WO2024256932A1 - Élément décoratif comprenant une pierre modifiée et procédé de fabrication d'un élément décoratif comprenant une pierre modifiée - Google Patents

Élément décoratif comprenant une pierre modifiée et procédé de fabrication d'un élément décoratif comprenant une pierre modifiée Download PDF

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Publication number
WO2024256932A1
WO2024256932A1 PCT/IB2024/055573 IB2024055573W WO2024256932A1 WO 2024256932 A1 WO2024256932 A1 WO 2024256932A1 IB 2024055573 W IB2024055573 W IB 2024055573W WO 2024256932 A1 WO2024256932 A1 WO 2024256932A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
decorative element
mixture
engineered stone
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2024/055573
Other languages
English (en)
Inventor
Rahul Patki
Marco Trevisan
Giorgia TORRI
Cristian BERTI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dal Tile LLC
Original Assignee
Dal Tile LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dal Tile LLC filed Critical Dal Tile LLC
Priority to EP24822913.0A priority Critical patent/EP4727778A1/fr
Priority to CN202480039684.8A priority patent/CN121335809A/zh
Publication of WO2024256932A1 publication Critical patent/WO2024256932A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18—Polyesters; Polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/005—Devices or processes for obtaining articles having a marble appearance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0845—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for smoothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/022—Feeding several successive layers, optionally of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • B29C67/244—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length by vibrating the composition before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • 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
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/805—Transparent material

