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    Araştırma belgesi

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    11 views26 pages

    US2022363600A1 Original Document 20230309143357

    Uploaded by

    Oya Üsküp
    Araştırma belgesi

    Copyright:

    © All Rights Reserved
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    of 26
    ca») United States c2) Patent Application Publication co) Pub. No.: US 2022/0363600 Al Grzeskowiak, II et al. US 202203636004 @) Pub. Date: Nov. 17, 2022 os) om i) en @) (60) METALLIC STON! METHODS ABS, SYS EMS, AND Applicant: Cam! MN ia Company LLC, Eden Prise, 'S) laventors: Jon Louls Grzeskowiak, HL, Prior Lake, MN (US); Martin E. Davis, Excelsog, MN (US): Michael Raymond Mead, Elysian, MN (US) Appl. No. 17/744,466 Filed: May 13, 2022 Related U. S. Application Data Provisional application No, 63/306.8%, filed on Feb 44,2022, provisional application No. 68/188,40, filed fon May 13, 2021, Publication Classification (51) Incl. Code 1434 (2006.01), cose 26010 (200601) cose sao (2006.01) Co4B aUas (2006.01) Co4B 4083 (2006.01) COB 1434 (2013.01); CO4B 26/10 (2013.01); CosB 4070067 (2013.01); Cou VAS? (2013.01): COMB 41/53 (2013.01) (C48 2111/00905 (2013.01) ABSTRACT tone slabs, and systems and methods of forming slabs, are escribed. Some example slabs include a first pattem defined by a fit particulate mineral mix and a second pattem defined by «second particulate mineral mix different From the frst particulate mineral mix. The first particulate nix includes greater than 50 weight percent of fist metallic pariles. Patent Application Publication Nov. 17,2022 Sheet 1 of 10 US 2022/0363600 Al FIG.1 Patent Application Publication Nov. 17,2022 Sheet 2 of 10 US 2022/0363600 A1 FIG. 2 ion Nov. 17,2022 Sheet 3 of 10 US 2022/0363600 Al € Old Patent Application Publication Nov. 17, 2022 Sheet 4 of 10 [} oot US 2022/0363600 Al FIG. 4 Patent Application Publication Nov. 17,2022 Sheet Sof 10 US 2022/0363600 A1 FIG. 5A Patent Application Publication Nov. 17,2022 Sheet 6 of 10 US 2022/0363600 A1 FIG. 5B Patent Application Publication Nov. 17,2022 Sheet 7 of 10 US 2022/0363600 A1 FIG. 6 Patent Application Publication Nov. 17,2022 Sheet 8 of 10 US 2022/0363600 A1 5™ Woking S784 Conpacng SS 7 FIG. 7 tug ™ 8005 Teakenwa ye yan Tima teme SP Patent Application Publication Nov. 17,2022 Sheet 9 of 10 US 2022/0363600 A1 Patent Application Publication ad Nov. 17, 2022 Sheet 10 of 10 Dispense First Particulate Mix Into First Regions of Mold 110 Dispense Second Particulate Mix Into Second Regions of Mold 1120 Vibrate And Compact Mineral Mixes to Form Molded Slab 1130 Cure Compacted Mineral Mixes Into Cured Slab 1140 Abrade Major Surface of Cured Slab 1150. ¥ Recover Abraded Material 1160| FIG. 14 US 2022/0363600 Al US 2022/0363600 Al METALLIC STONE SLABS, SYSTEMS, AND ‘METHODS CROSS-REFERENCE TO RELATED "APPLICATIONS. 0001] This pplication elaims priority to U.S. Application Ser. No, 63/306,876, filed on Feb, 4, 2022 and U'S. Appli- cation Ser. No. 68188403, filed ow May 13, 2021. The clisclosure of the poe applications are considered part of the disclosure of this application, and are incorporated in their entirety into this application ‘TECHNICAL FIELD 0002] ‘This document describes stone slab products, sys- tems, and processes for stone slab products, for example, stone slabs suitable for use in living or working spaces (@-., along a countertop, table, for, or the like) and having metal ‘components that provide a metallic finished surface BACKGROUND [0003] Stone slabs area commonly used building materia. Granite, marble, soapstone, and other quarried stones are often selected for use as countertops doe 10 ther aesthetic properties Stone slabs may also he formed from a combi- nation natural and other materials that can provide improved siaia-resistaat or heat-resistant properties, aesthetic charac- teristics, reproducibility, ete. Some stone slabs have been made from a combination of particulate mineral material and binder, such as a polymer resin or cement, and have a colored or veined pattern SUMMARY {0008} Some embodiments described herein include sys- tems and processes for forming stone slabs suitable for use in living or working spaces. In some optional embosiments, slabs can be manutctred by forming 2 cured and hardened slab tht inclndes a metal material. For example, slabs can ‘be mannfactured by at lest partly ling a slab mold with ‘one oF more particulate mineral mixes, including & particu lot mineral mix made up pataly, predominant, or com pletely of metal, resin binder andr one or more pigment, snd then curing andor hardening the contents ofthe slab ‘mold to fom a slab. In some embodiments, a sone slab includes muliple regions of diferent particulate mineral amines that have diferent characteristics, such as diferent ‘metal content, chemical composition, sheen (eg, metalic sheen), hardness, thickness, roughness, gloss, ee 10005) In an example entbodiment, a processed slab is formed fom a plurality of particulate mineral mixes, nd includes sab wid that is atleast 2 foo, lab length that extends perpendicular othe slab wid and thats at least 6 feo, the slab length and te slab wid defining a op mae surface, a slab thickness that extends perpendicular tothe slab width and the slab length, the slab length greater than the lb wid, the slab width pester than the slab thickness, snd fist patter defined by a fist partielate mineral mix ‘A first patter is defined by a first particulate mix, he fist, patiem exposed along the lop major surface ofthe slab, and the fist particulate mix comprising fist metalic panicles hhaving a fst mesh size and second metalic pares having 4 second anes size ditfren than the frst mesh size. 10006] Various embodiments can inchute some, al, or ‘none of te fllowing features. The fist metallic priles Nov. 17, 2022 ‘can make up greater than 10% by weight ("wt") of te ist, particulate mix. The second metallic partieles ean make up greater than 40 wt 9 ofthe first particulate mix, The frst inetalliepariles ean be between 200 US mesh and 400 US, sesh, The second metalic particles can he hetween $0 US, mesh and 100 US mesh, The frst metallic particles can be between 200 US mesh and 400 US mesh and make up between $ we % and 20 wt % of the fist particulate mix. The second metallic particles can be between 50 US mesh and 100 US mesh aad make up between 20 wi % and 75 wt % ofthe first particulate mix. The second particulate mineral six can make up greater than 10% ofthe overall wt % of the processed slab. The first metallic particles and the second rtallie materials can be a same material, The fist metallic particles and the second metalic particles can be stainless steel. The fist metallic panicles and the second metallic particles can be selected from the group consisting of copper, brass niekel, and aluminum. The first US mesh size can be less than 50% of the second US mesh size, The first pattern ean be exposed along the top major surface of the slab, and defining a first thickness that extends perpendicular to the slab width and the slab length, ancl a second pattem defined by a second particulate mineral mix dilereat fom the first particulate mineral mix, the socond pattem exposed ‘long the top major surface of the slab and defining a second thickness that extends perpendicular tothe slab width and the slab length, the is thickness ofthe frst pater different, than the second thickness of the second pattern. The first pattem can be exposed along a bottom major surface ofthe slab, The frst patter exposed along the top major surface of the slab can have a first texture based on the fist particulate ‘mineral mix, and the second pattern exposed along the top ‘major surface ofthe slab can have a second texture, cillerent, from the first texture, based on the second paniculate ‘nero mix, The frst texture can havea ist roughness and the second texture has 8 socond roughness that i different from the fist roughness, The fist pattern can have a first average gloss value and the second pattem can have a second average gloss value that is different from the first average gloss value. The fist patter can havea frst average thickness perpendicular to the sla width andthe slab lenath, andthe sevond patter can have a second average thickness perpendicular to the slab width and the slab length, and wherein the first average thickness is different from the second average thickness [0007] In an example implementation, a processed slab formed from a plurality of particulate mineral mixes ‘includes slab wid dat i at leat 2 feet a slab length that, extends perpendicular to the slab width and that isa least 6 fet, the slab length and the slab width defining a top major surface: a slab thickness that extends perpendiculat 10 the slab width and the slab length, the slab length greater than the slab width, te slab width greater than the slab thickness; and first pater defined by fist particulate mix, the first, patter exposed along the top major surface ofthe slab, and the first particulate mix comprising greater than 5O wt % of first metallic particles [0008] Various