Synthetic molded slabs, and systems and methods related thereto

Patent metadata

Field	Value
Publication number	US-12365158-B2
Application number	US-202318386909-A
Country	US
Kind code	B2
Filing date	Nov 3, 2023
Priority date	Aug 19, 2014
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

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).

First claim

What is claimed is:

1. A slab having a slab width and a slab length, the slab length extending perpendicular to and greater than the slab width, the slab comprising:
a first layer of a first particulate mineral mix, the first layer having a top edge extending substantially across the slab length;
a second layer of a second particulate mineral mix, the second layer having a bottom edge extending substantially across the slab length and substantially parallel to the top edge, wherein the second particulate mineral mix is different than the first particulate mineral mix; and
a front major surface defined by the slab width and the slab length, wherein the first layer and the second layer are at least partially exposed along the front major surface,
wherein the first layer prevents the second layer from occupying the first layer.

2. The slab of claim 1 , wherein the first layer is adjacent to the second layer such that the top edge is immediately proximate the bottom edge.

3. The slab of claim 1 , further comprising:
a rear major surface defined by the slab width and the slab length, wherein the rear major surface is parallel with the front major surface of the slab and distal from the front major surface by a slab thickness, and wherein the first layer and the second layer are at least partially exposed along the rear major surface.

4. The slab of claim 3 , wherein the top edge of the first layer and the bottom edge of the second layer are visible at the front major surface and the rear major surface.

5. The slab of claim 1 , wherein the top edge of the first layer is defined by a first plane and the bottom edge of the second layer is defined by a second plane and the first plane and the second plane are non-parallel to a plane of the slab width or a plane of the slab length.

6. The slab of claim 1 , wherein the first layer has a first layer width that varies across the slab length in a direction of the slab width.

7. The slab of claim 6 , wherein the second layer has a second layer width that varies across the slab length in the direction of the slab width.

8. The slab of claim 1 , further comprising:
a first lengthwise edge extending across the slab length;
a second lengthwise edge extending across the slab length opposite the first lengthwise edge, the first lengthwise edge and the second lengthwise edge separated by the front major surface; and
a third layer of a third particulate mineral mix, the third layer having a third layer boundary proximal to the second lengthwise edge, the third layer boundary extending substantially across the slab length and substantially parallel to a second layer boundary of the second layer, the second layer boundary proximal to the first lengthwise edge, wherein the third particulate mineral mix is different than the first particulate mineral mix and the second particulate mineral mix.

9. The slab of claim 1 , wherein the top edge of the first layer extends fully across the slab length.

10. The slab of claim 9 , wherein the bottom edge of the second layer extends fully across the slab length.

11. A slab having a slab width of at least 2 feet and a slab length of at least 6 feet, the slab comprising:
a first intermediate layer having a first vein extending across the entire slab length and having a first variable width across the slab length; and
a second intermediate layer having a second vein extending across at least a portion of the slab length and having a second variable width across the slab length, the second intermediate layer being immediately adjacent the first intermediate layer, wherein the first intermediate layer excludes the second intermediate layer from the first intermediate layer,
wherein the first variable width is different from the second variable width for at least two lengthwise positions of the slab.

12. The slab of claim 11 , wherein the first intermediate layer further comprises a first vein top edge topography and a first vein bottom edge topography, wherein the first variable width is defined by distances between the first vein top edge topography and the first vein bottom edge topography, and wherein the first vein top edge topography and the first vein bottom edge topography are different.

13. The slab of claim 11 , wherein the first intermediate layer further comprises a first vein top edge topography and the second intermediate layer further comprises a second vein bottom edge topography, and wherein the first vein top edge topography mirrors at least a portion of the vein bottom edge topography.

14. The slab of claim 13 , wherein the first intermediate layer further comprises a first vein bottom edge topography and the second intermediate layer further comprises a second vein top edge topography, wherein the first variable width is defined by first distances between the first vein top edge topography and the first vein bottom edge topography, wherein the second variable width is defined by second distances between the second vein top edge topography and the second vein bottom edge topography, and wherein the first distances change across the slab length at a different rate than the second distances across the slab length.

15. The slab of claim 11 , wherein the first intermediate layer comprises a first particulate mineral mix and the second intermediate layer comprises a second particulate mineral mix, and wherein the second particulate mineral mix is different than the first particulate mineral mix.

16. The slab of claim 11 , further comprising:
a third intermediate layer having a third vein extending across at least a portion of the slab length and having a third variable width, the third intermediate layer being immediately adjacent the second intermediate layer, and
wherein the wherein the third variable width is different from the second variable width and the first variable width for at least two lengthwise positions of the slab.

17. The slab of claim 16 , wherein the first intermediate layer is bowed in a direction towards a first long edge corresponding to the slab length and away from an opposing long edge along at least a portion of the first vein.

18. A slab comprising:
a major surface defined by a slab width and a slab length, the slab length extending perpendicular to and greater than the slab width;
a first layer of a first particulate mineral mix, the first layer having a first vein top edge topography and a first vein bottom edge topography; and
a second layer of a second particulate mineral mix, the second particulate mineral mix being different than the first particulate mineral mix, the second layer adjacent to the first layer and having a second vein top edge topography and a second vein bottom edge topography,
wherein the first vein top edge topography has aligned movement with the second vein bottom edge topography, and
wherein the first layer prevents the second layer from occupying the first layer.

19. The slab of claim 18 , wherein the first vein top edge topography is irregular to the second vein top edge topography.

20. The slab of claim 18 , wherein the first vein top edge topography has aligned movement with the second vein top edge topography.

Assignees

• Cambria Co Llc

Inventors

• Grzeskowiak Ii Jon Louis
• Davis Martin E

Classifications

• B44F9/04 Primary

  of stone surfaces, e.g. marble · CPC title

• B32B5/14

  characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces · CPC title

• B32B5/16

  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 title

• Y10T428/24802

  Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title