DESC:TECHNICAL FIELD
[0001] The present invention relates to a method of joining edges of light-colored stones to ensure seamless joints and improved aesthetic appeal. More particularly, it addresses the issues of edge darkening, commonly known as bleeding, caused by adhesive penetration into the porous surface of stones. Further, the present invention discloses an advanced, automated process integrating eco-friendly materials, nanotechnology, and AI-driven systems to enhance precision, durability, and sustainability in stone joining applications.
BACKGROUND
[0002] In the rapidly evolving landscape of construction and interior design, the demand for seamless and aesthetically pleasing surfaces has significantly increased. Light-colored stones, such as marble, granite, and sandstone, are widely used in flooring, walls, and countertops due to their natural beauty and versatility. However, achieving visually seamless joints between these stones remains a challenge, as conventional methods often result in darkened edges, compromising the overall appearance.
[0003] Conventional methods of joining light-colored stones involve the use of commercially available adhesives and sealers. These adhesives tend to penetrate the porous edges of the stones, leading to discoloration or darkening at the joints, a phenomenon referred to as "bleeding." Additionally, conventional processes often lack precision and rely heavily on manual application, resulting in inconsistent results and increased material wastage. The materials currently used are also not environmentally sustainable, adding to the ecological impact of these methods.
[0004] Further, the existing processes merely focus on the functional aspect of bonding the stones without addressing the need for aesthetic seamlessness, durability, or sustainability. They fail to leverage modern advancements in material science, automation, or artificial intelligence to improve the quality and efficiency of the process. Moreover, quality assurance in conventional methods is limited, as it relies on visual inspection rather than automated precision.
[0005] As a result, there is a need for a method that not only prevents the darkening of stone edges but also ensures seamless joints with improved durability and sustainability. The process should incorporate advanced automation, and integrated quality assurance to address the aesthetic, functional, and environmental challenges associated with conventional methods. As such, the present invention aims to fulfill these unmet needs and set a new standard for stone joining processes.
SUMMARY
[0006] In an embodiment, a method for joining edges of light-colored stones to achieve seamless joints and prevent the darkening of edges is disclosed. In one example, the method includes cleaning the stone surfaces using a biodegradable, pH-neutral cleaner to remove dirt and oil. The method further involves treating the stones with a bio-based fluoropolymer impregnator to render them water- and oil-repellent, followed by applying a nanocoating sealer to the edges to block pores and enhance durability. The stones are then affixed to a surface using hybrid adhesives with nano-reinforcements for superior bonding strength. Finally, the edges are joined using nano silica-enhanced adhesives to ensure minimal visibility of seams. The entire process can be automated using a robotic applicator system integrated with AI for precision and consistency, and quality assurance is performed through AI-based inspection to verify seamlessness and aesthetic appeal.
[0007] In another embodiment, a process for joining edges of light-colored stones to achieve seamless and durable joints is disclosed. In one example, the process includes cleaning the stones with a pH-neutral nano detergent cleaner to eliminate impurities and prepare the surface. The process further involves dipping the stones in a renewable fluoropolymer impregnator for 12–24 hours to enhance water and oil resistance, followed by drying. A nanomaterial-based sealer is then applied to the edges to fill micro-pores and prevent adhesive penetration. The stones are fixed to a surface using a nanocomposite adhesive, and the edges are joined with a specially formulated hybrid adhesive reinforced with silica nanoparticles to provide high strength and an invisible finish. The process integrates AI-controlled robotic applicators for precision in cleaning, sealing, and bonding, while real-time quality checks are conducted using advanced image analysis systems to ensure uniformity and flawless aesthetics.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate and not to limit the scope in any manner, wherein similar designations denote similar elements, and in which:
[0009] FIG. 1 illustrates the darkening of edges (bleeding) of light-colored stones when joined using a conventional process.
[0010] FIG. 2 illustrates the edges when joined as per the process described in the present invention.
[0011] FIG. 3 is a flowchart (300) that illustrates a method for joining edges of light-colored stones, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0012] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[0013] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[0014] The present invention addresses the limitations of conventional methods for joining edges of light-colored stones, which often result in darkened seams due to adhesive penetration into the porous edges. The method involves cleaning the stone with a pH-neutral cleaner to remove dirt and oil, followed by dipping the stone in a fluoropolymer-based impregnator to render it water- and oil-repellent. The edges are then sealed with a film-forming sealer to block micro-pores, preventing adhesive infiltration. The stone is affixed to a surface using a suitable tile adhesive, and the edges are joined with an advanced adhesive, such as epoxy or polyurethane, to ensure a seamless and durable finish. The present method not only eliminates the issue of edge darkening but also enhances the overall aesthetic appeal and longevity of the stone joints, offering an efficient solution to the challenges posed by traditional adhesive methods.
