Method of making an artificial stone

Abstract

A method of making an artificial stone is disclosed. The method comprises: (a) spreading a first artificial stone mixture at a first pattern on a manufacturing surface; (b) spreading a second artificial stone mixture across at least a portion of an area of the manufacturing surface, thereby covering at least a portion of the first mixture; and (c) flipping portions of the second artificial stone mixture and exposing portions of the first artificial stone mixture previously covered by the second artificial stone mixture, according to a manipulating pattern, wherein each one of the first artificial stone mixture and the second artificial stone mixture may include polymeric resin and aggregates, and wherein the first artificial stone mixture may differ from the second artificial stone mixture in at least one of: color, type of aggregates, resin, and size of aggregates.

Description

CST-P-017-PCTMETHOD OF MAKING AN ARTIFICIAL STONECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of Israeli Patent Application No. 315786, filed 19 September 2024, entitled “METHOD OF MAKING AN ARTIFICIAL STONE”. The contents of the above application is all incorporated by reference as if fully set forth herein in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates generally to tools for making artificial stones. More specifically, the present invention relates to a method of making an artificial stone by spreading and combining two different artificial stone mixtures on a manufacturing surface.BACKGROUND OF THE INVENTION

[0003] Artificial stones (also known in the art as artificial stones, agglomerated stone, etc.) are widely used as building materials e.g., for kitchen countertops, work surfaces, indoor and outdoor floors, wall claddings, dressing tables, bathtubs, washbowls, and interior articles. Artificial stone products are in great demand due to their ability to be manufactured in a wide variety of patterns and colors that cannot be found in nature and to show superior physical and mechanical performance when compared to natural stone.

[0004] These artificial stones are generally manufactured by mixing 5-20 wt.% unsaturated polyester thermoset or acrylic thermoset compositions and aggregate and / or mineral. The unsaturated polyester thermoset compositions comprise an oligomeric chain comprised of saturated dicarboxylic acids or its anhydride as well as unsaturated dicarboxylic acid or anhydride. These two acids are reacted with one or more di-alcohols. The Resin mixture also comprises a reactive solvent, e.g., styrene, and cobalt-octoate as a curing process accelerator. The acrylic thermoset compositions comprise monomeric units selected from acrylate, methacrylate, and any derivative thereof and a crosslinker. The aggregate and / or mineral can be any type of quartz, quartzite, feldspar, glass particles, clay, calcium carbonate, aluminum hydroxide, magnesium hydroxide, or any combination thereof. The mixture is substantially homogeneous across the entire slab.

[0005] In order to mimic the appearance of natural stones or to form patterns on artificial stones, pigments and different types of aggregates are used at different areas on the surfaceCST-P-017-PCT of the artificial stone. The pigments and / or aggregates are spread in a pattern on top and / or inside of the aggregate / resin mixture prior to pressing and heating.

[0006] There is a need for a method that may allow better spreading and combining of at least two types of mixtures. This new method may allow broader design and appearance options for artificial stones made from at least two different mixtures.SUMMARY OF THE INVENTION

[0007] Some aspects of the invention may be related to a method of making an artificial stone, comprising: (a) spreading a first artificial stone mixture at a first pattern on a manufacturing surface; (b) spreading a second artificial stone mixture across at least a portion of an area of the manufacturing surface, thereby covering at least a portion of the first mixture; and (c) flipping portions of the second artificial stone mixture and exposing portions of the first artificial stone mixture previously covered by the second artificial stone mixture, according to a manipulating pattern, wherein each one of the first artificial stone mixture and the second artificial stone mixture may include polymeric resin and aggregates, and wherein the first artificial stone mixture may differ from the second artificial stone mixture in at least one of: color, type of aggregates, resin, and size of aggregates.

[0008] In some embodiments, manipulating may be by at least one of, flipping, shoveling, mixing, and sweeping, of portions of the first mixture on top of the second mixture. In some embodiments, manipulating the first artificial stone mixture and the second artificial stone mixture may be by an automated manipulator.In some embodiments, the method may further include applying pigments at a second pattern on top of at least one of, the second artificial stone mixture, and the first artificial stone mixture. In some embodiments, applying the pigments is at least one of, after step (a), after step (b) and, after step (c). In some embodiments, the color may be determined based on at least one of: pigment level, pigment concentration, and pigment type.

