Synthetic molded slabs, and systems and methods related thereto

Patent metadata

Field	Value
Publication number	US-2016221384-A1
Application number	US-201615042881-A
Country	US
Kind code	A1
Filing date	Feb 12, 2016
Priority date	Jan 30, 2015
Publication date	Aug 4, 2016
Grant date	—

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).

First claim

1 .- 10 . (canceled)

11 . A synthetic molded slab comprising a quartz material, comprising:
a major surface defined by a set of particulate mineral mixes and having a rectangular shape that is at least 2 feet wide by at least 6 feet long and extending perpendicularly to a slab thickness, the major surface having at least a first predetermined pigmented vein pattern and a second predetermined pigmented vein pattern, wherein the first predetermined pigmented vein pattern comprises a first particulate mineral mix that occupies the entire slab thickness at a set of first regions that collectively provide the first predetermined pigmented vein pattern, and wherein the second predetermined pigmented vein pattern comprises a second particulate mineral mix that occupies the entire slab thickness at a set of second regions that collectively provide the second predetermined pigmented vein pattern, the first particulate mineral mix being absent from the set of second regions and the second particulate mineral mix being absent from the set of first regions, the first and second particulate mineral mixes being differently pigmented and each comprising a quartz material, one or more pigments, and one or more binders.

12 . The synthetic molded slab of claim 11 , wherein the first and second predetermined pigmented vein patterns do not overlap.

13 . The synthetic molded slab of claim 11 , wherein the second predetermined pigmented vein pattern is an inverse of the first predetermined pigmented vein pattern.

14 . The synthetic molded slab of claim 11 , wherein at least a portion of the first predetermined pigmented vein pattern fully surrounds at least a portion of the second predetermined pigmented vein pattern.

15 . The synthetic molded slab of claim 11 , wherein the major surface having at least the first predetermined pigmented vein pattern and the second predetermined pigmented vein pattern emulates the appearance of a quarried stone slab due at least in part to the different particulate mineral mixes.

16 . The synthetic molded slab of claim 11 , further comprising a third particulate mineral mix that is differently pigmented as compared to the first and second particulate mineral mixes.

17 . The synthetic molded slab of claim 16 , where the third particulate mineral mix forms a vein that extends across a full width of the major surface

18 . The synthetic molded slab of claim 16 , wherein the third particulate mineral mix forms a vein that does not extend through the entire thickness of the slab.

19 . The synthetic molded slab of claim 16 , wherein the major surface comprises a third predetermined pigmented vein pattern comprising the third particulate mineral mix.

20 . The synthetic molded slab of claim 19 , wherein the third particulate mineral mix occupies the entire slab thickness at a set of third regions, the first and second mineral mix being absent from the set of third regions.

21 . The synthetic molded slab of claim 20 , wherein the first, second, and third predetermined pigmented vein patterns do not overlap.

22 . A synthetic molded slab, comprising:
a major surface defined by a set of particulate mineral mixes and having a rectangular shape that is at least 2 feet wide by at least 6 feet long and extending perpendicularly to a slab thickness, the major surface having at least a first predetermined pigmented vein pattern and a second predetermined pigmented vein pattern, wherein the first predetermined pigmented vein pattern comprises a first particulate mineral mix that occupies the entire slab thickness at a set of first regions that collectively provide the first predetermined pigmented vein pattern, and wherein the second predetermined pigmented vein pattern comprises a second particulate mineral mix that occupies the entire slab thickness at a set of second regions that collectively provide the second predetermined pigmented vein pattern, the first particulate mineral mix being absent from the set of second regions and the second particulate mineral mix being absent from the set of first regions, the first and second particulate mineral mixes being differently pigmented.

23 . The synthetic molded slab of claim 22 , wherein the first and second particulate mineral mixes each comprise a quartz material and one or more binders.

24 . The synthetic molded slab of claim 22 , wherein the second predetermined pigmented vein pattern is an inverse of the first predetermined pigmented vein pattern.

25 . The synthetic molded slab of claim 22 , wherein the first and second vein patterns do not overlap.

26 . The synthetic molded slab of claim 22 , further comprising a third predetermined pigmented vein pattern comprising a third particulate mineral mix that is differently pigmented as compared to the first and second particulate mineral mixes.

27 . The synthetic molded slab of claim 26 , wherein the third particulate mineral mix forms a vein that does not extend through the full thickness of each respective slab.

28 . The synthetic molded slab of claim 27 , where the third particulate mineral mix forms a vein that extends across a full width of the major surface.

29 . The synthetic molded slab of claim 26 , wherein the third particulate mineral mix occupies the entire slab thickness at a set of third regions, the first and second mineral mix being absent from the set of third regions.

30 . The synthetic molded slab of claim 29 , wherein the first, second, and third predetermined pigmented vein patterns do not overlap.

Assignees

• Cambria Co Llc

Inventors

• Grzeskowiak Ii Jon Louis
• Davis Martin E

Classifications

• B29K2509/00

  Use of inorganic materials not provided for in groups {B29K2503/00 - B29K2507/00,} as filler · CPC title

• B29C39/12

  Making multilayered or multicoloured articles {(B29C39/021 takes precedence)} · CPC title

• C04B26/32

  containing silicon · CPC title

• B29C39/24

  Feeding the material into the mould · CPC title

• B29K2995/0021

  Multi-coloured · CPC title