SQIP v. Cambria - Complaint

Case 4:23-cv-00202-SDJ Document 7 Filed 04/25/23 Page 1 of 18 PageID #: 179
IN THE UNITED STATES DISTRICT COURT

FOR THE EASTERN DISTRICT OF TEXAS
SHERMAN DIVISION
SQIP, LLC,
Civil Action No. 4:23-cv-00202-SDJ_____
Plaintiff,
Jury Trial Demanded
v.
Cambria Company, LLC
Defendant.
FIRST AMENDED COMPLAINT FOR PATENT INFRINGEMENT
Pursuant to Federal Rule of Civil Procedure 15(a)(1), Plaintiff SQIP, LLC files this
Complaint against Cambria Company, LLC for willful infringement of U.S. Patent Nos.
9,511,516 and 10,376,912 (collectively, the “Patents-in-Suit”), based upon Defendant’s
unauthorized manufacture, use, offer for sale, sale and/or importation of Defendant’s infringing
products accused herein.
THE PARTIES
1. Plaintiff SQIP, LLC (“SQIP” or “Plaintiff”) is a Florida limited liability company
having an address at 4121 Seaboard Road, Orlando, Florida 32808.
2. Defendant Cambria Company, LLC (“Cambria” or “Defendant”) is a Minnesota
corporation with its headquarters at 31496 Cambria Avenue, Le Sueur, Minnesota 56058 and
regular and established places of business located at 301 W. Vista Ridge Mall Drive, Suite 400,
Lewisville, Texas 75067 and 5600 Nebraska Furniture Mart Dr., The Colony, Texas 75056.
Cambria may be served with process through its registered agent, CT Corporation System, 1999
Bryan St., Suite 900, Dallas, Texas 75201.
1
JURISDICTION AND VENUE
3. This action arises under the patent laws of the United States, 35 U.S.C. § 101, et
seq. This Court’s jurisdiction over this action is proper under 28 U.S.C. § 1331 (federal question
jurisdiction) and 28 U.S.C. § 1338 (jurisdiction over patent actions).
4. This Court has personal jurisdiction over Cambria in accordance with due process
and/or the Texas Long Arm Statute because, among other activities, Cambria conducts business
in this State by, for example, “recruit[ing] Texas residents, directly or through an intermediary
located in this state, for employment inside or outside this state.” TEX. CIV. PRAC. & REM. CODE
§ 17.042(3). For instance, each of the employment listings below advertise openings at Cambria
facilities in Colony, Texas and Dallas, Texas.
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https://cambria.wd1.myworkdayjobs.com/cambria_careers?locations=17913c8ccf2d1001ba1ae4
7e9dac0000&locations=b503aa9b8c331001b9bfdf5dd42c0000
5. Further, this Court has personal jurisdiction over Cambria because it has engaged,
and continues to engage, in continuous, systematic, and substantial activities within this State,
including the substantial marketing and sale of products within this State and this District. This
Court has personal jurisdiction over Cambria because it has committed acts giving rise to SQIP’s
claims for patent infringement within and directed to this District, has derived substantial
3
revenue from its goods provided to individuals in this State and this District, and maintains
regular and established places of business in this District, including at least its facilities and
showrooms in The Colony and Lewisville.
6. Cambria has committed and continues to commit acts in violation of 35 U.S.C.
§ 271, and has made, used, marketed, distributed, offered for sale, and/or sold products made by
infringing processes and infringing products in this State, including within this District, and
otherwise engaged in infringing conduct within or from this District. Such infringing products
include, but are not necessary limited to those Cambria engineered quartz slab products
identified in Exhibit 3. Such products, and products made by infringing processes, have been and
continue to be marketed, offered for sale, sold, distributed, and used in this District, and the
infringing conduct has caused, and continues to cause, injury to SQIP, including injury suffered
within this District by unfairly competing with products lawfully made using SQIP’s patented
inventions. These are purposeful acts and transactions in this State and this District such that
Cambria reasonably shown know and expect that it could be haled into this Court.
7. Venue is proper in this District under 28 U.S.C. §§ 1391, and 1400(b) because
Cambria has regular and established places of business (the facilities in Lewisville and The
Colony). Further, job offerings on Cambria’s website include a job located in The Colony.
Further, Cambria has voluntarily filed as the plaintiff at least five patent infringement lawsuits in
the State of Texas.
FACTUAL BACKGROUND
8. SQIP owns a portfolio of fifteen issued United States utility patents and an
additional eighteen international patents, all directed to engineered natural quartz surface
products used for various building purposes, such as kitchen and bathroom countertops, and
methods for making such products.
4
9. The Patents-in-Suit are a portion of SQIP’s patent portfolio.
10. Alex Xie is a member of SQIP.
11. Alex Xie has a long history of innovation of methods for manufacturing natural
quartz surface products. Further, Alex Xie has substantial experience in the use of methods for
manufacturing natural quartz surface products in industry.
12. Alex Xie is the sole inventor of the patents owned by SQIP, including the Patents-
in-Suit.
13. SQIP has licensed its patent portfolio, including the Patents-in-Suit, to a company
called Elite Quartz Mfg LLC (“Elite Quartz”), which manufactures natural quartz surface
products pursuant to at least some of SQIP’s patent portfolio.
14. Elite Quartz manufactures natural quartz surface products using the methods
described in the Patents-in-Suit.
15. The natural quartz surface products manufactured by Elite Quartz using the
methods described in the Patents-in-Suit are sold and distributed in the United States through a
company called Hirsch Glass Corp. d/b/a Spectrum Quartz (“Hirsch Glass”) and a company
called MS International, Inc. (“MSI”). Examples of Hirsch’s products and MSI’s products that
are manufactured by Elite Quartz using one or more of the methods claimed in the Patents-in-
Suit include products sold under the commercial names (i) Calacatta Miraggio Duo Quartz
(MSI), (ii) Calacatta Miraggio Duo Quartz (MSI), (iii) Calacatta Miraggio Cielo Quartz (MSI),
(iv) Calacatta Miraggio Gold Quartz (MSI), (v) Grandeur (Hirsch), (vi) Royal (Hirsch), (vii)
Sterling AP (Hirsch), and (viii) Impeccable AP (Hirsch).
16. Alex Xie is a shareholder in Hirsch Glass.
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THE PATENTS-IN-SUIT
17. United States Patent No. 9,511,516 (the “‘516 Patent”), titled “Method and
Apparatus for Manufacturing Quartz Slab,” was duly and legally issued by the United States
Patent and Trademark Office on December 6, 2016 and names Alex Xie as the sole inventor. A
true and correct copy of the ‘516 Patent is attached as Exhibit 1.
18. SQIP owns all substantial rights, title and interests in and to the ‘516 Patent,
including the exclusive right and standing to bring suit with respect to any past, present, and
future infringement. The ‘516 Patent is valid, enforceable, and in full force and effect.
19. United States Patent No. 10,376,912 (the “’912 Patent”), titled “Apparatus and
Method for Depositing Color Into Cracks of a Moving Formed Quartz Slab To Create Veins in
an Engineered Stone,” was duly and legally issued by the United States Patent and Trademark
Office on August 13, 2019 and names Alex Xie as the sole inventor. A true and correct copy of
the ‘912 Patent is attached as Exhibit 2.
20. SQIP owns all substantial rights, title and interests in and to the ‘912 Patent,
including the exclusive right and standing to bring suit with respect to any past, present, and
future infringement. The ‘912 Patent is valid, enforceable, and in full force and effect.
21.
CAMBRIA’S ACTIVITIES
22. As described below, Cambria makes, uses, imports, distributes, supplies, markets,
offers for sale, and/or sells Cambria branded products that infringe one or more claims of the
Patents-in-Suit, including but not limited Cambria’s engineered natural quartz surface products
identified in Exhibit 3 (collectively, the “Accused Products”).
6
23. Those products identified in Exhibit 3 as the “Accused ‘516 Patent Products” are
manufactured in a manner that uses one or more of the claimed methods described and claimed
in the ‘516 patent.
24. Those products identified in Exhibit 3 as the “Accused ‘912 Patent Products” are
manufactured in a manner that uses one or more of the claimed methods described and claimed
in the ‘912 patent.
25. Cambria was aware of the ‘516 Patent no later than February 2018, at which time
Hirsch Glass advised Cambria of the ‘516 Patent (See, Exhibit 4) and Cambria’s response
included the statement that “Cambria does not see any value to those patents, nor do we think
those patents merit any further discussion amongst our clients.” Exhibit 5.
26. In February 2021, Cambria filed a patent infringement lawsuit against Hirsch
Glass Corp. d/b/a Spectrum Quartz in the United States Federal Court for the Eastern District of
Virginia (later transferred to the United States Federal Court for the District of New Jersey), in
which Cambria relied on the ‘516 Patent as a basis for alleging that products sold by Hirsch
Glass were made by methods that infringed claims in Cambria’s asserted patents.
27. Cambria was also aware of the ‘912 Patent no later than December 2021, at which
time Cambria requested that SQIP grant a license to its portfolio of patents, including the
Patents-in-Suit, as part of a settlement offer to resolve Cambria’s ongoing litigation against
Hirsch Glass.
28. In response to Cambria’s request to license SQIP’s portfolio of patents, Hirsch
Glass’s counsel requested that Cambria disclose the processes used by Cambria to manufacture
the products for which Cambria sought a license.
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29. Cambria refused Hirsch Glass’ Counsel’s request for information concerning
Cambria’s manufacturing processes.
30. In the fall of 2022, Cambria again requested SQIP to grant Cambria a license to
SQIP’s patent portfolio, including the Patents-in-Suit, as a component to a settlement offer to
resolve the ongoing litigation between Cambria and Hirsch Glass.
31. Again, Hirsch Glass’ counsel requested that Cambria disclose its manufacturing
processes used to make the products for which Cambria sought a license.
32. Cambria refused Hirsch Glass’ Counsel’s request for information concerning
Cambria’s manufacturing processes.
33. Cambria’s repeated attempts to secure licenses to SQIP’s full patent portfolio is
indicative of Cambria’s knowledge of the Patents-in-Suit and Cambria’s knowledge that certain
of its products infringe such patents.
COUNT I
INFRINGEMENT OF U.S. PATENT NO. 9,511,516
34. SQIP incorporates by reference and realleges, as if fully set forth herein, all
preceding paragraphs.
35. As described below, in violation of at least 35 U.S.C. § 271(a), Cambria infringes
and/or has infringed, directly or indirectly, and literally or under the doctrine of equivalents, at
least claim 14 of the ‘516 Patent by importing, making, using, offering to sell, and/or selling the
Accused ‘516 Patent Products without a license or permission from SQIP, including in this
judicial district.
36. Further, in violation of at least 35 U.S.C. § 271(g), Cambria imports, offers to
sell, sells, and/or uses within the United States the Accused ‘516 Patent Products, which are
made by the process patented in at least claim 14 of the ‘516 Patent. Prior to the sale of the
8
Accused ‘516 Patent Products, the Accused ‘516 Patent Products are neither materially changed
by subsequent processes, nor do they become a trivial and nonessential component of another
product.
37. Claim 14 of the ‘516 Patent recites as follows:
14. A method comprising:

supplying a first mixture of quartz and resin to an inner chamber
of a mold;
wherein the mold has a top opening which leads to the inner
chamber, and the mold includes a first wall, a second wall, a
third wall, and a fourth wall, and a bottom which enclose the
inner chamber; and further comprising
using a computer processor to controllably supply the first

mixture to the inner chamber of the mold through a first region
of the top opening but not through a second region of the top
opening during a first state, and
using the computer processor to controllably supply the first

mixture to the inner chamber of the mold through the second
region of the top opening, but not through the first region of the
top opening during a second state.
38. On information and belief, the Accused ‘516 Patent Products are made by a
process of supplying a first mixture of quartz and resin to an inner chamber of a mold. This is
shown by the pictures of each Accused ‘516 Patent Product set forth on Exhibit 3 and which are
available on Cambria’s website at www.cambriausa.com.
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39. Further, Cambria has alleged that the Accused ‘516 Patent Products are made by a
process covered by the claims of Cambria’s United States Patent No. 9,993,942 (the “‘942
Patent”), which is attached hereto as Exhibit 6. Cambria’s ‘942 Patent states that “the mold 130
can be vertically oriented during the dispensation of the different particulate mineral mixes into
the mold 130.” Exhibit 6, at 4:47-49. Cambria’s ‘942 Patent describes that the particulate
mineral mixes dispensed into the mold “can comprise quartz material…that, when mixed with
pigments and a resin binder and subsequently compressed and cured, provides a hardened slab
product…”. Exhibit 6, at 3:67-4:3.
40. On information and belief, the Accused
‘516 Patent Products are made with a mold that has a
top opening which leads to the inner chamber, and the
mold includes a first wall, a second wall, a third wall,
and a fourth wall, and a bottom which enclose the
inner chamber. Cambria’s ‘942 Patent, with reference
to Figure 1A (reproduced adjacent this paragraph)
describes that the mold used in the process “can
include a shell portion that at least partially defines a space (shown in dashed lines in FIG. 1A)
for receiving the different particulate mineral mixes via an open upwardly facing opening 132 of
the mold 130.” Exhibit 6, at 4:50-54.
41. On information and belief, Cambria’s Accused ‘516 Patent Products are made
using a computer processor to controllably supply the first mixture to the inner chamber of the
mold through a first region of the top opening but not through a second region of the top opening
during a first state. In particular, Cambria’s Accused ‘516 Patent Products all include a first
10
partial vein comprised of a first mixture that extends over a first portion, but not a second
portion, of the length of the slab.
42. On information and belief, Cambria’s Accused ‘516 Patent Products are made
using the computer processor to controllably supply the first mixture to the inner chamber of the
mold through the second region of the top opening, but not through the first region of the top
opening during a second state. In particular, Cambria’s Accused ‘516 Patent Products all include
a second partial vein comprised of the first mixture that extends over the second portion, but not
the first portion, of the length of the slab.
43. Alex Xie has analyzed Cambria’s Accused ‘516 Patent Products and concluded,
based on the fact that the Accused ‘516 Patent Products each include at least a first partial
longitudinal vein and a second partial longitudinal vein, both made from the same quartz/resin
mixture, that do not overlap when viewed in cross-section, that it is highly likely Cambria’s
Accused ‘516 Patent Products were made using a process as described in claim 14 of the ‘516
Patent.
44. Alex Xie’s opinion is reinforced by Cambria’s attempt to secure a license to the
‘516 patent in December 2021 and the fall of 2022, but its refusal to disclose the manufacturing
process to Hirsch Glass’ counsel.
45. SQIP has been damaged as a result of the infringing conduct by Cambria alleged
above. Thus, Cambria is at least liable to SQIP in an amount that compensates SQIP for such
infringement, which by law cannot be less than a reasonable royalty, together with interest and
costs as fixed by this Court under 35 U.S.C. § 284.
11
46. Cambria’s infringement of SQIP’s ‘516 Patent has caused, and will continue to
cause, SQIP to suffer substantial and irreparable harm unless Cambria is enjoined by this Court
pursuant to 35 U.S.C. §283.
47. Cambria has been on notice of and has had actual knowledge of the ‘516 Patent
since at least February 2018.
48. Cambria has been aware that the Accused ‘516 Patent Products have been and
continue to be made using a process that infringes the ‘516 Patent since at least December 2021
when Cambria sought a license to the ‘516 Patent as part of a proposed settlement in its lawsuit
against Hirsch Glass.
49. Cambria’s infringement of the ‘516 Patent is, has been, and continues to be,
willful, intentional deliberate, and/or in conscious disregard of SQIP’s rights. Cambria’s willful
infringement entitles SQIP to increased damages under 35 U.S.C. § 284 and to attorneys’ fees
and costs incurred in prosecuting this action under 35 U.S.C. § 285.
COUNT II
INFRINGEMENT OF U.S. PATENT NO. 10,376,912
50. SQIP incorporates by reference and realleges, as if fully set forth herein, all
preceding paragraphs.
51. As described below, in violation of at least 35 U.S.C. § 271(a), Cambria infringes
and/or has infringed, literally or under the doctrine of equivalents, at least claim 1 of the ‘912
Patent by importing, making, using, offering to sell, and/or selling the Accused ‘912 Patent
Products without a license or permission from SQIP, including in this judicial district.
52. Further, in violation of at least 35 U.S.C. § 271(g), Cambria offers to sell, sells,
and/or uses within the United States the Accused ‘912 Patent Products, which are made by the
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process patented in at least claim 3 of the ‘912 Patent. Prior to the sale of the Accused ‘912
Patent Products, the Accused ‘912 Patent Products are neither materially changed by subsequent
processes, nor do they become a trivial and nonessential component of another product.
53. Claim 3 of the ‘912 Patent recites as follows:
1. A method comprising:
causing a first portion of a slab to move vertically out of alignment

with an area of the slab surrounding the first portion of the slab and
thereby introducing a first crack in the first portion of the slab by
using a first device located between the first portion and a ground
surface to cause a force to be applied to the first portion of the slab;
and
depositing a first material having a color into the first crack of the
slab, so that the first crack with the deposited first material becomes
a vein having the color of the first material;
wherein the first device causes the force to be applied to the first
portion of the slab from below the first portion of the slab, and
thereafter, the first material is deposited into the first crack of the
slab from above the first portion of the slab; and
wherein the first device continues to cause the force to be applied to

the first portion of the slab from below the first portion of the slab,
while the first material is deposited into the first crack of the slab
from above the first portion of the slab.
3. The method of claim 1 further comprising
causing a second portion of the slab to move vertically out of

alignment with an area of the slab surrounding the second portion of
the slab and thereby introducing a second crack in the second
portion of the slab by using a second device located between the
second portion and a ground surface to cause a force to be applied
to the second portion of the slab; and
depositing a second material having a color into the second crack of

the slab, so that the second crack with the deposited second material
becomes a vein having the color of the second material.
13
process that includes causing a first portion of a slab to move vertically out of alignment with an
area of the slab surrounding the first portion of the slab and thereby introducing a first crack in
the first portion of the slab by using a first device located between the first portion and a ground
surface to cause a force to be applied to the first portion of the slab.
process that includes depositing a first material having a color into the first crack of the slab, so
that the first crack deposited with the first material becomes a vein having a color of the first
material.
process in which the first device causes the force to be applied to the first portion of the slab
from below the first portion of the slab, and thereafter, the first material is deposited into the first
crack of the slab from above the first portion of the slab.
process in which the first device continues to cause the force to be applied to the first portion of
the slab from below the first portion of the slab, while the first material is deposited into the first
crack of the slab from above the first portion of the slab
process that includes causing a second portion of the slab to move vertically out of alignment
with an area of the slab surrounding the second portion of the slab and thereby introducing a
second crack in the second portion of the slab by using a second device located between the
second portion and a ground surface to cause a force to be applied to the second portion of the
slab
14
process that includes depositing a second material having a color into the second crack of the
slab, so that the second crack with the deposited second material becomes a vein having the color
of the second material.
60. Alex Xie has studied the Accused ‘912 Patent Products, and, based on his
expertise, concludes that the nature of the cracks in the Accused ‘912 Patent Products indicate
that a first portion of the slab receives pressure from below the slab from a device to push the
first portion of the slab out of alignment with a surrounding portion of the slab, which creates
randomized cracks in the slab into which a colorizing material is deposited to establish the
contrasting crack in the finished product. Further, Mr. Xie has concluded that the nature of the
cracks in the Accused ‘912 Patent Products indicate that a second portion of the slab also
receives pressure from below the slab, this time from a second device, to push a second portion
of the slab out of alignment with a surrounding portion of the slab, which creates more
randomized cracks in the slab into which a colorizing material is deposited to establish the
contrasting crack in the finished product
61. In particular, the appearance of the cracks in the Accused ‘912 Patent Products are
directionally random and of different sizes and shapes, which is indicative of the slab, while still
in the form of a damp particulate mixture, being cracked by applying pressure to a first area from
below the slab to cause it to be vertically out of alignment with the area surrounding the first area
and to deposit coloring in the resultant cracks while the cracks remain open, i.e., before the
pressure applied below the slab is relieved. Furthermore, in the Accused ‘912 Patent Products
there are cracks that move generally in an up and down direction, cracks that move generally in a
left and right direction, and, at times, cracks that move generally in other directions. The
15
different general direction of longer cracks indicates that the cracks were made by multiple
devices, with different orientations, pressing against the slab to create cracks.
62. Alex Xie’s opinion is reinforced by Cambria’s attempt to secure a license to the
‘912 patent in December 2021 and the fall of 2022, but its refusal to disclose the manufacturing
process to Hirsch Glass’ counsel.
63. Cambria has been aware that the Accused ‘912 Patent Products have been and
continue to be made using a process that infringes the ‘912 patent since at least December 2021
when Cambria sought a license to the ‘912 Patent as part of a proposed settlement in its lawsuit
against Hirsch Glass.
64. Cambria’s infringement of SQIP’s ‘912 Patent has caused, and will continue to
cause, SQIP to suffer substantial and irreparable harm unless Cambria is enjoined by this Court
pursuant to 35 U.S.C. §283.
65. Cambria’s infringement of the ‘912 Patent is, has been, and continues to be,
willful, intentional, deliberate, and/or in conscious disregard of SQIP’s rights. Cambria’s willful
infringement entitles SQIP to increased damages under 35 U.S.C. § 284 and to attorneys’ fees
and costs incurred in prosecuting this action under 35 U.S.C. § 285.
DEMAND FOR A JURY TRIAL
SQIP demands a trial by jury on all issues triable of right by jury pursuant to Rule 38 of
the Federal Rules of Civil Procedure.
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PRAYER FOR RELIEF
SQIP respectfully requests that this Court enter judgment in its favor and grant the
following relief:
(i) Judgment and Order that Cambria has infringed one or more claims of each of the
Patents-in-Suit;
(ii) Judgment and Order that Cambria must pay SQIP past and future damages under
35 U.S.C. § 284, including supplemental damages arising from any continuing,
post-verdict infringement for the time between trial and entry of the final
judgment, together with an accounting, as needed, as provided under 35 U.S.C.
§ 284;
(iii) Judgment and Order that Cambria must pay SQIP reasonable and ongoing
royalties on a go-forward basis after Final Judgment;
(iv) Permanent injunction prohibiting Cambria from further infringement of the
infringed claims of the patents-in-suit;
(v) Judgment and Order that Cambria must pay SQIP’s costs;
(vi) Judgment and Order that the Court find this case exceptional under the provisions
of 35 U.S.C. § 285 and order Cambria to pay SQIP its attorneys’ fees;
(vii) Judgment and Order that Cambria’s infringement has been willful;
(viii) Judgment and Order that all damages awarded to SQIP for Cambria’s
infringement be trebled pursuant to 35 U.S.C. §284; and
(ix) Such other and further relief as the Court deems just and proper.
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Dated: April 25, 2023 SCHEEF & STONE SOLID COUNSEL

113 E. Austin Street
Marshall, TX 75670
By: _____________________________
Michael C. Smith
Michael.Smith@Solidcounsel.com
Attorneys for Plaintiff, SQIP, LLC
27266848.1
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Case 4:23-cv-00202-SDJ Document 7-1 Filed 04/25/23 Page 1 of 20 PageID #: 197
EXHIBIT 1
USO0951 1516 B2
(12) United States Patent (10) Patent No.: US 9,511,516 B2

Xie (45) Date of Patent: Dec. 6, 2016
(54) METHOD AND APPARATUS FOR (56) References Cited
MANUFACTURING QUARTZ SLAB
U.S. PATENT DOCUMENTS
(71) Applicant: Alex Xie, West Windsor, NJ (US) 3,088,713 A * 5/1963 Gard ....................... BO1F 5,241
137/6O7
5,266.253 A * 11/1993 Dijkhuizen ......... B29C 37/0032
(72) Inventor: Alex Xie, West Windsor, NJ (US) 264,112
5,885,503 A * 3/1999 Bordener ................ B29C 35.02
264/254
(*) Notice: Subject to any disclaimer, the term of this 6,517,915 B1 2/2003 Banus
patent is extended or adjusted under 35 8.436,075 B2 5, 2013 Buskila et al.
8,702,886 B2 4/2014 Yaniv et al.
U.S.C. 154(b) by 322 days. 9,186,819 B1 * 1 1/2015 Grzeskowiak, II ..... B29C 31.10
2004/0175514 A1* 9, 2004 Stiattesi ................ B29C 39,025
428/15
(21) Appl. No.: 14/496,249 2006/0101752 A1* 5/2006 Sakai ...................... C04B 26,06
52,311.3
2012/0283384 A1* 11/2012 Cox ...................... B29C 39,003
(22) Filed: Sep. 25, 2014 524f786
* cited by examiner
(65) Prior Publication Data
Primary Examiner — Mary F Theisen
US 2016/OO898.18 A1 Mar. 31, 2016 (74) Attorney, Agent, or Firm — Walter J. Tencza, Jr.
(57) ABSTRACT
(51) Int. C. An apparatus including a mold having a top opening which
B29C 39/44 (2006.01) leads to an inner chamber. The mold may include a first,
B29C 39/00 (2006.01) second, third, and fourth walls, and a bottom which enclose
B29C 39/24 (2006.01) the inner chamber. The apparatus may further include a first
B29C 39/04 (2006.01) and/or second devices which are configured with respect to
B44F 9/04 (2006.01) the mold to supply first and/or second mixtures of quartz and
B29C 67/24 (2006.01) resin to the inner chamber of the mold. The apparatus may
include transportation sheet which lies in the inner chamber
(52) U.S. C. of the mold and on an inside surface of the third wall of the
CPC ............. B29C 39/44 (2013.01); B29C 39/003 mold, and which is sandwiched between the first wall and
(2013.01); B29C 39/04 (2013.01); B29C 39/24 the third wall of the mold and the second wall and the third
(2013.01); B29C 67/243 (2013.01); B29K wall of the mold. The first and second devices may include
2509/14 (2013.01); B44F 9/04 (2013.01) means for moving the mold to allow placement of the first
(58) Field of Classification Search and/or second mixtures in specific areas of the inner cham
None ber.
See application file for complete search history. 26 Claims, 10 Drawing Sheets
U.S. Patent Dec. 6, 2016 Sheet 1 of 10 US 9,511,516 B2
Fig. 1
Fig. 2
40a
MN NN
y y
114e
116a 116b 116C
D4
D5
210C
214a 214C
214 214b.
216
218
U.S. Patent Dec. 6, 2016 Sheet S of 10 US 9,511,516 B2
Fig. 5
312
314
40a 40g 4Of 40

40e
216 40C 50
Fig. 7
40a
40d
40b
50
402
Fig. 8
14
616 Computer
Interactive
Device
roller 44 Computer 620
PrOCeSSOr Computer
Memory
622
Motor
for
roller 8
604 606 608

