Title:
Method for manufacturing synthetic decorative stone with inlays
Kind Code:
A1


Abstract:
A method for manufacturing a synthetic decorative stone with inlays includes steps of: cutting or scrunching a stone or other solid decorating materials into thin small pieces; putting the thin small pieces in a bottom of a larger mold; mixing various materials which can form a synthetic stone with adhesives and then dumping them into the mold; taking out the mixed materials with the thin small pieces surrounded therein from the larger mold after being solidified; and then polishing the surface of the side with the thin small pieces. In accordance with the present invention, the synthetic decorative stone with inlays is made by using of various materials, which saves stone materials, creates a new inlay art and increases the decorative effect.



Inventors:
Zheng, Yu (Shenzhen, CN)
Application Number:
11/484127
Publication Date:
10/25/2007
Filing Date:
07/11/2006
Assignee:
CARDINY STONE (SHENZHEN) CO., LTD. (Shenzhen, CN)
Primary Class:
International Classes:
E04B1/00
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Primary Examiner:
FONSECA, JESSIE T
Attorney, Agent or Firm:
HAMRE, SCHUMANN, MUELLER & LARSON, P.C. (Minneapolis, MN, US)
Claims:
What is claimed is:

1. A method for manufacturing a synthetic decorative stone with inlays comprising steps of: cutting or scrunching a stone or other solid decorating materials into thin small pieces with different shapes; laying out a plurality of the thin small pieces in a bottom of a larger mold according to a predetermined pattern; mixing various materials which can form a synthetic stone with adhesives and then dumping them into the larger mold; taking out the mixed materials with the plurality of thin small pieces surrounded therein from the larger mold after the mixed materials is solidified, the solidified materials with the plurality of thin small pieces inlaid therein forms a synthetic decorative stone with inlays; and polishing the surface of synthetic decorative stone of the side with the plurality of thin small pieces.

2. The method as claimed in claim 1, wherein a cutting or scrunching tool is used for cutting or scrunching a stone or other solid decorating materials into pieces.

3. The method as claimed in claim 2, wherein the cutting or scrunching tool comprises ultrasonic or water jet.

4. The method as claimed in claim 1, wherein various materials which can form a synthetic stone comprise at least one kind of materials among marble power, quartzite power or fragments, granite power or fragments, and alumina powder.

5. The method as claimed in claim 1, wherein the adhesives comprise resin adhesive or other adhesive materials which can adhere stone materials tight with the synthetic materials.

6. The method as claimed in claim 1, wherein the adhesive materials comprise unsaturated epoxy resins or polyurethane adhesives.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a field of building stone, and more especially to a method for manufacturing a synthetic decorative stone with inlays.

2. Background of the Invention

A natural decorative stone is one type of building stones which has function of decoration and can be used for architectural decoration or furniture tops. With the development of architecture conformation and styles, more and more decorative stones are used. These decorative stones are exploited from nature. Continual increasing of exploiture requirement aggravates destroying to nature.

A synthetic decorative stone is a kind of appropriate substitute of natural decorative stone, especially a synthetic decorative stone which is made of some cut-off powder and fragments from natural decorative stones. Making use of synthetic decorative stones relieves the increasing requirements to nature stones and enriches the varieties of architectural materials. A synthetic decorative stone is provided for a wide range of ornamental and architectural uses.

The art of the stone inlay was used even in the ancient India, but by far this art is embodied by manual work none the less. However, it is of course not ensured that each product of each-time production is identical to another, so this art is unable to be industrialized, and the manufacturer using this way can not have mass production based on the identical design of the order from in modern commercial distribution field.

BRIEF SUMMARY OF THE INVENTION

A primary object of the present invention is to provide a method for manufacturing a synthetic decorative stone which increases the decorative effect through inlaying cut stones with different pattern and specificity in a synthetic stone tile.

To achieve the above-mentioned object, a method for manufacturing a synthetic decorative stone with inlays comprises steps of: cutting or scrunching a stone or other decorative materials into thin small pieces; laying out the thin small pieces in a bottom of a mold as inlay units; mixing various materials which can form a synthetic stone with adhesives and pigments then dumping them into the mold; taking out the mixed materials (a synthetic stone tile) with the thin small pieces from the mold after a typical process of making a synthetic stone tile; and then polishing the surface of the side with the thin small pieces.

In accordance with the present invention, the method for manufacturing a synthetic decorative stone tile with inlays utilizes modern technologies such as ultrasonic or water jet, which brings high manufacture efficiency. Inlaying stones or other decorative materials with various patterns, shapes, and amounts into a synthetic stone tile with various layout method saves stone materials, enrich the varieties of architectural decorative materials, and increases the decorative effect.

Other objects, advantages and novel features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a synthetic decorative stone in accordance with the preferred embodiment of the present invention, which includes a synthetic stone tile and a plurality of thin small pieces inlaid therein.

DETAILED DESCRIPTION OF THE INVENTION

A method for manufacturing a synthetic decorative stone with inlays in accordance with a preferred embodiment of the present invention includes steps as follows:

At the step 1, referring to FIG. 1, on the basis of requirements of different designs, cutting or scrunching a stone or other decorative materials into thin small pieces 12 with different shapes.

Then turn to the step 2, laying out a plurality of thin small pieces at a bottom of a larger mold (not shown) according to a predetermined pattern.

At the step 3, mixing various materials which can form a synthetic stone with adhesives and pigments then dumping them into the mold. The various materials include at least on kind of materials among marble power, quartzite power or fragments, granite power or fragments, and alumina powder. The various materials are mixed with adhesives and pigments, such as, resin adhesive, AB adhesive, unsaturated epoxy resins, polyurethane adhesives or other adhesive that can adhere all materials together. The various materials surround and stick the plurality of thin small pieces 12. The mixed various materials forms a synthetic stone tile 14 with various patterns and specificities.

At the step 4, referring to FIG. 3, taking out the synthetic stone tile 14 with the inlaid plurality of thin small pieces 12 from the larger mold after the synthetic stone tile 14 is solidified. The synthetic stone tile 14 with inlaid plurality of thin small pieces 12 forms a synthetic decorative stone 10.

Finally, at the step 5, turning upside down the synthetic decorative stone 10, polishing the surface of the side with the plurality of thin small pieces 12.

As shown in FIG. 1, a synthetic decorative stone 10 is achieved according to the manufacturing method in accordance with the present invention, which includes a synthetic stone tile 14 and a plurality of thin small pieces 12 inlaid therein. The patterns, shapes, and layout method of the plurality of thin small pieces 12 are various according to the desired visual effect.

The method for manufacturing a synthetic decorative stone with inlays in accordance with the present invention utilizes modern technologies such as ultrasonic or water jet, which brings high manufacture efficiency. Inlaying stones or other decorative materials with various patterns, shapes, and amounts into a synthetic stone tile with various layout method saves stone materials, enrich the varieties of architectural decorative materials, and increases the decorative effect.

It is believed that the present invention and its advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention.