Cracking and Coloring Engineered Quartz Slabs for Natural Veins

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Solution Overview

Problem

Quartz-based engineered stone lacks natural, random-looking veins and color patterns, which are desirable features in natural stones like marble and granite.

Innovation Solution

A method and apparatus that introduce controlled cracks in a quartz slab and deposit colored materials into these cracks to simulate veins, using a system of vertically drivable devices and a conveyor system controlled by a computer processor to create a matrix of cracks and veins, mimicking the appearance of natural stone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If colored materials are deposited into cracks in quartz slabs to create veins, then the aesthetic appearance and natural look of the stone is improved, but the manufacturing process complexity increases

Engineering Contradiction:
Improveaesthetic appearanceVSAvoidmanufacturing process complexity
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming cracks in the quartz slab before the final polishing stage. The cracks are created at controlled locations and depths, then colored materials are deposited into them. This sequence allows the veins to be formed during the manufacturing process itself, rather than requiring post-processing additions, thereby improving aesthetic appearance while managing manufacturing complexity through systematic planning.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements local quality by applying colored materials specifically to the crack regions where veins are desired, rather than uniformly treating the entire slab. The cracking device creates localized fractures at predetermined positions, and the coloring process targets these specific areas. This approach enhances the natural vein appearance in critical locations while minimizing the overall complexity of the manufacturing process.

Inventive Principle:
Principle #3Local quality

2Shape

If cracks are introduced into the quartz slab to create veins, then the natural stone appearance is improved, but the structural strength of the slab may be compromised

Engineering Contradiction:
Improvenatural stone appearanceVSAvoidstructural strength
Core Design Contradiction:
ShapeVSStrength

Solution Approach 1:

The cracking operation is performed as a preliminary step before final polishing and sealing. By creating the cracks early in the manufacturing process when the slab is still in a raw state, the structural integrity is maintained through subsequent processing steps. The cracks are then filled with colored materials and sealed, transforming potential weakness points into aesthetic features without compromising the overall strength of the finished product.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the potential harm of cracks (which could weaken the structure) into a beneficial aesthetic feature. By intentionally creating controlled cracks and filling them with colored materials, the manufacturing process transforms what would normally be considered defects into desirable vein patterns that mimic natural stone. This approach improves the natural stone appearance while the sealing and polishing processes restore and maintain structural strength.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 method effectively creates quartz slabs with realistic, random-looking veins and color patterns, enhancing their aesthetic appeal while maintaining the durability and resistance of engineered quartz.

Implementation Method 1

a first device which is configured vertically drivable to cause a force to be applied to a first portion of a slab to move vertically out of alignment with an area of the slab surrounding the first portion of the slab and thereby introduces a first crack in the first portion of the slab

Methodology Applied
Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a device for depositing a material having a color configured to deposit a first material having a color into the first crack of the slab, so that the first crack has the first material becomes deposited becoming a vein having the color of the first material

Methodology Applied
Scientific EffectDeposition: Deposition (physical)

Data Source

PatentEP3684517B1Apparatus and method for spraying color into cracks of a moving formed quartz slab to create veins in an engineered stone
Publication Date: 2023.07.12 SQIP LLC
  • EP3684517B1 patent drawingFigure 1
  • EP3684517B1 patent drawingFigure 2
  • EP3684517B1 patent drawingFigure 3

AI summary

An apparatus including a first device which moves a first portion of a soft, damp, slightly pressed slab out of alignment with a majority of the slab and thus introduces a first crack in the slab; and a device for spraying a first colored material into the first crack of the slab. The first device which moves the first portion of the slab out of alignment with the rest of the slab may include a first cylinder. The device for spraying the first colored material in the first crack of the slab may include a robotic apparatus. In at least one embodiment, the apparatus may also include a second device which moves a second portion of the slab out of alignment with the majority of the slab and thereby introduces a second crack in the slab.