WO2010097727A2

WO2010097727A2 - Engineered stone and methods of producing the same

Info

Publication number: WO2010097727A2
Application number: PCT/IB2010/050611
Authority: WO
Inventors: Ramon Albalak
Original assignee: Caesarstone Sdot Yam Ltd.
Priority date: 2009-02-24
Filing date: 2010-02-10
Publication date: 2010-09-02
Also published as: WO2010097727A3

Abstract

According to some embodiments, there is provided a method of producing an engineered stone slab, which includes, spreading a first layer of raw mixture of engineered stone, placing a separation layers on the first layer, spreading a second layer of raw mixture of engineered stone on the separation layer to form a stack of layers; and vibro-compacting the stack of layers to produce a stack of compacted layers of the raw mixture of engineered stone.

Description

ENGINEERED STONE AND METHODS OF PRODUCING THE SAME

BACKGROUND

As compared to natural stone compositions, such as granite and marble, engineered stone material, such as quartz containing stone material is stronger and more durable. In addition, quartz containing stone material may be cleaner, safer and more consistent than other stone surfaces. Furthermore, quartz containing stone materials may be more resistant to: breakage, scratching, stain, heat, chemicals, freeze-thaw damage and the like.

Composite stone material, such as for example, artificial marble, engineered stone and quartz surfaces, may be found in various settings and may be used for various purposes, such as, for example: Interior wall cladding, 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, countertops and backlashes.

SUMMARY

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above- described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements.

According to some embodiments, there is provided a method of producing an engineered stone slab, which includes, placing one or more separation layers between adjacent layers of raw mixture of engineered stone; and vibro-compacting the mixture to produce a stack of compacted layers of the raw mixture of engineered stone. According to some embodiments, the separation layer may be rigid or flexible. The separation layer may include a solid, a fluid, a liquid medium, a substance, a separation device, or any combination thereof. The separation layer may be disposable or reusable. The separation layer may be placed at any stage of the preparation process of the engineered stone. The separation layer may be removed at any step of the preparation process of the engineered stone.

According to some embodiments, the use of a separation layer in the method for producing engineered stone may allow for the simultaneous preparation of more than one engineered stone slab. In addition, the method may allow the production of slabs of engineered stone, which are thinner than would be produced in the absence of a separation layer. For example, the method may allow the production of slabs of engineered stone, which are thinner than 10 mm. For example, the method may allow the production of slabs of engineered stone, which are thinner than 7 mm. For example, the method may allow the production of slabs of engineered stone, which are thinner than 5 mm.

According to some embodiments, there is provided an engineered stone slab, having a thickness of less than 10mm prior to finishing process. The engineered stone slab may include inorganic particulate component. The inorganic particulate component may include silicon, basalt, glass, diamond, rocks, pebbles, shells, quartz containing materials, crushed quartz, sand, quartz particles, or any combination thereof. The finishing process may include calibrating, polishing, grinding, cutting, sawing, or any combination thereof. The finishing process may be performed after a curing process.

According to yet further embodiments, the use of a separation layer in the method for producing engineered stone may result in enhancing the efficiency of the preparation of engineered stone slabs and may reduce the costs of the preparation of such slabs.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed descriptions. BRIEF DESCRIPTION OF THE FIGURES

Examples illustrative of embodiments 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.

Fig. 1 -A schematic illustration of raw material layers and separation layers, according to some embodiments;

Fig. 2 - A schematic illustration of cross sections of engineered stone slab with supporting layer(s), according to some embodiments;

Figs. 3A-B - Schematic illustration of layering of raw mixture layers, separation layers, support layers and/or reinforcing layers, according to some embodiments;

Figs. 4A-F - Schematic illustrations of cross sections of engineered stone slabs and supporting layer(s), according to some embodiments;

Figs. 5A-B - Schematic illustration of a separation device and its use, according to some embodiments; and Fig. 6A-D - flow charts of a method of producing engineered stone slabs, according to some embodiments.

DETAILED DESCRIPTION

In the following description, various aspects of the disclosure will be described. For the purpose of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the disclosure. However, it will also be apparent to one skilled in the art that the embodiments may be practiced without specific details being presented herein. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiments.

As referred to herein, the terms "engineered stone", "composite stone", "composite stone material", "slab", "artificial marble", 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 "engineered stone", the terms "composite stone material", "slab", "artificial marble", "composite stone" and "quartz surfaces" are also covered.

As referred to herein, the term "raw mixture" is directed to a mixture of the various materials from which the engineered stone is composed of. For example, as further detailed below, the raw mixture may include raw materials, such as inorganic particulate material, aggregates, organic polymers, binders, and the like, and various additional additives (such as, for example, colorants, dyes, pigments, chemical reagents), and the like. The raw mixture may be spread and/or poured to a support or a temporary support (such as, for example, a rubber mold, paper, and the like) to form a cake, prior to being vibrocompacted and cured. Spreading and/or pouring of the mixture may be preformed in the form of layers and/or may be continuous.

