Patent Publication Number: US-9427998-B2

Title: Method and apparatus for forming an image in stone

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of non-provisional patent application Ser. No. 13/102,313, filed May 6, 2011, which in turn is a continuation-in-part of U.S. Pat. No. 7,958,822, issued Jun. 14, 2011. 
    
    
     FIELD 
     This invention relates to the formation of images in porous solid materials and more particularly to a method and apparatus for forming an image in a sheet of stone. 
     BACKGROUND 
     Stone such as marble and granite are used for many purposes including counter tops, door sills, decorative inlays and the like. For many applications, the natural colors and random patterns are desired for aesthetic reasons. 
     In some applications, it is desired to impregnate the natural stone with a design or image. Such applications include decorative replacements for stained glass and photographic images in monuments, etc. Prior attempts at such have produced limited results with superficial images that wear with time. 
     Some prior art includes methods of printing on stone. For example, U.S. Pat. No. 5,916,662 to Schmidt shows how to print on a coating on the stone. Unfortunately, the coating covers the stone and detracts from the aesthetic appeal of the stone and the coating can separate from the stone. 
     U.S. Pat. No. 6,569,277 to Gibbs shows how to transfer an image onto the surface of a material including a leaf and stone. Unfortunately, placing the image on the surface results in an image that is easily scratched. 
     U.S. Pat. No. 6,686,315 to Creed has a method of making a building material that simulates the look of marble or granite that may include lettering, etc. This method uses a coated substrate as in U.S. Pat. No. 5,916,662 and, therefore, does not present natural stone to the viewer. 
     U.S. Pat. No. 7,108,890 to Horne, et al, also requires a coating or matrix to be applied to the stone before introducing the image and, therefore, does not present natural stone to the viewer. 
     What is needed is a method of impregnating a stone material with an image that will augment the natural beauty of the stone with an indelible image. 
     SUMMARY 
     In one embodiment, a method of imbedding an image in a stone substrate is disclosed including printing an image onto a first planar surface of a stone by transferring inks directly from a printer to the first planar surface of the stone without the inks being deposited on an intermediate medium then waiting for the inks to transfer into the surface of the stone substrate. The above steps are repeated until the image is imbedded into the stone substrate. Optionally, the above steps are repeated by printing an image (e.g. a mirror image of the image) on the opposite side of the stone. 
     In another embodiment, a method of imbedding an image in a stone substrate is disclosed including printing an image onto the first surface of the stone substrate by transferring inks directly from a printer to the first planar surface of the stone without the inks being deposited on an intermediate medium then placing a moist towel over the first surface of the stone substrate, placing a weight/mass over the moist towel, and evacuating an opposing surface of the stone substrate. Next, waiting for the image to sublimate into the stone substrate then removing the moist towel and weight/mass. The above steps are then repeated until the image is imbedded into the stone substrate. 
     In another embodiment, a method of imbedding an image in a sheet of stone is disclosed including printing an image directly onto a first surface of the stone, whereby inks from a printer passes directly from the printer to the first surface of the stone without the inks being deposited on an intermediate medium and evacuating an opposing surface of the stone. Next, wait for the image to sublimate into the stone and then repeat the above steps until the image is imbedded into the stone. Optionally, these steps are repeated, printing an image from the opposite side of the stone, for example, a mirror image of the image is printed from the opposite side of the stone. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
         FIG. 1  illustrates an image to be imbedded into a stone substrate. 
         FIG. 2  illustrates a side view of the layers used in creating an image in stone of a first embodiment. 
         FIG. 3  illustrates a side view of the layers used in creating an image in stone of a second embodiment. 
         FIG. 4  illustrates a plan view of a finished image in stone. 
         FIG. 5  illustrates a flow chart of a method of imbedding an image in stone. 
         FIG. 6  illustrates a second flow chart of a method of imbedding an image in stone. 
         FIG. 7  illustrates a block diagram of a system for printing an image in stone. 
         FIG. 8A  illustrates a second block diagram of a system for printing an image in stone. 
         FIG. 8B  illustrates a third block diagram of a system for printing an image in stone. 
         FIG. 9  illustrates a schematic diagram of a typical computer system. 
         FIG. 10  illustrates a third flow chart of a method of imbedding an image in stone. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
     Referring to  FIG. 1 , a front plan view of a printed image  10  to be imbedded into a stone substrate  20  is shown. In some embodiments, the image has a border area  14  where no image is present, usually white. 
