Engineered stone and methods of manufacturing same

Abstract

Engineered stone, and methods of manufacturing same. An engineered stone comprises: a surface of the engineered stone, wherein the surface comprises one or more pores; and a sealant mixture including a sealant material and a functional component, wherein the functional component modifies one or more properties of said engineered stone.

Claims

1. An engineered stone comprising: a compacted and cured composite stone material comprising about 85-95% by weight natural quartz aggregates and about 5-15% by weight polymer resins, which forms an entirety of the engineered stone, such that the composite stone material forms both (i) a top surface of the engineered stone and (ii) an entire height of the engineered stone; wherein said top surface has surface pores therein that are spaced apart by said composite stone material, wherein said surface pores have different sizes; wherein only said surface pores are filled with a cured and dried functional sealant filling which directly touches said composite stone material; wherein the functional sealant comprises a functional component which modifies one or more properties of said engineered stone, wherein said functional component is selected from the group consisting of: an insect repelling agent, an insect eliminating agent, a scent material, an anti-slip material, a dirt repellent agent, a stain repellent agent, an ultraviolet protective agent.

2. The engineered stone of claim 1, wherein the functional component removes one or more properties of said engineered stone.

3. The engineered stone of claim 1, wherein said functional sealant comprises a polymeric compound.

4. The engineered stone of claim 1, wherein said functional sealant comprises wax.

5. The engineered stone of claim 1, wherein said functional sealant comprises sealant material cured with ultraviolet light.

6. The engineered stone of claim 1, wherein a top surface of the engineered stone having the pores filled with the sealant is flat.

7. The engineered stone of claim 1, wherein the pores are filled with at least a heat protective agent.

8. The engineered stone of claim 1, wherein the pores are filled with at least a fluorescent agent.

9. The engineered stone of claim 1, wherein the pores are filled with at least a phosphorescent agent.

10. The engineered stone of claim 1, wherein the pores are filled with at least a surface tension modifier.

11. The engineered stone of claim 1, wherein the entirety of the engineered stone, including the regions of the engineered stones that surround said pores, are uniformly and exclusively formed of said composite stone material.

12. The engineered stone of claim 1, wherein said pores comprise pores that are filled with said sealant that was brushed into said pores.

Description

BRIEF DESCRIPTION OF FIGURES

(1) Examples illustrative of embodiments of the invention are described below with reference to figures attached hereto. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with a same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale. The figures are listed below.

(2) FIG. 1A schematically illustrates an exemplary composite stone material prior to an improved sealing treatment, in accordance with an embodiment of the invention;

(3) FIG. 1B schematically illustrates the engineered stone of FIG. 1A following the improved sealing treatment, in accordance with an embodiment of the invention;

(4) FIG. 2 schematically illustrates an exemplary manufacturing system for the engineered stone shown in FIGS. 1A and 1B, the manufacturing system comprising an exemplary improved sealing treatment line (ISTL), in accordance with an embodiment of the invention; and

(5) FIG. 3 schematically illustrates a flow diagram of an exemplary method of operation of the ISTL shown in FIG. 2, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

(6) As referred to herein, the terms “composite stone”, “composite stone material”, “slab”, “artificial marble”, “engineered stone” and “quartz surfaces” may interchangeably be used. Thus, when referencing any of the terms “composite stone”, “composite stone material”, “slab”, “artificial marble”, “engineered stone” and “quartz surfaces”, it implies that all the terms are covered. For example, when referencing the term “composite stone”, the terms “composite stone material”, “slab”, “artificial marble”, “engineered stone” and “quartz surfaces” are also covered.