Definitions

  • a decorative element comprising an engineered stone and a method for manufacturing a decorative element comprising an engineered stone.
  • the invention relates to a decorative element comprising an engineered stone and to a method for manufacturing a decorative element comprising an engineered stone.
  • the decorative element of the invention is of the type normally manufactured in form of a slab and used as cladding of building surfaces and/or as a top for furniture, for example a kitchen countertop.
  • the engineered stone of the invention is often known on the market as quartz.
  • Said document discloses a method for manufacturing an engineered stone which comprises the step of: providing a inorganic filler, for example by grinding sand or quartz; mixing the stone or stone like material with a binder, for example a resin powder, in order to obtain a mixture; depositing the mixture in a mold of a press, having shape and dimension similar to those of the final article; press the mixture applying vacuum, with the accompanying application of a vibratory motion at pre-established frequency; the semi-product obtained is then hardened by means of a heat curing process to obtain the engineered stone; the engineered stone is then subjected to finishing steps like cutting or polishing.
  • a inorganic filler for example by grinding sand or quartz
  • a binder for example a resin powder
  • WO 2016/113652 discloses equipment and a method for creating programmable chromatic effect in an engineered stone by means of a computer-controlled machine.
  • the machine is an anthropomorphous robot or a cartesian robot provided with one or more nozzles for dispensing a coloring agent on the surface of a mixture in a temporary support.
  • the nozzle is connected to a tool that interacts with the surface of the mixture to create grooves or holes to receive the color in order to imitate marble veins.
  • this equipment needs a machine work of the mixture and provides for decor imitating natural stone with a relative low-quality resolution. This technology is slow and has limits in the dimension of the imitated veins that can be imitated.
  • WO20 19070621 discloses a method for improving the aesthetic quality of the engineered stone by inkjet printing a decor on a main surface of the stone.
  • engineered stone is formed by an inorganic filler which, in most of the cases, is prevalently formed by silica sand, in particular cristobalite.
  • Cristobalite represents the best choice for the inorganic filler for its hardness, durability and, most of all, for the aesthetical performances.
  • cristobalite, as well as other crystalline silica containing minerals can lead, if inhaled, to the development of a disease known as silicosis. For this reason, several attempts have been performed to identify alternative inorganic fillers. As disclosed, for example by US20220089485 and US20220332640, these attempts have been focused on glass-based fillers, or on feldspar. Nevertheless, it remains a challenge to identify non-crystalline silica based organic filler showing comparable aesthetic performances, limited cost and consistency of supply.
  • the present invention aims in the first place at providing an alternative decorative element, which, in accordance with several of its preferred embodiments, is directed to solve one or more of the problems arising in the state of the art.
  • the present invention according to its first independent aspect decorative element comprising a first layer made of an engineered stone, with the characteristic that the decorative element comprises a second layer disposed above of said first layer and wherein said second layer is made of an engineered stone.
  • the first layer is different from second layer.
  • the engineered stone comprises at least an inorganic filler and a binder, the binder being preferably polymeric, more preferably thermosetting.
  • the first composition comprises a content of crystalline silica being lower than 50% based on the weight of the first filler composition, preferably lower than 10% on a base weight, more preferably is free from crystalline silica.
  • “predominant in minerals containing crystalline silica” means that the second composition comprises a content of crystalline silica being equal or above 50% based on the weight of the second filler composition. In this way it may be possible to provide a decorative element having the desired aesthetic value, which is relatively easy to achieve with crystalline silica containing minerals, and at the same time limiting the overall content of crystalline silica.
  • the layer having a filler composition which is predominant in minerals containing crystalline silica can show a thickness equal or lower than the layer having a filler composition which is predominant in minerals different from minerals containing crystalline silica.
  • said first and second layer are both formed by filler composition predominant in minerals different from minerals containing crystalline silica, albeit having different composition so that, for example, aesthetically performing but expensive fillers like frits or recycled glass can be limited to only one of the layers, whereas cheaper fillers are used for the other layer so that the overall cost of the decorative element is reduced.
  • said first and second layer are both formed by filler composition predominant in minerals containing crystalline silica, albeit having different composition so that, for example, aesthetically performing but expensive fillers like cristobalite can be limited to only one of the layers, whereas cheaper fillers are used for the other layer so that the overall cost of the decorative element is reduced.
  • said first and second layer are configured such that the overall content of crystalline silica in the decorative element is below the 50%, preferably below 30%, more preferably below 25% based on the total weight of the decorative element.
  • the second layer can form less than a half of the thickness of the decorative layer, for example less than one third of said thickness.
  • the second layer can form an upper and visible layer of the decorative element, thereby providing for an enhanced visible effect, whereas the first layer can form the majority of the thickness of the decorative layer so that the content of crystalline silica is minimized, and the risk of silicosis reduced.
  • said first and second layer can comprise a different color.
  • the engineered stone forming the first layer comprises one or more first pigments, said first pigments being different form second pigments contained in the engineered stone forming the second layer.
  • one of said first and second layer can be transparent or translucent.
  • the other layer between said first and second layer is opaque.
  • the engineered stone of the forming said transparent or translucent layer can comprise a binder having an index of refraction which substantially identical to the index of refraction of the filler composition of the respective layer.
  • the engineered stone forming said transparent or translucent layer is free from pigment. In this way, the other layer of the decorative element can be visible through the transparent or translucent layer so that the transparent or translucent layer can act as a protective layer for the other layer.
