In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.

A synthetic stone for decorative purposes, countertops, flooring, and the like comprises, as a major component, magnesium compounds, and includes diamond or quartz sand. It is formed via a vibro-compression process that is conducted under vacuum and at ambient temperature. The synthetic stone slab is very hard, waterproof, mildew-proof, insect-proof, environmentally friendly, and low cost.

The present invention provides an apparatus for manufacturing artificial marble including a granite soil storage unit for supplying a granite soil; a granite soil heating unit for heating the soil; a resin storage unit for storing a thermoplastic polyurethane (TPU) resin; a mixing-transporting unit for accommodating the resin and the heated granite soil therein and melting and mixing them to produce and simultaneously transport an artificial marble slurry; a material guide unit for guiding the soil and the resin into the mixing-transporting unit; a discharge unit for discharging the slurry; a mold supply unit for continuously supplying a mold for accommodating and molding the slurry; a mold guide unit for guiding the mold to accommodate the slurry; a forming unit for forming an artificial marble by applying vibration and pressure to the slurry; an extraction unit for extracting the mold; and a lamination unit for laminating and storing the mold extracted.

The invention relates to the use of feldspar granules with a particular combination of oxide constituents in the manufacture of artificial agglomerate stone materials and to the agglomerate stone materials resulting thereof.

There is described a composition for synthetic stone. The composition having (a) 3 to 25 wt % acrylic resin, the acrylic resin having:(i) >50 upto 95 wt % methyl methacrylate and methyl methacrylate monomer residues, (ii) 4 to 40 wt % higher boiling point mono(alk)acrylate monomer, (iii) optionally, 0 to 10 wt % other acrylate or vinyl comonomer residues, and(iv) a crosslinking agent. The MMA residues of component (a)(i) are present in the acrylic resin in the form of a MMA residue containing (co)polyemer, comprising at least 80% residues of MMA by weight of the (co)polymer. The composition further having (b) 70 to 95 wt % filler; and (c) optionally, a coupling agent. The composition being especially useful for the manufacture of synthetic stone for use in outdoor applications.

A method for manufacturing a ceramic tile may involve providing a green tile having at least a green body with an upper surface. At least a first surface covering may be provided on the upper surface of the green body. The green tile may be fired to obtain a ceramic tile having a surface structure on its upper surface. At least one sinking agent may be applied on the upper surface of the green tile before providing the first surface covering. The sinking agent may determine the surface structure.

The invention provides a pourable composition comprising calcium sulfate hemihydrate; optionally, cement; one or more anionic surfactants selected from alkyl anionic surfactants, alkyl ether anionic surfactants, alkyl aryl anionic surfactants, and combinations thereof; one or more set accelerator additives; and water.

This invention relates to polymeric compositions for application onto natural stone in order to provide for long-term chemical, stain, and water resistance, along with antimicrobial properties. Many natural, unsealed stones do not have stain, etch, or water resistance. The described compositions were developed using a technology of chemical grafting that involves the use of prepolymers, monomers, catalysts, graft initiators, wetting agents, antimicrobial agents, and other ingredients. The composition, when thus applied to the stone surface allows it to obtain a graft polymerization, thereby forming a polymer film that is chemically attached to the natural stone, rather than typical physical bonding of other sealer compositions. The natural stones react with a graft initiator in the composition, which creates the reaction sites on the natural stone surface via free radical mechanisms. This in turn renders the natural stone to be receptive to attachment of monomers/prepolymers forming a polymeric film chemically bonded to the natural stone which then has the desired properties in terms of resistance to staining, etching, water penetration, etc., used in homes and light commercial applications, as well as for exterior use on building facades, monuments and the like.

A device and a method for heating and curing artificial stone with microwave are provided. The device includes a microwave curing cavity, within which an incompletely cured artificial stone is placed, and microwave is used to heat the artificial stone to completely cure the artificial stone; wherein, a frequency of the microwave is in a range of 3001120 MHz. The present disclosure provides a separately designed microwave curing cavity, and utilizes 3001120 MHz microwave having a large penetrating depth, to realize a rapid curing of a large-sized artificial stone.

An apparatus including a first conveyor device including a first conveyor belt; a second conveyor device including a second conveyor belt; a movement device; and a mold device including a mold; wherein the first conveyor device is connected to the second conveyor device so that when the movement device moves the first conveyor device, the second conveyor device also moves with respect to the mold device; wherein the first conveyor belt moves independent of the second conveyor belt; and wherein the first conveyor belt and the second conveyor belt move independent from the movement device. The apparatus may further include a first and second dispensing devices configured to dispense first and second materials, first and second gate devices to control height, and a computer processor to control the various components and the resulting ratio of first material to second material in a processed slab.