(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2015/0360507 A1
`BENTO LOPEZ. et al.
`(43) Pub. Date:
`Dec. 17, 2015
`
`US 20150360507A1
`
`(54) STRATIFIED AND AGGLOMERATED
`ARTIFICIAL STONE ARTICLE
`
`(71) Applicant: SENSERTS
`(Almeria) (ES)
`
`(72) Inventors: Jose Manuel BENITO LOPEZ,
`Cantoria (Almeria) (ES); Leopoldo
`GONZALEZ HERNANDEZ, Cantoria
`(Almeria) (ES); Juan Antonio JARA
`GUERRERO, Cantoria (Almeria) (ES)
`
`(73) Assignee: COSENTINO RESEARCH AND
`DEVELOPMENT, S.L., Cantoria
`(Almeria) (ES)
`
`(21) Appl. No.:
`
`14/759,263
`
`(22) PCT Filed:
`
`Jan. 11, 2013
`
`(86). PCT No.:
`S371 (c)(1),
`(2) Date:
`
`PCT/ES2O13AO7OOO6
`
`Jul. 6, 2015
`Publication Classification
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(51) Int. C.
`B44F 9/04
`E04B5/04
`B29C 43/28
`A47B 77/02
`(52) U.S. Cl.
`CPC ................. B44F 9/04 (2013.01); A47B 77/022
`(2013.01); E04B5/04 (2013.01); B29C 43/28
`(2013.01); B29C 2043/561 (2013.01)
`ABSTRACT
`(57)
`The present 1nvention relates to those articles that include any
`kind of agglomerated artificial Stone and polymerisable resin,
`Such as tiles or slabs, to be used as construction material,
`characterised for consisting of different strati or veins, of
`heterogeneous variable mass that provide a special aesthetic
`effect similar to the natural stone products.
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`STRATIFIED AND AGGLOMERATED
`ARTIFICIAL STONE ARTICLE
`0001 Stratified, agglomerated artificial stone articles with
`polymerisable resin and process for its manufacturing by
`vacuum vibro-compression system.
`
`TECHNICAL PART
`0002 The present invention relates to those articles that
`include any kind of agglomerated artificial stone and poly
`merisable resin, such as tiles or slabs, to be used as construc
`tion material, characterised for consisting of different stratior
`veins, of heterogeneous variable mass that provide a special
`aesthetic effect similar to the natural stone products that have
`a nature consisting in different layers or veins, depending on
`their lithological composition. A stratified product is
`achieved, where the layers (that can be considered as big size
`veins); they have a width and length of grater dimensions than
`the products existing in the state of the art, exceeding the
`technical limitation in this sense. This makes the naturalness
`of the resulting product to be higher. Also an object of the
`present invention is the process to manufacture tiles or slabs
`made of agglomerated artificial stone that include the con
`trolled placing of the heterogeneous multi-mass strati in a
`manufacturing process of agglomerated artificial stone
`articles with the vacuum vibro-compression system. This
`controlled and not random placement of the layers is another
`factor that allows increasing the natural look of the products,
`making them different to the current, where the introduction
`of veins is uncontrolled and thus, it does not follow any ruled
`or controlled placement pattern.
`0003. The regular processes to manufacture artificial stone
`tiles or slabs include, in general, a crushing stage for the
`different materials with different granulometries to create the
`fillers; another stage that consists of the addition of the resin
`with the catalyser and, optionally, a colouring agent; the mix
`of Such two previous stages until the homogenization of the
`materials with the resin; a later stage to model and compact
`the paste by a vacuum vibro-compression system; a harden
`ing stage consisting in the polymerization reaction of the
`resin by heating; ending with a cooling, cutting and polishing
`Stage.
