CN120206832A

CN120206832A - Method and apparatus for producing artificial stone slabs

Info

Publication number: CN120206832A
Application number: CN202510610047.8A
Authority: CN
Inventors: 阿历克斯·谢
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-12-09
Filing date: 2025-05-13
Publication date: 2025-06-27

Abstract

The present invention discloses a method and apparatus for producing artificial stone slabs. The method comprises placing broken pieces on a surface and using a height limiting device to disrupt the broken pieces so that the height of the highest point of the broken pieces from the support structure is substantially the same as the height of the height limiting device from the support structure. The method then comprises using a digital printing device in a primary digital printing step to print an image on at least a portion of the top and side walls of at least a portion of the broken pieces, and then placing an additional slightly moist composite material on at least a portion of the broken pieces. The method further comprises using a digital printing device in an additional digital printing step to print an image on at least a portion of the additional composite material, and then using a pressing roller to compact, flatten and stretch the broken pieces into a board.

Description

Method and apparatus for producing artificial stone slab

Cross reference to related applications

The present application is a continuation-in-part application of U.S. patent application Ser. No. 18/535,852, filed on day 11, 12, 2023, and also a continuation-in-part application of International patent application PCT/US2024/059224, filed on day 9, 12, 2024. The entire disclosures of each of the above applications are incorporated herein by reference.

Technical Field

The present invention relates to a method and apparatus for producing artificial stone slabs.

Background

This section provides background information related to the present disclosure, which is not necessarily prior art.

Quartz is the second most abundant mineral in the crust, and is one of the most rigid natural materials, one of its many uses being in "artificial stone". Artificial stone materials comprising quartz have become a common choice for surfaces and countertops in many countries around the world, including kitchen and bathroom countertops, tables and desktops, floor tiles, food service areas, wall coverings, and various other horizontal and vertical applications. The production of artificial stone generally involves mixing polymers, binders, resins, colorants, dyes, etc. with particulate materials such as ground quartz rock, crushed glass, rock, pebbles, sand, shells, silicon and other inorganic mineral materials. The particle size of these particulate materials, which are used together with a plurality of materials of different sizes, may vary from 400 mesh to 4 mesh. The polymer may include additives such as binders, curing agents, initiators, or combinations of the foregoing. The particulate material is mixed with a polymer, binder, resin, colorant, dye, etc., to provide a slightly moist mixture. This initial mixture may be processed through a pulverizer to reduce the size of the combined particles. The resulting finer mixture may be uniformly distributed into a support mold, tray, or other support structure. The mixture can be slightly compressed, so that the surface of the distributed material is smoother. The mold or tray containing the micro-wet mix is then moved onto a conveyor with a backing plate, and the treated micro-wet "mat" is then moved into a vacuum press where the material is compressed. The compressed material is then placed in a curing machine and heated to form a hardened artificial stone slab. After curing, the hardened slab is typically moved to a grinder to grind to a desired thickness, and then finished with a polisher.

Artificial stones, including quartz-based artificial stones, have many advantages over natural stones such as marble and granite, including generally higher hardness, higher strength, lower water absorption, stain resistance, scratch resistance, breakage resistance, chemical resistance, high temperature resistance, etc., but at the same time, disadvantages of artificial stones are also apparent, one of which is that artificial stones lack natural, random veins and color patterns, as compared to such natural stones.

Over the last 10 years, the use of alternative particulate materials in place of or in combination with quartz has begun. Such alternative materials include, for example, cristobalite, feldspar (including sintered feldspar), gibbsite or aluminium hydroxide, cullet (including frac glass), and other minerals and polycrystals thereof. Any of these fillers may be used in place of the quartz in the present disclosure.

There are various known methods, apparatuses and systems for producing artificial stone panels having a similar color pattern and texture to natural stone.

In various known methods, a composite material is mixed which may include or consist of particulate stone or minerals, quartz, glass, shells or mixed polymer resins, dyes, binders, curing agents, silicon of initiators, or any combination of the foregoing. The composite material may vary depending on a variety of factors such as particle size, resin ratio, colorant or composition. Notably, a colorant mixture of resin and colorant, or a colorant in liquid, powder, or other particulate form alone, may be considered a composite mixture. The composite material or materials may be made using the process disclosed in U.S. patent No. 10,376,912 B2 to achieve the aesthetic appeal of natural stone. Before or after this, the composite material may also be subjected to further processing, such as by the processes disclosed in U.S. Pat. Nos. 9,707,698 B1 and 10,843,977B2 to Xie, the contents of which are incorporated herein by reference.

U.S. patent 9,707,698B1 to Xie discloses, among other things, a process in which a composite material is subjected to layering, compression, and disruption of the composite material or materials to achieve the aesthetic appeal of natural stone. In the prior art disclosed processes, the composite material may be treated by lightly pressing the composite material, disturbing the composite material, or using a gate device to scrape any excess material off, prior to compressing the composite material using a press roll or the like, so that the upper surface of the composite material is substantially smooth.

In the prior art, for example, in U.S. patent application US20220048216A1 to tonelli, it is specifically mentioned to lay different materials together layer by layer on a substantially flat surface, then press the materials together or sandwich them together, then fold the materials and press them again. This will allow the colorant layer to be located on substantially the same horizontal level as the material and will not cause any mixing or deformation in the vertical direction.

In the prior art, such as U.S. Pat. Nos. 3,930,124B 1 and 5, 10843977 to Xie, colorants or composite mixtures of different colors are included in each crumb. Thus, the vein length does not extend to connect to other different pieces after compression, such as by a compression roller. The product formed by this process may be referred to as a "short vein" sheet.

One way to ensure that the side surface areas of a large number of pieces are covered with colorant is to have a device as taught in U.S. patent application 2019/0105800 (published 11, 4, 2019), similar to thank (Xie), the contents of which are incorporated by reference, wherein a nicking device or V-roller is connected to a computer controlled CNC, forming a groove through the composite material, upon which colorant is subsequently deposited/placed. The problem is that the work performed by the apparatus on the material creates straight, smooth-edged lines that are not as heavy as the desired imitation, which defects are exacerbated when rolling through the press rolls.

One existing method is to transfer or digitally print the pattern of natural stone on the flat surface of an artificial stone slab, thereby forming a realistic pattern resembling natural stone on an artificial stone slab. However, with this method, the printed surface is easily worn and the pattern is only on the flat surface of the stone plate. The exposed side profile will not conform to its upper surface when used in the manufacturing and installation process.

During the production of artificial stone, the flat surface of the green stone slab is ground off to obtain a flat surface, for example between 1 and 5mm, and then polished. The amount of material that is ground off from the surface of the green stone slab depends on the production process and quality control. The presently disclosed technology can produce artificial stone slabs having realistic patterns in natural stone that extend vertically (or in the depth direction) to the thickness of the stone slab (e.g., beyond the flat upper surface, etc.), by maintaining a full body pattern on the entire thickness (or substantially the entire thickness) of the stone slab, the patterns of the stone slab can be preserved even if a certain thickness is ground off on the flat upper surface.

Disclosure of Invention

Aiming at the problems existing in the prior art, the invention discloses a method and equipment for producing artificial stone boards.

A method of producing a cultured stone sheet comprising the steps of:

Compressing the micro-wetted composite material to form a dense composite material;

Crushing the compacted composite material into a plurality of composite material fragments;

placing at least a portion of the plurality of fragments onto a surface supported by a support structure, then

In the height limiting step, a plurality of fragments are disturbed by using a height limiting device so that the height of the highest point of the fragments relative to the supporting structure is approximately the same as the height of the height limiting device relative to the supporting structure, and then

In a digital printing step, printing an image onto at least a portion of the top and side walls of at least a portion of the plurality of fragments using a digital printing device, and then

Placing additional micro-wet composite material on at least part of the plurality of fragments, then

In an additional digital printing step, an image is printed onto at least a portion of the top and sidewalls of at least a portion of the additional micro-wet composite using a digital printing device, and then

The plurality of pieces are compacted, flattened and expanded into a slab using a press roll.

Further, after placing the additional micro-wet composite material onto at least a portion of the plurality of fragments, the additional micro-wet composite material is disturbed in an additional height limiting step using another height limiting device such that the height of the plurality of fragments and the additional composite material at its highest point relative to the support structure is substantially the same as the height of the other height limiting device relative to the support structure.

Further, after the additional digital printing step, the step of placing additional micro-wet composite and the additional digital printing step are repeated.

Specifically, the image printed in the additional digital printing step is substantially the same as the image printed in the one-time digital printing step, and is printed on top of the image printed in the one-time digital printing step.

Specifically, the primary digital printing step and the additional digital printing step each print a respective image by depositing a colorant on a predetermined area on the support structure.

Specifically, the colorant is in a liquid state.

Or the colorant is in the form of particles.

The invention also discloses a method for producing the artificial stone board, which comprises the following steps:

Placing the micro-wetted composite material onto a surface supported by a support structure;

Using a digital printing device in a digital printing step to deposit a colorant on a predetermined area of at least part of the top of at least part of the composite material on the support structure in a predetermined area, then

Placing an additional micro-wet composite on top of at least a portion of the composite and the colorant, then

Depositing a colorant in a predetermined area at least partially on top of at least a portion of the additional composite material using a digital printing device in an additional digital printing step, then

The composite material is pressed, flattened and stretched into a sheet using a press roll.

Further, after placing the slightly wet composite material on the surface supported by the support structure, the height limiting device is used to disrupt the composite material such that the height of the highest point of the composite material relative to the support structure is substantially the same as the height of the height limiting device relative to the support structure.

In particular, the colorant and the predetermined area deposited in the additional digital printing step are substantially the same as the colorant and the predetermined area deposited in the one-time digital printing step.

Specifically, the colorant is in a liquid state.

Or the colorant is in the form of particles.

Depositing the composite pieces on a surface;

Flattening at least some of the fragments on the surface using a height limiting device such that the flattened fragments have a height relative to the surface that is substantially the same as the height of the height limiting device relative to the surface, and then

Printing a first image on at least a portion of the fragment of the surface, then

Placing additional composite material on at least part of the fragments and the image on at least part of the fragments, then

Printing a second image on at least a portion of the additional composite material on the surface, then

The composite crumb and additional composite are compacted, flattened and expanded into a panel using a press roll.

Further, the first image and the second image are identical.

Further, after placement of the additional composite material, the additional composite material is flattened using a second height limiting device such that the height of the flattened fragments and additional composite material placed thereon relative to the surface is substantially the same as the height of the second height limiting device relative to the surface.

Drawings

The drawings described herein are for illustration of selected embodiments only, and not all possible embodiments, and are not intended to limit the scope of the invention.

