HK1243039A1 - Synthetic molded slabs, and systems and methods related thereto - Google Patents

Description

Synthetic molded slabs and systems and methods related thereto

Technical Field

Systems and processes are described herein for forming a synthetic molded slab product, such as a synthetic molded slab that is thermoformed or otherwise compacted into a selected slab shape using a mixture including particulate mineral material, a resin binder, and a pigment, that renders the synthetic molded slab suitable for use in a living or work space (e.g., along a countertop, table top, floor, etc.).

Background

Rubble slabs are common building materials. Granite, marble, soapstone and other quarried stones are often chosen for countertops due to their aesthetic characteristics. Despite the visual appeal of quarried stones, obtaining such quarried stone slabs can be quite expensive and they are often limited to natural color schemes.

The engineered stone slab may be formed from a man-made combination of materials that provide improved stain or heat resistance characteristics as compared to a rubble slab. Engineered stone is typically a combination of particulate mineral material and a binder such as a polymer resin or cement. Some engineered stone slabs, particularly those having a slab size that is large and a grainy appearance, clearly do not achieve the complex appearance and texture of a quarry stone slab.

Disclosure of Invention

Certain embodiments described herein include systems or processes for forming improved synthetic molded slabs suitable for use in living or work spaces (e.g., along a countertop, table top, floor, etc.). In certain embodiments, the synthetic molded slabs can be manufactured to have an appearance similar to one another, unlike quarry derived quarries, which are generally repeatable and intended to be part of the manufacturing process. However, in those embodiments, the appearance of each synthetic molded slab may provide a complex stripe or other veined pattern that mimics a quarried stone slab. For example, each slab can be formed from a combination of differently colored particulate mineral mixes that are vertically dispensed according to a predetermined pattern into vertically oriented molds (thereby facilitating the formation of selected stripes or other vein patterns), which are then turned to a horizontally oriented position for subsequent compression molding and solidification operations. As used herein, "differently colored" means having different combinations of pigments or otherwise having different visual appearances in terms of hue or visual texture.

Particular embodiments described herein include a synthetic molded slab comprising a quartz material. Alternatively, the synthetic molded slab may have a major surface that is at least 2 feet wide by at least 6 feet long and extends perpendicular to the slab thickness. The major surface may have at least one first pigmented vein extending substantially lengthwise from side to side, the first pigmented vein separating at least two other veins extending substantially lengthwise and positioned on opposite edges of the first pigmented vein. The first colored veins optionally have a vein thickness equal to and parallel to the slab thickness.

Certain embodiments described herein include a set of individually molded synthetic slabs. Each respective slab of the set may include at least four different particulate mineral mixes distributed in a series of successive layers according to a predetermined pattern for all of the individually molded synthetic slabs. Each of the four different particulate mineral mixes optionally includes a quartz material, one or more pigments, and one or more resin binders. In a preferred option, each respective slab may be rectangular and may have a major surface that is at least 2 feet wide and at least 6 feet long. At least one of the four different particulate mineral mixes may define a substantially lengthwise vein extending over a majority of the length of each respective slab such that the major surface of each respective slab in the set has a substantially lengthwise vein of similar location and color.

Other embodiments described herein include processes for forming synthetic molded slabs utilizing different particulate mineral mixtures. The process may include positioning the slab mold in a substantially vertical orientation. The process may further comprise dispensing a plurality of different particulate mineral mixes into the substantially vertically oriented mould so as to fill the mould space. Optionally, the mold space is at least 6 feet long by at least 2 feet wide, and the plurality of different particulate mineral mixes each comprise primarily quartz material. The process may further comprise: the mould is adjusted to a substantially horizontal orientation while the different particulate mineral mixes are positioned in the mould. Moreover, the process may include: the particulate mineral mixture disposed in the mold is simultaneously vibrated and compacted while the mold is in a substantially horizontal orientation.

Certain embodiments of the process of forming a synthetic molded slab include pouring a plurality of differently colored particulate quartz mixtures into a non-horizontally oriented mold according to a predetermined pattern. Optionally, the non-horizontally oriented mold defines an interior space having a first edge thickness that is less than and parallel to a second edge thickness proximate the upwardly facing opening of the mold. The process may also include compacting a plurality of differently colored particulate quartz mixtures disposed in the mold while the mold is in the horizontal orientation.

Additional embodiments described herein include a system for forming a synthetic molded slab using a combination of different particulate mineral mixes. The system may include a mold adjustment device configured to reposition the slab mold from a substantially vertical orientation to a substantially horizontal orientation. Alternatively, the slab mold may define a mold space that is at least 6 feet long by at least 2 feet wide. The system may also include one or more mineral aggregate distributors, each configured to vertically distribute a corresponding particulate mineral mixture into a slab mold held by the mold adjustment apparatus.