As referred to herein, the term "separation layer" is directed to a layer which capable of separating between two adjacent layers of raw mixture during the preparation of the composite stone. The separation layer may be rigid or flexible and may include a solid, a fluid, a liquid medium, a substance, a separation device, or any combination thereof. The length of the separation layer may be shorter, longer or equal to the length of the engineered stone slab. The separation layer may be disposable or reusable. The separation layer may be an integral part of the hardened composite stone slab. The separation layer may be reversibly attached to the hardened composite stone slab. The separation layer may be embedded, partially embedded or not embedded within the hardened composite stone slab.

As referred to herein, the term "reinforcing layer" and "reinforcement layer" may interchangeably be used and are directed to an additional layer that is used to separate between the separation layer and the raw mixture and may further be used to at least partially prevent direct contact between the separation layer and the raw mixture layer. The reinforcing layer may be the support layer and may be used in addition to or instead of a support layer. The reinforcing layer may be an integral part of the separation layer, or may be reversibly attached to the separation layer. The reinforcing layer may be an integral part of the final product (such as, for example, an engineered stone slab product). The reinforcing layer may be embedded, at least partially embedded or not embedded within the final product. The length of the reinforcing layer may be shorter, longer or equal to the length of the engineered stone slab. The reinforcing layer may be rigid or flexible. The reinforcing layer may provide mechanical support, rigidity and stiffness to the product.

As referred to herein, the term "support layer" is directed to an additional layer that is used to separate between the separation layer and the raw mixture and may further be used to at least partially prevent direct contact between the separation layer and the raw mixture layer. The support layer may be integral part of the separation layer, or may be reversibly attached to the separation layer. The support layer does not become part of the final product (such as, for example, an engineered stone slab product). The support layer may be rigid or flexible, solid, fluid, liquid, and the like. The support layer may provide flatness, parallelism and reduce to minimum calibration processes of the final product.

An engineered stone, such as, for example, artificial marble/composite stone stone/quartz surfaces and the like, may be composed of various materials. For example, the engineered stone may be composed mainly of organic polymer(s) and inorganic particulate component. 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 at various particle sizes and at 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 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. In addition, any desired amounts of various additives, may be added to blending of raw materials, at various stages of production to produce the raw mixture. 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, display pattern, 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 raw mixture may later be spread/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 raw mixture is spread/poured to form a cake, for example, substantially in the form of a desired slab (for example, at a size of 306 cm x 144 cm with or without wall shaping). The raw mixture may then be compacted by a special vacuum and vibration process such as vibrocomp action at high pressure such as about 100 Tons. Then, the compressed raw mixture may be placed in a curing and/or hardening kiln, for example, at a temperature in the range of 80⁰C to 115°C for 30 to 60 minutes until it hardens and assumes natural stone properties, but with greater performance and higher resistance to, for example, stains and impact. After completion of the compression and curing process, the slabs may be further processed, such as, for example, 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, 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.

According to some embodiments, in the process for the preparation of engineered stone slabs, a separation layer may be used for the separation between adjacent layers of the raw mixture, which may result in the formation of stacked layers of raw mixture. The use of the separation layers in the preparation process of the engineered stone, may result in the formation of a stack of individual engineered stone slabs, rather than in one slab of larger thickness, had the separation layers not been used. The thickness of the individual engineered stone slabs may be similar or different. The thickness of the individual engineered stone slabs may be in the range of 2-30mm. As detailed below, the separation layer may by rigid or flexible and may include any solid, fluid, substance, liquid medium, a tape, a separation device, and the like, or any combination thereof. The separation layer may be used, for example, during the spreading/pouring of the raw mixture to its support (such as, for example, rubber mold, paper coated/covered mold, and the like). Reference is now made to Fig. 1, which schematically illustrates raw mixture layers and separation layers. As shown in Fig. 1, raw mixture layers 10A-D are separated by separation layers 12A-C. The use of separation layers (such as separation layers 12A-C) results in the formation of stacked layers of raw mixture (such as layers 1 OA-D). Each of the raw mixture layers may be similar or different in composition (such as, for example, percentage (amount) of quartz material, percentage of additional additives), in appearance (such as, for example, in color, in shine, in texture, and the like) and/or size (such as, for example, length, width, thickness). All or some of the raw mixture layers may be further pressed and compacted simultaneously in the presence of the separation layers. In addition or alternatively, each of the raw mixture layers (such as layers 1 OA, 1 OB, 1OC and/or 10D) may further be pressed and compacted individually (in the vibrocompaction step mentioned above), with or without an adjacent separation layer (such as separation layers 12A-C).