FIG. 1 is a partial perspective view of a first apparatus described in accordance with one embodiment of the present disclosure;

FIG. 2 is a simplified perspective view of a portion of the first device of FIG. 1;

FIG. 3 shows a simplified top view of a portion of the first apparatus shown in FIG. 1, in which the kick-out device of the apparatus forms a groove in the composite material while retaining the random shape of the side walls of the crumb;

FIG. 4 shows a perspective view of a second apparatus described in accordance with one embodiment of the present disclosure;

FIG. 5 shows a simplified side view 400 of a composite material illustrating various fragment sizes and random orientations of the sides of the fragments;

FIG. 6 shows a photograph 500 of fragments entering a press roll after forming a colorant locus, and additional stacked fragments before the press roll;

FIG. 7 shows the fragments as they exit the roller in which they are pressed together to form a flat sheet in which the fragments deform and spread to form a "zig-zag" shaped through-body vein in the sheet;

FIG. 8 shows the finished slab after finishing, sanding and polishing after the process shown in FIGS. 6 and 7;

FIG. 9 shows a method flow diagram according to one embodiment of the present disclosure;

FIG. 10 shows a simplified block diagram of components used in the practice of the disclosed embodiments;

FIG. 11 shows a side view 1000 of a press roll in one embodiment of the present disclosure, the press roll being used to deform, spread, press a composite crumb into a sheet during operation;

FIG. 12 shows a side view 1100 of a pair of pressure rollers used in accordance with one embodiment of the present disclosure;

FIG. 13 shows an image 1200 of a slab produced using prior known techniques including coating the tiles with a colorant to form short ridges within each individual tile, but not with other tiles, which differs from the techniques disclosed herein in that long, connected ridges are present throughout the entire slab for long distances;

FIG. 14 shows an image 1300 of a single batch of slabs according to one embodiment of the present disclosure with a significantly different degree of expansion for the left side slab than for the right side slab as compared to a continuously produced slab;

FIG. 15 shows an image 1400 of a continuously produced mat with a degree of spread that is substantially uniform throughout the length of the mat according to one embodiment of the present disclosure;

FIG. 16 shows an image of a natural stone slab that may be used as an input for applying a colorant to pieces of material used to form the artificial stone slab;

FIG. 17 shows a distorted image (e.g., compressed, etc.) of the natural stone slab of FIG. 16, as described herein, to illustrate the expansion of the crumb and the colorant added thereto during compression of the crumb to form an uncured stone slab;

FIG. 18 shows an image of a shape-random fragment placed on a support structure, in which a trench is formed, the trench having jagged, non-smooth sidewalls, in accordance with the present disclosure;

Fig. 19 shows an image of the finished sheet after curing, with ridges therein formed by the unique formation of grooves described herein and shown in fig. 18.

FIG. 20 shows an image of a conventional micro-wetting material used to form a slab having a trench formed therein using cutting techniques known in the art, the trench having smooth sidewalls;

fig. 21 shows an image of the finished sheet after curing, with ridges formed by the formation of grooves (as shown in fig. 20) formed using cutting techniques known in the art.

FIG. 22 illustrates an exemplary system of the present disclosure configured for producing a stone slab;

FIG. 23 shows a side view of an example of an assembly configured to apply additional layers of material (e.g., a protective layer of material, a second layer of material, etc.) to the continuous compacted sheet of material as described in FIG. 22;

FIG. 24 shows an image of a natural stone slab that may be used as an input for applying a colorant to pieces of material used to form the artificial stone slab;

FIG. 25 shows an image of a fragment of material on a support structure with a colorant added thereto according to the image of the natural stone slab shown in FIG. 24;

FIG. 26 shows an image of a cured artificial stone slab formed from the material pieces of FIG. 25, the artificial stone slab including a vein pattern similar to the veins of the natural stone slab shown in the image of FIG. 24;

FIG. 27 shows a method flow diagram in accordance with an embodiment of the present disclosure, and

Figure 28 shows a side view of a composite material or randomly shaped pieces in different steps according to the flow chart in figure 27.

Corresponding numerals indicate corresponding parts throughout the several views.

Detailed Description

The following is a general overview of the present disclosure and is not a comprehensive disclosure of its full scope or all of its features.

One or more embodiments of the present disclosure provide a method and apparatus for producing artificial stone slabs in which the crumb size (or crumb size range) of the composite material may be varied widely to achieve a more realistic natural stone aesthetic. These pieces are then extruded into flat uncured stone slabs using one or a pair of rolls.

In at least one embodiment of the present disclosure, an aggregate mineral such as quartz and/or other minerals or glass particles (e.g., virgin aggregate material) may be combined with resins, colorants, and other additives in a high speed mixer to obtain a crushed micro-wet composite (e.g., micro-wet composite mixture of aggregate minerals, etc.). Such crushed micro-wet composite (or mixture) may be compressed into a dense composite mixture as known in the art.

After the dense composite mixture is produced, in at least one embodiment of the present disclosure, it may be broken into pieces in a controlled manner, such as by breaking up the dense composite mixture by a stirring device, wherein the rotational speed of the stirring device may be varied such that the faster the stirring device rotates, the smaller the pieces obtained from breaking up the dense composite mixture. Alternatively, the compacted composite mixture may be dropped onto a rigid grid or mesh and fragments of a desired size (or range of sizes) obtained by controlling the size of the rigid grid or mesh and/or the height of the drop. Still other methods may accomplish the crushing process to obtain randomly shaped pieces of the desired size. In either case, the densified composite is crushed to achieve the desired size (and/or size range) of the resulting fragments (e.g., about 90% or more of the fragments are substantially the same size or within the same size range, about 80% or more of the fragments are substantially the same size or within the same size range, about 50% or more of the fragments are substantially the same size or within the same size range, about 25% or more of the fragments are substantially the same size or within the same size range, etc.).

These randomly shaped pieces of the composite mixture are then uniformly distributed over a support structure, such as a conveyor belt, support mold or tray, PET (polyester) film, etc., such that there are no significantly more pieces of the composite mixture in any one region over which the pieces are distributed than in another region. The support structure may provide mechanical support to contain the fragments within a certain area and prevent contamination. Ideally, no smaller pieces are significantly packed in the area beside a large piece, so that no colorant can be deposited on the side walls of the large piece. In other words, the fragments are distributed on the support structure such that at least some of the side walls of at least some fragments (e.g., fragments walls that do not contact the support structure, etc.) are exposed (and/or do not contact other fragments or side walls of other fragments). In general, none of the square feet of the region should distribute more than 50% of the fragments than the other square feet of the region, and furthermore, if the shape of fragments is too high, the fragments may compress against each other due to their own weight and lose their original shape, especially when the resin content of the mixture is relatively high.

The advantage of handling and arranging randomly shaped pieces of these composite mixtures in this manner is that when additional layers of composite material are added in certain areas, such as by spraying the colorant on the front layer of the predetermined area, the colorant will also be sprayed onto the sidewalls of some randomly shaped pieces. The sidewalls may be randomly shaped (e.g., zigzagged, etc.) rather than smooth planar. This allows the colorant layer to be applied to more surface area than a slightly compressed composite (e.g., a material that is not broken and/or has no pieces of exposed sidewalls, etc.), where the surface is substantially flat or includes finely divided particles of a mixture, so that the colorant can only be coated or sprayed onto the upper surface of the composite. The number of randomly shaped pieces may vary and the height of randomly shaped pieces distributed on the conveyor belt may be greater or much greater than the prescribed distance between the press rolls and the conveyor belt or, in another approach, between pairs of press rolls. Thus, as randomly shaped pieces pass through the press roll, material accumulation occurs at the front end of the press roll. The height of the accumulation may be controlled by a number of factors including conveyor belt speed, press roll rotation speed, height or average height of randomly shaped pieces distributed on the conveyor belt, distance between press rolls and conveyor belt, or distance or gap between press roll pairs. Once passed through the roller or pair of rollers, the randomly shaped pieces of composite material are extruded by the roller or pair of rollers and deformed into a single body to form a flat (uncured) slab. Larger randomly shaped pieces also have a tendency to be pressed away from the press roll, while smaller randomly shaped pieces also tend to be pressed, thereby altering the streaks formed by the colorant deposited on the randomly shaped piece sidewalls.

It is noted that depending on the desired final design aesthetics, it may be desirable to cover more surface area of any particular randomly shaped fragment, and it may be important to cover more side walls or vertical surfaces of randomly shaped fragments. The press rolls will produce a great deal of stretch in the horizontal direction but little stretch in the vertical direction. Thus, if the colorant is only on the upper surface of the composite, or the upper surface of the composite is slightly flattened, the colorant will substantially remain on the upper surface after passing through the nip roller. For example, if a randomly shaped crumb has significantly more horizontal surface area, such as a flat disc, then substantially all of the colorant on the upper surface of the disc will remain on the top surface after passing through the press roll. This will result in the colorant appearing on the horizontal upper surface of the slab, rather than having full-body veins in the vertical direction. However, if the randomly shaped pieces are a cylinder with a height greater than the width and the colorant is applied to the entire height of the sidewall, the colorant on the vertical surface of the random shape will be elongated in the horizontal direction after being deformed by the press roll. The appearance of the blank then not only has a pronounced streak of colorant on the horizontal surface, but also a random streak throughout the entire body in the vertical direction.

In addition to the press rolls, other methods may be used to achieve the same result, such as pressing the composite material through a narrow opening, such as injection molding.

One embodiment of the present invention may include a CNC (computer numerical control) controlled kick-off device that uses a narrow head so that the device does not cut through (or cut through) randomly shaped pieces, causing them to break or compress. Instead, the device will nudge (or move aside) randomly shaped pieces and retain their random shape (e.g., it will not break the pieces or disrupt the existing shape of the pieces, etc.). An elongated narrow tail made of rigid flat plates is connected to the head and swings back and forth like a pendulum, pushing randomly shaped pieces aside, but without deforming or breaking the randomly shaped pieces by excessive force. Since randomly shaped pieces pushed aside are not broken or deformed (e.g., the side walls of the pieces do not merge or mesh together, but remain exposed, and do not come into contact with portions of other pieces, etc.), the device creates a channel through the pieces that has a somewhat random edge profile. In this way, once the channel walls are coated with colorant and drawn by the roller (e.g., horizontally, etc.), a more realistic tattoo effect is created. This is in sharp contrast to smooth groove walls formed in composite materials using V-shaped cutting wheel arrangements or any other form of cutting arrangement. After the channels are formed, an additional layer of composite material or colorant is applied to the predetermined area, which may include the channels. One example of such a method includes depositing colorant on top of certain areas of randomly shaped pieces using a CNC controlled spray gun. Thus, the side walls of the randomly shaped pieces that have been pushed by the kick-off device have colorant deposited thereon. Because of the close distance between each randomly shaped segment in the path of the deposited colorant, the colorant on each randomly shaped segment will spread (e.g., horizontally, etc.) to adjacent randomly shaped segments, thereby simulating the appearance of a continuous long vein in the slab after the slab passes through the press roll or pair of press rolls. Because each randomly shaped piece is extruded and deformed differently, the continuous long veins formed after the colorant is deposited on a series of adjacent particles will exhibit a random zig-zag pattern after the pressing and stretching process that better mimics the random long veins seen in natural stone.

The size of the randomly shaped pieces is important to control the amount of colorant used. Since the colorant is deposited only on the outer surface of any given randomly shaped crumb, as the size of the randomly shaped crumb becomes smaller, the volume of the composite material having the original color becomes smaller as compared to the color of the colorant until the particle size is small enough to change the color of the entire composite material to that of the colorant. Smaller pieces can result in an undesirable single color or short vein appearance after passing through the nip roll.

Another way to ensure that a large amount of vertical surface area is coated with colorant is to place randomly shaped pieces much larger than other pieces. The colorant may be applied to the large pieces of randomly shaped pieces before or after they are placed on the support structure. The placement of each large randomly shaped fragment may be controlled or predetermined (e.g., preselected based on the desired vein pattern being drawn, etc.). This will ensure that a significant portion of the side walls of the large randomly shaped pieces are coated with colorant and if there are enough large randomly shaped pieces together, after passing through the press rolls, the randomly shaped pieces will join to form a long zig-zag effect on the slab.

The larger the randomly shaped pieces distributed on the conveyor belt or the more randomly shaped pieces that accumulate before the press rolls relative to the distance between the press rolls and the conveyor belt, the greater the degree of deformation and stretching of the composite material after passing through the press rolls or pairs of press rolls. In turn, elongated veins are formed, the stretching or deformation of which is controlled to some extent, depending on how much composite material is deposited before the nip roll. If there is insufficient composite material deposited before the press roll, the amount of stretching or deformation of the composite material is small. In the extreme case, if the material is insufficient, the pieces will not be compressed and come out of the roll in the form of pieces rather than a flat sheet. If too much material is deposited before the nip roll, the composite material may be overstretched. Depending on the aesthetic requirements of the final design, a particular amount of stretching or deformation is required (e.g., controllable by the height of the accumulation of pieces before the rolls, the diameter of the rolls, the rotational speed of the rolls, the distance between the rolls and the support surface (or pair of rolls), etc.). In addition, the speed of the conveyor belt can be increased to cause more randomly shaped pieces to accumulate in front of the press roll, or the speed of the conveyor belt can be decreased to cause less randomly shaped pieces to accumulate in front of the press roll. The degree of stretching or deformation of the crumb (and the colorant added thereto) generally controls (or determines) the length of the veins, etc., that are created in the compressed material. In addition, the amount of resin in the mixture can also affect the degree of stretching (e.g., the greater the amount or percentage of resin in the mixture, the more moist the crumb and thus the more easily stretched or deformed by the press roll or pair of press rolls; etc.).

