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WO2025072188A1 - Dalles de pierre à faible teneur en silice cristalline, systèmes et procédés - Google Patents

Dalles de pierre à faible teneur en silice cristalline, systèmes et procédés Download PDF

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Publication number
WO2025072188A1
WO2025072188A1 PCT/US2024/048193 US2024048193W WO2025072188A1 WO 2025072188 A1 WO2025072188 A1 WO 2025072188A1 US 2024048193 W US2024048193 W US 2024048193W WO 2025072188 A1 WO2025072188 A1 WO 2025072188A1
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Prior art keywords
slab
crystalline silica
processed
low crystalline
less
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PCT/US2024/048193
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English (en)
Inventor
Jon Louis GRZESKOWIAK II
Martin E. Davis
Michael Raymond MEAD
Lauren WARMKA
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Cambria Co LLC
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Cambria Co LLC
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/20—Silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C04B2111/542—Artificial natural stone

Definitions

  • This document describes stone slab products, systems, and processes for stone slab products, for example, stone slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like) and having silica-based components that provide a low crystalline silica content.
  • Stone slabs are a commonly used building material. Granite, marble, soapstone, and other quarried stones are often selected for use as countertops due to their aesthetic properties. Stone slabs may also be formed from a combination natural and other materials that can provide improved stain resistant or heat resistant properties, aesthetic characteristics, reproducibility, etc. Some stone slabs have been made from a combination of particulate mineral material and binder, such as a polymer resin or cement, and have a colored pattern.
  • slabs having low crystalline silica content suitable for use in living or working, and systems and processes for forming such stone slabs.
  • slabs can be manufactured by forming a cured and hardened slab that includes a low crystalline silica material.
  • slabs can be manufactured by at least partially filing a slab mold with one or more particulate mineral mixes, including a particulate mineral mix made up partially, predominantly, or completely of low crystalline silica material, binder, and/or one or more pigments, and then curing and/or hardening the contents of the slab mold to form a slab.
  • a stone slab includes multiple regions of different particulate mineral mixes that have different characteristics, such as different low crystalline silica material content, chemical composition, sheen, hardness, thickness, roughness, gloss, etc.
  • an aspect disclosed herein is a processed slab formed from a plurality of particulate mineral mixes, including a slab width that is at least 2 feet, a slab length that extends perpendicular to the slab width and that is at least 6 feet, and a slab thickness extending perpendicular to the slab width and the slab length, the slab length greater than the slab width, the slab width greater than the first slab thickness; the processed slab having a crystalline silica content that is less than 50% by weight (wt %).
  • the processed slab where the crystalline silica content can be less than or equal to 1 wt %.
  • the first particulate mineral mix can include greater than 50 % of a low crystalline silica material selected from the group may include of fused quartz, soda-lime glass, nepheline syenite, feldspar, wollastonite, albite, and amorphous silica.
  • the processed slab may include quartz at an overall slab wt % that can be less than or equal to an overall slab wt % of the low crystalline material.
  • the tow crystalline silica material may include more than 30 wt % fused quartz.
  • the low crystalline silica material may include more than 30 wt % soda-lime glass.
  • the low crystalline silica material may include more than 30 wt % nepheline syenite.
  • the low crystalline silica material may include more than 30 wt % of feldspar.
  • the low crystalline silica material may include more than 30 wt % of amorphous silica.
  • the low crystalline silica material can have an abrasion resistance in a range from 80 to 90 on the taber index.
  • the processed slab may include quartz at a wt % that can be less than the low crystalline silica material wt %.
  • the processed slab where the processed slab may include a low crystalline silica material and a binder.
  • the processed slab may include a pigment at a pigment wt %.
  • the low crystalline silica material can have a b’ value that can be less than 0 in a hunter color space.
  • the processed slab can have a different pigment wt % that can be less than the pigment wt % when the low crystalline silica material can have the b greater than or equal to 0 in a hunter color space.
  • an aspect disclosed herein is a process of forming a processed slab from a plurality of different particulate mineral mixes, the process including dispensing a first low crystalline silica mineral mix to a first set of regions of a slab mold; dispensing a second low crystalline silica mineral mix to a second set of regions of the slab mold; contemporaneously vibrating and compacting the first particulate mineral mix and the second particulate mlnerai mix arranged in the slab mold so as to form a processed, molded slab that is generally rectangular and has a slab thickness and a major surface having a slab width of at least 2 feet and a slab length of at least 6 feet; and curing the processed molded slab into a cured slab.
  • the process where the first low crystalline silica mineral mix can include a predominate mineral material selected from the group may include of fused quartz, soda-lime glass, nepheline syenite, feldspar, wollastonite, albite, amorphous silica.
  • the second low crystalline silica mineral mix can include a predominate mineral material selected from the group may include ef fused quartz, soda-lime glass, nepheline syenite, feldspar, wollastonite, albite, amorphous silica.
  • the first low crystalline silica mineral mix and the second low crystalline silica mineral mix may include a binder.
  • the process may include abrading a major surface of the cured slab.
  • some embodiments described herein include stone slabs having a low crystalline silica content.
  • the particulate mineral mix can be arranged in a pattern, and/or can define some or all of a top major surface of the finished slab.
  • some embodiments described herein provide an aesthetic appearance that accentuates and/or exaggerates various characteristics of quarried stone slabs.
  • some stone slabs described herein provide a pattern having geometric characteristics suggestive of patterns of quarried stone slabs.
  • some embodiments described herein can provide stone slab products that have a tactile and/or visible texture.
  • one or more surfaces of the slab includes regions of different tactile and/or visible characteristics, for example different tactile and/or visible characteristics associated with the low crystalline silica composition of the stone slab.
  • some embodiments described herein can provide stone slab products that have a texture that resembles that of quarried stone.
  • some embodiments described herein can provide stone slab products that have an aesthetic appeal similar to that of quarried stone and with improved performance benefits such as heat and stain resistance and reproducibility, but without the cost and/or perceived environmental impact associated with stone quarrying.
  • FIG. 1 is a perspective view of an example processed slab., in accordance with some embodiments.
  • FIG. 2 is a d iagram of an example system for forming a processed slab product, in accordance with some embodiments.
  • FIG. 3 is a diagram of an example system for applying a surface treatment to texturize a processed slab product, in accordance with some embodiments.
  • FIGS. 4 and 5 are diagrams of example systems for applying a surface treatment to texturize a processed slab product, in accordance with some embodiments.
  • FIG. 6 is a flow diagram of an example process for producing a processed slab product, in accordance with some embodiments.
  • this document describes stone slabs, systems and methods that provide a slab having low crystallized silica materials.
  • the most common form of crystalline silica is quartz.
  • Other examples include cristobalite and tridymite.
  • some embodiments provide stone slabs that include a pattern, such as a pattern defined by a particulate mineral mix having a relatively low crystallized silica content.
  • processed stone slabs having textured faces can be manufactured by abrading a cured (e.g., hardened) slab having exposed regions of different component materials that abrade or erode differently (e.g., at different rates when subjected to a common treatment), and/or otherwise reveal different textures due to the abrasion.
  • hardened materials are worn down in different manners to produce one or more different surface characteristics based on the component materials (e.g., and in an example embodiment does not include imparting a pattern into soft, uncured materials and then allowing the pattern to harden).
  • an example stone slab includes varying texture that caricatures natural erosion and fissuring and/or provides different characteristics that create a predetermined aesthetic and tactile characteristics.