The systems and techniques described here may provide one or more of the following advantages. First, a system may be used to produce a plurality of synthetic molded slabs, each having a similar vein pattern and suitable for use in a living or work space (e.g., along a countertop, table top, floor, etc.). Such slabs may be formed from a combination of differently colored particulate mineral mixes that are vertically deposited into a vertically oriented mold according to a predetermined and repeatable dispensing pattern, thereby providing a selected vein pattern that mimics a quarried stone slab and is generally repeatable for each of a plurality of individually molded slabs.

Secondly, each slab in the system can be formed by a series of operations including at least a compression moulding operation in which the mould containing the particulate mineral mixture is positioned in a horizontal orientation after the mould is filled in a vertical orientation. For example, the differently colored particulate mineral mixture is poured vertically into a vertically oriented mold, which is then turned to a horizontally oriented position for subsequent compression molding operations (e.g., vibration-compaction molding, etc.) and (in certain embodiments) solidification operations. From there, some or all of the molds are removed from the hardened slab so that at least the major surfaces of the slab are polished to provide an appearance that mimics the complex striations and vein pattern of a quarry stone slab. In certain alternative embodiments, the polished major surface of each synthetic molded slab, unlike a quarry-derived quarry stone slab, provides a very similar appearance to the other slabs in the set of individually molded slabs. Furthermore, the pigment and particulate mineral mix can be selected to provide improved color combinations and visual effects over that which can be obtained with quarry derived quarry rubble slabs, and to provide a variety of color combination options that far exceed that which can be obtained with quarry derived rubble slabs.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

Drawings

Fig. 1A and 1B are perspective views of a synthetic molded slab during and after forming according to some embodiments.

Fig. 2 is a diagram of an exemplary system for forming a synthetic molded slab product, in accordance with certain embodiments.

Fig. 3 is a diagram of another exemplary system for forming a synthetic molded slab product according to other embodiments.

Fig. 4A and 4B are perspective and cross-sectional views of the slab mold adjustment apparatus of fig. 2 and 3 in a horizontal configuration.

Fig. 5 is another cross-sectional view of the slab mold adjustment apparatus of fig. 4A and 4B.

Fig. 6A-6C are perspective and cross-sectional views of the slab mold adjustment apparatus of fig. 4A and 4B in a vertical configuration.

Fig. 7 is a perspective view of an exemplary synthetic molded slab product formed by either of the systems of fig. 2 and 3.

Fig. 8 is a flow diagram of an exemplary process for forming a synthetic molded slab product.

Detailed Description

Referring to fig. 1A and 1B, a system may be used to produce one or more synthetic molded slabs 50 having a plurality of stripes or veins according to a predetermined pattern. Each slab 50 may include a quartz material and/or other particulate mineral material that, when mixed with a pigment and resin binder and subsequently compressed and solidified, provides a hardened slab product suitable for use in a living or work space (e.g., along a countertop, table top, floor, etc.). As shown in fig. 1A-1B, each slab 50 may optionally be formed from a combination of differently colored particulate mineral mixtures that are vertically poured into a vertically oriented mold 130 (see fig. 2) according to a predetermined and repeatable dispensing pattern, the vertically oriented mold 130 providing a generally repeatable selected stripe or other vein pattern for each individual molded slab. The slab mold is oriented vertically and filled from the open end. Successive layers of different particulate mineral mixes (e.g., different pigments, different mineral compositions, different additives, etc.) are poured vertically into the mold according to a predetermined and repeatable dispensing pattern until filling is complete. The open end is closed and the mold 130 is pivoted to a horizontal orientation (see apparatus 150 in fig. 2-3) and transported in the horizontal orientation for compaction, solidification, and other operations. As shown in fig. 1B, depending on the predetermined distribution pattern of the different particulate mixtures, the vertical distribution/stratification process can provide a stratification effect that mimics the veined appearance of a rough slab, such as granite or marble, including certain veils 51, 52, 53, and 54 that extend entirely over the length L of the hardened slab 50 (e.g., at least 2 feet wide by at least 6 feet long, and between about 3 feet to 5 feet wide and between about 6 feet to 14 feet long, preferably about 4.5 feet wide (more particularly, about 140cm wide) by about 10 feet long (more particularly, about 310cm long)). The other veins 55 may extend only partially over the length L of the blank 50. Such differently colored veins 51, 52, 53, 54 can not only extend the entire length of the slab product, but such veins 51, 52, 53, 54 (and portions of veins 55) can also extend through the thickness of the slab 50 (thereby providing a natural vein appearance even if the slab is cut and trimmed to a particular shape in a living or work space (e.g., along a countertop, table top, floor, etc.). Because each slab 50 in the set of individually molded slabs may include a different layer of particulate mineral mix vertically distributed within the mold 130 (see fig. 2) according to a predetermined and repeatable distribution pattern, the plurality of slabs 50 in the set of individually molded slabs may have substantially the same appearance as one another.