The rotational speed of the press roll or pair of rolls, the height between the belt and the press roll or the height between the pair of rolls (as previously described), also affects the degree of stretching or deformation of the randomly shaped pieces of composite material.

In one or more embodiments of the present disclosure, the colorant is deposited or sprayed along a predetermined pattern or trajectory connecting the plurality of fragments, not only on the surface of the fragments, but also along the height of the side walls of the fragments. After the colorant is deposited and passed through the nip roll, the resulting elongated through-body ridges will form continuous ridges in the processed slab.

More than one colorant may be deposited on a predetermined region of the composite crumb, and the colorants may or may not be deposited simultaneously. The amount of each colorant deposited can be computer controlled.

In one or more embodiments of the present disclosure, the size and/or location of randomly shaped pieces is controlled by a combination of methods of applying additional layers of composite material or colorant at specific locations to coat the surface area or vertical surface area of randomly shaped pieces in a desired amount. After the colorant is applied, the composite is treated by a press roll or pair of rolls or other similar stretching and compressing device to form the desired vein that better mimics natural stone. One or more embodiments of the present disclosure provide an apparatus and device that can push fragments aside, exposing randomly shaped fragments to more surface area or sidewalls, while still maintaining the shape of the fragments without breaking or deforming them.

In one or more embodiments of the present disclosure, variables (e.g., in computer memory, etc.) are stored and adjusted in a computer to control which colorants, the amount of each colorant, the deposition area of the colorant on the composite, and the degree of deformation and stretching of the composite after passing through one or more nip rollers. In at least one embodiment, the distance between the nip roller and the belt or the distance between the nip roller pair, the height and number of composite pieces, and the speed of the belt feeding the nip roller are controllable.

The significant advantages of the present invention are also represented by the ability to achieve continuous operation of the cloth relative to a one-at-a-time process of forming a single, distinct (uncured) slab at a time during the color formation process prior to vibration and compaction of the slab. In addition to cost savings, it is also aesthetically advantageous to produce slabs longer than standard slabs (which are typically about 3 to 3.6 meters in length). Because if a single slab is produced, the front or rear portion of the slab may be stretched to a significantly different extent than the middle portion because there is insufficient material to accumulate in front of the press rolls at these locations. For example, if 10 uncured slab lengths (as a single batch of material) are produced continuously, the material at the front and back of the slab may be discarded, the remainder being cut into pieces (having a more consistent texture) in length increments of about 3-3.6 meters for further processing.

Another significant advantage of the present disclosure is the ability to save material costs. It is very difficult to uniformly distribute the material over a sufficiently large area, for example, a slab region of about (1.5 to 2.2) meter x (3 to 3.6) meters and 60 mm thickness. The vibration and compaction steps may planarize localized areas but it is difficult to planarize if there is more material at one end of the slab than at the other. In order to accommodate such irregularities during the production process, the slab is typically produced thicker than necessary and ground to a suitable size in a later process step. For example, if the desired thickness of the final product is 30 mm, a slab of 36 mm thickness may be produced and then ground and polished to 30 mm, wasting additional 6mm of material. By flattening the excess material using a press roll or similar device, a more consistent and flat slab can be produced than in the prior art, allowing slabs thinner than 36 mm to be produced prior to grinding while maintaining a thickness of 30 mm in the final product.

In at least one embodiment, a method of producing a manufactured stone slab is provided that includes crushing and mixing composite minerals/materials, compressing the composite minerals/materials to form a compressed composite material, fragmenting the compressed composite material into a plurality of composite fragments, distributing the composite fragments onto a support structure, depositing a colorant onto predetermined areas of at least a portion of the sidewalls of some of the plurality of composite fragments, and compacting, flattening, and expanding the plurality of composite fragments into a slab using an apparatus.

The means for compacting, flattening and expanding the plurality of pieces may comprise a first press roll and a second press roll, wherein the plurality of pieces pass between the first press roll and the second press roll to compact, flatten and expand the plurality of pieces of the composite material into a sheet.

In at least one embodiment of the present disclosure, a portion of the plurality of pieces deposited with the colorant is arranged in a predetermined pattern on a support structure prior to pressing, flattening and expanding the plurality of pieces of composite material into a sheet using a device.

In at least one embodiment of the present disclosure, at least a first set of fragments of the plurality of fragments are arranged in a predetermined pattern on the support structure prior to depositing the colorant thereon.

In at least one embodiment, the means for depositing the colorant on at least a portion of the side walls of at least some of the randomly shaped pieces may be a digital printing device, similar to an ink jet printer or a dot matrix printer, that deposits (e.g., prints, etc.) the colorant over a specified area along the length and width of the randomly shaped pieces disposed on the support structure (e.g., in accordance with a predetermined image of a desired vein of the produced slab, etc.). The digital printing device may be CNC controlled as described herein.

In view of this, an image of the natural stone may be uploaded to a digital printing device (e.g., directly or through a computer device communicatively connected to the digital printing device, etc.), whereby the digital printing device may obtain an image of the natural stone. Image processing software may be used to map the image of the natural stone onto the controls of the printing device so that the printing device can print the image of the natural stone onto randomly shaped pieces on the support structure with the required resolution (e.g., map coordinates of the image to corresponding coordinates of the support structure, etc.). Digital printing devices may deposit (e.g., print, etc.) different colored colorants in liquid, powder, or granular form. For example, in some examples, the digital printing device may include at least one nozzle configured to move in X, Y and/or Z directions relative to the support structure to deposit a desired colorant (e.g., a desired color, quantity, etc.) onto fragments at a particular location on the support structure (e.g., based on an uploaded image, etc.). In other examples, the digital printing device may include a row (or multiple rows) of multiple nozzles that are spread across the width of the support structure, wherein particular nozzles are driven to deposit a desired colorant (e.g., a desired color, number, etc.) onto the fragments on the support structure (and thereby onto the fragments in particular locations) as the fragments move through (e.g., under, etc.) the nozzles (e.g., based on uploaded images, etc.). In some embodiments, the digital printing device may be an automated device for automatically printing different colored colorants onto the pieces, including at least a portion of the sidewalls of at least some of the pieces on the support structure, in liquid, powder, or granular form in response to receiving, acquiring an image of the natural stone, or the like.

In at least one embodiment, the press rolls may stretch the natural stone image printed on the crumb on the support structure to some extent (e.g., the natural stone image printed on the crumb on the support structure is a natural stone image that mimics or is based on uploading onto a device that deposits a colorant on the crumb, etc.), depending on the desired final aesthetics. To compensate for this, the uploaded natural stone image may be processed (or pre-processed) by a computer device (e.g., by computer software such as Photoshop, or other similar software available to AI or computer devices, etc.), causing the uploaded image to be compressed or distorted, etc., along an axis that coincides with the axis of the press roll or the press roll calendaring fragments on the support structure (e.g., causing the image to be distorted/compressed along the length or dimension of the slate in the image, etc.). Thus, the image printed on the scrap will take into account the degree of stretching caused by the press rolls. The image is then printed on the fragments, including on some of the side walls of some fragments, and stretched by the press rolls to obtain (in the uncured slab after compression) veins similar to those of the original image before compression. It should be appreciated that the resulting veins may not be exactly identical to the original image printed, and that there may be some degree of variation, randomness, and distortion. However, the resulting veins still provide a more realistic appearance of natural stone than previously.

The digital printing device herein may have a length and width, and a nozzle or nozzles, so that colorant may be deposited (by the printing device) at specific locations along the length and width of the fragments on the support structure. Each nozzle may deposit a specific amount of colorant at a specific location and time to deposit the colorant, print the desired natural stone image onto randomly shaped pieces on the support structure (e.g., according to the post-processing uploaded image, etc.). Computer means (via software contained therein) may be used to analyze the image and provide instructions to the support structure as to how to synchronize the conveyor belt speed, to the printing means to cause the printing means to deposit (e.g. print, etc.) ink or colorant on the crumb, and to the nip rollers to control the extent of nip roller calendering (e.g. nip roller speed, nip roller to conveyor belt spacing, etc.). The nozzle or nozzles of the printing means may be arranged (or adjusted by the printing means as required during operation) such that the distance between the nozzle and randomly shaped pieces should be at least about 1 mm from the highest point of the pieces on the support structure, not more than about 120 mm from the lowest point of the pieces on the support structure, and additionally, or adjusted according to the thickness of the slab to be produced. The closer the nozzle is to the randomly shaped fragment surface on the support structure, the higher the resolution of the printing. Conversely, the farther the nozzle is from the randomly shaped pieces on the support structure, the lower the resolution.

In fact, as noted above, whatever image is printed by the digital printing device on at least a portion of the side walls of certain fragments, the digital printing device will deform and stretch after the press roll process. This is the expected and desired characteristic for the press roll. In some cases, the original image may be distorted to be completely non-planar due to the pressing and stretching processes. In selecting the image to be printed on the crumb, this effect should be taken into account and the appropriate image selected to produce the desired colour, shade and vein upon further processing by the press rolls to better simulate natural stone.

In at least one embodiment, after compacting, flattening and expanding the randomly shaped pieces with at least some of the coated side walls into an uncured mat by a press roll or pair of press rolls, a second layer of material (where the uncured mat may be considered a first layer) may be distributed over the uncured mat. The second layer of material may be composed of a translucent or translucent mixture. The mixture may include mineral aggregate, cullet, resin, colorant, chemical additives, or combinations thereof. The second layer may be distributed or substantially uniformly distributed to cover the entire first layer (e.g., prior to cutting the first layer and/or curing the first layer).

In view of this, in at least one embodiment, another pair of press rolls may be used to press a second layer of uniform thickness and density in preparation for laying the second layer over the first layer. In pressing the second layer, a layer of PET film or other type of reinforcing film or mesh may be pressed over it to prevent the material in the second layer from breaking (before it is applied to the first layer) and then the second layer is uniformly applied over the first layer, with the PET film still over the second layer.

The uncured mat, including the first layer and the second layer thereon, may be further processed by vacuum, vibration, and compaction processes known in the art. The PET film on the upper surface of the second layer may be removed after the vacuum compaction process. The amount of material deposited to form the second layer may be controlled such that the height of the second layer is about 2 to 8 millimeters after vacuum, vibration and compaction. The resulting slab comprising the first and second layers may then be cured according to methods known in the art.

Subsequently, a large part of the second layer was removed from the cured plate by uniformly grinding off the upper surface of the cured plate using a grinder. For example, assuming a second layer 2 to 3mm high is formed, about 1.5 to 2.5 mm may be abraded away. Generally, the grinding machine should stop grinding before any material of the first layer is ground away.

In general, during the processing of artificial stone slabs, the slabs never become perfectly smooth after vacuum, vibration and compaction into uncured slabs. If a finished product with a thickness of 30 mm is required, a slab with a thickness of 34-39 mm is generally produced, and then the slab is ground to 30 mm to ensure that the upper and lower surfaces of the slab are flat and smooth.

In summary, the second layer of material (as described above) added to the uncured mat acts as a protective layer so that, when the top of the mat is ground to a flat surface, the material or amounts of material of the first layer are not ground away (to provide a smooth upper/lower surface) during grinding, thereby retaining the pattern printed on the upper surface of the first layer and subsequently compacting, flattening and stretching. The pattern of the upper surface of the first layer can be seen through the second layer due to the translucent or semi-transparent nature of the second layer.