  • the term “about” will be understood by persons of ordinary skill in the art and will vary to some extent on the context in which it is used. As used herein when referring to a measurable value such as an amount, a temporal duration, and the like, the term “about” is meant to encompass variations of ⁇ 20% or ⁇ 10%, including ⁇ 5%, ⁇ 1%, and ⁇ 0.1% from the specified value, as such variations are appropriate to perform the disclosed methods.
  • an example slab 50 can be formed from a combination of different particulate mineral mixes that are poured into different, designated regions of a respective mold (while the mold Is horizontally oriented, for example). These designated regions are repeated for each mold in a series of molds (described in more detail below) due to, for example, a set of stencil structures that can be positioned over each mold and that provide a predefined complementary and repeatable dispensation pattern for the particulate mineral mixes in each mold.
  • the predefined complementary and repeatable dispensation pattern for the particulate mineral mixes provides the selected striations and veining patterns that are generally repeatable for each separately molded slab.
  • the dispensation process can provide an aesthetic effect that emulates or accentuates a veined appearance of natural quarried stone slabs such as granite or marble, including an example region 51 and another example region 52 that extend partly or fully across a complete length L of the hardened slab 50.
  • the regions 51 and 52 have thicknesses that extend entirely through the thickness T of the slab 50, for example. Such thicknesses can provide an appearance in which the pattern defined by the particulate mineral mixes are visible through the entire thickness T of slab 50 along periphery edges, such as when slab 50 is cut for installation.
  • the finished slab 50 has a major surface 60 having various aesthetic and tactile features and characteristics such as color, sparkle, roughness, height, depth, sheen, and/or other characteristics. In some embodiments, the characteristics differ between regions in the finished slab 50. In an example embodiment, regions 51 and 52 have aesthetic appearances and/or tactile characteristics that differ from the other of regions 51 or 52. Alternatively or additionally, the entire major surface 60 has a consistent texture (e.g., consistent smooth, glossy surface) that differs in aesthetic characteristics between regions 51 and 52. such as different color, tonality, visible particle size/shape, etc.
  • the slab 50 is at least 3 feet wide by at least 6 feet long, e.g., between about 3 feet and 6 feet wide and between about 6 feet and 12 feet long, between about 4.5 feet and 5.5 feet wide and between about 10 feet and 11 feet long, and preferably a size selected from one of about 4.5 feet wide by about 10 feet long or about 5.5 feet wide by about 11 feet long. Not only can such regions
  • 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and 52 extend across the full length of the slab product, but such regions 51 and
  • each slab 50 in the set of separately molded slabs can include the layers of different particulate mineral mixes dispensed into the mold according to the predefined and repeatable dispensation patterns of complementary stencils, multiple slabs 50 in the set of separately molded slabs can have substantially the same appearance to one another.
  • the slab 50 comprises two different particulate mineral mixes that are separately dispensed into the mold through two complementary stencils (e.g., a first stencil that is essentially a negative of a second stencil).
  • three or more stencils may be used to repeatably pattern the distribution of three or more different particulate mineral mixes that are separately dispensed into the mold.
  • the different mixes dispensed into each mold according to the repeatable pattern can be compaction molded and cured in the mold so as to provide the hardened slab 50.
  • One or more of the mixes that are used to form the composite stone material include an inorganic component.
  • the inorganic component includes a low crystalline silica material.
  • the low crystalline silica material includes a high percentage by weight ef non-crystalline silica, such as amorphous silica, and a Sow percentage by weight of crystalline silica (e.g., quartz). Some examples of the low crystalline silica material include no crystalline silica (e.g., 0 wt %).
  • the low crystalline silica material facilitates production of a slab having a low overall crystalline silica content, such as less than or equal to 50 wt %, less than or equal to 40 wt %, less than or equal to 30 wt %, less than or equal to 20 wt %, less than or equal to 10 wt %, less than or equal to 5 wt %, less than or equal to 2 wt %, less than or equal to 1 wt %, or about or equal to 0 wt % overall crystalline silica content of the slab.
  • a low overall crystalline silica content such as less than or equal to 50 wt %, less than or equal to 40 wt %, less than or equal to 30 wt %, less than or equal to 20 wt %, less than or equal to 10 wt %, less than or equal to 5 wt %, less than or equal to 2 wt %, less than or equal to 1 w
  • the low crystalline silica material includes a variety of low crystalline silica materials, such as, for example, but not limited to: fused quartz, soda-lime glass, nepheline syenite, feldspar, wollastonite, albite, amorphous silica, and the like, or any combination thereof.
  • all of the different particulate mineral mixes e.g., that define respective veins or regions of the slab pattern
  • the tow crystalline silica material is provided as a blend of low crystalline silica grit, and low crystalline silica powder.
  • blends of the low crystalline silica material include a range from about 80 wt % grit to about 60 % grit, to a range from about 40 wt % powder to about 20 wt % powder (e.g., a range from about 75 wt % grit to about 65 % grit, to a range from about 35 wt % powder to about 25 wt % powder, or a range from about 72 wt % grit to about 68 % grit, to a range from about 32 wt % powder to about 28 wt % powder).
  • the low crystalline silica grit has a particle size meeting a mesh value threshold.
  • Mesh is a measurement of particle size used in determining the particlesize distribution of a granular material.
  • the size distribution of the low crystalline silica grit can be defined by a fraction having different mesh sizes.
  • the low crystalline silica grit can have 50+ Mesh (M) size fraction (e.g., larger than 50 M), a 50 M fraction, a 70 M fraction, a 100 M fraction, a 140 M fraction, or a 140- M fraction (e.g., smaller than 140 M).
  • M Mesh
  • the fractions listed sum to about 100, e.g., 100 % of the grit sizes.
  • the low crystalline silica grit has a +50 Mesh (M) size fraction in a range from about 0 to about 3 (e.g., in a range from about 0.01 to about 5, In a range from about 0.1 to about 8), a 50 M size fraction in a range from about 1 to about 50 (e.g., in a range from about 1 to about 40, in a range from about 1 to about 30), a 70 M size fraction in a range from about 10 to about 50 (e.g., in a range from about 10 to about 40, in a range from about 10 to about 30), a 100 M size fraction in a range from about 15 to about 50 (e.g., in a range from about 15 to about 40, in a range from about 15 to about 30), a 140 M size fraction in a range from about 1 to about 15 (e.g., in a range from about 1 to about 12, in a range from about 1 to about 10), a -140 M size fraction in a range from about 0 to
  • the low crystalline silica powder has a particle size distribution such that the majority of the particles have a diameter of less than 1300 ⁇ m, e.g., less than 800 ⁇ m, less than 500 ⁇ m, less than 200 ⁇ m, less than 100 ⁇ m, or less than 50 ⁇ m).
  • the particle size distribution can be defined using values for D90, D50, and/or D10. As used herein, the length unit of D90 represents 90% of particles, D50 represents 50% of particles, and D10 represents 10% of particles in the powders being smaller than this size.
  • the low crystalline silica powder has a particle size distribution such that the D90 is less than 100 ⁇ m, e.g., less than 80 ⁇ m, less than 50 ⁇ m; the D50 is less than 30 ⁇ m, e.g., less than 20 ⁇ m, less than 18 ⁇ m; and/or the D10 is less than 5 ⁇ m, e.g., less than 3 ⁇ m, less than 2 ⁇ m.
  • the particulate mineral mixes that define regions 51 and 52 predominately include the low crystalline silica material, such as at least 30 wt %, at least 50 wt %, at least 70 wt %, or more of a low crystalline silica material.