Referring now in more detail to fig. 1A-1B and 2, the mold 130 may be vertically oriented during the dispensing of the different particulate mineral mixes into the mold 130. For example, as described in more detail below, the mold 130 may include a housing portion that at least partially defines a space (shown in phantom in fig. 1A) for receiving different particulate mineral mixes via an upwardly-opening 132 of the mold 130. Optionally, each different particulate mineral mix is dispensed from a separate conveyor line (see fig. 2-3) that transports the respective mix to an area above the upwardly facing opening 132 so that the respective mix is then poured vertically into the mold 130. Each conveyor line can transport the respective mixture according to a predetermined pattern such that the different particulate mixtures pour a predetermined series of successive layers into the mold, some or all of which can form veins 51, 52, 53, 54, 55 of the slab 50. Alternatively, each of the successive layers of different particulate mineral mix may be dispensed in different amounts, thereby providing veins or streaks of different size and location. Moreover, each individual layer may have a different size at one end of the mold 130 than at the other end of the mold 130, further improving the complex striations and veining pattern in the hardened slab 50 to more closely mimic a quarried stone slab (e.g., a conventional quarry stone slab, etc.).

In this embodiment, the slab 50 includes four different particulate mineral mixes that are individually delivered and distributed into the upwardly facing openings 132 of the vertically oriented mold 130. The different mixtures may be compression molded in a mold (described in more detail below) and set to provide a hardened slab 50 of composite stone material (fig. 1B). The one or more mixtures used to form the mixture of composite materials may include organic polymer(s) and inorganic (mineral) particulate components. The inorganic (mineral) particulate component may include components such as: silicon, basalt, glass, diamond, rock, cobblestone, shell, a variety of quartz-containing materials such as, but not limited to: crushed quartz, sand, quartz particles, and the like. In this embodiment, all four different particulate mineral mixes each include a quartz material as a major component, which may include sand of various particle sizes and in various combinations. In the hardened slab 50 (fig. 1B), organic and inorganic materials can be joined using a binder, including, for example: monofunctional or polyfunctional silane molecules, dendritic molecules, etc., and the binder may be capable of binding the organic and inorganic components of the composite stone mixture. The binder may also comprise a mixture of various components, such as: an initiator, a hardener, a catalyst, a binding molecule, and a bridge, or any combination thereof. Some or all of the mixture dispensed in the mold 130 (fig. 1A) may include components that are combined in a mixing apparatus (not shown in fig. 1A) prior to being delivered to the mold 130. Mixing devices can be used to blend the raw materials (such as quartz materials, organic polymers, unsaturated polymers, etc.) in various proportions. For example, some or all of the mixture dispensed in the mold 130 may include about 8-95% quartz aggregate and about 5-15% polymer resin. In addition, various additives may be added to the raw materials in the mixing device, which may include metal flakes (e.g., copper particles, etc.), colorants, dyes, pigments, chemical agents, bacteriostatic substances, bactericides, and the like, or any combination thereof. In alternative embodiments, some or all of the amount of quartz aggregate (described above) may be replaced by or include porcelain and/or ceramic aggregate materials.

Still referring to fig. 1A-1B and 2, the mold 130 can be vertically oriented during dispensing of the mineral particulate mixture, whereby a major surface of the mold is positioned in a vertical or substantially vertical position (e.g., 90 degrees ± 10 degrees from horizontal). In these cases, each particulate mineral mixture is poured vertically into the mold and rests on a previously deposited layer of particulate mineral mixture (with the first layer then being deposited onto the closed bottom edge of the vertically oriented mold 130). Preferably, the mold 130 at least partially defines the length L and width W of the hardened slab 50 (as the mold 130 retains the particulate mineral mixture therein throughout the subsequent compaction and solidification processes). In certain embodiments, the width W of the slab 50 formed in the mold 130 is at least 2 feet, between about 3 feet and 5 feet, and preferably about 4.5 feet, and the length L of the slab 50 formed in the mold 130 is at least 6 feet, between about 6 feet and 15 feet, and preferably about 10 feet. Thus, for example, the slab 50 may have a width W of 4.5 feet and a length L of 10 feet. Alternatively, the slab 50 may have a width W of 26 inches and a length L of 10 inches. Other slab sizes within the above range are also hereby contemplated. As such, even though each blank 50 may have a substantial length L, some or all of the veins 51, 52, 53 and 54 may extend the entire length of the blank 50. Further, some of the veins 51, 52, 53 and 54 do not extend the entire length of the blank 50, at least some of those veins that do not extend the entire length of the blank 50 can optionally extend substantially the entire length of the blank 50, such that in an initial inspection, a person viewing the blank initially sees the separated portions of the veins joined to form a full length vein. Optionally, the thickness T at the lower edge of the mold 130 during vertical distribution of the mineral particulate mixture into the mold 130₁May be different from at the opening 132 thereofThickness T of₂. E.g. thickness T₂May be of thickness T₁About twice as much. Different thicknesses T may be used₁And T₂Resulting in: additional compaction of the particulate mineral mixture occurs near the lower edge of the slab as additional layers of particulate mineral mixture are deposited into the mold 130. After the mold 130 is rotated to the horizontal orientation for subsequent compaction and solidification of the slab 50, the mixture is more uniformly compacted together and the mold 130 defines an overall continuous thickness T (fig. 1B) of the slab 50. In certain embodiments, the thickness T of the slab 50 formed in the mold 130 is at least 0.2cm, between 0.2cm and 5cm, and preferably about 3 cm. Each mold 130 may be formed of a structure including a flexible polymer (including an elastomeric material), paper, wood, metal, or a combination thereof.

