WO2001066874A2

WO2001066874A2 - Stone surfacing for counters, walls, and floors

Info

Publication number: WO2001066874A2
Application number: PCT/US2001/007270
Authority: WO
Inventors: Arthur H. Duy
Original assignee: Duy Arthur H
Priority date: 2000-03-09
Filing date: 2001-03-07
Publication date: 2001-09-13
Also published as: AU2001247308A1; WO2001066874A3

Abstract

A composite stone slab (50, 82, 102, 112) includes a tessellating array of stone tiles (60, 90) having finished faces (62, 92) in a strictly coplanar relationship for having been assembled against a planar work surface (72) with the unfinished faces (64, 94) exposed. Abutting side surfaces (68, 96) of adjacent tiles (60, 90) are secured by a bonding region (100) of stone-penetrating adhesive (98) that traverses the seam at the abutting side surfaces and is enmeshed in the porous matrix of each adjacent tile (60, 90). The array is secured by a layer of mastic (78) to a substrate (80) that is attached to a support structure (84) at a predetermined installation location. Optionally, beveled edges (66) encircle the unfinished faces (64) of tiles (60), resulting in short side surfaces (68). The beveled edges (66) result in grooves (74) between unfinished faces (64) of adjacent tiles (60) in the array, which may be filled with tacking adhesive (76).

Description

STONE SURFACING FOR COUNTERS, WALLS, AND FLOORS

BACKGROUND The Field of the Invention This invention pertains to the structure, use, and manufacture of surfacing for counters, walls, and floors. In particular, the present invention pertains to finished surfaces of natural stone for use at residential and commercial facilities. Background Art

Finished stone surfaces for counters, walls, and floors are increasingly popular as interior and exterior elements of contemporary residential and commercial structures. Natural stone in such settings is both attractive and durable.

By way of example, illustrated in Figure 1 is the interior of the kitchen of such a residential structure. Shown there is a generally L-shaped counter 10 supporting at one end thereof a sink 12 and terminating at the other end thereof at a freestanding stove 14. Above counter 10, affixed to walls 16, 18, is a set of cabinets 20. Counter 10 has a countertop 22 that is a finished stone surface with an exposed perimeter 23. Between countertop 22 and cabinets 20 on walls 16, 18, are respective backsplash panels 24, 26, that are made of finished stone surfacing. More extensive portions of walls 16, 18, may also be finished stone surfaces, as well as all or portions of floor 28. If single-piece stone slabs are used as finished stone surfaces in the kitchen of

Figure 1, those stone slabs must be custom cut remote from the facility in which the kitchen is located. The custom cutting of a single-piece stone slab can occur only at highly specialized, capital-intensive fabrication plants that are capable of processing large pieces of stone. Custom stone cutting is thus expensive. Additionally, the transportation and installation of single-piece stone slabs is fraught with the risk of breakage, especially where the shapes of the stone slabs are irregular or characterized by discontinuities or apertures, such as the opening in countertop 22 in which sink 12 is set.

To overcome these disadvantages, the construction industry has resorted in the alternative to the in situ construction of finished stone surfaces through the assembly of stone tiles of a regular shape and manageable size into a tessellating array that is coextensive with the finished stone surface desired. The stone tiles in such composite stone slabs are typically square in shape, ranging in size on a side between 8 inches (19.6 cm) and 24 inches (61.0 cm). Stone tiles of rectangular shape may be appropriate in relation to a given finished stone surface; however, and other shapes of stone tiles are occasionally used.

A perspective view of such a stone tile 30 is illustrated in Figure 2 as having a finished face 32 with beveled edges 34 adjacent to and encircling the periphery thereof.

As appreciated to best advantage in Figure 2A this produces relatively short side surfaces 36 that are immediately adjacent to and encircling of an unfinished face 38 on the opposite side of stone tile 30 from finished face 32.

Figures 3 A - 3C depict typical steps in the use of stone tiles, such as stone tile 30, to construct finished stone surfacing.

As shown in Figure 3 A, the surface 40 of a structure 42 that is to be provided with stone finishing is first spread with a layer of mastic 44 that is capable of bonding stone to structure 42. Then as suggested by arrows A, stone tiles 30 are positioned in an array with unfinished faces 38 thereof resting on mastic 44 and with side surfaces 36 thereof in abutment as shown in Figure 3B. Opposed beveled edges 34 throughout the array form V-shaped grooves 46 between finished faces 32 of adjacent of stone tiles 30. Best efforts are undertaken before mastic 44 sets to bring finished faces 32 of all stone tiles 30 in the array into a strictly coplanar relationship.

This process is far easier to effect in theory, than in practice. All adjustments in the relative positions or orientations of finished faces 32 of stone tiles 30 must be effected by imposing forces on finished faces 32. Once unfinished faces 38 of stone tiles 30 have engaged mastic 44, however, manipulations of stone tiles 30 in the array are resisted; and the resistance increases as mastic 44 cures.

Moving a stone tile laterally along the surface of a layer of mastic bunches mastic up along the leading side surface of that stone tile. The mastic that bunches up is then caught between the leading side surfaces of stone tile being moved and the side surface of the stone tile toward which the lateral movement is occurring. Mastic caught between opposed side surfaces of adjacent stone tiles undesirably widens the gap between the finished faces of stone tiles in the array. During the process of assembling an array of stone tiles on layer of mastic, the layer of mastic acts much like a pneumatic reservoir. A force applied at one location on the surface of the layer of mastic is transferred to other locations on the surface of the layer of mastic. For example, urging an upstanding finished face downward into coplanar alignment with other finished faces in an array of stone tiles resting on a layer of mastic transfers forces through the mastic to all of the stone tiles in the array. Unless the original alignment of the finished faces of the other stone tiles is maintained by force, the movement of a single finished face in a desired manner will displace in a potentially undesirable manner some other finished face on a different stone tile.

Where a finished face of a single stone tile in an array is recessed relative to others, the recessed finished face must be moved outwardly of the assembly. In theory this could be accomplished with a suction grip applied to the finished face that is recessed, but this is not practical. Instead the raising of a recessed finished face is indirect: all of the aligned finished faces are depressed an equal distance into the assembly. The force applied to do so is transferred through the mastic as an outwardly directed force onto the stone tile that carries the recessed finished face. The forces applied to depress the aligned finished faces must be maintained, however. Otherwise, some of the aligned finished faces will react to the static forces produced in the mastic and will shift out of a previously established coplanar alignment. The maintenance of the positions of all of the stone tiles in a composite stone surface of any substantial size requires expensive machinery that is typically located only at specialized assembly facilities.