  • some of the particulate mineral mixes include a relatively low content of quartz by weight compared to the other components of the mixture (e.g., less than the low crystalline silica material by weight).
  • Some examples of the mineral mixes do not include quartz.
  • the particulate mineral mixes of regions 51 include quartz
  • the particulate mineral mix of region 52 does not include quartz.
  • the particulate mineral mixes can include quartz equal to or less than the low crystalline silica material by weight.
  • the low crystalline silica material includes fused quartz.
  • the fused quartz can provide the low crystalline silica material in a processed slab in a range from 5 wt % to 90 wt % of the processed slab (e.g., from 10 wt % to 90 wt %, from 25 wt % to 90 wt %, from 40 wt % to 90 wt %, from 50 wt % to 90 wt %, from 80 wt % to 90 wt %, from 50 wt % to 85 wt %, from 60 wt % to 85 wt %, or from 75 wt % to 85 wt %).
  • the low crystalline silica material includes sodalime glass.
  • the soda-lime glass can provide the low crystalline silica material in a processed slab in a range from 5 wt % to 90 wt % of the processed slab (e.g., from 10 wt % to 90 wt %, from 25 wt % to 90 wt %, from 40 wt % to 90 wt %, from 50 wt % to 90 wt %, from 80 wt % to 90 wt %, from 50 wt % to 85 wt %, from 60 wt % to 85 wt %, or from 75 wt % to 85 wt %).
  • the low crystalline silica material includes nepheline syenite.
  • the nepheline syenite can provide the low crystalline silica material in a processed slab in a range from 5 wt % to 90 wt % of the processed slab (e.g., from 10 wt % to 90 wt %, from 25 wt % to 90 wt %, from 40 wt % to 90 wt %, from 50 wt % to 90 wt %, from 80 wt % to 90 wt %, from 50 wt % to 85 wt %, from 60 wt % to 85 wt %, or from 75 wt % to 85 wt %).
  • the low crystalline silica material includes feldspar.
  • the feldspar can provide the low crystalline silica material in a processed slab in a range from 5 wt % to 90 wt % of the processed slab (e.g., from 10 wt % to 90 wt %, from 25 wt % to 90 wt %, from 40 wt % to 90 wt %, from 50 wt % to 90 wt %, from 80 wt % to 90 wt %, from 50 wt % to 85 wt %, from 60 wt % to 85 wt %, or from 75 wt % to 85 wt %).
  • the low crystalline silica material includes amorphous silica.
  • the amorphous silica can provide the low crystalline silica material in a processed slab in a range from 5 wt % to 90 wt % of the processed slab (e.g., from 10 wt % to 90 wt %, from 25 wt % to 90 wt %, from 40 wt % to 90 wt %, from 50 wt % to 90 wt %. from 80 wt % to 90 wt %, from 50 wt % to 85 wt %, from 60 wt % to 85 wt %, or from 75 wt % to 85 wt %).
  • the particulate mineral mixes that define regions 51 and 52 include low crystalline silica material by weight as an alternative to a ‘high' crystallized silica particulate mineral mix, e.g., a particulate mineral mix having a substantial quantity by weight of quartz.
  • a particulate mineral mix can include about 60 wt % quartz grit, about 30 wt % quartz powder, e.g.. in a range from about 50 to 70 % quartz grit, and about 40 wt % to about 20 wt % quartz powder.
  • the low crystalline silica mineral mixes defined herein include SO wt % low crystalline silica grit, about 30 wt % low crystalline silica powder, e.g., in a range from about 50 to 70 % low crystalline silica grit, and about 40 wt % to about 20 wt % low crystalline silica powder.
  • Low crystalline silica material can facilitate a finished stone slab having a desirable aesthetic appearance.
  • Some low crystalline silica materials described herein facilitate production of a stone slab 50 having a particular color, such as a relatively blue color, and/or the color can be achieved while using relatively iess or no pigment due to the characteristics of the low crystalline silica material.
  • a low crystalline silica material described herein such as soda-lime glass, nepheline syenite, feldspar, wollastonite, albite, amorphous silica
  • a finished slab having a blue color e.g., 'b : values equal to or less than 0 in the Hunter color space
  • less than or equal to 2 wt % pigment less than or equal to 1 wt % pigment, less than or equal to 0.5 wt % pigment, less than 0.2 wt % pigment.
  • the color of a low crystalline silica material can be described as having L, a, b values in a Hunter color space of: L in a range from 80.6 - 85.4, ‘a’ in a range from -2 to 5, and *b’ in a range from 0-9.
  • the color of the low crystalline silica material can alter the amount of pigment in a processed slab to achieve desired color values. For example, in instances in which the low crystalline silica material has a blue color, the quantity of pigment to achieve a desired color value for the slab may be reduced compared to slabs which include no low crystalline silica materials, or substantially transparent low crystalline silica materials.
  • the low' crystalline silica slabs may have less than or equal to 2 wt % pigment, less than or equal to 1 wt % pigment, less than or equal to 0.5 wt % pigment, less than 0.2 wt % pigment, or about 0 wt % pigment.
  • the particulate mineral mixes that define regions 51 and 52 include low crystalline silica material by weight in addition to a standard particulate mineral mix. Blending the quartz grit and/or powder with a low crystalline silica material reduces the overall content by weight of crystalline silica in a slab produced using such materials.
  • the particulate mineral mixes include about 30 wt % quartz grit, about 30 wt % low crystalline silica grit, about 12 wt % low crystalline silica powder, and about 12 wt % quartz powder, in general, the particular mineral mixes can include quartz grit to low crystalline silica grit in a ratio from about 1 : 1 wt:wt.
  • the particulate mineral mixes includes quartz grit in a range from about 1 wt % to about 40 wt % (e.g., in a range from about 5 wt % to about 30 wt % in a range from about 10 wt % to about 20 wt % in a range from about 10 wt % to about 15 wt %).
  • the particulate mineral mixes includes quartz powder in a range from about 1 wt % to about 30 wt % (e.g., in a range from about 5 wt % to about 20 wt % in a range from about 8 wt % to about 15 wt % in a range from about 10 wt % to about 12 wt %).
  • quartz and low crystalline silica material can complement one another and provide desirable visual, tactile, and/or structural characteristics in a finished stone slab. For example, such percentages of quartz can facilitate a bright white appearance, while maintaining a low overall crystalline silica content of the finished slab 50.
  • the inorganic materials can be linked using a binder, which may include for example, monofunctional or multifunctional silane molecules, dendrimeric molecules, and the like, that may have the ability to bind the inorganic components of the composite stone mix.
  • the binders may further include a mixture of various components, such as initiators, hardeners, catalysators, binding molecules and bridges, or any combination thereof.
  • Some or all of the mixes dispensed in the mold may include components that are combined in a mixing apparatus (not shown) prior to being conveyed to the mold.
  • the mixing apparatus can be used to blend raw material (such as the low crystalline silica material, organic polymers, unsaturated polymers, and the like) at various ratios to provide different particulate mineral mixes (e.g., different hardness, different resistance to abrasion, different pigments, different compositions, different additives) according to predefined and repeatable dispensation pattern into the mold until filled.
  • raw material such as the low crystalline silica material, organic polymers, unsaturated polymers, and the like
  • particulate mineral mixes e.g., different hardness, different resistance to abrasion, different pigments, different compositions, different additives
  • some or all of the mixes dispensed in the mold may include about 80-95% low crystalline silica materials to about 5-15% binders (e.g., such as about 12% binder).