According to further embodiments, the separation layer may remain/adhere/stick/bond/attach to the raw mixture layers and/or hardened slab and may further be a part of the raw mixture layers and/or the hardened engineered stone slab. The separation layer may be removed from the raw mixture layers and/or the engineered stone slab by various means, such as, for example, by mechanical means, electrical, magnetic, chemical, physical, ultrasonic, magnetic, peeling, and the like, or any combination thereof. The separation layer may be removed from the raw mixture layers/engineered stone at any stage of the preparation process. For example, the separation layer may be removed during or after the curing step; the separation layer may be removed during or after the processing of the hardened slabs, for example, during or after the mechanical finishing of the slabs (such as, for example, flattening, gauging, calibrating, polishing, and the like of the slab). According to some embodiments, the separation layer may not adhere/stick/ remain with the raw mixture layers and/or hardened slabs.

According to some embodiments, the separation layer may include a rigid or flexible solid, fluid, liquid medium, separation device, and the like, or any combination thereof. For example, the separation layer may include a solid. The solid separation layer may be rigid or flexible and may be comprised of various materials, such as, for example, metal, plastic (such as, for example, polyethylene terphthalate), marble, artificial marble, and the like, or any combination thereof. The solid separation layer may be placed at any stage of the preparation process. The solid separation layer may include, for example, a molding frame, a flat sheet, a smooth-surface sheet, a perforated sheet, a patterned sheet, a textured sheet, an embossed sheet, and the like. The use of non-smooth surface sheet (such as, for example, textured sheet, patterned sheet, embossed sheet) may result in the formation of patterned and/or engineered stone slabs. The solid separation layer may adhere/stick/attach/bond to the raw-mixture layer/hardened slab and may be removed from the mixture by, for example, mechanical means, such as, for example, by peeling the separation layer from the raw material layer/hardened slab. For example, the solid separation layer may be removed from the raw material layer/hardened slab by polishing/calibrating of the slab. According to other embodiments, the solid separation layer does not adhere/stick/attach to the raw material layer/hardened slab and may be removed. According to further embodiments, the separation layer, such as, for example, the solid separation layer may not be in direct contact with the raw mixture layer. In such settings, an additional, one or more reinforcing and/or support layers may be used. The reinforcing and/or support layer may separate between the separation layer and the raw mixture layer and may further be used to prevent direct contact between the separation layer and the raw mixture layer. The reinforcing and/or support layer may be integral part of the separation layer, or may be reversibly attached to the separation layer. The reinforcing and/or support layer may be rigid or flexible, and may include a solid, fluid, liquid, and the like. For example, the reinforcing and/or support layer may include an adhesive tape that may cover the top and/or bottom surface of the separation layer. For example, the reinforcing and/or support layer may include any substance, such as, for example, polyvinyl alcohol. For example, the reinforcing and/or support layer may include a plastic sleeve, a rubber sleeve, and the like. For example, the reinforcing and/or support layer may include a solid substance, such as, for example, an engineered stone, marble, and the like. The reinforcing and/or support layer may be removed at any step of the preparation process of the engineered stone and may be disposable or reusable. The removal of the reinforcing and/or support layer from the separation layer and/or from the raw mixture/hardened engineered stone slab may be performed by various means, such as, for example, mechanical, physical, ultrasonic, electrical, chemical, magnetic, and the like, or any combination thereof.

According to some settings, the length of the solid separation layer may be longer than the length of the raw mixture layer, such that the separation layer is protruding beyond the edge of the raw mixture layers/hardened engineered stone slab. According to other settings, the length of the separation layer may be shorter than the length of the raw mixture layers, such that continuous region of the raw mixture layers are formed at the edges of the engineered stone.

According to yet additional embodiments, the separation layer may include a fluid. The fluid separation layer may be flexible and may be comprised of various materials, such as, for example, polyvinyl alcohol. The separation fluid may be placed (poured) at any step of the preparation process of the engineered stone. For example, the raw mixture may be poured to its frame/support in layers (batches), wherein after each layer of raw mixture, a separation fluid layer is poured, such that the raw mixture layers are separated by the fluid separation layer. The fluid separation layer may be removed from the raw mixture layers/engineered stone at any stage of the preparation process. For example, the fluid separation layer may be removed during or after the curing step; the separation layer may be removed during or after the processing of the hardened slabs, for example, during or after the mechanical finishing of the slabs (such as, for example, flattening, gauging, calibrating, polishing, and the like of the slab). The fluid separation layer may be removed by various means, such as, for example, mechanical means (such as, for example, by peeling, brushing, polishing, and the like); chemical means (such as, for example, by dissolving in water), physical means; and the like, or any combination thereof. According to further embodiments, the fluid separation layer may not adhere/stick/ remain with the raw mixture layers and/or hardened slabs.

