Patent Application
20140272250
1. Technical Field
The present invention relates to a restructured slab. In more particular, the present invention relates to a slab such as stone, wood or the like which includes a primary component and a secondary component which fills a fissure, crack or break in the slab. The secondary component restoring the structural integrity and/or providing a continuous surface and the secondary component configured to provide a noticeable contrast in appearance to the primary component.
2. Background and Relevant Art
In recent years, natural stone has been increasingly utilized in homes, corporate/business buildings and other architectural projects. Modern advancements in manufacture have increased the availability of these products to a wider demographic than was previously possible. Other slab products are also often utilized in these projects. Reclaimed and slab wood, metals and other materials products are also often incorporated into similar projects.
One of the drawbacks of stone slabs, manufactured solid surface countertops, heavy wood planks and other such materials is that fissures, grooves, scratches, cracks and even breaks can occur in the material. A number of different techniques and systems have been developed to repair, fill, or resurface the perceived anomalies. The object of such repairs is to hide, cover-up or otherwise reduce the appearance that the anomalies ever existed. For example, a similar colored or textured filler may be utilized to fill a crack so that the end user does not notice that such anomaly ever occurred. Alternatively, the cost or value of such repaired item may be discounted, wholesaled or otherwise sold for less than full retail value due to the perceived imperfections.
In some cases, the material may be trashed, used for scrap or otherwise discarded due to the perceived deficiencies or loss in value from the anomaly. Alternatively, the countertop, slab, flooring, table or other element incorporating the repaired item may be replaced, clearanced or “sent to the bone yard” due to the perceived failure. The material may even be ground down to be utilized as a substrate for a manufactured product. Considering that natural stone, authentic or reclaimed wood, or other products are a scarce material that can be costly to obtain and even more costly to manufacture, the perceived diminution in value can result in unnecessary waste. Even where a use for the product is found, marginalization of desired applications can lead to under-utilization of expensive, rare or hard to find items.
The present invention is directed to a slab in which a fissure void, such as a break in the slab is filled with a filler element. The filler element being configured to secure a first lateral portion and a second lateral portion so as to restore the structural integrity and/or the continuity of the upper working surface of the slab. The filler element being designed to have material properties to emphasize that the filler element is comprised of a different material than the slab material. For example, the filler element may have a second fill component such as color, beads, glitter to emphasize and provide an overall look and feel of the slab which is different in nature than the original slab being repaired. In another embodiment, the filler element itself may be comprised of a material having a high contrast to the slab such as the utilization of a metallic filler element with a stone slab.
The slab material can be a broken slab of stone, such as a granite counter top. Alternatively, the slab material may comprise an antique or reclaimed wood slab having a large crack or other surface anomaly. According to one embodiment of the present invention, the filler element is utilized to repair an unintentionally cracked or broken solid surface material. According to another embodiment of the present invention, the previously broken slab may be intentionally sought out to provide a different design arrangement than a regular solid surface material. According to another embodiment of the present invention, the slab may be intentionally cut, cracked or otherwise altered to provide first, second and possibly one or a plurality of additional elements allowing the introduction of different material properties to emphasize design elements not contained in the original slab.
In one exemplary embodiment, multiple slab materials are combined using a filler element to create a combined element having a first portion which is comprised of a first material and second component comprising a second material. For example, a first element may comprise a reclaimed teak slab of wood, a second element may comprise a piece of granite, the filler element may comprise an epoxy filler with glass beads integrated therein. According to another embodiment of the present invention, a first portion may comprise one variety of natural stone and a second portion may comprise a different type of lateral stone. In yet another embodiment, a natural stone piece which is broken from a larger slab may be surrounded with a composite or glass material emphasizing the contrast between the natural stone and the other elements of the slab.
A fissure void 130 is positioned between first lateral portion 110 and second lateral portion 120. In the illustrated embodiment, fissure void 130 is a result of a crack or break. In the illustrated embodiment, fissure void 130 is jagged and winds angularly through slab 100. While the manner is which fissure void 130 was formed is not suggested, the crack or break could be the result of inherent weakness within slab 100. Alternatively, the crack or break could result from being dropped or impacted during manufacture, finishing, installation, transportation or through user error. Alternatively, the crack or break could occur intentionally to open the door to incorporating additional elements therein.