The mixture of the second layer may be formulated to be chemically and mechanically/physically compatible with the mixture of the first layer. In addition, the colorant may be formulated to be physically and chemically compatible with the composite material used to form the plurality of pieces.

One or more embodiments of the present disclosure provide methods and apparatus for producing artificial stone slabs having a pattern (e.g., stone slab with a full body pattern, etc.) that extends to the entire thickness (or substantially the entire thickness) of the stone slab.

In at least one embodiment, a process may be employed to uniformly place the composite material on the support structure. The composite material may be formed by a process wherein a majority of the plurality of randomly shaped pieces are between about 25 mm and about 250 mm as described herein. Then, in a height limiting step, the composite material or randomly shaped pieces may be passed under a height limiting device which is positioned at a predetermined height above the support structure. The height limiting means may slightly press and/or disturb the top of the higher composite material or randomly shaped pieces so that after this step the height of the highest point of the composite material or randomly shaped pieces to the support structure is substantially the same as the height of the height limiting means to the support structure. For example, the compressed or disturbed distance of the composite material or randomly shaped pieces may be 3 to 30 mm from their highest point. In addition, such height limiting measures will reduce the height variation of the entire composite or randomly shaped pieces (and/or form a plateau or generally flat upper surface on portions of the composite or randomly shaped pieces) such that when additional composite or randomly shaped pieces (and/or colorants, etc.) are added at a later step, some of the composite or randomly shaped pieces will rest on top of the flat area formed by the height limiting device without shifting or sitting at a low point between two larger composite or randomly shaped pieces. For example, the height limiting device may be a roller configured to disrupt or compact the composite material or randomly shaped pieces, or may be a doctor configured to disrupt or scrape the composite material or randomly shaped pieces. The disruption may include flattening or compacting the composite or randomly shaped pieces, breaking up the composite or randomly shaped pieces, pushing the composite or randomly shaped pieces aside so that the higher portions fall to a lower position, or any combination of these actions to ensure that the maximum height of the composite or randomly shaped pieces is properly set.

After the composite material or randomly shaped pieces pass under the restriction device in a height limiting step, a colorant may be deposited by the digital printing device onto at least some of the flat upper surfaces and/or at least some of the sidewalls of at least some of the composite material or randomly shaped pieces in a predetermined area in a digital printing step to print an image thereon. The height limiting device may ensure that the composite material or randomly shaped pieces are at an appropriate height so that the composite material or randomly shaped pieces do not contact one or more nozzles of the digital printing device. Furthermore, this can ensure that the distance between the nozzle of the digital printing device and any given point of the composite material or randomly shaped piece is as small as possible (e.g., within a desired range, less than a desired threshold, such as between about 1-30 millimeters, etc.) so as not to negatively affect the resolution of the digital printing. Since digital printing devices deposit colorant on uneven surfaces, the farther the surface is from the nozzles of the digital printing device, the more blurred or less resolved the print area.

The composite or randomly shaped pieces may then have an additional layer of composite or randomly shaped pieces deposited over at least some of the composite or randomly shaped pieces that have been coated with the digitally printed colorant on the support structure. In one example, the deposition of the additional layer of composite material or randomly shaped pieces may be about 3-20% of the weight of the composite material or randomly shaped pieces initially placed on the support structure. Most of the fragments in the composite material or the additional layer of randomly shaped fragments may be between 5 and 35 mm in diameter.

Alternatively, after the addition of the additional layer of composite material or randomly shaped pieces, the composite material or randomly shaped pieces on the support structure may be passed under another height limiting device which is arranged at a predetermined height above the support structure in an additional (or second) height limiting step. The height limiting device may slightly press and/or disrupt the top of the higher composite material or randomly shaped pieces such that the highest point of the composite material or randomly shaped pieces to the support structure is at substantially the same height as the height of the height limiting device to the support structure (e.g., the same height as in the one height limiting step, a different height greater than or less than the height in the one height limiting step, etc.). For example, the height limiting device may be a roller configured to disrupt or compact the composite material or randomly shaped pieces, or may be a doctor configured to disrupt or scrape the composite material or randomly shaped pieces. The disruption may include flattening or compacting the composite material or randomly shaped pieces, breaking up the composite material or randomly shaped pieces, pushing the composite material or randomly shaped pieces aside so that the higher portions fall to a lower position, or any combination of these actions to ensure that the maximum height of the composite material or randomly shaped pieces is properly set.

After the additional height limiting step, in an additional printing step, the composite material or randomly shaped pieces may be provided with an image printed thereon by depositing colorant on at least some of the flat upper surfaces and/or at least part of the sidewalls of at least some of the composite material or randomly shaped pieces using a digital printing device. The height limiting device may ensure that the composite material or randomly shaped pieces are at an appropriate height so that the composite material or randomly shaped pieces do not contact one or more nozzles of the digital printing device. Furthermore, this also ensures that the distance between the nozzle of the digital printing device and any given point of the composite material or randomly shaped piece is as small as possible (e.g. within a desired range, less than a desired threshold, etc., e.g. between about 1mm and 25 mm) so as not to negatively affect the resolution of the printing. Alternatively, the additional printing step may print substantially the same pattern or design as the first printing step, so that the same areas of different layers of composite material or randomly shaped fragments have the same colorant or image.

In this way, at least some portion of the additional layer of composite material or randomly shaped pieces placed on the support structure may have colorant deposited under and over it by one or more printing devices in addition to applying colorant to at least a portion of its sidewalls (e.g., colorant may be located between layers of composite material or randomly shaped pieces, etc.). This process of limiting the height of the composite or randomly shaped crumb, placing additional layers of composite or randomly shaped crumb, optionally re-limiting the height of the additional layers of composite or randomly shaped crumb, and depositing a colorant on at least a portion of the additional layers of composite or randomly shaped crumb may be repeated a number of times depending on the desired details of each layer and the final aesthetic requirements of the finished slab.

Following the above steps, the composite material or randomly shaped pieces, along with digital printing thereon (e.g., colorants, etc.), may be pressed, flattened and expanded into an uncured mat by a press roll or pair of press rolls as described herein. The uncured mat may then be cured as described herein.

It should be emphasized that in embodiments, the composite materials used herein (e.g., placed on a support structure, etc.) are initially combined from a composite material formed from dry sand, dry powder, resin, and other additives that are agitated by a high speed agitator. The composite material may then be compressed and controllably broken into randomly shaped pieces of a desired size range (as described herein). If stacked together for a period of time, the randomly shaped pieces are bonded together by gravity to form a stack of composite material. Therefore, the working time after obtaining composite materials or randomly shaped pieces is limited.

For example, one may apply oil and color flavoring to the surface of the dough while kneading the dough (e.g., during baking, etc.). As the dough is continuously kneaded, the oil and color flavoring applied to the surface of the dough eventually kneads into and out of the entire dough. If the kneading time is long enough, the dough becomes monochromatic. If kneading is not long, the oil and color flavoring will appear in a random pattern, and some gradual color transition will occur throughout the dough. The smaller the dough, the more easily the oil and color flavoring applied to the surface of the dough during kneading are mixed from outside the dough.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this section are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Example embodiments are described more fully below with reference to the accompanying drawings. The description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Fig. 1 is a partial perspective view of a first device 1 according to one embodiment of the invention shown in fig. 3.

Fig. 2 shows a close-up simplified perspective view of a portion of the first device 1. Wherein the display device 1 comprises a motor 18, a component 14, a shaft 16, a kick-out means 10 and a color spraying means 6. The color-spraying device 6 comprises pipes 7a and 7b, which feed the nozzles 6a and 6b, respectively. Shaft 16 is configured to be rotated in either the C1 (counterclockwise) or C2 (clockwise) direction by motor 18 and member 14 to rotate the dial 10 about shaft 16.

Fig. 3 shows a simplified top view of the first apparatus 1 in which the kick-out device 10 of the apparatus 1 forms channels 150 in the composite material 160 while maintaining a random shape (e.g., zigzagged, etc.) of the sidewalls of the pieces of the composite material 160 (e.g., where the sidewalls of some pieces are at least partially exposed, not in contact with the sidewalls of other pieces, etc.).

Fig. 4 shows a perspective view of a2 nd apparatus according to an embodiment of the present disclosure, wherein the 2 nd apparatus includes a roll apparatus 200 and a roll apparatus 300. The roll apparatus 200 includes an upper roll 202 and a bottom roll 210, and the roll apparatus 300 includes an upper roll 302 and a bottom roll 310. The roll apparatus 200 further includes a film collector 204 and a film dispenser 206. The roll apparatus 300 further includes a film takeup device 304 and a film release device 306.

Fig. 5 shows a simplified side view of a composite 400 illustrating various fragment sizes and random orientations of fragment sidewalls. Composite 400 includes a plurality of fragments, including fragment 402 and fragment 404. Fragment 402 has sidewalls 402a and 402b, and fragment 404 includes sidewalls 404a and 404b. The sidewalls 402a, 402b, 404a, and 404b are oriented differently relative to the belt surface of the belt 102. Fragments (including fragments 402 and 404) are formed from a mixture of materials (or a different mixture, or a different batch of mixtures) that have been previously compressed (e.g., as part of a first compression operation, etc.) and then crushed. The resulting fragments include fragments 402 and 404. In this regard, fragments 402 and 404 may be from the same compressed feed mixture (already crushed). Or fragment 402 may be from a first compressed raw material mixture (having been crushed to form fragments having a first size or range of sizes) and fragment 404 may be from a second compressed raw material mixture (having been crushed to form fragments having a second size or range of sizes different from the first size or range of sizes). Fragments from the first compressed and second compressed feedstock mixtures (including fragments 402 and 404, respectively) are then combined into a composite 400 comprised of fragments.

Fig. 6 shows a photograph 500 in which the fragments 504 are after the colorant track has been formed and before entering the platen roller 502. The region 504a of the fragment 504 is defined as the region where the fragment "piles up" or "accumulates" before the press roll 502. As described above, the pieces 504 may be obtained from a mixture of raw materials (or a different mixture or a different batch of mixtures) that have been previously compressed (e.g., as part of a first compression operation, etc.) and then crushed. In this example, the crumb 504 (and the colorant coated thereon) will be compressed by the press roller 502 (e.g., as part of a second compression operation, etc.).

Figure 7 shows the crumb 600 as it leaves the press rolls under which it is pressed together as part of a continuous slab and flattened and expanded (before the slab solidifies).

Fig. 8 shows a photograph 700 of a finished board after the process shown in fig. 6 and 7 and after pressing, curing, trimming, rough grinding and polishing.

Fig. 9 shows a flow chart 800 of a method according to one embodiment of the present disclosure.

Aggregate minerals such as quartz sand and flour (e.g., virgin aggregate materials, etc.) may be combined with resins, colorants, and other additives in a high speed mixer to obtain a slightly wet composite (or a composite mixture of slightly wet aggregate minerals) in step 802. Such a composite (or mixture) is compressed (e.g., by rollers, etc.) into a dense composite mixture (e.g., as part of a first compression step, etc.) at step 804. In certain embodiments, the compacted composite mixture does not include a colorant or does not have a colorant added thereto to form veins (as described herein, the colorant is added thereafter).

In step 806 of fig. 9, the compacted composite mixture (e.g., the compacted composite mixture in step 804) is broken into a plurality of pieces. The process of breaking up the compacted composite mixture into a plurality of fragments is preferably performed in a controlled manner, for example by disturbing the compacted composite mixture by means of a stirring device, wherein the rotational speed of the stirring device can be varied, so that the faster the stirring device is rotated, the smaller the fragments formed for breaking up the compacted composite material.

Alternatively, the compacted composite mixture may be dropped onto a rigid grid or mesh to break the compacted composite mixture into chunks of composite material or irregularly shaped pieces. By controlling the size of the screen and/or the height of the drop, a large portion of the crumb can be obtained, having the desired size or range of sizes.

Still other methods may obtain multiple fragments.