  • the decorative element can comprise an intermediate layer between the first and the second layer.
  • Said intermediate layer can preferably comprise a decorative pattern being visible through the transparent or translucent layer, so that the transparent or translucent layer forms a protective layer adapted to protect said decorative pattern from wear and scratch.
  • the intermediate layer can be formed according to two main alternatives which are below described.
  • by forming a decorative pattern in an intermediate layer it can be possible to standardize the process for manufacturing the engineered stone of the first and the second layer, as the decorative pattern can be made in a separate layer.
  • the intermediate layer can be formed by a thin layer of engineered stone comprising a printed pattern formed by colored pigments distributed according to a pattern.
  • the printed pattern is printed on the surface of one between the first and second layer.
  • with printed directly it is meant that the printing operation is performed directly on the layer, in contraposition with those embodiments where the printing operation is performed on a separate printing substrate, like a foil, which is subsequently provided on the first layer.
  • said pigments forming the printed pattern are inorganic pigments.
  • the filler composition forming the engineered stone of the first and/or the second layer can be in form of powder, granules, shards, grains, aggregates or any other particulate form although granules and powder forms are preferred.
  • the filler is in powder form having an average particle dimension lower than 45 pm, preferably lower than 20 pm.
  • the filler is preferably at least the 80% by weight of the engineered stone, preferably more than the 85% and more preferably more than 90%.
  • the filler can be in form of aggregates, grains and/or granules having a particles size distribution between 0,1 and 6,5 mm, preferably between 0,1 and 2mm, 0,1 and 0,7 mm.
  • the filler is composed by a combination of powder and grains, for example said combination can comprise at least 60 wt% of grains and/or granules and between 20 to 35 wt% of powder form wherein, for example, the granules have a particles size distribution between 0,1 and 6,5 mm and the powder have an average particle dimension lower than 45 pm, preferably lower than 20 pm.
  • the binder of the engineered stone forming the first and/or the second layer comprises, preferably substantially consists of, polyester resin preferably unsaturated polyester resin.
  • Less preferred alternative solutions for the binder comprise acrylic resin, epoxy resin, polyurethane, rubber, vinyl ester resin or the like.
  • the binder is preferably less than the 20% by weight of the engineered stone, preferably less than the 15% and more preferably less than 10%.
  • the engineered stone forming the first and/or the second layer can comprise additives, like for example coupling agents, catalyst or reagents to activate or speed up hardening of the binder, and/or temporary bonding agent like glues or thermoplastic resins that temporarily bonds the filler.
  • the additives comprise at least a silane-based coupling agent.
  • the additive can comprise crosslinkers and/ or catalysts to activate and/or accelerate curing of the binder.
  • the engineered stone forming the first and/or the second layer can comprise one or more coloring agents.
  • Said coloring agent can be in the form of dye or pigment. Pigments are normally preferred as they provide a better UV resistance to the final engineered stone. Pigments can be organic or inorganic, the latter are even more preferred as the UV resistance is further improved. Preferred colors for the coloring agent are black, yellow, white, red and green. Said coloring agent or agents can be distributed in the engineered stone in various form to form a decorative pattern that can be random or predetermined.
  • the decorative element has a substantially flat shape like a board, a tile or a slab.
  • the decorative element is a slab wherein with slab is intended a substantial rectangular and flat form, preferably comprising a surface of minimum 1,5 square meters.
  • the decorative element is in a shape that is sufficiently large to be versatile and adapted to be cut according to the dimension and shape of the final destination of the engineered stone itself, like for example a kitchen or bathroom countertops.
  • the slab has a length of at least 2 m, preferably at least 2,5 m, for example 3 m or more, and a width of at least 1 m preferably 1,5 m or more.
  • the slab preferably shows a thickness of at least 10 mm, preferably at least 20 mm for example 30 mm.
  • the first and the second layer can have different thicknesses. In this way, in this way the thicknesses configuration can be arranged in such a way to maximize the effect provided by any of the layers and by the specific combination of the thicknesses.
  • the invention relates to a method for manufacturing a decorative element that comprises the steps of:
  • the decorative element obtained through the method of the second independent aspect can be according to the first independent aspect.
  • the decorative element obtained through the method of the second independent aspect can comprise one or more of the features described in relation to the first independent aspect.
  • the filler composition, the engineered stone, the binder can comprise one or more of the features described in connection to the first independent aspect.
  • the carrier can comprise a mold having at least a bottom and side walls to contain the mixture.
  • the carrier can also comprise a lid to close the mold.
  • the mold and the lid can be made of rubber.
  • the carrier can comprise one or more paper sheets.
  • the mold can have the shape and dimension similar to those of the decorative element to be finally obtained.
  • the compacting step is conducted under vacuum, i.e. vacuum is generated in the mold to help extracting air between the mixture particles.
  • vacuum is generated in the mold to help extracting air between the mixture particles.
  • vibration is applied to the mold or frame during the compacting step thereby helping to compact of the mixture particles, so that the porosity of the engineered stone is significantly reduced.
  • both vacuum and vibration are applied to the mixture during the compression. In this way, it is possible to obtain a very high degree of compaction of the mixture that after curing will lead to an extremely low porosity.
  • the mixtures in the mold are carried to a curing station.
  • the cure of the binder can be obtained by means of radiation, heat, chemical curing or other suitable techniques.
  • the curing step is conducted at a temperature below 500°C, for example below 200°C, for example at room temperature.
  • the curing step can be thermally activated and continues in an exothermic reaction. The activation of the curing of the binder can occur at a temperature below 100°C.
  • the engineered stone After curing the engineered stone comprises a porosity below 1% in volume, more preferably below 0,5% in volume, even more preferably below 0,2%, in volume.
  • the engineered stone After curing, the engineered stone is extracted from the mold. In some, embodiments the engineered stone is cooled and/or conditioned before performing further steps.