Fig. 9
714
Computer
Interactive
Device
Computer 706
Processor Computer
Memory
704
Motor Motor
roller 116a for for
roller 116b roller 116C
708
710 712
Fig. 10
808
Computer
Interactive
Device
Computer 806
PrOCeSSOr Computer
Memory
804
Motor for
roller 216
US 9,511,516 B2
1. 2
METHOD AND APPARATUS FOR Each of the first and/or second devices and/or one or more
MANUFACTURING QUARTZ SLAB further devices may include means for moving the mold to
allow placement of the first and/or second and/or one or
FIELD OF THE INVENTION more further mixtures of quartz and resin in specific areas of
the inner chamber. Such means for moving the mold may
This invention relates to improved methods and apparatus include, for example, belts or racks and rollers, cable struc
concerning quartz, slabs. tures, hydraulic mechanism structure, pneumatic structure,
or other methods or combined methods of driving mecha
BACKGROUND OF THE INVENTION nism, which may be controlled by a computer or computer
10 processor.
Quartz is the second most abundant mineral in the Earth's In at least one embodiment, the first device includes a first
crust and one of the hardest naturally occurring materials. hopper, a first belt, and a first set of one or more rollers. In
One of its many uses is in “engineered stone'. Engineered at least one embodiment the first device may include a mold
stone, including quartz, has become a common Surfacing belt having grooves; one or more gears with protrusions
and countertop choice in many countries throughout the 15 which mesh with the grooves of the mold belt; and wherein
world. Its applications include kitchen and bathroom coun the mold is configured to be supported on the mold belt
tertops, tables and desktops, floor tile, food service areas, having grooves.
wall cladding, and various other horizontal and vertical The apparatus may include a second device which is
applications. configured with respect to the mold to Supply a second
The production of engineered Stone generally involves mixture of quartz and resin to the inner chamber of the mold,
particulate materials such as ground quartz rock, crushed while at the same time the first device is supplying the first
glass, rocks, pebbles, sand, shells, silicon, and other inor mixture of quartz and resin to the inner chamber of the mold.
ganic materials combined with polymers, binders, resins, The second device may include a second hopper, a second
colorants, dyes, etc. The particulate material(s) may be belt, and a second set of one or more rollers.
varying sizes ranging from four hundred mesh particle size 25 The first device may include a first valve, wherein the first
to four mesh particle size with multiple materials of different valve controls a size of a bottom opening of the first hopper
sizes used simultaneously. The polymer may include agents through which the first mixture of quartz and resin is
to Such as a binder, hardener, initiator, or combination of supplied to the first belt. The first belt may move to supply
Such. The particulate material(s) and polymers, binders, the first mixture of quartz and resin to the inner chamber of
resins, colorants, dyes, etc. are then mixed resulting in a 30 the mold. The first valve may control a size of a bottom
slightly damp mixture. This initial mixture may be processed opening of the first hopper through which the first mixture
through a crushing machine to reduce the size of the of quartz and resin is supplied to the first belt.
combined particles. The resultant, finer mixture may be The second device may include a second valve; and the
poured into a Supporting mold, tray, or other supporting second valve may control a size of a bottom opening of the
structure, after that, the slab is moved into a vacuumed press 35 second hopper through which the second mixture of quartz
machine to be pressed, and then, moved into a curing and resin is supplied to the second belt. The second belt may
machine to be cured into a hardened quartz slab. After move to Supply the second mixture of quartz and resin to the
curing, the slab is generally moved in a grinder to be grinded inner chamber of the mold.
to a desired thickness, followed by a polisher to finish the The first device may include a first hopper having a
product. 40 bottom opening, and a first funnel having a top opening and
Quartz based Stone has many advantages over natural a bottom opening; wherein the first funnel is fixed with
stone such as marble and granite. Compared to these natural respect to the first hopper so that the top opening of the first
stones quartz is harder, stronger, less water absorbent, and funnel receives the first mixture of quartz and resin which
more resistant to staining, scratching, breakage, chemicals, falls through the bottom opening of the first hopper. The first
and heat. One of the drawbacks of quartz is its perceived 45 device may be further comprised of a first motor for con
lack of natural, random looking veins and color patterns trolling an orientation of the first funnel so that the bottom
compared with natural stones. This invention addresses a opening of the first funnel can be placed at different loca
method of producing a quartz based slab with single color tions with respect to the top opening of the mold.
patterns or multiple color patterns and/or veins. The second device may include a second hopper having a
50 bottom opening, and a second funnel having a top opening
SUMMARY OF THE INVENTION and a bottom opening; wherein the second funnel is fixed
with respect to the second hopper so that the top opening of
In at least one embodiment of the present application, an the second funnel receives the second mixture of quartz and
apparatus is provided comprising a mold having a top resin which falls through the bottom opening of the second
opening which leads to an inner chamber. The mold may 55 hopper. The second device may be further comprised of a
include a first wall, a second wall, a third wall, and a fourth second motor for controlling an orientation of the second
wall, and a bottom which enclose the inner chamber. The funnel so that the bottom opening of the second funnel can
apparatus may further include first and/or second, and/or one be placed at different locations with respect to the top
or more further devices which are configured with respect to opening of the mold.
the mold to Supply a first, second, and/or one or more further 60 The apparatus may include a computer processor which
mixtures of quartz and resin to the inner chamber of the communicates with the first device to control how much of
mold. The apparatus may be further comprised of a trans the first mixture of quartz and resin is Supplied to the inner
portation sheet which lies in the inner chamber of the mold chamber of the mold by the first device. The computer
and on an inside surface of the third wall of the mold, and processor may communicate with the first device to cause
which is sandwiched between the first wall and the third wall 65 the first device to supply the first mixture of quartz and resin
of the mold and the second wall and the third wall of the to a first area of the inner chamber of the mold. The
mold. computer processor may communicate with the first device
US 9,511,516 B2
3 4
to cause the first device to supply the first mixture of quartz device. The computer processor may communicate with the
and resin to a second area of the inner chamber of the mold, first device to cause the first device to supply the first
which is different from the first area of the inner chamber of mixture of quartz and resin to a first area of the inner
the mold. chamber of the mold. The computer processor may com
In at least one embodiment, a method is provided which 5 municate with the first device to cause the first device to
includes Supplying a first mixture of quartz and resin to an Supply the first mixture of quartz and resin to a second area
inner chamber of a mold; wherein the mold has a top of the inner chamber of the mold, which is different from the
opening which leads to an inner chamber, and the mold first area of the inner chamber of the mold.
includes a first wall, a second wall, a third wall, and a fourth
wall, and a bottom which enclose the inner chamber. The 10 BRIEF DESCRIPTION OF THE DRAWINGS
method may further include closing the top opening of the
mold with a mold gate after the first mixture of quartz and FIG. 1 shows a front, top, and right perspective view of
resin has been Supplied to the inner chamber, turning the an apparatus in accordance with an embodiment of the
mold about ninety degrees; lifting a mold cover, including present invention;
the first wall, the second wall, the fourth wall, the bottom, 15 FIG. 2 shows a front, top, and right perspective view of
and the mold gate off of the third wall; and moving a slab a mold in for use with the apparatus of FIG. 1;
formed at least in part from the first mixture of quartz and FIG. 3 shows a front, top, and right perspective view a
resin on a transportation sheet sandwiched between the slab first further apparatus in accordance with first further
and the third wall. The first mixture may be supplied by a embodiment of the present invention;
first device including a first hopper, a first belt, and a first set FIG. 4 shows a front and top perspective view of second
of one or more rollers. further apparatus in accordance with a second further
The method may further include moving the mold on a embodiment of the present invention;
mold belt, which is moved by one or more gears; wherein FIG. 5 shows a front, top and right perspective view of a
each of the one or more gears has protrusions which mesh third further apparatus in accordance with a third further
with grooves of the mold belt. The method may further 25 embodiment of the present invention;
include Supplying a second mixture of quartz and resin to an FIG. 6 shows a front view of a fourth further apparatus in
inner chamber of a mold, wherein the second mixture is accordance with a fourth further embodiment of the present
different from the first mixture. The first mixture may be invention;
supplied by a first device including a first hopper, a first belt, FIG. 7 shows a front, top, and right perspective view of
and a first set of one or more rollers; and the second mixture 30 a fifth further apparatus in accordance with a fifth further
may be supplied by a second device including a second embodiment of the present invention;
hopper, a second belt, and a second set of one or more FIG. 8 shows a block diagram of a computer processor
rollers. and other components for controlling one or more aspects of
The first device may include a first valve; and the first the apparatus of FIG. 1;
valve may control a size of a bottom opening of the first 35 FIG. 9 shows a block diagram of a computer processor
hopper through which the first mixture of quartz and resin is and other components for controlling one or more aspects of
supplied to the first belt; and the first belt may move to the apparatus of FIG. 3; and
Supply the first mixture of quartz and resin to the inner FIG. 10 shows a block diagram of a computer processor
chamber of the mold. The second device may include a and other components for controlling one or more aspects of
second valve; wherein the second valve controls a size of a 40 the apparatus of FIG. 4.
bottom opening of the second hopper through which the
second mixture of quartz and resin is Supplied to the second DETAILED DESCRIPTION OF THE DRAWINGS
belt; and wherein the second belt moves to supply the second
mixture of quartz and resin to the inner chamber of the mold. FIG. 1 shows a front, top, and right perspective view of
The first device may include a first hopper having a 45 an apparatus 1 in accordance with an embodiment of the
bottom opening, and first funnel having a top opening and a present invention. The apparatus 1 includes hoppers 2, 12.
bottom opening; wherein the first funnel is fixed with respect and 22, valves 4, 14, and 24, conveyor belts 6, 16, and 26,
to the first hopper so that the top opening of the first funnel rollers 8, 10, 18, 20, 26, and 30, mold 40, rack 42, and gears
receives the first mixture of quartz and resin which falls 44 and 46. In at least one embodiment the rack 42 and gears
through the bottom opening of the first hopper, and the 50 44 and 46 may be replaced by or may be a belt.
method may further include controlling an orientation of the The hopper 2 has a top opening 2a leading to an inner
first funnel so that the bottom opening of the first funnel can chamber 2d. a peripheral side wall structure 2c, and a bottom
be placed at different locations with respect to the top opening 2b. The valve 4 is configured so that it can open and
opening of the mold. close the bottom opening 2b. When the bottom opening 2b
The second device may include a second hopper having a 55 is opened, particles placed into the inner chamber 2d through
bottom opening, and a second funnel having a top opening the top opening 2a fall through the opening 2b and onto the
and a bottom opening; wherein the second funnel is fixed conveyor belt 6. When the bottom opening 2b is closed by
with respect to the second hopper so that the top opening of the valve 4, then particles placed into the inner chamber 2d
the second funnel receives the second mixture of quartz and through the top opening 2a, do not fall through the opening
resin which falls through the bottom opening of the second 60 2b and remain in the inner chamber 2d.
hopper, and the method may further include controlling an Similarly or identically, the hoppers 12 and 22 have top
orientation of the second funnel so that the bottom opening openings 12a and 22a leading to inner chambers 12d and
of the second funnel can be placed at different locations with 22d, peripheral side wall structures 12c and 22c, and bottom
respect to the top opening of the mold. openings 12b and 22b, respectively. The valves 14 and 24
The method may further include using a computer pro 65 are configured so that they can open and close the bottom
cessor to control how much of the first mixture of quartz and openings 12b and 22b, respectively. When the bottom open
resin is supplied to the inner chamber of the mold by the first ings 12b and 22b are opened, particles placed into the inner
US 9,511,516 B2
5 6
chambers 12d and 22d through the top openings 12a and 22a rotational speed of each of belts 6, 16, and 26 can be
fall through the openings 12b and 22b, and onto the con controlled by controlling the rotational speed of the appro
veyor belts 16 and 26, respectively. When the bottom priate roller of rollers 8, 18, and 28. For example, the
openings 12b and 22b are closed by the valves 14 and 24, rotational speed of the belt 6 can be controlled by controlling
then particles placed into the inner chambers 12d and 22d the rotational speed of roller 8. If the rotational speed of a
through the top openings 12a and 22a, do not fall through particular roller of 8, 18, and 28, is raised, the amount of the
the openings 12b and 22b and remain in the inner chambers particular mixture of quartz and resin delivered to the inner
12d and 22d. chamber of 40g of the mold 40 is raised. If the rotational
The mold 40 includes walls 40a, 40b, 40C, and 40d, and speed of a particular roller of 8, 18, and 28 is lowered, the
closed bottom 40e which enclose an inner chamber 40g. A 10 amount of the particular mixture of quartz and resin deliv
top opening 40f leads to the inner chamber 40g. The bottom ered to the chamber of 40g of the mold is lowered. For
40e sits on the rack 42, or a belt, in at least one embodiment, example, raising the rotational speed of the roller 8 in the
which is moved in the direction D2 by rotating gears 44 and clockwise direction C1 causes the rotational speed of the
46. belt 6 to be increased which delivers more particles of the
In operation, the rollers 8, 10, 18, and 20 are caused to 15 first mixture of quartz and resin to the inner chamber 40g of
rotate in the clockwise direction C1 by a motor or motors not the mold 40, at the same time, by positioning the mold 40 by
shown. The rotation of the rollers 8 and 10 in the clockwise movement in the directions D2 or D3 shown in FIG. 1
direction C1, causes the belt 6 to rotate in the clockwise (moved through rack gear device or belt 42, controlled by
direction around the rollers 8 and 10. Particles falling the computer processor 602), a particular area of the formed
through the bottom opening 2b onto an outer Surface 6a of mixture in the inner chamber 40g of the mold 40 will receive
the belt 6 are moved in the direction D1, and after passing more of the first mixture of quartz and resin. The rotational
the roller 10, fall off of the belt 6, fall through the opening speed of the rollers 8, 10, and 18, in at least one embodiment
40f of the mold 40 and into the inner chamber 40g of the is controlled by computer processor 602 shown in FIG. 8.
mold 40. The computer processor 602 may be connected by commu
Similarly or identically, the rotation of the rollers 18 and 25 nications links to motors 604, 606, and 608 for rollers 8, 18,
20 in the clockwise direction C1, causes the belt 16 to rotate 28, respectively. Thus the computer processor 602 can
in the clockwise direction around the rollers 18 and 20. individually control the rotational speed of each of rollers 8,
Particles falling through the bottom opening 12b onto an 18, and 28, and thereby control the rotational speed of belts
outer surface 16a of the belt 6 are moved in the direction D1, 6, 16, and 26, and thereby control the amount of the
and after passing the roller 20, fall off of the belt 16, fall 30 particular mixture delivered to the inner chamber 40g.
through the opening 40f of the mold 40 and into the inner The computer processor 602 is also connected by com
chamber 40g of the mold 40. munications links to motor 616 for roller 44. Roller 46 may
Similarly or identically, the rotation of the rollers 28 and be a passive roller or idler roller. The computer processor
30 in the counter clockwise direction C2, causes the belt 26 602, in at least one embodiment is configured to send
to rotate in the counter clockwise direction around the rollers 35 commands or signals to motor 616 to cause the belt 42 to
28 and 30. Particles falling through the bottom opening 22b move back and forth, or stop, or slow down or speed up,
onto an outer surface 26a of the belt 26 are moved in the and/or oscillate, in the directions D2 and D3. The speed of
direction D2, and after passing the roller 28, fall off of the the back and forth movement or oscillation in the direction
belt 26, fall through the opening 40f of the mold 40 and into D2 and D3 can be controlled by the computer processor 602.
the inner chamber 40g of the mold 40. 40 The manner in which the motors 604-618 are controlled, in
The mold 40 moved on the gear 42 is moved back and at least one embodiment, may be determined by a computer
forth in the directions D2 and D3, in at least one embodi program stored in computer memory 622. Alternatively, or
ment. The computer processor 602 of FIG. 8 individually additionally, the manner in which the motors 604-618 are
controls the valves 4, 14, and 24 which control opening sizes controlled may be determined by input from a human
for openings 2b, 12b, and 22b, respectively. The computer 45 operator through a computer interactive device 620.
processor 602 also individually controls speeds of belts 6, By controlling the amounts of the first, second, and third
16, and 26 through, motors 604, 606, and 608, for rollers 8, mixture supplied to the chamber 40g and the speed of the
18, and 28, respectively. The rollers 10, 20, and 30 may be back and forth movement of the mold 40 or by controlling
idler or passive rollers in at least one embodiment. The the position of the mold 40 through the movement either in
position of the mold 40 (and/or movement), allows the 50 direction D2 or D3 should in FIG. 1, different aesthetic or
distribution of particles from the hoppers 2, 12, and 22 to the artistic patterns of combinations of the first, second, and
inner chamber 40g of the mold 40 to a desired pattern. third mixtures are obtained inside the chamber 40g. In
In at least one embodiment, the inner chamber 2d of the operation, when the chamber 40g is filled up to the top
hopper 2 may have located therein a first mixture of quartz opening 40f a mold gate 50 is put in position to cover the
and resin having a first color or first color mixture, the inner 55 mold opening 40f the mold 40 is then turned from the
chamber 12d of the hopper 12 may have located therein a vertical position of FIG. 1, to a horizontal or flat position. In
second mixture of quartz and resin having a second color or at least one embodiment, the mold gate 50 will prevent the
second color mixture, and the inner chamber 22d of the first, second, and third mixtures in the chamber 40g from
hopper 12 may have located therein a third mixture of quartz falling out of the chamber 40g.
and resin having a third color or third color mixture. 60 FIG. 2 shows the mold 40 filled up to the top opening 40f
Although three hoppers are shown in FIG. 1, i.e. hoppers 2, with a combination of the first mixture provided by the
12, and 22, in at least one embodiment, there would be at hopper 2, the second mixture provided by the hopper 12, and
least two hoppers, providing at least two different colors or the third mixture provided by the hopper 22. As one
color mixtures of quartz and resin. example, the first mixture provided by the hopper 2 may be
In at least one embodiment, roller 8 is controlled by the 65 located in area 60 between the bottom 40e and the line L1
first motor 604, roller 18 is controlled by a second motor 606 shown in FIG. 2. The second mixture provided by the hopper
and roller 28 is controlled by a third motor 608. The 12 may be located in the area 62 between the lines L1 and
US 9,511,516 B2
7 8
L2, and the third mixture 64 may be located in the area 64 the computer processor 602 by a motor as shown by FIG. 8.
between the line L2 and the top opening 40f. The side 40a In addition, the hoppers 2, 12, and 22 may be moved in the
may be transparent to allow the combination of the first, directions D2 and D3 along the length of the mold 40. The
second, and third mixtures to be seen through the side 40a. combined structure of hopper 2, valve 4, belt 6, and rollers
The mold 40 is shown in FIG. 1 as shaped as a rectangular 8 and 10 may be set at a different height from the combined
prism but the mold 40 can be or can be replaced by a mold structure of hopper 12, valve 14, belt 16, and rollers 18 and
in another shape. In at least one embodiment, the mold 40 is 20 to avoid collisions of hopper 2 and hopper 12 and related
placed under a setup including quartz and resin mixture components and to allow the hopper 2 and hopper 3 to
reserving tanks or hoppers and dropping belts which will traverse the entire length L3 shown in FIG. 2 of the mold 40,
carry a mixture of quartz and resin into the mold 40 at 10
and this movement may be controlled by the computer
predetermined rate. Some examples of possible setups are processor 602. In at least one embodiment the combined
shown in FIGS. 1, 3, 4, and 5, wherein the mold 40 may be structure of hopper 2, valve 4, belt 6, and rollers 8 and 10 and
the same as or substantially similar to the molds 114, 214,
and 314. the combined structure of hopper 12, valve 14, belt 16, and
Generally, speaking in at least one embodiment, the mold 15 rollers 18 and 20 may be placed on the same rack, track or
40 (or 114, 214, 314) is in a vertical position as shown in belt, so that the two combined structures are at the same
FIG. 1, and is closed on all sides except the top 40? and height; and in this embodiment, the two combined structures
except for an inserted transportation sheet 402. The trans can be moved back and forth in the directions D2 and D3 of
portation sheet 402 is placed along the inner side of 40c of FIG. 1. One of the two combined structures, such as for
the mold 40. This transportation sheet 402, shown in FIG. 1 example, including components 12, 14, 16, 18, and 20, may
is generally paper or laminated paper or fabric, but can be move pass the end of the mold 40 in the direction D2 of FIG.
another suitable material. The opposite large face/side 40a 1 to allow the space for the following combined structure,
of the mold 40 can be made of tempered glass or other Such as including components 2, 4, 6, 8, and 10 to drop the
transparent material allowing for viewing of the mixture in desired color of the mixture, but once a combined structure
the mold 40. 25 passes the end of the mold 40, either in the direction D2 or
The dropping belt or belts, such as belts 6, 16, and 26 in D3, the belt of that combined structure, (such as belt 16 of
FIG. 1, carry the mixture or mixtures which come out of the combined structure including components 12, 14, 16, 18.
reserving tanks or hoppers 2, 12, and 22, and drop the and 20 or belt 6 of combined structure including components
mixture or mixtures through the open top 40a of the mold 40 2, 4, 6, 8, and 10) is stopped so the mixture from that
into the moving mold 40. The movement of the mold 40 may 30 particular combined structure will not fall off of the particu
also be sped up for less mixture to be dropped in particular lar belt. In at least one embodiment, the hoppers 2, 12, and
area of mold 40, or slowed down or stopped to allow for 22 are fixed translationally with respect to their belts 6, 16,
more mixture to be dropped in particular area of the mold 40 and 26 (and corresponding rollers), so that when the hoppers
by a computer processor 602 of FIG. 8. The speed of the 2, 12, and 22 are moved the belts 6 (and rollers 8 and 10),
dropping belt or belts such as belts 6, 16, and 26 is controlled 35 16 (and rollers 18 and 20), and 26 (and rollers 28 and 30) are
by the computer processor 602. The reserving tank or hopper moved along the length of the mold 40. There may be
opening valve or valves 4, 14, and 24 may be controlled by separate motors, not shown, provided for this movement of
computer processor 602. The mold 40, in at least one the hoppers 2, 12, and 22, in conjunction with the belts and
embodiment, moves back and forth on the mold rack or belt rollers. Alternatively or additionally, the mold 40 may be
42 shown in FIG. 1, and the moving speed and direction of 40 moved on the mold rack or belt 42 instead, or both the
movement of the rack 42 is controlled by computer proces channel and mold can be moved by the computer processor
sor 602, such as by controlling the rotational direction or 602.
rotation speed of gears 44 and 46. In FIG. 1, the mold 40 has The valves 4, 14, and 24 of the mixture reserving tanks or
been put on a rack or belt structure 42, moved by motor hoppers 2, 12, and 22 cause the openings 2b, 12b, and 22b.
which is controlled by computer processor 602. The mold 40 45 to be opened to the appropriate size while the belts 6, 16, and
could also be pulled or pushed back and forth in the 26 are rotated by their respective rollers at the appropriate
directions D2 and D3 by other means in accordance with one speed along the open edge of the mold 40, and the mold 40
or more embodiments of the present invention, Such as a is moved to an appropriate position in the directions D2 and
cable structure, by a hydraulic mechanism structure, by a D3 by the rack 42 or belt 42 at the same time.
pneumatic structure, or other methods or combined methods 50 The opening size for to which the openings 2b, 12b, and
of driving mechanism, which could be controlled by a 22b are opened by the valve valves 4, 14, and 24, respec
computer or computer processor. tively, the speed of belts 6, 16, and 26, and the position of
By controlling having the valves 4, 14, and 24 control the the mold 40 are coordinated by the computer processor 602
opening size for the openings 2b, 12b, and 22b, the speed of so the appropriate quantity of specific color of quartz
the dropping belts 6, 16, and 26, and the position or 55 mixture are dropped into the appropriate area of the inner
movement of the mold 40, quartz and resin mixtures of chamber 40g mold 40.
different colors or compositions can be dropped into the In at least one embodiment, when the hoppers 2, 12, and
chamber 40g of the mold 40 to produce a pattern or veining 22 are moved translationally (along with their corresponding
in the formed mixture. This pattern or veining will appear as belt and rollers), once the particular hopper of hoppers 2, 12.
“layers' when viewed through the transparent mold cover or 60 and 22 reaches an end of the mold 40, it may stop and move
side 40a. the opposite direction as controlled by the computer pro
Once the mold 40 is filled with the mixtures, a mold gate cessor 602. This movement may continue back and forth as
50 shown in FIG. 6 is attached to close the opening 40f needed along the length of the mold 40 in the directions D2
shown in FIG. 1, so that the mold 40 is completely sealed on and D3. The movement of the hoppers 2, 12, and 22 may
all sides. 65 also be slowed down or stopped to allow for more mixture
Each of the mixture reserving tanks or hoppers 2, 12, and to be dropped in a particular area of the mold 40, or the mold
22 has a valve whose opening and closing is controlled by 40 may be moved by belt 42.
US 9,511,516 B2
9 10
Quartz and resin mixtures of different colors or compo by controlling the gear 116a-c to control the rack 118
sitions can be dropped to produce a pattern or veining. This movement. In FIG. 3, the mold 114 has been put on a rack
pattern or veining will appear as “layers' when viewed or belt structure including 118, 116a, 116b, 116c, moved by
through the transparent mold cover or side 40a. Once the a motor which is controlled by computer processor 602. In
mold is filled to the top opening 40f of FIG. 1, the cover or one or more embodiments of the present invention, the mold
gate 50 shown in FIG. 6 is attached along the open edge so 114 could also be pulled or pushed back and forth in the
that the mold 40 is completely sealed on all sides. direction D4 and D5 by other means, such as for example,
There could be multi-color mixtures dropped into hopper, a cable structure, by a hydraulic mechanism structure, by a
Such as hopper 2, to form a variegated mixture, then drop pneumatic structure, or other method or combined method
into the mold 40, or any of this kind of combination. The 10 of driving mechanism, which could be controlled by a
mold 40 is then rotated ninety degrees into a horizontal computer or computer processor. The inner chamber 102d of
position so the transportation sheet 402 shown in FIG. 1, the hopper 102 may contain one mixture of quartz and resin
FIG. 2, and FIG. 7 is on the bottom and the transparent cover of a particular color or color mixture, and the inner chamber
4.0a is on top. The mold cover which includes 40a, 40b, 40d. 104d of the hopper 104 may contain a different mixture of
40e, and mold gate 50 but not 40c, is removed upward 15 quartz and resin of a different color or color mixture. The
leaving the formed quartz mixture or slab 400 in resting on computer processor 702 may control the valves 106 and 108
top of the transportation sheet 402 and mold plate 40c as to control the amount of a particular mixture of quartz and
shown in FIG. 7. In at least one embodiment, the molded resin to be supplied to the inner chamber 114g of the mold
mixture is removed by pulling the transportation sheet 402 114. The computer processor 702 may be connected by
off the mold plate 40c and onto a transportation belt for communications links to motors for funnels 110 and 112.
transfer into a vacuum press machine. After the slab 400 of The computer processor 702 may control motors 714 and
FIG. 7, is pressed, it is moved into a curing machine. After 716 to move the funnels 110 and 112 back and forth in the
curing, the Surfaces of the cured slab are ground down to directions D5 and D4 at a speed or variable speed which can
desired thickness then polished to reveal the finished, pat also be controlled by the computer processor 702. When the
terned slab. The mold cover including 40a, 40b, and 40d. 25 inner chamber 114g of the mold 114 is filled with quartz and
mold gate 50 and plate 40c are returned for use in producing resin, the mold 114 can be placed in a horizontal or flat
another mixture formation. position with the opening 114f covered to prevent quartz and
The computer processor 602 is also connected by com resin from spilling out of the inner chamber 114g.
munications links to valves 4, 14, and 24 as shown in FIG. FIG. 4 shows a front and top perspective view of second
8. The computer processor 602 can control the amount of a 30 further apparatus 200 in accordance with a second further
particular mixture of quartz and resin that is applied to the embodiment of the present invention. The second further
inner chamber 40g of the mold 40 by controlling the amount apparatus 200 may include hoppers 202, 204, funnels 210
of opening and closing of the valves 4, 14, and 24, and speed and 212, and mold 214.
of belt 6.16 and 26, and the position and the movement of The hopper 202 includes top opening 202a, peripheral
the mold 40. Alternatively or additionally these valves may 35 wall 202b, bottom opening 202c, and inner chamber 202d.
also be controlled manually. The hopper 204 includes top opening 204a, peripheral wall
FIG. 3 shows a front, top, and right perspective view a 204b, bottom opening 204c., and inner chamber 204d. The
first further apparatus 100 in accordance with first further bottom opening 202c is configured to be opened or closed by
embodiment of the present invention. The first further appa a valve 206 and the bottom opening 204c is configured to be
ratus 100 includes hoppers 102 and 104, funnels 110 and 40 opened or closed by a valve 208.
112, mold 114, rack 118, and gears 116a, 116b, and 116c. The funnel 210 includes a top opening 210a, a peripheral
The hopper 102 includes top opening 102a, peripheral wall 210b, a bottom opening 210c, and an inner chamber
wall 102b, bottom opening 102c, and inner chamber 102d. 210d. The funnel 212 includes a top opening 212a, a
The hopper 104 includes top opening 104a, peripheral wall peripheral wall 212b, a bottom opening 212c, and an inner
104b, bottom opening 104c., and inner chamber 104d. The 45 chamber 212d.
bottom opening 102c is configured to be opened or closed by The mold 214 may be identical to the mold 114 of FIG.
a valve 106 and the bottom opening 104c is configured to be 3. The mold 214 includes a top opening 214f an inner
opened or closed by a valve 108. chamber not shown, analogous to inner chamber 114g of
The funnel 110 includes a top opening 110a, a peripheral FIG. 3., walls 214a, 214b, 214c, and a wall analogous to
wall 110b, a bottom opening 110c, and an inner chamber 50 wall 114d. and a bottom 214e. The mold 214 sits on a rack
110d. The funnel 112 includes a top opening 112a, a 218.
peripheral wall 112b, a bottom opening 112c, and an inner A computer processor 802 shown in FIG. 10, may control
chamber 112d. motors 808 and 810 for funnels 210 and 212 to move them
The mold 114 includes a top opening 114f an inner in the directions D7 and D6 for funnel 210 and D8 and D9
chamber 114g, walls 114a, 114b, 114c. 114d. and a bottom 55 for funnel 212, as shown in FIG. 4. The computer processor
114e. The mold 114 sits on a belt (or a rack gear structure) 802 of FIG. 10 may also control valves 206 and 208 similar
118 or conveyor belt which rides on rollers 116a, 116b, and to the control of valves 106 and 108. First and second
116c. Each of the rollers 116a-c may have a motor which is mixtures of quartz and resin may be placed in hoppers 202
controlled by computer processor 702 in FIG. 9. and 204. A motor 812 may also be controlled for the roller
FIG. 9 shows a block diagram of a computer processor 60 216 to turn the mold 214 ninety degrees from the vertical
702, a computer interactive device 706, a computer memory shown in FIG.4, to a horizontal position perpendicular to the
704, an motors 708, 710, and 712, for rollers 116a-c, position of FIG. 4, after the mold 214 is filled with a mixture
respectively. In operation the computer processor 702 may from hoppers 202 and 204 and after a mold gate similar or
control the rotational speed and rotational direction of the identical to mold gate 50 of FIG. 6 has been placed so that
gears 116a-116c, in order to control the back and forth 65 it completely covers the opening 214f.
movement, in the directions D4 and D5, of the mold 114 FIG. 5 shows a front, top and right perspective view of a
shown in FIG.3 or may control the position of the mold 114 third further apparatus 300 in accordance with a third further
US 9,511,516 B2
11 12
embodiment of the present invention. The third further a first device which is configured with respect to the mold
apparatus 300 includes hoppers 302, 304, 306, and 308, to supply a first mixture of quartz and resin to the inner
funnels 310 and 312 and mold 314. Each of the hoppers 302, chamber of the mold; and
304,306, and 308 may be identical or substantially similar a computer processor which is configured to control the
to the hopper 202 of FIG. 4, and may include a valve, similar 5 first device to supply the first mixture to the inner
to identical to valve 4, not shown. Each of the funnels 310 chamber of the mold through a first region of the top
and 312 may be identical to funnel 110 of FIG. 1. The mold opening but not through a second region of the top
314 may be identical to the mold 40 shown in FIG.1. In FIG. opening during a first state, and to Supply the first
5, the hoppers 302 and 306 drop material into the same mixture to the inner chamber of the mold through the
funnel 310 to form a new mixture. In FIG. 5, the hoppers 304 10
second region of the top opening, but not through the
and 308 drop material into the same funnel 312 to form a first region of the top opening during a second state.
new mixture. The valves of hoppers 302,304,306, and 308, 2. The apparatus of claim 1 wherein
not shown, may be computer processor controlled. The
funnels 310 and 312 may have their movement controlled the top opening has a length and a width, wherein the
through motors, not shown, which move the funnels 310 and 15 length is substantially greater than the width:
312 in the directions D10 and D11. wherein the computer processor is configured to cause the
FIG. 6 shows a front view of the mold 40 of FIG. 1 in first device to move along the length of the top opening
accordance with an embodiment of the present invention. to thereby change the first device from the first state to
The mold 40 includes a mold plate or side 40c, the trans the second state.
porting sheet 402, a mold cover or plate 40a which may be 3. The apparatus of claim 1 wherein
transparent tempered glass. A mold gate 50 may be provided the first device includes a first hopper, a first belt, and a
to cover the opening 40f of FIG. 1, so that quartz and resin first set of one or more rollers;
does not spill out from the inner chamber 40g of the mold wherein the top opening has a length and a width, wherein
40. the length is substantially greater than the width:
FIG. 7 shows a front, top, and right perspective view of 25 wherein the computer processor is configured to cause the
the mold 40, with the gate 50 attached, together with the side first hopper, the first belt, and the first set of one or more
or top 40a and sides 40b and 40d and a formed piece of rollers of the first device to move along the length of the