Referring now to fig. 2, in certain embodiments, the system 100 for forming a set of synthetic molded slab products (e.g., the slab 50 in fig. 1B, the slab 600 in fig. 7, etc.) is configured to vertically pour differently colored particulate mineral mixtures into vertically oriented molds that are then turned into a horizontally oriented position for subsequent compression molding operations (e.g., vibro-compaction molding, solidification, etc.). The system 100 in the depicted embodiment includes an input conveyor 110 and an output conveyor 120. A batch of slab molds 130 are transported on the input conveyor 110. Slab mold 130 provides the shape of a synthetic molded slab product that is at least three feet wide and at least six feet long, about 4.5 feet wide by about 10 feet long for certain embodiments depicted herein. The input conveyor 110 transports the slab mold 130 to a mold positioning station 140, the mold positioning station 140 configured to assist an operator in moving and/or orienting the slab mold 130.

In this embodiment, the slab molds 130 move horizontally (e.g., with respect to gravity) onto the apparatus 150, and the apparatus 150 is used to pivot each mold 130 between a vertical orientation and a horizontal orientation. In this embodiment, the apparatus 150 functions as a tilt table 150 configured to receive one or more of the slab molds 130, secure the slab molds 130, and pivot the slab molds 130 from a horizontal orientation to a vertical orientation (described above), wherein the opening edge (132 in fig. 1A) is positioned on top of the slab molds 130 when in the vertical orientation. For example, in this embodiment, the tipping table 150 is configured to receive and releasably hold one mold 130 at a time. Additional details of this particular embodiment of the tipping platform 150 are described further with respect to fig. 4A-6C. In an alternative embodiment, the tipping table 150 may be configured to receive and releasably hold a plurality of molds 130 at once.

Still referring to fig. 2, in this embodiment, the vertically oriented mold 130 in the apparatus 150 is configured to receive four differently colored mineral mixes (primarily comprising quartz material as described above) that can be delivered from four corresponding mixers and directed to an input device 160, such as a dispenser head or other material transport structure, 160. In this embodiment, each dispenser head 160 is configured to release a different particulate mineral mix (e.g., a different pigment, a different mineral composition, a different additive, or a combination thereof) than the other dispenser heads 160. Each dispenser head 160 is configured to controllably dispense its supply of the corresponding particulate mineral mix for input into the vertically oriented mold 130 held by the tipping table 150. For example, the distribution heads 160 may each be configured with a baffle or valve apparatus (not shown) that can be controlled to regulate the flow of the particulate mineral mixture from the distribution head 160 input into the mold 130. In these embodiments, the distribution head (or other input device for distributing the particulate mineral mixture into the mold 130) may be controlled according to a predetermined control algorithm so as to define successive layers of differently colored particulate mineral mixture for vertical distribution into the slab mold 130 held by the tipping table 150.

When the tipping table 150 holds the mold 130 in a vertical orientation, the upwardly facing opening 132 (fig. 1A) of the mold 130 is positioned below the output (e.g., with respect to gravity) of the mineral aggregate distributor 160. Thus, the particulate mineral mixture is dispensed from the output of the distributor 160 and then through the upwardly facing opening 132 of the die 130 (fig. 1A). Thus, the distributors 160 (each distributor 160 carrying a different particulate mineral mixture according to the pattern to be distributed by its corresponding distribution head) can be used to pour the respective mixture into the vertically oriented moulds 130 to provide a (repeatable for each mould 130 in the line) predetermined series of successive layers. As previously described, some or all of these successive layers of different particulate mineral mixes may form a lengthwise vein of a hardened slab (e.g., slab 50 in fig. 1B, slab 600 in fig. 7, etc.).

In the illustrated example, four mineral aggregate input devices 160 are used, but in other examples, a slab may be formed from between 1 and 20 different particulate mineral mixes, and more preferably between 3 and 8 different particulate mineral mixes (in certain embodiments a system including a corresponding number of input devices 160 will be provided). In certain examples, the number of mineral aggregate distributors 160 may correspond equally to the number of differently colored particulate mineral mixes used to produce the hardened slab product.

After the slab mold 130 held by the tipping table 150 (when in the vertically oriented orientation) has been sufficiently filled, the tipping table 150 pivots or otherwise adjusts the slab mold 130 to the horizontal orientation. The slab mold 130 (now a filled mold 180) moves from the tipping table 150 to the output conveyor 120 on a cushion of air provided by another mold positioning table 170. As shown in fig. 2, successive layers of different particulate mineral mixes distributed vertically into the mold 130 are generally distinct within the filled mold 180 and are arranged in a horizontal orientation on the output conveyor 120. Some or all of these successive layers of different particulate mineral mixes may form a lengthwise vein of the hardened slab (e.g., slab 50 in fig. 1B, slab 600 in fig. 7, etc.).