embodiments can include some, all, or rhone of the following features. The frst metallic particles ‘ean makeup greater than 10 wt % ofthe first particulate mix, ‘The second metallic panicles can make up greater than 40 wt ‘po the first particulate mix, The ist metalic particles ean be botwoon 140 US mesh and 400 US mesh. The second rstallie particles ean be between 50 US mesh and 140 US. US 2022/0363600 Al ‘mesh, The first metallic particles can be between 1400 US mesh and 400 US mesh and make up between $ wt % and 20 wt M% of the fist particulate mix. The second metalic particles can be between SO US mesh and 140 US mesh and make up between 20 wt % and 75 wt % of the frst, particulate mix. The second particulate mineral mix can make up greater than 10 wt % of the overall wt % of the processed slab The first metallic particles and the second metallic materials can be a same material. The first metallic particles and the second metallic particles can be stainless Steel. The frst metalic particles and the second metallic particles can be selected from the group consisting of ‘copper, brass, nickel, and aluminum. The first US mesh size ‘can be less than $0% of the second US mesh size. The first pattem ean be exposed along the top major surface of the slab, and defining a first thickness that extends perpendicular to the slab width and the slab length, anda second pattern defined by a second particulate mineral mix diferent from the frst particulate mineral mix, the second pattem exposed along the top major surface ofthe slab and defining a second thickness that extends perpendicular to the slab width and the slab length, te first thickness ofthe fist patter different than the second thickness of dhe second pattern, The fits, pattem can be exposed along a bottom major surface ofthe slab, The frst pattem exposed along the top mejor surface of the slab can havea fist texture based on the frst particulate mineral mix, and the second pattern exposed along the top inajr surface of the slab can havea second texture, diferent from the first texture, based on the second paniculate ‘mineral mix. The fits texture can have fist roughness and the second texture has a socons roughness tht is different fom the fist roughness. ‘Te first pattern can have a fits, average gloss value and the second pattem can have a second average gloss value that is different from the firs, average gloss value, The fist patter can have a fist average thickness perpendicular to the slab width and the slab length, ‘and the second pattera can have a second average thickness perpendicular to the slab width and the slab length, and ‘wherein the first average thickness is diferent from the second average thickness. [0009] In an example implementation, a process of form= ing a processed slab from a plurality of diferent particulate mineral mixes includes dispensing a frst particulate mineral imix to a fist set of regions of a slab mold, the first particulate mix comprising frst metallic panicles having a first mesh size and second metalic particles having a second ‘mesh size different than the frst mesh size; dispensing. a second particulate mineral mix to a second st of regions of the slab mold contemporancously vibrating and compacting the fist particulate mineral mix and the second particulate ‘mineral mix arranged in the slab mold so as to form a ‘processed molded slab that i generally rectangular and has ‘slab thickness and a majar surface having a slab width of at least 2 feet anda slab length of atleast 6 feet; and curing the processed molded slab into a cured slab [0010] Various embodiments can include some, all, or hone of the following features. The fist metallic particles ‘can make up greater than 10 wt % of the fist particulate mix and the second metallic particles ean make up greater than 40 wt % of the first particulate mix. The first metallic particles can be between 200 US mesh and 400 US mesh and make up between 5 wt % aad 20 wt % of he frst particulate mix. The second metallic particles can be between SO US. ‘mesh and 100 US mesh and make up between 20 wt % and Nov. 17, 2022 ‘75 wt % of the fst particulate mix, The process can include abrading the major surface of the cued slab at locations of the frst particulate mineral mix and the second particulate ‘mineral mix with an abrading head to partly remove portions tof the major surface such that the frst particulate mineral mix in the fit set of regions define a first thickness perpendicular to the slab width and the slab length, and the second particulate mineral mixin the second set of regions Aefine a second thickness perpendicular to the slab width and the slab length [0011] In an example implementation, a process of form- ing a processed slab from a plurality of difleeat particulate ‘mineral mixes includes dispensing a first particulate mineral, mix to a first set of regions of a slab mold, dispensing a second particulate mineral mix to a sacond set of regions of the slab mold, contemporaneously vibrating and compacting the frst particulate mineeal mix and the second particulate mineral mix arranged in the slab mold so as to fom a processed molded slab that is generally rectangular and has slab thickness and a major surface having a slab width of at least 2 fet anda slab length ofa least 6 feet, curing the processed molded slab into cured slab, and abrading the major surface of the cured slab at Iocations of the first particulate mineral mix and the second particulate mineral mix with an abrading head to partly remove portions ofthe rmgjor surface such that the first particulate mineral mix in the frst set of regions define a first thickness perpendicular to the slab width and the slab length, and the second particulate mineral mix inthe second set of regions define a second thickness perpendicular tothe slab width and the slab length [0012] Various implementations can include some, al, or fone ofthe following features, The fist particulate mineral six can havea fist hardness inthe cured slab andthe second particulate mineral mix can have a second hardness dillerent, ‘rom the first hardness in the cured slab, Abrading a potion ofthe major surface of the cured slab can include removing ‘an amount ofthe major surface inthe first set of regions to ‘fest average thickness perpendicular to the slab width and the slab length that is different from a socond average thiokness removed from the second set of regions, wherein a fist texture is based on the frst average thickness and a second texture is hased on the second average thickness. The first particulate mineral mix can include a fist percent volume of quartz, and the second particulate mineral mix can include a second percent volume of quartz that is less than the frst percent volume of quartz. One ofthe first set of regions and the second set of regions can define a majority of the major surface, and the other ofthe first set of regions ‘and the second set of regions can define a vein extending a least parly across the major surface. Abrading the major surface of the cured slab can include abrading substantially an entirety ofthe major surface. Abrading the major surface of the cured slab can include abrading using an abrasive brush. The first so of regions ean have frst texture and the second set of regions can have a second texture different, from the first texture. The first texture can have a frst roughness and the second texture can have a second rought- ness thats diferent from te fist roughness. The fist set of regions can have a first average gloss value and the second sel of regions can have a second average gloss value that is diferent from the fst average gloss Value, The fist set of regions can have a frst average thickness perpendicular to the slab width and the slab length, and the second set of US 2022/0363600 Al regions can have a second average thickness perpendicular to the slab width and the slab length, and wherein the first, average thickness is different from the second average thickness. Abrading the major surface can inchude passing 3 sequence of diflereat abrading brushes having different, abrasive grits over the entirety ofthe major surface. Abrad- ing the major surface can include passing the abrading head ‘over the entire major surface with consistent operating parameters. Abrading the major surface ean inelude passing ‘second abrading head over the entire major surface with ‘consistent operating parameters. [0013] The systems and techniques described here may provide one or more of the following advantages. Firs, some embodiments described herein include stone slabs having an appearance of metal, For example, some oral af the stone slab is defined by a particulate mineral mix that includes meta, such as stainles steel particles. The particu late mineral mix can be arranged in a vein or other pattern, andlor can define some or all of atop major surface of the finished slab. [0014] Second, some embodiments described herein pro- ‘vide an aesthetic appearance that aoventates andlor exag- ‘grates various characteristics of quaered stone slabs, For ‘example, some stone slabs describes herein