In certain embodiments, multiple "batches" of dense composite mixtures may be formed (at steps 802 and 804). The first batch of compacted composite mixture is then broken into a plurality of pieces (e.g., in step 806), the resulting pieces being mostly within a desired first size range. In addition, the second batch of compacted composite mixture is broken into a plurality of fragments (e.g., at step 806), a majority of the fragments produced being within a desired second size range (which may be different than the first size range). Further batches of the compacted composite mixture may also be broken into a plurality of pieces (e.g., in step 806), with a majority of the resulting pieces falling within a desired size range of a third, fourth, etc., respectively (which may be different from the first, second, etc. size ranges). In this way, fragments of different desired sizes (to be subsequently used in forming the slabs described herein) may be formed from the compacted composite mixture.

The size of the pieces may vary depending on the final aesthetic effect, but each of the plurality of pieces mentioned in step 806 may have a width, length and height, and the largest dimension of the width, length and height is preferably between 25 and 250 millimeters. The size of the pieces formed/used depends on the amount of vein required for the final aesthetic effect. In general, the larger the crumb, the larger the vein after processing by the press roll or pair of rolls.

The shape of each crumb is generally preferred to be random because the ridges created by the roller process may appear too mechanical or unnatural if the crumb is too uniform.

In step 808 of FIG. 9, the plurality of pieces are placed relatively uniformly on a support structure, such as a conveyor belt, to avoid areas of significantly more composite material than other areas. In so doing, in some embodiments, pieces of a particular/desired size (or desired size range) are selected (from among the available pieces formed in step 806) and placed onto the conveyor belt (e.g., randomly placed into a particular location on the conveyor belt, etc.). The fragments may be distributed on a conveyor belt with at least a portion of the side walls of a portion of the fragments (e.g., the walls of fragments not contacting the conveyor belt, etc.) exposed (and/or not contacting other fragments or the side walls of other fragments). In this way, the side walls of the fragments are exposed for application of the colorant (as described herein).

In some embodiments, at least one fragment (e.g., a fragment having one or more desired dimensions, etc.) is distributed at a particular predetermined location on the conveyor belt surface (e.g., based on a predetermined fragment location map to obtain a particular vein design, etc.) upon placement of the fragment onto the support structure (e.g., using the location placement control device described herein, or manually, etc.). This will help ensure proper spacing between the different sized and/or shaped pieces on the conveyor to produce the desired tattoo effect (of a particular location, length, etc.) in the resulting slab (as the pieces are compacted, flattened and stretched by the press rolls, etc.).

In step 810 of FIG. 9, a colorant is applied to the sidewalls of the plurality of fragments. In some embodiments, the colorant is applied to the side walls of the crumb such that the colorant is applied to substantially the entire height of the crumb side walls (e.g., by one or more devices described herein, including the color jet device 6, digital printing device, etc., described herein).

In some embodiments of the method 800, in connection with applying a colorant to sidewalls of a plurality of fragments, the method 800 may further include forming a trench in the plurality of fragments (as generally described herein), and applying a colorant to sidewalls of the plurality of fragments at the trench (e.g., to sidewalls of fragments forming the trench, etc.). In such examples, the grooves may be formed by moving at least a portion of the plurality of fragments while not substantially breaking or deforming the fragments (e.g., without changing or adjusting the shape of the original randomly shaped fragments, etc.). Further, in these embodiments, the grooves may have a non-linear pattern and/or may have a random edge profile that is not smooth (or non-cut). Further, in some embodiments, after the colorant is applied to the pieces at the trough in the first step, additional colorant may be applied to the pieces (e.g., reapplied to the trough, remote from the trough, etc.) (additional colorant is added as part of the second step of applying colorant (e.g., by a digital printing device, etc.)).

Furthermore, in some embodiments of method 800, in connection with applying a colorant to the sidewalls of a plurality of fragments, method 800 may include applying a colorant to the sidewalls of a plurality of fragments (e.g., by a digital printing device, by other nozzles, etc.) generally as described above (as a first step in applying a colorant to fragments). The method 800 may then include forming grooves (as generally described herein) in the plurality of pieces after the first step of applying the colorant. Then, in some embodiments, as a second step of applying colorant to the fragments (e.g., via a nozzle, etc.), additional colorant may be applied to the sidewalls of the plurality of fragments at the channel (e.g., on the sidewalls of the fragments forming the channel, etc.).

Further, in some embodiments of the method 800, using a digital printing device to apply (e.g., print, etc.) a colorant to the side wall of the crumb (at step 810), the digital printing device may be provided (e.g., uploaded, scanned, etc.) with an image of the natural stone (e.g., directly or through a computer device in communication with the digital printing device, etc.). The image may include a desired vein pattern to be incorporated into the artificial stone panel formed by the method 800. In this process, the image may be processed as described herein, taking into account the calendering of the fragments by the press rolls in step 812. In particular, the image may be compressed, for example along an axis coincident with the axis of the pressing roller calendaring the fragments on the support structure. The compressed image is then mapped onto the support structure (e.g., in X and Y coordinates, etc.), and printed onto the fragment on the support structure. The digital printing device then deposits (e.g., prints, etc.) a different color colorant in liquid, powder, or granular form onto the crumb, matching the vein pattern on the compressed image (crumb mapped onto the support structure).

In connection therewith, fig. 16 shows an example image of a desired natural stone pattern that can be provided to a digital printing device, and fig. 17 shows an example image after processing. As shown, the processed image of fig. 17 is compressed in a horizontal direction (as shown in fig. 17) (e.g., along an axis coincident with the axis of the fragment rolled by the press roll onto the support structure).

In step 812 of fig. 9, the shape-random crumb (and the applied colorant thereon) is compressed (e.g., as part of a second compression step, etc.) and stretched/deformed using a press roll, pair of press rolls, or other device (as generally described herein). Thus, in some embodiments, the crumb forms a continuous, compressed sheet of material on a conveyor belt (e.g., using a press roll, pair of press rolls, or other device), which is not cut or has not been cut (and has not yet solidified).

In some embodiments, a continuous compressed sheet of material (along a conveyor, through a conveyor, on a conveyor, etc.) enters a cutting device (e.g., disposed along a conveyor, etc.) from a press roll or pair of press rolls or other compression device. In step 814 of fig. 9, the continuous compressed sheet material (uncured or uncured) is cut (e.g., still on a conveyor belt, etc.) by a cutting device to form a desired length of compressed sheet material (from the continuous compressed sheet of material) (again, before the compressed sheet is cured and before any curing steps are performed in method 800).

In step 816 of fig. 9, the cut compressed slate of desired length is processed and then cured to form a cured panel (cured artificial stone panel). For example, the cut sheet material may be transported (e.g., by a conveyor or a different conveyor, etc.) from the conveyor of the cut material to a vibration and vacuum compaction device and then transported to a curing oven for curing. The solidified slab may be further processed (e.g., cooled by a cooling tower, etc.), resized, ground to a desired thickness, polished, etc., as desired.

In at least one embodiment of the present disclosure, a densified composite/mixture as specified in step 804 is formed.

An advantage of processing and placing a plurality of fragments in this manner is that when additional layers of composite material are added in certain areas, such as by spraying the colorant on the first few layers of the predetermined area, the colorant will also be applied to the side walls of randomly shaped fragments. The sidewalls are generally randomly shaped (e.g., zigzagged, serrated, etc.) rather than being smooth, so that the surface area of the colorant layer is greater than a slightly compressed composite material having a substantially flat surface, and so the colorant is applied substantially only to the upper surface (see also FIGS. 16-18 and corresponding discussion below).

The number of randomly shaped pieces distributed on the conveyor belt may vary and the height of the randomly shaped pieces distributed on the conveyor belt may be greater or much greater than the specified distance between the press roll and the conveyor belt or, in another approach, between the two press rolls of a pair of press rolls. Thus, as randomly shaped pieces pass through the press roll, material accumulation occurs at the front end of the press roll. The height of the accumulation may be controlled by a number of factors including conveyor belt speed, press roll rotation speed, random-shaped crumb height or average height, distance between press rolls and conveyor belt, or distance between press roll pairs. In this way, the accumulated pieces (and the colorant coated on the pieces) will typically accumulate in front of the press rolls, so that a sufficient number of pieces are compressed and stretched by the press rolls to create the desired tattoo effect in the resulting mat. The height of this pile (which can be varied by adjusting the speed of the conveyor belt and the height of the first press roll) can in turn be used to vary, for example, the length of the ridges formed in the slab. Accordingly, randomly shaped pieces of the composite (and the colorant applied thereto) will be extruded through the rollers to form a flat uncured mat. The larger the randomly shaped pieces (and the colorant coated thereon), the more tendency to squeeze off the press roll and toward smaller randomly shaped pieces, thereby altering the vein pattern formed by the colorant deposited on the randomly shaped piece sidewalls.

In one or more embodiments of the present disclosure, a film dispenser and a film receiver are attached to the press rolls, each of which is mounted as the press rolls calender the crumb (and colorant). The composite is a mixture of slightly wet particles that may stick to the press roll. To prevent this, a protective film may be applied to the press roll using a film dispenser (e.g., a film dispenser roll) upstream of the location where the press roll contacts the random crumb. Downstream of the pressure roller, a film take-up device (e.g., a film take-up roller) may be used to remove or roll up the used film. A PET protective film may also be used between the crumb and the conveyor to prevent the micro-wet crumb from sticking to the conveyor.

For example, randomly shaped pieces deposited (or accumulated) in front of the press roll may have a height of about 100 millimeters from the belt, and the gap between the press roll and the belt may be about 30 millimeters (e.g., the height of the deposited pieces may be about 2-4 times (or more or less), or about 4 times or less the size of the gap between the press roll and the belt, etc.). Randomly shaped pieces are deformed into a flat sheet having a height of about 30 mm after leaving the press roll due to the pressing of the roll. The composite material has a certain elasticity and thus the final height may be slightly greater than the height of the press roll. Since the colorant is also applied to the side walls of randomly shaped pieces (before the pieces pass through the press rolls), then the colorant veins will not only appear on the upper surface of the slab, but will also extend through the thickness of the slab, thereby creating a pleasing natural random appearance of the whole body veins.

In one or more embodiments of the present disclosure, multiple sets of press rolls may be used sequentially to progressively press the material through multiple press rolls or pairs of press rolls. For example, the height of randomly shaped pieces stacked in front of the rollers may be about 100 mm from the conveyor belt, the gap between the first roller and the conveyor belt or between the first pair of rollers may be 30mm, and the gap between the second roller and the conveyor belt or between the second pair of rollers may be about 28 mm.

In one or more embodiments of the present disclosure, randomly shaped pieces may be placed on a stationary support structure and a press roll or pair of rolls may be designed to move back and forth along a track to compact the randomly shaped pieces, similar to rolling dough with a rolling pin. The height of the press roller or the press roller pair can be adjusted.

It is noted that while it is desirable to cover more surface area of any particular randomly shaped fragment, it is also important to cover more side walls or vertical surfaces of randomly shaped fragments, depending on the desired final design aesthetics. The press rolls impart a significant stretching of the composite material in the horizontal direction, but little stretching in the vertical direction. Thus, if the colorant is only on the upper surface of the composite, or the upper surface of the composite is slightly flattened, the colorant will remain substantially on the upper surface after passing through the nip roller. For example, if a randomly shaped crumb has significantly more horizontal surface area, such as a flat disc, substantially all of the colorant on the upper surface of the disc remains on the upper surface after passing through the press roll. This will result in the colorant appearing on the horizontal upper surface of the slab, rather than the appearance of full body coloration in the vertical direction. However, if the randomly shaped pieces are a cylinder having a height greater than the width and the colorant is applied to the entire height of the sidewall (e.g., smeared over the entire height of the sidewall or substantially the entire height of the sidewall, etc.), the colorant on the randomly shaped vertical surfaces will elongate and deform in the horizontal direction after passing through the nip rollers. The appearance of the mat then may not only appear as visible colorant veins on the horizontal surface, but also as random veins in the vertical direction throughout the body of the mat (e.g., throughout the entire thickness of the body of the mat or substantially throughout the entire thickness of the body of the mat, etc.).