Optionally, the system 100 may be configured to provide a substantially more "widthwise" or transverse vein 192 (as compared to the substantially "lengthwise" veins 51, 52, 53 and 54 (fig. 1B) defined by successive layers of different particulate mineral mixes previously poured into the mold 130 when the mold 130 is on the tipping table 150). Alternatively, these widthwise veins 192 may be thinner and more widely distributed than the generally "lengthwise" veins defined by successive layers of different particulate mineral mixes. Also, these widthwise veins 192 may be formed of a material having a different coloration than the particulate mineral mix dispensed from the input device 160. For example, the system may be configured to controllably dispense particulate mineral mix for the widthwise veins 192 to selected locations or in a selected pattern for each mold, after which the mold is advanced to a top mold attachment operation 194 or a vibratory compaction press 195 (fig. 2), providing a predetermined pattern of widthwise veins 192 that is repeatable for each filled mold. In some alternative cases, the widthwise veins 192 may not extend through the entire thickness of the hardened slab (which may be different than some or all of the substantially lengthwise veins 51, 52, 53, and 54 (fig. 1B)).

Still referring to fig. 2, the outfeed conveyor 120 may be configured to transport each filled mold 180 to one or more subsequent stations in the system 100 for shaping the hardened slab. For example, each filled mold 180 may continue to a subsequent station where a top mold attachment 194 is positioned on the filled mold 180 to encase the layer of particulate mineral mix between the mold 130 and a top cover mold part (not shown in fig. 2). From there, the filled mold 180 (now including the top-covering mold part) proceeds to a subsequent station where a vibratory compaction press 195 applies compaction pressure, vibration and vacuum to the contents within the filled mold 180 to transform the particulate mixture into a rigid slab. After the vibrocompaction operation, the filled mold 180 (with the compacted and hardened slab therein) proceeds to a setting station 196 where the material used to form the slab (including any resinous binder material) is set via a heating process or other setting process to further strengthen the slab inside the filled mold 180. After the slab has sufficiently solidified (and optionally after the slab is cooled), the main mold 130 and the top mold cover part are removed from the hardened and solidified slab at the mold removal station 197. The primary mold 130 is then returned to the input conveyor 110 (fig. 2). The hardened and solidified slab then moves, in some embodiments, to a polisher station 198 where the major surface of the slab is polished to a finish such that the appearance of the complex striations and vein pattern mimics a quarry stone slab. Alternatively, the buffing machine station 198 is not implemented so that the resulting slab has a major surface that is more textured than a smooth buffed surface. In certain embodiments of the system 100, the polished or otherwise exposed major surface of each synthetic molded slab can provide a substantially repeatable appearance for other slabs (from the other filled molds 180 in fig. 2).

Referring now to fig. 3, another exemplary system 200 for forming a synthetic molded slab product may be configured to simultaneously fill a plurality of vertically oriented molds 130, thereby increasing productivity in certain situations. The system 200 is substantially similar in layout and operation to the system 100 (fig. 2) with the input conveyor 110, the output conveyor 120, the mold positioning stations 140 and 170, the slab mold 130, and the filled mold 180. However, the system 200 includes eight mineral aggregate input devices 160, with four input devices 160 arranged to feed four different particulate mineral mixes into a first vertically oriented mold 130 fixed to the tipping table 150, and another set of four input devices 160 arranged to feed four different particulate mineral mixes into a second vertically oriented mold 130 fixed to a second tipping table 150 (not visible in fig. 3).

Thus, operation of system 200 is substantially similar to operation of system 100 (fig. 2), except that plurality of molds 130 are oriented substantially vertically and filled simultaneously, then adjusted to a horizontal orientation and moved to output conveyor 120 as filled molds 180. As shown in fig. 3, filled molds 180 that are filled simultaneously (in this embodiment, using two adjacent tipping tables 150) may have substantially the same veined appearance defined by successive layers of different particulate mineral mixes poured into each mold according to a predetermined pattern.

Referring now to fig. 4A and 4B, each tilt station 150 in the system 100 or 200 may be configured to receive the mold 130 in a horizontal orientation. The tipping platform 150 is positioned vertically below the fill chute 301 with respect to gravity. In the systems 100 and 200 (fig. 2 and 3, respectively), a chute 301 is located vertically below the gap(s) 166 at the end of the belt 164 to direct filling, for example, from the mineral aggregate distributor 160 into the slab mold 130. The tipping platform 150 includes a set of supports 302 connected by pivot points 306a and 306b (not visible) and a platform base 304. The support 302 provides support to raise the table base 304 from the floor, and the pivot points 306 a-306 b provide bearings by which the table base 304 can tilt relative to the support 302.

