Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    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. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    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. 
         [0004]    2. Background and Relevant Art 
         [0005]    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. 
         [0006]    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. 
         [0007]    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. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    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. 
         [0009]    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. 
         [0010]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of a slab of material having a crack, break or other void according to one aspect of the present invention. 
           [0012]      FIG. 2  is a perspective view of a slab of material in which a filler element has been utilized in connection with the void of  FIG. 1  according to one aspect of the present invention. 
           [0013]      FIG. 3  is a cross-sectional view of a slab of material in which a filler element has been utilized in connection with a void according to one aspect of the present invention. 
           [0014]      FIGS. 4A ,  4 B,  4 C and  4 D is a perspective view of a slab of material in which a filler element has been utilized in connection with a fissure void and in which a second fill component is utilized in connection with the filler element to emphasize the contrast between the filler element and the slab of material according to one aspect of the present invention. 
           [0015]      FIG. 5  is a perspective view of a slab of material in multiple breaks in the slab create a plurality of fissure voids and in which a filler element has been utilized in connection with the plurality of fissure voids according to one aspect of the present invention. 
           [0016]      FIG. 6  is a perspective view of a slab of material in which a plurality of fissure voids are formed by cuts in the slab and in which a filler element has been utilized in connection with the plurality of fissure voids according to one aspect of the present invention. 
           [0017]      FIG. 7  is a perspective view of a slab of material in which a metal filler element has been utilized in connection with the fissure void and in metal layer circumscribes the slab according to one aspect of the present invention. 
           [0018]      FIG. 8  is a perspective view of a slab of material in which the first lateral portion comprises a first type of stone such as granite and the second lateral portion comprises a second type of stone such as a second type of granite and the fill component is designed to provide a contrast between the first lateral portion and the second lateral portion according to one aspect of the present invention. 
           [0019]      FIG. 9  is a perspective view of a slab of material in which a first lateral portion comprises a solid manufactured surface, a second lateral portion comprises a natural stone component and a third lateral portion comprises a solid surface manufactured surface which is same material as the first lateral portion according to one aspect of the present invention. 
           [0020]      FIG. 10  is a depiction of another implementation of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]      FIG. 1  is a perspective view of a slab  100  according to one aspect of the present invention. In the illustrated embodiment, slab  100  is comprised of a solid surface material such as stone, wood, a manufactured product or other material. Slab  100  has an outer periphery  102  which defines the size and shape of the slab material. Slab  100  includes a First lateral portion  110  and a second lateral portion  120 . First lateral portion includes an upper surface  112  and second lateral portion  120  includes an upper surface  122 . 
         [0022]    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. 
         [0023]    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. 
         [0024]    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. 
         [0025]      FIG. 2  is a perspective view of a  100  slab of material in which a filler element  140  has been utilized in connection with fissure void  130  according to one aspect of the present invention. In the illustrated embodiment, filler element  140  fills the entire cross-sectional area of fissure void  130 . As a result, filler element  140  extends from first sidewall  132  to second sidewall  134 . As a result, slab appears to have a substantially continuous and unbroken configuration, such that upper surface  112  of first lateral portion  110  and upper surface  122  of second lateral portion  120  is coextensive with an upper surface of filler element  140 . Additionally, filler element  140  can be configured to provide structural integrity to slab  110 . For example, according to one embodiment of the present invention, filler element  140  is comprised of a material which binds to first sidewall  132  and second sidewall  134  so as to secure first lateral portion  110  relative to second lateral portion  120 . 
         [0026]    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. 
         [0027]    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. 
         [0028]      FIG. 3  is a cross-sectional view of a slab  100   a  in which a filler element  140   a  has been utilized in connection with fissure void  130   a  according to one aspect of the present invention. In the illustrated embodiment, filler element  140   a  includes a fill component  142   a  and a contrast component  144   a . Fill component  142   a  comprises a substantially clear or translucent material that allows contrast component  144   a  to be readily identifiable or seen within filler element  140   a . In the illustrated embodiment, fill component  142   a  comprises a plastic, epoxy, resin or other composite which is designed to secure a first lateral portion  110   a  of slab  100  to second lateral portion  120   a  of slab  100   a . Fill component  140   a  is designed to securely fasten to first sidewall  132   a  and second sidewall  134   a . Fill component  142   a  provides the overall length and cross-sectional dimensions of component  142   a.    