quartz and resin mixture 400 on a transporting sheet 402, on top opening to thereby change the first device from the
a mold plate 40c. The mold cover gate 50 is removed to first state to the second state.
accept quartz and resin mixture when the mold 40 is in the 30 4. The apparatus of claim 3 wherein
vertical position of FIG.1. In operation, the formed, but not the first device includes a first valve; and
pressed and not cured mixture 400, which was drop formed wherein the first valve controls a size of a bottom opening
in the inner chamber 40g of the mold 40, is thereafter pulled of the first hopper through which the first mixture of
by grabbing the transporting sheet 402, moved to a press quartz and resin is Supplied to the first belt;
machine, and then moved into a curing machine. To make 35 and wherein the first belt moves to supply the first mixture
another slab. Such as for example, a slab with the same or of quartz and resin to the inner chamber of the mold.
similar overall mixture and/or pattern of quartz and resin, or 5. The apparatus of claim 3 wherein
another slab with a different mixture and/or pattern of quartz the computer processor communicates with the first
and resin, but similar or identical in dimensions to the device to control a rotational speed of at least one roller
formed slab 400, a new transporting sheet, analogous or 40 of the first set of one or more rollers to thereby control
identical to sheet 402 is placed on the mold plate 40c. Then the amount of the first mixture supplied to the inner
the mold cover, including 40a, 40d, and 40b is lowered onto chamber of the mold.
the mold plate 40C, then the complete mold 40 is rotated 6. The apparatus of claim 1 further comprising
ninety degrees to a vertical position, the cover gate 50 is a second device which is configured with respect to the
moved away, and the mold 40 is ready to accept the next 45 mold to Supply a second mixture of quartz and resin to
batch of quartz and resin mixture in the manner and/or the inner chamber of the mold, while at the same time
configurations of FIG. 1, FIG. 3, FIG.4, or FIG. 5. The side the first device is Supplying the first mixture of quartz
or top 40a of the mold may be made of clear tempered glass and resin to the inner chamber of the mold; and
to allow the pattern of quartz and resin which is being wherein the computer processor which is configured to
formed in the inner chamber 40g of the mold 40 to be seen. 50 control the second device to supply the second mixture
The rest of the mold 40 such as the mold plate 40c, bottom to the inner chamber of the mold through a third region
40e, and sides 40b and 40d may be made of steel or other of the top opening but not through a fourth region of the
metal. top opening during a third state, and to supply the
Although the invention has been described by reference to second mixture to the inner chamber of the mold
particular illustrative embodiments thereof, many changes 55 through the fourth region of the top opening, but not
and modifications of the invention may become apparent to through the third region of the top opening during a
those skilled in the art without departing from the spirit and fourth state.
scope of the invention. It is therefore intended to include 7. The apparatus of claim 6 wherein
within this patent all such changes and modifications as may the first device includes a first hopper, a first belt, and a
reasonably and properly be included within the scope of the 60 first set of one or more rollers;
present inventions contribution to the art. the second device includes a second hopper, a second belt,
I claim: and a second set of one or more rollers; and
1. An apparatus comprising: wherein the top opening has a length and a width, wherein
a mold having a top opening which leads to an inner the length is substantially greater than the width:
chamber, and the mold including a first wall, a second 65 wherein the computer processor is configured to cause the
wall, a third wall, and a fourth wall, and a bottom which first hopper, the first belt, and the first set of one or more
enclose the inner chamber; rollers of the first device to move along the length of the
US 9,511,516 B2
13 14
top opening to thereby change the first device from the receives the first mixture of quartz and resin which falls
first state to the second state; and through the bottom opening of the first hopper;
wherein the computer processor is configured to cause the and further comprising a first motor for controlling an
second hopper, the second belt, and the second set of orientation of the first funnel so that the bottom opening
one or more rollers of the second device to move along 5 of the first funnel can be placed at different locations
the length of the top opening to thereby change the with respect to the top opening of the mold.
second device from the third state to the fourth state. 13. An apparatus comprising:
8. The apparatus of claim 7 wherein a mold having a top opening which leads to an inner
the first device includes a first valve; and chamber, and the mold including a first wall, a second
wherein the first valve controls a size of a bottom opening
10 wall, a third wall, and a fourth wall, and a bottom which
of the first hopper through which the first mixture of enclose the inner chamber; and
quartz and resin is Supplied to the first belt; a first device which is configured with respect to the mold
to supply a first mixture of quartz and resin to the inner
wherein the first belt moves to supply the first mixture of chamber of the mold; and
quartz and resin to the inner chamber of the mold; 15 a second device which is configured with respect to the
wherein the second device includes a second valve; and mold to Supply a second mixture of quartz and resin to
wherein the second valve controls a size of a bottom the inner chamber of the mold, while at the same time
opening of the second hopper through which the second the first device is Supplying the first mixture of quartz
mixture of quartz and resin is Supplied to the second and resin to the inner chamber of the mold; and
belt; 2O wherein
wherein the second belt moves to supply the second the first device includes a first hopper having a bottom
mixture of quartz and resin to the inner chamber of the opening, and first funnel having a top opening and a
mold. bottom opening;
9. The apparatus of claim 7 wherein wherein the first funnel is fixed with respect to the first
the computer processor communicates with the first 25 hopper so that the top opening of the first funnel
device to control a rotational speed of at least one roller receives the first mixture of quartz and resin which falls
of the first set of one or more rollers to thereby control through the bottom opening of the first hopper;
the amount of the first mixture supplied to the inner and further comprising a motor for controlling an orien
chamber of the mold; tation of the first funnel so that the bottom opening of
and wherein the computer processor communicates with 30 the first funnel can be placed at different locations with
the second device to control a rotational speed of at respect to the top opening of the mold;
least one roller of the second set of one or more rollers wherein the second device includes a second hopper
to thereby control the amount of the second mixture having a bottom opening, and a second funnel having
supplied to the inner chamber of the mold. a top opening and a bottom opening;
10. The apparatus of claim 1 wherein 35 wherein the second funnel is fixed with respect to the
the computer processor communicates with the first second hopper so that the top opening of the second
device to control how much of the first mixture of funnel receives the second mixture of quartz and resin
quartz and resin is Supplied to the inner chamber of the which falls through the bottom opening of the second
mold by the first device. hopper;
11. An apparatus comprising: 40 and further comprising a second motor for controlling an
a mold having a top opening which leads to an inner orientation of the second funnel so that the bottom
chamber, and the mold including a first wall, a second opening of the second funnel can be placed at different
wall, a third wall, and a fourth wall, and a bottom which locations with respect to the top opening of the mold.
enclose the inner chamber; and 14. A method comprising
a first device which is configured with respect to the mold 45 Supplying a first mixture of quartz and resin to an inner
to supply a first mixture of quartz and resin to the inner chamber of a mold;
chamber of the mold; wherein the mold has a top opening which leads to the
further comprising inner chamber, and the mold includes a first wall, a
a mold belt having grooves; second wall, a third wall, and a fourth wall, and a
one or more gears with protrusions which mesh with the 50 bottom which enclose the inner chamber; and further
grooves of the mold belt; comprising
and wherein the mold is configured to be supported on the using a computer processor to controllably Supply the first
mold belt having grooves. mixture to the inner chamber of the mold through a first
12. An apparatus comprising: region of the top opening but not through a second
a mold having a top opening which leads to an inner 55 region of the top opening during a first state, and
chamber, and the mold including a first wall, a second using the computer processor to controllably supply the
wall, a third wall, and a fourth wall, and a bottom which first mixture to the inner chamber of the mold through
enclose the inner chamber; and the second region of the top opening, but not through
a first device which is configured with respect to the mold the first region of the top opening during a second state.
to supply a first mixture of quartz and resin to the inner 60 15. The method of claim 14 further comprising
chamber of the mold; and closing the top opening of the mold with a mold gate after
wherein the first mixture of quartz and resin has been Supplied
the first device includes a first hopper having a bottom to the inner chamber; and
opening, and first funnel having a top opening and a turning the mold about ninety degrees;
bottom opening; 65 lifting a mold cover, including the first wall, the second
wherein the first funnel is fixed with respect to the first wall, the fourth wall, the bottom, and the mold gate off
hopper so that the top opening of the first funnel of the third wall;
US 9,511,516 B2
15 16
moving a slab formed at least in part from the first mixture wherein the first belt moves to supply the first mixture of
of quartz and resin on a transportation sheet sand quartz and resin to the inner chamber of the mold;
wiched between the slab and the third wall; and wherein the second device includes a second valve; and
wherein the transportation sheet has an area, and the third wherein the second valve controls a size of a bottom
wall has an area; and opening of the second hopper through which the second
wherein the area of the transportation sheet is greater than mixture of quartz and resin is Supplied to the second
the area of the third wall. belt;
16. The method of claim 14 wherein
the first mixture is supplied by a first device including a wherein the second belt moves to supply the second
first hopper, a first belt, and a first set of one or more 10
mixture of quartz and resin to the inner chamber of the
mold.
rollers.
17. The method of claim 16 wherein 24. The method of claim 22 further comprising
the first device includes a first valve; and controlling a rotational speed of at least one roller of the
wherein the first valve controls a size of a bottom opening first set of one or more rollers to thereby control the
of the first hopper through which the first mixture of 15 amount of the first mixture Supplied to the inner cham
quartz and resin is Supplied to the first belt; ber of the mold; and
and wherein the first belt moves to supply the first mixture controlling a rotational speed of at least one roller of the
of quartz and resin to the inner chamber of the mold. second set of one or more rollers to thereby control the
18. The method of claim 16 further comprising amount of the second mixture Supplied to the inner
controlling a rotational speed of at least one roller of the chamber of the mold.
first set of one or more rollers to thereby control the 25. A method comprising
amount of the first mixture Supplied to the inner cham Supplying a first mixture of quartz and resin to an inner
ber of the mold. chamber of a mold;
19. The method of claim 14 further comprising wherein the mold has a top opening which leads to an
using a computer processor to control how much of the 25 inner chamber, and the mold includes a first wall, a
first mixture of quartz and resin is Supplied to the inner second wall, a third wall, and a fourth wall, and a
chamber of the mold by the first device. bottom which enclose the inner chamber;
20. A method comprising wherein the first mixture is supplied by a first device;
Supplying a first mixture of quartz and resin to an inner wherein the first device includes a first hopper having a
chamber of a mold; 30
bottom opening, and a first funnel having a top opening
wherein the mold has a top opening which leads to an and a bottom opening:
inner chamber, and the mold includes a first wall, a wherein the first funnel is fixed with respect to the first
second wall, a third wall, and a fourth wall, and a hopper so that the top opening of the first funnel
bottom which enclose the inner chamber; and
wherein the first mixture is supplied by a first device 35 receives the first mixture of quartz and resin which falls
including a first hopper, a first belt, and a first set of one through the bottom opening of the first hopper;
or more rollers; and and further comprising controlling an orientation of the
further comprising first funnel so that the bottom opening of the first funnel
moving the mold on a mold belt, which is moved by one can be placed at different locations with respect to the
or more gears; and 40 top opening of the mold.
26. The method of claim 25
wherein each of the one or more gears has protrusions Supplying a second mixture of quartz and resin to the
which mesh with grooves of the mold belt. inner chamber of the mold;
21. The method of claim 20 further comprising wherein the second mixture is Supplied by a second
Supplying a second mixture of quartz and resin to an inner device;
chamber of a mold, wherein the second mixture is 45
different from the first mixture. wherein the second device includes a second hopper
22. The method of claim 21 wherein having a bottom opening, and a second funnel having
the first mixture is supplied by a first device including a a top opening and a bottom opening;
first hopper, a first belt, and a first set of one or more wherein the second funnel is fixed with respect to the
rollers; 50 second hopper so that the top opening of the second
and the second mixture is Supplied by a second device funnel receives the second mixture of quartz and resin
including a second hopper, a second belt, and a second which falls through the bottom opening of the second
set of one or more rollers. hopper;
23. The method of claim 22 wherein and further comprising controlling an orientation of the
the first device includes a first valve; and 55 second funnel so that the bottom opening of the second
wherein the first valve controls a size of a bottom opening funnel can be placed at different locations with respect
of the first hopper through which the first mixture of to the top opening of the mold.
quartz and resin is Supplied to the first belt; k k k k k
EXHIBIT 2
US010376912B2
(12) United States Patent (10) Patent No.: US 10 ,376 ,912 B2
Xie (45) Date of Patent: * Aug. 13 , 2019
(54 ) APPARATUS AND METHOD FOR (2013.01); B05D 5 /061 (2013.01); C04B
DEPOSITING COLOR INTO CRACKS OF A 41/009 (2013.01); C04B 41/45 (2013 .01 );
MOVING FORMED QUARTZ SLAB TO C04B 41/4574 ( 2013 .01); C04B 41/61
CREATE VEINS IN AN ENGINEERED (2013 .01); B29C 39 / 20 ( 2013 .01 ); C04B
STONE 41/4576 (2013 .01)
(71) Applicant: Alex Xie , West Windsor, NJ (US) ( 58 ) Field of Classification Search
CPC .. .. . . . . . . .. . ............. BO5D 3 /12
(72) Inventor : Alex Xie , West Windsor, NJ (US) See application file for complete search history .
( * ) Notice : Subject to any disclaimer, the term of this (56 ) References Cited
patent is extended or adjusted under 35 U .S. PATENT DOCUMENTS
U . S . C . 154 (b ) by 0 days .
This patent is subject to a terminal dis 704 ,621 A * 7 /1902 Czermak ............... B29C 45 /006
264/ 152
claimer . 1,597 ,103 A 8/ 1926 Oberherr
(21) Appl. No.: 16 /259,816 (Continued )
(22) Filed : Jan . 28 , 2019 FOREIGN PATENT DOCUMENTS
CN 204842049 U 12 /2015
(65 ) Prior Publication Data FR 002627424 AL 8 /1989
US 2019 /0201928 A1 Jul. 4 , 2019 Primary Examiner — Xiao S Zhao
Related U .S . Application Data (74 ) Attorney , Agent, or Firm — Walter J. Tencza , Jr .
(60 ) Continuation -in -part of application No. 16 / 131, 103, (57 ) ABSTRACT
filed on Sep . 14 , 2018 , now Pat. No. 10 , 189,041, An apparatus including a first device which moves a first
(Continued ) portion of a soft, damp, slightly pressed slab out of align
ment with a majority of the slab and thus introduces a first
(51) Int. Ci. crack in the slab ; and a device for spraying a first colored
C04B 41/61 ( 2006 .01) material into the first crack of the slab . The first device
C04B 41/45 ( 2006 .01) which moves the first portion of the slab out of alignment
B05C 9 / 10 ( 2006 .01 ) with the rest of the slab may include a first cylinder. The
B05B 1/20 (2006 .01) device for spraying the first colored material in the first crack
B05D 3 / 12 ( 2006 .01 ) of the slab may include a robotic apparatus. In at least one
B05D 5 / 06 (2006 . 01) embodiment, the apparatus may also include a second
(Continued ) device which moves a second portion of the slab out of
(52 ) CPC
U .S. CI. B05B 12 / 02 ( 2013 .01 ); B05B 1/ 20
alignment with the majority of the slab and thereby intro
duces a second crack in the slab .
(2013 . 01); B05C 9 / 10 (2013. 01 ); B05C 13/ 02
(2013.01); B05D 1/02 (2013 .01); B05D 3/ 12 12 Claims, 18 Drawing Sheets
20 .
.
.
242 V
-
-
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-
-
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.
190
+
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40 .
US 10 ,Page
376 ,2912 B2
Related U . S . Application Data 4 , 343 ,752 A 8/ 1982 Cann
9 / 1985 Langner
4 ,540, 037 A
which is a division of application No. 15 /860, 328, 4 ,623, 561 A 11/1986 Groothuizen
filed on Jan . 2 , 2018 , now Pat. No . 10 ,099 , 236 . 4 ,721 ,634 A * 1 / 1988 McKinnon B28B 1/005
427/263
(51) Int au 5 , 266 ,253 A 11/ 1993 Dijkhuizen
C04B 41/00 (2006 .01) 5 ,795,513 A 8 / 1998 Austin
5 ,885, 503 A 3 / 1999 Bordener
B05B 12 /02 ( 2006 .01 ) 6 , 389,666 B1 5 / 2002 Grothe
B05C 13/ 02 (2006 .01) 6 ,517 ,915 B1 2 / 2003 Banus
B05D 1 /02 ( 2006 .01) 6 ,702, 967 B2 3 /2004 Overholt et al.
B29C 39 /20 ( 2006 .01) 7 ,815 ,827 B2 10 /2010 Cruz
8 ,436 ,075 B2 5 / 2013 Buskila et al.
8 ,702 ,886 B2 4 /2014 Yaniv et al.
(56 ) References Cited 9 , 186 ,819 B1 11/ 2015 Grzeskowiak , II
9 ,718 ,303 B2 8 / 2017 Greskowiak , II et al.
U .S . PATENT DOCUMENTS 2004 /0175514 A1 9 / 2004 Stiattesi
2006 /0101752 A1 5 /2006 Sakai
1,735,674 A 11/ 1929 Copeland 2012 /0148811 A1 6 /2012 Rha
1 ,935 , 985 A 11 / 1933 Oberherr 2012 /0283384 AL 11 /2012 Cox
1 ,949 ,517 A 3 / 1934 Van Der Pyl 2014 /0017486 A1 * 1/ 2014 Yoo .. B29C 67/ 0011
2 ,044 ,585 A 6 / 1936 Macht 428 / 325
2 , 140 , 197 A 12 / 1938 Batcheller 2014 /0127450 AL 5 /2014 Riman
3 ,088,713 A 5 / 1963 Gard 2015 /0344377 AL 12/2015 Lee
3 ,318 ,984 A 5 / 1967 Dussel 2016 /0236984 AL 8 /2016 Riman
4 ,013 ,616 A 3 / 1977 Wallace
4 ,209 ,486 A 6 / 1980 Ross * cited by examiner
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US 10 ,376 , 912 B2
APPARATUS AND METHOD FOR compared with natural stones . This invention addresses a
DEPOSITING COLOR INTO CRACKS OF A method of producing a quartz based slab with single color
MOVING FORMED QUARTZ SLAB TO patterns or multiple color patterns and /or veins.
CREATE VEINS IN AN ENGINEERED
STONE SUMMARY OF THE INVENTION
CROSS REFERENCE TO RELATED In at least one embodiment, an apparatus is provided
APPLICATION (S ) comprising a device which moves a first portion of a slab out
of alignment with a majority of the slab and thereby intro
The present application is a continuation in part of and 10 duces a first crack in the slab ; and a device for spraying a
claims the priority of U .S . patent application Ser. No . first colored material into the first crack of the slab . The slab
16 / 131 , 103, titled " APPARATUS AND METHOD FOR typically is in a soft, damp, slightly pressed state when the
SPRAYING COLOR INTO CRACKS OF A MOVING first portion of the slab is moved out of alignment with the
FORMED QUARTZ SLAB TO CREATE VEINS IN AN majority of the slab .
ENGINEERED STONE ” , filed on Sep . 14 , 2018 which is a 15 In at least one embodiment, the device which moves the
divisional of and claims the priority of U .S . patent applica first portion of the slab out of alignment with the rest of the
tion Ser. No. 15/860 , 328 , titled “ APPARATUS AND slab includes a first lift bar. The device for spraying the first
METHOD FOR SPRAYING COLOR INTO CRACKS OF colored material in the first crack of the slab may include a
A MOVING FORMED QUARTZ SLAB TO CREATE
VEINS IN AN ENGINEERED STONE” , filed on Jan . 2 , 20 with first spray bar having a plurality of nozzles fixed thereto ,
2018 . the plurality of nozzles of the first spray bar arranged
in a substantially straight line .
FIELD OF THE INVENTION In at least one embodiment, the apparatus may include a
device which moves a second portion of the slab out of
This invention relates to improved methods and apparatus 25 alignment with the majority of the slab and thereby intro
concerning quartz slabs. duces a second crack in the slab , while the first portion of the
slab is out of alignment with the majority of the slab in
BACKGROUND OF THE INVENTION response to the device which moves the first portion of the
slab out of alignment with the majority of the slab . The
Quartz is the second most abundantmineral in the Earth 's 30 apparatus may include a device for spraying a second
crust and one of the hardest naturally occurring materials . colored material into the second crack of the slab , which
One of its many uses is in " engineered stone” . Engineered differs from the device for spraying the first colored material
stone , including quartz , has become a common surfacing into the first crack of the slab , such that the first colored
and countertop choice in many countries throughout the material is configured to be sprayed into the first crack of the
world . Its applications include kitchen and bathroom coun - 35 slab while the second colored material is sprayed into the
tertops, tables and desktops, floor tile , food service areas, second crack of the slab .
wall cladding , and various other horizontal and vertical In at least one embodiment, the apparatus may also
applications . include a conveyor device ; wherein the conveyor device is
The production of engineered stone generally involves configured to move the slab over a least a portion of the
particulate materials such as ground quartz rock , crushed 40 device which moves the first portion of the slab out of
glass, rocks, pebbles , sand , shells , silicon , and other inor - alignment with the majority of the slab .
ganic materials combined with polymers , binders , resins, The conveyor device may be configured to move the slab
colorants , dyes, etc. The particulate material(s) may be over a least a portion of the device which moves the second
varying sizes ranging from four hundred mesh particle size portion of the slab out of alignment with the majority of the
to four mesh particle size with multiple materials of different 45 slab .
sizes used simultaneously . The polymer may include agents The device for spraying the first colored material in the
to such as a binder, hardener, initiator, or combination of first crack of the slab may include a first spray bar having a
such . The particulate material(s) and polymers, binders, plurality of nozzles fixed thereto , with the plurality of
resins , colorants , dyes , etc . are then mixed resulting in a nozzles of the first spray bar arranged in a substantially
slightly dampmixture. This initialmixture may be processed 50 straight line. The device for spraying the second colored
through a crushing machine to reduce the size of the material in the second crack of the slab may include a second
combined particles. The resultant, finer mixture may be spray bar having a plurality of nozzles fixed thereto , with the
poured into a supporting mold , tray, or other supporting plurality of nozzles of the second spray bar arranged in a
structure . Themold or tray containing the damp mixture is substantially straight line .
then moved onto a conveyor belt with a backing sheet, then 55 The device which moves the first portion of the slab out
a processed damp “ slab ” is moved into a vacuum press ofalignment with the majority of the slab may include a first
machine to compress the material. The compressed material lift bar ; and the device which moves the second portion of
is then placed into a curing machine to be heated into a the slab out of alignment with the majority of the slab may
hardened quartz slab . After curing, the hardened slab is include a second lift bar.
generally moved to a grinder to be grinded down to a desired 60 In at least one embodiment, the apparatus may include a
thickness, followed by a polisher to finish the product. computer processor; and a computer memory ; wherein the
Quartz based stone has many advantages over natural computer processor is programmed by software in the
stone such as marble and granite . Compared to these natural computer memory to control the device which moves the
stones quartz is harder, stronger, less water absorbent, and first portion of the slab out of alignment with the majority of
more resistant to staining, scratching, breakage , chemicals , 65 the slab and thereby introduces the first crack in the slab ; and
and heat. One of the drawbacks of quartz is its perceived the device for spraying the first colored material into the first
lack of natural, random looking veins and color patterns crack of the slab .
US 10 ,376 ,912 B2
A method is provided in at least one embodiment which move vertically out of alignment with an area of the slab
may include moving a first portion of a slab out of alignment surrounding the first portion of the slab and thereby intro
with a majority of the slab and thereby introducing a first ducing a first crack in the first portion of the slab by using
crack in the slab ; and spraying a first colored material into a first device located between the first portion and a ground
the first crack of the slab . The method may also include 5 surface to cause a force to be applied to the first portion of
moving a second portion of a slab out of alignment with a the slab ; and spraying a first material having a color into the
majority of the slab and thereby introducing a second crack first crack of the slab , so that the first crack sprayed with the
in the slab ; and spraying a second colored material into the first material becomes a vein having the color of the first
second crack of the slab ; and wherein the second portion of material.
the slab is moved out of alignmentwith the majority of the 10 The method may further include moving the slab over at
slab while the first portion of the slab is moved out of least a portion of the first device before causing the first
alignment with the majority of the slab .
The method may employ further method steps , and may portion of the slab to move vertically out of alignment.
employ structure as previously noted and as further noted in The method may further include causing a second portion
the present application . 15 of
V the slab to move vertically out of alignment with an area
In at least one embodiment an apparatus is provided of the slab surrounding the second portion of the slab and
comprising a first device which is configured to cause a first thereby introducing a second crack in the second portion of
portion of a slab to move vertically out of alignment with an the slab by using a second device located between the
area of the slab surrounding the first portion of the slab and second portion and a ground surface to cause a force to be
thereby introduces a first crack in the first portion of the slab , 20 applied to the second portion of the slab ; and spraying a
wherein the first device is configured to be located between second material having a color into the second crack of the
the first portion and a ground surface , when the first crack is slab , so that the second crack sprayed with the second
introduced ; and a device for spraying a material having a material becomes a vein having the color of the second
color configured to spray a first material having a color into material .
the first crack of the slab , so that the first crack sprayed with 25 The first and the second material may be the same or
the first material becomes a vein having the color of the first substantially the same.
material. The method may further include causing a plurality of
The apparatus may also include a conveyor device which further portions of the slab to move vertically out of align
is configured to move in a first direction , and wherein the ment with corresponding areas of the slab surrounding the
conveyor device is configured to move the slab over at least 30 corresponding plurality of further portions of the slab and
a portion of the first device . thereby introducing a corresponding plurality of further
The apparatus may also include a second device which is cracks in the plurality of further portions of the slab by using
configured to cause a second portion of the slab to move a plurality of further devices each located between each of
vertically out of alignment with an area of the slab surround the corresponding portions and the ground surface ; and
ing the second portion of the slab and thereby introduces a 35 spraying a material having a color into the plurality of
second crack in the second portion of the slab , wherein the further cracks of the slab , so that the plurality of further
second device is configured to be located between the cracks of the slab become veins having a color of a sprayed
second portion and a ground surface , when the second crack material.
is introduced ; and wherein the device for spraying a material The first device and the plurality of further devices may
having a color is configured to spray a second material 40 be arranged in a matrix of a plurality of rows and columns.
having a color into the second crack of the slab , so that the Each of the first device , the second device , and the
second crack sprayed with the second material becomes a plurality of further devices may be a cylinder.
vein having the color of the second material . Acomputer processor may control the steps of causing the
The apparatus may further include a plurality of further first portion of a slab to move vertically out of alignment
devices which are configured to cause a corresponding 45 with an area of the slab ; and spraying the first material
plurality of further portions of the slab to move vertically out having a color into the first crack of the slab .
of alignment with corresponding areas of the slab surround
ing the corresponding plurality of further portions of the slab BRIEF DESCRIPTION OF THE DRAWINGS
and thereby introduce a corresponding plurality of further
cracks in the plurality of further portions of the slab , wherein 50 FIG . 1 shows a top, left , and front perspective view of an
each the plurality of devices is configured to be located apparatus in accordance with an embodiment of the present
between its corresponding portion and the ground surface , invention , with the apparatus of FIG . 1 , in a first state ;
when the corresponding crack is introduced , and wherein the FIG . 2 shows a top , left, and front close up perspective
device for spraying the material having a color is configured view of a portion of the apparatus of FIG . 1 , with part of the
to spray material having a color into the plurality of further 55 apparatus of FIG . 1 visible in FIG . 2, which is not visible in
cracks of the slab , so that the plurality of further cracks of FIG . 1 , with the apparatus of FIG . 1 in the first state ;
the slab become veins having the color of the particular FIG . 3 shows a close up side view of a portion of the
sprayed material. apparatus of FIG . 1, with the apparatus of FIG . 1 in the first
The first device and the plurality of further devices may state ;
be arranged in a matrix of a plurality of rows and columns. 60 FIG . 4 shows a perspective view of the apparatus of FIG .
Each of the first device, the second device, and the 1, with the apparatus of FIG . 1 in a second state ;
plurality of further devices may be cylinders. FIG . 5 shows a caster railing which can be used instead
A computer processormay be provided for controlling the of a lift bar in the apparatus of FIG . 1;
first device , the second device , the plurality of further FIG . 6 shows image of a slab with a crack formed in
devices , and the device for spraying. 65 accordance with an embodiment of the present invention ;
In at least one embodiment a method is provided which FIG . 7 shows side view wherein someone of the compo
may include the steps of causing a first portion of a slab to nents of the apparatus of FIG . 1, have been replaced ;
US 10 ,376 ,912 B2
in
FIG . 8 shows a simplified block diagram of a computer The apparatus 1 also includes U -shaped member 3 , post
processor and components which communicate with and/or5 , member 7, member 9 , member 11 , gear 13 , and gear 15 .
are controlled by the computer processor; and The U -shaped member 3 may have openings 3a and 3b
FIG . 9 shows a perspective view of a robotic apparatus, a through which the rod or tracks 8 and 10 are inserted .
spraying device , a plate with a matrix of openings in 5 In operation , the U - shaped member 3 may be moved by
accordance with an embodiment of the present invention , a the servo motor 2 to cause the U -shaped member 3 to slide
matrix of cylinders and holes , and an apparatus for convey in the directions D1 or D2, on the rods or tracks 8 and 10 ,
ing a slab , without the slab shown ; while the rods or tracks 8 and 10 remain stationary .
FIG . 10 shows a perspective view of the robotic appara In addition , the lift bars 12 and 14 and spray bars 20 and
tus , the spraying device , the slab , the sheet, the plate covered 10 22 together may be rotated to change their orientation with
by the slab , and the apparatus for conveying the slab ; respect to the conveyor belt 26 , with respect to the U -shaped
FIG . 11 shows a front view of the robotic apparatus , the member
spraying device , the slab , the sheet, the plate covered by the direction .3 For , and with respect to the conveyor belt length
example , in FIG . 1, the conveyor belt 26 is
slab , and the apparatus for conveying the slab , with all shown perpendicular or substantially perpendicular to the
cylinders in their lowered positions;
FIG . 12 shows a front view of the robotic apparatus , the rods or tracks 8 and 10 , and with respect to the direction
spraying device , the slab , the sheet, the plate covered by the arrows or directions D1 and D2, but lift bars 12 and 14 and
slab , and the apparatus for conveying the slab with one spray bars 20 and 22 may be rotated (while the conveyor belt
cylinder raised , causing one or more cracks to form in the 26 remains stationary ) to be at a different angle with respect
slab above ; 20 to the rods or tracks 8 and 10 , and with respect to the
FIG . 13 shows a perspective view of the robotic appara - direction arrows or directions D1 and D2 , and with respect
tus, the spraying device, and the plate with the matrix of to conveyor belt 26 or rotated to be parallel to the rods or
openings in accordance with an embodiment of the present tracks 8 and 10 , and parallel to the direction arrows or
invention , with specific openings of the plate shown dark - directions D1 and D2.
ened indicating raised cylinders and others shown not dark - 25 Also , the servo motor 6 can drive the lift bars 12 and 14
ened indicating lowered cylinders in a first state for the up and down in the directions U1 and D1, shown in FIG . 3 ,
plurality of cylinders ; by driving members 7 , 11, and 17 up and down to cause the
FIG . 14 shows a perspective view of the robotic appara - members 19 and 21 to go up and down , and the attached lift
tus, the spraying device , and the plate , with different open - bars 12 and 14 to go up and down in the directions U1 and
ings shown darkened indicating raised cylinders and others 30 D1, shown in FIG . 3 .
shown not darkened indicating lowered cylinders, in a The servo motor 4 can drive lift bars 12 and 14 and the
second state for the plurality of cylinders, which is different servo motor 40 can drive spray bars 20 and 22 from zero to
from FIG . 13 ; one hundred and eighty degrees, with respect to the con
FIG . 15 shows a perspective view of the robotic appara veyor belt 26 . For example , in FIG . 1, the liftbars 12 and 14
tus , the spraying device , and the plate, with different open - 35 and spray bars 20 and 22 are ninety degrees with respect to
ings shown darkened indicating raised cylinders and others the length of the conveyor belt 26 . The servo motor 4 can
shown not darkened indicating lowered cylinders in a third drive lift bars 12 and 14 , the servo motor 40 can drive spray
state for the plurality of cylinders , which is different from bars 20 and 22 , to orient the components 12 , 14 , 20 , and 22 ,
FIGS. 13 and 14 ; parallel to the conveyor belt 26 ( ninety degree rotation from
FIG . 16 shows a perspective view of the robotic appara - 40 FIG . 1 ), or at some other angle , or a one hundred and eighty
tus , the spraying device , a slab that has been processed degree rotation which causes ends 20a and 20b to swap
through the first three states of FIGS. 13 - 15 to a fourth and locations and ends 22a and 22b to swap locations.
final state , the sheet, the plate covered by the slab , and a In at least one embodiment, colorant is sprayed onto a
portion of an apparatus for conveying the slab ; surface , and / or in the cracks of the surface, such as cracks 16
FIG . 17 shows a simplified block diagram of a computer 45 and 18 shown in FIG . 1 , of the slab 30 through one or more
processor and components which communicate with and/ or of nozzles 24 and 25 .
are controlled by the computer processor ; and The conveyor belt 26 and the roller 28 may be part of an
FIG . 18 shows a front view of the robotic apparatus , the overall conveyor device , and the belt 26 and roller 28 may
spraying device, the slab , the sheet, the plate covered by the be driven by a motor not shown in FIG . 1.
slab , and part of the apparatus for conveying the slab , with 50 FIG . 2 shows a top , left, and front close up perspective
all cylinders except one cylinder, extended above the plate , view of a portion of the apparatus 1 of FIG . 1 , with part of
so that the slab rests on the cylinders and not on the plate , the apparatus 1 of FIG . 1 visible in FIG . 2 , which is not
and cracks are introduced as a result of one cylinder being visible in FIG . 1 , with the apparatus 1 of FIG . 1 in the first
lowered . state .