provide a vein patter having geometric characteristics suggestive of vein pattems of quarried stone slabs. The vein patteras are created by a particulate mineral mix having a high metal content such thatthe composition, color, sheen, and/or other characteristics difer from a vein patter of a quarried stone slob [0015] Thicd, some embodiments described herein pro- ‘vide a vein that has the appearance of metal. For example, ‘not only does the vein pattern have a metalic shimmer, but in some embodiments, at least a portion of a top major surface looks and/or fels like metal. The vein patter may’ have a substantially consistent surface appearance over the ‘entire surface ofthe vein. For example, the vein pattern has 2 substantially consistent metal surface and does not have the appearance of metal flakes or particles in a non-metal imix. Altematively or additionally, the vein pattern has a varied metal surface that has the appearance of metal lakes or particles in a metal mix/carier [0016] Fourth, a system can provide stone slab products ‘that have a tactile and/or visible texture. For example, in some embodiments, one of more surfaces of the slab inchudes regions of different tactile andr visible character- istics Fifth, the system can provide stone sla products that hhave a texture that resembles that of quarried stone. Sixth, the system cin provide stone slab products that have an ‘aesthetic appeal similar to that of quarried stone and with improved performance benetis such as heat and stain re tance and reproducibility, but without the cost andlor en ‘ronmental impact associated with stone quarrying. Seventh, the system can modily existing stone slab products 10 provide additional product options from common base product [0017] The details of one or more implementations ae set, forth in the accompanying drawings and the description below, Other features and advantages will be apparent from the description and drawings, and from the claims. DESCRIPTION OF DRAWINGS. 10018] FIG. 1 is a perspective view of an example pro- cessed slab, in accordance with some embodiments. Nov. 17, 2022 [0019] FIG. 2is 2 perspective cross-sectional view of the ‘example processed sla, in accordance with some embodi- ses [0020] FIG. 3 is perspective view of an example pro- cessed sla, in accordance with some embodiments, [0021] FIG. 4 is sie view of an example processo slab Uundengoing an example surface treatment process, in accor- ddance with some embodiments [0022] FIGS. SA and SB are enlarged sectional perspee- tive views of example processed slabs, in accordance with, some embodiments [0023] FIG. 6 is an enlarged perspective view of an ‘example processed sla, in accordance with some embodi- ses [0024] FIG. 7 is a diagram of an example system for Torming a processed slab product, in accordance with some embodiments. [0025] FIG. 8 is a diogram of an example system for applying a surface treatment to texturize a processed slab product, in accordance with some embodiments. [0026] "FIGS. 9 and 10 are diagrams of example systems orapplying a surface treatment to texturizea processed slab product, i accordance with some embodiments [0027] FIG.11 isa ow diagram of an example process for producing a processed slab product, in accordance with some embodiments DETAILED DESCRIPTION [0028] In general, this document describes stone slabs, systems and methods that provide a slab having one or more sical components. For example, some embodiments pro vide stone slabs that include a pattem, such asa vein patter, defined by a particulate mineral mix having a relatively high metal particulate content. The example pattern provides an aesthetic appearance of a metal pattern or vein on a major surface of the stone slab. Additionally, this document Lescribes systems and techniques in which processed stone slabs having textured faces canbe manufactured by abradiag cured (eg, hanlened) slab having exposed rexions of ifereat component materials that abrade or erode difer- ently (eg, at different rates when subjected to a common treatment), andior otherwise reveal different textures due to the abrasion. For example, hardened materials are worn ‘down in different manners to produce one or more different surface characteristics based on the component materials (ex, and in an example embodiment does not include imparting a pattem into soft, uncured materials and then allowing the pattern to harden). In some embodiment, an example stone slab includes varying texture tat caricatures natural erosion and fissuring andor provides different char- acteristics that create a predetermined aesthetic and tactile characteristics. [0029] Referring 10 FIG. 1, an example processed slab 80 is shown having. first region SI ofa primary or background fill, second region $2, and a third region 83 that include striations or veins (e.g. according toa predefined pattern). ‘The region $1, region 52, andlor region 53 have features that, differ in one or more respects. In an example embodiment, the regions 82 andlor 88 are defined by a particulate mineral mix having a relatively high metal content, The exposed surface of regions 52 have a metallic aesthetic appearance. Alternatively or additionally, the regions 82 andior 83 have ‘surface characteristics or textures that differ compared to tone another and primary or background fill §1, such as a US 2022/0363600 Al itfrent roughness (or smoothness, gloss, metallic sheen, or ofher perceptible difrence. [0030] In various example embodiments, slab $0 includes any une, combination, patter, andor proporion of parcuate fils and mixes. For example, the processed slab 50 can include two, thee, four, ive en, oF any appropriate number of particulate mineral mixes (ea, dispensed Sequatally or otherwise maintained separately within the slab mold) 0 provide any appropriate number of regions. ‘The regions provide an sesthtic appearance of diferent percopliblepattemsiveins. In another example, the primary fll $1 may not occupy a majoety ofthe processed slab $0 (a, the processed slab 50 may inclwle a substantially continuous collection of regions without aay one of the particulate fill types oecupying an ientfably primary or ‘major portion ofthe volume of the processed sab $0) Ia some embodiments, processed slab 80 includes one or more regions $1, $2, $3 of differen particulate mineral mixes andlor diferent surface characteris (ea. according 10 a predefined pattem) 10031] ‘The processed slab $0 has a width W and a length Far example, the slab 80 sat east 2 fet wide by at east, 6 feet log, and between aboot 3 fet and S feet wide and beeen about 6 fet and 14 feet ong or about 45 feet wide {imore paicularly, about 140 em wide) by bout 10 feet ong {aore partcualy, about, 310 cm Hong). In genera, the length Land the width W define a top major surface 60(e-., face) and a botiom major surfce (ex. five) 61. The processed slab 0 albo has a thickness T hotween the top mnajor surface 60 and the bottom major surface 61. The periphery ofthe processed slab 80 includes a calleston of ge faces 62 10032] Example slab $0 includes a quartz material andor ‘other particulate mineral material tht, when mixed with pigments and a resin binder and subsequently compessed sand cured, provides a hardened sab prot stable Tor use in living or working spaces (e, along a countertop, table, flor, oF the like). As shown in FG. 1, ech slab $0 may be foraied fom combination of particulate mineral mixes tht have diffrent hardnes or resistances to abrasion, diferent ‘material compositions, and optionally diferent colors and textures. The paiculate mineral mixes ar arranged in. skb mold (e., slab mold 730 shown in FIG. 7,0 provide the predetermined regions of selected striationsveins andlor ‘other pattems. In some embodiments, the patterns are gen- erally repeatable for each separately molded slab, lor ‘example by dispensing different particulate mineral mixes (ex, diferent hardness, dlfrea resistance 10 abrasion, diferent pigments, tfrent compositions, diferent ad tives) according to predefined ant repeatable dispensation patter ito the mold uti filled, The molds closed and then transpored for compaction, curing, abrading, and other operations 10033] As shown in FIG. 1, he pattem of regions 81, 52, sand 53 provide a surface appearance having one oF more ‘veins or oter visible features. In some embodiments, veins 52 and $3 extend at east partly acts the major surfaces 60, 61 andor the edges 62 (he thickness T), For example, slab 450 can include a widthwvise vein that extends partly or entirely in a genorlly widkhwise direction, a lengthwise ‘ein that extends par or etrelyin.a generally lengthwise dliecton, Akematively oe additionally, one oF moe veins extend in angled or varying directions panty or entirely ssross the length andor wich W ofthe processed slab 0 Nov. 17, 2022 In some embodiments, the veins also extend partly or entirely (Such as vein'S2!) through the thickness of the processed slab 50 (eg. thereby providing a vein appearance even when the slab is cut and edged to specific shapes in living or working space, such as along a countertop, table, floor or the like). In