Metallic Stone Slab Composition for Quarried-Stone Veining
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Solution Overview
Problem
Existing stone slabs lack the ability to replicate the aesthetic and tactile characteristics of quarried stones while providing improved durability and resistance to stains and heat, and do not effectively incorporate metal components for a metallic finish.
Innovation Solution
Manufacturing stone slabs with a combination of particulate mineral mixes, including varying metallic content, mesh sizes, and textures to create patterns resembling quarried stone veins, and using a binder to consolidate these mixes into a hardened slab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stone slabs are used to achieve aesthetic properties, then the visual appeal is maintained, but durability and resistance to stains and heat are insufficient
Solution Approach 1:
The patent applies composite materials by combining metal particles (providing durability, heat resistance, and stain resistance) with binder materials and pigment particles to create a manufactured slab that replicates the aesthetic properties of natural stone while superior performance characteristics. The composite structure allows each component to contribute its beneficial properties.
Solution Approach 2:
The patent utilizes parameter changes by varying the size, concentration, and distribution of metal particles within the slab composition. Different mesh sizes (e.g., 100 mesh, 200 mesh, 400 mesh) are employed to create varied metallic effects and textures, allowing control over the visual appearance and physical properties of the final product.
2Manufacturing precision
If metal components are incorporated to provide metallic finish, then aesthetic appeal and durability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the metal component into multiple discrete particles of different sizes rather than using solid metal blocks or sheets. This particle-based approach allows the metal to be uniformly distributed throughout the slab matrix, creating consistent metallic finishing across the surface while simplifying the manufacturing process.
Solution Approach 2:
The patent implements local quality by creating regions with varying metal particle concentrations and sizes within different areas of the slab. This allows for heterogeneous metallic effects, such as veining patterns or gradient finishes, where specific locales have enhanced metallic characteristics while other areas maintain different aesthetic properties.
3Adaptability or versatility
If multiple particulate mineral mixes with different characteristics are used, then aesthetic variety and texture are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining multiple particulate mineral mixes containing different metal particle sizes, pigment particles, and binder materials into a single integrated slab product. This consolidation of multiple material components into one manufactured item achieves aesthetic variety and textured surfaces while streamlining the manufacturing process through simultaneous incorporation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting slabs exhibit a metallic appearance and texture, enhancing the aesthetic appeal while offering improved durability and resistance to stains and heat, without the environmental impact of quarrying.
Implementation Method 1
The first particulate mix includes first metallic particles having a first mesh size and second metallic particles having a second mesh size different than the first mesh size... The resulting slabs exhibit a metallic appearance and texture
Data Source
AI summary
Stone slabs, and systems and methods of forming slabs, are described. Some example slabs include a first pattern defined by a first particulate mineral mix and a second pattern defined by a second particulate mineral mix different from the first particulate mineral mix. The first particulate mix includes greater than 50 weight percent of first metallic particles.