FIG. 10 shows a simplified block diagram 900 of components used by one embodiment of the present disclosure. Block diagram 900 shows a computer processor 902, a computer memory 904, and a computer interaction device 906. The computer interaction device 906 may include a computer touch screen, a computer mouse, and/or a computer keyboard, among others. Block 900 also shows the kick-out device 10 previously shown in fig. 1 and 2.

As shown in fig. 10, the computer processor 902 communicates with at least the color spraying device 6, the kick-out device 10, the placement position control device 908, the speed control devices 912 of the press rollers 202 and 302, the height control devices 910 of the press rollers 202 and 302, and the speed control mechanism 102a of the conveyor belt 102.

One embodiment of the present disclosure may include a CNC controlled deflector 10, programmed by computer software stored in computer memory 904, for example, using a computer processor 902, using a narrow head at one end 10a of the deflector 10 so that the deflector 10 does not score (or cut) through randomly shaped pieces causing them to break or compress. Rather, the deflector 10 is configured to push or move a plurality of randomly shaped pieces slightly aside and retain their random shape (e.g., without changing or substantially changing the shape of the pushed or moved pieces, etc.).

The deflector 10 has one end 10a and an opposite end 10b. The kick-out device 10 has a head portion 10c and a tail portion 10d.

As shown in FIG. 2, the tail 10d is elongated, having a width W1, a length L1, and a height H1. The width W1 is preferably the same throughout the length L1. The dimensions of W1, L1 and H1 may be 2 mm, 90 mm and 80 mm, respectively, so that the tail 10d is elongate.

The elongated narrow tail 10d is preferably made of a flat, stiff plate, attachable to the head 10c, and configured to swing back and forth by rotating about the axis 16 like a pendulum to further push randomly shaped pieces aside, but not so hard as to deform or break the randomly shaped pieces. The distance of oscillation may vary depending on design requirements (e.g., the width of the groove to be formed), and the force of oscillation may vary depending on the particular formula used to form randomly shaped pieces. The oscillation of the deflector 10 creates a channel in the plurality of pieces that has a certain randomness in its edge profile due to the random shape of the pieces being pushed aside without breaking or deforming or substantially without breaking or deforming (e.g., the shape of the pieces does not change or substantially does not change, retains its general starting shape, etc., as the pieces are pushed or moved). In this way, once the channel walls are coated with colorant and stretched by the nip roller or pair of nip rollers, a more realistic tattoo effect is created. This is in contrast to smooth channel walls formed through composite materials using, for example, V-shaped cutting wheel devices or any other form of known cutting device.

In connection with the foregoing, for example, FIG. 18 illustrates a plurality of randomly shaped fragments 1602 placed on a support structure 1604.

Grooves 1606 are formed in the fragments 1602 in the manner described above, whereby some fragments 1602 are moved or pushed aside (e.g., away from other fragments to form grooves 1606 therebetween, etc.), while the moved fragments 1602 do not substantially break or deform or change shape. In this manner, the resulting grooves 1606 (e.g., elongated grooves, etc.) form a non-linear pattern and have random edge profiles with the sidewalls of the grooves being non-smooth (e.g., jagged, etc.). The side walls of the pieces forming the channel do not merge or mesh together (because the pieces are simply moved aside without breaking their shape), but remain exposed, without contact with other pieces, etc. Thus, when colorant is applied to the fragments at the trough, the additional surface area of the sidewall may be used to receive colorant. Accordingly, as shown in fig. 19, the ridges formed on the slab are generally zigzag (based on randomly shaped pieces being moved/pushed to form grooves/ridges (which, accordingly, have a non-smooth random edge profile, and more closely resemble cracks in natural stone)).

In contrast, in conventional slab forming operations, where the grooves are cut into soft, slightly wet material, the sidewalls of the grooves are smooth (any pieces of material in the material will deform, thereby forming smooth sidewalls). In one embodiment, as shown in fig. 20, the grooves 1806 are formed in the generally slightly wet material 1808 by such a conventional cutting operation and used to form a slab. It can be seen that conventional trench 1806 has smooth sidewalls. Accordingly, as shown in fig. 21, the veins formed in the slab are also relatively smooth (which form smooth trench walls/veins using conventional cutting operations).

After the grooves are formed, a composite material or colorant may be applied to the predetermined area. One embodiment of such a method includes depositing colorant on a region of a plurality of randomly shaped fragments using a spray gun or color-spraying device 6 as shown in FIG. 2 controlled by a CNC (and/or computer processor 902). In this manner, colorant is deposited on the sidewalls of the plurality of randomly shaped pieces that are moved by the deflector 10. Because of the close proximity of each randomly shaped crumb along the colorant deposition path, the colorant on each randomly shaped crumb stretches over adjacent randomly shaped crumb and the slab simulates a continuous long streak after passing through a press roll (such as press roll 202 or 302 in fig. 4). Since each randomly shaped piece is extruded and deformed to a different degree, the continuous long ridges will have a certain random zigzag pattern that better mimics the random ridges in natural stone.

The size of the randomly shaped pieces is important to control the amount of colorant used. As randomly shaped pieces become smaller in size, the volume of the original color of the composite will also become smaller until the particle size is small enough to change the overall color of the composite to that of the colorant. Upon passing through a press roll (such as press roll 202 or 302 in fig. 4), the smaller pieces may result in an undesirable single color or short burst appearance.

Another way to ensure that the colorant coats a large vertical surface area is to place randomly shaped pieces that are significantly larger than other pieces on a conveyor belt, such as conveyor belt 102, or other support structure. For example, a placement position control 908, shown in FIG. 10, which is controlled by the computer processor 902, may control the location of placement of each large randomly shaped fragment on the conveyor belt 102 or other support structure. For example, the position may be determined based on the desired veins, such that large, randomly shaped pieces are placed at specific positions on the conveyor belt with respect to the roll arrangement 200 or 300, etc. This will ensure that a significant portion of the side walls of large randomly shaped pieces are coated with colorant and if sufficient of these large randomly shaped pieces are brought together, they will join together when they pass through a press roll (e.g., press roll apparatus 200 and 300), creating a long vein effect.

The larger or more randomly shaped pieces distributed on the conveyor belt 102 of fig. 1, the greater the degree of deformation and stretching of the composite material after passing through the press rolls 202 and 302. Thereby forming an elongated vein of controlled stretch depending on how much of the composite material is deposited prior to the press roll 202 or 302. If there is insufficient composite material deposited in front of the press rolls 202 and/or 302, the amount of stretching of the composite material is small as shown in fig. 4. In extreme cases, if insufficient material is deposited, the crumb will not be compressed and will leave the roll as a crumb rather than a slab. If too much material builds up before the press rolls 202 and/or 302, the stretching of the composite material may be excessive. Depending on the aesthetic requirements of the final design, a specific amount of stretch is required. In addition, the computer processor 902 may increase the speed of the conveyor belt 102 to cause more randomly shaped pieces to accumulate in front of the press roller 202 or 302, or decrease the speed to cause less randomly shaped pieces to accumulate in front of the press roller 202 or 302.

The rotational speed of the rolls or roll pairs 202 and 302 (controlled by the computer processor 902 through the roll speed control 912) and the height of the conveyor belt 102 between the rolls or roll pairs 202 and 302 (controlled by the computer processor 902 through the roll height control 910) also affects the degree of deformation of randomly shaped pieces of the composite material.

In one or more embodiments of the present disclosure, the colorant is deposited, such as by the color-spraying device 6, along a predetermined pattern or trajectory that connects the fragments by depositing the colorant both on the surface of the fragments and along the height of the side walls of the fragments. For example, a particular fragment on the conveyor belt 102 may be identified (e.g., by the computer processor 902 via an imaging device, etc.), and the color spraying device 6 may be operated to spray the identified fragment exclusively or in a particular pattern that connects the identified fragments, etc. Subsequent to the deposition of the colorant and the passage through the rollers 202 and 302, the subsequently elongated through-body ridges will appear as continuous ridges on the surface of the resulting mat.

Control of crumb size generally depends on a variety of factors, including the desired final design aesthetics, and the method of depositing additional layers of composite material or colorant to the crumb surface region or sidewall. After the colorant has been applied, the desired pattern will be formed on the individual or multiple pieces. This method is used in conjunction with the press rolls 202 and 302 to achieve the desired effect.

Still other embodiments utilize instruments and devices other than the above-described deflector 10 to push the fragment aside to expose more surface area or side walls of the fragment while still maintaining the shape of the fragment without breaking or deforming it.

Variables may be adjusted and stored in computer memory 904 for controlling the degree of deformation and stretching of the composite after passing through press rolls 202 and 302 by computer software executed by computer processor 902. In at least one embodiment, the distance between the rollers and the conveyor belt, the height and number of composite pieces, and the speed of the conveyor belt 102 feeding the rollers 202 and 302 are all controlled by the computer processor 902.

In at least one embodiment, the computer processor 902 may process the natural stone image or compressed or distorted natural stone image in the computer memory 904 and communicate with the color spraying device 6 to deposit a colorant on at least a portion of the sidewalls of at least a portion of the plurality of fragments based on the natural stone image or compressed or distorted natural stone image.

FIG. 11 is a simplified side view 1000 of a press roll 1002 rotatably mounted on a member 1004 in accordance with one embodiment of the present disclosure during operation wherein at least a portion of a plurality of fragments 1050 of a composite material are being compressed by the press roll 1002, the remainder of the fragments 1050 being compressed as the conveyor belt 1006 moves in the direction D1 to move the fragments 1050 toward the press roll 1002. The component 1052 represents a piece of scrap pressed into one piece by the roller 1002 and having through-veins (e.g., extending through the thickness of the slab or substantially through the thickness of the slab, etc.) throughout the compressed uncured slab. Fig. 11 also shows a steel plate 1008 over which the conveyor belt 1006 moves.

Fig. 12 shows a simplified side view 1100 schematic of an upper press roll 1102 rotatably mounted to a member 1104 during operation in one embodiment of the present disclosure wherein at least a portion of a plurality of fragments 1150 of a composite material are compressed by the upper press roll 1102 and a lower press roll 1108, and the remainder of the fragments 1150 will be compressed as the conveyor belt 1106 moves in the direction D4 to move the fragments 1150 toward the gap between the press roll pairs 1102 and 1108. Component 1152 represents a fragment pressed into one piece by the combination of press roll pairs 1102 and 1108, which has a full-body vein extending through the entire compressed uncured mat (e.g., extending through the thickness of the mat or substantially through the thickness of the mat, etc.). Fig. 12 also shows a steel plate 1112 over which the conveyor belt 1106 moves.

In the embodiment shown in fig. 12, the lower press roller 1108 below the conveyor belt 1106 also rotates to help ensure that no braking effects due to friction between the upper press roller 1102 and the conveyor belt 1106 occur.

The arrangement of the press roller pairs can be up and down, as shown in fig. 12, or can be in a configuration with a certain offset, such as left and right arrangement or incomplete up and down or incomplete left and right arrangement, as required, and is not shown in the figure.

In contrast to fig. 13, which shows a slab produced using techniques known in the art, which include coating the pieces with a colorant to form short ridges within each individual piece, but which do not connect with short ridges formed in other pieces, the disclosed technique provides the appearance of long connected ridges over a considerable distance throughout the slab.

One significant advantage of one or more embodiments of the present disclosure is the ability to continuously produce material rather than producing one sheet at a time. In addition to cost savings, producing slabs with lengths greater than standard slab lengths (standard slab lengths typically about 3-3.6 meters) is aesthetically advantageous. This is because if a single slab were to be produced, the front or rear portion of the slab could be stretched to a significantly different extent than the middle portion because there was not enough material build up before the rolls at these locations. For example, if 10 lengths of uncured mat are continuously produced (e.g., as one continuous length of material along the conveyor 102), the front and back portions of the mat may be discarded and the remaining length of material cut into 3.2 meter length increments for further processing (e.g., for curing, etc.).