The force imposed upon a layer of mastic by individual stone tiles gives rise to corresponding, an oppositely-directed reaction force imposed on each stone tile by the mastic. When a plurality of stone tiles is urged into a coplanar relationship on a layer of mastic, the stone tiles will have a tendency to rebound out of alignment when the forces are released that created the coplanar relationship. Thus, if all finished faces in an array of stone tiles can be maneuvered into a coplanar relationship, it will be necessary thereafter to maintain that coplanar relationship, and the corresponding forces that brought each stone tile into the coplanar relationship, until the supporting layer of mastic has been fully cured. This can consume substantial time and resources.

Ultimately, whatever the extent of the coplanar alignment created among finished faces 32 in an array of stone tiles 30, it is the practice in the trade to obscure defects in abutment and coplanar alignment through the use of beveled edges 34. Beveled edges 34 give rise to grooves 46 between finished faces 32 of adjacent stone tiles 30. Grooves 46 are then filled with a grouting 48, as illustrated in Figure 3C. A composite stone slab 50 results that has a finished surface that is usually uneven and that is discontinuous, being interrupted by a lattice of grouting 48.

Composite stone slabs, such as composite stone slab 50, have other drawbacks. Fluid on the finished surface of a composite stone slab seeps into and through the grouting between adjacent stone tiles, forming hospitable reservoirs of moisture where bacteria are sustained under and between those stone tiles.

Grouting between adjacent stone tiles is susceptible to unsightly discoloration, cracking, and pitting. These must either be endured or remedied through regular repair and replacement.

SUMMARY OF THE INVENTION It is a general object of the present invention to increase the availability of natural stone as finishing surfacing in commercial and residential facilities.

In particular, it is an object of the present invention to provide a finished composite stone surface in which the finished faces of all of the constituent stone tiles are strictly coplanar.

It is an object of the present invention to provide a finished composite stone surface as described above that can be assembled by workers having no special construction skills.

Yet a further object of the present invention is finished composite stone surfacing in which the seams between individual constituent stone tiles are attractively sealed from penetration by fluid.

An additional object of the present invention is finished composite stone surfacing that maintains an attractive appearance for an extended period of use.

In particular it is an object of the present invention to avoid degradation of the appearance of finished composite stone surfaces arising as a result of the aging of the grouting between adjacent constituent stone tiles.

Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. To achieve the foregoing objects, and in accordance with the invention as embodied and broadly described herein, a finished surface is provided for installation at a residential or commercial facility. The finished stone surface includes a tessellating array of stone tiles disposed in edge-to-edge contact. Each of the stone tiles in the array includes a planar finished face, a plurality of side surfaces adjacent to and encircling of the finished face, and an unfinished face on the stone tile opposite from the finished face. The side surfaces of adjacent stone tiles in the array are in abutting contact, defining a seam between those stone tiles that lacks any appreciable gaps. A bonding region of stone penetrating adhesive traverses the seam and is enmeshed in the matrix of the stone tiles immediately adjacent to and on either side of the seam.

As a consequence of the method disclosed herein for constructing a finished stone surface according to teachings of the present invention, the finished faces of the stone tiles in the array are in coplanar alignment. These finished faces collectively define a finished composite stone surface. Typically, the stone-penetrating adhesive is applied to a seam between adjacent stone tiles from the edges of the side surfaces abutted at the seam that are located opposite from the finished faces of the stone tiles. As a result, in a transverse cross section of a seam between abutting side surfaces of adjacent stone tiles, the lateral extent of the bonding region of stone-penetrating adhesive along the unfinished faces of the adjacent stone tiles is greater than the lateral extent of the bonding region along the finished faces of the adjacent stone tiles.

Transparent, flowable polyester-based, acrylic-based, or epoxy-based stone adhesives are examples of stone-penetrating adhesives capable of bonding the abutting side surfaces of adjacent stone tiles in the manner required by the teachings of the present invention.

A composite stone surface constructed according to teachings of the present invention may also include a rigid substrate having an exposed surface that is at least as extensive as the finished composite stone surface being constructed. The exposed surface of the substrate is adhered to the unfinished faces of the stone tiles in the array by a layer of mastic. The substrate is attached to a support structure that is positioned at a residential or commercial facility at the predetermined location where the finished composite stone surface is to be installed. Attachment of the substrate to the support structure can occur either before or following use of the layer of mastic to adhere the array of stone tiles to the substrate.

The present invention also includes a stone tile for use in a tessellating array of stone tiles in a finished composite stone surface for a residential or commercial facility. The stone tile includes a planar finished face and a plurality of side surfaces adjacent to, encircling of, and usually perpendicular to the finished face. An unfinished face is provided on the side of the stone tile opposite from the finished face. Stone tiles made from granite or marble are the most common.

Optionally, beveled edges encircle the periphery of the unfinished face intermediate the unfinished face and the side surfaces of the stone tile. Such beveled edges are typically planar and oriented at a uniform bevel angle relative to corresponding individual side surface of the stone tile. Such beveled edges result in relatively short side surfaces immediately adjacent to the finished face of the stone tile. Opposed pairs of the beveled edges on adjacent of the stone tiles in the array cooperate to form grooves between the unfinished faces of adjacent of the stone tiles in the array. These grooves are filled with an adhesive that tacks the array together for further processing. A layer of mastic is used to adhere a supporting substrate to the unfinished faces and to the lattice of adhesive therebetween.