  • binders e.g., such as about 12% binder
  • An example of a binder is a polymer resin material.
  • various additives may be added to the raw materials in the mixing apparatus. Such additives may include, for example, metallic pieces (e.g., copper flecks or the like), colorants, dyes, pigments, chemical reagents, antimicrobial substances, fungicidal agents, and the like, or any combination thereof.
  • the particulate mineral mix includes one or more additional components, such as between 3 wt % and 30 wt % binder (e.g.. silicon), between 4 wt % and 25 wt % binder, between 4 wt % and 15 wt %, between 4 wt % and 8 wt % binder, or about 15 wt % binder, and/or a range from about 0.1 wt % to 5 wt % pigment (e.g., a range from about 0.2 wt % to 3 wt % pigment, or a range from about 0.5 wt % to 2 wt % pigment).
  • binder e.g. silicon
  • binder e.g. silicon
  • 4 wt % and 25 wt % binder between 4 wt % and 15 wt %, between 4 wt % and 8 wt % binder, or about 15 wt % binder
  • the particulate mineral mixes include one or more pigments that can impact the aesthetic appearance of regions 51 or 52, including the color, tonality, etc.
  • the pigment of the particulate mineral mixes includes T1O2 pigment.
  • T1O2 pigment can brighten or lighten the appearance of the regions 51 or 52.
  • the addition of a TiOs pigment e.g., within the wt % described above can facilitate an aesthetic appearance that is similar or complementary to the appearance of stainless steel fixtures or appliances commonly found in kitchens and living spaces.
  • One example of the low crystalline silica mix includes about 61 wt % low crystalline silica grit, about 27 wt % low crystalline silica powder, about 11 wt % binder, about 1 wt % pigment.
  • Another example of the low crystalline silica mix includes about 61.5 wt % low crystalline silica grit, about 27 wt % low crystalline silica powder, about 11 wt % binder, about 0,5 wt % pigment.
  • low crystalline silica mix includes about 30 wt % low crystalline silica grit, about 30 wt % quartz grit, about 13 wt % low crystalline silica powder, about 13 wt % quartz powder, about 11 wt % binder, about 1.5 wt % pigment.
  • Another example of the low crystalline silica mix includes about 60 wt % quartz grit, about 27 wt % low crystalline silica powder, about 11 wt % binder, about 1,5 wt % pigment.
  • first or second particulate mineral mix include metal materials that provides a metal appearance on a surface of the finished slab 50, e.g., the appearance of a metallic pattern having one or more metallic widthwise and/or lengthwise veins. Such an appearance can emphasize or exaggerate patterns that may be found in quarried stone slabs, and/or create a unique veined or patterned appearance that simulates, but is not found in, quarried slabs.
  • one or more regions having a relatively high content of metal materials, and one or more regions having a relatively high content of another low crystalline silica content facilitates a finished slab having an overall low crystalline silica content.
  • the inorganic particulate component may include one or more metals, such as stainless steel, carbon steel, brass, copper, bronze, aluminum, zinc, titanium, gold, silver, iron, magnesium, tungsten, nickel, tin, platinum, cobalt, chromium, vanadium, molybdenum, beryllium, bismuth, gallium, indium, palladium etc., one or more of silicon, basalt, glass, diamond, rocks, pebbles, shells, a variety of quartz containing materials, such as, for example, crushed quartz, sand, quartz particles, and the like, and/or any combination thereof.
  • metals such as stainless steel, carbon steel, brass, copper, bronze, aluminum, zinc, titanium, gold, silver, iron, magnesium, tungsten, nickel, tin, platinum, cobalt, chromium, vanadium, molybdenum, beryllium, bismuth, gallium, indium, palladium etc.
  • silicon basalt, glass, diamond, rocks, pebbles, shell
  • a gloss meter e.g., “BYKmac i” meter, available from BYKGARDNER
  • SG graininess
  • Si sparkle index
  • S a sparkle amount
  • textured alloy veins and textured non-alloy veins exhibit graininess (SG), sparkle index (Si), and sparkle amount (Sa) that are meaningfully different.
  • Example alloy veins exhibit a sum of SG, Si, and Sa (“sparkle sum”), measured in some embodiments at a 15° angle.
  • the sparkle sum ranges from about 40 to about 200, about 40 to about 160, or about 50 to about 150 (e.g., at regions 51 and/or 52). In some embodiments, the sum of SG, Sj, and Sa, measured at a 15“ angle, is greater than 40. Some examples of the veins exhibit sparkle sums ranging from about zero to about 35. in some embodiments, the sum of SG, Si, and Sa. measured at a 15“ angle, is less than 40. [0053] Such sparkle values can be associated with predetermined aesthetic surface characteristics that provide a unique and desirable stone slab suitable for work surfaces and/or other building applications.
  • the surface characteristics and aesthetics are, alternatively or additionally, measurable and quantifiable as a transparency which can promote appealing visual characteristics.
  • the transmittance through a thickness of finished stone slab e.g., having a thickness of 1 cm
  • the surface characteristics and aesthetics are, alternatively or additionally, measurable and quantifiable as a diffusiveness which can be useful in promoting a bright white appearance.
  • the surface characteristics and aesthetics are, alternatively or additionally, measurable and quantifiable as an abrasion resistance which can be useful in reducing damage to major surfaces of the slab during handling, Installation, and use.
  • the slab has an abrasion resistance as measured on the Taber Index in a range from 50 to 250 (e.g., from 60 to 200, from 70 to 150, from 75 to 100, from 80 to 90, or about 85).
  • the surface characteristics and aesthetics are, alternatively or additionally, measurable and quantifiable as a vein height, a vein roughness, and background roughness.
  • the vein height is a distance the region 51 and/or 52 extends above or below the thickness of the major surface 60, for example.
  • the region roughness is measured by a surface roughness tester, such as a “Mitutoyo SJ210” available from MITUTOYO, or “MarSurf PS 10" roughness meter available from MAHR GROUP.
  • the roughness of the primary fill is measured by a roughness tester similar or the same to the roughness tester used for the region.
  • the average region roughness ranges from between 10 ⁇ m and 180 ⁇ m, between 20 ⁇ m and 130 ⁇ m, between 30 ⁇ m and 90 ⁇ m, between 40 ⁇ m and 60 ⁇ m, between 50 ⁇ m and 60 ⁇ m, and about 55 ⁇ m.
  • the average background roughness (e.g., the roughness of the primary fill region 51) ranges from between 0 ⁇ m and 30 ⁇ m, between 1 ⁇ m and 20 ⁇ m, between 2 ⁇ m and 18 ⁇ m, between 3 ⁇ m and 15 ⁇ m, between 5 ⁇ m and 15 ⁇ m, or about 10 ⁇ m.
  • region 51 includes a roughness between about 0 ⁇ m and 6 ⁇ m, 1 ⁇ m and 4 ⁇ m, or about 1 ⁇ m and 2 ⁇ m, such as for a region 51 that has been subjected to a polishing operation and/or exhibits a relatively high gloss.
  • region 51 includes a roughness between about 1 ⁇ m and 10 ⁇ m, 2 ⁇ m and 8 ⁇ m, or about 4 ⁇ m and 6 ⁇ m, such as for a region 51 that has a relatively matte finish.
  • Such roughness values can be associated with a predetermined tactile and aesthetic surface characteristics that provide a unique and desirable stone slab suitable for work surfaces and/or other building applications.