Reference is now made to Fig. 2, which demonstrates schematic illustration of cross sections of engineered stone slab, during its preparation process. As shown in Fig. 2, a cross section of engineered stone 20, demonstrates the raw mixture layers 22A-B, which are completely separated by separation layer 24. Raw mixture layers may be similar or different in size, composition and/or appearance. Separation layer 24 may include a solid, a fluid, a liquid medium, and the like. The separation layer may further come in contact with one or more reinforcing and or support layers (not shown in Fig. 2). Separation layer 24 may or may not adhere/attach to the raw mixture layers 22A and/or 22B. The length of separation layer 24 may be longer than the raw mixture layers, such that separation layer 24 has protrusions (shown as protrusions 26A and 26B). The protrusions of separation layer (24) may be used, for example, to allow the physical removal of the separation layer from the raw mixture layers. The removal of the separation layer may be performed at various stages of the preparation process, for example, before the vibrocompaction step, after the vibrocompaction step, before the curing step, after the curing step, and the like. The removal of the separation layer may be performed by various means, such as, for example, by mechanical means, physical means, chemical means, magnetic means, ultrasonic means, and the like, or any combination thereof. Reference is now made to Figs. 3A-B, which schematically illustrates layering of raw mixtures, separation layers and reinforcing and/or support layers, in the preparation of engineered stone slabs. As shown in Fig. 3A, Panel I, on top of raw mixture layer 120A, which was poured/spread onto a frame, reinforcing layer (such as reinforcing layer 122A) is placed. The reinforcing layer may be at least partially embedded within the raw mixture layer. As shown in Fig. 3A, panel II, on top of the raw mixture layer-reinforcing layer (120A- 122A), a separation layer, such as, for example, separation layer 124, is placed. The length of separation layer 124 may be longer than the raw mixture layer. The length of separation layer 124 may be shorter than the raw mixture layer. The length of separation layer 124 may be the same as that of the raw mixture layer. Next, as shown in Fig. 3A, panel III, an additional reinforcing layer (such as reinforcing layer 122B) is placed on top of separation layer 124. The reinforcing layers (such as 122A and 122B) may be identical or different in size, composition, properties and/or appearance. As shown in Fig. 3A, Panel IV, an additional raw mixture layer (such as raw mixture layer 120B) is spread/poured on top of the separation layer 124 and reinforcing layer 122B. As shown in Fig. 3A, panel V, after completion of the preparation process, the reinforcing layer may be an integral part of the engineered stone product (such as engineered stone slabs 123A-B). As shown in Fig. 3B, Panel I, on top of raw mixture layer 130A, which was poured/spread onto a frame, separation layer (such as separation layer 132A) is placed. As shown in Fig. 3B, panel II, a support layer (such as support layer 134) is placed on top of separation layer 132A. The support layer may include a solid, fluid, liquid, and the like. As shown in Fig. 3B, Panel III, on top of support layer 134 an additional separation layer (such as separation layer 132B) is placed. The length of separation layers 132A-B may be longer than the raw mixture layer. The length of separation layers 132A-B may be shorter than the raw mixture layer. The length of separation layer 132A-B may be the same as that of the raw mixture layer. The separation layers (such as 132A and 132B) may be identical or different in size, thickness, composition, properties and/or appearance. As shown in Fig. 3B, Panel IV, an additional raw mixture layer (such as raw mixture layer 130B) is spread/poured on top of separation layer 132B. During the preparation process of the engineered stone slab (as detailed herein), the support layer is removed and does not form an integral part of the engineered stone product and thus, only the final products (for example, the hardened engineered stone slabs, 133A-B) are obtained, as shown, for example, in Fig. 3B, panel V.

According to some embodiments, the support layer may also function as the separation layer. In such case, there may be no need for a separation layer in addition to the support layer. According to yet additional embodiments, the reinforcement layer may also function as the separation layer. In such case, there may be no need for a separation layer in addition to the reinforcement layer.