some embodiments, each processed slab 50 in aset of separately molded slabs can ince the regions of different particulate mineral mixes dispensed into the ‘mold (eg, such as mold 730 shown in FIG. 7) according to predefined and repeatable dispensation patterns, such that ‘ultple slabs $0 inthe set of separately molded slabs can have substantially the same appearance to one another. [0034] The different mixes canbe compaction molded and cured in the mold (eg, all particulate mineral mixes are initially uncured and then contemporaneously cured in the old) so as fo provide the hardened slab 80, One or more of the mixes that are used to form the composite stone material can include organe polymer(s) and inorgani (eg, mineral) particulate component The inorganic particulate component ‘may include one or more metals, sich as stainless stel, brass, copper, bronze, aluminum, zine, titanium, gol, silver, iron, magnesium, tungsten, nickel, tin, et., one or more of silicon, basalt, glass, diamond, rocks, pebbles, shells, a varity of quartz containing materials, such as, for example, crushed quartz sand, quartz panicles, and the like, and/or any combination there. Inan example embodiment, one or more of the mixes include a substantial percentage of metal by weight. For example, one or more ofthe mixes include predominately metal (¢., more metal than quartz of other riineral composition by weight). A particulate mineral mix that defines repion 52 includes predominately metal, and particulate mineral mixes that define regions S1 and $3 include predominately quart. In some embodiments all of the pariculate mineral mixes of regions 81,2, and 83,(e., that make up the entirety of slab 50) include a quartz material suc a atleast 3 wi %, at least 5 wt %, at east 7 ‘wt %, oF more of a quartz material, Alternatively, some of the particulate mineral mixes include quartz and some of the rineral mixes (eq, that are predominantly metal) do not include quar. For example, the particulate mineral mixes of regions $1 and §3 include quartz, and the particulate mineral mix of region $2 does not include quartz [0035] In the hardened, cured form of the slab $0, the ‘ryanie and inorganic materials can be Tinked using a binder, ‘which may include for example, mono-funetional or multi- functional silane molecules, dendrimerie molecules, and the like, that may have the ability to bind the organic and inorganic components of the composite stone mix. The binders may fuer include @ mixture of various compo- rents, such as initiators, hardeners, eatalysators, binding molecules and bridges, or any combination thereol. Some or all of the mixes dispensed in the mold may include com- ponents that sre combined in a mixing apparatus prior 10 being conveyed to the mold. The mixing apparatus can be used to blend raw material (Such as the quartz material, ‘etal material, organic polymers, unsaturated polymers, and the Tike) at various ratios [0036] In various example embodiments, some or all of the particulate mineral mixes of slab $0 include about 1-98% quar aggregates and about 3-15% polymer resins, In addition, various additives may be added to the raw mate- rials in the mixing apparatus, such additives may include colorants, dyes, pigments, chemical reagents, antimicrobial substances, fungicidal ageats, andthe like, or any combi- US 2022/0363600 Al nation thereof Ia altemative embodiments, some or all of the quantity of quartz ageregates (mentioned above) can be replaced with o inelude porcelain andor ceramic ageregate material. In an example embodiment, lab $0 includes first, particulate mineral mix that defines region S1, a second particulate mineral mix that defines region $2, a tind particulate mineral mix that defines region $3, andor one or ‘moze particulate mineral mixes that define one oF moee regions of slab $0. In various example embodiments, the first particulate mineral mix that defines region S1 andioe the ‘third particulate mineral mix that defines region $3 includes ‘greater than 50 wt % quartz, such as between 50 wi Mand 5 wt 96, between 50 wt % and 75 wt %, between 50 wt % and 65 w1%, or bout $$ wt % quartz. The fist particulate ‘mineral mix and/or thied particulate mineral mix includes Iewcen 3 wt % and 15 wt % resin binder, between 3 Wt % and 10 wt % resin binder, or between 5 wt % and 10 wt % resin binder. The fist particulate mineral mix andior third particulate mineral mix includes betwaen $ wt % and $0 wt % silicon, between 10 wt % and 45 wi % silicon, between 15 wt 4 and 40 wt % silicon, of about 35 wt % silicon Altematively or additionally, the first parculate mineral ‘mix andr the third particulate mineral mix includes one or ‘more addtional components such as between 0.1 wt % and 3.01%, 0.5 wt Yoand 2wt%, orabout 1 wi% styrene, and/or between 0.1 wt % and § w1% pigment, 0.2 wt % and 3 wt °% pigment, or about 0.4 wt % pigment, For example, the first particulate mineral mix includes about $7 wt % quartz, about 35 wt % silicon, about 7 wt % resin binder, and about 5 wt % additives, such as styrene and pigment 10037] The second particulate mineral mix that defines region 52 does not include predominately quartz. For ‘example, the second particulate mineral mix that defines region $2 includes a predominately metal composition and includes relatively small amount of quar or uo quae. La Various example embodiments, the second particulate min- eral mix includes greater than 50 wt % metal particulate, ‘greater than 60 wt % metal particulate, greater than 70 wt % ‘metal particulate, greater than 80 we % metal particulate, ot more. The second pariulate mix includes less than 5O wt % «quartz, les than 40 wt % quartz, less than 30 wt % quartz, less than 20 wt % quart, less than 15 wt % quartz less than 10 wt 9% quart, ess than $ wt % quartz, or about O wt % quartz, or between 2 wt % and $0 wi % quartz, between 3 wt % and 40 wt % quartz, or between 5 wt % and 30 wt % quartz. Altematively or additionally, the second particulate ‘mineral mix includes one or more additional components, such as between 5 Wt % and 30-Wt 2% silicoa, between 7 wt 9% and 25 wt % silicon, between 10 wt % and 20 wt % silicon, oF about 15 wt % silicon, between 0.1 wt % and 3 ‘wt 9% styrene, 0.3 wt % and 2 wt % styrene, or about 0.5 wt ‘Sh styrene, and/or besween 01 wi % and Sw % pigment 0.2 ‘wt % and 3 wt % pigment, or about 05 wi % pigment. For ‘example, the second particulate mineral mix includes about 74 wi % metal particulate, about 13 wi % silicoa, about 7 wt % quartz, and about 6 wt % additives. In some embod ‘ments, the second particulate mineral mix does not inelude quartz or includes les than Jt % quart 0038] The metal composition of the second particulate ‘mineral mix includes metal material that provides a metal appearance on a surface of the finshed slab $0. In an ‘example embodiment, the second region 52 provides the appearance of a metallic vein patter having one oF more metallic widthwise andlor lengthwise veins, Such en appeat- Nov. 17, 2022 ‘ance can emphasize or exaggerate vein pattems that may be found in quarried stone slabs, andor create a unigue veined or pattered appearance that simulates, but is aot found i, quarried slabs. In some embodiments, the metalic vein creates the appearance of flow or movement across the surface ofthe sib, and can crete the impression of a vein pattern formed by molten metal that has cooled and hard- ened into the visible pattern, {0039] The composition of the metal materia in the par- ticlate mineral mix has been found to impact the metallic appearance ofthe vein or pattem of the second region $2 in the finished slab 80, In some embodiments, the particulate mineral mix includes only a relatively finer metal powder (€., 140 US mesh to 400 US mesh or smaller) and doesnot Include larger metal particulate. In some embodiment, the particulate mineral mix includes only a relatively courser metal particulate (et, grit of 40 US mesh to 50 US mesh or larger), and does not inelude finer meal powder. In an example embodiment, the second particulate mineral mix includes multiple metal components having different par- ticle size ranges, such as relatively finer powder and a relatively courser metal grit. In various example embodi- ments the second particulate mineral mix ineludes between Swi and 45 ws, between 10 wt% and 30 1%, or about 15 wt % of a metal powder (e., 140 US mesh 10 400 US mesh or smaller), and between 20 wt % and 100 wt % between 30 wt % and 80 wt %, between $0 wt % and 75 wt %, or about 60 wt % ofa relatively coarser metal grit (ez, 140 US mesh 9 $0 US mesh or lager). Such ranges have been found to promote a distinct metal appearance on a surface ofthe finished slab {0040] In an example embodiment, the metal powder includes only a single mesh size between 140 US mesh (2, 105 mierons) and 400 US mesh (eg. 37 microns), soc as 140 US mesh, 170 US mesh, 200 US mesh, 230 US mesh, 270US mesh, 325 US mesh, or 400 US mesh For example, the metal powder is specified/qualitied using a single mesh size (eg., 95% of material is smaller than the specitied! qualified mesh size, and in some embextiments may