IP Library Granted Patent US 11,628,593
Granted Patent B2
US 11,628,593 · App. 15/722,804 · Granted Apr 18, 2023

Method for manufacturing an engineered stone and an engineered stone

Inventors: Terry Adams (Dallas, TX); Claudio Caselli (Dallas, TX)
Assignee: Dal-Tile, LLC
B28B1/005B28B7/007B28B11/001B28B11/048B29C67/243B29C70/44C04B20/0076C04B26/04C04B26/06C04B26/16C04B26/18C04B28/04C04B40/0067C04B40/0263C04B40/0272B29C67/244B29C2791/006B29C2791/008B29K2509/14C04B2111/54
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Quick Facts
Patent No.
US 11,628,593
App. No.
15/722,804
Granted
Apr 18, 2023
Kind
B2
Abstract

A method for manufacturing an engineered stone, the method including: providing a mixture comprising at least a stone or stone like material and a binder; compacting the mixture; curing the binder; and printing on at least a top surface of the engineered stone.

Claims (25)

1. A method for manufacturing an engineered stone, the method comprising:

providing a mixture comprising at least a particulate material and a binder;

adding a coloring agent to the mixture in such a manner to provide a basic décor;

compacting the mixture;

curing the binder to form an engineered stone;

polishing a top surface of the cured engineered stone;

printing a pattern with at least one ultraviolet (UV) curable inorganic ink on the top surface of the cured engineered stone, the printed pattern having a resolution up to 600 dots per inch (dpi); and

curing the printed pattern,

wherein the printing is an inkjet digital printing step comprising applying a plurality of dots of ink to the top surface of the cured engineered stone,

wherein the basic décor is a veined effect imitating a natural stone,

wherein the basic décor is created on the entire thickness of the engineered stone,

wherein the basic décor and the printed pattern are both visible on at least the top surface of the cured engineered stone,

wherein the basic décor is created before the compacting step, and

wherein the printing step is performed after the compacting step.

2. The method according to claim 1 , further comprising adding a coloring agent to the mixture to provide a basic color.

3. The method according to claim 1 , wherein the basic décor defines a background for the printed pattern.

4. The method according to claim 1 further comprising providing a primer on at least the surface to be printed before the printing step.

5. The method according to claim 1 further comprising providing a protective layer to partially or entirely coat at least the top surface of the cured engineered stone.

6. The method according to claim 5 , wherein the protective layer is a transparent or translucent layer and is provided above the printed pattern.

7. The method according to claim 6 , wherein the protective layer comprises a cured resin.

8. The method according to claim 7 , wherein the cured resin comprises an acrylic or epoxy resin.

9. The method according to claim 5 , wherein the step of providing the protective layer comprises dispensing a curable resin and curing the curable resin so as to form the protective layer.

10. The method according to claim 1 , wherein the printed pattern comprises an imitation of a natural stone.

11. The method according to claim 10 , wherein the printed pattern comprises an imitation of veins and/or flakes of a natural stone.

12. The method according to claim 1 , further comprising printing a printed pattern on a second surface of the cured engineered stone that is different than the top surface of the cured engineered stone.

Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 23, 2023
From: DALTILE CORPORATION
To: DAL-TILE, LLC
Reel/Frame 062450/0200 →
CORRECTIVE ASSIGNMENT TO CORRECT THE REMOVE PROPERTY NUMBERS 7130711 AND 7333877 PREVIOUSLY RECORDED AT REEL: 48051 FRAME: 692. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Apr 2, 2019
From: MOHAWK CARPET, LLC
To: DALTILE CORPORATION
Reel/Frame 049108/0769 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 17, 2019
From: MOHAWK CARPET, LLC
To: DALTILE CORPORATION
Reel/Frame 048051/0692 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 30, 2017
From: ADAMS, TERRY; CASELLI, CLAUDIO
To: MOHAWK CARPET, LLC
Reel/Frame 044259/0802 →
Cited By (1)
US 12,384,072