`0004 Including at least two different mass mixing stages
`is the essential characteristic of the process described in the
`present invention. In each one of them, there are different
`petrous and artificial materials, in different proportions, com
`positions and granulometry, which mixed in their Suitable
`stage that include the resin and other additives like, for
`example, a catalyser and, optionally, a colouring agent; they
`are distributed in a controlled manner and not randomly in the
`mould giving place, after the vacuum vibro-compression,
`hardening, cooling, cutting and polishing stage to a petrous
`agglomerated article Such as a tile or slab made of artificial
`stone that has an heterogeneous multi-mass decorative effect
`which shows an aesthetic look similar to natural stone, with a
`greater layer effect than those vein effects achieved until now
`and described in the state of the art, thus Surpassing the
`existing technical limitation.
`
`STATE OF THE ART
`0005. Currently, petrous agglomerated articles are used as
`decorative Surfaces in interior and exterior spaces, such as
`kitchen worktops, bathrooms, flooring, exterior staircases,
`etc., being an important condition for these products as these
`
`also provide good technical characteristics in that related to
`resistance, a look as close as possible to natural stone which
`design can be defined by different layered minerals, with
`different granulometries and varied colours.
`0006 Different techniques are already known to manufac
`ture artificial stone articles that show anaesthetic effect simi
`lar to that of natural stone.
`0007 For example, in the ceramic sector, the document
`WO2005068.146, owned by Sacmi, provide a plant to make
`tiles or ceramic slabs that include a mean to feed a mixture of
`powders which have different characteristics and colours to a
`hopper that has the shape of a rectangular box; this hopper has
`a loading opening and an unloading opening defined between
`the front and the back sides. Through the unload opening,
`place a strip of powder present in the hopper over an under
`lying moving reception Surface which moves forward; this
`strip has the same width and thickness of the hopper unload
`ing opening; compress the powder strip characterised
`because compacting takes place over the reception Surface.
`The object of this plant is to provide with a method to manu
`facture tiles or ceramic slabs especially, but not exclusively, in
`a continuous cycle press.
`0008 Amongst others, the process marketed by Breton
`S.p.A (Italy) that developed the technology named “Breton
`Stone' and that is described in the U.S. Pat. No. 4,698,010
`(Marcello Toncelli, 6 Oct. 1987) where aggregates of a mate
`rial with variable particles are mixed with a binder (organic or
`inorganic), and after such mixture has been made homoge
`neous, it gets to a mould which is also moved inside a press
`where it is submitted to pressure and vibration on vacuum
`conditions, hardening the mix which results in blocks that can
`be cut into others of different dimensions.
`0009. The product placed in the market by the authors of
`the present application as Silestone(R), consisting in a natural
`quartz, agglomerate and bound with polyester resin, which is
`based on the patent ES 2 187 313, describes the process to
`manufacture artificial stone slabs made of a mix of crushed
`materials of different granulometries of silica, granite, quartz,
`ferrosilicon and/or other materials such as plastics, marble
`and metals, with liquid polyester resins by vacuum vibro
`compression, heating, cooling and polishing, especially
`applicable to the use in interiors and decoration.
`0010. The writing authors have also developed some slabs
`similar to these previously described in that related to the
`fillers but that use as polymer resin only a liquid methacrylate
`resin, PCT/ES2005/000152, so the slabs resulting are more
`resistant to ultra-violet light that can be used in walls, stair
`cases and decoration of exteriors without risk of deterioration
`that can be caused by the continuous exposure to Sun rays.
`0011. In the above mentioned cases, the different look of
`the slabs is achieved depending on the composition and the
`granulometry of the products included as fillers, giving colour
`to different proportions of fillers with various colours and
`afterwards, making homogeneous all the fillers until achiev
`ing a more or less uniform colour.
`0012. In other cases, the processes designed imply the
`creation of the said “veins' thus imitating the natural stone.
`(0013 Amongst others, the process described in EP 0970
`790 is based in the use of a machine, object of the said patent,
`that first causes cavities in the surface of the mix that will
`build the slab, and later, such cavities are filled with the
`desired colorant.
`0014) Another method described in the patent application
`WO 03/027042 includes two alternatives depending if the
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`binding product that builds the slab is of the “cement” kind or
`of the “polymer resin' using the powder pigment in the first
`case and the liquid pigment in the second. Once the base mix
`is made by a granulated material and a binding product, it is
`placed on a holder and it is sprayed on the surface with the
`liquid containing the pigment in a local and random manner
`so the patches or spots of a different colour appear without
`causing pigment agglomeration. Then, the mix is Submitted
`to the compressing on vacuum vibro-compression stage and
`later to that of hardening, cooling, cutting and polishing.