inckude insignificam amounts of particles outside of the specitied! qualified mesh range). Altematively or altionally, the metal powder includes two or more particle sizes, such 2 two or more of 140 US mesh, 170 US mesh, 200 US mesh, 230 US mesh, 270 US mesh, 325 US mesh, or400 US mesh, For example, the metal powder is specified‘qualifid using multiple mesh sizes (en each of which 95% of material 4s smaller than the specified qualified mesh size). {0041} In an example embodiment, the metal grit is @ single particulate size range, such as ony a single mesh siz, ‘The metal grit has a mesh sizeof 50 US mesh, 60 US mesh, 7OUS mesh, 80 US mesh, 100 US mesh, 120 US mesh, or 140 US mesh. For example, the metal powder is specified! qualified using single mesh size (e., 95% of material is smaller than the specifed/qualified mesh size, and in some embodiments may inchide aesthetically "insignificant amounts of particles outside ofthe specified/quaified mesh range. In some embodiments the metal grit ineldes mul- tiple eatvely larger mesh sizes, suchas two or more of SO US mesh, 60 US mesh, 70 US mesh, 80 US mesh, 100 US mesh, 120 US mesh, or 140 US mesh, for example. For «example, the ical grit is speviti/qualfed using multiple nes sizes (ez. in eachof which 95% of materials smaller than the specified qualified mesh size). In_an example embodiment, the specified/qualified size of the metal grit US 2022/0363600 Al does not overlap with the specified qualified size of the metal powder and the metal grit is at least 150%, 200%, 250%, 300%, 400%, 500%, oF greater than 500% of the spesifiedquaiid size of the metal powder. [0042] combination of substantial wt 8% of a relatively finer meal pide with a substantial wt % of a relatively courser metal grit can impart a desired metallic elet of ‘ezion 82 in the finished slab 80, For example an overall wt ‘eo greater than 50% metal material that includes selected ratio of relatively finer metal powder with a relatively courser metal grt ean provide a desired metalic shoen,Inan ‘example embodient, the ratio af elatively course metal itt relatively finer metal powder in the second particulate Inineal mix is between 1021 and 1:2, 8:1 and 1:1, 6: and 2:1, or about 41. Such ratios can provide distinct metalic ‘ppearance of region 82 in the finished slab, such as whea the metal matcial is stainless steel, brass, copper. bronze, sluminum, zinc, titeniom, gold, ster, iron, magnesium, {tungsten nickel, oft, nan example embodiment, both the relatively finer metalic powder and the relatively courser metalic grit are a same mtr ype. For example, both the relatively finer metalic powder and the relatively couser etl grit ae stainless ste, both are brass, both are copper, bother are bronze, bot ate aluminum, bot are zinc, ‘oth ae titanium, both re gold, both are silver, both are ito, both are magnesia, both are tungsten, both are nick, or both are tn. Alternatively or atonll, the relatively ‘course metallic grit and the relatively finer metallic powder ae dferent metal types andor inlude multiple etl ype. [0043] The second pacticulate mineral mi includes pig ‘ment that can impact the aesthetic appearance of region $2, including the color, tonality, et. Inan example embodiment, the second paniculate mineral mix 82 inludes «pigment that enhances the metal aesthetic appearance ofreion 82. Forexample, the pigment ofthe second particulate mineral tnx includes 02 pigment. Suc pigment can brighten or Tighten the appearance af the stainless stel metal appear ace in region 52. In some embodiments, the addition of a “TO? pigment (eg. within the wt % described above) ca facilitate an aesthetic appearance that is similar or comple mentary to the appearance of stiless steel fixtures or appliances commonly found in kitchens and ving spaces. 10044] In an example embodiment, the meta component (5) ofthe particulate mineral mix are primarily or ently stainless ste. Stainless stel paniculste has relatively low reactivity with other components of the palate mineral rmx. In se, the appearance of stainles stel (ein region '32) can complement common materials in living/working spaces in which the finished. slab is installed, such as Stainless steel fixtures and appliances in Kitchen. Alterna tivoly rationally stainless soo canfeiitate a region $2 that doesnot significantly change in appearance ove the life of the finished slab $0, and can maintain a consistent aealic sheen. Moreover, a region $2 defined pedomi- nately by stainless stel pariculate is resistant t0 food procs and materials commonly encountered in ving and Working spaces 10045] In some example embodiments, the metal compeo- nen() ofthe particulate mineral mi include ras, eopper, byonze, sluminum, zinc tani, gol, siver, ion, magne sium, tungsten, nickel, andor tn. Such materials ean be used wo provide a dsint appearance (e, wna, shen, texture, gos, et). Altomatvely or addtional, such met. als can promote changing appeanace over time. For Nov. 17, 2022 example, a region $2 defined partly, predominately, or entirely of copper, brass, etc, can develop a patina or ‘weathered look over time, enhancing the aesthetic value andlor uniqueness ofthe finished slab 50 [0046] In various example embodiments, the fst, second, third, andlor other particulate mineral mixes may be pre- dominately metal. For example, fit, second, third, andor other particulate mineral mixes that define regions 81, 52, 53, andior other regions may have a predominately metal composition (eg, having a composition as described above with respect tothe second pariculate mineral mix). In some embodiments, te finished slab 50 has an overall composi- tion that includes a significant metal portion. In various exemplary embodiments, the overall weight percentage of ital ofthe finshed slab 80 is greater than 1 wt %, greater than 2 wt % greater than $ wt, greater than 10 wt %, greater than 20 wt %, greater than 30 wt %, greater than 40 wt %, areater than 50 wt %, greater than 60 wt %, greater than 70 wt, greater than 80 wt", greater than 90 wi %, or more. For example, the overall metal composition ofthe slab is berween $ wt % and 90 wt 8%, between $ wt % and 60 wt 9%, between 10 wt % and 30 wt %, between 20 wt % ‘and 90 wt %, betveen 30 wi % and 90 wi %, oF between 40 1w1% and 90 v1 %, In some embodiments, the overall wt % of region $2 that defines a metallic vein (¢., the overall wt ‘ofthe second particulate mineral mixin the finished slab) is botwoon 0.5 wt ®% to 50 wt %, 0.5 wt % t0 15 wt % oF Tt % wo $ wi %, Such ranges can provide a slab having 2 significant metal appearance while providing a durable work surface that can be cut and fabricated fo installation in a living/work space [0047] In some examples, the metallic sheen that is visible in veins having a substantial metallic content (¢g., alloy veins) can be characterized in multiple ways. The metallic sheen can be characterized using one oF more techniques corresponding 10 the surface fnish ofthe sample. In some embodiments, such as fr slabs having a high gloss finish, a goniophotomicter (eg, RHOPOINT IQ meter available from PHOPOINT INSTRUMENTS) can be used to measure gloss ata predetermined angle and reflectance haze. For example, ‘8 goniophotometer is used to measure gloss at a predeter- mined angle of 20°, 60°, 85°, etc. The metallic sheen of some example alloy veins exhibit a gloss value (measured at, anangle of 60°) of 100+ and a reflectance haze eater than 10, in an example embodiment. [048] In various example embodimeats, alloy veins exhibit gloss values and reflectance baze values that are dlfereat than non-ally veins or surfaces, In some embodi- ‘ments, non-alloy portions exhibit reflectance haze values ranging from between about 1 and about 10, or about I and about 8, andr gloss measurements ranging from about 40 to about 80. In various example embodiments, alloy vein portions exhibit higher gloss and reflectance haze values, such as gloss greater than 80 and/or reflectance haze greater than 15. In various example embodiments, the gloss ofthe alloy veins between about 75 and about 250, about 85 and bout 225, or about 100 and about 225. Alternatively or additionally, the reflectance haze values ofthe alloy vein is, between about 10 and about 80, about 12 and about 60, or about 15 and about 50. Such values are associated with a distinct metallic surface characteristics and overall appear- [0049] In some embodiments, such as slabs having a textured finish, a gloss meter (eg,, “BYK-mae i” meter, US 2022/0363600 Al available ftom BYK-GARDNER) can be used © measure sraininess ($_G), sparkle index ($j), and sparkle amount (S.a)-In various example embodiments, texturedalloy veins and textured non-llow veins exhibit graininess (SG), sparkle index (Si), and sparkle amount (Sa) that are ‘meaningflly different Example alloy veins exhibita sum of SG, $i, and S_a, measured ata 15° angle, ranging fom about 40 io about 17S, about 40 to about 16, oF about 50 0 about 150. In some embodiments the sum of $_G, Sj, and S_a, measured ata 15” angle, is areater than 40, Example nonvalloy veins exhibit sums ranging from about zex0 to about 33. In