  • such roughness values can be associated with a noticeable contrast between different regions, including regions 51 and/or 52 with relatively higher roughness and region 51 with relatively tower roughness.
  • a roughness of regions 51 or 52 may be between 2 and 200 times greater, 2 and 175 times greater, 2 and 150 times greater, 5 and 100 times greater, 10 and 150 times greater, or about 25 times greater than a roughness of the other region.
  • the roughness values can be predictably obtained based on the particulate mineral mixes that define regions 51 and 52, respectively (e.g., including the particle size, shape, distribution, hardness, composition, etc.), and/or surface abrasion, polishing, or other treatments after the slab has been hardened and at least partially cured.
  • roughness e.g., region roughness, background roughness
  • sparkle e.g., graininess, sparkle index, sparkle amount, sparkle sum
  • gloss and/or reflectance haze measurements can be performed as a test of finished product. For example, after a slab is cured and finished , a quality control operation is performed that includes measurement of roughness (e.g., region roughness, background roughness), sparkle (e.g., graininess, sparkle index, sparkle amount, sparkle sum), reflectance haze and/or gloss of the slab.
  • the quality control operation can be performed to determine if the slab is within predetermined ranges (e.g., of roughness (e.g., region roughness, background roughness), sparkle (e.g., graininess, sparkle index, sparkle amount, sparkle sum), gloss, reflectance, haze, and/or other characteristics.
  • predetermined ranges e.g., of roughness (e.g., region roughness, background roughness), sparkle (e.g., graininess, sparkle index, sparkle amount, sparkle sum), gloss, reflectance, haze, and/or other characteristics.
  • the quality control operation can be used to qualify a product for sale (e.g., that it is within the predetermined specification for a conforming slab), and/or for categorization purposes (e.g., to group the slabs with other similar slabs have similar roughness, sparkle, gloss/ reflectance haze values, to label the slab for sale as a high gloss/reflectance version of the product or to label the slab for sale as a low gloss/reflectance version of the product, etc.).
  • categorization purposes e.g., to group the slabs with other similar slabs have similar roughness, sparkle, gloss/ reflectance haze values, to label the slab for sale as a high gloss/reflectance version of the product or to label the slab for sale as a low gloss/reflectance version of the product, etc.
  • multiple measurements are obtained at various locations of the slab, such as at predetermined locations of alloy and nonalloy material, according to a predetermined pattern for the example slab. Measurements obtained for the alloy material locations are compared to specified acceptable alloy ranges, and/or measurements obtained for the nonalloy material locations are compared to specified acceptable nonalloy ranges. In some embodiments, a pass/fail determination is made to determine whether the slab conforms to the specified ranges. Alternatively or additionally, measured values are stored and associated with an identifier specifically associated with the measured slab. The measured values are used in one or more subsequent operations, such as io match the measured slab with another slab having similar or complementary values.
  • Various slabs described herein provide robust strength suitable for installation in living/working spaces in a variety of configurations.
  • Structural strength of slabs can be characterized using a three point flexural test.
  • structural strength can be characterized based on a modulus of rupture (MOR) (e.g., determined according to ATSM International C99/C99M - 18 “Standard Test Method for Modulus of Rupture of Dimension Stone” (2016).
  • MOR modulus of rupture
  • MOR modulus of rupture
  • one or more regions 51 and 52 can be characterized by reflectivity. Reflectivity is measured under defined conditions to identify direct reflection, diffuse reflection, and total reflection values. For example, a surface location of the slab is illuminated by a predefined light source at a predefined angle of incidence, such as 15 degrees, 30 degrees, 45 degrees, etc. The reflected light is measured and quantified, including direct, diffuse, and total reflectance, for example. The resulting values provide an indicator of the magnitude of the reflected light, as well as whether light is reflected evenly in many directions, intensely focused in certain directions (e.g., providing a quantifiable “sparkle” effect), etc.
  • region 51 and/or 52 exhibits a relatively high direct reflectivity and/or diffuse reflectively (e.g., while also having a textured/non- smooth surface).
  • the relatively high reflectivity e.g., relatively high diffuse reflectivity
  • the reflection values provide a numeric indicator of relative similarity/difference.
  • reflectivity e.g., direct, diffuse, and/or total
  • regions 51 and 52 based on the surface texture and characteristics of the materials that define these regions.
  • a smooth, glossy surface can exhibit a relatively higher direct reflection and/or relatively lower diffuse reflection.
  • a textured surface can exhibit a relatively higher diffuse reflection.
  • reflectivity e.g., direct, diffuse, and/or total
  • reflectivity provides a metric to qualify a set of slabs having the same characteristics.
  • the systems, materials, and processes described herein facilitate manufacturing of a set of slabs having a predefined pattern and appearance.
  • Reflectivity of one or more of regions 51 and 52, of slabs of a same type having the same predefined pattern have reflectivity values (e.g., at a same location on the slab/within a same region 51 and 52) that are consistent (e.g., without 15 %, within 10 %, within 5 %, within 2 %, etc.) of one another.
  • the system 200 for forming a set of processed slab products (e.g., slab 50) Is configured to dispense particulate mineral mixes (e.g., that are differently resistant to abrasion when formed into th® cured slab) into the slab mold 230.
  • the slab mold 230 are then advanced to a subsequent compression molding operation (e.g., vibro-compaction molding, curing, etc.).
  • the system 200 includes a conveyor 210.
  • a collection of slab mold 230 are transported on the conveyor 210.
  • the slab mold 230 provide a form for processed molded slab products that are at least three feet wide and at least six feet long, and about 4.5 feet wide by about 10 feet long, for example.
  • the conveyor 210 transports the slab mold 230 to a dispenser 260 (e,g., a mineral aggregate distributor).
  • the dispenser 260 is configured to release different particulate mineral mixes (e.g., different cured resistances to abrasion, different textures, different pigments, different mineral compositions, different additives, or a combination thereof).
  • multiple dispensers 260 may be used (e.g., each dispenser configured to dispense different particulate mineral mix or combination of mixes).
  • the slab mold 230 receives the different mineral mixes (comprising mostly a quartz material as described above) from the dispenser(s) 260.
  • the dispenser 260 can be configured with a shutter or valve apparatus that is controllable to regulate the flow of particulate mineral mix from the dispenser 260 for input to the slab mold 230.
  • the dispensing heads (or other inputs for distributing the particulate mineral mixes to the slab mold 230) can be controlled according to a predetermined control algorithm so as to define successive layers or regions of the different particulate mineral mixes for dispensation into the slab mold 230.
  • the slab mold 230 is filled with a primary fill region 291 and two other different types of particulate mineral mixes to create two different types of patterns such as a region 292 and a region 293.
  • multiple dispensers 260 can be used to dispense different particulate mixes into different regions of the slab.
  • the slab may be formed from a number of different particulate mineral mixes, such as between 2 and 20 different particulate mineral mixes (e.g., and the system includes a corresponding number of dispensers 260 or a single dispenser 260).
  • the number of dispensers 260 can correspond equally to the number of differently pigmented particulate mineral mixes used to create the slab product.
  • the filled molds 280 are then moved to one or more subsequent stations in the system 200 for forming the hardened slab.
  • each of the filled molds 280 can continue to a subsequent station in which a top mold attachment 294 is positioned over the filled mold 280 so as to encase the layers of particulate mineral mixes between the slab mold 230 and a top cover mold piece.