`Another variation of the method consists in, that before or
`after adding the pigment solution, the Surface of the mix is
`treated with an instrument like a rake that makes a wave
`movement so the colour mix is unevenly spread. The results
`of this treatment after having added the mix with the pigment
`is that the pigment patches or spots placed on the Surface are
`distributed acquiring the desired vein effect.
`0015. In the application for international patent WO2009/
`010406 a process to manufacture tiles or slabs of artificial
`stone is described and it includes the basic stages of crushing
`of the different materials that made up the fillers with differ
`ent granulometry, another stage that includes the resin and the
`catalyser and, optionally, the colour pigment, the mix of Such
`stages until the homogenization of the materials with the
`resin, a stage of moulding and compressing of the mass got
`from the vacuum vibro-compression and a hardening stage by
`polymerization of the resin by heating, finishing with a cool
`ing, cutting and polishing stage. The incorporation of veins
`that extend through the total thickness of the tile or slab, also
`acquires a tri-dimensional effect but its formation takes place
`by the incorporation of colouring agents to the Surface of the
`paste in the mould, which are treated with a tool so they
`penetrate inside the paste and, like that, the vein acquires a
`tri-dimensional character.
`0016. In the U.S. Pat. No. 3,318,984 in favour of Christina
`Germain Louis Dussel, she makes reference to an artificial
`stone manufacturing process by the mix of thermosetting
`resins and mineral materials starting from the preparation of
`marble mixes or pastes of different colours sprayed together
`with a controlled mix of polyester resins. One of the pastes
`means the main portion of the artificial marble while the other
`or other pastes will be the spots or veins that will appear in the
`Surface of the manufactured products. In Such process the
`load of the different pastes is made loading by hand the
`different materials to the mould or by the use of a feeding
`mechanism with pre-defined settings, which will allow manu
`facturing elements with different colours in a single opera
`tion.
`0017. The application of the international patent
`WO2006/134179 presented by the holder of the present
`invention, describes a process for the manufacturing of arti
`ficial stone with polymerisable resin with a tri-dimensional
`vein effect by a vacuum vibro-compression system, achieving
`such vein effect by the addition of liquid or solid colouring
`mixed with the resin and added either at the mixing stage in
`upper mixers or in the inside of the homogenization ring
`either in the belt that carries the feeding mechanism or even
`inside it. The vein can be added in parts of the process where
`a later mix is made so the vein spreads throughout the entire
`tile.
`0.018. However, with the methods mentioned in the state of
`the art simulations of the natural stone are achieved where the
`artificial character is still kept because the formation of veins
`is made by colouring always with pigmented resin that makes
`
`a greater difference between the veins and the rest of the
`product. Also, such veins have a width, length and situation in
`the product that makes that their similarity to natural stone is
`not completely satisfactory.
`0019 Especially, the great technical limitation is in the
`fact that, when creating the vein by liquid stages or Solid
`pigments, the width that can be achieved of this is always very
`small (maximum 10 mm), so the stratified effects of certain
`natural Stones cannot be achieved.
`0020. Also, a sufficient length of the veins cannot be
`achieved and the maximum length achieved in the state of the
`art is of circa 100 mm. In addition, in all the cases, these veins
`are placed in a randomly position in the mix, and sometimes
`areas of great concentration can be found and others, on the
`contrary, almost without veins.
`0021 All these technical limitations are translated, in
`most of the cases, in obtaining a product that keeps a certain
`artificial degree, being far from what natural stones are.
`0022. The technical limitation related to a predetermined
`width and length is mainly due to the loss of mechanical
`properties of the material in the vein area, due to the use in the
`composition of the vein of a larger amount of resin which
`necessary involves that the technical details of the product in
`these areas, such as hardness, resistance to UV light, shine,
`etc. are below the rest.
