(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2011/0034586 A1
`Buskila et al.
`(43) Pub. Date:
`Feb. 10, 2011
`
`US 2011 0034586A1
`
`(54) ARTIFICIAL MARBLE, AND SYSTEMAND
`METHOD OF PRODUCING ARTIFICAL
`MARBLE
`(76) Inventors:
`
`Liat Eliahu Buskila, Kibbutz
`Sdot-Yam (IL); Yaakov Gal.
`Kibbutz Sdot-Yam (IL); Eran
`Pinhas Goldberg, Nesher (IL);
`Ruti Harel, Sdot-Yam (IL); Yaacov
`Ron, Hauzat Barak (IL); Alon
`Golan, Ramot Yizhak Nesher (IL)
`Correspondence Address:
`ETAN MEHULAL LAW GROUP
`E"2. Hist PO Box 2081
`
`(21) Appl. No.:
`(22) Filed:
`
`12/923,399
`Sep. 20, 2010
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 12/232,844,
`filed on Sep. 25, 2008.
`
`(60) Provisional application No. 60/960,322, filed on Sep.
`25, 2007, provisional application No. 61/272.432.
`filed on Sep. 24, 2009.
`
`Publication Classification
`
`(51) Int. Cl.
`C08K 3/36
`B29C 43/02
`
`(2006.01)
`(2006.01)
`
`(52) U.S. Cl. ......................................... 523/216; 264/101
`
`ABSTRACT
`(57)
`Artificial marble, and system and method of producing arti
`ficial marble. A method of producing a stone slab comprises:
`placing into a frame a plurality of coated lumps of composite
`stone material; removing Substantially all air among the plu
`rality of lumps; pressing the content of said frame; and curing
`the content of said frame to form the stone slab. An artificial
`stone slab comprises: a plurality of coated lumps of compos
`ite stone material which are Substantially in contact with one
`another.
`
`Produce lumps
`
`
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`41 O
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`Coat / dust the lumps
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`Place the coated lumps into container
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`Position the lumps to be in contact
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`430
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`440
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`Remove air between the lumps
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`450
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`Cure the container
`
`
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`Cut the cured material
`
`460
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`470
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`Polish the cured material
`
`480
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`Produce lumps
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`410
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`
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`Coat / dust the lumps
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`
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`420
`
`
`
`
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`Place the coated lumps into container
`--
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`430
`
`
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`Position the lumps to be in contact
`
`
`
`
`
`Remove air between the lumps
`
`440
`
`450
`
`
`
`
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`Cure the container
`
`
`
`
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`Cut the cured material
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`Polish the cured material
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`470
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`
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`480
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`FIG. 4
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`ARTIFICIAL MARBLE, AND SYSTEMAND
`METHOD OF PRODUCING ARTIFICAL
`MARBLE
`
`PRIORAPPLICATIONS DATA
`0001. This patent application claims priority and benefit
`from U.S. Provisional Patent Application No. 61/272.432.
`titled “Artificial Marble, and System and Method of Produc
`ing Artificial Marble', filed on Sep. 24, 2009, which is hereby
`incorporate by reference in its entirety. This patent applica
`tion further claim priority and benefit from, and is a Continu
`ation-In-Part (CIP) of, U.S. patent application Ser. No.
`12/232,844, titled “Artificial Marble and Methods, filed on
`Sep. 25, 2008, published on Apr. 23, 2009 as United States
`Patent Application Publication Number 2009/0105391,
`which is incorporated herein by reference in its entirety; and
`which, in turn, claims priority and benefit from U.S. Provi
`sional Patent Application No. 60/960,322, titled “Artificial
`Marble and Methods”, filed on Sep. 25, 2007, which is also
`incorporated herein by reference in its entirety.
`
`FIELD
`
`0002 Some embodiments are related to the field of artifi
`cial marble.
`
`BACKGROUND
`0003 Quartz is a common oxide; it is the crystalline form
`of silicon dioxide (SiO2), and is considered one of the hardest
`materials in nature. Quartz may be used, for example, for
`production of various stone materials. Quartz-containing
`stone materials may be used, for example, in the preparation
`of slabs, Surfaces, or the like. QuartZ-containing Stone mate
`rial may be used for various purposes, for example: interior
`wall cladding, fireplace mantles and Surroundings, wainscots
`and wall bases, bank teller lines, tables and desktops, elevator
`cab walls and floors, floor tile and stair treads, food service
`areas, shower and tub Surrounds, toilet compartment parti
`tions, window seats, countertops and backsplashes, or the
`like.
