Textured stone slabs, systems, and methods

Patent metadata

Field	Value
Publication number	US-12151395-B2
Application number	US-202217744501-A
Country	US
Kind code	B2
Filing date	May 13, 2022
Priority date	May 13, 2021
Publication date	Nov 26, 2024
Grant date	Nov 26, 2024

Abstract

Stone slabs, and systems and methods of forming slabs, are described. Some example slabs include a first pattern defined by a first particulate mineral mix and a second pattern defined by a second particulate mineral mix different from the first particulate mineral mix. Locations of the first pattern have a first average thickness perpendicular to the slab width and the slab length, and locations of the second pattern have a second average thickness perpendicular to the slab width and the slab length that is different from the first average thickness.

First claim

What is claimed is:

1. A processed slab formed from a plurality of particulate mineral mixes, 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, the slab length and the slab width defining a top major surface that is contoured;
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; and
a first pattern defined by a first particulate mineral mix, the first pattern exposed along the top major surface of the slab and exposed along a bottom major surface of the slab, and defining a first thickness that extends perpendicular to the slab width and the slab length, the first pattern exposed along the top major surface of the slab defining a first plane; and
a second pattern defined by a second particulate mineral mix different from the first particulate mineral mix, the second pattern exposed along the top major surface of the slab and exposed along the bottom major surface of the slab, and defining a second thickness that extends perpendicular to the slab width and the slab length, the first thickness of the first pattern different from the second thickness of the second pattern,
wherein at least a portion of the second pattern is recessed from the first plane, projects from the first plane, or is both recessed from and projects from the first plane.

2. The processed slab of claim 1 , wherein the first pattern is exposed along a bottom major surface of the slab.

3. The processed slab of claim 1 , wherein the first pattern exposed along the top major surface of the slab has a first texture based on the first particulate mineral mix, and the second pattern exposed along the top major surface of the slab has a second texture, different from the first texture, based on the second particulate mineral mix.

4. The processed slab of claim 3 , wherein the first texture has a first roughness and the second texture has a second roughness that is different from the first roughness.

5. The processed slab of claim 1 , wherein the first pattern has a first average gloss value and the second pattern has a second average gloss value that is different from the first average gloss value.

6. The processed slab of claim 1 , wherein the first pattern has a first average thickness perpendicular to the slab width and the slab length, and the second pattern has a second average thickness perpendicular to the slab width and the slab length, and wherein the first average thickness is different from the second average thickness.

7. A processed slab 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, the slab length and the slab width defining a top major surface;
a first region exposed along the top major surface of the slab and exposed along a bottom major surface of the slab and having a first average thickness perpendicular to the slab width and the slab length; and
a second region exposed along the top major surface of the slab and exposed along a bottom major surface of the slab and having a second average thickness perpendicular to the slab width and the slab length,
wherein the first average thickness is different from the second average thickness.

8. The processed slab of claim 7 , wherein the first region has a first hardness and the second region has a second hardness that is different from the first hardness.

9. The processed slab of claim 7 , wherein the first region has a first texture and the second region has a second texture that is different from the first texture.

10. The processed slab of claim 7 , wherein the first region has a first gloss and the second region has a second gloss that is different from the first gloss.

11. The processed slab of claim 7 , wherein the first region comprises a background of the processed slab defined by a first particulate mineral mix.

12. The processed slab of claim 11 , wherein the second region comprises a vein of the processed slab defined by a second particulate mineral mix.

13. The processed slab of claim 12 , further comprising a tactile transition between the first average thickness and the second average thickness.

14. The processed slab of claim 7 , further comprising:
a third region exposed along the top major surface of the slab having a third average thickness perpendicular to the slab width and the slab length,
wherein the third average thickness is different from the first average thickness.

15. The processed slab of claim 14 , wherein the second average thickness is different from the third average thickness.

16. The processed slab of claim 7 , wherein at least a portion of the second region projects above the top major surface.

17. A processed slab comprising:
a primary fill comprising a first particulate mix in a first location and exposed along a top major surface of the slab and exposed along a bottom major surface of the slab;
a vein comprising a second particulate mix in a second location and exposed along the top major surface of the slab and exposed along the bottom major surface of the slab;
the top major surface and the bottom major surface each defined by a slab width and a slab length that extends perpendicular to the slab width; and
a slab thickness between the top major surface and the bottom major surface that varies between the first location and the second location.

18. The processed slab of claim 17 , wherein a difference between a first thickness at the first location and a second thickness at the second location is between 0.01 mm and 10 mm.

19. The processed slab of claim 17 , further comprising an edge face proximate the top major surface, wherein the vein extends at least partially along the edge face.

20. The processed slab of claim 17 , wherein at least a portion of the vein projects above the top major surface.

Assignees

• Cambria Co Llc

Inventors

• Grzeskowiak Ii Jon Louis
• Davis Martin E

Classifications

• B44C1/222

  using machine-driven mechanical means · CPC title

• C04B26/02

  Macromolecular compounds · CPC title

• C04B2111/00612

  as one or more layers of a layered structure · CPC title

• C04B2111/00413

  Materials having an inhomogeneous concentration of ingredients or irregular properties in different layers · CPC title

• C04B2111/54

  Substitutes for natural stone, artistic materials or the like · CPC title