`0023. So, a manufacturing process for stratified artificial
`stone articles by vacuum vibro-compression technology that
`includes to the regular process the creation of at least, two
`pastes or heterogeneous pastes of petrous agglomerated
`material of different granulometry is the object of the present
`invention. These pastes are placed in a controlled manner over
`the compacting mould and, after the compacting stage by
`vacuum vibro-compression, hardening and finishing, they
`will become the artificial stone article of the present invention
`that have in its total structure the same technical properties.
`0024. By this system of application of layers by the cre
`ation of different mixes the dimensions of the current veins,
`reaching a stratum width from 10 mm to 3400 mm preferably
`500 mm and lengths that could cross the product in length and
`width, being the limit of length the dimension of the tile, as it
`can be 3400 mm, preferably 1700 mm. These strati (or large
`size veins), together with the location control of the said,
`make that the naturalness of the product is elevated, being
`difficult to know if it is an artificial or natural product.
`0025. Also object of the present invention are the articles,
`such as artificial stone tiles or slabs that have veins made by
`strati of different masses, these being made by fillers of vari
`able granulometry and the corresponding polymerisable resin
`and also additives, characterised because the veins present a
`width from 10 to 3400 mm, preferably, 500 mm, and length
`from 100 to 3400 mm, preferably 1700 mm, being these
`artificial stone articles to be achieved by the process of the
`present invention.
`0026. The artificial stone articles of the present invention
`are apt for interiors and exterior decoration in walls, floors,
`staircases, etc. with a similar design to that of natural stone,
`created by tri-dimensional stratus of agglomerated paste or
`mass of artificial stone with controlled composition, thick
`ness and weight which manage to overcome the disadvan
`tages of the veining products such as the Small dimension of
`the width and length of the vein, the conservation still of a
`certain character due to the use of one with a high content of
`resin and to the fact of not being able to achieve the stratified
`effects in a controlled manner.
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`EXPLANATION OF THE INVENTION
`0027. The present invention is a process to manufacture
`artificial stone products, amongst others, tiles or slabs that
`include the following stages:
`0028 a) Crushing stage of the different materials with
`varied granulometry making up the fillers;
`0029 b) Obtaining by the addition and mix of the stage
`that contains the resin with the catalyser, the accelerant,
`the binding material and, optionally the colouring agent;
`0030 c) Mix of the products of the stages a) and b) until
`the homogenization and achievement of at least two
`pastes or masses of different granulometry. This process
`shall be independently made as many times as number of
`masses or pastes to be achieved. Each mass or paste,
`hereinafter called stratus, can be differentiated from the
`other thanks to its composition (granulometry, pigmen
`tation, etc.)
`0031 d) Transportation of the different strati by a con
`veyor belt to the feeding or distribution mechanism. This
`download implies the ordered placing of the different
`strati in an independent manner and depending on the
`final design that is to be achieved. For this, the different
`strati are downloaded in the feeding or distribution
`mechanism, one after the other and in a certain amount.
`0032 e) Download of the strati, placed in an ordered
`manner in the previous stage, from the distributor to the
`mould which creates the design and dimension of the
`slab.
`0033 f) Protecting the mass that makes up the slabs
`with Kraft-type paper, or an elastomer, similar to a rub
`ber coating:
`0034 g) Moulding and compressing of the paste in each
`mould by vacuum vibro-compression;
`0035 h) Hardening by polymerization of the resin by
`heating:
`0036) i) Finish with a cooling, sizing, polishing and
`cutting stage.
`0037. The process designed in the present invention is
`different to the processes known in the state of the art in the
`actions carried out during the stages c), d) and e).
`0038. During stage c), at least two pastes or masses of
`different composition are achieved (different granulometry,
`pigmentation, etc.) which will become the different strati of
`the stratified artificial stone product. On the contrary, the
`processes known in the state of the art only include the cre
`ation of a single paste with a single composition to create the
`final product, due to the later processes of mixing and homog
`enization.
