Synthetic Molded Slabs With Stenciled Veining Patterns
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Solution Overview
Problem
Existing technologies fail to efficiently produce innovative engineered stone slabs that replicate the complex look and texture of quarried stones, with existing engineered stones lacking the aesthetic appeal and natural veining patterns of quarried stones.
Innovation Solution
A system and process for forming synthetic molded slabs using differently pigmented particulate mineral mixes dispensed through complementary stencils into molds, followed by compression molding and curing, to create slabs with repeatable and predefined striations and veining patterns emulating quarried stone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If engineered stone slabs are formed from man-made combination of materials, then stain-resistant and heat-resistant properties are improved, but aesthetic appeal and natural veining patterns are worsened
Solution Approach 1:
The patent divides the engineered stone slab into multiple layers, each containing different particulate mineral mixes with distinct veining patterns. This segmentation allows each layer to contribute specific aesthetic characteristics while maintaining the overall stain-resistant and heat-resistant properties of the engineered stone construction.
Solution Approach 2:
Different regions of the engineered stone slab are given different local qualities by incorporating various particulate mineral mixes with different pigments and veining patterns into specific layers. This creates localized aesthetic variations that emulate natural quarried stone while maintaining consistent performance properties throughout the slab.
2Productivity
If existing engineered stone slabs are produced, then manufacturing efficiency is improved, but ability to replicate complex look and texture of quarried stones is worsened
Solution Approach 1:
The patent incorporates veining patterns and aesthetic features into the engineered stone slabs during the manufacturing process itself, rather than attempting to replicate them afterward. The particulate mineral mixes are prepared and layered with predetermined veining patterns before the slab is formed, allowing complex textures to be created efficiently during production rather than requiring post-processing.
3Ease of manufacture
If natural quarried stone slabs are used, then aesthetic properties and natural veining patterns are improved, but cost and availability are worsened
Solution Approach 1:
The patent creates engineered stone slabs that copy and emulate the aesthetic properties of natural quarried stones by using particulate mineral mixes with carefully selected pigments and veining patterns. The multi-layer construction with different mineral mixes replicates the complex appearance of natural stone while providing the consistency, availability, and cost-effectiveness of manufactured materials.
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 process produces slabs with consistent veining patterns and aesthetic appeal similar to quarried stones, offering a variety of color combinations and visual effects beyond natural stones, suitable for use in living or working spaces.
Implementation Method 1
The first distributor outputs the first pigmented particulate mineral mix through a first stencil positioned over the slab mold and into the slab mold according to a first stencil pattern
Implementation Method 2
The process may further include vibrating and/or compacting the pigmented particulate mineral mixes arranged in the slab mold so as to form a synthetic molded slab
Data Source
AI summary
This document describes systems and processes for forming synthetic molded slabs, which may be suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).