The abutting short side surfaces of such stone tiles can be bonded directly with stone-penetrating adhesive. Then mastic is spread in a layer directly on the array of unfinished faces, and a substrate is laid on the layer of mastic. No adhesive for tacking the array is required. It is possible in the alternative to spread the mastic on a supporting substrate and then place the substrate with the mastic downward on the array of unfinished faces. The present invention contemplates methods for assembling finished composite stone surfacing suitable for installation on a counter, a wall, or a floor at a residential or commercial facility. The present invention also includes methods for installing the finished composite stone surfacing at those locations and for appropriately edging the perimeter of such composite stone surfaces. BRIEF DESCRIPTION OF THE DRAWINGS In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to a specific embodiment thereof which is illustrated in the appended drawings. Understanding that these drawings depict only a typical embodiment of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

Figure 1 is a perspective view of the interior of the kitchen of a residential structure depicting a counter, walls, and a floor upon which stone surfacing may be desirable;

Figure 2 is a perspective view of a prior art stone tile used in the in situ construction of finished composite stone surfacing suitable for installation on the counter, the walls, or the floor of the kitchen depicted in Figure 1;

Figure 2A is an elevation cross section view of the stone tile of Figure 2 taken along section line 2A-2 A shown therein;

Figures 3A - 3C depict steps in a method for using stone tiles of the type shown in Figures 2 and 2A to construct finished composite stone surfacing;

Figure 4 is a perspective view of a first embodiment of a stone tile incorporating teachings of the present invention; Figure 4A is an elevation cross section view of the tile of Figure 4 taken along section line 4A-4A shown therein;

Figures 5 A - 5G depict steps in a method for using stone tiles of the type illustrated in Figures 4 and 4A to construct finished composite stone surfacing;

Figure 6 is a perspective view of a second embodiment of a stone tile incorporating teachings of the present invention;

Figure 6A is an elevation cross section view of the tile of Figure 6 taken along section line 6A-6A shown therein;

Figures 7 A - 7G depict steps in a first embodiment of a method for using stone tiles of the type illustrated in Figures 6 and 6A to construct finished composite stone surfacing; Figures 8 A - 8F depict steps in a second embodiment of a method for using stone tiles of the type illustrated in Figures 6 and 6A to construct finished composite stone surfacing; Figures 9A - 9B depict steps in a method for joining the edges of a pair of finished composite stone surfaces manufactured according to the methods illustrated in Figures 7A - 7G and 8A - 8F;

Figure 10 is a perspective view in partial breakaway of a pair of complementary stone corner tiles incorporating teachings of the present invention;

Figures 11A - HE depict steps in a method for using corner tiles of the type illustrated in Figure 10 to construct a backsplash assembly or an edging assembly for use on the perimeter of finished stone surfacing;

Figures 12A - 12B depicts steps in a method for securing a backsplash panel assembly of the type illustrated in Figure HE to the perimeter of a finished composite stone surface manufactured according to the methods illustrated in Figures 7A - 7G and 8A - 8F;

Figures 13 A - 13B depicts steps in a method producing an edging assembly from the backsplash assembly illustrated in Figure 1 IE and securing the edging assembly to the perimeter of a finished composite stone surface manufactured according to the methods illustrated in Figures 7A - 7G and 8A - 8F; and

Figures 14A - 14B illustrate a second embodiment of an edging assembly for the perimeter of finished stone surfacing and steps in a method for securing that second embodiment of an edging assembly to the perimeter of a finished stone surface manufactured according to the methods illustrated in Figures 7A - 7G and 8A - 8F.

DESCRIPTION OF THE PREFERRED EMBODIMENT The above and several other problems existing in relation to stone tile slabs can be remedied by using stone tiles incorporating teachings of the present invention in methods disclosed herein that also embody teachings of the present invention.

Figures 4 and 4A illustrate a first embodiment of a stone tile 60 incorporating such teachings. Stone tile 60 is seen to have a planar finished face 62 and an unfinished face 64 opposite therefrom. In contrast to stone tile 30 of Figures 2 and 2A, stone tile 60 is provided with beveled edges 66 that are adjacent to and encircling of unfinished face 64. This results in relatively short side surfaces 68 on stone tile 60 that adjacently encircle finished face 62 and are perpendicular thereto. As seen in Figure 4A, each of beveled edges 66 is oriented at a single bevel angle A_B to a corresponding adjacent side surface 68 of stone tile 60.

Steps for utilizing stone tiles, such as stone tile 60, to efficiently fabricate a strictly planar finished composite stone surface are illustrated in Figures 5A - 5G. As suggested by arrows B in Figure 5A, stone tiles 60 are inverted and placed on an assembly table 70 in a tessellating array with finished faces 62 directly engaging the work surface 72 of assembly table 70 and with side surfaces 68 in abutment with each other. It is essential among the teachings of the present invention that work surface 72 of assembly table 70 be absolutely planar. Accordingly, it is recommended that assembly table 70, or at least work surface 72 thereof, be constructed of a material that will reliably maintain the planar quality of work surface 72, regardless of the impact of stone tiles thereupon, and regardless of any contact thereby with water, adhesives, or solvents. Assembly table 70 could, for example, provide the planar work surface required in a method informed by teachings of the present invention, if work surface 72 is made of a hard and structurally well-supported, thick sheet of metal, such as steel.

The planar quality of work surface 72 insures that all of finished faces 62 of all stone tiles 60 placed thereon assume a coplanar relationship. Stone tiles 60 are freely slidable longitudinally along work surface 72, thereby facilitating the abutment of side surfaces 68 of adjacent stone tiles 60. The arranging of stone tiles 60 on work surface 72 is not conducted against the complicated resistance of a system by which all of the stone tiles are interconnected by a layer of curing mastic 44, as in the prior art method illustrated in Figures 3A - 3C.

Adjacent opposed beveled edges 66 form V-shaped grooves 74 between unfinished faces 64 of adjacent stone tiles 60 in the resulting array. Grooves 74 are filled with a waterproof adhesive 76 as illustrated in Figure 5C, and adhesive 76 is cured, sealing the seams between adjacent stone tiles 60.

Optionally, but in addition thereto, the seam between adjacent abutting side surfaces 68 is provided with a water vapor barrier at the time that stone tiles 60 are placed on work surface 72. Toward this end side surfaces 68 may be painted with a silicone liquid before the assembly, or thin ribbons of waterproof plastic may be sandwiched between abutting side surfaces 68. An epoxy liquid can be painted on side surface 68 for the same purpose, provided that the assembly of the array can be accomplished deftly in a short time period. Alternatively, after stone tiles 60 have been assembled in abutting relationship on work surface 72, a stone-penetrating adhesive of the type to be described subsequently in fuller detail is utilized as a water vapor barrier and for structural purposes.

Thereafter, as shown in Figure 5D, a layer of mastic 78 capable of bonding stone to wood or other rigid construction material is spread over the array of unfinished faces 64 of stone tiles 60 and adhesive 76 therebetween. A rigid substrate 80 made, for example, of construction timber is then rested upon mastic 78 as illustrated in Figure 5E.