some embodiments, the sum of S_G, S i, and S_a, measured at 15° angle, is less than 40, 10050] In various example embostiments, sib includes alloy veins or portions and non-lly veins or portions, and the surface characteristics differ at locations of the alloy veins or portions compared to the nonalloy veins or por- tions. In an example embodiment. finished stone slab includes a fist region (eg. alloy vein) that exhibits a gloss value (¢@, average gloss value) of between about 75 and about 250, out 85 andl about 225, or about 100 and about 225, anda reflectance haze value (e., average reflectance haze value) of between about 10 and about 80, about 12 and about 60, or about 15 and about 50, The finshed stone slab additionally inches a second region (eg, now-lloy vein) that exhibits a gloss valve (eg, average glss valve) of ‘between about 40 and about $0, and a reflectance haze value (2, average eletance haze value of between abot 1 and about 10, oF about 1 and about 8 0051] In some implementations, gloss andor reflectance haze measurements can be performed as a test of finished ‘oduct. For example, ater a slab is cured and finished, a quality control operation is performed that includes mea- surement of reflectance haze andor gloss of the sl. The quality control operation can be performed to determine if the slab is within predetermined ranges (eg.. of gloss, reflectance, haze, alo other characteristics. The quality ‘control operation can be used t0 qualify a product forsale (a, that itis within the predetermined specification for a conforming slab, andlor fr categorization purposes (e. 0 ‘xoup the slabs with other similar slabs have similar goss! rellectance haze values, label the slab fr sale as a high losseetance version ofthe prxict orto label the slab for sale as a low glosvreflectance version of the product, tc). In an example embodiment, multiple measurements are obisined at various locations ofthe slab, such as at ‘predetermined locations of alloy and non-alloy material, scconding toa predetermined pate forthe eximple sla, Measurements obiined for the alloy material locations are ‘compared to speificd acceptable alloy anges, andor mea- surements obtained forthe non-llow material locations are ‘compared to specified acceptable non-alloy ranges. In some ‘embodiments, a pass/fail detemnination is made o determine ‘whether the siab conforms tothe specified ranges. Altema- tively or additionally, measured values are stored and asso- ciated with an identifier specifically associated with the measured sla. The measured values are used in one or mare subsequent operations, such as to match the measured slab ‘with another slab having similar or complementary values. 10052] Various slabs described herein provide robust strength suitable for installation in living working spaces in 4 variety of configurations. In an example embodiment, finished slabs having one or more particulate mineral mixes of significant or predominate metal composition (eg. a8 Nov. 17, 2022 described above) provide a strong and consistent flexural sirength across the entirety of the slab. For example, the Aexural strength at location of a second particulate mineral mix defined by significant metal composition isnot signif cantly loverdiferent tha flexural strength at locations of first paniculate mineral mix defined by predominately quartz. lternatively or additionally, the exural strength at locations where frst and second particulate mineral mixes interface with one another isnot significantly lower than locations within a region defined entirely by the frst or second particulate mineral mixes. For example, the flexural strength of such regions is within 75%, 80%, 85%, 90%, 95%, or about 100% of one another. profile of flexural streagth across a width of length ofthe slab is ns relatively consistent, without locations of significant relative weak ness. For example, the profile of flexural strength across a ‘width or length ofthe slab varies by less than 25%, less than 15%, less than 10%, less than 5%, or less. [0053] In an example embodiment, finshed slabs having fone oF more particulate mineral mixes of significant or predominate metal composition (eg. 3s described above) exhibit significant structural strength For example, finished slabs having one or more paticulate mineral mixes of significant or predominate metal composition (eg, a8 described above) exhibit litle to no change in strength between material cross setions with and without a metallic vein, Sinictural strength of ally and non-alloy slabs ean be characterized using a three-point flexural test. For example, structural strength can be characterized based on a modulus of rupture (MOR) (eg, determined according to ATSM International C99/C99M—18 “Standard Test Method for Medilus of Rupture of Dimension Stone” (2018). [054] In an example embodiment, 12°x12"%2 em fin- ished slab portions having single alloy vein running in a straight line across the ceater is divided into five equally sized specimens by cutting across the alloy vein, with the alloy material st the expected modulus of rupture (MOR) breaking point (e., the center of a 3-point bending span). All five specimens are tested in accordance with the ATSM International C99ICOOM—18 “Standard Test Method for Modulus of Rupture of Dimension Stone”. In an example embodiment, the average MOR for the five alloy veined specimens was 9.9920.22 ksi. Tests of similar, but non- veined, specimens showed thatthe average MOR outside the alloy vein was 10.45:1.50 ksi. Based on a comparison of those results, the specimens exhibited only an approximate 4.53% strength difference between alloy-veined and. non veined areas. MOR values for both the alloy-veined and ‘on-veined examples were significantly higher than MOR of 44.00 ksi, which in some examples ean be a standard MOR, for a hardened slab product suitable for use ia living or working spices (ex, along a countertop, table, flor, oF the like, [0055] _As shown in FIGS. 1 and 2, exemplary regions 81, 52, and 83 have thicknesses that extend entirely through the thickness T ofthe slab §, Such thicknesses can provide an appearance in which the pattem defined by the particulate ‘mineral mixes are visible through the entre thickness T of slab 50 along periphery edges, such as when slab $0 is cut fr installation, [0056] The finished slab $0 has a major surface 69 having Various aesthetic and tactile features and characteristics, In an example embodiment, one or more of regions 51,52, $3, have an aesthetic appesrance andlor wctile characteristic US 2022/0363600 Al that dfs fom another of region 81, $2, 83 (eg. a8 described in additional detail wih reference © FIGS. 3-11). “Altematvely or additionally, the entie major surface hos @ consistent texture (eg, consistent smooth, glossy surface) that ders in aesthette charactrstis between regions S1, 52, andlor 8, such as different color, tonality, visible pate sizelshape, et. For example, both regions defined by a predominately quart particulate mineral mix (¢2. region 51) and regions defined by predominately metal particulate mine! mixes (eq. regions 82 and'3) having a consistent smooth, glossy surface, as istratedin FIG. 2 [0087] Referring to FIG. 3, anoiber example processed slab 380 is shown having fist region 381 of a primary ‘background fill nd second and third regions 382,383 that include srtons or veins (ex, according 0 a predefined pattem). In various example embodiments, example pro- cessed slab 380 inclides one or more features described above with reference to example slab 80 10058] One or more ofa top major surece 360, a bottom ingjor surface 361, andor edges 362 have a tactile andr visible texture, For example, the primary fil 81, region 352, andlor region 388 have surecefestres that fer in fone oF more respects. In an example enkodiment, the regions 382 and 383 ae recessed Below of raised above the average thickness of the procested slab, Allematvely or ‘ditionally, the regions 382 and 353 have a surface char- sctrsties ce texte that differs compared to primary or background fill 381, such as a different roughness (or sesocthness), gos, o other tatelypereptiblediference [0059] In various example embodiments, slab 350 includes any somber, combination, patter, andor propor tion of particulate fils and mixes. For example, the pro- cessed slab 350 can inlude to, three four, ive en, or any appropriate number of particulate mineral mixes to provide any appropriate numberof regions (eg dllerent percep- Aiblepaterseins).Inanother example, the primary ill 381 ‘may not oecupy a majoiy of the processed slab 380 (es. the processed shib 380 may incinde a substantially contin ‘ous colletion of regions without aay one ofthe panculate fll ypes occupying an ientifiably primary’ or major potion ‘of the volume of the processed slab 80). In some embodi- ‘ments, processed slab 380 inclodes one or more regions 381, 352, 353 of diferent palate mineral mixes andor dit- Tere surface characteristics (eg, according oa predefined pater. 