`0004 As compared to other natural stone compositions,
`Such as granite and marble, quartZ-containing stone material
`may be stronger and more durable than natural Stone compo
`sitions. In addition, quartz-containing Stone material may be
`cleaner, safer and more consistent than other stone Surfaces.
`Furthermore, quartZ-containing Stone materials may be, for
`example, more resistant to breakage, Scratching, stain, heat,
`chemicals, freeze-thaw damage, or the like.
`0005. The production of quartz-containing stone material
`may include, for example, mixing of inorganic quartz matrix
`and organic polymers that may be bound by linker com
`pounds. The binding between the inorganic quartz matrix and
`the organic polymers may influence the resistance of the final
`composition of the quartz-containing Stone material.
`
`SUMMARY
`
`0006. Some embodiments include, for example, artificial
`marble, as well as Systems and methods for producing artifi
`cial marble.
`0007. In some embodiments, a method of producing a
`stone slab comprises: placing into a frame a plurality of
`coated lumps of composite Stone material; removing Substan
`
`tially all air among the plurality of lumps; pressing the content
`of said frame; and curing the content of said frame to form the
`stone slab.
`0008. In some embodiments, the placing comprises: plac
`ing the plurality of coated lumps into the frame in accordance
`with a position in which the plurality of coated lumps are
`Substantially in contact with one another.
`0009. In some embodiments, the method comprises: prior
`to placing the plurality of coated lumps, producing the plu
`rality of coated lumps.
`0010. In some embodiments, the producing comprises:
`scooping a first inorganic particulate material and a polymer
`material to produce lumps of composite stone material; and
`mixing a secondinorganic particulate material with the lumps
`to produce coated lumps.
`0011. In some embodiments, the method comprises: dur
`ing the mixing, automatically selecting coated lumps that are
`greater than a threshold size.
`0012. In some embodiments, the method comprises: dur
`ing the mixing, automatically ejecting from a mixer the
`selected coated lumps that are greater than the threshold size.
`0013. In some embodiments, the method comprises: Sub
`stantially continuously feeding lump-forming materials into
`the mixer, and Substantially continuously ejecting from the
`mixerformed coated lumps that are greater than the threshold
`S17C.
`0014. In some embodiments, at least one of the plurality of
`coated lumps comprises a dusted lump.
`0015. In some embodiments, at least one of the plurality of
`coated lumps comprises an inner core and an outer layer,
`wherein a property of the inner core has a first value, and
`wherein the same property of the outer layer has a second,
`different, value.
`0016. In some embodiments, the property comprises a
`property selected from the group consisting of color, texture,
`density, chemical composition, hardness, opacity, transpar
`ency, and porousivity.
`0017. In some embodiments, at least 95 percent of the
`formed Stone slab comprises coated lumps.
`0018. In some embodiments, at least 90 percent of the
`formed Stone slab comprises dusted lumps.
`0019. In some embodiments, the method comprises: cut
`ting the stone slab; and polishing the stone slab.
`0020. In some embodiments, the at least one of the first
`inorganic particulate material and the second inorganic par
`ticulate material comprises quartz.
`0021. In some embodiments, the producing further com
`prises: adding one or more colorants to at least one of the first
`inorganic particulate material and the second inorganic par
`ticulate material.
`0022. In some embodiments, the producing further com
`prises: mixing a third inorganic particulate material with the
`coated lumps to produce multi-layer coated lumps.
`0023. In some embodiments, an artificial stone slab com
`prises: a plurality of coated lumps of composite Stone mate
`rial which are substantially in contact with one another.
`0024. In some embodiments, the plurality of coated lumps
`are substantially gap-free.
`0025. In some embodiments, the stone slab comprises
`Substantially exclusively said plurality of coated lumps.
`0026. In some embodiments, at least 99 percent of the
`stone slab comprises said plurality of coated lumps.
`0027. In some embodiments, at least 97 percent of the
`stone slab comprises said plurality of coated lumps.
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`Feb. 10, 2011
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`0028. In some embodiments, at least 95 percent of the
`stone slab comprises said plurality of coated lumps.
`0029. In some embodiments, substantially each of the plu
`rality of coated lumps is in direct contact with at least one
`other coated lump of the plurality of coated lumps.