55
FIG . 3 shows a close up side view of a portion of the
DETAILED DESCRIPTION OF THE DRAWINGS apparatus 1 of FIG . 1 , with the apparatus 1 of FIG . 1 in the
first state .
FIG . 1 shows a top , left, and front perspective view of an FIG . 4 shows a perspective view of the apparatus 1 of
apparatus 1 in accordance with an embodiment of the FIG . 1, with the apparatus 1 of FIG . 1 in a second state, in
present invention , with the apparatus of FIG . 1 , in a first 60 which the lift bars 12 and 14 , together with the spray bars 20
state . The apparatus 1 includes servo motor 2 , servo motor and 22 have been driven to be at a substantial longitudinal
4 , servo motor 6 , rods or tracks 8 and 10 , lift bars 12 and 14 , angle with respect to the conveyor belt 26 by the servo motor
spray bars 20 and 22 , a plurality of nozzles 24 , a plurality of 4 and servo motor 40 .
nozzles 25 , spray bar structure 41, spray bar rotation servo FIG . 5 shows a caster railing which can be used instead
motor 40 , conveyor belt 26 , roller 28 , formed quartz slab 30 , 65 of a lift bar in the apparatus of FIG . 1 ;
and backing sheet 32 . The formed quartz slab 30 in FIG . 1, FIG . 6 shows an image of a soft or damp slab 130 (which
is shown in a soft or damp form . may be similar to or identical to the slab 30 of FIG . 1 ) with
US 10 ,376 ,912 B2
a crack 130a formed in accordance with one or more 30 . After that portion of the slab 30 passes through that
embodiments of the present invention . different height level, for example after a portion of the slab
FIG . 7 is a side view , wherein the components 2 , 3, 4 , 6 , 30 passes lift bar 12 , the crack 16 will close. Similarly after
7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 17 , 19 , and 21 have been a portion of the slab 30 passes lift bar 14 , the crack 18 will
removed and replaced by an apparatus 100 including com - 5 close . The spraying color material into the cracks 16 and 18 ,
ponent 114 which can be adjusted upwards in the U2 generally is programmed to occur when the cracks 16 and 18
direction or downwards in the D2 direction to set at a occur , not after.
different height level with respect to surface level of belt 26 . In at least one embodiment of the present invention , a
This can also cause the passing through quartz slab surface different height level causes a portion of a formed quartz
30a ' to crack at a different height point, but the crack lines 10 slab surface 30a to crack at a different height level point,
generally only occur in a direction perpendicular to the while a crack exists, color material is sprayed into the
conveyor belt moving direction . In FIG . 7 , the slab is cracks, such as 16 and 18 . The spraying of color material can
identified as slab 30 ', the slab surface as 30a ', the cracks as be done by a human with a spray gun , or by a spray bar or
16 ' and 18', because the cracks 16 ' and 18 ' will be somewhat bars, such as 20 and 22 , as described in this invention , orby
different from the cracks 16 and 18 , and therefore the slab 15 robot with a way to detect crack area and spray into cracks.
30 ' and the slab surface 30a' will be somewhat different from In addition , the direction of crack lines, such as lines 16
the soft and/ or damp and/ or wet slab 30 and surface 30a and 18 can be controlled by the rotatable lift bars 12 and 14
shown in FIG . 1 . in one or more embodiments of the present invention .
In at least one embodiment, the long lift bars 12 and 14 The lift bars 12 and 14 are sitting on top of members 19
can be driven up in the direction U1, shown in FIG . 3 , by 20 and 21, which are connected to gear 13 , and which can cause
servo motor 6 to push up the section of the conveyor belt 26 the lift bars 12 and 14 to rotate to a certain direction as
while a formed soft and damp quartz slab 30 passes through desired , from zero to one hundred eighty degrees, driven by
on the conveyor belt 26 , causing the quartz slab surface at a servo motor 4 and controlled by the computer 202 . The lift
the points 16 and 18 , above the lift bars 12 and 14 , bars 12 and 14 can be raised when cracks in certain area of
respectively, to crack , along the length direction of the lift 25 the surface of a passing through quartz slab on belt are
bars 12 and 14 . needed , and at the same time when the cracks occur, the
Each of the spray bars 20 and 22 contains a series of spray colorant is sprayed into the cracks , such as shown for cracks
nozzles, 24 and 25 , respectively, positioned above the pass - 16 and 18 , with colorant 27 and 29 shown in FIG . 3 ,
ing quartz slab 30 on the belt 26 , controlled by a computer controlled by computer processor 200 .
processor 202 , and will send bursts of colorant 27 and 29 , 30 In general, the higher the lift bars 12 and 14 are raised , the
shown in FIG . 3 , onto the cracks 16 and 18 of the quartz slab wider the cracks 16 and 18 on the surface of 30a of the
30 . passing through quartz slab 30 will be, and therefore when
In at least one embodiment, the spray bars 20 and 22 are sprayed , the deeper the colorant 27 and 29 on the inner
always in a fixed orientation with respect to the lift bars 12 walls , such as 16a and 18a of the cracks 16 and 18 , will
and 14 so that the spray bar 20 is always right above lift bar 35 penetrate , and the denser of the colorant 27 and 29 on walls ,
12 and the spray bar 22 is always right above left bar 14 , such as 16a and 18a of cracks 16 and 18 will be . I.e .
driven by servo motor 4 and 40, controlled by computer typically more penetration means darker and deeper crack
processor 202 . veins.
Generally , in at least one embodiment, if the lift bars 12 When a substantial longitudinal direction (along the
and 14 are rotated to a certain degree by servo motor 4 , the 40 length of the slab 30 ) crack veins in a quartz slab are needed ,
servo motor 40 is programmed to rotate spray bars 22 and 24 the bars 12 and 14 are rotated to that orientation , such as
to exactly the same degree in order to line up components shown in FIG . 4 , and the bar structure, including bars 12 and
12 , 14 with 22 , 24 , as shown, for example , in FIG . 4 , so that 14 , can be moved on tracks or rods 8 and 10 , so it can be
in this way , when spraying occurs the color can get into the moved in and out underneath the conveyor belt 26 to be
cracks, such as cracks 16 and 18 as shown in FIG . 3 . 45 positioned at desired area . If more crack lines are needed in
Generally , it is critical, in at least one embodiment , that the longitudinal direction , the conveyor belt 26 can be
components 12 , 14 and 22 , 24 be controlled , such as by stopped , in response to the computer processor 202 , and the
computer processor 202 to be at the same orientation , such lift bar structure , including bars 12 and 14 , can continue to
as shown in FIG . 4 , in order to position spray bar 20 directly move on tracks 8 and 10 to a desired area and colorant can
above and aligned with lift bar 12 , and spray bar 22 directly 50 be sprayed into cracks above the lift bars in the manner
above and aligned with lift bar 14 , so that the series of previously described .
nozzles 24 directly above lift bar 12 , and the series of Lift bars 12 and 14 can be equipped with bearings, so it
nozzles 25 directly above lift bar 14 can spray color mate - can have less resistance when raised against the moving
rial, down into cracks caused by lift bars 12 and 14 . If spray conveyor belt 26 . For example , in FIG . 5 , a caster railing 52
bar 20 is not aligned with lift bar 12 and spray bar 22 is not 55 can be used as a lift bar, instead of lift bar 12, to achieve the
aligned with lift bar 14 , most of the color material will be same result . In such an embodiment, the circular cross
sprayed outside of the cracks. section of the caster wheel 52a of the caster railing 52 can
In addition , generally speaking as shown by FIG . 3 , be replaced in substituted in FIG . 3 for the circular cross
cracks 16 and 18 typically occur, in at least one embodiment, section of the bar 12 .
when the portion of the slab 30 passes through a different 60 FIG . 7 shows an apparatus 100 which replaces various
height level, such as for example measured from gear or components shown in FIG . 3 . The apparatus 100 may
component 13 . Due to lift bar 12 , a first portion of the slab include a junction plate 114 , a first belt structure including
30 is moved upwards out of alignment with the majority of belt 104 and rollers 102 and 106 , and a second belt structure
the slab 30 . Due to lift bar 14 , a second portion of the slab including belt 110 , and rollers 108 and 112 . By adjusting the
30 is move upwards out of alignment with the majority of 65 junction plate 114 , up and down in the directions U2 and D2
the slab 30 , at the same time that the first portion of the slap between two separate belt structures different height levels
30 is moved out of alignment with the majority of the slab with respect to the surface level of a moving conveyor belt
US 10 ,376 ,912 B2
10
26 , this also causes , in at least one embodiment, the passing of the conveyor apparatus 300 , which includes rollers 302 ,
through formed quartz slab surface 30a above the junction 303 , 308 and 309 . The conveyor apparatus 300 includes a
plate 114 area to crack , but the crack lines are substantially plurality of belts 306a -306i, shown in FIG . 16 , each of
only in the cross direction of the moving belts 104 and 110 which may be parallel to all of the other belts of 306a -i.
ormoving quartz slab 30 . Any height difference may cause 5 There are grooves on rollers 302 and 309 in order to keep the
the passing through slab 30 surface to crack at the height belts in alignment during movement. FIG . 9 also shows a
different point, and colorant may be sprayed into the cracks plate 450 , which has a plurality of openings 452 . Some of
16 ' and 18 ' at the same time.
FIG . 4 shows lift bars 12 and 14 and spray bars 20 and 22 are openings
the 452 , such as opening 452e, shown in FIG . 9 ,
in a diagonal orientation with respect to a length of the 10 as opening 452f,a are
shown with raised cylinder, and other openings, such
shown without a raised cylinder.
conveyor belt 26 , wherein the conveyor belt 26 has a width FIG . 17 shows a simplified block diagram 500 of a
which is substantially less than its length . computer processor 502 and components which communi
Once the entire formed quartz slab passed the lift bar area cate with and/ or are controlled by the computer processor
and desired area of crack lines created and colorant sprayed
502
into the desired section of the (the on -off of all nozzles on 15 5 . The computer processor 502 , computer memory 504 ,
the spray bars 20 and 22 can be controlled separately if computer display 506 , and computer interactive device 508
needed ) cracks, the quartz slab 30 is transferred to a vacu - may be similar or identical to the components 202, 204 , 206 ,
umed press machine . When the press machine is lowered and 208 previously described with respect to FIG . 8 , except
onto the quartz composite material 30 , the cracks 16 and 18 as described in this application .
( or 16 ' and 18 ') sprayed with colorant will become lines of 20 The computer processor 502 may control the conveyor
the colorant in the quartz slab that simulate veins in natural apparatus 300 , the robotic apparatus 400 (which may
stone on the surface of the slab after the slab 30 has been include the spraying device 402 ), and a plurality of cylinders
cured , grinded , and polished . 330 . The plurality of cylinders 330 may include a matrix of
FIG . 8 shows a simplified block diagram 200 including a a plurality of cylinders corresponding with and aligned with
computer processor 202 and components communicating 25 the matrix of a plurality of openings 452. The cylinders 330
ithReferring
and /or controlled
to FIG . 8 , bythethediagram
ht
computer
200,processor 202 .
shows a computer may include cylinders 330a -p shown in FIG . 12 .
processor 202 , a computer memory 204 , a computer display The robotic apparatus 400 may be any known robotic
206 , a computer interactive device 208 (such as a computer apparatus which is controlled by computer processor 502 , in
accordance with a computer program stored in computer
mouse , touchscreen , or computer keyboard ), and in simpli- 30 memory 504 to move the spraying device 502 to any
fied block diagram form , the conveyor device motor for location above the plate 450 and simultaneously within a
conveyor belt 26 , the first servo motor 2 , the second servo perimeter of the plate 450 , shown in FIG . 10 , and conse
motor 4 , the third servo motor 6 , the nozzles 24 , and the quently above the slab 350 and within the perimeter of the
nozzles 25 . The computer processor communicates with and
controls the components 26 , 2, 4 , 6 , 24 , and 25 , as well as 35 slab 350 when the slab 350 overlaps the plate 450 as shown
components 204 , 206 , and 208 . in FIG . 10 .
In operation , the computer processor 202 is programmed The conveyor apparatus 300 may be controlled by the
by computer software stored in the computer memory 204 , computer processor 502 , as programmed by computer soft
and /or controlled by the computer interactive device 208 to ware stored in the computer memory 504 . The cylinders , and
control the components 26 , 2 , 4 , 6 , 24 , 25 , 24a , and 25a . 40 specifically the movement of the cylinders up and down, the
In one or more embodiments , spray bars 20 and 22 may height of the cylinders or distance , and /or whether a par
be replaced by a human hand with a spray gun , in order to ticular cylinder , such as cylinder 330f, protrudes through and
add randomness in missing some of the crack area , wherein above an opening of the plate 450 , are controlled by the
said randomness may be desired . In other embodiments , a computer processor 502 as programmed by computer soft
robot sprayer with a photo sensor may replace spray bars 20 45 ware stored in computer memory 504 .
and 22 , wherein the photo sensor is used to spot or detect E ach of cylinders 330a - p may be a solid cylinder. In FIG .
cracks and spray in the cracks as desired. There may be other 12 , except for cylinder 330f, the other cylinders of 330a- p do
ways to spray into the cracks. not protrude above the top surfaces of the belts 306a- 306i,
Even though the rotation of the lift bars 12 and 14 are such as top surface 307a of the belt 306a . The top surfaces
shown in one or more embodiments , as driven by servo 50 the belts 306b -i, typically are at the same height level or
motor 4 and controlled by computer processor 202 , in of distance above the top surface 450a of the plate 450 .
alternative embodiments, the rotation of lift bars 12 and 14 If all of cylinders 330a - p are below the top surface 307a
can occur by hand. ( and the other top surfaces of belts 306b-i) then the slab 350
Even though the up and down movement of FIG . 1 , of the
member 7 in FIG . 2 is driven by servo motor 6 and 55 passes tional
over the region of the plate 450 , without any addi
cracks being generated .
controlled by the computer processor 202 in one or more
embodiments , in alternative embodiments , the up and down However, when a cylinder 330f protrudes above the top
movement of the member 7 can be implemented manually, surfacesurface su307a of the belt 306a ( and thus above the top
such as by a hand jack . surfaces of the belts 306b - 306i), the slab 350 is pushed
Even though the device including member 3, move in 60 upwards in the direction U1, shown in FIG . 12 , at that
directions D1 and D2, in at least one embodiment, as shown location, to cause one or more cracks to occur in the slab
in FIG . 1 , driven by servo motor 2 and controlled by the 350.
computer 202 , themember 3 , and components fixed thereto As shown in FIG . 9, there are gaps between adjacent belts
can be rolled in the directions D1 and D2, shown in FIG . 1 , of the belts 306a- 306i, which permit one or more of the
in alternative embodiments by hand . 65 cylinders 452 to protrude through the gaps between adjacent
FIG . 9 shows a perspective view of a robotic apparatus belts , and to thus push up the slab 350 in the direction U1,
400 , a material spraying or depositing device 402 and part at particular locations.
US 10 ,376 ,912 B2
12
In at least one embodiment, thebelts 306a -i are preferably and sixteen columns of a rectangular matrix of cylinders ,
parallel to each other and the gaps between adjacent belts of each cylinder similar or identical to cylinder 330a .
belts 306a -i, preferably have the same width , W1 shown in FIG . 14 shows a perspective view of the robotic apparatus
FIG . 10 . 400 , the spraying device 402, and the plate 450 shown in
In at least one embodiment, the openings 452 shown in 5 FIG . 13 . FIG . 14 differs from FIG . 13 , in that different
FIG . 14 are arranged in a matrix with a plurality of rows and cylinders are raised , and therefore shown darkened . For
a plurality of columns. The distance between adjacent rows example , a cylinder corresponding to opening 452c is raised ,
of the openings 452 is about the width W2 of one ofthe belts of the beltopening
through 452 and protrudes above the surface 307a
306a, and above surfaces of the other belts 306b -1,
306a - 306i, wherein each of the belts 306a -i, typically has 10 and a cylinder corresponding to opening 452d is not raised
the same width W2. above the surface 307a . In the second state a different
FIG . 10 shows a perspective view of the robotic apparatus
400 , the spraying device 402, and the conveyor apparatus plurality of raised cylinders compared to the first state of
FIG . 13 , is caused by the computer processor 502 , in order
300 , which have been previously described , as well as a slab to form additional and different cracks or fissures in slab 350
350 and a sheet 311 which have been moved intointo position
position toto 15 according to a desired design . Once the cracks or fissures are
be processed on top of the plate 450. created , spraying device 402 attached to the robotic arm
FIG . 11 shows a front view of the robotic apparatus 400 , apparatus 400 , is controlled by the computer processor 502
the spraying device 402 , the conveyor device or apparatus to deposit dye or colored material on top of the formed
300 , the slab 350 and the sheet 311 in position to be cracked or fissured area . After the dye or colored material is
processed on top of the plate 450. FIG . 11 shows cylinders 20 deposited , all of the cylinders of 330a - p , or similar or
330a -330p , all in a lowered state . identical cylinders are returned to a lowered state by the
FIG . 12 shows a front view of the robotic apparatus 400 , computer processor 502 below the top surface 307a of the
the spraying device 402 , the conveyor device or apparatus belt 306? and corresponding top surfaces of the belts 306b -i.
300 , the slab 350 and the sheet 311 in position to be FIG . 15 shows a perspective view of the robotic apparatus
processed on top of the plate 450 . FIG . 12 shows cylinders 25 400 , the spraying device 402, and the plate 450 shown in
330a, 3300 , 330c , 330d, 330e , 330f, 330g, 330h , 330i, 330j, FIG . 13 . FIG . 15 differs from FIG . 13 and FIG . 14 , in that
330k , 3301, 330m , 300n , 3000 , and 330p, with only cylinder different cylinders, of cylinders 330a -p are raised, shown
330f raised so that its leading top edge or top surface is darkened . For example , a cylinder corresponding to opening
above the top surface 307a of the belt 306a , and the 452e is raised , above the top surface 307a of the belt 306a,
corresponding top surfaces of the belts 306b -306i. This 30 and above the top surfaces of belts 306b - i and a cylinder
causes the sheet 311 and the slab 350 to also rise at the corresponding to opening 452f is not raised above the top
location of cylinder 330f, causing cracks and fissures to form surface 307a of the belt 306a . In the third state of FIG . 15 ,
on the top surface of slab 350 above and around cylinder a different plurality of raised cylinders of cylinders 330a - p
330f. compared to the first and second states , is caused by the
FIG . 13 shows a perspective view of the robotic apparatus 35 computer processor 502 in order to form additional and
400 , spraying device 402 and the plate 450. The plate 450 different cracks or fissures in the slab 350 according to a
has a plurality of openings 452 . Some of the openings 452 , desired final design . Once the cracks or fissures are created ,
such as opening 452a are shown darkened to represent a the computer processor 502 is programmed to cause spray
raised cylinder, of cylinders 330a -p , above the top surface ing device 402 attached to the robotic arm apparatus 400 to
307a of the belt 306a and above the top surfaces of other 40 deposit dye or colored material on top of the formed cracked
belts 306b -i similar or identical to cylinder 330f shown in or fissured area . After the dye or colored material is depos
FIG . 12 , and some of the openings 452 , such as opening ited , all of the cylinders, such as 330a - p are returned to a
452b are shown not darkened to represent a lowered cylin - lowered state , so they do not protrude above the top surface
der, similar or identical to what is shown for cylinders 330a -i 307a of the belt 306a or any of the other top surfaces of the
except 330f, in FIG . 12 , which are below the top surface 45 belts 306b -i.
307a of the belt 306a and below the top surfaces of the other FIG . 16 shows a perspective view of the robotic apparatus
belts 306b - 306i. Not shown in FIG . 13 are conveyor device 400 , spraying device 402, the slab 350 , sheet 311, and
or apparatus 300 , sheet 311 and slab 350 which generally conveyor device 300 . The slab 350 has been processed
would be on top of the plate 450 . In this first state of through the above first, second and third states for the
cylinders 330a -p , a plurality of raised cylinders is caused by 50 cylinders . Lines or veins 360 , 361 and 362 are formed during
the computer processor 502 in order to form cracks or states the second , first, and third states for the cylinders ,
fissures in slab 350 according to a desired final design . Once respectively.
the cracks or fissures are created , spraying device 402 In accordance with a method in one or more embodiments
attached to a robotic arm of the robotic apparatus 400 is of the present invention , particulate quartz , resin and other
controlled by computer processor 502 , as programmed by 55 additives are mixed into a damp mixture and evenly distrib
computer software in the memory 504 to deposit dye or u ted into a mold tray with or without a bordering frame. The
colored material on top of the formed cracked or fissured damp mixture is deposited on top of a paper like sheet 311.
area. After the dye or colored material is deposited , all of the The length and width of this mixture formation or slab 350 ,
cylinders 330a - p are controlled by the computer processor can vary .
502 to return to a lowered state , below the top surfaces of the 60 The damp mixture formation or slab 350 is slightly
belts 306a- i. pressed on the top by a roller or by a flat plate . This slightly
In at least one embodiment, for the matrix of the plurality compacts themixture formation into a consistency similar to
of openings 452 there is an aligned matrix of a plurality of damp
Domn soil
soil.
corresponding cylinders, similar or identical to cylinders The slightly pressed mixture formation or a slab 350 is
330a -p . For example, if there are eight rows and sixteen 65 transported via a conveyor apparatus 300 , such as by belts
columns for a rectangular matrix of openings 452, then there 306a - i moved by roller 302 in FIG . 9 , until the slab 350 is
would be , in a least one embodiment, an aligned eight rows overlapping the plate 450 , and generally completely within
US 10 ,376 ,912 B2
13 14
and /or encompassed by the perimeter of the plate 450 . The different amount of dye or colored material on the cracked
plate 450 has an array of holes or openings 452. This areas. This will allow for the control of the width and depth
conveying action may be accomplished in a variety of of the resultant veins.
methods not shown in the figures such as a device grasping Once finished , the entire slab 350, as modified , is moved
the sheet 311 and dragging it onto the plate 450, and out of 5 by the conveyor apparatus 300 , into a vibrating, vacuumed
the plate 450 after it has been processed . Through these heavy - duty press machine. Once it is pressed , the slab 350
is moved to a curing machine . After curing , the slab is
holes 452, cylinders, such as cylinders 330a -p , which may trimmed
be air, hydraulic , electric magnetic, or other kind of cylin reveal theandfinished
ground down to desired size then polished to
ders , or the like may be controlled to rise or drop perpen 10 In at least one ,embodiment
veining patterned slab .
, the present invention can
dicular to the plane in which the slab 350 is sitting on . These raise certain points of the slab 350 through an array of
cylinders 330a - p are controlled by the computer processor cylinders 330a -p and similar cylinders of a matrix . A robotic
502, shown in FIG . 17 , and may be raised independently, apparatus 400 controls a spray device 402 which deposits or
with different forces and varying distances . Although only sprays colorant in liquid , powder or quartz and resin mixture
one row of cylinders 330a -p are shown in FIG . 12 , in at leastSt 1515 in particle form , in any area of the plane in coordination with
one embodiment, there would typically be a matrix of a the group of the raised cylinders of cylinders 330a -p
plurality of rows by a plurality of columns, so that there is The plurality of cylinders 330 by themselves or om
one cylinder for each of the openings 452 of the plate 450 . bination the plate 450 and /or in combination with other
By controlling the rise of certain cylinder or cylinders (or components may be considered a device which moves a first
first group of cylinders) of the cylinders 330a -p or similar 20 portion of a slab out of alignment with a majority of the slab
cylinders corresponding to the matrix of holes 452 , through and thereby introduces a first crack in the slab . The plurality
the holes 452 of the plate 450, each cylinder pushes up on of cylinders 330 and the plate 450 may be replaced by a
the bottom of the slab 350 through the sheet 311 . This causes physical structures having other shapes , for example the
the top surface of the mixture formation above the cylinders cylinders 330 may be replaced by a plurality of rectangular
330a -p or similar cylinders to crack and fissure . Since the 25 solids. The plurality of cylinders 330 may be considered a
cylinders 330a - p , and similar cylinders, are controlled by device which applies pressure to a slab at one or more
computer processor 502, in accordance with computer pro locations . Each of the openings 452 of the plate 452 , in a
gramming stored in computer memory 504 , the resultant isleastapproximately
one embodiment, is circular and has a diameter which
equal to , or slightly larger than the diam
cracks and fissures will have a certain level of controlled
red by 30 eter of each of the cylinders 330 , to allow each of the
randomness . This controlled randomness is desired by 30 cylinders to move upwards in the direction U1 through their
design . corresponding opening of openings 452 and then move
Once the pattern of cracks and fissures have formed , a downwards opposite the direction
different color of dye or quartz and resin mixture in liquid , cylinder of cylinders 330 retracts. U1, when the particular
powder, or small particle form can be placed , deposited ,, 35
sprayed , or in combination, onto the surface of the mixture mentvariety of methods may be used to control the move
of the spray device 402 . In the described embodiment
formation over the cracked areas by spraying device 402 of a six axis robotic arm is used , however there are many other
the robotic apparatus 400 . The different color of dye or methods including but not limited to gantry structure devices
quartz and resin mixture in liquid , powder, or small particle with spray or delivery device 402 controlled by a computer
form may be placed , deposited , sprayed , such as by device 40 processor.
402 of the robotic apparatus 400 or in combination , onto the In at least one embodiment of the present invention , the
surface of the mixture formation over the second pattern of cylinders 330 may be all raised beyond the top surface 307a
the cracked areas through the control of the computer of the belt 306a , except for cylinder 3300 ( or some other
processor 502 . At this point, the first group of cylinders that cylinder ), which may be lower than the rest of the cylinders
formed the first pattern of cracks and fissures can be dropped 45 330 as shown in FIG . 18 , before the slab 350 is placed on the
or lowered in height through control of the computer pro cylinders 330 . After the cylinders 330 are placed in the
cessor 502 . configuration of FIG . 18 , then the slab 350, can be placed
At this time, the second group of cylinder or cylinders of onto the tops of the cylinders 330 , by simply dropping the
330a- p or similar cylinders of a matrix may be raised slab 350 onto the cylinders (i.e . the conveyor apparatus 300
through control of the computer processor 502 , and the 50 may not be used , or some other apparatus for conveying may
second set of corresponding cracks and fissure on the surfacebe used ). When the slab 350 is dropped onto the cylinders
of the mixture formation will occur. A different color of dye330 , with the cylinders arranged as in FIG . 18 , cracks C1 and
or quartz and resin mixture in liquid , powder, or small C2 will be introduced at the location where 3300 is lowered .
particle form is then deposited by spraying device 402 . The plurality of cylinders 330 may all initially be at their
The above process may be repeated until the final 55 highest height, with respect to a ground surface 490 . After
designed pattern is created . the slab 350 is lowered onto the plurality of cylinders 330,
A second color of dye or quartz and resin mixture , which one or more of the cylinders 330 may be selectively lowered
could be different from the slab 350 and different from the by the computer processor 502 to introduce cracks into the
first color of filling material could be used if needed . The slab 350, similar or identical to cracks C1 and C2 shown in
spraying device 402 may be supplied with solid , liquid or 60 FIG . 18 .
gaseous material depending on the desired aesthetic. A The ground surface 490 is shown in FIGS. 11 , 12 , and 18 .
variety of methods for supplying the spraying device 402 Although the invention has been described by reference to
exist, including but not limited to air hosing , tubing , or particular illustrative embodiments thereof, many changes
storage tanks. and modifications of the invention may become apparent to
The width of the cracks and fissures can be partially 65 those skilled in the art without departing from the spirit and
controlled by raising the cylinders 330a - p and similar cyl-
scope of the invention . It is therefore intended to include
inders of a matrix to varying heights, and by deposit within this patent all such changes and modifications as may
US 10 ,376 , 912 B2
15 16
reasonably and properly be included within the scope of the alignment with an area of the slab ; and depositing the
present invention 's contribution to the art. first material having a color into the first crack of the
slab .
I claim : 9 . The method of claim 1 wherein
1. A method comprising 5 the slab is a damp particulate mixture.
causing a first portion of a slab to move vertically out of 10. A method comprising
alignment with an area of the slab surrounding the first causing a first portion of a slab to move vertically out of
portion of the slab and thereby introducing a first crack alignment with an area of the slab surrounding the first
in the first portion of the slab by using a first device portion of the slab and thereby introducing a first crack
in the first portion of the slab by using a first device
located between the first portion and a ground surface located between the first portion and a ground surface
to cause a force to be applied to the first portion of the to cause a force to be applied to the first portion of the
slab ; and slab ; and
depositing a first material having a color into the first spraying a first material having a color into the first crack
crack of the slab , so that the first crack with the 15 of the slab , so that the first crack sprayed with the first
deposited firstmaterial becomes a vein having the color material becomes a vein having the color of the first
of the first material; material;
wherein the first device causes the force to be applied to further comprising causing a plurality of further portions
the first portion of the slab from below the first portion of the slab to move vertically out of alignment with
of the slab , and thereafter, the first material is deposited 20 corresponding areas of the slab surrounding the corre
into the first crack of the slab from above the first sponding plurality of further portions of the slab and
portion of the slab ; and thereby introducing a corresponding plurality of further
wherein the first device continues to cause the force to be cracks in the plurality of further portions of the slab by
applied to the first portion of the slab from below the using a plurality of further devices each located
first portion of the slab , while the first material is 25 between each of the corresponding portions and the
deposited into the first crack of the slab from above the ground surface; and
first portion of the slab . spraying a material having a color into the plurality of
2 . The method of claim 1 further comprising further cracks of the slab , so that the plurality of further
moving the slab over at least a portion of the first device cracks of the slab become veins having a color of a
before causing the first portion of the slab to move 30 sprayed material; and
vertically out of alignment. wherein the first device and the plurality of further
3 . The method of claim 1 further comprising devices are arranged in a matrix of a plurality of rows
causing a second portion of the slab to move vertically out and columns.
of alignment with an area of the slab surrounding the 11. A method comprising
second portion of the slab and thereby introducing a 35 causing a first portion of a slab to move vertically out of
second crack in the second portion of the slab by using alignment with an area of the slab surrounding the first
a second device located between the second portion and portion of the slab and thereby introducing a first crack
a ground surface to cause a force to be applied to the in the first portion of the slab by using a first device
second portion of the slab ; and located between the first portion and a ground surface
depositing a second material having a color into the 40 to cause a force to be applied to the first portion of the
second crack of the slab , so that the second crack with slab ; and
the deposited second material becomes a vein having depositing a first material having a color into the first
the color of the second material. crack of the slab , so that the first crack deposited with
4 . The method of claim 3 wherein the first material becomes a vein having the color of the
the first device is a first cylinder; and 45 firstmaterial;
the second device is a second cylinder. causing the first crack to close and the first portion of the
5 . The method of claim 1 further comprising slab to move vertically back into alignment with the
causing a plurality of further portions of the slab to move area of the slab surrounding the first portion by no
vertically out of alignment with corresponding areas of longer applying the force to the first portion of the slab
the slab surrounding the corresponding plurality of 50 after the first material is deposited into the first crack ;
further portions of the slab and thereby introducing a and
corresponding plurality of further cracks in the plurality wherein the slab is a damp particulate mixture .
of further portions of the slab by using a plurality of 12 . A method comprising
further devices each located between each of the cor causing a first portion of a slab to move vertically out of
responding portions and the ground surface ; 55 alignment with an area of the slab surrounding the first
depositing a material having a color into the plurality of portion of the slab and thereby introducing a first crack
further cracks of the slab , so that the plurality of further in the first portion of the slab by using a top surface of
cracks of the slab become veins having a color of a a first device located between the first portion and a
deposited material. ground surface to cause a force to be applied to the first
6 . The method of claim 5 wherein 60 portion of the slab ; and
each of the first device and the plurality of further devices depositing a first material having a color into the first
is a cylinder. crack of the slab , so that the first crack deposited with
7 . The method of claim 1 wherein the firstmaterialbecomes a vein having the color of the
the first device is a cylinder. firstmaterial;
8 . The method of claim 1 further comprising 65 further comprising causing a plurality of further portions
wherein a computer processor controls the steps of caus of the slab to move vertically out of alignment with
ing the first portion of a slab to move vertically out of corresponding areas of the slab surrounding the corre
US 10 ,376 , 912 B2
17
sponding plurality of further portions of the slab and
thereby introducing a corresponding plurality of further
cracks in the plurality of further portions of the slab by
using a plurality of top surfaces of a plurality of further
devices, respectively , each located between each of the 5
corresponding portions and the ground surface ; and
depositing a material having a color into the plurality of
further cracks of the slab , so that the plurality of further
cracks of the slab become veins having a color of a
deposited material; and 10
wherein the first device and the plurality of further
devices are arranged with respect to each other so that
none of the top surfaces of any of the first device and
the plurality of further devices , overlap any of the other
top surfaces of any of the first device and the plurality 15
of further devices ; and
wherein the slab is a damp particulate mixture .
* * *
EXHIBIT 3
Accused Accused
CAMBRIA '516 Patent '912 Patent
PRODUCT NAME Product Image Products Products
Abbey x
Annicca x x
Beckington x
Bentley x
Berkeley x
Berkshire Brass Sculpted x
Berkshire Brass Smooth x
Berkshire Satin Ridge x
Berkshire Steel Sculpted x
Blackbrook x
Bridport x
Brittanicca Gold Cool x x
Brittanicca Gold Warm x x
Brittanicca Warm x x
Brittaniccca x x
Carrick x
Cashel x
Charlestown x
Clare x
Clovelly x x
Colton x
Copeland x
Delamere x
Delgatie x x
Dovestone x
Page 1 of 3
Ella x x
Everleigh x x
Falconwood x
Gladstone x x
Hailey x x
Harlow x
Hawksmoore x
Haydon x
Hemsworth x
Inverness Bronze x
Inverness Cobalt x
Inverness Frost x
Inverness Gold x
Inverness Platinum x
Ironsbridge x x
Ivybridge x
Kendal x
Lakedale x
Mackworth x
Mammoth Cave x
Notting Hill x
Oakleigh x
Portrush x x
Ridgegate x
Ruxley x
Skara Brae x x
Southport x x
St Giles x
Page 2 of 3
Sutherland x
Travella x
Whitendale x
Windrush x
Woodcroft x
Page 3 of 3
EXHIBIT 4
EXHIBIT 5
Fish & Richardson P.C.