As previously described, the mold positioning table 308 provides a mechanism (e.g., rollers, conveyors, actuating arms, etc.) for moving the slab molds into the tilt table 150 between the table base 304 and the top plate 310 (e.g., when the tilt table is in a horizontal configuration). Optionally, film 320 extends across the surface of top plate 310 between top plate 310 and slab mold 130. The film 320 is fed from a feed roll 322 and collected by a take-up roll 324. In use, the optional film provides a protective barrier between the top plate 310 and the filler material deposited into the mold (e.g., to maintain the top plate 310 clean during repeated use in a series of molds 130). The predetermined length of film 320 may be used once for each die filling operation or sequentially for multiple die filling operations before advancing to take-up roll 324 and providing a new length of film 320 from feed roll 322. A set of actuators 350 controllably position the top plate 310 apart from the table base 304 and slab mold 130.

Fig. 5 is another cross-sectional view of the tipping platform 150 of fig. 1-3B. In the illustrated view, the slab mold 130 is positioned in a horizontal orientation within the tilt table 150. The set of actuators 350 is actuated to bring the die shim 402 into contact with the outer periphery of the slab die 130. The set of actuators 350 is actuated to move the top plate 310 toward the slab mold 130, compressing the mold shims 402 between the slab mold 130 and the top plate 310. OptionallyThe combination of the mold shim 402 and the slab mold 130 includes a slight asymmetry in the form of a trapezoidal cuboid (e.g., see T described with respect to fig. 1A)₁And T₂). In the configuration shown in fig. 5, the slab mold provides three edges and one major face in the form of a six-sided trapezoidal rectangular parallelepiped, and the film 320 and the top plate 310 form the other major face. The open end 410 of the slab mold 130 forms a sixth side (e.g., a fourth edge) in the form of a trapezoidal cuboid. In this embodiment, the major faces are oriented at a slight angle to be non-coplanar, with the cuboid having a relatively large thickness (T of FIG. 1A) along the openable end 410₂) And a thickness along the opposite edge (T of fig. 1A) that is less than the thickness along the openable end 410₁). With the tipping table 150 in the configuration shown in fig. 5, the slab mold 130 is ready to be repositioned to a vertical orientation for filling.

Referring now to fig. 6A-6C, the tilt table 150 of fig. 1-5 can adjust the slab mold 130 to a vertical orientation by pivoting about pivot points 306A-b. Specifically, slab mold 130 is oriented to a vertical position by pivoting table base 304, mold positioning table 308, top plate 310, mold shim 402, and film 320 relative to support 302 at pivot points 306 a-306 b. As shown in fig. 6B, in the illustrated example, the slab mold 130 is partially filled with successive layers of different particulate mineral mixes 502 (e.g., partially through a mold filling process; with respect to another example, additionally referring to fig. 1A). As discussed in the description of fig. 2 and 3, the different particulate mineral mix is controllably released via the input device 160 and poured into the chute 301 through the open end 410 (under gravity in this embodiment) and into the slab mold 130. The different particulate mineral mixes 502 include various designs and selected mixes (primarily including quartz material in this embodiment) to pour vertically into the mold 130 in successive layers, which may result in different textured layers 506 a-506 b. As previously described with respect to fig. 1A and 1B, some or all of the vein layers 506 a-506B can extend substantially from side to side and over the length L of the slab mold 130.

As beforeAs described, in this embodiment, the slab mold 130 provides a trapezoidal rectangular parallelepiped form. In the illustrated vertical orientation, the asymmetry of the slab mold 130 occurs from top to bottom, forming a very slight "V" shape (e.g., also referred to as T described with respect to fig. 1A)₁And T₂Description of (d). In certain embodiments, the asymmetry may be selected to at least partially compensate for the effect of gravity on the slight compaction of the different particulate mineral mix 502 at the lower edge of the mold 130 as the mix fills the slab mold 130. Optionally, the vibrator 530 vibrates and/or shakes the slab mold 130 and the particulate mineral mixture 502, thereby facilitating complete filling of the mold 130. Once the slab mold 130 is sufficiently filled with the particulate mineral mixture 502 from the distributor 160 (fig. 2 and 3) according to the predetermined pattern, the slab mold 130 becomes the filled mold 180 (refer to fig. 2 and 3).

Referring now to fig. 6c, an enlarged view of the chute 301 and the open end 410 (also referred to as the upwardly facing opening 132 in fig. 1A) of the slab mold 130 is shown. In this embodiment, the open end 410 includes a mold end cap 520 and the mold end cap 520 is movable about a pivot point 522 to selectively open and close the openable end 410. When the slab mold 130 is sufficiently filled with the filler 502, the mold end caps 520 pivot to a closed position to provide a sixth side of a rectangular parallelepiped shape (e.g., to close the open ends of the filled mold). The tipping table 150 then adjusts the filled mold from a vertical orientation (fig. 6A to 6C) to a horizontal orientation (refer to fig. 4A to 5). The actuator 350 is activated to release the filled mold 180 from the tipping table 150 and the filled mold 180 can be moved out of the tipping table 150 onto the output conveyor 120 (fig. 2 and 3).

