Metallic stone slabs, systems, and methods

Patent metadata

Field	Value
Publication number	US-12459864-B2
Application number	US-202217744466-A
Country	US
Kind code	B2
Filing date	May 13, 2022
Priority date	May 13, 2021
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

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. The first particulate mix includes greater than 50 weight percent of first metallic particles.

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; 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 mix, the first pattern exposed along the top major surface of the slab, and the first particulate mix comprising first metallic particles having a first mesh size; a second pattern defined by a second particulate mix; wherein the first pattern defines at least one vein having a first measured gloss at 60 degrees of 75 or greater; and wherein the second pattern defines at least one region having a second measured gloss at 60 degrees that is different than the first measured gloss.

2 . The processed slab of claim 1 , the first particulate mix further comprising second metallic particles having a second mesh size different than the first mesh size wherein the first metallic particles make up greater than 10% by weight of the first particulate mix.

3 . The processed slab of claim 2 , wherein the second metallic particles make up greater than 40% by weight of the first particulate mix.

4 . The processed slab of claim 1 , wherein the first metallic particles are between 140 US mesh and 400 US mesh.

5 . The processed slab of claim 2 , wherein the second metallic particles makes up greater than 10% of the overall weight percent of the processed slab.

6 . The processed slab of claim 2 , wherein the first metallic particles and the second metallic particles are a same material.

7 . The processed slab of claim 6 , wherein the first metallic particles and the second metallic particles are stainless steel.

8 . The processed slab of claim 6 , wherein the first metallic particles and the second metallic particles are selected from the group consisting of copper, brass, nickel, and aluminum.

9 . The processed slab of claim 1 , wherein the first pattern exhibits an average gloss value greater than 80 and an average reflectance greater than 15.

10 . The processed slab of claim 1 , wherein the first particulate mix comprises greater than 30 weight percent of first metallic particles.

11 . 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; 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 mix, the first pattern exposed along the top major surface of the slab, and the first particulate mix comprising greater than 30 weight percent of first metallic particles; a second pattern defined by a second particulate mix; wherein the first pattern corresponds to a first region exhibiting a first average reflectance haze, and the second pattern corresponds to a second region exhibiting a second average reflectance haze, and wherein the first average reflectance haze is greater than 10 and the second average reflectance haze is less than 8.

12 . The processed slab of claim 11 , wherein the first metallic particles are stainless steel particulate having a specified size between 50 US mesh and 140 US mesh.

13 . The processed slab of claim 11 , wherein the first metallic particles are selected from the group consisting of copper, brass, nickel, and aluminum.

14 . The processed slab of claim 11 , wherein the first pattern defines at least one vein having a measured graininess, S_G, a measured sparkle index, S_i, and a measured sparkle amount, S_a, wherein the sum of S_G, S_i, and S_a, is greater than 35.

15 . The processed slab of claim 11 , wherein the first pattern defines at least one vein having a measured gloss at 60 degrees of 75 or greater.

16 . The processed slab of claim 1 , wherein the first pattern corresponds to a first region exhibiting a first average reflectance haze, and the second pattern corresponds to a second region exhibiting a second average reflectance haze, and wherein the first average reflectance haze is different than the second average reflectance haze.

17 . The processed slab of claim 11 , wherein the overall weight percentage of metal of the finished slab is greater than 2 wt %.

18 . The processed slab of claim 11 , wherein the first particulate mix comprises greater than 10% by weight of the first metallic particles.

Assignees

• Cambria Co Llc

Inventors

• Grzeskowiak Ii Jon Louis
• Davis Martin E
• Mead Michael Raymond

Classifications

• C04B41/457

  Non-superficial impregnation or infiltration of the substrate · CPC title

• C04B2111/00905

  as preforms · CPC title

• C04B41/53

  involving the removal of at least part of the materials of the treated article, {e.g. etching, drying of hardened concrete (C04B41/0036 - C04B41/0054 take precedence)} · CPC title

• C04B2111/00525

  for metallic surfaces · CPC title

• C04B40/0067

  making use of vibrations · CPC title