3200 RBC Plaza
60 South Sixth Street
Minneapolis, MN 55402
612 335 5070 main
612 288 9696 fax
March 21, 2018

John C. Adkisson
Principal
Via E-Mail adkisson@fr.com
612 337 2533 direct
Charles Quinn
Graham Curtin, P. A.
4 Headquarters Plaza
Morristown, NJ 07962-1991
Re: Notice of Intellectual Property Rights by Cambria Company LLC
Dear Mr. Quinn:
Thank you for your responsive letter.
Suffice it to say that Cambria continues to have the same concerns as expressed in my letter of
February 6. After being put on notice of Cambria’s intellectual property rights, your client continues
to flagrantly disregard those rights. All of the designs I specifically identified in my February 6
letter are still being offered for sale on the Spectrum Quartz website as of today.
With respect to Cambria’s ‘303 utility patent, we note that you have not argued that your client does
not infringe it. With respect to your invalidity assertions, we disagree that European Patent
Application 6 944 443 anticipates and/or renders obvious the claims of Cambria’s ‘303 patent.
Perhaps most fundamentally, the ‘443 publication is not prior art, as it first published on November
18, 2015, sixteen months after the August 2014 priority date of the Cambria ‘303 patent. We also
note that you have provided minimal analysis of the dependent claims of the ‘303 patent. In short,
your silence on the issue of infringement – combined with the deficiencies in your invalidity
presentation – provide us with no assurances that your client will respect Cambria’s IP rights in the
‘303 patent.
Your response regarding Cambria’s D’332 patent is even more troubling. Again, you have not
articulated any reason that Spectrum Quartz’s slabs do not infringe the D’332 patent. Your
arguments regarding Cambria’s products critically miss the point – the question for design patent
infringement is whether “in the eye of any ordinary observer, giving such attention as a purchaser
usually gives, two designs are substantially the same, if the resemblance is such as to deceive such
an observer, inducing him to purchase one supposing it to be the other.” Gorham v. White, 81 U.S.
511, 528 (1871). The issue is not whether Cambria’s slabs are reproducible – it is whether an
ordinary observer would believe that Spectrum’s designs are substantially the same as the designs
claimed in the D‘332 patent. Your letter is silent on that point, which we must take as an
acquiescence of our infringement position as articulated in my February 6 correspondence.
Charles Quinn
March 21, 2018
You have also failed to identify any specific design or product –quartzite or otherwise—that
Cambria’s D’332 patented Brittanicca design remotely resembles. Cambria’s Brittanicca design is
an innovative, patented design created as a result of extensive engineering, research and
development, and investment by Cambria. And your citation to a general statement from a
Consumer Reports website about the differences between quartz and quartzite does not constitute
prior art.
Finally, with respect to your reference to intellectual property owned by Hirsch Glass, please be
advised that Cambria does not see any value to those patents, nor do we think those patents merit
any further discussion amongst our clients.
I look forward to a prompt response that addresses the issues raised above.
Sincerely,
/s/ John C. Adkisson
John C. Adkisson
JCA/mla
61651158.docx
2
EXHIBIT 6
|ANA MARIATITAT DE LA MAISON MARTIN MAI US009993942B2
(12) United States Patent ( 10) Patent No.: US 9,993,942 B2

Grzeskowiak, II et al. (45) Date of Patent: Jun . 12, 2018
(54 ) PROCESSED SLABS , AND SYSTEMS AND B29C 67 /244 (2013 .01 ); B29D 99/ 001
METHODS RELATED THERETO ( 2013.01); B44F 9 / 04 ( 2013.01); C04B 35 /634
( 2013 .01 ); C04B 40 /0067 ( 2013 .01) ; C04B
@(71) Applicant: Cambria Company LLC , Eden Prairie , 40 /0259 ( 2013.01); B29D 99/0039 (2013 . 01 )
MN (US) (58 ) Field of Classification Search
@(72) Inventors : Jon Louis Grzeskowiak , II, Prior CPC ........... E04G 11/ 32 ; B28B 7 /08 ; B28B 7 /082 ;
B28B 1/ 005 ; B28B 1 /008 ; B28B 1 /04;
Lake, MN (US); Martin E . Davis, B28B 1 /08 ; B28B 1 /004 ; B28B 1 / 16 ;
Excelsior, MN (US ) B28B 13 /022 ; B28B 13/023 ; B28B
(73 ) Assignee : Cambria Company LLC , Eden Prairie ,
@
13 /0245 ; B28B 23 /0075 ; B28B 23 /0081
MN (US ) See application file for complete search history .
( * ) Notice : Subject to any disclaimer, the term of this (56 ) References Cited
patent is extended or adjusted under 35 U .S . PATENT DOCUMENTS
U .S . C . 154 (b ) by 376 days .
178 ,308 A 6 / 1876 Leathers et al.
(21) Appl.No.: 14/879,477 1 ,212 ,331 A 1/ 1917 Denivelle
(Continued )
(22) Filed : Oct. 9, 2015
FOREIGN PATENT DOCUMENTS
(65 ) Prior Publication Data ?? 2896383 7 /2017
US 2016/0052334 A1 Feb . 25, 2016 CN 1718403 1 / 2006
Related U .S. Application Data (Continued )

(60 ) Division of application No. 14 /878 ,393, filed on Oct . OTHER PUBLICATIONS
8 , 2015, now Pat . No. 9,718, 303 , which is a
(Continued ) International Search Report and Written Opinion for PCT/US2015 /
045693 , dated Jan . 4 , 2016 , 17 pages .
(51) Int. Ci. (Continued )
B28B 13 /02 ( 2006 .01)
B29C 31 / 10 ( 2006 .01 ) Primary Examiner — Timothy Kennedy
B44F 9 /04
B29D 99 / 00
( 2006 .01)
( 2010 .01)
(74) Attorney, Agent, or Firm — Fish & Richardson P.C .
B28B 1/00 ( 2006 . 01) (57) ABSTRACT
B29C 67/24 ( 2006 .01) This document describes systems and processes for forming
(Continued ) improved synthetic molded slabs suitable for use in living or
(52 ) U .S . CI. working spaces (e .g., along a countertop, table , floor, or the
CPC . . . ... . B28B 13 /022 (2013 .01 ); B28B 1 /005 like ).
(2013 .01); B28B 13 /023 ( 2013 .01); B28B
13/0245 ( 2013. 01) ; B29C 31 / 10 ( 2013.01) ; 35 Claims, 11 Drawing Sheets
Input From Mixer # 1
- Input From Mixer # 2
Input From Mixer # 3
**** Input From Mixer # 4
160
5100
-
192
192
50
L 170
SENARAI
ASU S 180
Top Mold Altachment
130 Vibro -compaction Press

5130
110
Molo Reiurn Line
1962 am on Curing Station
Mold Removal
1973
1982 Polisher
US 9,993 ,942 B2
Page 2
Related U . S . Application Data 8 , 398, 954

B2 3 /2013
8 , 436, 075
B2 . 5 /2013
Gordienko
Buskila et al.
continuation of application No. 14 /463 ,494 , filed on 8,636,941 B1 1/2014 Ciuperca
Aug. 19 , 2014 , now Pat. No . 9 , 186 ,819 . 8,702 , 886
B2 4 / 2014 Yaniv et al.
9 , 186, 819
B1 11/ 2015 Grzeskowiak , II et al.
9 ,289 ,923
B1 3 / 2016 Grzeskowiak , II et al.
(51) Int . Ci.
C04B 35 /634 ( 2006 .01 )
9 , 427 , 896
B1 8 / 2016 Xie
9 , 511 ,516
B2 12/2016 Xie
C04B 40 /00 ( 2006 .01 ) 9 ,671,274B16 /2017 Xie
C04B 40 /02 (2006 .01) 9 ,707 ,698
B1 7 / 2017 Xie
2002 /0081388 A1 6 / 2002 Batliner et al.
2004 /0032044 A1 2 / 2004 Toncelli
(56 ) References Cited 2004 /0175514 Al 9 /2004 Stiattesi
2005 /0013991 Al 1/2005 Yang
U .S . PATENT DOCUMENTS 2006 /0101752 A1 5 /2006 Sakai et al.
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U . S . Patent Jun. 12 , 2018 Sheet 11 of 11 US 9 , 993, 942 B2
7007
Position Slab Mold In 5710
Vertical Orientation
Dipsense
H OLDE
Dispense Multiple S (20
Different Particulate
Mixes
Adjust Mold to 5730

Horizontal Orientation
r740
Vibrate and Compact
Particulate Mixes
Cure Compacted 15750