`0039. During stage d) the different strati, with different
`composition, are transported in a conveyor belt from the
`mixers to the feeding or distributing mechanism, where they
`are placed or deposited on the said, in a certain order, to create
`the final desired product. On the contrary, the processes
`known of the state of the art do not include the controlled,
`ordered and stratified placement of the veins that are part of
`the product in the distributor or feeding mechanism.
`0040. At last, stage e) makes reference to the controlled
`directed and non-directed download of the strati placed in an
`ordered manner and present in the feeding mechanism or
`distributor to the mould.
`0041. On the contrary, the processes of the state of the art
`do not include the download of the different strati already
`placed in an ordered manner in the feeding mechanism
`directly to the mould.
`
`DESCRIPTION OF THE DRAWINGS
`0042 Drawing 1 represents a cross-wise cut of the feeding
`mechanism with a certain distribution of the different strati
`according to the present invention.
`0043. Drawing 2 represents the effect achieved in the final
`product from the distribution of the strati of drawing 1.
`0044) Drawing 3 represents another design of the stratified
`article where there are different granulometries in the differ
`ent strati.
`0045 Drawing 4 represents a slab with vein effect accord
`ing to the state of the art.
`
`DETAILED DESCRIPTION AND PREFERRED
`PERFORMANCE METHOD OF THE
`INVENTION
`0046. The goal of the present invention is, then, the
`achievement of a stratified agglomerated product that is
`capable of overcoming the technical limitations in that related
`to the width and length of the veins in the products currently
`known in the state of the art and to its controlled disposition in
`the core of the product. When increasing the dimension of the
`veins, a stratified effect is achieved in the final product which
`has an even more natural look.
`0047. So, object of the present invention are the articles
`such as tiles and/or slabs made of artificial stone that have
`veins built by stratiof different masses, these being created by
`fillers of different granulometry and the corresponding poly
`merisable resin and also additives, characterised because the
`veins present a width from 10 to 3400 mm, preferably, 500
`mm, and length from 100 to 3400 mm, preferably, 1700 mm.
`0048. To the effects of the present invention, the use of
`natural and artificial materials of variable granulometry is
`considered which will be part of the fillers, amongst others:
`marble, dolomite, opaque quartz, clear quartz, silica, crystal,
`mirror, cristobalite, granite, albite, basalt, ferrosilicon, etc. It
`also considers the use of other filler materials such as: colour
`plastics, metals, woods, graphite, etc. The said materials are
`part of the different strati, preferably with the following com
`position and granulometry:
`0049) 10% to 70% of micronized filler, with a granu
`lometry between 0.0001 mm to 0.75 mm:
`0050 0% to 80% of crushed fillers, named “crushed 1.
`with a granulometry between 0.76 mm and 1.20 mm:
`and optionally,
`0051 0% to 50% of crushed fillers, named “crushed 2
`with a granulometry between 1.21 mm and 15 mm.
`0.052 The proportions of the different fillers are calculated
`in 96 of weight over the total weight that includes the fillers
`and the resin in the stratus.
`0053. The percentage of each granulometry in each stratus
`depends of the design of the slab to be achieved, modifying
`Such percentages depending on the final result to be achieved.
`0054 The resin that is part of the paste is preferably unsat
`urated polyester resin; even if it also considers the use of other
`polymerisable and thermosetting resins such as: methacrylate
`resin, epoxy, unsaturated polyester, vinyl, etc.
`0055. The resin is part of the total mix of each stratus in a
`percentage between a 6% and a 30% of weight, being the
`percentage selection preferably between 7 and 20%.
`0056. Other additives that are part of the fillers are the
`catalyser, the accelerant, the binding product and, optionally,
`the colouring agent.
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`0057. So, the process of the present invention, designed to
`get the stratified artificial stone products consists of the fol
`lowing stages:
`0.058
`a) Crushing stage of the different materials with
`varied granulometry making up the fillers;
`0059 b) Obtaining by the addition and mix of the stage
`that contains the resin with the catalyser, the accelerant,
`the binding material and, optionally the colouring agent;
`0060 c) Mix of the products of the stages a) and b) until
`the homogenization and achievement of at least two
`pastes or masses of different granulometry. This process
`shall be independently made as many times as number of
`masses or pastes to be achieved. Each mass or paste,
`hereinafter called stratus, can be differentiated from the
`other thanks to its composition (granulometry, pigmen
`tation, etc.)