[0009] In some embodiments, the method may further include pressing and hardening the first and second mixtures. The method may further include at least one intermediate pressing following at least one of: step (a), step (b), and step (c).

[0010] In some embodiments, the polymeric resin may be selected from: unsaturated polyester thermoset resin and acrylic thermoset resin, silicone resin, epoxy resin, polyurethane resin or any combination thereof. In some embodiments, the aggregates mayCST-P-017-PCT be selected from: quartz, quartzite, feldspar, glass particles, clay, calcium carbonate, aluminum hydroxide, magnesium hydroxide, amorphous silica, ceramic frit, ceramic frit, porcelain particles, aluminum oxide or any combination thereof.

[0011] In some embodiments, the manufacturing surface may be selected from a list consisting of: a conveyor, and a mold. In some embodiments, the first pattern may cover between 10 to 100 % of the area of the manufacturing surface.

[0012] In some embodiments, the method may further include spreading a third artificial stone mixture at a third pattern on at least one of the first artificial stone mixture and the second artificial stone mixture, wherein the third artificial stone mixture may differ from the first artificial stone second artificial stone mixture in at least one of: color, type of aggregates, and size of aggregates.

[0013] In some embodiments, the method may further include spreading a fourth artificial stone mixture at a fourth pattern on at least one of the first artificial stone mixture, the second artificial stone mixture, and the third artificial stone mixture, wherein the fourth artificial stone mixture may differ from the first artificial stone mixture, the second artificial stone mixture, and the third artificial stone mixture in at least one of: color, type of aggregates, and size of aggregates.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings in which:

[0015] Fig. 1 is a flowchart of a method of making an artificial stone according to some embodiments of the invention;

[0016] Figs. 2A, 2B, 2C, 2D, 2E, and 2F are illustrations of various steps in the method of making the artificial stone, according to some embodiments of the invention; and

[0017] Figs. 3A and 3B are nonlimiting examples for real designs of artificial stone slabs according to some embodiments of the invention.

[0018] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of someCST-P-017-PCT of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0019] One skilled in the art will realize the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

[0020] Some aspects of the invention may be directed to a methos of making an artificial stone using at least two different artificial stone mixtures. Artificial stone mixtures according to embodiments of the invention may include polymeric resin and aggregates. Therefore, the at least two different artificial stone mixtures may differ in at least one of: color, resin, type of aggregates, and the size of aggregates.

[0021] The method according to embodiments of the invention includes a novel spreading and mixing method at which at least a portion of one artificial stone mixture covers a pattern made from another artificial stone mixture, and mixing or manipulating step is done in order to bring into the visible surface portions of the covered artificial stone mixture.

[0022] In some embodiments, each mixture may include at least 5 wt.% of polymeric resin. In some embodiments, the polymeric resin may be selected from: unsaturated polyester thermoset resin, acrylic thermoset resin, epoxy resin, silicone resin, polyurethane resin or any combination thereof. In some embodiments, the acrylic binder may include a plurality of monomeric units selected from acrylate, or any derivative thereof.

[0023] In some embodiments, the acrylate is selected from methacrylate, methyl methacrylate (MMA), 2-ethylhexyl acrylate (2-EHA), methacrylic acid, 2-ethylhexyl methacrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl methacrylate, isobomyl acrylate, isobomyl methacrylate, and any derivative or combination thereof. In some embodiments, the monomeric unit comprises 2-EHA and MMA. In some embodiments, the MMA and 2-EHA are present at a weight ratio ranging from 5: 1 to 3: 1, respectively.CST-P-017-PCT

[0024] In some embodiments, the polymeric binder may be cross-linked. For example, cross-linked acrylic polymer may include a cross-linker selected from the group comprising of: triethylene glycol diacrylate, trimethylolpropane triacrylate (TMPTA), trimethylolpropane trimethacrylate (TMPTMA), pentaerythritol tetraacrylate, dipentaerithritol hexaacrylate, dendritic acrylates, and methacrylates having at least two functional groups, or any derivative or combination thereof.