Another significant advantage of one or more embodiments of the present disclosure is the ability to save material costs. It is very difficult to uniformly distribute the material over a sufficiently large area, for example, the slab may have an area of about (1.5 to 2.2) meter x (3 to 3.6) meters and a thickness of 60 millimeters. The vibration and compaction steps may planarize localized areas but it is difficult to planarize if there is more material at one end of the slab than at the other. In order to accommodate such irregularities during the production process, the slab is typically produced thicker than necessary, and then ground to the correct dimensions in a later process step. For example, if a final product thickness of 30 mm is desired, a slab with a thickness of 36 mm may be produced and then ground and polished to 30 mm, which wastes more 6 mm of material. By flattening the excess material using a press roll or similar device, a more consistent and flat slab can be produced than in the prior art, allowing a slab to be produced that is thinner than 36 mm while still maintaining a thickness of 30 mm for the final product.

Fig. 14 shows an image 1300 of a single-lot produced mat, with the left side mat stretched to a significantly different degree than the right side mat, as compared to a continuously produced mat, in accordance with one embodiment of the present disclosure.

FIG. 15 shows an image 1400 of a continuously produced mat, wherein the degree of stretch is over the whole, according to one embodiment of the present disclosure

The slabs are substantially uniform in length.

Fig. 22 shows a system 2000 configured to produce an artificial Dan Banpi of the present invention (e.g., generally consistent with method 800, method 800 may be performed by system 2000, etc.), in accordance with one embodiment of the present disclosure.

As shown, the example system 2000 includes a mixing unit 2002 configured to combine (or mix) aggregate minerals (e.g., virgin aggregate materials, etc.) such as quartz or glass gravel and powder with resins, colorants, and/or other additives to obtain a micro-wet composite (or micro-wet composite mixture of aggregate minerals) (e.g., substantially the same as step 802 of the method 800 described previously; etc.). After mixing, the composite (or mixture) is conveyed to a first compression unit 2010 by a conveyor 2008 (e.g., a conveyor belt or other support surface, etc.). The first compression unit 2010 is configured to compress the composite material on the conveyor belt 2008 in this example into a dense composite mixture (e.g., as part of a first compression step, etc.) (e.g., substantially the same as step 804 of the method 800 described above, etc.). The conveyor 2008 is then configured to convey the compacted composite mixture to a crushing unit 2012, the crushing unit 2012 being configured to crush the compacted composite mixture into a plurality of fragments. As described above, such disruption of the compressed composite mixture/material may be by a stirring device, dropping the compressed composite mixture/material onto a screen, or disrupting the compacted composite mixture into pieces by other available methods (e.g., substantially the same as step 806 of method 800 described above; etc.).

Once formed, the fragments (formed in the crushing unit 2012) are sent by the conveyor 2008 to a placement unit 2014 configured to place the fragments on a support structure 2016 (e.g., conveyor belt, etc.), as generally described in step 808 of the method 800. During this process, the fragments 2040 may be placed substantially uniformly on the support structure 2016 (e.g., distributed across the width of the support structure 2016, etc.) to avoid situations where some areas of the fragments 2040 are significantly more distributed than others. In at least one embodiment, the conveyor 2008 and the support structure 2016 may be identical, or the support structure 2016 may be placed on top of the conveyor belt 2008 in front of the first compression unit 2010. Accordingly, the support structure 2016 is configured to convey the fragments 2040 to the color application unit 2018. As the fragments 2040 are moved by the support structure 2016 by the system 2000 (in the direction of arrow 2020 in FIG. 22), the color application unit 2018 is configured to apply a colorant to the fragments 2040 on the support structure 2016, and in particular to at least portions of the sidewalls of at least portions of the fragments 2040 (e.g., as generally described in connection with step 810 of the method 800, etc.).

In the illustrated embodiment, the color application unit 2018 includes a digital printing device 2022 (as generally described herein) configured to move to the color application unit 2018 (via the support structure 2016) at the fragment 2040 and apply (e.g., print, etc.) colorant to the fragment 2040 by the color application unit 2018. In this regard, the digital printing apparatus 2022 includes a nozzle 2024 configured to move in X, Y and Z directions relative to the support structure 2016 (and fragments 2040 on the support structure 2016). For example, the nozzle 2024 is operative to move in the X and Y directions (e.g., via a gantry and corresponding support 2026, etc.) to deposit (e.g., print, etc.) a desired colorant (e.g., a desired color, amount of color, etc.) onto the fragments 2040 on the support structure 2016 at a particular X, Y location on the support structure 2016. In addition, the nozzle 2024 is also operated (by the actuator 2028) to adjust the vertical distance (in the Z direction) between the nozzle 2024 and the fragment 2040 so that the nozzle 2024 may maintain a desired distance from the fragment 2040 on the support structure 2016. Although the digital printing apparatus 2022 is described above as including one nozzle 2024, it should be understood that the digital printing apparatus 2022 may include multiple nozzles (as generally described herein) in other embodiments, where the nozzles operate (or do not operate) in a manner similar to the nozzle 2024.

Further, in some embodiments of the system 2000, the color application unit 2018 may also include a device (e.g., a kicker device 10, etc.) configured to form a groove (as generally described herein) in the fragment 2040 when the fragment 2040 is on the support structure 2016 (e.g., before a colorant is added to the fragment 2040, etc.). Then, once the groove is formed in the fragments 2040, the color application unit 2018 (e.g., digital printing device 2022, etc.) operates to apply colorant to at least a portion of the sidewalls of at least some of the fragments 2040 at the groove (e.g., to the sidewalls of the fragments 2040 forming the groove, etc.).

Once the colorant is added to the fragments 2040 on the support structure 2016, the support structure 2016 is configured to move the fragments 2040 (and colorant) to the second compression unit 2030. The second compression unit 2030 is configured to compress and expand the fragments 2040 (as generally described herein, e.g., with reference to step 812 of the method 800). During this process, the fragments 2040 form a continuous, compacted (and uncured) slab 2042 on the support structure 2016. In the illustrated embodiment, the second compression unit 2030 includes a compression roller (e.g., compression roller 1002, etc.) configured to compress the fragments 2040 into a compressed slab 2042 (the entire slab 2042 having integral veins, e.g., as discussed herein in fig. 11, etc.).

Next, in the system 2000, the support structure 2016 is configured to transfer the continuous compressed mat 2042 from the second compression unit 2030 to the cutting unit 2032. The cutting unit 2032 is configured to receive a continuous compressed slab 2042 of material into the cutting unit 2032 while the slab 2042 is on the support structure 2016 and cut the continuous compressed slab 2042 to a desired length (e.g., as generally described in connection with step 814 of the method 800, etc.). In the illustrated embodiment, the cutting unit 2032 includes a cutting blade 2034 configured to move in the Z-direction (e.g., vertically by an actuator 2036, etc.) to cut the continuous compressed slab 2042 into desired lengths (where each cut length of the slab 2042 is uncured).

Finally, in the system 2000, the cut slabs 2042 are transported from the support structure 2016 to the finishing station 2038, where the cut slabs are vacuum pressed (e.g., by a vacuum press, etc.) and then cured (e.g., in an oven, kiln, etc.) to form cured slabs (e.g., artificial stone slabs, etc.). The solidified slab may be further processed (e.g., cooled (e.g., in a cooling tower, etc.), sized, ground to a desired thickness, polished, etc.) as desired.

Fig. 23 illustrates an embodiment of an assembly 2100 included in the system 2000 for adding additional layers of a second material 2102 (e.g., a protective layer of material, a second composite layer of material, etc.) to a continuous compressed mat 2042 after the mat 2042 exits the second compression unit 2030 (e.g., press roll 1002, etc.) and before the mat is transferred to the cutting unit 2032.

As shown, the assembly 2100 includes a second material (layer) 2102 stored on a platform 2104 (generally a storage unit, etc.). Platform 2104 is configured to send second material (layer) 2102 to press roll pair 2106. As the mat 2042 leaves the press rolls 1002 of the second compression unit 2030, the pair of press rolls 2106 is configured to press the second material 2102 into a generally uniformly thick and dense layer that is configured to be laid on top of the continuous compressed mat 2042 (the second compression unit 2030 operates to compress the fragments 2040 into the continuous compressed mat 2042, as described above). In at least one embodiment, the pair of pressure rollers 2106 can be a single pressure roller.

The assembly may also include a supply of PET film 2108. In connection therewith, the PET film 2108 is fed (via rollers 2110, etc.) into a pair of press rolls 2106, thereby pressing the second material 2102 together (e.g., to substantially the same thickness and/or density, etc.) with the PET film 2108 to inhibit cracking of the second material 2102 in the second layer (prior to application to the continuous compressed slab 2042). Then, the pair of rollers 2106 directs the second material 2102 and the PET film 2108 (collectively identified as second layer 2044 in fig. 23) onto the upper surface of the continuous compressed mat 2042 on the support surface 2016 (wherein the second material 2102 and the PET film 2108 (as second layer 2044) are substantially uniformly laid down on the upper surface of the continuous compressed mat 2042). The support surface 2016 then conveys the layered material to a cutting unit 2032, the combined mat is cut to a specified length, and the mat is then conveyed to a vacuum press for compaction in the manner generally described above (after vacuum compaction in the manner generally described herein, at least a portion of the PET film 2108 may be removed from the mat as desired).

Figures 24-26 illustrate features of the present disclosure in which images of natural stone materials can be used to create similar patterns in artificial stone slabs. In connection therewith, fig. 24 shows an image of the pattern required for natural stone to be implemented in artificial stone slabs. The image is mapped (e.g., the pattern in the image is mapped, etc.) onto the patch on the support structure, and then, as shown in fig. 25, a colorant is applied to the patch according to the mapping (e.g., by a digital printing device, manually, etc.). These fragments are then processed as described herein to form an artificial Dan Banpi as shown in fig. 26, which has a texture pattern similar to that of the original image.

Fig. 27 shows a process flow diagram (or method) 2200 of an embodiment for producing a cultured stone slab according to one embodiment of the present disclosure. At step 2202 of fig. 27, the composite material may be uniformly placed on the support structure. The composite material may be formed into a plurality of randomly shaped pieces by a process of compressing and controllably crushing the composite material (such as the processes generally described herein, etc.), most randomly shaped pieces having a desired size range based on weight. It should be noted that although the composite material or randomly shaped pieces may be placed relatively uniformly on the support structure, the upper surface may always be somewhat uneven due to the size and distribution of the composite material or randomly shaped pieces.

In step 2204 of FIG. 27, in a height limiting step, the composite material may be passed under a height limiting device disposed at a predetermined height above the support structure. The height limiting device may slightly compress and/or disrupt the top end portions of the higher composite material or randomly shaped pieces such that the highest point of the composite material or randomly shaped pieces is substantially the same height relative to the support structure as the height limiting device. For example, the top portion of the higher composite or randomly shaped fragment may be compressed or disturbed a distance of about 3-30 mm (e.g., from the highest point of the composite or randomly shaped fragment initially placed on the support structure). In addition, such height limiting effect will reduce the height variation of the entire composite or randomly shaped pieces, and therefore, when additional composite or randomly shaped pieces are added in a later step, portions of the composite or randomly shaped pieces will rest on top of the flat areas formed by the height limiting device without substantially moving or settling to lower points between larger composite or randomly shaped pieces. Embodiments of the height limiting device may be a roller configured to disrupt or compress the composite material or randomly shaped pieces, or a doctor configured to disrupt or scrape the composite material or randomly shaped pieces. The disruption may include flattening or compressing the composite material or randomly shaped pieces, breaking up the composite material or randomly shaped pieces, pushing the composite material or randomly shaped pieces apart so that the higher portions fall to a lower position, or any combination of these actions to ensure that the maximum height of the composite material or randomly shaped pieces is set to be appropriate.