`0061 d) Transportation of the different strati by a con
`veyor belt to the feeding or distribution mechanism. This
`download implies the ordered placing of the different
`strati in an independent manner and depending on the
`final design that is to be achieved. For this, the different
`strati are downloaded in the feeding or distribution
`mechanism, one after the other and in a certain amount
`0062 e) Download of the strati, placed in an ordered
`manner in the previous stage, from the distributor to the
`mould which creates the design and dimension of the
`slab.
`0063 f) Protecting the mass that makes up the slabs
`with Kraft-type paper, or an elastomer, similar to a rub
`ber coating
`0064 g) Moulding and compressing of the paste in each
`mould by vacuum vibro-compression;
`0065 h) Hardening by polymerization of the resin by
`heating
`0.066
`i) Finish with a cooling, sizing, polishing and
`cutting stage
`0067. The process starts with the stage a) where the start
`ing material is prepared being crushed until achieving the
`desired granulometry, mixing the different percentages of
`each granulometry and then downloading it in the planetary
`mixers.
`0068. The preparation of different compositions of fillers
`with variable granulometry, which will be, in the end, the
`different homogenised pastes that are part of the strati of the
`final product is considered. In general, and for the creation of
`the products included in the present invention, at least two
`different compositions of masses with fillers of variable
`granulometry have to be prepared, even if pending on the
`final product to be achieved, the preparation of up to 20
`different compositions of masses with fillers of different
`granulometry is considered.
`0069. These different fillers are distributed in different
`mixers with the possibility that each one of them receives the
`optional addition of a solid colouring agent or pigment.
`0070 If the colouring agent is liquid, it is added in the
`resin stage.
`0071. In the stage b) the preparation of the additivated
`resin is made with the catalyser and the accelerant. This
`catalyzer can be any that creates free radicals, known from the
`state of the art. The peroxides and peroxidicarbonates are
`those preferred. They can be presented in powder (for
`example, dilauryl perioxide or di-(4-ter-butil-ciclohexile)
`peroxi-di-carbonate or a mixture of both, or liquid (for
`
`example, tert-butyl perbenzoate or tert-butyl peroxi-2-ethyil
`hexanoate or a mixture of both).
`0072 The accelerant can be a cobalt composed derived
`from caprylic acid, for example, cobalt octoate at 6%, a bind
`ing product and optionally the colouring agent.
`0073. The proportion of this resin in the composition of
`each paste shall be established by the composition of each
`stratus, being the resin percentage between a 6% and a 30% in
`weight, being, preferably, the selection of a percentage of
`between 7 and 20%.
`0074 The stage c), means, as previously stated, obtaining
`different masses, pastes or strati which are independently
`prepared in each mixer and always avoiding a later homog
`enization existing in the regular processes.
`0075. During stage d) the different strati are transported in
`a conveyor belt from the mixers to the feeding or distributing
`mechanism, where they are placed or deposited, in a certain
`order, sequence or amount desired. If drawing 1 is checked,
`where two different strati have been prepared (mass 1 and
`mass 2), these have been downloaded on the feeding system
`following this frequency: mass 2, mass 1, mass 2, mass 1.
`mass 2 and mass 1.
`0076 Considering performing a controlled download of
`the strati in the feeding or distribution mechanism in an
`ordered manner with the volume and amounts desired, the
`device includes weighting means, such as, belts or hoppers
`which allow defining and controlling the amount of paste that
`will create a stratus in the final product.