Slab
Polish a Major Ls 760

Surface of Slab to
Display Veined
Appearance
FIG . 8
US 9, 993,942 B2
PROCESSED SLABS , AND SYSTEMS AND 2 feet wide by at least 6 feet long and extending perpen
METHODS RELATED THERETO dicularly to a slab thickness. The major surface may at least
a first pigmented vein extending generally lengthwise from
CROSS -REFERENCE TO RELATED edge - to -edge that separates at least two other veins extend
APPLICATION (S ) 5 ing generally lengthwise and positioned on opposing edges
of the first pigmented vein . The first pigmented vein option
This divisional of U . S . patent application Ser . No. 14 /878 , ally has a vein thickness equal to and parallel to the slab
393, filed on Oct. 8 , 2015 , which is a continuation of U .S . thickness.
patent application Ser. No . 14 /463 ,494 filed on Aug . 19 , Some embodiments described herein include a set of
2014 . the entire contents of which are incorporated herein by 10 separately molded synthetic slabs . Each respective slab of
reference . the set may include at least four different particulate mineral
mixes distributed in the series of successive layers according
TECHNICAL FIELD to the predefined pattern for all of the separately molded
synthetic slabs. The four different particulate mineral mixes
This document describes systems and processes for form - 15 may each optionally comprise a quartz material, one or more
ing synthetic mold slab products , for example , a synthetic pigments , and one or more resin binders . In one preferred
mold slab that is thermoformed or otherwise compacted to
a selected slab shape from a mixture including particulate
option , each respective slab may be rectangular and may
havemajor surface with a width or at least 2 feet and a length
mineral material, resin binder, and pigments so that the of at least 6 feet. At least one of the four different particulate
synthetic molded slab is suitable for use in living or working 20 mineral mixes may define substantially lengthwise veins
spaces (e .g., along a countertop , table , floor, or the like ). extending for a majority of the length of each respective slab
such that the major surface of each respective slab in the set
BACKGROUND has similarly positioned and colored substantially length
wise veins.
Quarried stone slabs are a commonly used building mate - 25 Other embodiments described herein include a process of
rial. Granite , marble , soapstone, and other quarried stones forming a synthetic molded slab from different particulate
are often selected for use as countertops due to their aes mineral mixes . The process may include positioning a slab
thetic properties . Despite the visual appeal of quarried stone, mold in a substantially vertical orientation . The process may
such quarried stone slabs can be quite expensive to obtain also include dispensing multiple different particulate min
and are generally limited to naturally occurring color 30 eral mixes into the substantially vertically oriented mold so
schemes . as to fill a mold space . Optionally, the mold space is at least
Engineered stone slabs may be formed from a man -made 6 feet long by at least 2 feet wide , and the multiple different
combination of materials that can provide improved stain particulate mineral mixes each comprise predominantly a
resistant or heat-resistant properties compared to quarried quartz material. The process may further include adjusting
stone slabs. Engineered stone is typically a combination of 35 the mold to a substantially horizontal orientation while the
particulate mineral material and a binder, such as a polymer different particulate mineral mixes are positioned in the
resin or cement . Some engineered stone slabs, especially mold . Also , the process may include contemporaneously
those of a larger slab size and having a granular formation vibrating and compacting the particulate mineral mixes
appearance , can fall noticeably short of the complicated look arranged in the mold while the mold is in the substantially
and texture of quarried stone slabs. 40 horizontal orientation .
Some embodiments of a process of forming a synthetic
SUMMARY molded slab include pouring multiple differently pigmented
particulate quartz mixes into a non -horizontally oriented
Some embodiments described herein include systems or mold according to a predetermined pattern . Optionally , the
processes for forming improved synthetic molded slabs 45 non -horizontally orientated mold may define an internal
suitable for use in living or working spaces (e . g ., along a space having a first edge thickness that is smaller than and
countertop , table, floor, or the like). In particular embodi- parallel to a second edge thickness proximate to an upwardly
ments , the synthetic molded slabs can be manufactured so as facing opening of the mold . The process may also include
to have a similar appearance to one another that, unlike compacting the multiple differently pigmented particulate
quarried stone slabs taken from a quarry , is generally repeat- 50 quartz mixes arranged in the mold while the mold is in the
able and predefined as part of the manufacturing process . In horizontal orientation .
those embodiments, however, the appearance of each syn - Additional embodiments described herein include a sys
thetic molded slab can provide complex striations or other tem forming a synthetic molded slab using a combination of
veining patterns that emulate a quarried stone slab . For different particulate mineralmixes. The system may include
example , each slab can be formed from a combination of 55 a mold adjustment apparatus configured to reposition a slab
differently pigmented particulate mineral mixes that are mold from a substantially vertical orientation to a substan
vertically dispensed according to predefined pattern into a tially horizontal orientation . Optionally, the slab mold may
vertically oriented mold (thereby facilitating the selected define a mold space that is at least 6 feet long by at least 2
striations or other veining patterns ), which is then shifted to feet wide . The system may also include one or more mineral
a horizontally oriented position for subsequent compression 60 aggregate distributors that are each configured to dispense a
molding and curing operations . As used herein , " differently corresponding particular mineral mix vertically into the slab
pigmented ” means having different pigment combinations mold retained by the mold adjustment apparatus.
or otherwise having a different visual appearance in color The systems and techniques described herein may provide
tone or visual texture . one ormore of the following advantages . First, a system can
Particular embodiments described herein include a syn - 65 be used to produce a plurality of synthetic molded slabs that
thetic molded slab comprising a quartz material. Optionally, each have similar vein patterns and that are suitable for use
the synthetic molded slab may have a major surface at least in living or working spaces (e.g., along a countertop , table ,
US 9 ,993,942 B2
floor, or the like ). Such slabs can be formed from a combi- other particulate mineral material that, when mixed with
nation of differently pigmented particulate mineral mixes pigments and a resin binder and subsequently compressed
that are vertically deposited according to predefined and and cured , provides a hardened slab product suitable for use
repeatable dispensation pattern into a vertically oriented in living or working spaces (e . g., along a countertop , table,
mold , which provides the selected veining patterns that 5 floor, or the like ). As shown in FIGS . 1A - B , each slab 50
emulate a quarried stone slab and that are generally repeat-
may optionally be formed from a combination of differently
able for each slab in the plurality of separately molded slabs.
pigmented particulate mineral mixes that are vertically
Second, each slab in the system can be formed from a poured according to predefined and repeatable dispensation
series operations including at least a compression molding pattern into a vertically oriented mold 130 (refer to FIG . 2 ),
operation in which the mold containing the particulate 10 which provides the selected striations or other veining
mineralmixes are positioned in a horizontal orientation after patterns that are generally repeatable for each separately
the mold is filled in the vertical orientations. For example , molded slab a slab mold is oriented vertically and filled from
the differently pigmented particulate mineral mixes are an open end. Successive layers of different particulate min
vertically poured into the vertically oriented mold , which is eral mixes (e . g ., different pigments, differentmineral com
then shifted to a horizontally oriented position for a subse - 15 positions, different additives, or the like ) are vertically
quent compression molding operation ( e . g ., vibro - compac - poured according to predefined and repeatable dispensation
tion molding , or the like) and ( in some embodiments ) a pattern into themold until filled . The open end is closed , and
curing operation . From there, some or all of the mold is the mold 130 is pivoted to a horizontal orientation (refer to
removed from the hardened slab so that at least a major the apparatus 150 in FIGS . 2 - 3 ) and then transported in the
surface of the slab is polished to provide an appearance of 20 horizontal orientation for compaction , curing, and other
the complex striations and veining patterns that emulate a operations . As shown in FIG . 1B , depending upon the
quarried stone slab . In some optional embodiments , the predefined dispensation pattern of the different particular
polished major surface of each of the synthetic molded slabs mixes, the vertical dispensation / layering process can pro
provides an outer appearance that is remarkably similar to vide a layering effect that emulates the veined appearance of
the other slabs in the set of separately molded slabs, unlike 25 quarried stone slabs such as granite or marble, including
quarried stone slabs taken from a quarry . Moreover, the some veins 51, 52 , 53, and 54 that extend fully across a
pigments and particulate mineral mixes can be selected to complete length L of the hardened slab 50 (e. g., at least 2
provide color combinations and visual effects that improved feet wide by at least 6 feet long, and between about 3 feet
upon and offer a variety of color combination options far and 5 feet wide and between about 6 feet and 14 feet long,
beyond what is available from quarried stone slabs taken 30 preferably about 4 .5 feet wide (more particularly, about 140
from a quarry . cm wide ) by about 10 feet long (more particularly , about,
The details of one or more implementations are set forth 310 cm long ) ). Other veins 55 may extend only partially
in the accompanying drawings and the description below . across the length L of the slab 50 . Not only can such
Other features and advantages will be apparent from the differently pigmented veins 51 , 52, 53 , and 54 extend across
description and drawings, and from the claims. 35 the full length of the slab product, but such veins 51, 52 , 53 ,
and 54 ( and also partial vein 55 ) can also extend through the
DESCRIPTION OF DRAWINGS thickness of the slab 50 (thereby providing a natural vein
appearance even when the slab is cut and edged to specific
FIGS. 1A and 1B are perspective views of a synthetic shapes in living orworking spaces (e .g., along a countertop ,
molded slab during and after formation, in accordance with 40 table, floor, or the like ). Because each slab 50 in the set of
some embodiments . separately molded slabs can include the layers of different
FIG . 2 is a diagram of an example system for forming a particulate mineralmixes dispensed vertically into the mold
synthetic molded slab product, in accordance with some 130 (refer to FIG . 2 ) according to the predefined and
embodiments. repeatable dispensation pattern , multiple slabs 50 in the set
FIG . 3 is a diagram of another example system for 45 of separately molded slabs can have substantially the same
forming a synthetic molded slab product, in accordance with appearance to one another.
other embodiments. Referring now to FIGS . 1A - B and 2 in more detail, the
FIGS . 4A and 4B are perspective and cross -sectional mold 130 can be vertically oriented during the dispensation
views of a slab mold adjustment apparatus of FIGS . 2 and of the different particulate mineral mixes into the mold 130 .
3 in a horizontal configuration . 50 For example , as described in more detail below , the mold
FIG . 5 is another cross -sectional view of the slab mold 130 can include a shell portion that at least partially defines
adjustment apparatus of FIGS. 4A and 4B . a space ( shown in dashed lines in FIG . 1A ) for receiving the
FIGS . 6A -6C are perspective and cross -sectional views of different particulate mineral mixes via an open upwardly
the slab mold adjustment apparatus of FIGS. 4A and 4B in facing opening 132 of the mold 130 . Optionally , each
a vertical configuration . 55 different particulate mineral mix is dispensed from a sepa
FIG . 7 is a perspective view of an example synthetic rate conveyor line ( refer to FIGS. 2 - 3 ) that transports the
molded slab product formed by either of the systems of respective mix to a region above the upwardly facing
FIGS. 2 and 3 . opening 132 so that the respective mix is then vertically
FIG . 8 is a flow diagram of an example process for poured into the mold 130. Each conveyor linemay transport
forming a synthetic molded slab product. 60 the respective mix according to a predefined pattern so that
the different particular mixes pour into the mold a predeter
DETAILED DESCRIPTION mined series of successive layers , some or all of which can
form the veins 51 , 52, 53, 54 , 55 of the slab 50 . Optionally ,
Referring to FIGS. 1A and 1B , a system can be used to each of the successive layer of the different particulate
produce one or more synthetic molded slabs 50 having a 65 mineral mixes can be dispensed in different amounts,
number of striations or veins according to a predefined thereby providing differently sized and positioned veins or
pattern . Each slab 50 can comprise a quartz material and/or striations. Furthermore, each individual layer may be dif
US 9,993 , 942 B2
ferently sized at one end of the mold 130 compared to the 10 feet. Thus, for example , the slab 50 may have a width W
other end of the mold 130 , thereby further enhancing the of 4 .5 feet and a length L of 10 . Alternatively , the slab 50
complex striations and veining patterns in the hardened slab may have a width W of 26 inches and a length L of 10 . Other
50 so as to increasingly emulate a quarried stone slab ( e. g., slab sizes described in the above -mentioned ranges are also
a traditional quarried granite slab or the like ). 5 contemplated herein . As such , even though each slab 50 can
In this embodiment, the slab 50 comprises four different be quite large in length L , some or all of the veins 51 , 52 ,53,
particulate mineral mixes that are separately conveyed and and 54 can nevertheless extend across the full length of the
dispensed into the upwardly facing opening 132 of the slab 50 . Additionally , some of the veins 51, 52, 53, and 54
vertically oriented mold 130 . The different mixes can be that do not extend across the full length of the slab 50 , at
compaction molded and cured in the mold (described in 10 least
more
m detail below ) so as to provide the hardened slab 50 acrosssome the
of those veins can optionally extend substantially
full length of the slab 50 so that a person viewing
(FIG . 1B ) of composite stone material. One or more of the the slab initially visualizes separated portions of the vein as
mixes that are used to form the composite stonematerial can being connected form a full-length vein during an initial
include organic polymer(s ) and inorganic (mineral) particu 15 view . Optionally , during the vertical dispensation of the
late component. The inorganic (mineral) particulate compo - 15
nent may include such components as silicon , basalt, glass , mineral particular mixes into the mold 130 , the mold 130
diamond, rocks , pebbles, shells, a variety of quartz contain may have a thickness T? at its lower edge that is different
ing materials, such as, for example , but not limited to : from the thickness T , at its upper opening 132 . For example,
crushed quartz , sand , quartz particles , and the like, or any the thickness T , may be about twice the thickness T . The
combination thereof. In this embodiment, all four different 20 different thicknesses T , and T , may be used to account for
particulate mineralmixes each comprise a quartz material as the additional compaction of the particulate mineral mixes
a predominant component, which may include sand of that occurs near the lower edge of the slab as additional
various particle sizes and of different combinations . In the layers of the particulate mineral mixes are deposited into the
hardened slab 50 ( FIG . 1B ), the organic and inorganic mold 130 . After the mold 130 is rotated to a horizontal
materials can be linked using a binder, which may include 25 orientation for subsequent compaction and curing of the slab
for example , mono - functional ormultifunctional silane mol- 50 , the mixture is more evenly compacted together and the
ecules , dendrimeric molecules, and the like, that may have mold 130 defines a generally continuous thickness T (FIG .
the ability to bind the organic and inorganic components of 1B ) of the slab 50 . In some embodiments, the thickness T of
the composite stone mix . The binders may further include a the slab 50 formed in the mold 130 is at least 0 . 2 cm ,
mixture of various components , such as initiators , hardeners , 30 between about 0 . 2 cm and 5 cm , and preferably about 3 cm .
catalysators , binding molecules and bridges, or any combi- Each mold 130 may be formed of structure that comprises a
nation thereof. Some or all of the mixes dispensed in the flexible polymer ( including an elastomeric material), paper,
mold 130 (FIG . 1A ) may include components that are wood , metal or a combination thereof.
combined in a mixing apparatus (not shown in FIG . 1A ) Referring now to FIG . 2 , in some embodiments , a system
prior to being conveyed to the mold 130 . The mixing 35 100 for forming a set of synthetic molded slab products ( e . g .,
apparatus can be used to blend raw material (such as the the slab 50 in FIG . 1B , the slab 600 in FIG . 7 , or the like )
quartz material, organic polymers, unsaturated polymers, is configured to vertically pour differently pigmented par
and the like ) at various ratios . For example , some or all of ticulate mineralmixes into a vertically oriented mold , which
the mixes dispensed in the mold 130 may include about is then shifted to a horizontally oriented position for a
8 - 95 % quartz aggregates to about 5 - 15 % polymer resins . In 40 subsequent compression molding operation ( e . g ., vibro
addition , various additives may be added to the raw mate compaction molding, curing, etc .). The system 100 in the
rials in the mixing apparatus, such additives may include depicted embodiment includes an input conveyor 110 and an
metallic pieces (e . g ., copper flecks or the like ), colorants, output conveyor 120 . A collection of slab molds 130 are
dyes, pigments, chemical reagents, antimicrobial sub - transported on the input conveyor 110. The slab molds 130
stances, fungicidal agents, and the like, or any combination 45 provide a form for synthetic molded slab products that are at
thereof. In alternative embodiments , some or all of the least three feet wide and at least six feet long, and about 4 .5
quantity of quartz aggregates (mentioned above ) can be feet wide by about 10 feet long in some embodiments
replaced with or include porcelain and /or ceramic aggregate depicted herein . The input conveyor 110 transports the slab
material. molds 130 to a mold positioning table 140 , which is con
Still referring to FIGS. 1A - B and 2 , the mold 130 can be 50 figured to help operators move and /or orient the slab molds
vertically oriented during dispensation of the mineral par 130 .
ticular mixes in that a major surface of the mold is posi In this embodiment, the slab molds 130 are moved
tioned in a vertical position or a generally vertical position horizontally ( e . g ., relative to gravity ) onto an apparatus 150
( e. g ., 90 degrees from the horizontal + / - 10 degrees ). In such for pivoting each mold 130 between a vertical orientation
circumstances, each mineral particulate mix is vertically 55 and a horizontal orientation . The apparatus 150 in this
poured into the mold and rests on a previously deposited embodiment serves as a tip table 150 , which is configured to
layer of a mineral particular mix (with the first layer being accept one or more of the slab molds 130 , secure it, and pivot
deposited instead on a closed bottom edge of the vertically the slab mold 130 from the horizontal orientation to the
oriented mold 130 ) . Preferably, the mold 130 at least par - vertical orientation (described above ) with an open edge
tially defines a length L and a width W of the hardened slab 60 (numeral 132 in FIG . 1A ) positioned at the top of the slab
50 (because the mold 130 retains the particulate mineral mold 130 when in the vertical orientation . For example , in
mixes therein throughout the subsequent compaction and this embodiment, the tip table 150 is configured to receive
curing processes ). In some embodiments , the width W of the and releasably retain one mold 130 at a time. Additional
slab 50 formed in the mold 130 is at least 2 feet, between details of this particular embodiment of the tip table 150 are
about 3 feet and 5 feet, and preferably about 4 . 5 feet, and the 65 described further in connection with FIGS. 4A -6C . In alter
length L of the slab 50 formed in the mold 130 is at least 6 native embodiments , the tip table 150 can be configured to
feet, and between about 6 feet and 15 feet, preferably about receive and releasably retain multiple molds 130 at a time.
US 9,993 , 942 B2
Still referring to FIG . 2, in this embodiment, themold 130 Optionally, the system 100 may be configured to provide
vertically oriented in the apparatus 150 is configured to one more generally " widthwise ” or transverse veins 192 (as
receive four differently pigmented mineral mixes (compris compared to the generally " lengthwise” veins51, 52 , 53, and
ing mostly a quartz material as described above),which can 54 (FIG . 1B ) defined by the successive layers of different
be conveyed from four corresponding mixers and directed to 5 particulate mineral mixes previously poured into the mold
inputs 160 such as dispenser heads or other material trans 130 while at the tip table 150). Optionally, these widthwise
port structures . In this embodiment, each dispenser head 160 veins 192 may be thinner and spread further apart than the
generally “ lengthwise ” veins defined by the successive
is configured to release a different particulate mineral mix layers of different particulate mineral mixes. Also , these
( e.g ., different pigments , different mineral compositions, 10 widthwise
different additives, or a combination thereof) compared to a different veins 192 may be formed from a material having
the other dispenser heads 160 . Each dispenser head 160 is dispensed from the inputsthan
pigmentation
160
the particulate mineral mixes
. For example , the system can
configured to controllably dispense its supply of correspond be configured to controllably dispense the particulate min
ing particulate mineral mix for input into the vertically eral mix for the widthwise veins 192 in a selected location
oriented mold 130 retained by the tip table 150 . For
example, the dispensing heads 160 are each configured with mold attachment operation 194 or a vibro - compaction press
a shutter or valve apparatus (not shown ) that is controllable 195 ( FIG . 2 ), thereby providing a predetermined pattern of
to regulate the flow of particulate mineral mix from the the widthwise veins 192 that is repeatable for each of the
dispensing head 160 for input to the mold 130 . In such filled molds. In some optional circumstances , the widthwise
embodiments , the dispensing heads (or other inputs for 20 veins 192 may not extend through the full thickness of the
distributing the particulate mineral mixes to the mold 130 ) hardened slab (which can be different from someor all of the
can be controlled according to a predetermined control generally lengthwise veins 51 , 52, 53 , and 54 (FIG . 1B )) .
algorithm so as to define successive layers of the differently Still referring to FIG . 2 , the output conveyor 120 can be
pigmented particulate mineral mixes for vertical dispensa configured to transport each of the filled molds 180 to one
tion into the slab mold 130 retained by the tip table 150 . 25 or more sequent stations in the system 100 for forming the
When the tipping table 150 retains a mold 130 in the hardened slab . For example , each of the filled molds 180 can
vertical orientation , the upwardly facing opening 132 ( FIG . continue to a subsequent station in which a top mold
1A ) of the mold 130 is positioned below ( e .g ., relative to attachment 194 is positioned over the filled mold 180 so as
gravity ) the outputs of the mineral aggregate distributors to encase the layers of particular mineralmixes between the
160 . As such , the particulate mineral mixes that are dis - 30 mold 130 and a top cover mold piece ( not shown in FIG . 2 ) .
pensed from the outputs of the distributors 160 and then From there , the filled mold 180 (now including the top cover
through the upwardly facing opening 132 (FIG . 1A ) of the mold piece continues to a subsequent station in which a
mold 130 . As such , the distributors 160 ( each carrying a vibro - compaction press 195 applies compaction pressure ,
different particulate mineral mix according to a pattern vibration , and vacuum to the contents inside the filled mold
dispensed by its corresponding dispensing head ) can be used 35 180 , thereby converting the particulate mixes into a rigid
to pour the respective mix into the vertically oriented mold slab . After the vibro - compaction operation , the filled mold
130 to provide a predetermined series of successive layers 180 (with the compacted and hardened slab therein ) pro
(which are repeatable for each mold 130 in the line ). As ceeds to a curing station 196 in which the material used to
previously described , some or all of these successive layers form the slab ( including any resin binder material) are cured
of different particulate mineral mixes can form the length - 40 via a heating process or other curing process , thereby further
wise veins of the hardened slab ( e.g ., the slab 50 in FIG . 1B , strengthening the slab inside the filled mold 180 . After the
the slab 600 in FIG . 7 , or the like). slab is fully cured (and , optionally , after the slab is cooled ),
In the illustrated example , four mineral aggregate inputs the primary mold 130 and the top mold cover piece are
160 are used , although in other examples, the slab may be removed from the hardened and cured slab at a mold
formed from between 1 and 20 different particulate mineral 45 removal station 197 . The primary mold 130 is then returned
mixes, and more preferably between 3 and 8 different to the input conveyor 110 (FIG . 2 ). Then , in some embodi
particulate mineral mixes (which , in some embodiments, ments , the hardened and cured slab is moved to a polisher
would provide a system that would include a corresponding station 198 , in which a major surface of the slab is polished
number of inputs 160 ). In some examples , the number of to a smooth finish , thereby an appearance of the complex
mineral aggregate distributors 160 can correspond equally to 50 striations and veining patterns that emulate a quarried stone
the number of differently pigmented particulate mineral slab . Alternatively, the polisher station 198 is not imple
mixes used to create the hardened slab product. mented so that the resulting slab has a more textured major
After the slab mold 130 retained by the tipping table 150 surface rather than a smooth , polished surface . In some
has been sufficiently filled (while in the vertically oriented embodiments of the system 100 , the polished or otherwise
orientation ), the tip table 150 pivots or otherwise adjusts the 55 exposed major surface of each of the synthetic molded slabs
slab mold 130 to a horizontal orientation . The slab mold 130 can provide an outer appearance that is substantially repeat
(now a filled mold 180 ) is moved out of the tip table 150 , on able for the other slabs (from the other filled molds 180 in
a cushion of air provided by another mold positioning table FIG . 2 ).
170 , to an output conveyor 120 . As shown in FIG . 2 , the Referring now to FIG . 3 , another example system 200 for
successive layers of different particulate mineral mixes that 60 forming a synthetic molded slab product can be configured
were vertically dispensed into the mold 130 are generally to contemporaneously fill multiple vertically oriented molds
noticeable in the filled molds 180 are arranged in the 130 , thereby increasing the production rate in some circum
horizontal orientation on the output conveyer 120. Someor stances . The system 200 is substantially similar in layout and
all of these successive layers of different particulate mineral operation to the system 100 (FIG . 2 ), having the input
mixes can form the lengthwise veins of the hardened slab 65 conveyor 110 , the output conveyor 120 , the mold position
( e.g ., the slab 50 in FIG . 1B , the slab 600 in FIG . 7 , or the ing tables 140 and 170 , the slab molds 130 , and the filled
like ). molds 180. The system 200, however, includes eight of the
US 9,993 , 942 B2
10
mineral aggregate inputs 160 , with four inputs 160 arranged sixth side (e. g ., the fourth edge ) of the trapezoidal cuboid
to feed four different particulate mineralmixes into a first form . In this embodiment, the major faces are oriented at a
vertically oriented mold 130 secured to the tip table 150 , and slight angle so as to be non - coplanar, with the cuboid having
another set of four inputs 160 arranged to feed the four a relatively greater thickness ( T , from FIG . 1A ) along the
different particulate mineral mixes into a second vertically 5 openable end 410 and a thickness ( T , from FIG . 1A ) along
oriented mold 130 secured to a second tip table 150 (not the opposing edge that is less than the thickness along the
visible in FIG . 3 ). openable end 410 . With the tip table 150 in the configuration
Accordingly , the operation of the system 200 is substan shown in FIG . 5, the slab mold 130 is ready to be reposi
tially similar to that of the system 100 ( FIG . 2 ), except that
multiple molds 130 are substantially vertically oriented and 10 tioned to a vertical orientation for filling .
Referring now to FIGS.6A -6C , the tip table 150 of FIGS .
contemporaneously filled before being adjusted to horizon 1 -5 can adjust the slab mold 130 to the vertical orientation
tal orientations and moved to the output conveyor 120 as by pivoting about pivot points 306a -b . In particular, the slab
filled molds 180 . As shown in FIG . 3 , the filled molds 180 mold 130 is oriented to the vertical position by pivoting the
that were simultaneously filled in this embodiment, using
the two adjacent tip tables 150 ) can have substantially the 1515 table
tab base 304, the mold positioning table 308 , the top plate
same appearance of veins defined by the successive layers of 310 , the mold gasket 402, and the film 320 , on the pivot
different particulate mineral mixes poured into each of the points 306a - 306b relative to the supports 302 . As shown in
molds according to a predetermined pattern . FIG . 6B , in the illustrated example, the slab mold 130 is
Referring now to FIGS. 4A and 4B , each tip table 150 in partly filled with successive layers of different particulate
the system 100 or 200 can be configured to receive the mold 20 mineral mixes 502 (e .g., partially through the mold filling
130 in a horizontal orientation . The tip table 150 is located process ; refer also to FIG . 1A for another example ). As
vertically below a fill chute 301, with respect to gravity . In discussed in the descriptions of FIGS. 2 and 3 , the different
the systems 100 and 200 (FIGS . 2 and 3 , respectively ) , the particulate mineral mixes are controllably released via the
chute 301 is positioned vertically below the gap (s ) 166 at the inputs 160s and poured (under the force of gravity in this
end of the belts 164 , e . g., to direct fill from the mineral 25 embodiment) into the chute 301, through the open end 410 ,
aggregate distributor 160 into the slab mold 130 . The tip and into the slab mold 130. The different particulate mineral
table 150 includes a collection of supports 302 and a table mixes 502 includes multiple , variously designed and
base 304 connected by a pivot point 306a and a pivot point selected mixes ( including predominantly a quartz material in
306b (not visible ). The supports 302 provide support to this embodiment ) vertically poured into the mold 130 in
elevate the table base 302 above a floor, and the pivot points 30 successive layers , which can create different vein layers
306a -306b provide a bearing upon which the table base 302 506a- 506b . As previously described in connection with
can tilt relative to the supports 302 . FIGS. 1A and 1B , some or all of the vein layers 506a - 506b
As previously described , the mold positioning table 308 can extend substantially from edge to edge and across the
provides a mechanism (e. g ., rollers, conveyors , actuator length L of the slab mold 130 .
arms, etc .) to move the slab mold into the tip table 150 35 As discussed previously , the slab mold 130 in this
between the table base 302 and a top plate 310 ( e .g ., while embodiment provides a trapezoidal cuboid form . In the
the tip table is in a horizontal configuration ). Optionally , a illustrated vertical orientation , the asymmetry of the slab
film 320 extends across the surface of the top plate 310 , mold 130 occurs from top to bottom , forming a very slight
between the top plate 310 and the slab mold 130 . The film “ V ” shape (e .g ., refer also to the description of T , and T2
320 is fed from a feeder roll 322 and is collected by a takeup 40 described in connection with FIG . 1A ). In some embodi
roll 324 . In use , the optional film provides a protective ments , the asymmetry can be selected to at least partly offset
barrier between the top plate 310 and filler material depos - the effects of gravity on the slight compaction of the
ited into the mold (e .g., to maintain the cleanliness of the top different particulate mineralmixes 502 at the lower edge of
plate 310 during repeated use with a series of molds 130 ). the mold 130 as the mixes fill the slab mold 130 . Optionally ,
Predetermined lengths of the film 320 can be used once per 45 a vibrator 530 vibrates and/ or shakes the slab mold 130 and
mold filling operation , or for multiple mold filling opera - the particulate mineral mixes 502 to promote a complete
tions before being advanced to the takeup roll 324 and a filling of the mold 130 . Once the slab mold 130 is suffi
fresh length of the film 320 is provided from the feeder roll ciently filled with the particulate mineralmixes 502 accord
322. A collection of actuators 350 controllably position the ing to the predefined pattern from the distributors 160
top plate 310 apart from the table base 302 and the slab mold 50 (FIGS. 2 and 3 ), the slab mold 130 becomes the filled mold
130 . 180 ( refer to FIGS . 2 and 3 ) .
FIG . 5 is another cross- sectional view of the tip table 150 Referring now to FIG . 6C , an enlarged view of the chute
of FIGS. 1- 3B . In the illustrated view , the slab mold 130 is 301 and the open end 410 ( refer also to the upwardly facing
positioned in a horizontal orientation within the tip table opening 132 in FIG . 1A ) of the slab mold 130 . In this
150. The collection of actuators 350 are actuated to bring a 55 embodiment, the open end 410 includes a mold end cap 520 ,
mold gasket 402 into contact with the outer periphery of the and the mold end cap 520 is movable about a pivot point 522
slab mold 130 . The collection of actuators 350 are actuated to selectably open and close the openable end 410 . When the
to move the top plate 310 toward the slab mold 130 , slab mold 130 is sufficiently filled with the filler 502, the
compressing the mold gasket 402 between the slab mold 130 mold end cap 520 is pivoted to the closed position to provide
and the top plate 310 . Optionally , the combination of the 60 the sixth side of the cuboid form ( e . g ., to close the open edge
mold gasket 402 and the slab mold 130 includes a slight of the filled mold . The tip table 150 then adjusts the filled
asymmetry in the form of a trapezoidal cuboid (e . g ., refer to mold from the vertical orientation (FIGS. 6A -6C ) to the
T , and T , described in connection with FIG . 1A ). In the horizontal orientation ( refer to FIGS. 4A -5 ). The actuators
configuration shown in FIG . 4 , the slab mold provides three 350 can be activated to release the filled mold 180 from the
edges and a onemajor face of a six -sided trapezoidal cuboid 65 tip table 150 , and the filled mold 180 can be moved out of
form , and the film 320 and the top plate 310 form another the tip table 150 and onto the output conveyor 120 (FIGS.
major face . An open end 410 of the slab mold 130 forms the 2 and 3 ).
US 9,993 , 942 B2
11
Referring now to FIG . 7 , an example synthetic molded (about 90 degrees from the horizontal + / – 10 degrees ) by the
slab product 600 can be formed by either of the systems of tip table 150 (FIGS. 2 and 3 ). The process 700 may also
FIGS. 2 and 3 using a combination of differently pigmented include the operation 720 of dispensing multiple different
particulate mineralmixes that are vertically poured accord particulate mineral mixes into the vertically oriented mold .
ing to predefined pattern into the mold 130 . In some embodi- 5 For example , as previously described , differently pigmented
ments, the synthetic molded slab product 600 can provide a mixes comprising predominantly a quartz material (e . g ., a
veined appearance that emulates quarried stone slabs such as mix including the particulate quartz material, one or more
granite or marble , depending upon the predefined dispensa - pigments, and one or more resin bonders ) can be fed into a
tion pattern of the different particular mixes. For example , vertical pour operation using one of the distributors 160
the major surface 612 of the slab 600 can be polished and 10 (FIGS. 2 and 3 ). Next, the process 700 may include the
provide at least some veins 602 , 606 , and 608 that extend operation 730 of adjusting the mold to a horizontal orien
fully across a complete length of the hardened slab 600 tation while the different particulate mineral mixes are
(which may be about 6 feet to about 14 feet long, and positioned in the mold . Again , such an operation can be
preferably about 10 feet long in this embodiment). Other performed , for example ,by the tip table 150 (FIGS. 2 and 3 )
veins 605 and 609 may extend only partially across the 15 or another mold adjustment apparatus. The process 700 may
length of the slab 50 , and some veins 605 have much smaller further include the operation 740 of contemporaneously
size ( although perhaps a much darker hue ). Not only can vibrating and compacting the particulate mineral mixes
such differently pigmented veins (602, 605 , and 605 , for arranged in the mold while the mold is in the horizontal
example ) extend across the full length of the slab product, orientation . In such circumstances , the operation 740 may
but such veins can also extend through the thickness 610 of 20 provide a compacted slab of composite stone material. Also ,
the slab 600 from the first major face 612 to the opposing in some embodiments , the process 700 may further include
major face 614 (thereby providing a natural vein appearance the operation 750 of curing the compacted slab . The process
even when the slab is cut and edged to specific shapes in 700 may also include the operation 760 of polishing a major
living or working spaces ( e.g ., along a countertop, table, surface of the slab to provide a veined appearance on the
floor , or the like ) . Additionally , at least themajor surface 612 25 polished surface of the slab , including but not limited to the
of the slab 600 may include a plurality of veins 607 that are examples described above .
oriented in a transverse direction relative to the veins 602 , Although a number of implementations have been
605 , 606 , 608 and 609 . Such veins may be defined , for described in detail above , other modifications are possible .
example , by the secondary dispenser 190 ( refer to FIGS . 2 For example , the logic flows depicted in the figures do not
and 3 ). Some of these “ widthwise ” veins 607 can extend 30 require the particular order shown , or sequential order, to
fully across a complete width of the hardened slab 600 achieve desirable results . In addition , other steps may be
(which may be about 2 feet and about 6 feet wide, and provided , or steps may be eliminated , from the described
preferably about 4 .5 feet wide in this embodiment). Because flows, and other components may be added to , or removed
each slab 600 in the set of separately molded slabs ( refer, for from , the described systems. Accordingly , other implemen
example , to the system in FIGS . 2 and 3 ) can include the 35 tations are within the scope of the following claims.
layers of different particulate mineral mixes dispensed ver
tically into the mold 130 according to the predefined and what is claimed is :
repeatable dispensation pattern ,multiple slabs 600 in the set 1. A process of forming a processed slab from different
can have similarly positioned veins in themajor surface and particulate mineral mixes , comprising :
can provide substantially the same appearance to one 40 positioning a slab mold in a substantially non -horizontal
another. orientation ;
The synthetic molded slab 600 can be cut, milled , dispensing multiple different particulate mineral mixes
machined , or otherwise processed to various shapes and into the substantially non -horizontally oriented mold so
sized (e .g ., to provide custom -fit countertop surfaces with as to fill a mold space that is at least 6 feet long by at
optional holes for sinks, faucets , or other amenities ) . For 45 least 2 feet wide , the multiple different particulate
example , a section 630 is cut away from the synthetic mineral mixes being differently pigmented ;
molded slab product 600 . With the veins 602 and 605 adjusting the mold to a substantially horizontal orienta
extending into the interior 606 and /or across the thickness tion while the multiple different particulate mineral
610, cutting and /or processing of the synthetic molded slab mixes are in the mold ; and
product 600 shows the veins 602, 605 , 606 , 608 and 609 in 50 vibrating and compacting the multiple different particu
a manner that emulates the aesthetics of quarried stone slabs . late mineralmixes arranged in the mold while the mold
FIG . 8 is a flow diagram of an example process 700 for is in the substantially horizontal orientation .
forming a synthetic molded slab product ( such as slab 50 or 2 . The process of claim 1 , wherein the dispensing com
600 described above). In some implementations, the systems prises depositing the multiple different particulate mineral
100 or 200 of FIGS. 2 and 3 can be used to perform the 55 mixes into themold according to a predefined and repeatable
process 700 . The process 700 may include the operation 710 pattern so as to define successive layers of multiple different
of positioning a slab mold in a non -horizontal orientation , particulate mineral mixes .
such as a substantially vertical orientation or another orien - 3 . The process of claim 2 , wherein at least some of the
tation that extends transverse to the horizontal. In such an successive layers of multiple different particulate mineral
operation , a major face of the mold (which will define a 60 mixes provide lengthwise veins of the processed slab .
major face of the slab product ) can be positioned in a 4 . The process of claim 1 , wherein the dispensing multiple
substantially vertical position (about 90 degrees from the different particulate mineral mixes comprises pouring mul
horizontal + / - 30 degrees (preferably + /– 10 degrees)), for tiple differently pigmented particulate quartz mixes into the
example , by a tip table or another mold adjustment appara - substantially non - horizontally oriented mold according to a
tus . In some embodiments depicted above herein , the major 65 predetermined pattern .
face of themold (which will define a major face of the slab 5 . The process of claim 4 , wherein the substantially
product) can be positioned in a vertically oriented position non -horizontally oriented mold defines a mold space having
US 9,993 , 942 B2
14
a first edge thickness that is smaller than and parallel to a wherein the first and second particulate mineral mixes are
second edge thickness proximate to an upwardly facing dispensed according to a predefined pattern to provide
opening of the mold . at least a first vein extending generally lengthwise from
6 . The process of claim 5 , wherein the vibrating and edge- to - edge defined by the first particulate mineral
compacting is contemporaneous and provides a rectangular 5 mix .
processed slab having a thickness that is generally constant 21 . The process of claim 20 , comprising dispensing a third
at its four edges . particulate mineral mix into the substantially vertically
7 . The process of claim 4 , wherein the pouring according oriented mold , wherein the third particulate mineral mix is
to the predetermined pattern provides successive layers of
differently pigmented particulate quartz mixes, wherein at 10 least the firstaccording
dispensed
vein is
to the predefined pattern such that at
separate and substantially unmixed with
least some of the successive layers of differently pigmented respect to a third vein defined by the third particulate mineral
particulate quartz mixes provide lengthwise veins of the mix .
processed slab . 22. The process of claim 20 , comprising vibrating the
8 . The process of claim 7 , wherein the successive layers
of differently pigmented particulate quartz mixes provide at 15 particulate mineral mixes arranged in the mold while the
least a first vein extending generally lengthwise from edge - mold is in the substantially horizontal orientation .
to - edge . 23 . The process of claim 20 , wherein the first and second
9 . The process of claim 8 , wherein the first vein is defined particulate mineral mixes are dispensed according to a
by a first particulate quartz mix , a second vein is defined by predefined pattern to provide the first vein and a second vein ,
a second particulate quartz mix , and a third vein is defined 20 and wherein each of the first and second veins has a vein
by a third particulate quartz mix . thickness equal to and parallel to the slab thickness .
10 . The process of claim 9 , wherein the first vein is 24 . The process of claim 20 , wherein the first and second
substantially unmixed with respect to at least second and particulate mineral mixes each comprise between 8 % and
third veins extending generally lengthwise and positioned on 95 % quartz material .
opposing sides of the first vein . 25 25 . The process of claim 23 , wherein at least one of the
11 . The process of claim 8 , wherein the first vein is lengthwise veins has a vein width on a front major face of
defined by a first particulate quartz mix , and the second and the processed slab that is greater than the slab thickness .
third veins are defined by a second particulate quartz mix . 26 . The process of claim 23 , wherein at least one of the
12 . The process of claim 8 , comprising dispensing a lengthwise veins has a vein width on a front major face of
particulate mineral mix to provide a transverse vein . 30 the processed slab that is less than the slab thickness .
13 . The process of claim 12 , wherein dispensing the 27 . A process of forming a processed slab , comprising :
particulate mineralmix to provide the transverse vein occurs positioning a slab mold in a substantially non -horizontal
after adjusting the mold to a substantially horizontal posi orientation;
tion . dispensing more than one particulate mineral mixes into
14 . The process of claim 3 , wherein at least two of the 35 the slab mold while the slab mold is retained in the
lengthwise veins each have a vein thickness equal to and substantially non -horizontal orientation , and
parallel to the slab thickness. vibrating and compacting the more than one particulate
15 . The process of claim 14 , wherein at least one of the mineral mixes after adjusting the mold to a substan
lengthwise veins has a vein width on a front major face of tially horizontal orientation .
the processed slab that is greater than the slab thickness. 40 28 . The process of claim 27 , wherein the substantially
16 . The process of claim 14 , wherein at least one of the non -horizontal orientation is a substantially vertical orien
lengthwise veins has a vein width on a front major face of tation .
the processed slab that is less than the slab thickness . 29 . The process of claim 28 , wherein the step of dispens
17 . The process of claim 3 , wherein at least one of the ing comprises depositing the more than one particulate
veins is visible on both a front major surface and a rear major 45 mineral mixes into the mold according to a predefined and
surface of the processed slab . repeatable pattern so as to define successive layers of the
18 . The process of claim 8 , wherein the dispensing more than one particulate mineral mixes .
comprises depositing the multiple different particulate min 30 . A processed slab formed according to the process of
eral mixes into an open end of the mold . claim 1 , wherein the processed slab has a length of at least
19 . The process of claim 8 , comprising adjusting a mold 50 6 feet, a width of at least 2 feet and a slab thickness between
end cap from an open position to a closed position before about 0 .2 cm and 5 cm .
adjusting the mold to the substantially horizontal orienta - 31. The processed slab of claim 30 , wherein at least one
tion . of the multiple different particulate mineral mixes is dis
20 . A process of forming a processed slab from particulate pensed to provide at least one lengthwise vein of the
mineral mixes, comprising: 55 processed slab extending from edge - to - edge of the pro
positioning a slab mold in a substantially vertical orien - cessed slab and having vein thickness equal to and parallel
tation ; to the slab thickness .
dispensing at least first and second particulate mineral 32 . The processed slab of claim 30 , wherein the multiple
mixes into the substantially vertically oriented mold so different particulate mineral mixes are dispensed to provide
as to fill a mold space that is at least 6 feet long by at 60 a first vein of the processed slab defined by a first particulate
least 2 feet wide ; quartz mix , and a second vein of the processed slab defined
adjusting the mold to a substantially horizontal orienta - by a second particulate quartz mix , the first and second veins
tion while the first and second particulate mineral being differently pigmented .
mixes are positioned in the mold ; and 33 . The processed slab of claim 32 , wherein the multiple
compacting the particulate mineralmixes arranged in the 65 different particulate mineral mixes are dispensed to provide
mold while the mold is in the substantially horizontal the first vein , the second vein , and a third vein of the
orientation ; processed slab , wherein the first vein is defined by the first
US 9 ,993,942 B2
15
particulate quartz mix , and the second and third veins are
16
defined by the second particulate quartz mix .
34 . The processed slab of claim 32 , wherein the first and
second veins of the processed slab each have a vein thick
ness equal to and parallel to the slab thickness.
35 . The processed slab of claim 30 , wherein the slab
thickness of the processed slab is the same at its four edges.
* * * * *