[0015] The primary objective of the present invention is to provide a process for joining edges of light-colored stones that eliminates the problem of darkened seams (bleeding) caused by adhesive penetration. To achieve this, the present disclosure aims to introduce a method that prevents adhesive from seeping into the porous edges of the stones, ensuring a seamless and visually appealing finish. The method's objective is to enhance the durability and longevity of the stone joints by using advanced materials such as fluoropolymer-based impregnators and film-forming sealers. Additionally, the present disclosure seeks to improve the efficiency and consistency of the process through automation, reducing material wastage and ensuring uniform application. Furthermore, the present invention aims to promote environmental sustainability by using eco-friendly materials and processes throughout the method.
[0016] The present invention provides a process for joining edges of light-colored stones, such as marbles, granites, and sandstones, to achieve seamless joints while eliminating darkening (bleeding) commonly caused by adhesive penetration. The process includes cleaning the stones using a pH-neutral cleaner to remove dirt and oil, dipping the stones in a fluoropolymer-based impregnator containing perfluoroalkyl methacrylate polymers for 4 to 24 hours to render them water- and oil-repellent, and sealing the edges with a film-forming sealer made of thermoplastic acrylic resin to block micro-pores. The stones are then fixed to a surface using a suitable tile adhesive and joined at the edges with advanced adhesives, such as epoxy or polyurethane, ensuring strong and durable bonding. Unlike conventional methods, the present invention integrates advanced materials such as fluoropolymer impregnators and film-forming sealers to prevent adhesive penetration and improve joint aesthetics. Furthermore, the inclusion of specific polymers and molecular compositions enhances durability and edge protection, offering a seamless, visually appealing finish. The process also addresses scalability and environmental sustainability by enabling uniform application, reducing material wastage, and using formulations compatible with diverse light-colored stones.
[0017] As according to the present invention, the pH-neutral cleaner is a cleaning solution that has a pH level of around 7, which is considered neutral (neither acidic nor alkaline). These cleaners are designed to effectively remove dirt, oils, and other contaminants from surfaces without causing damage or altering the natural composition of the material being cleaned. In the present invention, the pH-neutral cleaner works as the first step in preparing the stone surfaces for subsequent treatments. The reason for using a pH-neutral cleaner is that it gently cleans the surface without causing any chemical reactions or damage that could affect the stone’s appearance or integrity. Light-colored stones, like marble and granite, can be sensitive to harsh acidic or alkaline cleaners, which can potentially cause etching, discoloration, or surface degradation. By using pH-neutral cleaner, the stone remains in its natural, unaltered state.
[0018] Further, the cleaner works by breaking down and removing oils, dust, grease, and other contaminants that may be present on the stone's surface. It step is critical because any residual dirt, oils, or other impurities could interfere with the adhesion of the fluoropolymer-based impregnator, sealer, or adhesives applied in the subsequent steps. The cleaner ensures that the stone is free of contaminants, creating a pristine surface that maximizes the effectiveness of the later treatments. By starting with a pH-neutral cleaner, the method guarantees that the stone is properly prepped for a uniform application of the fluoropolymer and other sealers, which will help to avoid any issues with bonding or darkened seams.
[0019] As according to the present invention, the fluoropolymer-based impregnator is a specialized treatment solution that uses fluoropolymer compounds, such as perfluoroalkyl methacrylate polymers, to penetrate the surface of porous materials like stones, making them highly resistant to water, oil, and other contaminants. In the present invention, the fluoropolymer-based impregnator is applied to light-colored stones to create a protective barrier that prevents adhesive from seeping into the stone’s edges, which could cause darkening or staining (known as "bleeding"). The impregnator works by filling the microscopic pores in the stone, providing an oil- and water-repellent surface that keeps adhesives from penetrating the stone’s porous structure. It ensures that the stone edges remain clean, uniform in color, and resistant to staining, allowing for seamless and aesthetically pleasing joints when the edges are joined. Additionally, the impregnator enhances the durability of the stone by making it less susceptible to staining from everyday oils and water, ensuring long-lasting visual appeal and strength.