  • the method can comprise a calibration step and/or a squaring step.
  • Calibration and squaring are mechanical machining steps that have the scope of providing to the engineered stone the final desired shape and dimension.
  • calibration has the scope of flattening one or both the main surfaces of the slab made of engineered stone.
  • the mixtures can be provided in different forms, for example in form of a pasty material or a slip, although a dry form, for example incoherent particulate, is preferred.
  • the binder, in the uncured state can be provided in solid or liquid form.
  • the uncured binder can show some adhesive behavior that tends to stick the filler particles together.
  • the pre-compaction can lead to a stretching of the mixture and of the pigments contained therein so that also the resulting decor is stretched in the advancing direction of the mixture between the rollers. Thanks to the combination of a pre-compacted layer and non-pre-compacted layer, the resulting decorative element can show a non-stretched decor while showing some of the advantages of precompaction.
  • the non-pre-compacted layer can be provided on the carrier forming a layer having a thickness which can be at least the double of, preferably at the least three or four time larger than, the thickness of the same layer after the compaction step and/or the curing steps.
  • the pre-compacted layer is applied first on the carrier and the non-pre-compacted layer is provided secondly on the carrier.
  • the precompacted mixture can show a certain rigidity and/or flatness that can help subsequent operation that will be better described below.
  • the non-pre- compacted layer is applied first on the carrier and the pre-compacted layer is provided secondly on the carrier.
  • the method can comprise one or more steps for forming a decorative pattern on the decorative element.
  • Said decorative pattern can be provided according to several measures either alone or in combination each other
  • the method can comprise a step of printing, preferably inkjet printing, a decorative pattern on the surface of the pre-compacted layer.
  • Said inkjet printing can be performed using pigment containing inks, said pigments can preferably be inorganic pigments albeit organic pigments are not excluded.
  • a decorative foil as described in connection with the first independent aspect is provided on top of the first layer.
  • the first layer in the carrier is the pre-compacted mixture and the second mixture is provided after providing the decorative foil.
  • a first coloring agent or a first set of coloring agent can be added to the mixture.
  • the first coloring agent, or first set of coloring agent can be uniformly distributed in the mass of mixture to provide basic color of the engineered stone.
  • the first coloring agent, or first set of coloring agent can be distributed according to a random motif, like a random veined effect or a dotted effect.
  • a second coloring agent or second set of coloring agent can be provided according to a predetermined motif e.g. a veined effect imitating the veins or flakes of a marble, a granite or any natural stone.
  • the predetermined pattern can be formed using computer-controlled machines, like for example an anthropomorphous robot or a cartesian robot, provided with one or more nozzles for dispensing the coloring agent. The nozzle is connected to a tool that interacts with the surface of the mixture to create grooves or holes to receive the coloring agent.
  • said predetermined motif is obtained using computer-controlled machines like those described in WO 2016/113652.
  • Figure 1 shows a perspective view of a decorative element according to a first embodiment of the invention
  • Figure 2 shows on an enlarged scale the section along plane II-II of figure 1;
  • Figure 3 shows some steps in a method for manufacturing the decorative element of figure 1;
  • Figure 4 shows the view of figure 2 of a decorative element according to a second embodiment
  • Figure 5 shows some steps in a method for manufacturing the decorative element of figure 4.
  • Figure 6 shows the view of figure 2 of a decorative element according to a second embodiment
  • Figure 7 shows some steps in a method for manufacturing the decorative element of figure 6.
  • the decorative element 1 is made of engineered stone, wherein the engineered stone comprises an inorganic filler composition and a cured organic binder that bonds together the particles of inorganic filler. Represents between 85 and 95% based on the weight of the engineered stone.
  • the binder is preferably a thermosetting resin and more in particular an unsaturated polyester resin, and represents less than the 15% of the weight of the engineered stone.
  • the decorative element 1 comprise a lower first layer 4 and an upper second layer 5.
  • the first layer 4 shows a thickness T2 that being bigger than the thickness T3 of the second layer 5
  • the thickness T2 of the first layer 4 is three fourth of the thickness T1 of the decorative element 1 or more.
  • the first layer 4 and the second layer 5 are made respectively of a first and of a second engineered stone being different in that they comprise a different filler composition.
  • the first engineered stone of the first layer 4 is formed by silica-based minerals having mainly amorphous silica, for example a feldspathoid named nepheline.
  • the second engineered stone of the second layer 5 is formed by silica-based minerals having mainly crystalline silica, for example cristobalite.
  • the engineered stone comprise a composition being a mixture between the first and the second engineered stone.
  • the decorative pattern 3 is formed in the second layer 5 by of a coloring agent mixed in the second engineered stone and disposed according to the decorative pattern 3 so that the decorative pattern 3 is present in the entire thickness T3 of the second engineered stone.
  • the first and the second engineered stone forming the first and the second layer 4 and 5 can comprise a second coloring agent being the same or a similar color.
  • the first and the second layer 4 and 5 are white and the second layer 5 only comprising black veins formed by a first coloring agent being present only in the second layer 5.
  • Figure 3 shows some steps of a method for forming decorative element of figures 1 and 2.
  • a first and a second mixture for forming the first and the second engineered stone are prepared, wherein said mixtures comprise the respective filler composition, the binder, one or more additive coupling agents, for example catalyst or reagents to activate or speed up hardening of the binder, and the desired coloring agent.
  • the method comprises a first step SI, wherein a first mixture 10 for forming the first engineered stone is deposited from a first hopper 11 on a first belt 12 that conveys the first mixture 10 through at least a couple of rollers 13 that pre-compacts the first mixture 10 and forms a strip of pre-compacted first mixture 10 that is delivered in a mold 14.
  • the mold being a rubber mold.
  • the method then comprises a second step S2 wherein a second mixture 15 is provided from a second hopper 16 into the mold 14 above the first mixture 10. It is noted that the second mixture 15 is not pre-compacted before being fed in the mold 14.