10060] ‘The processed slab 30 has 2 width Wanda length L (ea at least 2 feet wide by at lest 6 fet long, and ‘rwcen about 3 feet and feet wide and between about 6 foot an! 14 foot long, preferably about 4.5 feet wide (more particularly, about 140m wide) by about 10 fet long nore Particularly, about, 310 cm ong). In genera, te length L nd the width W define a top major surface 360 (eg, fice) and a bottom major surlace (e fae) 361. The processed slab 350 also has a thickness T between the top major surface 360 and the botiom mje surlace 361. The peinh= cry ofthe processed slab 380 inchudes a collection of edge faces 382 10061] Esch slab 350 can comprise a quartz material andlor other particulate mineral material that, when mixed ‘with pigments and a resin binder and subsequently com- ‘pressed and cure, provides hardened Slab product suitable far use i living oF Working space (2. aloug a couaterop, tube, flor, o the lke). AS shown in FIG. 3, each slab 380, ‘may be formed Irom combination particulate mineral Nov. 17, 2022 sixes that have different hardnesses andlor resistances to abrasion, and optionally different colors and textures. The particulate mineral mixes are arranged ina slab mold (eg, slab mold 730 shown in FIG. 7), to provide the predeter. ined regions of selected strationsveine and/or other pat= ‘ems. In some embodiments te pattems may be generally repeatable for each separately molded slab, for example by dispensing different particulate mineral mixes (eg, dillerent harnesses, diferent resistance to abrasion, different pig- ments, dffereat mineral compositions, diferent additives) ‘according to predefined and repeatable dispensation pattem into the mold until filled. The mold is closed and then transported for compaction, curing, abrading, and other operations. [0062] As shown in FIG. 3, the pattem of regions 381, 382, and 353 provide a surface appearance having one oF ‘more veins or other visible features. In some embodiments, veins 382 and 353 extend at least partly across the major surfaces 360, 361 an the edges 362 (the thickness), For ‘example, slab 350 can include a widkhwise vein that extend’ parly or entirely in a generally widthwise direction, a Tengthwise vein that extends partly or entirely ina generally lengthwise direction. Altematively or additionally, one or ‘more veins extend in angled or varying directions partly or entirely aoross the Ienath L andor width W ofthe processed slab 380, Insomte embodiments, the veins also extend parly (uch as vein 352 or entirely (such as vein 353! through the thickness of the processed slab 380 (e.g, thereby providing 1 vein appearance even when the slab is cut and edged to specific shapes in living or working space, such as along a countertop, table, floor, or the like). In some embodiments, each processed slab 350 ina set of separately molded slabs can include te regions of ffernt particulate mineral mixes, Aispensed into the mold (e., such as mold 730 shown in FIG. 7) acconting o predetined and repeatable dispensation pattems, soch that multiple slabs 380 i te se of separately ‘molded slabs ean have substantially the same appearance 10 ‘ne another. [0063] The different mixes can be compaction molded and cored in the mold so as to provide the hardened slab 380, (One ormoreaf the mixes tat are used to form the composite stone material can include organic polymer(s) and inorganic (mineral) particulate component. The inorganic (mineral) particulate componeat may include such components 28 silicon, basalt, glass, diamond, rocks, pebbles, shells, a variety of quartz containing materials, such as, for example, but not limited to: crushed quartz sand, quart patcles, and the lke, or any combination thereo. In this embodiment, all, four different paniculate mineral mixes each comprise a quart material as a predominant component, which may Include sand of various particle sizes and of different com- binations. Altematively, one or more particulate mineral iixes (that define one or mare of regions 381, 382, 353, ete, inelude litle or no quartz, such as less than 50 wt % quartz less than 40 wt % quartz less than 30 wt % quart, Jess than 20 wt % quart, less than 15 wt % quartz ess than 10 we % quar, less than $ wt % quartz less than 1 wt % quartz, or no quartz. Such composition ean provide an appearance that emphasizes characterises of one or mone diferent components ofthe particulate mineral mix, suchas ‘metal appearance. Allematively or aditionally, such com- position can create a substantially different appearance between two or more ofthe particulate mineral mixes that, sake up slab 50, such as dillereat appearances between 3 US 2022/0363600 Al frst portculte mineral mix tats predominately quar and f second particulate mineral mix that is predominately met. 10064] In th hardened, cured form ofthe slab 380, the ‘organic and inorganic materials can be linked sing binder, ‘which may include for example, mono-funtional or multi- functional silane molecules, dendimerie molecules, and the lke, that may have the ability to bind the oman and inorganic components of the composite stone mix. The binders may fuer include @ mixture of various compe- nents, such as inition, hardeners, catlysator, binding ‘molecules and bridges, o any combination thereof Some or all of the mixes dispensed in the mold may inchude com- ‘ponents tat are combined in « mixing epparats prior 19 being conveyed to the mold. The mixing apparatus can be use to blend raw material (such as the quan material, ‘onganie polymers, unsaturated polymers, and the like) at ‘arous ratios. For example, some or all of the mixes dispensed in the mokd 780 may include about 8.95% quartz aggregates to about 515% polymer resins. In adktion, ‘various additives may be added to the raw material in the mixing apparatus, soch additives: may inehide metalic pieces (ex, copper flecks or the lke), colorants, dyes, Pigments, chemical reagents, antimicrobial substances, fune sicidal agents, andthe like, or any combination thereof. In alternative embodiments, some or all of the quantiy’ of «quartz agregates (mentioned above) canbe replaced with ar include porcelain andor ceramic apgregate material {0068} ‘The regions 31, 382, and 353 each have aditirent, harness andor resistivity to abrasion when cured and hardened. In some embodiments, the dffrences in hardness sandlor resistivity to abrasion can be duet dllrenes ia the popestes and characteristics of the different paniculate ‘mineral mixes used in the formation of the slab 360, including particulate composition eg quartcontent, other tinea content, pariculate size), binder content, pigment content, average particle size, average particle hardness, andor average particle britness. In various example ‘embodimens, one or more othe particulate mineral mixes has relatively higher percent volume of quartz compared (9 ‘one of more ofthe atber particulate mineral mixes. For ‘example, the first particulate mineral mix (8. loations af primary fil 1) has a percent volume of quartz (QI) between 50% and 95%, 68% and 85%, or shout 75%. The second particulate mineral mix (elections of veins $2 and $3) has a percent volume of quar (Q2) that i less than the percent volume of quartz f the ist particulate mineral mix. Jn various example embodiments, Q2 is between O% and 95%, Ps and 90%, orabout 80% of QI. In various example embodiments, Qis between 1% and 95%, 2% and 30%, 3% and 20%, or about 13%, Altematvely or adtionally, other ‘components ofthe paniculate mineral mx canbe controlled to provide different characteristics ofthe respective mineral mixes in the hardened slab. For example, in some embosl ments the fst particulate mineral mix includes between 70% and 8% volume of quart, between % to 10% volume ofpigment, and between 10% and 20% volume resin binder. ‘The second parculste mineral mix inches between 50% and 70% volume of quartz, between 10% and 30% volume pigment, and between 5% and 30% resin binder. Altema- tively oF additional, in some embodiment, the fst par- ticulate mineral ax includes between SO wt 9 and 80% wt 9% qurte andthe second particule mineral mix includes ‘rsicen Ow % and 20 we % quartz and arater than 50 wt Nov. 17, 2022 % metal material eg. a signilicant metal composition such as described above wih reference to FIGS. 12). In some embodiments, one oF more pigmentation layers may be applied aver andor between the particulate mineral mixes. For example, some pigmentation layers may include rla- tively low volumes of quartz (¢.g., between 5% and 30%) and relatively high volumes of pigment (eg, between 10% and 30%) andor resin binder (ep. betwen 50% and 70%). Svch relative compositions of fist and second pariulate tineral mixes falta diferent response to abrasion opea- tions that facilitates @ finished surface having regions of disint texture, los, thickness, andor other perceptible surface characterises assccated with locations of the respective paiculate mineral mixes. In some embodiments, ‘arious miner! particulate components are ineluded such Silicon, basal, glass, diamond, rocks, pebbles, abel, a ‘arity of quart containing materials, such a, fr example, but no limited to: erushed quart, sand, quart parle, and the like, or aay combination thereof, to fciitate a