Synthetic molded slabs, and systems and methods related thereto
This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).
1. A synthetic molded slab comprising a quartz material, comprising:
a major surface at least 2 feet wide by at least 6 feet long and extending perpendicularly to a slab thickness, the major surface having at least a first pigmented vein extending generally lengthwise from edge-to-edge that separates at least two other veins extending generally lengthwise and positioned on opposing edges of the first pigmented vein, wherein the first pigmented vein has a vein thickness equal to and parallel to the slab thickness, wherein the slab comprises at least four different particulate mineral mixes distributed in a series of successive layers according to a predefined pattern, a first of the four different particulate mineral mixes defining the first pigmented vein extending generally lengthwise from edge-to-edge of the slab, in which at least the first of the four different particulate mineral mixes is separated from and forms a substantially unmixed layer with respect to others of the at least four different particulate mineral mixes according to the predefined layer pattern.
2. The synthetic molded slab of claim 1 , further comprising a plurality of transverse pigmented veins extending transversely to and intersecting the first pigmented vein, the transverse pigmented veins having a different color than the first pigmented vein.
3. The synthetic molded slab of claim 2 , wherein at least one of the transverse pigmented veins extends generally widthwise from edge-to-edge.
4. The synthetic molded slab of claim 2 , wherein the transverse pigmented veins are thinner than the first pigmented vein.
5. The synthetic molded slab of claim 1 , wherein the slab comprises the different mineral mixes that each includes the quartz material, one or more pigments, and at least one binder.
6. The synthetic molded slab of claim 5 , wherein the slab comprises at least four differently colored mineral mixes distributed in a series of successive layers according to a predefined pattern, a first of the four differently colored mineral mixes defining the first pigmented vein extending generally lengthwise from edge-to-edge of the slab.
7. The synthetic molded slab of claim 6 , wherein at least a second of the four differently colored mineral mixes defines the two other veins extending generally lengthwise and positioned on opposing edges of the first pigmented vein.
8. The synthetic molded slab of claim 7 , wherein the two other veins extend generally lengthwise from edge-to-edge of the slab.
9. The synthetic molded slab of claim 8 , wherein the major surface of the slab is polished and emulates the appearance of a quarried stone slab due at least in part to the four differently colored mineral mixes distributed in the series of successive layers according to the predefined pattern.
10. A set of separately molded synthetic slabs, each respective slab of the set comprising at least four different particulate mineral mixes distributed in the series of successive layers according to a predefined pattern for all of the separately molded synthetic slabs, the four different particulate mineral mixes each comprising a quartz material, one or more pigments, and one or more resin binders, wherein each respective slab is rectangular and has major surface with a width of at least 2 feet and a length of at least 6 feet, wherein at least one of the four different particulate mineral mixes defines substantially lengthwise veins in which said at least one of the four different particulate mineral mixes is separated from and forms a substantially unmixed layer with respect to others of the at least four different particulate mineral mixes according to the predefined layer pattern, said substantially lengthwise veins extending for a majority of the length of each respective slab such that the major surface of each respective slab in the set has similarly positioned and colored substantially lengthwise veins.
11. The set of separately molded synthetic slabs of claim 10 , wherein at least one of the substantially lengthwise veins of each respective slab extends fully lengthwise from edge-to-edge of the respective slab.
12. The set of separately molded synthetic slabs of claim 11 , wherein the major surface of each respective slab of the set further comprises a plurality of transverse pigmented veins extending transversely to and intersecting the substantially lengthwise veins, the transverse pigmented veins having a different color than the substantially lengthwise veins.
13. The set of separately molded synthetic slabs of claim 12 , wherein the transverse pigmented veins of each respective slab are thinner than said at least one of the substantially lengthwise veins of the respective slab.