[0020] Further, the fluoropolymer-based stone impregnator used in the present invention preferably consists of a specific combination of compounds, including Poly (Hexadecyl Acrylate/2-Hydroxyethyl Methacrylate/Octadecyl Acrylate/3,3,4,4,5,5,6,6,7,7,8,8,8-Tridecafluorooctyl Methacrylate). This unique blend of polymers works synergistically to create a highly effective barrier on the surface of the stone, making it resistant to both water and oil penetration. The impregnator penetrates the stone's pores, filling them and forming a protective layer that prevents adhesives from seeping into the stone’s edges. It prevents the darkening effect (bleeding) typically caused by adhesive penetration and ensures that the stone edges maintain a uniform, light color.
[0021] As according to the present invention, the nanomaterial-based sealer is a type of coating that uses nanoparticles, typically made from materials such as silica or titanium dioxide, to enhance the performance of the sealer. These nanoparticles are extremely small (usually in the range of 1 to 100 nanometers), allowing them to penetrate deeper into the micro-pores of the stone's surface and create a highly effective protective barrier. In the present invention, the nanomaterial-based sealer is applied to the edges of light-colored stones to block micro-pores and prevent the adhesive from seeping into the stone, which could lead to darkening (bleeding) of the edges. The small size of the nanoparticles allows the sealer to form a dense and uniform film that seals the stone’s surface more effectively than traditional sealers, ensuring superior protection against moisture, oils, and other contaminants. The sealer not only prevents adhesive penetration but also improves the durability and longevity of the stone, enhancing both its aesthetic appeal and resistance to environmental factors.
[0022] Further, the sealer is designed to effectively block micro-pores in the stone’s edges, providing an additional layer of protection. The film-forming sealer is composed of thermoplastic acrylic resins or a mixture of these resins, which ensures a durable and protective coating. Preferably, the thermoplastic acrylic resin is a copolymer of methyl methacrylate and butyl methacrylate with a molecular weight greater than 3000. This composition ensures that the sealer forms a strong, flexible film that tightly adheres to the stone's edges, further enhancing its resistance to moisture, oils, and other contaminants, while preventing adhesive penetration. By sealing the pores effectively, the sealer plays a crucial role in maintaining the aesthetic appearance and integrity of the stone joints.
[0023] As according to the present invention, the nanocomposite adhesive is a type of adhesive that incorporates nanoparticles, such as silica, alumina, and titanium dioxide, into its base material to enhance its properties. In the present invention, the nanocomposite adhesive is used to bond the light-colored stones to the substrate and to join the edges of the stones. The incorporation of nanoparticles strengthens the adhesive, improving its bonding capabilities, flexibility, and resistance to environmental factors such as moisture and temperature fluctuations. These enhanced properties ensure a more durable, robust bond that resists breakage or weakening over time. Additionally, the nanocomposite adhesive helps prevent the darkening of the edges, as it reduces the likelihood of seepage into the stone’s porous structure. It results in a cleaner, more seamless appearance at the joints, while also contributing to the long-term performance and stability of the stone installation.
[0024] As according to the present invention, the silica-reinforced adhesive is an advanced adhesive that incorporates silica nanoparticles into its formulation to enhance its strength, flexibility, and overall performance. In the present invention, the silica-reinforced adhesive is used to join the edges of light-colored stones, providing superior bonding strength while maintaining a seamless, invisible joint. The addition of silica improves the adhesive’s mechanical properties, such as tensile strength and durability, allowing the joint to withstand external forces and environmental stresses. Additionally, silica’s unique properties, such as high surface area and excellent interaction with the stone surface, ensure a strong and uniform bond, preventing the adhesive from seeping into the porous edges of the stone and causing darkening (bleeding). This results in a clean, durable, and aesthetically pleasing finish for stone installations, with improved resistance to wear and long-lasting performance.
[0025] Figure 1 illustrates a schematic view (100) of the darkening of edges (bleeding) of light-colored stones when joined using a conventional process. Its typical result of joining the edges (101) of light-colored stones using conventional methods, where adhesive penetration causes the edges of the stone to darken. This "bleeding" (102) effect can be seen extending up to 10 mm from the joint, compromising the aesthetic appearance of the stone surface. The darkened edges create a visible seam that detracts from the seamless appearance that is desired in stone installations.
[0026] Fig. 2 illustrates a schematic view (200) of the edges when joined as per the present invention. The joints (201) appear seamless without the darkening of edges. It shows the result of joining the edges (202) of light-colored stones using the process disclosed in the present invention. In this figure, the edges of the stones remain light and uniform in color, with no visible darkening (bleeding) at the joints. The method successfully prevents adhesive penetration into the porous edges, ensuring a seamless, aesthetically pleasing appearance for the stone surface. The result is a clean, uninterrupted edge that enhances the overall visual appeal of the installation.