Orice mastic 78 has cured, the assembly of substrate 80, stone tiles 60, and adhesive 76 is lifted from assembly table 70, as suggested in Figure 5F by arrows C, and inverted into the orientation shown in Figure 5G. The result is a composite stone slab 82 that can be permanently installed at a residential or commercial facility by attachment to a support structure, such as counter support framing 84 illustrated. Counter support framing 84 would suggest the use of composite stone slab 82 as a countertop. Were composite stone slab 82 instead to be used as finished surfacing for a wall, a suitable support structure for composite stone slab 82 might take the form of wall framing or wall- hung support brackets. In the use of composite stone slab 82 as a finished floor surfacing, such a support structure might be an underlayment or a floor joist.

Finished faces 62 of individual stone tiles 60 of composite stone slab 82 are automatically coplanar, as indicated in Figure 5G by the common plane P₆₂ thereof. The seams between adjacent stone tiles 60 of composite stone slab 82 are sealed from penetration by water from the finished surface thereof. Composite stone slab 82 is easily assembled without expensive milling equipment or specially trained personnel.

A second embodiment of a stone tile 90 incorporating teachings of the present invention is shown in Figures 6 and 6 A. Stone tile 90 is there seen to have a planar finished face 92 and an unfinished face 94 opposite therefrom. In contrast to stone tile 60 of Figures 4 and 4 A, stone tile 90 has no beveled edges. Therefore, stone tile 90 includes side surfaces 96 that are encircling of and adjacent to both finished face 92 and unfinished face 94. Typically, side surfaces 96 will be perpendicular to finished face 92, although certain construction contingencies will require differing arrangements, as will be explored subsequently.

Steps for utilizing stone tiles, such as stone tiles 90, to efficiently fabricate a strictly planar finished composite stone surface are illustrated in Figures 7A - 7G. As suggested by arrows E in Figure 7A, stone tiles 90 are the inverted and placed on assembly table 70 in a tessellating array with finished faces 92 directly engaging work surface 72 and with side surfaces 96 in abutment with each other. As a result of the absence of beveled edges about the periphery of stone tiles 90, no grooves are formed between unfinished faces 94 of adjacent stone tiles 90 in the resulting array.

In the method illustrated in Figures 7A - 7G, a stone-penetrating adhesive 98 is used at each seam between adjacent stone tiles 90 for the purpose of bonding abutting side surfaces 96 together directly. As shown in Figure 7B, stone-penetrating adhesive 98 is applied at the seam between pairs of abutting side surfaces 96 from the edges of side surfaces 96 that are adjacent to unfinished faces 94 of adjacent stone tiles 90.

An appropriate adhesive for use as stone-penetrating adhesive 98 must be able to percolate into the porous matrix of the stone of stone tiles 90. While all stone is possessed of a degree of porosity, the use of very hard stone in stone tiles 90 will correspondingly require an adhesive that is capable of penetrating a very fine level of porosity. Once adequate penetration into the porous stone matrix has occurred, the adhesive must be capable of setting up as a very hard, waterproof material that continuously fills any gaps at the seam between each pair of abutting surfaces 96. On either side of that seam, the adhesive must become thoroughly enmeshed with the porous matrix of the abutting stone tiles 90 before setting up occurs. An adhesive found suitable in this demanding role is a polyester-based, transparent, flowing stone adhesive marketed by Akemi Company located at Lechstr 28, D-90451, Nϋrnberg, Germany, and distributed on behalf thereof in the United States of America by Axson North America, Inc. located at 1611 Hults Drive, Eaton Rapids, Michigan 48827 United States of America This adhesive is identified at these sources as Product No.4700. Transparent flowing stone adhesives are also available from these sources that are acrylic- based and epoxy-based. The latter while significantly more expensive than the former, or than Product No. 4700, is particularly suited for use with stone surfacing for outdoor applications.

Alternative sources exist for adhesives suitable in the role of a stone-penetrating adhesive according to the teachings of the present invention. Polyester-based, acrylic- based, and epoxy-based stone adhesives of various viscosities are also manufactured by an Italian concern, General Adhesives, on behalf of which products are distributed in the United States of America by General Chemical Engineering Inc. located at 2027 South 4130 West Street, Suite D, Salt Lake City, Utah 84104 United States of America. Similar adhesives can be secured from Superior Adhesives Inc. located at 11 1 1 Godfrey Avenue, Box No. 1, Grand Rapids, Michigan 49503 United States of America. An enlarged cross-sectional view of the seam between a typical pair of such abutting side surfaces 96 is shown in Figure 7C. There, it can be seen that stone- penetrating adhesive 98 has permeated the porous matrix of each of stone tiles 90 adjacent to abutting side surfaces 96. As stone-penetrating adhesive 98 is applied from the edges of side surface 96 adjacent to unfinished faces 94, it is currently believed that stone- penetrating adhesive 98 permeates the porous matrix of stone tiles 90 to a greater extent on either side of the seam between side surfaces 96 at unfinished faces 94 than at finished faces 92.

Accordingly, in Figure 7C on the side of the seam adjacent to unfinished faces 94, stone-penetrating adhesive 98 has infused laterally into the matrix of stone tiles 90 to a distance D_. At finished faces 92, however, stone-penetrating adhesive 98 has infused laterally into the matrix of stone tiles 90 only a distance D₂ that is less than distance D,. Accordingly, a bonding region 100 of stone-penetrating adhesive 98 between adjacent stone tiles 90 is shown in Figure 7C to assume a generally trapezoidal shape in a transverse cross section of the seam between abutting side surfaces 96. Bonding region 100 traverses that seam. Along unfinished faces 94 to either side of that seam, bonding region 100 has a length L, that is approximately twice the distance D,. Along finished faces 92 to either side of that seam, bonding region 100 has a length L₂ that is less than length L,, but that is approximately twice the distance D₂.

The tendency of a stone-penetrating adhesive to form a bonding region of trapezoidal shape in a transverse cross section of a seam between abutting side surfaces of stone tiles has been verified experimentally and found to be increasingly pronounced for stone-penetrating adhesives that require an extended period of time in which to set up. Stone-penetrating adhesives that are slow to set up not only exhibit extended penetration into the porous stone matrix at a seam between adjacent tiles, but also produce a more pronounced penetration differential between the side of the seam from which the stone- penetrating adhesive is applied and the side of the seam opposite therefrom. While this penetration differential may not be readily apparent visually in the case of fast set-up stone-penetrating adhesives, the penetration differential can be confirmed by a break test of the seam at the bonding region. When the seam is broken the portion of the porous stone matrix on one side of the seam that is enmeshed with the stone-penetrating adhesive separates from the balance of the stone tile on that side of the seam and assumes the generally trapezoidal shape consistent with a porous matrix penetration differential on the part of the stone-penetrating adhesive.