  • the method then comprises a decoration step S3 for forming the decorative pattern 3.
  • a robotic arm 17 delivers the second coloring agent into the second mixture 15 according to a predetermined pattern to form the decorative pattern 3.
  • the robotic arm 17 is adapted to carve a groove in the second mixture 15 in the mold 14 and deliver the coloring agent in the groove or deliver a quantity of second mixture 15 pre-mixed with the second coloring agent in the groove.
  • the mold 14 with the mixtures 10 and 15 advances in an advancing direction A to a compacting station 19 for a compaction step S4.
  • Said compacting station 19 comprises a vibrating unit 20 and a vacuum unit 21, for the application of vibration and vacuum on the mixtures 10, 15 in the mold 14.
  • the mold 14 is then carried to a curing station 22 where the binder is cured in a curing step S5.
  • the cure of the binder is activated at a temperature below 200 °C and then continues as an exothermic reaction.
  • a slab 23 of engineered stone which is now made of a coherent material having a porosity below 0,2%.
  • the slab 23 is then extracted from the mold 15 and carried to multiple mechanical machining station for finishing operations.
  • the slab 23 is calibrated to flatten the slab itself. Thanks to the precompacting operation, the calibration operation is improved so that less waste material is formed. This is particularly advantageous in combination with firsts mixtures 10 rich in non-crystalline silica that could be relative expensive.
  • Figure 4 shows a second embodiment wherein the second layer 5 is transparent.
  • the second engineered stone forming the second layer 5 is free from coloring agent, comprises filler composition wherein the inorganic filler, for example cristobalite, is selected for being transparent and with a selected index of refraction and the binder is transparent and has the same index of refraction of the filler composition.
  • the inorganic filler for example cristobalite
  • the decorative element 1 comprises an intermediate layer 6 in the form of a decorative foil having a printed pattern, forming the decorative pattern 3, that is visible through the second layer 5.
  • Figure 6 differs from the embodiment of figure 4 in that the decorative pattern 3 printed directly in the engineered stone and is formed substantially an intermediate layer 6, at the interface between the first and the second layer 4, 5 formed by engineered stone with pigments distributed therein.
  • Figure 7 shows some steps in a method for manufacturing the decorative element 1 of figure 6. The method of figure 7 differs from the method of figure 6 in that the decoration step S3 is performed by inkjet printing the decorative pattern 3 directly on the first mixture in the mold 14 , by means of an inkjet printer 25.
  • the present invention relates to one or more of the items as listed below:
  • a decorative element comprising a first layer made of an engineered stone, wherein the engineered stone comprise an inorganic filler bonded by means of a binder, preferably a cured thermosetting resin, with the characteristic that the decorative element comprises a second layer disposed above of said first layer and wherein said second layer is made of an engineered stone.
  • first and the second layer can have a first filler composition which is predominant in minerals different from minerals containing crystalline silica, and the other layer can has a second filler composition which is predominant in minerals containing crystalline silica.
  • the first filler composition comprises a content of crystalline silica being lower than 50% based on the weight of the first filler composition, preferably lower than 10% on a base weight, more preferably is free from crystalline silica; and/or the second filler composition comprises crystalline silica above 50 % on a weight basis, more preferably above 90 % weight.
  • said first filler composition filler composition can be composed of at least 50% weight, preferably at least 75% weight, more preferably at least 90% weight or even entirely by amorphous silica, feldspathoid, calcareous minerals or other minerals different from minerals containing crystalline silica.
  • At least one between the first and the second layer can be transparent or translucent.
  • the decorative element according to item 10 wherein the transparent or translucent layer is free from pigment.
  • 12.- The decorative element according to item 10 or 11, wherein the layer which is transparent or translucent can show a thickness which is below 3 mm, more preferably below 2 mm.
  • the decorative foil can comprise a polymer-based or paper-based sheet, having a printed decor on top of it.
  • the binder can be a thermosetting resin, preferably unsaturated polyester.
  • engineered stone can also comprise other additives like, for example, crosslinkers, coupling agents and pigments.
  • the carrier can comprise a mold having at least a bottom and side walls to contain the mixture, the carrier can also comprise a lid to close the mold.
  • a method for manufacturing a decorative element made of an engineered stone that comprises the steps of:
  • the method comprises the steps of pre-compacting at least one between the first mixture and the second mixture before said first or second mixture is provided onto the carrier.
  • non-pre-compacted layer can be provided on the carrier forming a layer having a thickness which can be at least the double of, preferably at the least three or four time larger than, the thickness of the same layer after the compaction step and/or the curing steps.
  • the method can comprise a step of printing, preferably inkjet printing, a decorative pattern on the surface of the pre-compacted layer.
  • the decorative pattern can be formed by spraying a pigment in the first or second layer; and/or by carving a groove in the first or second layer and delivering a colored mixture in the groove.
  • the step of compacting the mixture can involve a vibro-vacuum compaction step.
  • the carrier can comprise a mold having at least a bottom and side walls to contain the mixture, the carrier can also comprise a lid to close the mold.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un élément décoratif (1) comprenant une première couche (4) constituée d'une pierre artificielle, la pierre modifiée comprenant une charge inorganique liée au moyen d'un liant, de préférence une résine thermodurcissable durcie. L'ivnention est caractérisée en ce que l'élément décoratif comprend une seconde couche (5) disposée au-dessus de ladite première couche et ladite seconde couche étant constituée d'une pierre artificielle.
PCT/IB2024/055573 2023-06-14 2024-06-07 Élément décoratif comprenant une pierre modifiée et procédé de fabrication d'un élément décoratif comprenant une pierre modifiée Ceased WO2024256932A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP24822913.0A EP4727778A1 (fr) 2023-06-14 2024-06-07 Élément décoratif comprenant une pierre modifiée et procédé de fabrication d'un élément décoratif comprenant une pierre modifiée
CN202480039684.8A CN121335809A (zh) 2023-06-14 2024-06-07 包括工程石材的装饰元件和用于制造包括工程石材的装饰元件的方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363508031P 2023-06-14 2023-06-14
US63/508,031 2023-06-14