SQIP v. Cambria - Complaint

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Case 4:23-cv-00202-SDJ Document 7 Filed 04/25/23 Page 1 of 18 PageID #: 179

IN THE UNITED STATES DISTRICT COURT

Cambria Company, LLC

FIRST AMENDED COMPLAINT FOR PATENT INFRINGEMENT

9,511,516 and 10,376,912 (collectively, the “Patents-in-Suit”), based upon Defendant’s

products accused herein.

1. Plaintiff SQIP, LLC (“SQIP” or “Plaintiff”) is a Florida limited liability company

having an address at 4121 Seaboard Road, Orlando, Florida 32808.

2. Defendant Cambria Company, LLC (“Cambria” or “Defendant”) is a Minnesota

Bryan St., Suite 900, Dallas, Texas 75201.

JURISDICTION AND VENUE

jurisdiction) and 28 U.S.C. § 1338 (jurisdiction over patent actions).

facilities in Colony, Texas and Dallas, Texas.

showrooms in The Colony and Lewisville.

6. Cambria has committed and continues to commit acts in violation of 35 U.S.C.

the State of Texas.

methods for making such products.

9. The Patents-in-Suit are a portion of SQIP’s patent portfolio.

10. Alex Xie is a member of SQIP.

manufacturing natural quartz surface products in industry.

products pursuant to at least some of SQIP’s patent portfolio.

described in the Patents-in-Suit.

Sterling AP (Hirsch), and (viii) Impeccable AP (Hirsch).

16. Alex Xie is a shareholder in Hirsch Glass.

true and correct copy of the ‘516 Patent is attached as Exhibit 1.

the ‘912 Patent is attached as Exhibit 2.

identified in Exhibit 3 (collectively, the “Accused Products”).

in the ‘516 patent.

in the ‘912 patent.

Patents-in-Suit, as part of a settlement offer to resolve Cambria’s ongoing litigation against

28. In response to Cambria’s request to license SQIP’s portfolio of patents, Hirsch

the products for which Cambria sought a license.

Cambria’s manufacturing processes.

SQIP’s patent portfolio, including the Patents-in-Suit, as a component to a settlement offer to

resolve the ongoing litigation between Cambria and Hirsch Glass.

Cambria’s manufacturing processes.

of its products infringe such patents.

35. As described below, in violation of at least 35 U.S.C. § 271(a), Cambria infringes

36. Further, in violation of at least 35 U.S.C. § 271(g), Cambria imports, offers to

37. Claim 14 of the ‘516 Patent recites as follows:

14. A method comprising:

using a computer processor to controllably supply the first

using the computer processor to controllably supply the first

available on Cambria’s website at www.cambriausa.com.

product…”. Exhibit 6, at 3:67-4:3.

40. On information and belief, the Accused

‘516 Patent Products are made with a mold that has a

top opening which leads to the inner chamber, and the

mold includes a first wall, a second wall, a third wall,

and a fourth wall, and a bottom which enclose the

inner chamber. Cambria’s ‘942 Patent, with reference

to Figure 1A (reproduced adjacent this paragraph)

describes that the mold used in the process “can

the mold 130.” Exhibit 6, at 4:50-54.

portion, of the length of the slab.

the first portion, of the length of the slab.

process to Hirsch Glass’ counsel.

costs as fixed by this Court under 35 U.S.C. § 284.