[0027] Let us consider a practical scenario to illustrate the working of the present disclosure. Consider a scenario where a contractor is tasked with installing light-colored marble tiles on a wall in a high-traffic area, such as a commercial building lobby. Using the method of the present invention, the contractor begins by cleaning the marble tiles with an eco-friendly, pH-neutral cleaner to remove any dirt, oils, or contaminants from the surface. The tiles are then dipped in a fluoropolymer-based impregnator for 12 hours, ensuring that the stone is water- and oil-repellent. After the impregnation, the edges of the tiles are sealed with a film-forming sealer that blocks micro-pores and prevents any adhesive from seeping in. The tiles are then securely fixed to the wall using a high-performance tile adhesive. Once the tiles are in place, the edges are joined using a silica-reinforced adhesive that ensures a strong bond and a seamless, visually appealing finish. The present method prevents darkening at the joints, resulting in a flawless installation that enhances the overall aesthetic of the space while ensuring long-lasting durability.
[0028] FIG. 3 is a flowchart (300) that illustrates a method for joining edges of light-colored stones, in accordance with an embodiment of the present invention. The method begins at step 302, the stone surface is cleaned using a pH-neutral cleaner to remove any dirt, oil, or impurities. The process then moves to step 304, where the stone is immersed in a fluoropolymer-based impregnator for a duration of 12 to 24 hours to render the stone water- and oil-repellent. In step 306, a film-forming sealer is applied to the edges of the stone to seal the micro-pores and prevent adhesive penetration. The process then proceeds to step 308, where the stone is fixed to the substrate using a suitable tile adhesive to ensure secure bonding. At step 310, the edges of the stone are joined using a high-strength adhesive, such as epoxy or polyurethane, to achieve a seamless and durable joint. The method concludes at step 312, where the completed installation is inspected to ensure that the joints are seamless and the stone surface maintains its aesthetic appeal without any darkening or bleeding at the edges.
[0029] At step 302, the method involves cleaning the light-colored stone with a general-purpose pH-neutral cleaner to remove any dirt, oil, or contaminants that may interfere with subsequent treatments. The said cleaning process is essential for ensuring that no residue or impurities are left on the surface of the stone, which could affect the adhesion of the sealers and adhesives. The cleaner used is biodegradable and eco-friendly, ensuring that the process is environmentally friendly while effectively preparing the stone for further treatment. The cleaner’s pH-neutral formula is gentle enough to maintain the integrity and appearance of the stone without causing any damage to its surface, ensuring a pristine surface for the next steps.
[0030] At step 304, the stone is dipped into a fluoropolymer-based impregnator after cleaning, which is left on the stone for a period of 4 to 24 hours. The said treatment renders the stone highly resistant to water and oil, preventing these substances from being absorbed into the porous surface of the stone. The fluoropolymer-based impregnator contains perfluoroalkyl methacrylate polymers that form a protective barrier on the stone’s surface. The said impregnation process not only enhances the durability of the stone but also minimizes the risk of adhesive penetration during the later stages of the process. By preventing absorption, it ensures that the edges of the stone remain clean, uniform in color, and free from darkening or staining.
[0031] At step 306, the method involves applying a film-forming sealer to the edges of the stone. The sealer, typically made from a mixture of thermoplastic acrylic resins or a combination of methyl methacrylate and butyl methacrylate copolymer, forms a protective film over the edges. The film is designed to seal the micro-pores in the stone, effectively preventing adhesive from seeping into the edges and causing darkened seams (known as bleeding). The sealer creates a smooth, impermeable barrier, ensuring that the adhesive bonds only to the stone’s surface, where it is intended, and not to the porous inner edges. This step enhances both the aesthetic appearance and the longevity of the stone joints.
[0032] At step 308, the method involves fixing the stone to the floor, wall, or any other intended surface using a suitable tile adhesive. The adhesive used in this step is specifically chosen to ensure a strong, durable bond that secures the stone firmly to the surface. The adhesive is applied evenly to the back of the stone, ensuring that it adheres properly and remains in place throughout the curing process. The stone is then carefully pressed into position, ensuring precise alignment with neighboring stones. This step is essential for the stability of the installation and sets the foundation for a seamless appearance once the edges are joined.
[0033] In step 310, once the stone is fixed to the substrate, the edges are joined using an advanced adhesive, such as epoxy, polyurethane, or polyurea, which ensures a strong, seamless bond between adjacent stones. The adhesive is carefully applied to the edges of the stone, filling any gaps between the pieces and ensuring that the joints are invisible to the naked eye. This advanced adhesive is designed to remain strong and flexible over time, allowing the stone to maintain its structural integrity while also preventing darkening along the joints. The high-performance adhesive ensures that the joint remains durable, strong, and aesthetically pleasing, creating a seamless appearance across the entire surface.