Fissure void 130 includes a first sidewall 132 and a second sidewall 134. First sidewall 132 corresponds with first lateral portion 110. Second sidewall 134 corresponds with second lateral portion 120. The distance between first sidewall 132 and second sidewall 134 defines a cross-sectional dimension of fissure void 130. The length of fissure void 130 is defined by the position of fissure void 130 along slab 100, including the angle, extent to which fissure void 130 is straight, winding or otherwise extends along slab 100. In the illustrated embodiment, fissure void 130 creates a complete separation between first lateral portion 110 and second lateral portion 120. It will be appreciated by those skilled in the art that a fissure void may extend through only a portion of slab 100. Additionally, the fissure void may not extend through the entire thickness of the slab. The fissure void may comprise a crack or groove. According to one embodiment, the fissure void may change along the length of the slab. For example, the fissure void may begin as a crack somewhere in the middle of the slab and extend to a periphery of the slab where a clear break extending through the entire thickness of the slab is present. Alternatively, the fissure void may be a missing portion of the slab. One portion of fissure void may be natural while another portion of the fissure void is cut, etched or otherwise man-made.
Slab 100 is one example of a first component which forming the body of the slab or other slab, plank, manufactured surface or related material. First lateral portion 110 is one example of a first portion of the first component. Second lateral portion is one example of a second portion of the first component. Fissure void 130 is one example of a void or fissure component. Fissure component can comprise a crack, break, slot, groove or other discontinuity within the first component. According to one embodiment of the present invention, the fissure component creates an identifiable degree of separation between the first portion and the second portion.
Filler element 140 is designed to have a different composition, color, design, reflectivity or otherwise draw a contrast to the composition of first lateral portion 110 and second lateral portion 120. In this manner, filler element 140 provides a secondary component to slab 100 than first lateral portion 110 and second lateral portion 120. In this manner, the presence of a fissure void 130 such as a break, crack, groove, cut, scratch is utilized as an opportunity to create a different type of slab, instead of a failure which diminishes the ability to utilize, install or otherwise take advantage of the slab.
In the illustrated embodiment, the cross-sectional dimensions of filler element 140 are determined based on the separation of first lateral portion 110 and second lateral portion 120 and from the thickness of slab 100. During manufacture of slab, filler element is injected, pressed, flowed or otherwise introduced into fissure void 130 between first lateral portion 110 and second lateral portion 120. According to one embodiment of the present invention, the filler element does not extend along the entire length of the fissure void. According to another embodiment of the present invention, the filler element does not completely extend through the entire thickness of the slab component. According to another embodiment of the present invention a board, brace or other support is provided underneath the slab to add strength to the portion of the slab coextensive with the fissure void.
In the illustrated embodiment contrast component 144a is contained within fill component 142a. Contrast component 144a is depicted as a plurality of colored beads comprised of glass, plastic, ceramic, metal, wood or other material. Contrast component 144a provides an element that further highlights the presence of filler element 140a while emphasizing that is separate and different than first lateral portion 140a and second lateral portion 120a. As a result, instead of attempting to mask the presence of a fissure void 130, filler element instead emphasizes the presence, shape, form, length and design of the fissure void.
As will be appreciated by those skilled in the art, a variety of types and configuration of filler elements and filler voids can be utilized without departing from the scope and spirit of the present invention. For example, according to one embodiment of the present invention, filler element is comprised of glass. According to another embodiment of the present invention the filler element is comprised of epoxy, plastic, resin, glue, composite or other material. According to one embodiment of the present invention, the contrast component is an integrated component of the filler element. For example, a color may be added to the filler element which provides additional contrast between the filler element and other portions of the slab. According to another embodiment of the present invention, the contrast element is a completely separate feature such as a bead, glitter, ribbon, feather, leaf or other design component.
In the illustrated embodiment, filler element 140b is design to highlight the separation between first lateral portion 110b and second lateral portion 120b. For example, filler element 140b includes a fill component 142b and a contrast component 144b. In the illustrated embodiment contrast component 144b comprises colored glitter. Additionally a second contrast component such as a color added to filler element can be included. For example, fill component can comprise a substantially clear glass to which a purple color has been added. The contrast component can comprise a silver or gold glitter. In the embodiment, first lateral portion and second lateral portion comprise a white marble slab with grey veins. The ability to emphasize the difference between the filler element and the rest of the slab provides and opportunity for creativity, functionality and design opportunity which far surpass the use of an original or repaired unitary slab.