prede- temnined response to abrasion operations [0066] The metal composition of one or more particulate ties can be selected to allect a hardness ofthe cued slab 350 ina region defined by te paiculte mineral mix. Inn example embodiment, one or more particulate mineral ties inludes predominately metal, sch s grater than 50 ‘1% of sinless ste! material. Such a compotion can provide a region that has relatively lower hardaess andlor less resistance to abrasion in the hardened slab 50, 08 compared to regions defined by paniculate mineral mixes having relatively high quartz composition. [0067] In some embodiments the regions 381 can define a muajority of the major surface 360, ad regions 382 and 383 can deine one oF me veins extening t east partly across the major surface 360, For example, the primary fill ean occupy the regions 361 within the skb 30, and other particulate mineral mines form the regions 382 and 383, ‘which extend partly or entirely aerosthe surfices and edges of the slab 380, [006e} Ia some implementations, substantially the extre tnsjr sufae 360 can be abraded substantially uniformly. For example, the same type and duration of abrasion canbe applied acres the ene major surface 360 (eg. causing substantially all of the primary fil exposed atthe major surface 360 ia the reioas 381 to erode to substantially the Same average depth, and causing the regions 352 and 35310 each erade other own respective averae depts across the erie major surface 360, {0069} In some implementations, the fst set of regions cam have a ist textare and the second set of regions can fave a second texture different from the Bist texture, For example, the region 381 may have a sooth, lossy texture, while the regions 382 andor 389 may have a relatively rough, mate texture. {W0TO] FIG. 4 is aside view of the procesed sab 380 undergoing an example surface treatment proces. An abra- sive brush 200 abrades substantially all oF the top major surface 360 of the processed slab 380 to expose a processed fave, For example, te aesive brush 200 applies the same abrasion (¢.g., same abrasion parameters) over the entire top. tmsjr surface 360 without distinction between repions of iflerent particulate mineral nes (€., resions 381,382, 4353), As the abrasive brush 200i rated and drawn aerse ‘he op major surface 360, a small amount ofthe processed slab 350 a the op major surface 360 is removed US 2022/0363600 Al [0071] The primary fill 381, the veins 382, and the veins 353 are formed fiom diferent mineral particule mixes juving diferent physical characteris, such as difeest cured hardoesses, textures, material composition (¢2., re- dlominately metal, prsdominately quar, et.) andlor ress tanees to abrasion in the processed slab $0. As such, the primary fll 381, snd the veins 382 and 383 define diferent regions of dllorent cured harnesses, textures, or resistances to abrasion across the top major surface 360. When stb- {ected to abrasion by the abrasive brash 20, the primary fill 351, the vein 352, and the vein $8 erode or otherwise react to the abrasion at relatively dierent rates andor in diferent [0072] nan example embodiment, tbe veins 352 and 383 a relatively susceptible to the abrasion of brash 200 and relatively more materi x removed at locations of veins 352 and 383 98 compared to region 381 (eg, during each pass of brush 200 andr over the course ofan entire abraing operation) In an example embodiment, the veins 382 andor 353 are defined by a paniculate mineral mix of pedomi- nately metal and relatively less or no quartz For example, the vein 352 envdes to an average thickness Ty and the ‘primary fill 381 erodes to an average thickness, In some ‘embosimenis the major fill 381 can be relatively less resistant to abrasion than the veins 382, 383, w provide a substatlly inverse effete, withthe primary ill having an average thickness T, andthe veins 382, 383 having an verge thickness T,). As such afer abrasion, the majo top face 360 has a thickness that varies betwoen locations of primary fil 381 and veins 382 and 383 (¢, elative to an verge thickness of th processed slab), and inslues peaks, valleys, and plateaus that canbe felt andor seen. In some cembexhimens, the rstiting texture can have @ mate finish appearance andor texture, alos finish appearance andor texture, or combinations of Boh (ea primarily glossy surface with mate textured veins running 2s i). [0073] tn some implementations, abradiag the major su face 360 ofthe cued sab 380 can include abrading by at least one of an abrasive brush ad mechanical aplication af an abrasive fuid compound. For example, the example abrision brush 200 can be used to apply Mid compound containing abrasive material the major sulace 360 10074] Insome implementations, each ofthe textures can be define by one or more of roughaess, los, and average thickness extending perpendicular tothe slab wid and the slab length. For example, the region 381 and the regions 382,383 can each be made up of mineral particulate mixes ‘that each have particles that are more counded or more faceted in shape, or have paniculates or binders that have selatively diflereat ia terms of light absorption and reflec- Livy, or exhibit relatively diffrent levels of receptivity polishing. In another example, as deserted above, the texture can be defined by some areas having. dierent thicknesses than others (eg. the example veins 382, 353 hhave an example thickness of T, wheres the example primary fil has an example thickness of Ty, resulting in boundaries where the transitions between the diferent thick nesses can bo felt oF Soe. 10075] One or more diferent characterises of the par ticulate mineral mixes that define regions 381, 382, 353, andor different sure treatments of regions 381, 352388, Yields one oe more perceptible dilleences in the fashed Slab nan example embodiment, ane oF mor regions can be characterized by rllectivity, Reflectivity is mecsured under Nov. 17, 2022 defined conditions to identity direct reflection, diffe reflection, and toa reflection values. Por example, a surface location of the slab (eg., a locaton on region 352) is illuminated by a predefined light source at a predefined tangle of incidence, such as 15 degrees, 30 depres, 45 degrees te. The reflected light is measured and quantified, including direct, diffuse, and total reflectance, for example. ‘The resulting values provide an indicator ofthe magnitude of the reflected light, as well as whether Tight is reflected evenly in many directions, intensely focused in certain directions (e., providing & quantifiable “sparkle” effet), ere. {0076] In an example embodiment, region 382 (e2., defined by a particulate mineral mix having a high metal content exhibits a relatively high dret reflectivity andor diffuse reflectvely (ea, while also havin a textured /non smooth surface). The relatively high reflectivity (eg. ela- tively high difse reflectivity) can representa relatively high metallic sheen, luster, andor intensity. In an example embodiment, region 382 is defined by a fist (x. averaue) diffe reflection anda second fe, average) direct rellee- tion. {0077] In some embodiments the reflection values pro- idea numeric indicator of relative similarity difference, For example, reflectivity (e., dre, difuse, andor total) difer between regions 351,352, 353, based on the surface texture tnd characteristics ofthe materials tht define these rezions. ‘A smooth, lossy surfice can exhibit @ relatively higher rect reflection andlor reatvely lower diffs reflection. A textured, metallic surface can exhibit a relatively higher diffuse reflection. {0078} Aitematively or additionally, reflectivity (ex, direc, diffse, and/or total) provides a metic to qualify set of slabs having the same characterises. For example, the systems, materials, and processes descrip herein facilitate manufacturing of a set of slabs having @ predefined pattern and appearance. Reflectivity of one oF more of regions 381, 352, 353, of slabs ofa same type having the same predefined paltern have relectivity values eat same location on the slabivithin a same region 381, 352, 383) that are consistent (eg, without 15%, within 10%, within 5%, within 2%, et.) of one another. {0079] FIGS. $A and SB are enlarged sectional perspee- tive views of example processed slabs. In various example embodiments, slib 500 may inchce one or more features of slab 80 andor 380 described above with reference to FIGS, 1 through 4 [0080] The slab $00 has a major surface (or face) S10 that is generally defined by an average thickness T ofa primary fil $81 (ea pariculate mix that makes up a majority of te volume of the slab $00). collection of veins $82 and collection of veins $53 extend partly andr entirely across tie major surface $10 andlor through the thickness ofthe slab $00. The veins 582 are recessed below the major surface 510 to an average thickness T, and the veins 858 are be recessed below the major surface $10 to an average thick- ness T, that is different from T, and/or Ts. The difference between the thicknesses, and’ provide the major surface 510 with athree-

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