`0030. In some embodiments, at least one of the coated
`lumps is greater than a threshold value.
`0031. In some embodiments, at least one of the plurality of
`coated lumps comprises a dusted lump.
`0032. In some embodiments, at least one of the plurality of
`coated lumps comprises an inner core and an outer layer,
`wherein a property of the inner core has a first value, and
`wherein the same property of the outer layer has a second,
`different, value.
`0033. In some embodiments, the property comprises a
`property selected from the group consisting of color, texture,
`density, chemical composition, hardness, opacity, transpar
`ency, and porousivity.
`0034. In some embodiments, one or more of the plurality
`of coated lumps comprises: a lump in which a first inorganic
`particulate material and a polymer material are scooped into
`a composite stone material which is mixed with a second
`inorganic particulate material.
`0035. In some embodiments, the at least one of the first
`inorganic particulate material and the second inorganic par
`ticulate material comprises quartz.
`0036. In some embodiments, at least one of the first inor
`ganic particulate material and the second inorganic particu
`late material further comprises one or more colorants added
`thereto.
`0037. In some embodiments, the stone slab comprises
`substantially uniformly distributed coated lumps.
`0038. Some embodiments may provide other and/or addi
`tional benefits and/or advantages.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`0039 For simplicity and clarity of illustration, elements
`shown in the figures have not necessarily been drawn to scale.
`For example, the dimensions of some of the elements may be
`exaggerated relative to other elements for clarity of presen
`tation. Furthermore, reference numerals may be repeated
`among the figures to indicate corresponding or analogous
`elements. The figures are listed below.
`0040 FIGS. 1A-1F are schematic illustrations of modified
`mixing blades, in accordance with some demonstrative
`embodiments.
`0041
`FIG. 2 is a schematic illustration of a front view of a
`drum mixer, in accordance with Some demonstrative embodi
`mentS.
`0042 FIGS. 3A-3B are schematic illustrations of artificial
`marble, in accordance with Some demonstrative embodi
`mentS.
`0043 FIGS. 3C-3J are images of demonstrative artificial
`marble slabs, in accordance with Some demonstrative
`embodiments.
`0044 FIG. 4 is a schematic flow-chart of a method of
`producing a slab of material, in accordance with some
`demonstrative embodiments.
`
`004.5 FIGS.5A-5T are images of demonstrative artificial
`marble slabs, in accordance with Some demonstrative
`embodiments.
`
`DETAILED DESCRIPTION
`0046. In the following detailed description, numerous spe
`cific details are set forth in order to provide a thorough under
`standing of some embodiments. However, it will be under
`stood by persons of ordinary skill in the art that some
`embodiments may be practiced without these specific details.
`In other instances, well-known methods, procedures, compo
`nents, units and/or circuits have not been described in detail
`So as not to obscure the discussion.
`0047. Some embodiments may be used in conjunction
`with one or more embodiments which are described in U.S.
`patent application Ser. No. 12/232,844, titled “Artificial
`Marble and Methods, filed on Sep. 25, 2008, published on
`Apr. 23, 2009 as United States Patent Application Publication
`Number 2009/0105391, which is incorporated herein by ref
`erence in its entirety; and which, in turn, claims priority and
`benefit from U.S. Provisional Patent Application No. 60/960,
`322, titled “Artificial Marble and Methods', filed on Sep. 25,
`2007, which is also incorporated herein by reference in its
`entirety.
`0048. A composite stone material, such as, for example,
`artificial marble, engineered stone, quartz, Surfaces, compos
`ite stone, or the like, may be composed of various materials.
`For example, a composite Stone material may be composed
`mainly of organic polymer(s) and inorganic particulate com
`ponent. The inorganic particulate component may include
`components such as, for example, silicon, basalt, glass, dia
`mond, rocks, pebbles, shells, a variety of quartz-containing
`materials, such as, for example, but not limited to: crushed
`quartz, Sand, quartz particles, or the like, or any Suitable
`combination thereof. For example, the inorganic quartz mate
`rial may include sand of various particle sizes and of different
`combinations.
`0049 Linkage between the organic and inorganic com
`pounds may be carried out and/or facilitated by using binder
`molecules, such as, for example, mono-functional or multi
`functional silane molecules, dendrimeric molecules, and the
`like, that may have the ability to bind the organic and inor
`ganic components of the composite stone. The binders may
`further include a mixture of various components, such as, for
`example, initiators, hardeners, catalysators, binding mol
`ecules and bridges, or any suitable combination thereof.