Publications (1)

Publication Number Publication Date
WO2024256932A1 true WO2024256932A1 (fr) 2024-12-19

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PCT/IB2024/055573 Ceased WO2024256932A1 (fr) 2023-06-14 2024-06-07 Élément décoratif comprenant une pierre modifiée et procédé de fabrication d'un élément décoratif comprenant une pierre modifiée

Country Status (3)

Country Link
EP (1) EP4727778A1 (fr)
CN (1) CN121335809A (fr)
WO (1) WO2024256932A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999022947A1 (fr) * 1997-11-03 1999-05-14 Mihai Dragnea Imitation pierre pour constructions ornementales et son procede de fabrication
US9707698B1 (en) * 2017-03-23 2017-07-18 Alex Xie Method and apparatus for forming marbelized engineered stone
US20200102247A1 (en) * 2018-09-27 2020-04-02 Foshan Yixin Stone Co., Ltd Multilayer artificial stone and preparation method thereof
US20230139870A1 (en) * 2017-10-02 2023-05-04 Dal-Tile, Llc Method for manufacturing an engineered stone and an engineered stone

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999022947A1 (fr) * 1997-11-03 1999-05-14 Mihai Dragnea Imitation pierre pour constructions ornementales et son procede de fabrication
US9707698B1 (en) * 2017-03-23 2017-07-18 Alex Xie Method and apparatus for forming marbelized engineered stone
US20230139870A1 (en) * 2017-10-02 2023-05-04 Dal-Tile, Llc Method for manufacturing an engineered stone and an engineered stone
US20200102247A1 (en) * 2018-09-27 2020-04-02 Foshan Yixin Stone Co., Ltd Multilayer artificial stone and preparation method thereof

Also Published As

Publication number Publication date
CN121335809A (zh) 2026-01-13
EP4727778A1 (fr) 2026-04-22

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