Reference is now made to Fig. 4A-F, which demonstrates schematic illustration of cross sections of engineered stone slabs at various stages of the preparation process with various separation layers/raw mixture layers. As shown in Fig. 4A, a cross section of engineered stone 30, demonstrates raw mixture layers 32A- B, which are at least partially separated by separation layer 34. The raw mixture layers may be similar or different in size, composition and/or appearance. Separation layer 34 may include a solid, a fluid, a liquid medium, and the like. Further shown are reinforcing and/or supporting layers 35A-B, which are further used to separate between the separation layer and the raw mixture layers. Reinforcing and/or supporting layers 35A-B may or may not adhere/attach to the raw mixture layers 32A and/or 32B, respectively. The length of separation layer 34 may be shorter than the raw mixture layers, such that the raw mixture layers 32A-B are not completely separated and a continuous region of the raw mixture layers at all or some of the edges (such as, edges 33 A-B) of the engineered stone is formed. The formation of the continuous region of the raw mixture layers at the edges of the engineered stone may ensure structure stability at later stages of the preparation process, such as, for example during polishing and calibration of the hardened engineered stone slab. The removal of the reinforcing layers and/or the separation layer may be performed at various stages of the preparation process of the engineered stone, such as, for example, after the vibrocomp action step, before the curing step, after the curing step, after mechanical finishing, and the like. For example, as shown in Fig. 4B, a cross section of hardened engineered stone slab (that is, engineered stone after the curing stage), 40, demonstrates the hardened mixture layers 42A-B, which are at least partially separated by separation layer 44. Further shown are reinforcing layers/supporting layers 45A-B, which further used to separate between the separation layer and the raw mixture layers. Cutting (for example, by sawing/trimming) the edges of the hardened engineered stone at the indicated locations 46A-B, which correspond to inner region, within the continuous region of the mixture layers that are not separated by the separation layers, results in the formation of a partially processed hardened engineered stone. As shown in Fig. 4C, the hardened engineered stone (such as the one produced in Fig. 4B) may further be proceed by separation and/or removal of separation layer (50) and/or support layers (52A-B) from the hardened engineered stone. The removal of the separation layer and/or the support layer result in the formation of two individual, separate hardened engineered stone slabs, 54A-B, which may be further processed to any desired finish. The resulting individual, separate hardened engineered stone slabs may be similar or different in size, composition and/or appearance. The removal of the separation layer and/or the support layers may be performed by various means, such as, for example by chemical means, dissolving (for example, dissolving by water or other dissolving fluids), physical means, mechanical means, and the like, or any combination thereof. The separated separation layer (such as separation layer 50) and/or supporting layers (such as supporting layers 52A-B) may be reusable and/or disposable. As shown in Fig. 4D, the hardened engineered stone (such as the one produced in Fig. 4B) may further be processed by separation and/or removal of separation layer (60) and/or reinforcing layers (62A-B) from the hardened engineered stone. The removal of the separation layer and/or the reinforcing layer result in the formation of two individual, separate hardened engineered stone slabs, 64A-B, which may be further processed to any desired finish. The resulting individual, separate hardened engineered stone slabs may be similar or different in size (such as, for example, length, thickness, width), composition (percentage of quartz particles, amount of various additives, and the like) and/or appearance (such as, for example, color, shine, texture, and the like). The removal of the separation layer and/or the reinforcing layers may be performed by various means, such as, for example by chemical means (dissolving by water), physical means, mechanical means, and the like, or any combination thereof. As shown in Fig. 4D, the separation layer (such as separation layer 60) may be completely separated from the individual, separate hardened engineered stone slabs, 64 A-B. The reinforcing layers (such as reinforcing layers 62A-B) may stick/adhere to the hardened engineered stone slabs, 64A-B, and may later be removed, at will, from the engineered stone slabs. In addition or alternatively, the reinforcing layers (such as reinforcing layers 62A-B) may remain as integral part the hardened slabs and provide mechanical support to the engineered stone slab, as well as to provide enhanced properties to the engineered stone, such as, for example, enhanced structural stability, enhance the appearance of the engineered stone (such as, for example, by adding a pattern to the surface of the slab, changing the texture of the surface of the slab, changing the color of the slab, changing the brightness of the slab, and the like). The separation layer (such as separation layer 60) and/or reinforcing layers (such as reinforcing layers 62A-B) may be reusable and/or disposable. As further shown in Fig. 4E, the separation layer (such as separation layer 70) may be completely separated from the individual, separate hardened engineered stone slabs, 74A-B. The reinforcing layers (such as reinforcing layers 72A-B) may become an integral part the hardened slabs and may be completely, or at least partially embedded within the engineered stone slab, and thus provide mechanical support to the engineered stone slab, as well as to provide enhanced properties to the engineered stone. According to further embodiments, and as illustrated in Fig. 4F, a reinforcement layer may be used, without the use of a separate support layer. In such a setting, the reinforcement layer (such as layer 76) may function both as a reinforcing layer and a support layer. According to some embodiments, and as shown in Fig. 4F, panel I, the reinforcing layer (such as reinforcing layer 76) may be cut/sliced along its length (for example along axis 77, which may be located at various thicknesses), such that the individual hardened engineered stone slabs (slabs 78A-B) may be separated. Cutting of the reinforcement layer may be performed at any stage of the preparation process (for example, after vibrocompaction of the raw mixture, after hardening of the raw mixture, and the like). Cutting through the reinforcement layer, may result in the formation of individual engineered stone slabs that are separated at the region wherein the reinforcement layer is placed. As shown in Fig. 4F, panel II, within each of the resulting individual engineered stone slabs (slabs 78A-B), a slice of reinforcement layer (such as reinforcement layer slices 79 A-B) is at least partially embedded. The reinforcement layer slices (such as slices 79A-B) were created by the cutting of reinforcement layer 76. The thickens of the reinforcement layer that is at least partially embedded within the resulting individual engineered stone slabs may be identical or different between the various slabs, and is determined by the cut of the reinforcement layer. According to yet additional embodiments, the separation layer may include a separation device. The separation device may include, for example a retracting device, that may be placed between two layers of raw mixture and, after processing of the engineered slab, may be removed. The separation device may be reusable and may be comprised of various materials, such as, for example, metal, hardened plastic, and the like. The separation device may be placed at any step of the preparation process of the engineered stone. For example, the raw mixture may be poured to its frame/support in layers (batches), wherein after each layer of raw mixture, a separation device is placed, such that the raw mixture layers are separated by the separation device. The amount and/or composition of the raw mixture that is poured/spread at each layer (batch) may be similar or different. The composition and amount of raw mixture poured at layer (batch) may determine the final properties and/or thickness, respectively of the engineered stone slabs produced at the end of the process. The separation device may be placed within a support layer, such as, for example, in the form of a support sleeve that separates between the separation device and the raw mixture. The separation device may completely or partially separate between adjacent layers of raw mixture. The separation device may be removed from the raw mixture layers/engineered stone at various stages of the preparation process. For example, the separation device may be removed during or after the curing step. The separation device may be removed by, for example, mechanical means and/or physical means. Reference is now made to Fig. 5A-B, which illustrates a separation device and its use, according to some embodiments. As shown in Fig. 5A, top panel, separation device, such as separation device 80 may be constructed of two parallel surfaces, such as surfaces 82A-B. Surfaces 82A-B may be connected by retracting hinges, such as hinges 84A-D. The hinges are interconnected by a common axis (86), which is in the form of a helical screw. When turning helical axis, 86, by central bolt (88), the hinges fold, thus reducing the vertical distance between surfaces 82A-B. Lower panel of Fig. 5A illustrates separation device at a retracted state. As shown in Fig. 5B, panel A, a cross section of engineered stone 90, demonstrates raw mixture layers 92A-B, which are at least partially separated by separation device 94. Further shown is supporting layer 95, which is in the form of a sleeve, which separates and prevents direct contact between the separation device and the raw mixture layers. Supporting layer 95 may or may not adhere/attach to the raw mixture layers 92A and/or 92B. The length of separation device 94 is shorter than the raw mixture layers, such that the raw mixture layers 92A-B are not completely separated and a continuous region of the raw mixture layers at some or all edges (93 A-B) of the engineered stone is formed. The formation of the continuous region of the raw mixture layers at the edges of the engineered stone may ensure structure stability at later stages of the preparation process, such as, for example during polishing and calibration of the hardened engineered stone slab. After curing of the engineered stone, the separating device may be retracted (as demonstrated in Fig. 5B, panel B). Once fully retracted, the separation device may be removed from within the supporting layer, to result in slab 96 of Fig. 5B, panel C. Slab 96 may be further processed, for example, by trimming/sawing the edges of the slab at the indicated locations 97A-B, which correspond to the continuous region of the mixture layers that are not separated by the separation device. After trimming the slab, as shown in Fig.4D, the supporting layer (such as support sleeve 95) may be removed and two individual, separate hardened engineered stone slabs, 98A-B are produced. The individual, separate hardened engineered stone slabs may be further processed to a desired finish and appearance. The resulting individual, separate hardened engineered stone slabs may be similar or different in size, composition and/or appearance.