Referring now to fig. 7, an example synthetic molded slab product 600 may be formed by either of the systems of fig. 2 and 3 using a combination of differently colored particulate mineral mixes poured vertically into the mold 130 according to a predetermined pattern. In some embodiments, the synthetic molded slab product 600 may provide a textured appearance that mimics a quarry stone slab, such as granite or marble, according to a predetermined distribution pattern of different particulate mixtures. For example, a major surface 612 of the slab 600 may be polished and provide at least some veins 602, 606, and 608 that extend completely across the length of the hardened slab 600 (which may be about 6 feet to about 14 feet long, and preferably about 10 feet long in this embodiment). Other veins 605 and 609 may extend only partially over the length of the slab 50, and some veins 605 may be of much smaller size (but may be of much darker hue). Such differently colored veins (e.g., 602, 605, and 605) can not only extend the entire length of the slab product, but such veins can also extend through the thickness 610 of the slab 600 from a first major face 612 to an opposite major face 614 (thereby providing a natural vein appearance even when the slab is cut and trimmed to a particular shape in a living or work space (e.g., along a countertop, table top, floor, etc.). Further, at least the major surface 612 of the slab 600 may include a plurality of veins 607, the plurality of veins 607 oriented laterally with respect to the veins 602, 605, 606, 608, and 609. Such veins may be defined, for example, by secondary distributors 190 (see fig. 2 and 3). Some of these "width-wise" veins 607 may extend completely across the entire width of the hardened slab 600 (which may be about 2 feet and about 6 feet wide, and preferably about 4.5 feet wide in this embodiment). Because each slab 600 in the set of individually molded slabs (e.g., with reference to the systems of fig. 2 and 3) may include different layers of particulate mineral mix vertically distributed within the mold 130 according to a predetermined and repeatable distribution pattern, the plurality of slabs 600 in the set may have similarly positioned veins in the major surface and may provide substantially the same appearance as one another.

The synthetic molded slab 600 may be cut, milled, machined, or otherwise machined into various shapes and sizes (e.g., to provide a custom countertop surface with optional holes for sinks, faucets, or other fixtures). For example, the sections 630 are cut from the synthetic molded slab product 600. The veins 602 and 605 extend into the interior 606 and/or extend through the thickness 610, and the synthetic molded slab product 600 is cut and/or machined to exhibit veins 602, 605, 606, 608, and 609 in a manner that mimics the aesthetics of a quarried stone slab.

Fig. 8 is a flow diagram of an exemplary process 700 for forming a composite molded slab product, such as the slab 50 or 600 described above. In some embodiments, the system 100 of fig. 2 and 3 may be used to perform the process 700. Process 700 may include operation 710: the slab mold is positioned in a non-horizontal orientation, such as a substantially vertical orientation or another orientation transverse to the horizontal extension. In such an operation, the main faces of the moulds (which will define the main faces of the slab product) may be positioned in a substantially vertical position (about 90 degrees +/-30 degrees (preferably +/-10 degrees) with respect to the horizontal), for example by a tipping table or another mould adjustment device. In certain embodiments depicted above, the major faces of the mold (which will define the major faces of the slab product) can be positioned in a vertically oriented position (about 90 degrees +/-10 degrees from horizontal) by the tipping table 150 (fig. 2 and 3). The process 700 may also include an operation 720: a plurality of different particulate mineral mixes are distributed into a vertically oriented mould. For example, as previously described, a differently colored mixture comprising primarily quartz material (e.g., a mixture comprising particulate quartz material, one or more pigments, and one or more resin binders) may be fed to a vertical pouring operation using one of the distributors 160 (fig. 2 and 3). Thereafter, the process 700 may include operations 730: the mould is adjusted to a horizontal position while the different particulate mineral mixes are positioned in the mould. Again, such operation can be performed, for example, by the tipping table 150 (fig. 2 and 3) or another mold adjustment device. The process 700 may also include an operation 740: while the mold is in a horizontal orientation, the particulate mineral mixture disposed in the mold is simultaneously vibrated and compacted. In these instances, operation 740 may provide a compacted slab of composite stone material. Moreover, in certain embodiments, the process 700 may also include the operations 750: the compacted slab is allowed to set. The process 700 may also include an operation 760: the major surface of the slab is polished to provide a textured appearance on the polished surface of the slab including, but not limited to, the examples described above.

Although various embodiments are described in detail above, other modifications can be made. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims.

Claims (23)

1. A synthetic molded slab comprising a quartz material, comprising:

a major surface at least 2 feet wide by at least 6 feet long and extending perpendicular to slab thickness, the major surface having at least a first colored vein extending substantially lengthwise from side to side, the first colored vein separating at least two other veins extending substantially lengthwise and positioned on opposite edges of the first colored vein, wherein the first colored vein has a vein thickness equal to and parallel to the slab thickness.

2. The synthetic molded slab of claim 1, further comprising: a plurality of transverse pigmented veins extending transverse to and intersecting the first pigmented vein, the transverse pigmented veins having a different color than the first pigmented vein.