(7) A composite stone material, such as, for example, artificial marble/engineered stone/quartz surfaces, may be composed of various materials. For example, a composite stone material may be composed mainly of inorganic particulate component and organic polymer(s). The inorganic particulate component may include such components as silicon, basalt, glass, diamond, rocks, pebbles, shells, a variety of quartz containing materials, such as, for example, but not limited to: crushed quartz, sand, quartz particles, and the like, or any combination thereof. For example, the inorganic quartz material may include sand of various particle sizes and in different combinations. Linkage between the organic and inorganic compounds may be carried out and/or facilitated by using binder molecules, such as, for example, mono-functional or multifunctional silane molecules, dendrimeric molecules, and the like, that may have the ability to bind the organic and inorganic components of the composite stone. The binders may further include a mixture of various components, such as initiators, hardeners, catalysts, binding molecules and bridges, or any combination thereof. The manufacturing process of the composite stone material may include blending of raw material (such as inorganic quartz and organic polymers, unsaturated polymers, and the like, such as polyester) at various ratios. For example, the composite stone material may include about 85-95% natural quartz aggregates to about 5-15% polymer resins. For example, the composite stone material may include about 93% natural quartz aggregates and about 7% polymer resins.

(8) In addition, various additives may be added to the blending of the raw materials, at various stages of production. For example, such additives may include, colorants, dyes, pigments, chemical reagents, antimicrobial substances, fungicidal agents, and the like or any combination thereof. As a result of adding various additives to the blending of raw materials, the additives may be present in the final composite stone product and may further change various characteristics of the composite stone. Such characteristics may include, for example, physical properties, such as: color, texture, and the like; chemical properties, such as, for example, chemical resistance, pH properties, and the like; biological properties, such as, for example, antibacterial properties, antimicrobial properties, fungicidal properties, and the like; and mechanical properties, such as, for example, strength, scratch resistance, impact resistance, and the like. The resulting mixture may later be poured to a support or a temporary support, such as rubber, paper, plastic or any other polymeric material, water soluble paper, silicon sheet, or the like, with or without a support frame or a shaping frame, a mold such as a rubber tray mold or any other appropriate support. The mixture is poured substantially in the form of a desired slab (for example, at a size of 308 cm×145 cm with or without wall shaping). The mixture may then be compacted by a special vacuum and vibration process such as vibrocompaction at high pressure, such as about 100 Tons. Then, the compressed mixture may be placed in a curing and/or hardening kiln, for example, at a temperature in the range of 80° C. to 115° C. for 30 to 60 minutes until they harden and assume natural stone properties, but with greater performance and higher resistance to stains and impact, as detailed below. After completion of the casting process, the slabs may be flattened, gauged, calibrated and polished to a high and enduring shine or any desired finish to be used at various settings, such as, for example, interior wall cladding, sinks, fireplace mantles and surroundings, wainscots and wall bases, bank teller lines, table and desktops, elevator cab walls and floors, floor tile and stair treads, food service areas, shower and tub surrounds, toilet compartment partitions, window seats and countertops.

(9) In a further embodiment of this invention, portions of the slab may be masked or covered by mechanical or chemical means prior to sealing, such that only uncovered/unmasked portions of the slab receive the sealing comprising additional functional additives. Optionally, the sealing may not comprise the functional additives. For example, a pattern may be cut out of an adhesive film and attached to the slab prior to sealing. The sealant mix is then applied only to the exposed portions of the slab, creating a contrast in gloss between the different areas of the slab. In a further example, applying a sealant mix containing a dye of pigment to uncovered/unmasked areas would create a color change only in the exposed areas, thus leading to a colored design on the slab following removing the masking medium.

(10) In some embodiments of the invention, the masking medium may comprise an adhesive film adapted to be deactivated by UV radiation. The adhesive on the adhesive film may then be deactivated by a same UV station used to cure the sealant.

(11) Reference is made to FIG. 1A, which schematically illustrates an exemplary composite stone material 100 prior to an improved sealing treatment, and to FIG. 1B which schematically illustrates engineered stone 100 following the improved sealing treatment, all in accordance with an embodiment of the invention.