[0034] In step 312, after the adhesive has been applied and the edges have been joined, an AI-driven quality assurance system inspects the joints for uniformity, seamlessness, and visual consistency. Using machine vision technology, the AI system captures high-resolution images of the stone joints and analyzes the edges for any visible darkening, inconsistencies, or imperfections. If the system detects any deviations from the ideal result, it can alert the operator or automatically adjust the process to correct the issue. The present AI-driven inspection ensures that every stone installation is flawless, free from visible seams, and meets the desired aesthetic standards. By incorporating real-time adjustments based on the inspection results, the method guarantees the highest level of precision and efficiency throughout the process.
[0035] The present disclosure offers several technical advantages over conventional methods for joining edges of light-colored stones. Its integration of multiple sensor technologies and AI-driven automation ensures precision and uniformity in each step, eliminating human error and material wastage. Further, the enhanced automation facilitates a highly consistent application of cleaners, impregnators, sealers, and adhesives, resulting in a seamless, visually appealing joint. Additionally, the use of advanced materials such as bio-based fluoropolymer impregnators, nanomaterial-based sealers, and silica-reinforced adhesives significantly improves the durability, water- and oil-repellency, and strength of the stone joints, while preventing adhesive penetration that causes darkening (bleeding). Moreover, the method incorporates sustainable practices by utilizing eco-friendly, biodegradable cleaners and renewable materials, reducing its environmental impact. Overall, the present invention combines innovation in materials, automation, and sustainability to offer a highly efficient, reliable, and environmentally conscious solution to stone jointing.
[0036] The present disclosure provides a concrete and tangible solution to a significant technical problem in the field of stone installation, particularly the issue of darkened seams (bleeding) when joining edges of light-colored stones. The present invention offers specific technical features and functionalities, such as the use of a fluoropolymer-based impregnator that makes the stone water- and oil-repellent, preventing adhesive penetration into the porous edges. Additionally, the integration of a nanomaterial-based sealer ensures that the edges are effectively sealed, blocking micro-pores to enhance both durability and aesthetic appeal. The method also incorporates automation, where robotic systems controlled by AI ensure precise and consistent application of the cleaning, sealing, and adhesive steps. Furthermore, the use of advanced adhesives, such as silica-reinforced epoxy, ensures strong, invisible bonds that maintain the stones' seamless appearance. These work collectively offer a highly efficient, reliable, and visually pleasing solution to the longstanding problem of adhesive-related discoloration in stone jointing.
[0037] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
,CLAIMS:CLAIMS
We Claim:
1. A process for joining edges of light-colored stones, the process comprising:
cleaning the light-colored stones with a pH-neutral cleaner to remove dirt, oil, or impurities from the surfaces;
immersing the cleaned stones in a fluoropolymer-based impregnator for a duration of 12 to 24 hours to render the stones water- and oil-repellent;
applying a nanomaterial-based sealer to the edges of the stones to block micro-pores and prevent adhesive penetration;
affixing the stones to a surface using a nanocomposite adhesive to ensure secure bonding; and
joining the edges of the stones with a silica-reinforced adhesive to achieve seamless and durable joints.
2. The process as claimed in claim 1, wherein the pH-neutral cleaner is biodegradable and eco-friendly to reduce environmental impact.

3. The process as claimed in claim 1, wherein the fluoropolymer-based impregnator comprises perfluoroalkyl methacrylate polymers for enhanced water- and oil-repellent properties.

4. The process as claimed in claim 1, wherein the nanomaterial-based sealer comprises thermoplastic acrylic resin reinforced with silica nanoparticles to fill micro-pores and enhance edge durability.
5. The process as claimed in claim 1, wherein the nanocomposite adhesive comprises epoxy resin blended with nano-reinforcements for improved bonding strength and flexibility.

6. The process as claimed in claim 1, wherein the silica-reinforced adhesive is a hybrid formulation comprising epoxy and polyurethane with silica nanoparticles for reducing seam visibility and enhancing joint durability.

7. The process as claimed in claim 1, further comprising automating the cleaning, impregnating, sealing, fixing, and joining steps using a robotic applicator system integrated with artificial intelligence.

8. The process as claimed in claim 1, further comprising performing a quality assurance step, wherein an AI-based system inspects the joints using image analysis to verify uniformity and seamlessness.

9. The process as claimed in claim 1, wherein the method is applicable to light-colored stones, including marble, granite, sandstone, and engineered stones, with thicknesses ranging from 12 mm to 24 mm.