According to some embodiments there is thus provided a method for the preparation of an engineered stone slabs, the method includes preparing a raw mixture (composed of organic polymer(s), inorganic particulate component(s) and additional additives), pouring/spreading the mixture to a support or temporal support, continuously or in layers (batches), wherein between the raw mixture layers, a separation layer (with or without reinforcing and/or separation layers) is added. The composition of the raw mixture spread/poured at each layer may be similar or different. The amount of the raw mixture poured at each layer may be similar or different. The separation layer may be rigid or flexible and may include any solid, a fluid, a liquid medium, a separation device, and the like. When using more than one separation layer in the process, the separation layers may be similar or different in size, amount, texture and/or composition. For example, the separation layer may include a solid, such as, for example a solid sheet that may be placed on top of each layer of raw mixture. The solid sheet used may be similar or different between different layers of raw mixture. For example, the separation layer may include fluid that may be poured over each raw mixture layer. For example, the separation layer may include a separation device that may be placed between adjacent layers of raw mixture. The separation layer may completely or partially separate between the adjacent layers of raw mixture layers. After the raw mixture and the separation layers have been placed/poured, the engineered stone may be further processed. For example, the engineered stone may be pressed and compacted (vibrocompaction). After the vibrocompaction, the separation layers may be separated and/or removed from the engineered stone. The engineered stone may be further processed, for example, by curing of the engineered stone slabs. After the curing process, if not yet removed, the separation layers may be separated and/or removed from the engineered stone, to result in individual hardened engineered stone slabs. The individual engineered stone slabs may further be processed, for example by calibration, polishing, and the like. The resulting individual hardened engineered stone slabs may be similar or different in their size (such as length, width, thickness), in their composition (such as, for example in the percentage (amount) of quartz material, percentage of additional additives), and/or in their appearance (such as, for example, in color, in shine, in texture, and the like). If not yet removed, and if so desired, the separation layers may be removed from the engineered stone by various means, such as, for example, mechanical means, physical means, chemical means, and the like, or any combination thereof. Likewise, if used and if so desired, the reinforcing and/or supporting layers may be separated/removed at any step of the preparation process of the engineered stone slab. The method for the preparation of an engineered stone slabs exhibit several advantages over methods known in the art. The method allows for several individual slabs of engineered stone to be produced simultaneously, wherein the resulting slabs may be similar or different (for example, in size, composition and/or appearance). The method may further be applied to produce slabs, which are thinner than ordinarily obtained slabs, by overcoming practical limitations of lower limit of slab thickness which may be encountered with prior art methods. The method may be used to increase the effective throughput of a production line, thus increasing efficiency and lowering costs. The method may result in lowering costs of production of engineered stone slabs, by reducing the use of various disposables (such as, for example, paper) in the preparation process. The method may result in faster production as some steps of calibration and polishing may be eliminated due to the use of the separation layer in the production of the engineered stone. In addition, as explained above, when using patterned separation layers, slabs with enhanced appearance are obtained at lower costs and reduced production and processing time.