(12) Composite stone material 100 comprises an engineered stone 102, including microscopic pores 104. Engineered stone 102 may be manufactured by any manufacturing process used to produce engineered stone, as known in the art. In accordance with an embodiment of the invention, a sealant mix 106 is applied to the pores 104, the sealant mix comprising one or more functional components. The functional components are adapted to add properties to engineered stone 100. For example, the functional components may include pigments and dyes; antibacterial components; scent essences; indicator chemicals which provide a visual indication responsive to ph, bacteria, temperature, or other conditions which may affect one or more properties of the engineered stone, or any combination thereof; ultra violet (UV) protection agents; fluorescent components; anti-slip agents; and the like; or any combination thereof.

(13) Reference is made to FIG. 2, which schematically illustrates an exemplary manufacturing system 1000 for engineered stone 100 shown in FIGS. 1A and 1B, the manufacturing system comprising an exemplary improved sealing treatment line 1001, in accordance with an embodiment of the invention. Improved sealing treatment line (ISTL) 1001 is adapted to apply sealant mix 106 to pores 104 on engineered stone 100, and further adapted to seal the pores by curing and drying the sealant mix. It may be appreciated by a person skilled in the art that the configuration described below for ISTL 1001 is for illustrative purposes only, and is not intended to be limiting in any manner. ISTL 1001 may comprise numerous configurations based on production demand and production requirements.

(14) In accordance with some embodiments of the invention, ISTL 1000 comprises a transport system 101 adapted to move engineered stone 100 along the treatment line to different treatment stations, for example, a conveyor belt; a first station 150 comprising equipment adapted to spray sealant mix 106 onto the surface of engineered stone 100; a second station 151 comprising equipment adapted to brush sealant mix 106 over the surface of engineered stone 100 and into microscopic pores 104; a third station 152 comprising equipment adapted to remove excess sealant mix 106 from the surface of engineered stone 100; and a fourth station 153 comprising equipment adapted to cure and dry sealant mix 106 inside pores 104. ISTL 1000 may include any number of stations 150-153 as may be necessary to meet production requirements and demands. Optionally, stations 150-153 may include any number or type of equipment as may be necessary to meet production requirements and demands.

(15) ISTL 1000 may be a fully automatic line wherein engineered stone 100 is automatically moved by transport system 101 through stations 150-153, the equipment in each station automatically activated. Optionally, ISTL 1000 may be a semi-automatic line wherein engineered stone 100 is automatically moved by transport system 101 through stations 150-153, and the equipment in each station is activated by trained personnel. Optionally, ISTL 1000 may be a semi-automatic line wherein engineered stone 100 is moved by transport system 101 through stations 150-153 responsive to instructions received from trained personnel, and the equipment in each station is automatically operated once the engineered stone is detected at the station. Optionally, ISTL 1000 may be a semi-automatic line wherein the operation of transport system 101 and the equipment in workstations 150-153 are activated by trained personnel. Optionally, some of the workstations 150-153 may operate automatically and others activated by trained personnel. Optionally, some of the equipment at each workstation 150-153 may be automatically operated and other equipment activated by trained personnel. Optionally, ISTL 1000 may be a semi-automatic line combining any of the previously described embodiments.

(16) First workstation 150 comprises a spray gun 103 adapted to spray sealant mix 106 onto the surface of engineered stone 100, and a storage container 107 adapted to store the sealant having one or more functional components to be used by the spray gun. Sealant 106 is fed through a feed line 108 from storage tank 107 to spray gun 103. First station 151 optionally comprises a detection device 105 adapted to detect when engineered stone 100 is correctly positioned under spray gun 103, prior to spraying of sealant 106.

(17) Second station 151 comprises a first brush 109A adapted to brush sealant mix 106 over the surface of engineered stone 100 and into pores 104. First brush 109A may be connected to an electronic speed controller/pneumatic lifting lowering system (ESC/PLLS) 110A adapted to control a speed of rotation of the brush and/or to lower and lift the brush from the surface of engineered stone 100. In some embodiments of the invention, first brush 109A may comprise a plurality of brushes. It is noted that the term “brush” as referred to herein may cover one or more brushes and/or one or more brushing systems. In case there is more than one brush, the brushes may be the same or different from each other.