         [0029]    In the illustrated embodiment contrast component  144   a  is contained within fill component  142   a . Contrast component  144   a  is depicted as a plurality of colored beads comprised of glass, plastic, ceramic, metal, wood or other material. Contrast component  144   a  provides an element that further highlights the presence of filler element  140   a  while emphasizing that is separate and different than first lateral portion  140   a  and second lateral portion  120   a . 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. 
         [0030]    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. 
         [0031]      FIG. 4A  is a perspective view of a slab  100   b  in which a filler element  140   b  has been utilized in connection with the fissure void  130   b . In the illustrated embodiment, slab  100   b  comprises a first lateral portion  110   b  and a second lateral portion  120   b  in which the first lateral portion  110   b  is comprised of the same material as second lateral portion  120   b . For example, first lateral portion  110   b  is comprised of a marble slab and second lateral portion  120   b  is also comprised of the marble slab. In the instance in which the first lateral portion  110   b  and second lateral portion  120   b  are formed from a cracked or broken piece of the same material, any veins in the marble would be present from the portion of first lateral portion  110   b  adjacent to fissure void  130  to extent of second lateral portion  120   b  positioned on the other side of fissure void  130 . This creates a unique and unitary design. 
         [0032]    In the illustrated embodiment, filler element  140   b  is design to highlight the separation between first lateral portion  110   b  and second lateral portion  120   b . For example, filler element  140   b  includes a fill component  142   b  and a contrast component  144   b . In the illustrated embodiment contrast component  144   b  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. 
         [0033]      FIG. 4B  is a perspective view of a multi-part slab  200  according to one aspect of the present invention. In the illustrated embodiment, slab elements  202 ,  204 ,  206 ,  208 ,  210 ,  212 ,  214  and  216  comprise the majority of the slab elements. Slab elements  202 - 216  are arranged in substantially the same configuration as they were arranged before the slab was broken into slab elements  202 - 216 . In this manner, the overall look of multi-part slab  200  is that of an original, but broken slab of solid surface material. In this manner, the end user can appreciate the overall look, dimension and feel of the original slab. 
         [0034]    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. 
         [0035]    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. 
         [0036]      FIG. 4C  is a perspective view of a structured solid surface component  300  comprised of first lateral portion  302 , second lateral portion  304 , third lateral portion  306  and fourth lateral portion  308 . In the illustrated embodiment, lateral portions  302 - 308  comprise squares of the same slab material. A first cross void element  310  is intersected by a second cross void element  312 . In the illustrated embodiment first cross void element  310  and second cross void element  312  are substantially straight and linear in nature. First cross void element  310  intersects second cross void element  312  perpendicularly at a right angle. First cross void element  310  and second cross void element  312  having a substantially uniform width such that lateral portions  302 - 308  are arranged in a square. 
         [0037]    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. 
         [0038]    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. 
         [0039]      FIG. 4D  is a perspective view of a structured sold surface component  400  according to one embodiment of the present invention. In the illustrated embodiment, structured solid surface component  400  comprises first lateral portion  402 , second lateral portion  404 , third lateral portion  406  and fourth lateral portion  408 . A center slab portion  410  is also depicted. Center slab portion  410  is substantially circular in nature and is designed to fit into circumferential portions of lateral portions  402 - 408 . 
         [0040]    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 . 
         [0041]    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.  FIG. 4D  depicts a contrast component  434 . 
         [0042]      FIGS. 5 and 6  depict the addition of a filler medium into a void in the slab material. According to one embodiment of the present invention, a filler is flowed into a crack, break, groove, slot or other discontinuity within the slab. A backing may be provided to ensure the retention and proper filling of the discontinuity or other void. According to another embodiment of the present invention, the filler material is injected or extruded into the fissure void. A variety of types and configurations of filler materials can be utilized. For example, a resin, acrylic, epoxy, glass, polymer or other material can be utilized. According to another embodiment of the present invention a recycled material can be utilized for one or both of the filler material and the contrast material. A variety of types and configurations of filling the discontinuity can be utilized by those skilled in the art without departing from the scope and spirit of the present invention. 
         [0043]      FIG. 7  is a perspective view of a slab of material in which a metal filler element has been utilized in connection with the fissure void and in metal layer circumscribes the slab according to one aspect of the present invention. In the illustrated embodiment a stone slab  500  is illustrated. Stone slab  500  provides the bulk of the body of the slab. Stone slab  500  comprises a first slab component  502  and a second slab component  504 . In the illustrated embodiment a metal fill element  506  is utilized to fill the discontinuity in the slab that separates first slab component  502  and second slab component  504 . A metal boundary  508  is also provided. Metal boundary  508  circumscribes the outer periphery of stone slab  500 . Metal boundary may be comprised as the same material as metal fill element  506 . Alternatively, metal fill element  506  may be comprised of a secondary metal material to provide an additional level of layering or appearance. Metal boundary may provide additional structural integrity according to one aspect of the present invention. 
         [0044]      FIG. 8  is a perspective view of a slab of material in which the first lateral portion comprises a first type of stone such as granite and the second lateral portion comprises a second type of stone such as a second type of granite and the fill component is designed to provide a contrast between the first lateral portion and the second lateral portion according to one aspect of the present invention. In the illustrated embodiment, a composite stone slab  600  is depicted. Composite stone slab includes a first granite component  602  and a second granite component  604 . First granite component may be of a different color, grain, texture or may otherwise be formed of a different stone material than second granite component. 
         [0045]    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 . 
         [0046]      FIG. 9  is a perspective view of a slab of material in which a first lateral portion comprises a solid manufactured surface, a second lateral portion comprises a natural stone component and a third lateral portion comprises a solid surface manufactured surface which is same material as the first lateral portion according to one aspect of the present invention. In the illustrated embodiment, a multi-part slab  700  is depicted. Multi-part slab  700  includes a first quartz slab component  702 , a colored glass component  704  and a colored glass component  706 . By utilizing a quartz slab component  702 , which may be a broken piece from a larger original stone slab, a piece of stone material which was likely to be discarded may be recycled, reclaimed or otherwise repurposed. 
         [0047]    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,  FIG. 9  depicts a first interface  708  and a second interface  710 . 
         [0048]    As will be appreciated by those skilled in the art, the specific compositions, designs, textures, looks and feels of the slab materials depicted in  FIGS. 1-9  are illustrative in purpose.  FIGS. 1-9  are not intended to limit the scope or extent of possible alternatives of restructured slabs within the scope of the present invention. A variety of slab materials, filler materials, enhancement features can be utilized without departing from the scope and spirit of the present invention. For example, the slab may comprise a cracked or broken piece of glass, stone, wood, manufactured material or other material which is conducive for a secondary filler material. According to another embodiment of the present invention, the filler material is designed to provide primarily a different look and feel of the slab and is not structural in nature. According to another embodiment of the present invention, the restructured slab does not have a substantially continuous surface, but instead is designed to have differing material properties. 
       LIST OF REFERENCE NUMBERS 
       [0000]    
       
         
           
               100  Slab (first component) 
               102  Outer periphery 
               110  First lateral portion (first portion) 
               112  Upper Surface 
               120  Second lateral portion (second portion) 
               122  Upper Surface 
               130  Fissure Void 
               132  first sidewall 
               134  second sidewall 
               140  filler element 
               142  fill component 
               144  contrast component 
               200  multi-part slab 
               202 - 216  slab elements 
               220  first fissure 
               222  multi-part fissure 
               230  filler element 
               232  fill component 
               236  fill component 
               236  contrast component 
               300  structured solid surface component 
               302 - 308  first-4th lateral portions 
               310  first cross void element 
               312  second cross void element 
               320  a filler element 
               322  fill component 
               324  contrast components 
               300  structured solid surface component 
               302 - 308  first-4th lateral portions 
               310  a first cross void element 
               312  an intersecting void element 
               320  a filler element 
               322  fill component 
               324  contrast components 
               400  structured solid surface component 
               402 - 408  first-4th lateral portions 
               410  center slab portion 
               420 - 426  void elements 
               428  circular void element 
               430  filler element 
               432  fill component 
               434  contrast components 
               500  stone slab 
               502  first slab component 
               504  second slab component 
               506  metal fill element 
               508  metal boundary 
               600  composite stone slab 
               602  first granite component 
               604  second granite component 
               606  ground granite filler 
               700  multi material slab 
               702  quartz slab component 
               704  colored glass component 
               706  colored glass component 
               708  first interface 
               710  second interface

Technology Category: 4