[0025] In another example, cross-linked polyester may include styrene, triethylene glycol diacrylate, triethylene glycol dimethacrylate or any derivative or combination thereof.

[0026] In some embodiments, each artificial stone mixture may include at least 80 wt.% aggregates. In some embodiments, the aggregates may be selected from quartz, quartzite, feldspar, nepheline, amorphous silica, glass particles, frits, grits, fused silica, calcium carbonate, marble particles, ceramic particles, porcelain grit or frit or any combination thereof. In some embodiments, the aggregates (also known as inorganic filler) is in the form of a plurality of particles having a median diameter ranging from 0.001 to 10 mm or more. In some embodiments, the inorganic filler may include a mixture of two or more types of aggregates, for example, 50 wt.% quartzite and 50 wt.% quartz, or 20 wt.% quartzite and 80 wt.% quartz.

[0027] Each one of the artificial stone mixtures may further include, one or more pigments, and additional additives. For example, between 0.1 to 10 wt.% of one or more types of additives may be added to any one of the artificial stone mixtures. In some embodiments, the additive may be selected from, a UV stabilizer, a wetting agent, an antibacterial additive, an emulsifier, a mechanical toughener, a scratch resistance additive, a coupling agent, and any combination thereof. In some embodiments, the artificial stone mixture may further comprise a coupling agent (e.g., a silane). In some embodiments, the weight percentage of the coupling agent is between 0.001 to 1 wt.%.

[0028] In some embodiments, each artificial stone mixture may be mixed in a mixer, as known in the art.

[0029] Reference is now made to Fig. 1 which is a flow chart of a method of making an artificial stone according to some embodiments of the invention. In step 10, the method may include spreading a first artificial stone mixture at a first pattern on a manufacturing surface. A nonlimiting example for a first pattern comprising first mixture 15 spread on a manufacturing surface 5, is illustrated in Fig. 2A. The First pattern may be made byCST-P-017-PCT spreading the first artificial stone mixture 15 at specific places on top of manufacturing surface 5. In some embodiments, manufacturing surface 5 may be selected from, a mold, a conveyor, and the like.

[0030] In some embodiments, the first pattern may cover between 10 to 100 % of the area of manufacturing surface 5. For example, the first pattern may cover between 10 to 90%, between 20 to 60%, between 20 to 70%, between 15 to 50%, between 15 to 40%, between 10 to 30% of the area of manufacturing surface 5, or any value or range in between.

[0031] In step 20, the method may include spreading a second artificial stone mixture across at least a portion of an area of manufacturing surface 5, thereby covering at least a portion of the first mixture. In the nonlimiting example illustrated in Fig. 2B, second mixture 25 spread in manufacturing surface 5 may at least partially cover first mixture 15. For example, second mixture 25 may cover between 10 to 100%, between 10 to 90%, between 20 to 60%, between 20 to 70%, between 15 to 50%, between 15 to 40%, between 10 to 30% of the area of manufacturing surface 5, or any value or range in between. In some embodiments, second mixture 25 may cover the entire first pattern. In a nonlimiting example, the first mixture may cover the entire manufacturing surface 5 and the second mixture may fully cover the first mixture, thereby also covering manufacturing surface 5.

[0032] In some embodiments, the first artificial stone mixture may differ from the second artificial stone mixture in at least one of: color, type of aggregates, resin, and size of aggregates. In some embodiments, the color may be determined based on at least one of: pigment level, pigment concentration, and pigment type. For example, the first mixture may include a grey pigment and the second mixture white pigment. In another example, the first mixture may include 2 wt.% of grey-brown pigment and the second mixture may include 0.5 wt.% of grey-brown pigment. In yet another example, the first mixture may include quartzite and feldspar, and the second mixture may include quartz.