`0050. The manufacturing process of the composite stone
`material may include, for example, blending of raw material
`(such as, for example, inorganic quartz and organic polymers,
`unsaturated polymers, and the like, Such as polyester) at vari
`ous 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. Other suitable values, ratios, or
`percentage values may be used.
`0051 Optionally, suitable amounts of various one or more
`additives may be added to blending of raw materials, at vari
`ous stages of production. For example, Such additives may
`include colorants, dyes, pigments, chemical reagents, antimi
`crobial Substances, fungicidal agents, and the like, or any
`combination thereof.
`0052. As a result of adding various one or more additives
`to the blending of raw materials, the additives may be present
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`in the final composite stone product, and may further change
`various characteristics of the final composite stone product.
`Such characteristics may include, for example, physical prop
`erties, such as: color, texture, display pattern, and the like;
`chemical properties, such as, for example, chemical resis
`tance, pH properties, and the like; biological properties. Such
`as, for example, antibacterial properties, and the like; and/or
`mechanical properties, such as, for example, strength, Scratch
`resistance, impact resistance, and the like.
`0053. The resulting mixture may later be poured to a Sup
`port 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 rubbertray mold or any other appro
`priate support. The mixture is poured substantially in the form
`of a desired slab (for example, at a size of 306 cmx144 cm
`with or without wall shaping).
`0054 The mixture may then be compacted by a special
`vacuum and vibration process Such as vibrocompaction at
`high pressure, such as about 100 tons. Then, the compressed
`mixture may be placed in a curing and/or hardening kiln, for
`example, at a temperature in the range of 80°C. to 115°C. for
`30 to 60 minutes until it hardens and assumes natural stone
`properties, but with greater performance and higher resis
`tance to stains and impact, as detailed below.
`0055. After completion of the casting process, the slabs
`may be flattened, gauged, calibrated and polished to a high
`and enduring shine or any desired finish to be used at various
`settings, such as, for example, interior wall cladding, 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.
`0056 Composite stone material that may be composed
`mainly of organic polymer(s) and inorganic quartz matrix,
`manufactured as described hereinabove may possess
`enhanced properties as compared to natural Stones. For
`example, the composite stone material may exhibit flexural
`strength in the range of about 485-545 Kg/Cm. For example,
`the composite stone material may exhibit flexural strength of
`about 515 Kg/Cm. Water absorption by weight of the com
`posite stone material may be at the range of about 0 to 0.04
`percent. For example, water absorption by weight of the com
`posite stone material may be about 0.02 percent. Compressive
`strength of the composite Stone material may be in the range
`of 2000-2400 Kg/Cm. For example, compressive strength of
`the composite stone material may be about 2200 Kg/Cm.
`Freezing compressive strength (after 25 cycles of freeze
`thaw) of the composite stone material may be in the range of
`1800-2400 Kg/Cm. For example, freezing compressive
`strength (after 25 cycles of freeze-thaw) of the composite
`stone material may be about 2082 Kg/Cm. Absorption of the
`composite stone material may be in the range of 0 to 0.004
`percent. For example, absorption of the composite stone
`material may be about 0.002 percent. Density of the compos
`ite stonematerial may be in the range of 60 to 80 g/Cm. Mohs
`hardness of the composite stone material, as may be deter
`mined by a scratch test may be in the range of 5-8, on a scale
`of 1-10, wherein 10 is diamond. For example, Mohs hardness
`of the composite stone material may be about 6.5. Taber
`abrasion index at 1000 cycles of the composite stone material
`may be in the range of 110-270. Thermal expansion of the
`composite stone material may be in the range of 7.5-10 (XO.
`
`000001 in/in/deg, C.). Stain resistance of the composite stone
`material may be in the range of 50-64 (wherein the maximal
`rating is 64). Ball impact resistance of the composite stone
`material may be in the range of 80 to 200 cm. Radiant heat
`resistance of the composite Stone material demonstrates no
`damage. Likewise, boiling water and high temperature do not
`demonstrate an effect on the composite stone material.
`0057. As referred to herein, the terms “lumps”, “lumps of
`artificial', 'lumps of composite stone material”, “nuggets'.
`and “blobs' may interchangeably be used.