3. The synthetic molded slab of claim 2, wherein at least one of the transverse pigmented veins extends substantially widthwise from side to side.

4. The synthetic molded slab of claim 2, wherein the transverse pigmented veins are thinner than the first pigmented vein.

5. The synthetic molded slab of claim 1, wherein the slab comprises different mineral mixtures each comprising a quartz material, one or more pigments, and at least one binder.

6. The synthetic molded slab of claim 5, wherein the slab comprises at least four different colored mineral mixes distributed in a series of successive layers according to a predetermined pattern, a first of the four different colored mineral mixes defining the first colored veins extending generally lengthwise from one edge of the slab to the other.

7. The synthetic molded slab of claim 6, wherein a second of the at least four different colored mineral mixes defines two other veins extending generally lengthwise and positioned on opposite edges of the first colored vein.

8. The synthetic molded slab of claim 7, wherein the two other veins extend generally lengthwise from one edge of the slab to the other.

9. The synthetic molded slab of claim 8, wherein the major surface of the slab is polished and mimics an appearance of a quarried stone slab at least in part due to the four different colored mineral mixes distributed in the series of successive layers according to the predetermined pattern.

10. A set of individually molded synthetic slabs, each respective slab of the set comprising at least four different particulate mineral mixes distributed in a series of successive layers according to a predetermined pattern for all of the individually molded synthetic slabs, the four different particulate mineral mixes each comprising a quartz material, one or more pigments, and one or more resin binders, wherein each respective slab is rectangular and has a major surface that is at least 2 inches wide and at least 6 feet long, wherein at least one of the four different particulate mineral mixes defines substantially lengthwise veins extending over a majority of the length of each respective slab such that the major surface of each respective slab in the set has similarly positioned and colored substantially lengthwise veins.

11. The set of individually molded synthetic slabs of claim 10, wherein at least one of the substantially lengthwise veins of each respective slab extends in the full length direction from one side of the respective slab to the other.

12. The set of individually molded synthetic slabs of claim 11, wherein the major surface of each respective slab of the set further comprises a plurality of transverse pigmented veins extending transverse to and intersecting the substantially lengthwise veins, the transverse pigmented veins having a color different from the substantially lengthwise veins.

13. The set of individually molded synthetic slabs of claim 12, wherein the transverse pigmented veins of each respective slab are thinner than the at least one of the substantially lengthwise veins of the respective slab.

14. A process for forming a synthetic molded slab from a mixture of different particulate minerals, comprising:

positioning a slab mold in a substantially vertical orientation;

dispensing a plurality of different particulate mineral mixes into a substantially vertically oriented mold so as to fill a mold space at least 6 feet long by at least 2 feet wide, each of the plurality of different particulate mineral mixes consisting essentially of a quartz material;

adjusting the mold to a substantially horizontal orientation while the different particulate mineral mix is positioned in the mold; and

simultaneously vibrating and compacting the particulate mineral mixture disposed in the mold while the mold is in the substantially horizontal orientation.

15. The process of claim 14, wherein the dispensing comprises depositing the plurality of different particulate mineral mixes substantially vertically into the mold according to a predetermined and repeatable pattern so as to define successive layers of the plurality of different particulate mineral mixes.

16. The process of claim 15, wherein at least some of the successive layers of the plurality of different particulate mineral mixes provide a lengthwise vein of the synthetic molded slab.

17. The process of claim 14, wherein said dispensing a plurality of different particulate mineral mixes comprises pouring a plurality of differently colored particulate quartz mixes into said substantially vertically oriented mold according to a predetermined pattern.

18. The process of claim 17, wherein the substantially vertically oriented mold defines the mold space, a first edge thickness of the mold space being less than and parallel to a second edge thickness proximate an upwardly facing opening of the mold.

19. The process of claim 18, wherein the simultaneous vibrating and compacting provides a rectangular molded slab having a substantially constant thickness at four edges thereof.

20. The process of claim 17, wherein said pouring according to said predetermined pattern provides successive layers of differently colored particulate quartz mixture, wherein at least some of said successive layers of differently colored particulate quartz mixture provide a lengthwise vein of said synthetic molded slab.

21. A synthetic molded slab formed according to the process of claim 14.

22. A system for forming a synthetic molded slab using a combination of different particulate mineral mixes, comprising:

a mold adjustment apparatus configured to orient a slab mold from a substantially vertical orientation to a substantially horizontal orientation, the slab mold defining a mold space at least 6 feet long by at least 2 feet wide; and

one or more mineral aggregate distributors each configured to vertically distribute a corresponding particulate mineral mixture into the slab mold held by the mold adjustment apparatus.

23. The system of claim 22, wherein the one or more mineral aggregate distributors comprise a distribution head configured to distribute at least first, second, third and fourth differently colored particulate mineral mixtures, wherein the distribution head outputs the at least first, second, third and fourth differently colored particulate mineral mixtures in accordance with a predetermined control algorithm so as to define successive layers of differently colored particulate mineral mixtures for vertical distribution into the slab mold held by the mold adjustment apparatus.