Reference is now made to Figs. 6A-D, which illustrates flow charts of methods of producing engineered stone slabs, according to some embodiments. As shown in Fig. 6A, at step 100, raw mixture (composed of organic polymer(s), inorganic particulate component(s) and additional additives) is prepared. At step 102, the raw mixture is poured and spread to a support or temporary support continuously or in layers (batches). At step 104, a separation layer is placed on top of the layer of raw mixtures. At step 106, additional layer of raw mixture is spread on top of the separation layer. The amount and/or composition of the raw mixture may be similar or different at different layers. In step 108, the engineered stone mixture is further processed, for example, by vibrocompaction. At step 110, the stack (or individual) engineered stone is cured and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At optional step 112, the edges of the cured engineered stone (stack of slabs or individual slabs) are cut away and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At step 114, the separation layer is separated and/or removed from the hardened engineered stone so as to result in formation of individual slabs of engineered stone. At step 116, the separated engineered stone slabs may be further processed, for example by calibration and polishing to a desired finish. As shown in Fig. 6B, at step 200, raw mixture (composed of organic polymer(s), inorganic particulate component(s) and additional additives) is prepared. At step 202, the raw mixture is poured and spread to a support or temporary support continuously or in layers (batches). At step 204, a reinforcement layer is placed on top of the raw mixture layer. At step 206, a separation layer is placed on top of the reinforcement layer, which is located on the layer of raw mixture. At step 208, an additional reinforcement layer is placed on top of the separation layer. At step 210, an additional layer of raw mixture is spread on top of the reinforcement layer. The amount and/or composition of the raw mixture may be similar or different at different layers. At step 212, the engineered stone mixture is further processed, for example, by vibrocompaction. At step 214, the stack (or individual) engineered stone is cured/hardened and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At optional step 216, the edges of the cured engineered stone (stack of slabs or individual slabs) are cut away and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At step 218, the separation layer is separated and/or removed from the hardened engineered stone so as to result in formation of individual slabs of engineered stone, wherein the reinforcement layers (if not removed) form an integral part of the engineered stone slabs and may be at least partially embedded within the engineered stone slabs. At step 220, the separated engineered stone slabs may be further processed, for example by calibration and polishing to a desired finish. As shown in Fig. 6C, at step 300, raw mixture (composed of organic polymer(s), inorganic particulate component(s) and additional additives) is prepared. At step 302, the raw mixture is poured and spread to a support or temporary support continuously or in layers (batches). At step 304, a separation layer is placed on top of the raw mixture layer. At step 306, a support layer is placed on top of the separation layer, which is located on the layer of raw mixture. At step 308, an additional separation layer is placed on top of the support layer. At step 310, an additional layer of raw mixture is spread on top of the reinforcement layer. The amount and/or composition of the raw mixture may be similar or different at different layers. At step 312, the engineered stone mixture is further processed, for example, by vibrocompaction. At step 314, the stack (or individual) engineered stone is cured/hardened and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At optional step 316, the edges of the cured engineered stone (stack of slabs or individual slabs) are cut away and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At step 318, the separation layer and/or support layer are separated and/or removed from the hardened engineered stone so as to result in formation of individual slabs of engineered stone. At step 320, the separated engineered stone slabs may be further processed, for example by calibration and polishing to a desired finish. As shown in Fig. 6D, at step 400, raw mixture (composed of organic polymer(s), inorganic particulate component(s) and additional additives) is prepared. At step 402, the raw mixture is poured and spread to a support or temporary support continuously or in layers (batches). At step 404, a reinforcement layer is placed on top of the raw mixture layer. At step 406, an additional layer of raw mixture is spread on top of the reinforcement layer. The amount and/or composition of the raw mixture may be similar or different at different layers. At step 408, the engineered stone mixture is further processed, for example, by vibrocomp action. At step 410, the stack (or individual) engineered stone is cured/hardened and optionally, mechanical finishing (such as, for example, grinding, polishing, brushing, and the like) may be applied. At step 412, cutting through the reinforcement layer (along its length) may be performed, such that individual separated engineered stone slabs are formed. The cut reinforcement layer becomes an integral part of the individual separated engineered stone slabs such that the reinforcement layers are at least partially embedded within each of the slabs (step 414). At step 416, the separated engineered stone slabs may be further processed, for example by calibration and polishing to a desired finish.

