Synthetic molded slabs, and systems and methods related thereto
This document describes systems and processes for forming synthetic molded slabs, which may be suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).
1. A set of separately molded synthetic slabs having generally the same rectangular major surface appearance defined by a same set of particulate mineral mixes, each respective slab of the set comprising at least two different particulate mineral mixes positioned relative to one another according to at least two predefined stencil patterns for each of the synthetic slabs in the set of separately molded synthetic slabs, wherein a first mix of the at least two different particulate mineral mixes occupies a full thickness of each respective slab at first regions in which a second mix of the at least two different particulate mineral mixes is absent, and the second mix of the at least two different particulate mineral mixes occupies the full thickness of each respective slab at second regions in which the first mix of the at least two different particulate mineral mixes is absent, the at least two 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 a major surface with a width of at least 3 feet and a length of at least 6 feet.
2. The set of separately molded synthetic slabs of claim 1 , wherein the at least two predefined stencil patterns comprises at least a first predefined pattern that defines a first pigmented vein and a second predefined pattern that defines a second pigmented vein of each of the synthetic slabs in the set of separately molded synthetic slabs.
3. The set of separately molded synthetic slabs of claim 2 , wherein at least a portion of the first pigmented vein at least partly surrounds at least a portion of the second pigmented vein.
4. The set of separately molded synthetic slabs of claim 1 , wherein the substantially repeated rectangular major surface is polished.
5. The set of separately molded synthetic slabs of claim 1 , wherein the substantially repeated rectangular major surface appearance emulates the appearance of a quarried stone slab due at least in part to the different particulate mineral mixes distributed according to at least the two predefined stencil patterns.
6. The set of separately molded synthetic slabs of claim 1 , wherein the at least two predefined stencil patterns having a predefined and repeatable pattern so as to define complementary regions of the at least two different particulate mineral mixes.
7. The set of separately molded synthetic slabs of claim 2 , wherein the first pigmented vein extends across the full length of the major surface of each respective slab.
8. The set of separately molded synthetic slabs of claim 7 , wherein the major surface has a size selected from one of: about 4.5 feet wide by about 10 feet long, or about 5.5 feet wide by about 11 feet long.
9. The set of separately molded synthetic slabs of claim 1 , wherein the resin binder comprises a silane.
10. The set of separately molded synthetic slabs of claim 1 , wherein the resin binder comprises dendrimeric molecules.
11. The set of separately molded synthetic slabs of claim 1 , wherein the first mix comprises between 5% and 15% polymer resins.
12. The set of separately molded synthetic slabs of claim 1 , further comprising a third particulate mineral mix that is differently pigmented as compared to the first and second particulate mineral mixes.
13. The set of separately molded synthetic slabs of claim 12 , wherein the third particulate mineral mix forms a vein that does not extend through the full thickness of each respective slab.
14. A set of separately molded synthetic slabs having generally the same rectangular major surface appearance defined by a same set of particulate mineral mixes, each respective slab of the set comprising at least two different particulate mineral mixes positioned relative to one another according to at least two predefined stencil patterns for each of the synthetic slabs in the set of separately molded synthetic slabs, wherein a first mix of the at least two different particulate mineral mixes occupies a full thickness of each respective slab at first regions in which a second mix of the at least two different particulate mineral mixes is absent, and the second mix of the at least two different particulate mineral mixes occupies the full thickness of each respective slab at second regions in which the first mix of the at least two different particulate mineral mixes is absent, the at least two 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 a major surface with a width of at least 3 feet and a length of at least 6 feet; wherein the third particulate mineral mix forms a vein that extends across a full width of the major surface.
15. The set of separately molded synthetic slabs of claim 14 , wherein the third particulate mineral mix forms a vein that does not extend through the full thickness of each respective slab.
16. The set of separately molded synthetic slabs of claim 15 , wherein the first pigmented vein extends across the full length of the major surface of each respective slab.