     Referring to  FIG. 2 , a side view of the layers used in creating an image in stone of a first embodiment is shown. To create an image in a stone substrate  20 , one or more repetitions of the following steps are performed until the image  12  is imbedded/sublimated in the stone substrate  20 , being visible from both sides. The steps include printing an image using a computer printer and placing the image  10  face down on the on the substrate  20 , placing a moistened towel  22  completely covering the image  10  and placing a planar weight  24  over the moistened towel  22 . The image  10 , moistened towel  22  and planar weight  24  are left on the stone substrate  20  for a period of time to allow inks from the printed image to leach into the stone substrate  20 . In some embodiments, the image  10 , moistened towel  22  and planar weight  24  is left on the stone substrate  20  for from eight to twelve hours. Once the time period is finished, the image  10 , moistened towel  22  and planar weight are removed from the stone substrate  20  and the steps repeated as needed using a new printed image  10 . In some embodiments, the stone substrate  20  is sanded each time, before applying the image. The grit of the sandpaper is optionally increased (finer) each successive iteration of the method. For example, before the first image is imbedded, a 36-grit cup wheel is used to slightly texture the stone substrate  20 . Before the second image is imbedded, 30-grit sandpaper is used to begin to polish the stone substrate  20 . Before the third image is imbedded, 50-grit sandpaper is used to further polish the stone substrate  20 , and so fourth. It is preferred to use diamond sand paper. Any form of abrasion is anticipated including, but not limited to, we sanding, dry sanding, chemical etching, etc. Being that the image  10  is sublimated into the stone substrate  20 , the image  10  remains after abrasion. 
     It is preferred that the moistened towel be a white towel so as to not introduce any dyes during the image transfer. 
     The stone substrate  20  is preferably a planar substrate of stone such as marble or granite. A preferred stone substrate  20  is marble. A preferred marble is white Thasos Greek marble. Although the present invention works well on many varieties of stone substrates  20 , it has been found that pale white Thasos Greek marble performs best. The image  12  is formed throughout the stone substrate  20 ; therefore, it is visible from the front side of the stone substrate  20  as well as from the back side of the stone substrate  20 , one side being the mirror opposite of the other. 
     Referring to  FIG. 3 , a side view of the layers used in creating an image in stone of a second embodiment is shown. In this embodiment, a source of negative air pressure is provided to urge inks from the printed image  10  through the stone substrate  20 . To create an image in a stone substrate  20 , one or more repetitions of the following steps are performed until the image  12  is imbedded in the stone substrate  20 , being visible from both sides. The steps include placing the stone substrate  20  on a negative pressure table  32 , placing the image  10  face down on the on the substrate  20 , placing a moistened towel  22  completely covering the image  10  and placing a planar weight  24  over the moistened towel  22 . The stone substrate  20  is left with the image  10 , moistened towel  22  and planar weight  24  for a period of time to allow inks from the printed image to leach into the stone substrate  20 . In some embodiments, the stone substrate  20  is left with the image  10 , moistened towel  22  and planar weight  24  for from eight to twelve hours. Once the time period is finished, the image  10 , moistened towel  22  and planar weight are removed from the stone substrate  20  and the steps repeated as needed using a new printed image  10 . 
     The negative pressure table  32  is a source of negative pressure to urge inks from the printed image  10  through the stone substrate  20 . In the example shown, the negative pressure (vacuum) table  32  has a fan  34  for evacuating air from beneath the stone substrate  20 . In some embodiments, a gasket  30  is provided to prevent air from leaking in between the stone substrate  20  and the negative pressure table  32 . 
     Referring to  FIG. 4 , a plan view of a finished image in stone of the present invention is shown. In some embodiments, the printed image  10  is printed as a mirror copy of the final image so that when it is transferred to the stone substrate  20 , it appears as the image was intended. In other embodiments, the printed image  10  is printed as a direct copy of the final image so that when it is transferred to the stone substrate  20 , it appears as a mirror copy of the final image, but since the image is imbedded in the stone substrate  20 , it is visible from the opposite side of the stone substrate  20 . Since the image is imbedded within the stone substrate  20 , it is possible to polish, sand, grind, sand blast, texture, etc.; the stone substrate without damaging or loosing the image. 
     Referring to  FIG. 5 , a flow chart of a method of imbedding an image in stone is shown. The first step in creating an image in a stone substrate  20  is to texture  100  the stone substrate  20 , preferable with diamond sandpaper. In some embodiments, this step is omitted. The next step is to place a printed image face down  102  on the on the substrate  20 . Next, a moistened towel  22  is placed completely covering the image  10 . Next, a mass or planar weight  24  is placed  106  over the moistened towel  22 . In some embodiments, the steps include evacuating  108  the opposing side of the stone substrate  20 , in some embodiments placing the stone substrate  20  on a negative pressure table  32 . The image  10 , moistened towel  22  and planar weight  24  are left on stone substrate  20  for a period of time  110  to allow inks from the printed image to leach into the stone substrate  20 . In some embodiments, the image  10 , moistened towel  22  and planar weight  24  are left on the stone substrate  20  for from eight to twelve hours. Once the time period is finished, the image  10 , moistened towel  22  and planar weight are removed from the stone substrate  20  and if the image is not yet as clear as desired  112 , the steps are repeated as needed using a new printed image  10 . It is preferred to repeat the steps with as little time between repetitions so as to preclude the inks from the print image from drying before the next repetition. 
     Referring to  FIG. 6 , a second flow chart of a method of imbedding an image in stone is shown. The first step in creating an image in a stone substrate  20  is to texture  100  the stone substrate  20 , preferable with diamond sandpaper. In some embodiments, this step is omitted. The next step is to place a printed image face down  102  on the on the substrate  20 . Next, a moistened towel  22  is placed completely covering the image  10 . Next, a mass or planar weight  24  is placed  106  over the moistened towel  22 . In some embodiments, the steps include evacuating  108  the opposing side of the stone substrate  20 , in some embodiments placing the stone substrate  20  on a negative pressure table  32 . The image  10 , moistened towel  22  and planar weight  24  are left on stone substrate  20  for a period of time  110  to allow inks from the printed image to leach into the stone substrate  20 . In some embodiments, the image  10 , moistened towel  22  and planar weight  24  are left on the stone substrate  20  for from eight to twelve hours  110 . Once the time period is finished, the image  10 , moistened towel  22  and planar weight are removed  111  from the stone substrate  20  and the moistened towel  22  is placed over the stone substrate  20  and the planar weight  24  is placed over the moistened towel  22  for a period of time  113 . Once the planar weight  24  and moist towel  22  is removed, the image is viewed and if the image is not yet as clear as desired  112 , the steps are repeated as needed using a new printed image  10 . It is preferred to repeat the steps with as little time between repetitions so as to preclude the inks from the print image from drying before the next repetition. 
     Referring to  FIG. 7 , a block diagram of a system for printing an image in stone will be described. A processing system  210  includes a storage media  240  that has stored there with at least one image file  242 . The image file  242  is sent to the printer  280  as known in the industry and the printer  280  prints the image directly onto the stone  20 . The stone is optionally situated on a vacuum table  32 . The printer  280  deposits ink (any color or type of ink, including plain and phosphorescent inks) in the form of the image on a first side of the stone  20  and the optional vacuum table  32  creates a negative pressure on the opposing side of the stone  20 , thereby accelerating the movement/sublimation of the ink into the stone  20 . In some embodiments, a gasket  30  is situated between the optional vacuum table  32  and the stone  20 . Although any method of evacuating the opposing side of the stone  20  is anticipated, the exemplary vacuum table  32  has a fan  34  that evacuates air from the table  32 . 
     In some embodiments, the stone  20  with printed image is left on the optional vacuum table  32  until the inks are properly sublimated into the stone  20  and/or dries, perhaps for several hours. In some embodiments, after the inks are properly sublimated into the stone  20 , the printer  280  reprints the image or prints an overlay, modified image or alternate section of the image on the first side of the stone  20 . In this way, the print system provides for stacked layers of ink (again, any color or type of ink, including plain and phosphorescent inks) from the printer  280  to produce greater depth of ink layers and/or dimensional aspects to the finished stone  20 . 
     Referring to  FIGS. 8A and 8B , block diagrams of a system for printing an image in stone will be described. As in  FIG. 7 , a processing system  210  includes a storage media  240  that has stored there with at least one image file  242 . The image file  242  is sent to the printer  280  as known in the industry and the printer  280  prints the image directly onto the stone  20 . The printer  280  deposits ink (any color or type of ink, including plain and phosphorescent inks) in the form of the image on a first side of the stone  20 . 
     After the image is printed on the first side of the stone, the stone is optionally moved onto a vacuum table  32 . The optional vacuum table  32  creates a negative pressure on the opposing side of the stone  20 , thereby accelerating the movement of the ink into the stone  20 . In some embodiments, a gasket  30  is situated between the optional vacuum table  32  and the stone  20 . Although any method of evacuating the opposing side of the stone  20  is anticipated, the exemplary vacuum table  32  has a fan  34  that evacuates air from the table  32 . 
     In some embodiments, a moistened towel  22  is placed over the image and stone  20 . In some embodiments, a moistened towel  22  is placed over the image and stone  20  and a mass  24  is placed over the moistened towel. This step improves absorption/sublimation into the stone substrate  20 . 
     In some embodiments, the stone  20  with printed image is left on the optional vacuum table  32  until the inks are properly sublimated into the stone  20  and/or dries, perhaps for several hours. In some embodiments, after the inks are properly sublimated into the stone  20 , the stone  20  is repositioned against the printer  280  and the printer  280  reprints the image or prints an overlay, modified image or alternate section of the image on the first side of the stone  20 . In this way, the print system provides for stacked layers of ink from the printer  280  to produce greater depth of ink layers and/or dimensional aspects to the finished stone  20 . After the subsequent print image is deposited, the stone  20  is again optionally moved to the vacuum table  32  and the above steps are repeated. The cycle is repeated as necessary to properly sublimate the image into the stone  20 . 
