Simulated granite

Abstract

The invention is a ceramic synthetic stone product that is comprised of a brick material. The product is formed by precisely grinding out distortions of an over-sized precursor product, and grinding off at least one side of the die skin of the over-sized precursor product, therein exposing an interior surface that looks like granite. The interior surface is substantially off-white or gray with black crystalline specks. The product is a brick, a tile, an architectural stone, a curvilinear block, a trapezoidal block, or a decorative plate. The major constituents of the brick material are clay, oxide pigments, and a binder. Recycled granite can also be added as well as shale, kaolin and feldspar. The method of making the product is also disclosed.

1 . A ceramic synthetic stone product that is comprised of a brick material selected, so that when ground, the grinding exposes an interior surface of the brick material that is similar in appearance to a grade of granite.  
   
   
       2 . The product, as claimed in  claim 1 , wherein said interior surface is covered by a die skin.  
   
   
       3 . The product, as claimed in  claim 2 , wherein said die skin is disproportionately rich in a plastic amorphous component of said brick material.  
   
   
       4 . The product, as claimed in  claim 2 , wherein said interior surface is a composite of crystalline components and amorphous components, where the crystalline components are not masked by the amorphous components.  
   
   
       5 . The product, as claimed in  claim 2 , wherein said product is a vitrified brick, a tile, an architectural stone, a curvilinear block, a trapezoidal block, or a decorative plate.  
   
   
       6 . A ceramic synthetic stone product that is comprised of a brick material covered by a die skin, wherein said product is formed by reducingly grinding off at least one side of the die skin, thereby exposing an interior surface.  
   
   
       7 . A ceramic synthetic stone product, wherein said product is formed by precisely, reducingly grinding out distortions of an over-sized precursor product covered by a die skin, and reducingly grinding off at least one side of the die skin of the over-sized precursor product, thereby exposing an interior surface.  
   
   
       8 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product is a vitrified brick, a tile, an architectural stone, a curvilinear block, a trapezoidal block, or a decorative plate.  
   
   
       9 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said interior surface is similar in appearance to granite.  
   
   
       10 . The ceramic synthetic stone product, as claimed in  claim 9 , wherein the die skin is ground off all but one side of said product.  
   
   
       11 . The ceramic synthetic stone product, as claimed in  claim 10 , wherein the interior surface is fine ground to a polished finish.  
   
   
       12 . The ceramic synthetic stone product, as claimed in  claim 10 , wherein the interior surface is coated with a ceramic glaze.  
   
   
       13 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product is comprised of feldspar.  
   
   
       14 . The ceramic synthetic stone product, as claimed in  claim 10 , wherein the interior surface is finely ground to a polished surface.  
   
   
       15 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product is comprised of kaolin.  
   
   
       16 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product has beveled edges.  
   
   
       17 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product has rounded corners.  
   
   
       18 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product is comprised of: clay, oxide pigments; and a binder.  
   
   
       19 . The ceramic synthetic stone product according to  claim 18 , wherein said product is further comprised of: granite materials.  
   
   
       20 . The ceramic synthetic stone product according to  claim 19 , wherein said product is further comprised of: silica.  
   
   
       21 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said product is comprised of: shale; oxide pigments; and a binder.  
   
   
       22 . The ceramic synthetic stone product, as claimed in  claim 6 , wherein said interior surface has the appearance of a grade of granite.  
   
   
       23 . The ceramic synthetic stone product, as claimed in  claim 7 , wherein said interior surface has a speckled whitish or gray, or earth tone brown, or pink, or red, or black, or green, or blue, or a blend thereof appearance.  
   
   
       24 . The ceramic synthetic stone product, as claimed in  claim 1 , wherein said interior surface has an appearance of a speckled whitish or gray, or earth tone brown, or pink, or red, or black, or green, or blue, or a blend thereof.  
   
   
       25 . A method for making a ceramic synthetic stone product, said method comprising: 
 forming an oversized precursor product comprised of a brick based material, wherein said precursor product has at least one side;    firing the oversized precursor product forming a ceramic stone material; and    grinding at least one side therein exposing the underlying interior surface, whereby said grinding reduces the oversized precursor product to the ceramic synthetic stone product of a desired dimension.