quarried stone. US 2008 315448 A1 relates to a process for manufacturing artificial stone boards with polymerizable resins with a "veined effect" by means of the vibro-compaction under vacuum system comprising a first grinding phase of the different materials forming the filler, a second phase containing a resin with the catalyst and optionally a third phase consisting of the mixing of the two previous phases until the homogenization of the materials with the resin, a fourth phase of moulding and compaction of the obtained paste by vibro-compression under vacuum, a fifth hardening phase by polymerization of the resin by means of heating and a last cooling, cutting and polishing phase. WO 2016/028780 A1 describes systems and processes form improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like). The synthetic molded slabs can be manufactured so as to have a similar appearance to one another that, unlike quarried stone slabs taken from a quarry, is generally repeatable and predefined as part of the manufacturing process. In those embodiments, however, the appearance of each synthetic molded slab can provide complex striations or other veining patterns that emulate a quarried stone slab. For example, each slab can be formed from a combination of differently pigmented particulate mineral mixes that are vertically dispensed according to predefined pattern into a vertically oriented mold (thereby facilitating the selected striations or other veining patterns), which is then shifted to a horizontally oriented position for subsequent compression molding and curing operations. EP 0558247 A2 describes a patterned shaped article is produced by a method which includes the steps of supplying a first material (11) onto a given surface (8) until the first material forms a layer of predetermined thickness, removing part of the layer to form at least one concave portion (20) in the layer, filling the at least one concave portion with at least one kind of second material (12, 13) different in color and quality from the first material, and causing the first and second materials to set into an integral mass. When the first material is dry, the second material may be either dry or wet. When the first material is wet, the second material is dry and the moisture of the first wet material is absorbed before the step of removing part of the layer of the first material. SUMMARY The invention is defined in the appended claims. Described herein are systems and processes for forming synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like). The synthetic molded slabs can be manufactured using, for example, a set of stencils that separate differently pigmented particulate mineral mixes into predetermined regions of a series of molds, thereby providing molded slabs having a similar appearance to one another (which, unlike quarried stone slabs taken from a quarry, can be generally repeatable and predefined as part of the manufacturing process). As used herein, "differently pigmented" means having different pigment combinations or otherwise having a different visual apparent in color tone or visual texture. The appearance of each synthetic molded slab can provide the complex striations and veining patterns that emulate a quarried stone slab. For example, each slab can be formed from a combination of differently pigmented particulate mineral mixes that are separately dispensed into two or more partial molds which combine to facilitate the selected striations and veining patterns. The slabs may be subsequently processed by compression molding and curing operations. Particular embodiments