(18) Third station 152 comprises a second brush 109B adapted to remove excess sealant mix 106 from the surface of engineered stone 100. Second brush 109B may be connected to an ESC/PLLS 110B adapted to control a speed of rotation of the brush and/or to lower and lift the brush from the surface of engineered stone 100. Optionally, third station 152 is not required, as station 151 may also be adapted to perform the functions of the third station. In some embodiments of the invention, second brush 109B may comprise a plurality of brushes.

(19) Fourth station 153 comprises a UV tunnel 111, which comprises a UV light 112 adapted to cure and dry sealant mix 106 inside pores 104. Fourth station 153 further comprises an extractor 114 adapted to extract contaminated air from tunnel 111, the air removed to the ambient through an exhaust duct 115. The fourth station optionally comprises a blower 113 adapted to blow substantially clean air into UV tunnel 111.

(20) Reference is made to FIG. 3, which schematically illustrates a flow diagram of an exemplary method of operation of ISTL 1001 shown in FIG. 2, in accordance with an embodiment of the invention. The method of operation is described for engineered stone 100 shown in FIGS. 1A and 1B, comprising, for example, an artificial marble slab.

(21) [STEP 301] Artificial marble slab 100, which comprises an engineered stone 102 including microscopic pores 104, and was manufactured by any manufacturing process used to produce engineered stone as known in the art, is placed on conveyor belt 101.

(22) [STEP 302] Slab 100 is transported by conveyor belt 101 to station 150 where the slab is positioned under spray gun 103. Determining proper positioning of slab 100 under spray gun 103 may be optionally done by detection device 105.

(23) [STEP 303] Upon proper positioning of slab 100 under spray gun 103, sealant mix 106 flows from storage tank 107 through feed pipe 108, to the spray gun. Spray gun 103 sprays sealant mix 106 over surface of slab 100.

(24) [STEP 304] Slab 100 is transported by conveyor belt 101 to station 151 where the slab is positioned under first brush(es) 109A.

(25) [STEP 305] First brush(es) 109A is(are) lowered onto the surface of slab 100 by ESC/PLLS 110A, and brushes sealant mix 106 into pores 104 in the slab. The rotational speed of first brush(es) 109A and the pressure exerted by the brush(es) on the surface of slab 100 may be controlled by ESC/PLLS 110A.

(26) [STEP 306] Slab 100 is transported by conveyor belt 101 to station 152 where the slab is positioned under second brush 109B.

(27) [STEP 307] Second brush(es) 109B is(are) lowered onto the surface of slab 100 by ESC/PLLS 110B, and brushes excess sealant mix 106 from the surface of the slab. The rotational speed of second brush(es) 109B and the pressure exerted by the brush on the surface of slab 100 may be controlled by ESC/PLLS 110B.

(28) [STEP 308] Slab 100 is transported by conveyor belt 101 to station 153, where the slab is introduced into UV tunnel 111 and placed under UV light 112

(29) [STEP 309] UV light 112 is activated and sealant mix 106 inside pores 104 is cured and dried by the UV light. Clean air is optionally blown into UV tunnel 111 by optional blower 113. Contaminated air inside the tunnel is removed by extractor 114 through exhaust duct 115 to the external ambient. Alternatively, curing and/or drying may be by heat or other means other than UV.

(30) [STEP 310] Slab 100 is transported by conveyor belt 101 out of station 153 having finished the improved sealing treatment.

(31) In the description and claims of embodiments of the present invention, each of the words, “comprise” “include” and “have”, and forms thereof, are not necessarily limited to members in a list with which the words may be associated.

(32) The invention has been described using various detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments may comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the invention that are described and embodiments of the invention comprising different combinations of features noted in the described embodiments will occur to persons with skill in the art.