Stone-penetrating adhesive 98 is permitted to set up, forming bonding region 100 illustrated in Figure 7C. Then as shown in Figure 7D, a layer of mastic 78 capable of securing stone to wood or other rigid construction material is spread over the array of stone tiles 90 that are secured together by bonding regions 100 of stone-penetrating adhesive 98. A surface 79 of a substrate 80 of wood or other rigid construction material is then rested upon mastic 78 as illustrated in Figure 7E.

Once mastic 78 has cured, the assembly of substrate 80, stone tiles 90, bonding regions 100, and mastic 78 is lifted from assembly table 70, as suggested in Figure 7F by arrows F, and inverted into the orientation shown in Figure 7G. The result is a composite stone slab 102 that can be permanently installed at a residential or commercial facility by attachment to a support structure, such as counter support framing 84 shown.

Finished faces 92 of individual stone tiles 90 of composite stone slab 102 are automatically coplanar as indicated in Figure 7G by the common plane P₉₂ thereof. The seams between adjacent stone tiles 90 of composite stone slab 102 are sealed from penetration by water from the finished surface thereof. Composite stone slab 102 is easily assembled without expensive milling equipment or specially trained personnel.

As mentioned earlier in relation to the inventive method depicted in Figures 5A-5G, and in particular in relation to the step of that method illustrated in Figure 5C, a stone-penetrating adhesive, such as stone-penetrating adhesive 98, can be utilized even to bond abutting relatively short side surfaces 68 of the type arising on stone tiles 68 illustrated in Figures 4 and 4A as a result of the provision of beveled edges 66 adjacent to and encircling of unfinished face 64. Under such circumstances, once stone- penetrating adhesive 98 has set up in a bonding region that traverses the seam between adjacent abutting short side surfaces 68, stone tiles 60 are tacked in position in the resulting array. Consequently, the need toward that end of an adhesive, such as adhesive 76 shown in Figures 5C-5G, is largely obviated. Therefore, a mastic, such as mastic 78, can be used both to secure the array of stone tiles 60 to a rigid substrate, and to fill V-shaped grooves 74 between adjacent unfinished faces 64 in the array of stone tiles 60. It is recommended, however, that the array of stone tiles 60 not be lifted alone from work surface 72 of assembly table 70, without the reenforcement of a supporting substrate of the type used in the method discussed immediately below.

Steps in a second embodiment of a method for utilizing stone tiles, such as stone tile 90, to efficiently fabricate an improved and completely planar finished composite stone surface are illustrated in Figures 8A-8F.

As suggested by arrows G in Figure 8A, stone tiles 90 are inverted and placed on an assembly table 70 in a tessellating array with finished faces 92 directly engaging work surface 72 and with side surfaces 96 in abutment with each other. No grooves are formed between unfinished faces 94 of adjacent stone tiles 90 in the resulting array.

Stone-penetrating adhesive 98 is used to bond side surfaces 96 of each stone tile 90 to corresponding abutting side surfaces 96 of other stone tiles 90 in the array. As shown in Figure 8B, stone-penetrating adhesive 98 is applied to each pair of abutting side surfaces 96 from the edges thereof adjacent to unfinished faces 94 of the array of stone tiles 90.

An enlarged cross sectional view of the seam between a typical pair of such abutting side surfaces 96 is shown in Figure 8C. There, it can be seen that stone- penetrating adhesive 98 has permeated the porous matrix of stone tiles 90 adjacent to abutting side surfaces 96. As stone-penetrating adhesive 98 is applied from the edges of side surfaces 96 adjacent to unfinished faces 94, stone-penetrating adhesive 98 permeates the portion of the porous matrix of stone tiles 90 adjacent to each of abutting surfaces 96 to a greater extent at unfinished face 94 than at finished face 92. Accordingly, at unfinished face 94 of each of stone tiles 90 in Figure 8C, stone- penetrating adhesive 98 has become enmeshed with the porous matrix of stone tiles 90 to a distance D,. At finished faces 92, however, stone-penetrating adhesive 98 has become enmeshed with the porous matrix of stone tiles 90 only to a distance D₂ that is less than distance D,. Accordingly, bonding region 100 between adjacent stone tiles 90 is shown in Figure 8C to assume a generally trapezoidal shape in a transverse cross section of the seam at abutting side surfaces 96. Bonding region 100 traverses that seam. Along unfinished faces 94, bonding region 100 has a length L, that is approximately twice the distance D,. Along finished faces 92, bonding region 100 has a length L₂ that is less than length L₂, but that is approximately twice the distance D₂.

Thereafter, as suggested in Figure 8D by arrows H, stone tiles 90 interconnected by bonding regions 100 are lifted from assembly table 70 and inverted into the orientation shown in Figure 8E. The result is a composite stone slab 112 that can be permanently installed at a residential or commercial facility.

To do so, as illustrated in Figure 8E, substrate 80 is secured to counter support frame 84, and a layer of mastic 78 capable of bonding stone to wood or other rigid construction material is spread on upper surface 79 of substrate 80. Then as indicated by arrows J, composite stone slab 112 is lowered onto mastic 78. Once mastic 78 has cured, composite stone slab 112 is permanently installed.

Finished faces 92 of individual stone tiles 90 of composite stone slab 112 are automatically coplanar as indicated in Figure 8F by the common plane P₉₂ thereof. The seams between adjacent stone tiles 90 of composite stone slab 112 are sealed from penetration by water from the finished surface thereof. Composite stone slab 112 is easily assembled without expensive milling equipment or specially trained personnel.

The size of any desired finished stone surface may exceed the size of a composite stone slab that can be safely manipulated by working persons at a residential or commercial facility. Accordingly, Figures 9A and 9B depict steps in a method for joining the edges of finished stone surfacing manufactured according to the inventive methods disclosed above. The method illustrated relies on splining, although other measures for effecting the joinder of the edges of finished stone surfacing are appropriate.

Shown on the right side of Figure 9A is one end of composite stone slab 112 that has been permanently installed by way of mastic 78 and substrate 80 to counter support framing 84. Substrate 80 terminates in an end surface 116 that is flush with the exposed side surface 96 of the outermost stone tile 90-1 in the array of stone tiles 90 in composite stone slab 112. A splining groove 118 has been cut into end surface 116.