In step 2206 of FIG. 27, after the composite material or randomly shaped pieces pass under the height limiting device, a colorant may be deposited by the digital printing device onto at least some of the flattened (or height limited) upper surfaces and/or at least some of the sidewalls of at least some of the composite material or randomly shaped pieces to print an image. The height limiting device may ensure that the composite material or randomly shaped pieces are at an appropriate height so that the composite material or randomly shaped pieces do not come into contact with one or more nozzles of the digital printing device. But also to ensure that the distance between the nozzle and any given point of the composite or randomly shaped piece is as small as possible so as not to adversely affect the resolution of the digital printing. Since digital printing devices deposit colorant on uneven surfaces, the farther the surface is from the nozzles of the digital printing device, the more blurred or less resolved the print area.

At step 2208 of fig. 27, a composite material or randomly shaped fragment on a support structure (e.g., a first layer of material on the support structure, etc.) may be placed on an upper surface of at least a portion of the composite mixture or randomly shaped fragment thereof that has been placed on the support structure with a colorant applied thereto by a digital printing device (e.g., an additional layer of composite material or randomly shaped fragment may be placed on the first layer of material that has been placed on the support structure, etc.). An example of the number of additional composite or randomly shaped pieces placed may be about 3-20% (by weight) of the initial number of composite or randomly shaped pieces initially placed on the support structure. Additional composite or randomly shaped pieces are placed, most of which (by weight) have a diameter of, for example, between about 5mm and 35 mm.

In an optional additional height limiting step, step 2210 of FIG. 27, composite material or randomly shaped pieces may be passed under a height limiting device (e.g., a second height limiting device, etc.) disposed at a predetermined height above the support structure. The height limiting device may slightly compress and/or disrupt the top portion of the higher composite material or randomly shaped pieces such that the highest point of the composite material or randomly shaped pieces is substantially the same height (or distance) from the support structure as the height limiting device. Likewise, embodiments of the height limiting device may be a roller for disturbing or compressing the composite material or randomly shaped pieces, or may be a doctor blade for disturbing or scraping the composite material or randomly shaped pieces. The disruption may be flattening or compressing the composite or randomly shaped pieces, breaking up the composite or randomly shaped pieces, pushing the composite or randomly shaped pieces apart, causing the higher portions to drop to a lower position, or any combination of these actions to ensure that the maximum height of the composite or randomly shaped pieces is set to be appropriate.

In step 2212 of FIG. 27, in an additional digital printing step (e.g., a second digital printing step, etc.), a colorant may be deposited by a digital printing device onto at least a portion of the sidewalls (and at least a portion of the planar upper surface) of the portion of the composite material or randomly shaped pieces on the support structure to print an image thereon. The height limiting device (e.g., as part of an optional additional height limiting step, etc.) may ensure that the composite material or randomly shaped pieces are at an appropriate height, thereby ensuring that no composite material or randomly shaped pieces are in contact with one or more nozzles of the digital printing device. Furthermore, this ensures that the distance between the nozzle and any given point of the composite or randomly shaped fragment is as small as possible so as not to adversely affect the resolution of the printing. Alternatively, the additional digital printing step may print substantially the same pattern or design as the first printing step, so that the same areas of the composite material or randomly shaped pieces of the different/additional layers have the same colorant or image.

In this manner, using one or more printing devices, colorant can be deposited below and above the support structure in addition to coating portions of its sidewalls with colorant, at least in part on additional composite or randomly shaped pieces (e.g., additional layers, etc.) on the support structure. The operations of steps 2204-2212 may be repeated multiple times as desired for the desired final aesthetic effect.

At step 2214 of FIG. 27, the composite or randomly shaped crumb may be compacted, flattened and expanded into an uncured mat using a press roll or pair of press rolls (as described herein). The uncured sheet material may then be cured (as described herein).

Fig. 28 shows a side view of each step 2302-2314 (which may generally correspond to steps 2202-2214 of process flow diagram 2200) associated with process 2300 of an embodiment of the disclosed method for producing a cultured stone slab. Each view contains an arrow to illustrate the movement (direction) of the material (and support structure) therein.

At step 2302 of FIG. 28 (generally corresponding to step 2202 of FIG. 27), composite material or randomly shaped pieces 2316 are placed on a support structure. As described herein, in embodiments, the majority of randomly shaped pieces contained in the composite material are of a desired size range by weight and are obtained by a process that compresses and controllably crushes the composite material.

In step 2304 of fig. 28 (generally corresponding to step 2204 of fig. 27), composite material or randomly shaped pieces placed on a support structure are moved (or passed) past a height limiting device 2318 in a single height limiting step. As shown, at least a portion of the composite material or randomly shaped pieces have been flattened (e.g., to form a flat upper surface or plateau, etc.).

In step 2306 of fig. 28 (generally corresponding to step 2206 of fig. 27), in a single digital printing step, composite material or randomly shaped pieces on a support structure are deposited with a digital printing device 2320 on top and/or side walls of at least some of the composite material or randomly shaped pieces. It can be seen that the upper flat surface of the composite material or randomly shaped pieces is approximately the same distance from the nozzle of digital printing device 2320.

At step 2308 of fig. 28 (generally corresponding to step 2208 of fig. 27), an additional layer of composite material or randomly shaped crumb 2322 is placed over the existing at least a portion of the composite material or randomly shaped crumb on the support structure (which has been coated with the colorant at step 2306). Thus, additional layers of composite material or randomly shaped fragments 2322 are also placed over the colorant added/printed in step 2306 (e.g., such that the colorant is deposited (or sandwiched) between the composite material or randomly shaped fragments 2316 (or first layer of composite material or randomly shaped fragments) and the additional composite material or randomly shaped fragments 2322 (or second layer of composite material or randomly shaped fragments).

At step 2310 of fig. 28 (generally corresponding to step 2210 of fig. 27), in an optional additional height-limiting step, at least a portion of the top end of the additional layer of composite material or randomly-shaped pieces is flattened by a height-limiting device 2324 (e.g., the additional layer of composite material or randomly-shaped pieces passes or moves under the height-limiting device 2324, etc.). The height limiting device 2324 may be the same device (or the same type of device) as the height limiting device 2318, or may be a different device.

In step 2312 of fig. 28 (generally corresponding to step 2212 of fig. 27), an additional layer of composite material or randomly shaped crumb is deposited by digital printing device 2326 on top of and/or on the sidewalls of the composite material or randomly shaped crumb of at least a portion of the additional layer in an additional digital printing step. The digital printing device 2326 may be the same device (or the same type of device) as the digital printing apparatus 2320, or may be a different device. Also, as shown, the upper flat surface of the additional layer of composite material or randomly shaped crumb 2322 is approximately the same distance from the nozzle of the digital printing device 2326.

In step 2314 of fig. 28 (generally corresponding to step 2214 of fig. 27), a combination of multiple layers of material is compacted, flattened and expanded into an uncured mat using a press roll 1002 or press roll pair 1002 (as described herein).

While the present disclosure has been described with reference to specific illustrative embodiments thereof, many variations and modifications of the invention may be apparent to those skilled in the art without departing from the spirit and scope of the invention. This patent is therefore intended to cover all such changes and modifications as may be reasonably and properly included within the scope of the disclosure's contribution to the art.

Example embodiments are provided to make the disclosure more thorough and to fully convey the scope thereof to those skilled in the art. For a thorough understanding of embodiments of the present disclosure, we list many specific details, such as examples of specific components, devices, and methods. It will be apparent to those skilled in the art that the embodiments may be embodied in many different forms without the specific details and should not be construed as limiting the scope of the invention. In some embodiments, well-known processes, well-known device structures, and well-known techniques have not been described in detail.

The particular dimensions, particular materials, and/or particular shapes disclosed herein are examples and are not intended to limit the scope of the present disclosure. The particular values and ranges of values for the given parameters disclosed herein are not exclusive of other values and ranges of values that may be useful in one or more embodiments disclosed herein. Furthermore, any two particular values of a particular parameter described herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value of the given parameter may be interpreted as disclosing that any value between the first value and the second value may also be used for the given parameter). For example, if parameter X of embodiments herein has a value a while parameter X of embodiments also has a value Z, it is contemplated that parameter X may have a range of values from about a to about Z. Also, it is contemplated that two or more value ranges of the disclosed parameters (whether nested, overlapping, or different) encompass all possible combinations of value ranges that may be stated using the endpoints of the disclosed ranges. For example, if the value range of the parameter X illustrated herein is 1-10, or 2-9, or 3-8, it is also contemplated that other value ranges for the parameter X are possible, including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," and "includes" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, flows, and operations described herein should not be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically indicated as an order of performance. It should also be understood that additional steps or alternative steps may also be employed.

When an element or layer is referred to as being "on," "engaged," "connected" or "coupled" to another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer or intervening elements or layers may also be present. In contrast, when an element is referred to as being "directly on," "directly engaged with," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should also be interpreted in a similar fashion (e.g., "between" and "directly between", "adjacent" and "directly adjacent", etc.). As used herein, the term "and/or" and the phrase "at least one" include any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. The terms "first," "second," and other numerical terms used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the embodiments.

Spatially relative terms, such as "inner," "outer," "back," "lower," "upper," "bottom," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature's illustrated in the figures. In addition to the orientations depicted in the drawings, the spatially relative terms may be used to encompass different orientations of the device in use or operation. For example, if the device in the figures is turned over, other elements or features described as "below" or "on" the back would then be oriented "on" the other elements or features. Thus, the example term "below" may include both directions of "above" and "below. The device may be otherwise oriented (rotated 90 degrees or other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments is intended to be illustrative and description, but is not exhaustive or limiting of the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but may be interchanged where applicable and used in selected embodiments even if not specifically shown or described. The same may be varied. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A method of producing a cultured stone sheet comprising the steps of:

2. The method of claim 1, wherein:

after placing the additional micro-wet composite material onto at least a portion of the plurality of fragments, the additional micro-wet composite material is disturbed in an additional height limiting step using another height limiting means such that the height of the plurality of fragments and the additional composite material at its highest point relative to the support structure is substantially the same as the height of the other height limiting means relative to the support structure.

3. The method of claim 1, wherein:

After the additional digital printing step, the step of placing additional micro-wet composite and the additional digital printing step are repeated.

4. The method of claim 1, wherein:

The image printed in the additional digital printing step is substantially identical to the image printed in the one-time digital printing step and is printed on top of the image printed in the one-time digital printing step.

5. The method of claim 1, wherein:

the primary digital printing step and the additional digital printing step each print a respective image by depositing a colorant on a predetermined area on the support structure.

6. The method of claim 5, wherein:

The colorant is in a liquid state.

7. The method of claim 5, wherein:

the colorant is in the form of particles.

8. A method of producing a cultured stone sheet comprising the steps of:

9. The method as recited in claim 8, wherein:

After placing the slightly wet composite material on the surface supported by the support structure, the composite material is disturbed using the height limiting device such that the height of the highest point of the composite material relative to the support structure is substantially the same as the height of the height limiting device relative to the support structure.

10. The method as recited in claim 8, wherein:

11. The method as recited in claim 8, wherein:

The colorant and predetermined area deposited in the additional digital printing step are substantially the same as the colorant and predetermined area deposited in the one digital printing step.

12. The method as recited in claim 8, wherein:

The colorant is in a liquid state.

13. The method of claim 8, wherein:

the colorant is in the form of particles.

14. A method of producing a cultured stone sheet comprising the steps of:

Depositing the composite pieces on a surface;

15. The method as recited in claim 14, wherein:

The first image and the second image are identical.

16. The method of claim 14, further comprising:

after placement of the additional composite material, the additional composite material is flattened using a second height limiting device such that the flattened fragments and the additional composite material placed thereon have a height relative to the surface that is substantially the same as the height of the second height limiting device relative to the surface.