  • the filled mold 280 (e.g., including the top cover mold piece) advances to a subsequent station in which a vibrocompaction press 295 applies compaction pressure, vibration, and/or vacuum to the contents inside the filled mold 280, converting the particulate mixes into a rigid slab.
  • the filled mold is subjected to a curing station 296 in which the material used to form the slab (including any binder material) are cured via a heating process or other curing process, strengthening the slab inside the filled mold 280.
  • the contents of the filled molds are initially uncured.
  • each of the plurality of particulate mineral mixes within the filled molds include uncured binder.
  • the particulate mineral mixes are contemporaneously subjected to pressure, vibration, vacuum, and/or heat in order to contemporaneously harden/cure each of the particulate mineral mixes to form the finished slab.
  • the filled mold does not include some portions of previously hardened/cured particulate mineral mixes and a region pattern defined by an unhardened/un hardened particulate mineral mix.
  • the slab mold 230 and the top mold cover piece are removed from the hardened and cured slab at a mold removal station 297.
  • the slab mold 230 is then returned to the conveyor 210.
  • the hardened and cured slab Is moved to a surface treatment station 298, in which a major surface of the slab is abraded, to reveal a complex abraded surface having a predetermined texture and pattern.
  • the abraded or otherwise exposed major surface of each of the processed molded slabs can provide an outer appearance that is substantially repeatable for the other slabs (from the other filled molds 280 in FIG. 8).
  • FIG . 3 is a d iagram of an example system 300 for applying a surface treatment to texturize a low crystalline silica processed slab product (e.g., a face treatment apparatus), in accordance with some embodiments.
  • the system 300 is included in the example surface treatment station 298 of FIG. 2.
  • the system 300 is configured to modify at least a portion of at least one face of a cured and hardened processed stone slab by abrading the slab to reveal visible and/or tactile differences in the depth and/or roughness of different materials exposed at the processed face(s).
  • a collection of hardened and cured slabs 330 (e,g., the hardened and cured slabs removed at the example mold removal station 897) are transported on a conveyor 310 to a surface treatment station 340.
  • the hardened and cured slabs 330 include a primary fill region 391 (e.g. the primary fill region 51 of the example slab 50, the primary fiil 891 after it has been cured and hardened, etc.), and/or one or more regions 392 and 393.
  • the primary fill region 391 is made of a first particulate mineral mix that differs in one or more characteristics as compared to second and third particulate mineral mix region 392, 393.
  • the surface treatment station 340 modifies a major surface 332 of the hardened and cured slabs 330.
  • the surface treatment station 340 includes one or more abrasive brushes 342 configured to contact the major surface 332 vertically and rotate about a rotational axis arranged substantially perpendicular to the major surface 332.
  • the one or more abrasive brushes 342 rotate in contact with the major surface 332 as they are drawn across the major surface to provide substantially the same amount (e.g., duration) of abrasion to all areas of the major surface 332.
  • the movement of the one or more brushes 342 across the major surface 332 is independent of the region of the slab (e.g., independent of whether the brush is in contact with 391 , 392, 393).
  • One or more abrasive fluid compound applicators 344 can be used to apply abrasion promoters and/or water to the areas being treated to modify the action of the abrasive brushes 342, to control the temperature of the process, and/or to reduce the production of dust.
  • the selection of brush type, vertical pressure, rotational speed, lateral direction, lateral pattern, abrasive grit, water flow, and slab advancement speed can all be controlled to further control the abrasion process.
  • the abrasion process may be applied evenly to provide a uniform level of abrasion, or it may be applied unevenly across the major surface 332 to provide an intentionally nonuniform level of abrasion.
  • the one or more abrasive brushes include silicon carbine, diamond, or other abrasive brushes such as diamond abrasive brushes available from Tenax USA of Charlotte, NC. in some embodiments, a series of brushes having differing abrasive grit ratings are used in sequence.
  • abrasive brush application pressures are between 0.5 bar to above 8.0 bar, between 0.8 bar to 4 bar.
  • the abrasive brushes 342 can be spun at speeds ranging from 200 RPM to 1500 RPM, 300 RPM to 1200 RPM, ar between 400 RPM to 550 RPM. to some implementations, water is applied to the abrasion site at flow rates ranging from zero to 4 gallons per minute or more. In some embodiments, the abrasive brushes 342 are advanced across the major surface 610 at speeds ranging from below 3000 to above 18000.
  • abrasive brushes 342 abrade the major surface 332, small amounts of the major surface 332 are removed to provide a processed major surface 352 of a processed stone slab product 350.
  • the primary fill region 391 is harder and/or more abrasion resistant than the regions 392, 393 such that the areas of the regions 392, 393 exposed at the major surface 332 (e.g., face areas) recede beiow a piane generally defined by the primary fill region 391.
  • the resulting processed slab has a slab thickness that varies (e.g,, between regions 391 , 392, 393), with the average thickness of the primary fill region 391 generally thicker than the average thickness of the regions 392, 393).
  • the exposed surface can resemble the appearance of a topographical or relief map of a plain with valleys running through it.
  • the primary fill region 391 is softer or less abrasion resistant than the regions 392, 393, the areas of the major surface 332 exposed at the major surface 332 may recede below bumps and mounds made up of the regions 392, 393.
  • the exposed surface can resemble the appearance of a topographical or relief map of a plain with hills or mountain ranges rising from it.
  • materials which can cause the regions 391 , 392, or 393 to be softer include naturai/synthetic micas, talc, calcite, and limestone.
  • the region 392 is softer than the primary fill region 391, and the region 393 is harder than the primary fill region 391.
  • the resulting texture of the major surface has features that are both raised (e.g., region 393) and recessed (e.g., region 393) relative to the average thickness.
  • the processed major surface 352 has a texture that can be seen and/or felt due to the differences in average slab thicknesses in regions of the primary' fill region 391 , the region 392, and the region 393.
  • the processed stone slab product 350 produced by the example system 300 can be the example processed slab 50.
  • the processed stone slab product 350 may be further processed.
  • the major surface 352 may be polished to round or blunt sharp peaks, or the peaks may be polished or flattened to define flattened raised regions resembling plateaus.
  • the system 300 includes a calibration station arranged before or after the surface treatment station 340.
  • the major surfaces 332 of the cured slabs 330 can polished, planed, smoothed, and/or otherwise provided with a substantially even surface across the entire major surface 332 prior to being abraded.
  • the processed major surfaces 352 of the cured slabs 330 can be partly polished, planed, smoothed, or otherwise modified to have a collection of plateaus that define a substantially common plane across the processed major surface 352.
  • steps may be omitted (e.g., the abrasion is performed on the major surface 332 in the form that exists after mold removal 397 without subjecting the slab to an intermediate planning or calibration operation).
  • the major surfaces 332 of the cured slabs 330 are calibrated to provide a substantially even surface across the entire major surface 332 prior to being abraded.
  • the slab is then finished (e.g. , for use in subsequent fabrication and installation operations) without polishing the major surfaces 332 of the cured slabs 330.
  • Such a sequence can facilitate a desired textured surface (e.g., including regions of differing thickness, such as a raised or recessed region pattern), while having a relatively low gloss regions and/or surface smoothness).
  • the major surfaces 332 of the cured slabs 330 are subjected to a polishing operation in addition to both calibration and abrading operations.
  • Such a sequence can facilitate a desired textured surface (e.g., including regions of differing thickness, such as a raised or recessed region pattern), while having relatively high gloss regions and/or surface smoothness).