`0.058 As referred to herein, the terms, “composite stone
`material”, “artificial marble”, “engineered stone' and “quartz
`Surfaces' may interchangeably be used.
`0059. As referred to herein, the term “colorant” may
`include dyes, pigments, colorants, and the like, or any com
`bination thereof in any form, Such as liquid, paste, fluid, or the
`like.
`0060. As referred to herein, the terms “blade”, “leg,
`"hook in relation to a mixing device may interchangeably be
`used. For example, the terms “mixer blade' and mixer leg
`may interchangeably be used.
`0061 According to some embodiments, lumps of com
`posite material may be prepared and may further be used for
`the manufacturing of artificial marble and artificial marble
`slabs. The lumps of composite material may be comprised of
`various compositions of Such materials as inorganic quartz
`matrixes, polymers, binders, resins, colorants, dyes, pig
`ments, and the like. The lumps of composite materials may
`assume any three-dimensional shape. Such as, for example,
`squared shape, rounded shape, spiked shape, diamond-like
`shape, and the like, and may further be prepared in any size.
`The lumps of composite material may further exhibit any
`Surface type, such as Smooth Surface, uneven Surface, rigid
`Surface, and the like. The lumps of composite material may
`further be used for the preparation of artificial marble that
`may exhibit various patterns that may beformed by the lumps
`of composite material.
`0062 According to some embodiments, lumps of com
`posite material may be manufactured Such that they acquire a
`Substantially rounded shape, with a Substantially smooth Sur
`face and a Substantially rigid texture. Upon their production,
`the lumps may retain their structure under various conditions.
`The lumps of composite material may include Such materials
`as inorganic quartz matrix. Such as sand, of various particle
`sizes and/or any other material that may contain inorganic
`quartz; a mixture of polymers, such as unsaturated polyester
`diluted with styrene; additional mixtures that may include
`Such materials as silane molecules, binders, hardeners, initia
`tors, inhibitors, pigments, dyes, colorants, and the like. Upon
`manufacturing of the lumps of composite materials, the
`lumps may further be used for the preparation of patterned
`artificial marble articles, such as patterned artificial marble
`slabs, wherein the lumps formed into the artificial marble
`articles may create the exhibited pattern of the artificial
`marble.
`0063. According to some embodiments, the inorganic
`quartz material may include sand of various particle sizes and
`indifferent combinations. For example, the quartz containing
`sand may include particles of a size of about of 0.05 mm to 10
`mm. The quartz containing sand may include particles of a
`size of about of 0.05 mm to 8 mm. The quartz containing sand
`may include particles of the size of about 0.05 mm to 7 mm.
`The quartz containing sand may include particles of the size
`of about 0.05 mm to 6 mm. The quartz containing sand may
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`US 2011/0034586 A1
`
`Feb. 10, 2011
`
`include particles of the size of about 0.05 mm to 5.5 mm. The
`quartz containing sand may include particles of the size of
`about 0.05 mm to 5 mm.
`0064. In some embodiments, the inorganic quartz material
`may further include ground/milled sand of various particle
`sizes and in different combinations. For example, the ground/
`milled quartz containing sand may include grounded particles
`of the size of about 1 to 65 microns. The ground/milled quartz
`containing sand may include particles of the size of about 10
`to 60 microns. The ground/milled quartz containing sand may
`include particles of the size of about 20 to 55 microns. The
`ground/milled quartz containing sand may include particles
`of the size of about 30 to 50 microns. The ground/milled
`quartz containing sand may include particles of the size of
`about 38 to 45 microns. The inorganic quartz material may
`further include Such materials as basalt, glass, diamond,
`rocks, pebbles, shells, silicon, and any other material that may
`contain inorganic quartz.
`0065. In some embodiments, the lumps of composite
`material may further include resin that may be mixed with the
`quartz particles to allow formation of the lumps structures.
`The resin may be comprised of polymers and binders. The
`polymers may include, for example, such materials as poly
`ester, unsaturated polyester and the like, that may be diluted
`with, for example styrene. For example, the polymer may be
`comprised of 65% of unsaturated polyester, diluted with 35%
`styrene. The binders may include a mixture of various com
`ponents, such as initiators, hardeners, catalysators, binding
`molecules and bridges, such as Silan bridges, and any other
`component that is known in the art and may be used for the
`preparation of composite Stone material. In some embodi
`ments, resin may be or may include various types of material
`(s), for example, polyester, Epoxy, acrylic, vinylester, thermo
`plastic materials or products, or the like.