     Referring to  FIG. 9 , a schematic diagram of a computer system will be described. Although shown in its simplest form, having a single processor, many different computer architectures are known that accomplish similar results in a similar fashion and the present invention is not limited in any way to any particular computer system. The present invention works well utilizing a single processor system as shown in  FIG. 9 , a multiple processor system where multiple processors share resources such as memory and storage, a multiple server system where several independent servers operate in parallel (perhaps having shared access to the data or any combination). In this, a processor  210  is provided to execute stored programs that are generally stored for execution within a memory  220 . The processor  210  can be any processor or a group of processors, for example an Intel Pentium-4® CPU or the like. The memory  220  is connected to the processor and can be any memory suitable for connection with the selected processor  210 , such as SRAM, DRAM, SDRAM, RDRAM, DDR, DDR-2, etc. Firmware and other parameters are typically stored in read-only memory or flash  225  that is connected to the processor  210  and may include initialization software known as BIOS. The initialization software usually operates when power is applied to the system or when the system is reset. 
     Also connected to the processor  210  is a system bus  230  for connecting to peripheral subsystems such as a hard disk  240 , a CDROM  250 , a graphics adapter  260 , a keyboard/mouse  270  and a printer  280 . 
     The graphics adapter  260  receives commands and display information from the system bus  230  and generates a display image that is displayed on the display  265 . 
     In general, the hard disk  240  stores programs, executable code and data persistently, while the CDROM  250  provides removable media storage. These peripherals are meant to be examples of input/output devices, persistent storage and removable media storage. Other examples of persistent storage include core memory, FRAM, flash memory, etc. Other examples of removable media storage include CDRW, DVD, DVD writeable, compact flash, other removable flash media, floppy disk, ZIP®, etc. In some embodiments, other devices are connected to the system through the system bus  230  or with other input-output connections. Examples of these devices include printers; graphics tablets; joysticks; and communications adapters such as modems and Ethernet adapters. 
     Referring to  FIG. 10 , a third flow chart of a method of imbedding an image in stone will be described. The first step in creating an image in a stone substrate  20 , which is optional, is to texture  1100  the stone substrate  20 , preferable with diamond sandpaper. Being optional, in some embodiments, this step is omitted. Any form of abrasion is anticipated including, but not limited to, we sanding, dry sanding, chemical etching, etc. Being that the image  10  is sublimated into the stone substrate  20 , the image  10  remains after abrasion. 
     The next step is to print the image  1102  on the substrate  20  using any object printer known in the industry (e.g. printers used for printing on clothing). Although the stone  20  is shown in a fixed location beneath the printer  280  (e.g. the printer&#39;s print-head is moved or deflected across the image area), any printer  280  that is capable of printing on a solid object is anticipated, including printers that move over the stone  20  and/or printers that move the stone  20  beneath the print head and/or print area, as known in the industry. Next, a moistened towel  22  is optionally placed  1104  over the image  10 . Next, a mass or planar weight  24  is optionally placed  1106  over the moistened towel  22 . In some embodiments, the steps include evacuating  1108  the opposing side of the stone substrate  20 , for example, placing the stone substrate  20  on a negative pressure table  32 . The optional moistened towel  22  and optional planar weight  24  are left over the image on stone substrate  20  for a period of time  1110  to allow inks (any color or type of ink, including plain and phosphorescent inks) from the printed image to sublimate into the stone substrate  20 . In some embodiments, the moistened towel  22  and planar weight  24  are left on the image on the stone substrate  20  for from eight to twelve hours. Once the time period completes, the moistened towel  22  and planar weight are removed  1111  from the image on the stone substrate  20 . After the planar weight  24  and moist towel  22  is removed, the image is viewed and if the image is not yet as clear as desired  1112 , the steps are repeated as needed using a new printed image  10 . It is preferred to repeat the steps with as little time between repetitions so as to preclude the inks from completely drying before the next repetition. 
     It is fully anticipated that an image  10  be printed on one side of the stone  20  and a mirror of the image  10  be printed on the opposite side of the stone  20  for additional effects and clarity. Further, it is fully anticipated that an image  10  be printed on one side of the stone  20  and a modified mirror image  10  be printed on the opposite side of the stone  20  to achieve additional effects and three-dimensional appearances. For example, the outer edges of objects in an image  10  are printed from one side of the stone  20  and the inner areas of the objects in mirror form are printed from the opposite side of the stone  20 , yielding an image in stone that appears somewhat three-dimensional. 
     Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
     It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.