While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced be interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.

EXAMPLES

Table 1 herein below provides a summary of the thickness (width, in millimeters (mm)) of various engineered stone slabs produced by the use of separation layers. Table 1 indicates the thickness of the stack of the layers of the engineered stone, and the thickness of the individual engineered stone slabs products. Also indicated are the number and composition of the separation layers used in the preparation process.

Table 1

Claims

CLAIMSWhat is claimed is:

1. A method of producing an engineered stone slab comprising:

spreading a first layer of raw mixture of engineered stone;

placing a separation layer on the first layer of raw mixture of engineered stone;

spreading a second layer of raw mixture of engineered stone on the separation layer to form a stack of layers; and

vibro-compacting the stack of layers to produce a stack of compacted layers of the raw mixture of engineered stone.

2. The method of claim 1, further comprising hardening the stack to produce a stack of engineered stone slabs.

3. The method of claim 1, further comprising spreading a multiplicity of layers of raw mixture of engineered stone, separated by separation layers, prior to the step of vibro-compacting.

4. The method of claim 1, further comprising placing a reinforcement layer on the first layer of raw mixture prior to placing the separation layer.

5. The method of claim 1, further comprising placing a reinforcement layer on the separation layer prior to spreading the second layer of raw mixture.

6. The method of claim 1, further comprising placing a support layer on the separation layer prior to spreading the second layer of raw mixture.

7. The method of claim 1, wherein the separation layer is further adapted to function as a support layer and/or reinforcing layer.

8. The method of claim 2, further comprising separating between at least two adjacent engineered stone slabs to obtain at least one separated engineered stone slab.

9. The method of claim 2, further comprising removing the separation layer, thereby separating between two adjacent engineered stone slabs.

10. The method of claim 2, further comprising cutting through the separation layer, thereby separating between two adjacent engineered stone slabs.

11. The method of claim 10, further comprising finishing at least one surface of a separated engineered stone slab.

12. The method of claim 1, wherein the separation layer is rigid or flexible.

13. The method of claim 1, wherein the separation layer comprises metal sheet, polyethylene terphthlate sheet, marble sheet, artificial marble sheet, polyvinyl- alcohol, or any combination thereof.

14. The method of claim 1, wherein the separation layer comprises a flat surface, a frame, a patterned surface, or any combination thereof.

15. The method of claim 1, wherein the thickness of the individual engineered stone slabs is smaller than 5 mm.

16. An engineered stone slab, having a thickness of less than 5 mm prior to finishing process.

17. The engineered stone slab of claim 16, comprising inorganic particulate component.

18. The engineered stone slab of claim 17, wherein said inorganic particulate component comprises silicon, basalt, glass, diamond, rocks, pebbles, shells, quartz containing materials, crushed quartz, sand, quartz particles, or any combination thereof.

19. The engineered stone slab of claim 16, wherein the finishing process comprises calibrating, polishing, grinding, cutting, sawing, or any combination thereof.

20. An engineered stone slab, produced by a process comprising:

spreading a first layer of raw mixture of engineered stone; placing a separation layer on the first layer;

21. The engineered stone slab of claim 20, wherein said process further comprises hardening the stack to produce a stack of engineered stone slabs.

22. The engineered stone slab of claim 20, wherein said process further comprises spreading a multiplicity of layers of raw mixture of engineered stone, separated by separation layers.

23. The engineered stone slab of claim 20, wherein said process further comprises placing a reinforcement layer on the first layer of raw mixture prior to placing the separation layer.

24. The engineered stone slab of claim 23, further comprising placing a reinforcement layer on the separation layer prior to spreading the second layer of raw mixture.

25. The engineered stone slab of claim 20, wherein said process further comprises placing a support layer on the separation layer prior to spreading the second layer of raw mixture.

26. The engineered stone slab of claim 20, wherein the separation layer is adapted to function as a support layer and/or reinforcing layer.

27. The engineered stone slab of claim 21, wherein said process further comprises separating between at least two adjacent engineered stone slabs to obtain at least one separated engineered stone slabs.

28. The engineered stone slab of claim 21, wherein said process further comprises removing at least one of the one or more separation layers.