  • the polishing operation can facilitate roughness and/or sparkle measurements within predetermined ranges (e.g., such as predetermined roughness and sparkle measurements).
  • FIGS. 4-5 are diagrams of example systems 400 and 500 for applying a surface treatment to texturize a processed slab product.
  • the systems 400 and 500 are included in the example surface treatment station 298 (FIG, 2).
  • the systems 400 and 500 include one or more features of the example system 300 described with reference to FIG. 3.
  • the system 400 includes a surface treatment station 440.
  • the surface treatment station 440 includes one or more cylindrical abrasion tools 442.
  • the tool 442 is an abrasive brush that contacts the surface being processed and rotates substantially perpendicular to the surface about an axis that is substantially parallel to the surface.
  • the tool 442 can resemble a planning head configured to grind against the surface. The different materials in different areas of the surface abrade differently from each other due to the differences in their respective particulate mineral mixes, leaving behind a processed surface with a tactile and/or visual texture.
  • the movement of the tool 442 across the major surface of the slab is independent of the region of the slab (e.g., independent of whether the brush is in contact with a particulate mineral mix), such that the tool 442 is consistently applied across the entire major surface of the slab.
  • the system 500 includes a surface treatment station 540.
  • the surface treatment station 540 has a nozzle 542 configured to perform abrasive blasting (e.g., sandblasting).
  • abrasive blasting e.g., sandblasting
  • a stream of abrasive material is forcibly propelled against the surface.
  • the different materials in different areas of the surface abrade differently from each other due to the differences in their respective particulate mineral mixes, leaving behind a processed surface with a tactile and/or visual texture.
  • application of the abrasive blasting across the major surface of the slab is independent of the region of the slab, such that the abrasive blasting is consistently applied across the entire major surface of the slab.
  • the example systems 400, 500 may also use an abrasion promoter, such as an abrasive liquid or paste.
  • surface treatment stations may use a substantially nonabrasive brush or pad in combination with a paste, powder, or liquid that provides the abrasive properties.
  • surface treatment stations may use chemical etching, such as an acid or solvent for which the different materials in the slab react differently, to chemically etch the major surfaces of hardened and cured slabs.
  • surface treatment stations may use any appropriate combinations of the described tools, or any other appropriate tool or substance that can be used to abrade or erode the surface of a hardened and cured processed stone slab.
  • the example systems 400, 500 may be configured with one or multiple stages of abrasion using one or multiple different types of abrasives, abrasion tools, abrasion patterns (e.g., the abrasion tool can be draw across the surface in predetermined straight lines, curves, circles), application pressures, grits, speeds, directions across the major surfaces, speeds across the major surfaces, any combination of these and/or other appropriate variables that can affect the abrasion of processed stone slabs.
  • abrasives e.g., the abrasion tool can be draw across the surface in predetermined straight lines, curves, circles
  • application pressures grits
  • speeds directions across the major surfaces
  • speeds across the major surfaces e.g., any combination of these and/or other appropriate variables that can affect the abrasion of processed stone slabs.
  • FIG. 6 is a flow diagram of an example process 600 for producing a processed slab product from a plurality of different particulate mineral mixes.
  • the process 600 is performed by parts or all of the example systems 200500 described with reference to FIGS. 25.
  • a first particulate mineral mix is dispensed into a first set of regions of a slab mold.
  • a first particulate mineral mix is deposited into the slab mold to become one or more regions.
  • a second particulate mineral mix is dispensed into a second set of regions of the slab mold.
  • the dispenser dispenses primary fill into the slab mold.
  • th® first particulate mineral mix and the second particulate mineral mix arranged in the slab mold are contemporaneously vibrated and compacted so as to form a molded slab that is generally rectangular and has a slab thickness and a major surface having a width of at least 2 feet and a length of at least 6 feet.
  • a vibro-compaction press applies compaction pressure, vibration, and/or vacuum to the contents inside the filled mold, thereby canverting the particulate mixes into a rigid slab.
  • the compacted first particulate mineral mix and the compacted second particulate mineral mix are cured into a cured slab.
  • the curing station heats or otherwise cures the compacted slabs to further strengthen the slabs inside the filled molds.
  • the first particuiate mineral mix can include one or more first component materials having a first hardness, particle size, particle shape, composition, resistance to abrasion, etc.
  • the primary fill may be made up of a particulate mineral mix that includes a binder and a component having a particular hardness, particle size, particle shape, composition that cures relatively hard and/or with a high abrasion resistance
  • the regions may be made up of a particulate mineral rnix and a binder that includes a component having a particular hardness, particle size, particle shape, composition that cures somewhat softer and/or with a lower abrasion resistance (e.g., allowing the binder to erode away to expose more hard particuiate, possibly resulting in a surface like sandstone or fine sandpaper).
  • the particulate mineral mix composition results in particulates (e.g., observable in a region or other region of a finished slab) with rounded facets and a microscopically bumpy surface, spherical shapes, round shapes, ovular shapes, ovoid shapes, rounded disc shapes, sharp edges, irregular shapes, and combinations thereof.
  • the major surface of the cured slab is abraded at locations of the first particulate mineral mix and the second particulate mineral mix with an abrading head to partly remove portions of the major surface such that the first particulate mineral mix in the first set of regions define a first thickness perpendicular to the slab width and the slab length, and the second particulate mineral mix in the second set of regions define a second thickness perpendicular to the slab width and the slab length.
  • the surface treatment stations 240, 240, and/or 540 can be used to abrade the major surface, and due to the differences (e.g., hardness, particle size, particle shape, composition, abrasion resistance) among regions of the primary fill and the regions, the various regions abrade or erode to different depths resulting in the primary fill and the regions having different thicknesses across the major surface 232.
  • differences e.g., hardness, particle size, particle shape, composition, abrasion resistance
  • example process 600 optionally includes a material recovery operation 660.
  • Abraded material removed from the slab is recovered and treated.
  • abraded material is subjected to a separation process that separates material particles based on density, specific gravity, and/or other characteristics.
  • the abraded material is passed through one or more centrifuge processes until the abraded material is segregated into individual material compositions or types.
  • the segregated material is recycled for reuse in a particulate mineral mix to be used in forming a finished slab.
  • a finished slab can include one or more regions defined partly or entirely of material recovered/recycled from a previous molded slab.
  • abrading a portion of the major surface of the cured slab includes removing an amount of the major surface in the first set of regions to an average first thickness perpendicular to the slab width and the slab length that is at least partly different from a second average thickness removed from the second set of regions, wherein the first texture is based on the first average thickness and the second texture is based on the second average thickness.
  • one of the first set of regions and the second set of regions can define a majority of the major surface, and the other of the first set of regions and the second set of regions can define a region extending at least partly across the major surface.
  • the primary fill occupies a first set of regions within the slab 350, and other particulate mineral mixes form the one or more regions, which extend partly or entirely across the surfaces and edges of the slab.
  • abrading the major surface of the cured slab includes abrading substantially the entire major surface.
  • the system 200 can be configured to apply the same type of abrasion across the entire major surface 232 (e.g., causing substantially ail of the primary fill region 291 exposed at the major surface 232 to erode to substantially the same average depth, and causing the regions 292 and 293 to each erode to their own respective average depths across the entire major surface 232).
  • abrading the major surface of the cured slab can include abrading by at least one of an abrasive brush and mechanical application of an abrasive fluid compound.
  • the example abrasive brushes 242 can be used to apply a fluid compound containing abrasive material to the major surface 232.