[0033] In some embodiments, additional patterns from additional artificial stone mixtures may be spread and added near and / or on top of the first pattern. In the nonlimiting example illustrated in Figs. 2C and 2D, a third artificial stone mixture 16 may be spread at a third pattern on at least one of first artificial stone mixture 15 and second artificial stone mixture 25. In another nonlimiting example illustrated in Figs. 2C and 2D, a fourth artificial stone mixture 17 at a fourth pattern may be spread on at least one of first artificial stone mixture 15, second artificial stone mixture 25, and third artificial stone mixture 16.CST-P-017-PCT

[0034] In the nonlimiting example, illustrated in Figs. 2C and 2D, third artificial stone mixture 16 may at least partially cover first artificial stone mixture 15; fourth artificial mixture 17 may at least partially cover first artificial stone mixture 15 and third artificial stone mixture 16, and second artificial stone mixture 25 covers all the not previously covered areas of manufacturing surface 5, and at least partially covers first artificial stone mixture 15, third artificial stone mixture 16, and fourth artificial mixture 17.

[0035] In some embodiments, first artificial stone mixture 15, second artificial stone mixture 25, third artificial stone mixture 16, and fourth artificial stone mixture 17 may differ from each other in at least one of color, the type of aggregates, resin, and the size of aggregates.

[0036] In step 30, the method may include at least partially flipping portions of the second artificial stone mixture and exposing portions of the first artificial stone mixture previously covered by the second artificial stone mixture according to a manipulating pattern. The outcome of the flipping process may include exposed portions 35 of first mixture 15 previously covered by second mixture 25, as illustrated in Fig. 2E. In some embodiments, each exposed portion 35, may include substantially integrated first mixture 15. The flipping may at least partially change the sequence of the mixtures, where a portion of second mixture 25 is covered by exposed portion 35.

[0037] As used herein, integrated mixture refers to a mixture where different components are thoroughly combined and evenly distributed, often with specific properties or functionalities. In the embodiments of the present invention, each one of first artificial stone mixture 15 and second artificial stone mixture 25 is a different integrated mixture. First artificial stone mixture 15 differs from second artificial stone mixture 25 in at least one of: color, type of aggregates, resin, and size of aggregates.

[0038] In some embodiments, when additional mixtures, such as, third mixture 16 and / or fourth mixture 17, were spread on manufacturing surface 5, as disclosed herein above, the manipulation in step 30, may further expose portions 36 of third mixture 16 and / or portions 37 of fourth mixture 17, as illustrated in the nonlimiting example of Fig. 2F.

[0039] As used herein, a manipulating pattern includes all the locations at which the portions of covered mixture(s) are exposed by the manipulating process. In a nonlimiting example, when each one of first mixture 15 and second mixture 16 cover 100% of manufacturing surface 5, first mixture 15 may be visible only at locations of theCST-P-017-PCT manipulating pattern. In another nonlimiting example, the manipulating pattern may include the locations of: exposed portions 35, exposed portions 36, exposed portions 37, and any combination thereof.

[0040] In some embodiments, the method may further include applying pigments at a second pattern 40 on top of at least one of, second artificial stone mixture 25, and first artificial stone mixture 15, as illustrated in Fig.2E. In some embodiments, the pigment may be applied following step 10, following step 20, and / or following step 30. In some embodiments, more than one type of pigment pattern may be applied. For example, fine pigment pattern 45 may be applied in the vicinity of portions 35, as shown in Fig. 3A, and more coarse pigment pattern 40, as shown in Figs. 2E and 3B. In some embodiments, pigment pattern 40 may include “cloud-like” pigment structures.

[0041] In some embodiments, the method may further include pressing and hardening the first and second mixtures, in order to form an article, (e.g., a slab). In a nonlimiting example, a vibrating press may be used, followed by inserting the pressed mixtures into an oven at a temperature of 70-110C to be cured for 30-90- minutes, to form the article.

[0042] In some embodiments, an intermediate pressing step may be added between the spreading steps, for example, after the completion of step 10, after spreading any one of the other mixtures, and the like. In some embodiments, any pressing method known in the art may be used for pressing the mixtures. In a nonlimiting example, a pressing roller(s) may be applied during the intermediate press. In some embodiments, an additional calibration and / or polishing steps may be conducted to the pressed and cured article, as known in the art.