In the illustrated embodiment, multi-part slab 200 includes a plurality of fissures. For example, multi-part slab 200 includes a first fissure 220 and a multi-part fissure 222. First fissure 220 and multi-part fissure are filled with filler element 230. Filler element 230 comprises a fill component 232 and a contrast component 236. Filler element 230 has been utilized in connection with the fissure voids of first fissure 220 and multi-part fissure 222. Contrast component 236 is utilized in connection with the filler element 232 to emphasize the contrast between the filler element 230 and the slab of material from which multi-part slab 200 is derived.
As will be appreciated by those skilled in the art, a variety of types and configurations of multi-part slabs can be provided without departing from the scope and spirit of the present invention. For example, the slab elements of multi-part slab can be substantially varied in size as a result of the breaking of an original slab into several different size and shaped pieces. In another embodiment, the slab elements may be equally sized stripes or squares of an original slab. In another embodiment, the slab elements may be circles cut from an original slab where the filler element comprises a substantial portion of the slab between the original slab. In another embodiment, the slab elements are selected from two or more different slabs. For example, some slab elements may be from black granite and the other slab elements are from white marble. Alternatively, slab elements can be from wood, stone, leather or other materials.
A filler element 320 has been utilized in connection with first cross void element 310 and second cross void element 312. Filler element 320 comprises 320 comprises a fill component 322 and contrast component 324. In the illustrated embodiment contrast component comprises plastic or dried flowers to emphasize the filler element relative to lateral portions.
A variety of types and configurations of structured solid surface components can be utilized without departing from the scope and spirit of the present invention. For example, a structured solid surface can have a plurality of component pieces sized, spaced and selected to provide a desired size, shape and pattern desired according to one aspect of the present invention. The size, shape and positioning of the void elements can be selected to further accentuate the contrast between the component pieces and the filler elements. For example, a plurality of horizontal voids that are cut can be intersected by wavy linear voids arranged vertically to intersect the horizontal voids. In another embodiment, the voids are arranged at various angles that may or may not intersect.
A first void element 420 is positioned between lateral portion 402 and lateral portion 404. A second void element 422 is positioned between lateral portion 402 and lateral portion 408. A third void element 422 is positioned between lateral portion 408 and lateral portion 406. A fourth void element 426 is positioned between lateral portion 404 and lateral portion 406. A circular void element 428 is also depicted. Circular void element 428 is positioned between center slab portion 410 and lateral portions 402-408. In this manner a nexus is provided between an intentionally and uniformly cut portion of structured solid surface 400 and intentional breaks formed between lateral portions 402-408.
In the illustrated embodiment a filler element 430 has been utilized in connection with the void elements 420-428. Filler element incorporates a fill component 432 comprising a leather strap to emphasize the contrast between the filler element 430 and the other components of structured solid surface component 400 according to one aspect of the present invention.
Additionally a ground granite filler 606 is depicted. Ground granite filler 606 fills the discontinuity within slab 600. Ground granite filler 606 may be designed to provide additional contrast between first granite component 602 and second granite component 604. Alternatively, ground granite filler 606 may be designed to complement or even match one or both of first granite component and second granite component 604.
Quartz slab component 702 is bordered by colored glass component 704 and colored glass component 706. In this manner, a full slab can be utilized within an architectural, building or other design application. Furthermore, the color, texture and other material properties of quartz slab component are accentuated by the differing material properties, color, transparency of colored glass components 704 and 706. Thus a broken piece of stone, rather than being discarded becomes an opportunity to create something useful, functional and having a improved appearance to regular stone. Additionally,
As will be appreciated by those skilled in the art, the specific compositions, designs, textures, looks and feels of the slab materials depicted in
The present invention claims the benefit of priority to U.S. Provisional Patent Application No. 61/798,752, entitled “Restructured Slab,” filed on Mar. 15, 2013, the entire content of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61798752 | Mar 2013 | US |