A second counter support framing 84a is illustrated to the right of counter support framing 84 in Figure 9A. Second counter support framing 84a is secured to the same interior as is counter support framing 84. The finished surface of composite stone slab 1 12 is to be extended to the right, over second counter support frame 84a. For this purpose, a composite stone slab 102 of the type manufactured according to the steps of the method illustrated in Figures 7A - 7G is utilized. Composite stone slab 102 includes an array of stone tiles 90 secured to each other at the abutting side surfaces thereof by bonding regions 100 and adhered to a substrate 80a by a layer of mastic 78a. Substrate 80 has been cut at an end surface 120 flush with side surface 96 of outermost stone tile 90- la in the array of stone tiles 90 in composite stone slab 102. End surface 120 has been provided with a splining groove 122 that corresponds in position and size to splining groove 118 in end surface 116 of substrate 80 on the left side of Figure 9A. As suggested by arrows K in Figure 9A, composite stone slab 102 is to be abutted against composite stone slab 112 and supported by second counter support framing 84a. To effect a permanent and secure abutment, opposite edges of a splining piece 124 are entered, respectively, into splining groove 118 in end surface 116 of substrate 80 and into splining groove 122 in end surface 120 of substrate 80a. Appropriate types of construction adhesive are utilized in the process to bond splining piece 124, substrate 80, and substrate 80a together at the abutment of end surface 116 with end surface 120. The result is illustrated in Figure 9B.

Side surface 96 of outermost stone tile 90-1 in composite stone slab 112 is bonded to side surface 96 of outermost stone tile 90- la of composite stone slab 102 by stone- penetrating adhesive 98 applied from finished faces 92 immediately above the joint effected at splining piece 124. As a result, stone-penetrating adhesive 98 will permeate the matrix of outermost stone tiles 90-1 and 90- la to either side of the seam between abutting side surfaces 96 to a greater extent at finished faces 92 than at unfinished faces 94.

Finished faces 92 of individual stone tiles 90 of composite stone slab 112 are coplanar with finished faces 92 of individual stone tiles 90 of composite stone slab 102 as indicated in Figure 9B by the common plane P₉₂ thereof. The seams between the adjacent abutting stone tiles 90 of each of composite stone slab 112 and composite stone slab 102 are sealed from penetration by water from the finished surfaces thereof. Composite stone slab 102 and composite stone slab 112 are easily joined to produce a single, extensive composite stone slab without expensive milling equipment or specially trained personnel. The successful installation of composite stone slabs incorporating teachings of the present invention will on most occasions be enhanced by the application of suitable stone edging about the periphery of the installed composite stone surface. Figure 10 depicts a pair of complementary stone corner tiles 130, 132, which find utility in edging practices in relation to the invention disclosed herein.

Stone corner tile 130 has a planar finished face 134 and an unfinished face 136 opposite therefrom. Stone corner tile 130 can be seen to include side surfaces 138 that are adjacent and perpendicular to finished face 134, but side surfaces at that orientation to finished face 134 do not collectively fully encircle stone corner tile 130. Instead, a leading edge 140 of stone corner tile 130 is provided with an inclined side surface 139 that is oriented at an acute inclination angle S₁₃₉ to finished face 134.

Stone corner tile 132 correspondingly includes a finished face 144, an unfinished face 146 opposite therefrom, and side surfaces 148 that are adjacent and perpendicular to finished face 144, but that do not collectively fully encircle stone corner tile 132. Instead, stone corner tile 132 includes an inclined side surface 149 that is oriented at an acute inclination angle S₁₄₉ to finished face 144 at a leading edge 150 of stone corner tile 132.

To use stone corner tiles 130, 132, to construct right-angle edging for a stone surface, the sum of the size of inclination angle S₁₃₉ and the size of inclination angle S₁₄₉ should be 90°. In most cases, it is expected that angle S_]39 and angle S₁₄₉ will be equal in size. Stone corner tiles 130, 132, are thus shown by way of example in Figure 10 as having inclined side surfaces 139, 149, respectively that are each oriented at 45° to finished faces 134, 144, thereof. Nonetheless, variations in these parameters are appropriate under specific circumstances.

Illustrated in Figures 11 A - 11 E are typical steps for utilizing complementary stone counter tiles, such as stone counter tiles 130, 132, to efficiently fabricate backsplash panels or edging for inventive finished stone surfacing of the types previously disclosed.

An angle jig 151, depicted in Figure HA, is utilized for this purpose. Angle jig 151 has planar upper surfaces 152, 154, that intersect at a vertex 156 in a jig angle Aj of 90 ° . In Figure 11 A, stone corner tile 130 has been inverted and placed on angle jig 151 with finished surface 134 thereof directly engaging upper surface 152 of angle jig 151. Leading edge 140 of stone corner tile 130 is positioned at vertex 156 of angle jig 151. As suggested by arrow M in Figure 11 A, stone corner tile 132 is inverted and placed on angle ig 151 with finished surface 144 thereof directly engaging upper surface 154 of angle ig 151. Leading edge 150 of inclined side surface 149 is positioned at vertex 156 between upper surfaces 152, 154, of angle jig 151. Jig angle Aj is equal to the sum of the size of inclination angle S,₃₉ of inclined side surface 139 of stone counter tile 130 and the size of inclination angle S_M9 of inclined side surface 149 of stone counter tile 132. Accordingly, when leading edge 140 of inclined side surface 139 of stone counter tile 130 and leading edge 150 of inclined side surface 149 of stone corner tile 132 are received at vertex 156 of angle jig 151, inclined side surface 139 of stone corner tile 130 abuts inclined side surface 149 of stone corner tile 132 in the manner illustrated in Figure 1 IB.

Stone-penetrating adhesive 98 is then used to bond inclined side surface 139 of stone corner tile 130 to abutting inclined side surface 149 of stone corner tile 132. To do so, stone-penetrating adhesive 98 is applied to the seam between inclined side surface 139 and inclined side surface 149 from the edges thereof located, respectively, at unfinished faces 136, 146. Stone-penetrating adhesive 98 permeates the porous matrix of each of stone corner tiles 130, 132, at abutting inclined side surfaces 139, 149, respectively, to form a bonding region 160. Thereafter as shown in Figure 11 C, a layer of mastic 162 capable of bonding stone to wood or other rigid construction material is spread over unfinished face 136 of stone corner tile 130 and unfinished face 146 of stone corner tile 132. The working end 164 of an elongated substrate 166 of wood or other rigid construction material is then rested on mastic 162 with elongated faces 168, 170, of substrate 166 being substantially parallel to upper surface 152 of angle jig 151. The terminus 172 of working end 164 is as a result disposed against the portion of mastic 162 on unfinished face 146 ofstone corner tile 132, parallel to upper surface 154 of angle jig 151.