  • the first set of regions can have a first texture and the second set of regions can have a second texture different from the first texture.
  • the primary fill may have a smooth, glossy texture, while the region may have a relatively rougher, matte texture.
  • the roughness of the primary' fill and/or the region may be quantified by Ra, Rq, and Rz values. Alternatively or additionally, roughness of the primary fill and/or the region may be characterized based on roughness meter measurements.
  • the low crystalline silica material were used to produce one or more test slabs.
  • Each of the different low crystalline silica materials can have one or more characteristic effects (e.g., a color, compression, transparency, clarity, and/or texture effect) on the finished slab.
  • fused quartz is a pure form of amorphous silica and generally does not impart color, e.g. , blue color, in the slab.
  • the following examples include recipes by which test slabs were produced using low crystalline silica material in grit (%grit) and powder (%powder) form, a binder (%binder), and a pigment (%pigment), unless indicated otherwise.
  • the values of ‘L,' ‘a,’ and ‘b’ refer to values in the Hunter color space.
  • the values express color as *L’ for perceptual lightness, and 'a' and ‘b’ values which, when combined, determine values for the four unique colors of human vision: red, green, blue and yellow.
  • test slabs were produced using standard ‘high’ crystalline silica material, e.g. quartz grit and powder.
  • Formulation 1 test slabs were used as a comparator against other test slabs.
  • Test slabs were produced using the following ratios:
  • the example low crystalline silica material e.g., Formulation 2
  • the example low crystalline silica material was determined to be 100 wt % amorphous silica and both grit and powder forms were used in the slab productions as described above.
  • Slabs produced using Formulation 2 grit and/or powder can have a high binder demand which may be due to the particle size distribution.
  • Formulation 2 has a blue color In the powder/grit raw material. The blue undertone may be advantageous in specific designs or mixes.
  • the test slabs produced using Formulation 2 have an overall more glassy look, and smooth texture.
  • Some examples made with Formulation 2 had a silky texture and a spongy feeling compared to Formulation 1 which may be related to poor compaction.
  • Grits grains of Formulation 2 appear clear and clean, e.g., low to no contamination, compared to Formulation 1.
  • Formulation 2 powder has a white color and an opacity similar to other Formulation 1 and has a blue color.
  • Formulation 2 has a Mohs hardness of greater than or equal to 5.
  • Formulation 2 was tested to have the following composition: SiOs: 58-59% CaO: 14-15%; AI2O 3 : 20-21%; K 2 O: 3.5-4.5%; MgO: 12%; Na2O: ⁇ 1%; Fe2O 3 : ⁇ 1%; TiO 2 : 0%; ZnO: ⁇ 0.1%; ZrO 2 : ⁇ 0.1%; Cl: ⁇ 0.1%; P2O5: ⁇ 0.1 %; SrO: ⁇ 0.1%; SO 3 : ⁇ 0.1%; NiO: ⁇ 0.01%; and Pb: 0%.
  • Formulation 1 was tested to have an abrasion resistance on the Taber Index of 88.8.
  • the Formulation 2 powder has a lower b value than Formulation 1 (e.g., less yellow/more blue) and a lower a value as well (e.g., less red/more green) contributing to a blue-green appearance.
  • Test slabs were produced using the following ratios:
  • Examples of slabs produced using Formulation 2 resulted in a polymeric aesthetic with blue color undertones. Some examples of the slabs had a more glassy finish compared to Formulation 1 . Some examples had lower transparency than Formulation 1 with similar pigment dose. A yellow pigment may be used to alter the blue undertone, which in some cases may increase the opacity of produced slabs.
  • some pigment e.g., TiOa
  • Formulation 2 grit used with cristobalite powder makes a slab having a semiwhite color with some transparency depending on TiOz dose compared to Formulation 1. Increasing the Formulation 2 powder particle size may reduce binder demand and compaction in some cases.
  • Some examples had reduced compaction compared to Formulation 1 , while having up to 5% more binder. Some examples had a brown color compared to
  • feldspar #1 has a more white color than the feldspar #2.
  • Feldspar #2 has a pink color.
  • Both feldspar powders are smaller in size than the Formulation 1 powder, with the feldspar #1 powder being the smallest particle size observed.
  • the feldspar #1 powder has color closest to the Formulation 1 powder.
  • Test Slab Group 3 was produced using quartz grit (%Quartz Grit) and low crystalline silica material (%Powder). The compression of the test slab group 1 was similar to Formulation 1 . The color was dissimilar to test slabs produced using Formulation 1. An increased pigment dose may be used to reduce the color difference.
  • Test Slabs Group 4 [00121] The grit and powder had a pink color compared to Formulation 1. This resulted in test tiles having a peach/tan color.
  • Another example of a low crystalline silica material Including nepheline syenite was used to produce test slabs.
  • the following slab recipes was used to produce the test slabs.
  • the particle size of the nepheline syenite powder is closest to the Formulation 1 powder.
  • Example - Soda-Lime Glass Another example of a low crystalline silica material including soda-lime glass was used to produce test slabs. The following slab recipes was used to produce the test slabs.
  • the soda-lime glass powder has a lower b value than Formulation 1 (e.g., less yellow/more blue) and a lower a value as well (e.g., less red/more green) contributing to a blue-green appearance.
  • the particle size of the soda lime glass grit is smaller than the Formulation 1 grit material.
  • test slabs had increased grey color and similar transparency to test slabs produced using Formulation 2 as the low crystalline silica materials. Other test slabs had a white color with similar transparency to test slabs produced using Formulation 2. Some test slabs had a white/blue color with similar transparency to test slabs produced using Formulation 2. Other test slabs had a brown color and similar transparency to test slabs produced using Formulation 2.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne des dalles de pierre, et des systèmes et des procédés de formation de dalles. Certains exemples de dalles comprennent un motif défini par un mélange minéral particulaire présentant une faible teneur en silice cristalline.
PCT/US2024/048193 2023-09-25 2024-09-24 Dalles de pierre à faible teneur en silice cristalline, systèmes et procédés Pending WO2025072188A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5028569A (en) * 1987-05-14 1991-07-02 Gte Products Corporation Ceramic article, raw batch formulation, and method
US20070181035A1 (en) * 2005-06-29 2007-08-09 Wantling Steven J Wax formulations for lignocellulosic products, methods of their manufacture and products formed therefrom
US20140361471A1 (en) * 2013-06-07 2014-12-11 Solidia Technologies, Inc. Rapid curing of thin composite material sections
US11485045B1 (en) * 2019-12-24 2022-11-01 Cambria Company Llc Stone slabs, systems, and methods
US20230048652A1 (en) * 2021-08-06 2023-02-16 Cosentino Research & Development, S.L. Tiles or slabs of compacted ceramic material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5028569A (en) * 1987-05-14 1991-07-02 Gte Products Corporation Ceramic article, raw batch formulation, and method
US20070181035A1 (en) * 2005-06-29 2007-08-09 Wantling Steven J Wax formulations for lignocellulosic products, methods of their manufacture and products formed therefrom
US20140361471A1 (en) * 2013-06-07 2014-12-11 Solidia Technologies, Inc. Rapid curing of thin composite material sections
US11485045B1 (en) * 2019-12-24 2022-11-01 Cambria Company Llc Stone slabs, systems, and methods
US20230048652A1 (en) * 2021-08-06 2023-02-16 Cosentino Research & Development, S.L. Tiles or slabs of compacted ceramic material

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