[0043] Reference is now made to Figs. 3A and 3B which are nonlimiting examples for real designs of artificial stone slabs according to some embodiments of the invention. Slabs 100a and 100b are made using the method disclosed herein above. Slabs 100a and 100b may include a bright area made from a first artificial stone mixture comprising a bright pigment, and portions (e.g., islands) 35 made from a second mixture comprising a darker pigment. Slabs 100a and 100b may further include fine pigment pattern 45 applied at the vicinity of portions 35; and coarse pigment pattern 40. Patterns 40 and 45 were added in order to mimic veins and areas with different colors as in a natural marble.

[0044] Unless explicitly stated, the method embodiments described herein are not constrained to a particular order or sequence. Furthermore, all formulas described herein are intended as examples only and other or different formulas may be used. Additionally, someCST-P-017-PCT of the described method embodiments or elements thereof may occur or be performed at the same point in time.

[0045] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

[0046] Various embodiments have been presented. Each of these embodiments may of course include features from other embodiments presented, and embodiments not specifically described may include various features described herein.

Claims

CST-P-017-PCTCLAIMS1. A method of making an artificial stone, comprising:(a) spreading a first artificial stone mixture at a first pattern on a manufacturing surface;(b) spreading a second artificial stone mixture across at least a portion of an area of the manufacturing surface, thereby covering at least a portion of the first mixture; and(c) flipping portions of the second artificial stone mixture and exposing portions of the first artificial stone mixture previously covered by the second artificial stone mixture, according to a manipulating pattern, wherein each one of the first artificial stone mixture and the second artificial stone mixture comprises polymeric resin and aggregates, and wherein the first artificial stone mixture differs from the second artificial stone mixture in at least one of: color, type of aggregates, resin, and size of aggregates.

2. The method of claims 1, wherein manipulating the first artificial stone mixture and the second artificial stone mixture is by an automated manipulator.

3. The method according to any one of claims 1 to 2, further comprising: applying pigments at a second pattern on top of at least one of, the second artificial stone mixture, and the first artificial stone mixture.

4. The method of claim 3, wherein applying the pigments is at least one of, after step (a), after step (b) and, after step (c).

5. The method according to any one of claims 1 to 4, wherein the color is determined based on at least one of: pigment level, pigment concentration, and pigment type.

6. The method according to any one of claims 1 to 5, further comprising: pressing and hardening the first and second mixtures.

7. The method according to any one of claims 1 to 6, further comprising at least one intermediate pressing following at least one of: step (a), step (b), and step (c).

8. The method according to any one of claims 1 to 7, wherein the polymeric resin is selected from: unsaturated polyester thermoset resin and acrylic thermoset resin, silicone resin, epoxy resin, polyurethane resin or any combination thereof.

9. The method according to any one of claims 1 to 8, wherein the aggregates are selected from: quartz, quartzite, feldspar, glass particles, clay, calcium carbonate,CST-P-017-PCT aluminum hydroxide, magnesium hydroxide, amorphous silica, ceramic frit, ceramic frit, porcelain particles, aluminum oxide or any combination thereof.

10. The method according to any one of claims 1 to 9, wherein the manufacturing surface is selected from a list consisting of: a conveyor, and a mold.

11. The method according to any one of claims 1 to 10, wherein the first pattern covers between 10 to 100 % of the area of the manufacturing surface.

12. The method according to any one of claims 1 to 11, further comprising: spreading a third artificial stone mixture at a third pattern on at least one of the first artificial stone mixture and the second artificial stone mixture, wherein the third artificial stone mixture differs from the first artificial stone second artificial stone mixture in at least one of: color, type of aggregates, and size of aggregates.

13. The method according to claim 12, further comprising: spreading a fourth artificial stone mixture at a fourth pattern on at least one of the first artificial stone mixture, the second artificial stone mixture, and the third artificial stone mixture, wherein the fourth artificial stone mixture differs from the first artificial stone mixture, the second artificial stone mixture, and the third artificial stone mixture in at least one of: color, type of aggregates, and size of aggregates.

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