For convenience of subsequent discussion, a first spline groove 174 is shown cut in elongated face 168 of substrate 166 in the vicinity ofstone corner tiles 130, 132, while a second splining groove 176 is shown cut in elongated face 170 at a distance from stone corner tiles 130, 132.

Once mastic 162 has cured, the assembly of substrate 166, mastic 162, stone corner tiles 130, 132, and bonding region 160 is lifted from angle jig 151 as suggested by arrow N. The result is a backsplash panel assembly 180 that can be permanently installed in conjunction with a finished composite stone countertop at a commercial or residential facility in a manner to be described below. With minor modification, backsplash panel assembly 180 can be converted into an edging assembly and secured to the perimeter of a finished composite stone surface in steps of a method that will also be described thereafter.

The installation of backsplash panel assembly 180 in conjunction with a finished composite stone slab 1 12 is illustrated in the sequence of Figures 12A and 12B. In Figure 12 A, composite stone slab 112 is seen to include an array ofstone tiles 90 having abutting side surfaces secured by bonding regions 100. Composite stone slab 112 is secured by a layer of mastic 78 to a substrate 80 of wood or other suitable construction material. Substrate 80 has been permanently secured to a counter support structure that includes counter support framing 84 and a vertical member 184. End surface 116 of substrate 80 is flush with side surface 96 of the outermost stone tile 90-1 in the array of stone tiles 90 in composite stone slab 112.

A splining groove 118 has been cut in end surface 116 of substrate 80 at a distance below finished face 92 of stone tile 90-1 at the periphery of the array of stone tiles 90 in composite stone slab 112 that is equal to the distance of second splining groove 176 away from side surface 138 ofstone corner tile 130 in backsplash panel assembly 180. A layer of mastic 186 is applied to side surface 96 of stone tile 90-1, end surface 116 of substrate 80, and the elongated face of vertical member 184 opposite from counter support framing 84.

Backsplash panel assembly 180 is then oriented with working end 164 of substrate 166 in a vertical position and is advanced laterally as suggested by arrows L in Figure 12A. The opposed edges of splining piece 188 are captured, respectively, in splining groove 118 in end surface 116 of substrate 80 and in second splining groove 176 in elongated face 170 of substrate 166. The portion of elongated face 170 below stone corner tile 130 is thereby brought to bear against mastic 186, while side surface 138 of stone corner tile 130 comes to rest upon finished face 92 ofstone tile 90-1 in the manner shown in Figure 12B.

Stone-penetrating adhesive 98 is then applied to the seam between side surface 138 of stone corner tile 130 and finished face 92 of stone tile 90-1, creating a bonding region 190 therebetween. Once stone-penetrating adhesive 98 has set up, composite stone slab 112 and backsplash panel assembly 180 together function as a finished composite stone countertop and backsplash guard of the type appropriate for use in the kitchen depicted in Figure 1. The installation of a modified form of a backsplash panel assembly, such as backsplash panel assembly 180, to provide edging for the periphery of a finished composite stone surface is illustrated in the sequence of steps in Figures 13A and 13B.

An edging assembly 200 is illustrated in Figure 13 A. Edging assembly 200 is produced by removing from backsplash panel assembly 180 a portion 201 of substrate 166 of backsplash panel assembly 180 that is illustrated in Figure 13A in phantom.

Edging assembly 200 is to be installed on the perimeter of composite stone slab 112. To do so, composite stone slab 112 has been adhered to substrate 80 by mastic 78 with side surface 96 of outermost stone tile 90-1 among the array of stone tiles 90 in composite stone slab 112 extending a relatively small distance D_λ beyond end surface 116 of substrate 80. The elongated face of vertical member 184 is aligned with end surface 116. Optionally, side surface 148 ofstone corner tile 132 of edging assembly 200 can project a distance D₂ beyond elongated face 168 of substrate 166, although this may not be necessary where distance D, is sufficiently large. A layer of mastic 202 is applied to end surface 116 of substrate 80 and the portion of the elongated face of vertical member 184 that is adjacent to end surface 116. Then, as suggested by arrows Q, edging assembly 200 is advanced into contact with mastic 202, capturing the opposite edges of a splining piece 204, respectively, in splining groove 118 in end surface 116 of substrate 80 and in first splining groove 174 in elongated face 168 of substrate 166. As a result, side surface 96 of outermost stone tile 90-1 in the array of stone tiles 90 in composite stone slab 112 is abutted by side surface 148 of stone corner tile 132 of edging assembly 200 as shown in Figure 13B.

Stone-penetrating adhesive 98 is then applied to the seam between side surface 96 of outermost stone tile 90-1 and side surface 148 of stone corner tile 132, creating a bonding region 206 therebetween. When stone-penetrating mastic 202 has set up, composite stone slab 112 and edging assembly 200 together function as a finished countertop with stone edging for use in a kitchen such as that depicted in Figure 1.

A second embodiment of an edging assembly 210 is illustrated in Figure 14A. Edging assembly 210 includes a trio of rounded stone edging tiles 212, 214, 216, of varying length attached in a generally parallel relationship thereamong by an adhesive 218 to a substrate 220. Substrate 220 includes a terminus 222 and an elongated face 224 that are embedded in adhesive 218. Elongated face 226 on the opposite side of substrate 220 from elongated face 224 has a splining groove 228 cut thereinto.

Edging assembly 210 is to be permanently installed at the perimeter of composite stone slab 112. Side face 96 of outermost stone tile 90-1 in the array of stone tiles 90 in composite stone slab 1 12 projects a distance D, beyond end surface 116 and the elongated face of vertical member 184 that is aligned therewith. Correspondingly, but optionally, side surface 230 of the uppermost rounded edging tile 212 may project a distance D₂ beyond elongated face 226 of substrate 220.

A layer of mastic.202 is applied to end surface 116 of substrate 80. Edging assembly 210 is advanced thereto ward as suggested by arrows R in Figure 14 A. Opposite ends of a splining piece 232 are correspondingly captured, respectively, in splining groove 118 in end surface 116 of substrate 80, and in splining groove 228 in elongated face 226 of substrate 220 in the manner shown in Figure 14B.

Side surface 96 of outermost stone tile 90-1 in the array of stone tiles 90 in composite stone slab 112 abuttingly engages side surface 230 of upper rounded edging tile 212. Stone-penetrating adhesive 98 is then applied to the seam between side surface 96 of outer stone tile 90-1 and side surface 230 of uppermost rounded edging tile 212, forming a bonding region 236 therebetween.