`0066. According to some embodiments, the lumps of
`composite material may further include a colorant that may
`include various dyes, pigments, colorants or any combination
`thereof. The colorants may be in the form of liquid, powder,
`paste, and the like, or any combination thereof. The colorants
`may include any organic or non-organic colorant. The colo
`rants may further be diluted with various materials, such as
`polyester, styrene, butylbenzoate, methoxy propyl acetate,
`and the like. The colorants may be added at various stages
`during the manufacturing process of the lumps of composite
`material. The colorants may be added in various concentra
`tions and various amounts during various stages of the manu
`facturing process. Furthermore, one or more colorants and/or
`a combination of colorants may be added during various
`stages of the manufacturing procedures of the lumps of com
`posite materials.
`0067. According to some embodiments, the preparation of
`lumps of composite material may be performed in one or
`more mixing devices. The mixing devices may include any
`known mixing device, such as, for example, a mixer, a vertical
`axis mixer, a drum mixer, palletizer, and the like, or any
`combination thereof. In addition, the modifications to the
`mixing device may also be performed, wherein said modifi
`cations may aid in the preparation process of the lumps of
`composite material.
`0068 According to some demonstrative embodiments,
`the preparation of lumps of composite material may be per
`formed using a mixer. The mixer may include any kind of
`mixer, Such as a vertical axis mixer. For example, the mixer
`may include a vertical mixer as described in United States
`
`Patent Application Publication Number 2008/0181049, titled
`“Vertical-Axis Mixing Machine for Processing Mixes', pub
`lished on Jul. 31, 2008, which is incorporated herein by
`reference in its entirety. Other suitable mixers may be used.
`0069. In some embodiments, the mixer may have one or
`more mixing legs that may be attached to a common arm (that
`may be aligned with the revolving axis) and may thus revolve
`around a common axis. The mixing legs may be placed at
`varying distances from each other and may be located at any
`angle relative to the common axis. The mixer legs may
`revolve independently from each other, the mixer legs may
`revolve in Synchronization with each other, or any combina
`tion thereof. The mixer may further include a container (such
`as a mixing bowl), into which various components of the
`lumps composition may be added at an appropriate, prede
`termined order; at an appropriate time schedule; and at appro
`priate mixing conditions.
`0070 Mixing conditions may include such conditions as
`mixing speed, mixing temperature and mixing blades that
`may be used. For example, mixing speed may be measured in
`units of rotational speed (rounds per minute (rpm)) and/or in
`units of peripheral speed (m/sec). For example, mixing speed
`may vary between different stages of the manufacturing pro
`cess of the lumps of composite material and may be in the
`range of for example, 1 to 15 m/sec. The mixing speed may
`include mixing at low speed, such as, for example in the range
`of about 1 to 2 m/sec. For example, mixing temperature may
`be measured as the environment temperature or the container
`temperature at which the mixing procedure is being per
`formed. For example, the mixing temperature may be in the
`range of 4 to 40 degrees Celsius. For example, the mixing
`temperature may be performed at room temperature, such as,
`for example, at the temperature of about 25 degrees Celsius.
`0071. In addition, one or more of the mixing blades (mix
`ing legs) used in the mixer may be adapted to be used for the
`formation of the lumps of the composite material. According
`to some embodiments, one or more of the mixer blades (legs)
`may be modified and adapted such that, at the end of the
`blades, at the region that contacts the materials to be mixed, an
`extended surface area may form. The extended Surface area
`may be achieved, for example, by attaching an extension of
`various forms to the end of the mixing blade. The extension
`may assume various forms, such as, but not limited to: a flat,
`quadrangular plate; a plate that may be comprised of at least
`two flat Surfaces; a spoon shaped plate, curved plate, and the
`like. The extension may further be situated at various angles
`as compared to the perpendicular axis of the mixer blade. In
`Some embodiments, no additional spoon or spoons may be
`required, and the rod that is in the mixer may be used.
`0072 Reference is made to FIG. 1, which schematically
`illustrates modified mixing blades, according to some
`embodiments. As shown in FIG. 1A, which illustrates a front
`view of a modified mixing blade, according to Some embodi
`ments, an extension (such as extension 4 in FIG. 1A) may be
`attached to the mixing end (such as end 6) of the mixing blade
`(such as mixing blade 8). Extension 4 may have