`0077. Additionally, the device includes means that allow
`performing a download in movement of the different pastes in
`the feeding or distribution mechanism in a way that the speed
`and trajectory of the movement can be controlled to achieve a
`design of each stratus in the final product. As the paste down
`load is continuous, and thanks to the fact that the movement of
`the feeding system can be controlled, the strati can be down
`loaded in a heterogeneous and controlled manner. This is, the
`closer the feeding system gets to the stratus downloading
`area, more paste is downloaded and, as it moves further away,
`the amount is reduced. This Swinging movement of the feed
`ing system will allow drawing a strati design like that shown
`in the example in Drawing 1 where a certain tilt has been
`included in the strati setting in the feeding system. The com
`bination of the weighting and movement means allows con
`trolling the strati dimensions, for example, width, length,
`shape, etc. in the final product.
`0078 Next, in stage e), the groups of strati made and
`present in the feeding mechanism are downloaded so they
`will be distributed along the pressed mould to achieve a
`stratified final product in all the dimensions of the slab, this is,
`visible strati both in the upper and lower surface, as in the
`laterals. The download over the mould can be made in two
`different ways:
`0079 1. By a belt over where the straticoming from the
`feeding system have been downloaded.
`0080 2. Directly placing the exit of the feeding system
`over the mould and downloading the stratus from the
`conveyor belt directly to the mould.
`I0081. Once the strati are distributed in the mould stages f),
`g), h) and i) take place which are regular and known for the
`state of the art.
`I0082 So, the mould with the strati is protected with a
`paper or rubber. Once the mixture is protected and placed in
`the mould, it is taken to a vacuum vibro-compression press,
`which is in charge of squeezing and compressing the material
`
`

`

`US 2015/0360507 A1
`
`Dec. 17, 2015
`
`but first it has to pass by a vacuum and then the material is
`Squeezed by vibro-compression, following the method
`designed and described by the Italian company Breton SPA.
`as described in the U.S. Pat. No. 4,698,010.
`0083. The pressed tile is driven to an oven that is at a
`temperature between 80° C. and 110° C. for the resin to
`polymerise. The time of stay of each slab in the oven is from
`30 to 60 minutes.
`0084. Once outside the oven, the slab is cooled for about
`24 hours at room temperature in order to, later, calibrate,
`polish and cut it.
`0085. As final results, there is a slab with a stratified effect
`existing in all of its dimensions where the strati (which can be
`considered as big size veins) have a width and length of
`greater dimensions than the products existing in the state of
`the art. Thus, the final design is going to depend both of the
`shape, colour and granulometry of the materials that create
`the pastes or strati, as of the design provided with the different
`systems described in the present invention, achieving a
`petrous agglomerate with a more natural look, with more
`movement, more depth and a controlled stratified effects in all
`the dimensions of the product.
`
`EXAMPLES
`
`Example 1
`I0086 Crushing in mills of the starting material until
`achieving the desired granulometry to finally get the filler
`material with the following granulometry distribution:
`I0087 Crushed filler 1 of granulometry between 0.76
`1.2 mm
`I0088 Crushed filler 2 of granulometry between 1.21-15
`
`Micronized filler of granulometry between 0.05
`I0089
`0.75 mm
`0090. Now the crushed filler 1 and micronized filler are
`added to a planetary mixer where they are mixed with the
`resin, the catalyser, the accelerant and the colouring agent, in
`the following proportions to build paste 1:
`0091 69% crushed filler 1, 20% micronized filler, 11%
`resin, (% calculated over the total weight of the fillers and
`resin mixture)
`0092 0.2% of accelerant in proportion to the resin amount
`0093 2% of binding material in proportion to the resin
`amount
`0094 2% of catalyser in proportion to the resin amount
`0095 4% of black colouring agent in proportion to the
`resin amount
`0096 Mixture starts until homogenization and obtaining
`the first paste which will be transported by a conveyor belt to
`the feeding mechanism.
`0097. Simultaneously, the crushed filler 1, crushed filler 2
`and micronized filler are added in a planetary mixer where the
`catalyser, the accelerant, the binding and the colouring agent
`are mixed with the resin in the following proportions to
`achieve mass 2.
`0098 34% crushed filler 1, 40% crushed filler 2, 17%
`micronized filler, 9% resin, (% calculated over the total
`weight of the fillers and resin mixture)
`0.2% of accelerant in proportion to