Once stone-penetrating adhesive 98 has set up, composite stone slab 112 and edging assembly 210 together function as an edged, composite stone countertop suitable for installation in a kitchen, such as that depicted in Figure 1.

The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

What is claimed is:

Claims

1. A finished surface for installation on a counter, a wall, or a floor at a residential or commercial facility, said finished surface comprising: a. a support structure positioned at the residential or commercial facility at a predetermined installation location for said finished surface; b. a rigid substrate attached to said support structure, said substrate having an exposed surface substantially coextensive with said finished surface; c. a layer of mastic on said exposed surface of said substrate; and d. a tessellating array ofstone tiles disposed on said layer of mastic in edge-to-edge contact, said array being coextensive with said finished surface, and each of said stone tiles in said array comprising: i. an unfinished face adhered by said layer of mastic to said exposed surface of said substrate; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and iii. a planar finished face on said stone tile opposite from said unfinished face, said finished face being adjacent to and encircled by said plurality of side surfaces, and said finished faces of said stone tiles in said array being in coplanar alignment defining said finished surface.

2. A finished surface as recited in Claim 1, wherein abutting of said side surfaces of said adjacent of said stone tiles define seams between said stone tiles in said array, and wherein said finished surface further comprises bonding regions of stone- penetrating adhesive traversing said seams and being enmeshed in the matrix of each of said stone tiles on opposite sides of said seams.

3. A finished stone surface as recited in Claim 2, wherein in a transverse cross section of said seams, said bonding regions having an extent along said unfinished faces of said stone tiles on opposite sides of said seams that is greater than the extent of said bonding regions along said finished faces of said stone tiles on opposite sides of said seams.

4. A finished surface as recited in Claim 1 , wherein said side surfaces of said stone tiles in said array are bonded to said side surfaces of said adjacent of said stone tiles in said array with a stone-penetrating adhesive.

5. A finished surface as recited in Claim 4, wherein said stone-penetrating adhesive is applied to said side surfaces of said adjacent of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

6. A finished surface as recited in Claim 1, wherein each of said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces thereof.

7. A finished surface as recited in Claim 6, wherein opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array, and wherein said finished surface further comprises an adhesive filling said grooves.

8. A finished surface for installation on a counter, a wall, or a floor at a residential or commercial facility, said finished surface comprising: a. a support structure positioned at the residential or commercial facility at a predetermined installation location for said finished surface; b. a rigid substrate attached to said support structure, said substrate having an exposed surface substantially coextensive with said finished surface; c. a layer of mastic on said exposed surface of said substrate; d. a tessellating array ofstone tiles disposed on said layer of mastic in edge-to-edge contact, said array being coextensive with said finished surface, and each of said stone tiles in said array comprising: i. an unfinished face adhered by said layer of mastic to said exposed surface of said substrate; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and iii. a planar finished face on said stone tile opposite from said unfinished face, said finished face being adjacent to and encircled by said plurality of side surfaces, and said finished faces of said stone tiles in said array being in coplanar alignment defining said finished surface; and e. a stone-penetrating adhesive bonding said side surfaces of said stone tiles in said array to said side surfaces of said adjacent of said stone tiles in said array.

9. A finished surface as recited in Claim 8, wherein said stone-penetrating adhesive is applied to said side surfaces of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

10. A finished surface as recited in Claim 8, wherein each of said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array.

11. A finished surface as recited in Claim 10, wherein said grooves are filled with an adhesive.

12. A finished surface as recited in Claim 10, wherein said grooves have a V-shaped transverse cross section.

13. A countertop for installation at a residential or commercial facility, said countertop comprising: a. a counter support positioned at the residential or commercial facility at a predetermined installation location for said countertop; b. a substrate of rigid construction material attached to said counter support, an exposed surface of said substrate being substantially coextensive with said countertop; c. a layer of mastic on said exposed surface of said substrate; d. a plurality of stone tiles collectively being coextensive with said countertop, said plurality ofstone tiles being secured to said substrate by said layer of mastic, and each of said stone tiles comprising: i. an unfinished face adhered to said layer of mastic; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles abutting said side surfaces of adjacent of said stone tiles; and iii. a planar finished face adjacent to and encircled by said plurality of side surfaces, said finished faces of said stone tiles in said array being in coplanar alignment defining said countertop; and e . a stone-penetrating adhesive bonding said side surfaces of said stone tiles in said array to said side surfaces of said adjacent of said stone tiles in said array.

14. A countertop as recited in Claim 13, wherein each of said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array.

15. A countertop as recited in Claim 14, wherein said grooves are filled with an adhesive.

16. A countertop as recited in Claim 14, wherein said grooves have a V-shaped transverse cross section.

17. A countertop as recited in Claim 13, wherein said stone-penetrating adhesive is applied to said side surfaces of said adjacent of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

18. Stone surfacing for installation at a residential or commercial facility, said stone surfacing comprising: a. a tessellating array ofstone tiles disposed in edge-to-edge contact, said array being coextensive with said stone surfacing, and each of said stone tiles in said array comprising: i. an unfinished face; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles in said array being in abutment with said side surfaces of adjacent of said stone tiles in said array, abutting of said side surfaces of adj acent of said stone tiles defining seams between said stone tiles; and iii. a planar finished face on said stone tile opposite from said unfinished face, said finished face being adjacent to and encircled by said plurality of side surfaces, and said finished faces of said stone tiles in said array being in coplanar alignment defining said stone surfacing; and b. bonding regions of stone-penetrating adhesive traversing said seams and being enmeshed in the matrix of said stone tiles on opposite sides of said seams.

19. Stone surfacing as recited in Claim 18, further comprising: a. a rigid substrate having an exposed surface substantially coextensive with said stone surfacing; and b. a layer of mastic on said exposed surface of said substrate adhering thereto said unfinished faces of said stone tiles in said array.

20. Stone surfacing as recited in Claim 19, wherein each said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces thereof.

21. Stone surfacing as recited in Claim 20, wherein opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array, and wherein said stone surfacing further comprises an adhesive filling said grooves.

22. Stone surfacing as recited in Claim 18, wherein said stone-penetrating adhesive is applied to said side surfaces of said adjacent of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

23. Stone surfacing as recited in Claim 18, wherein said stone-penetrating adhesive is a polyester-based, transparent, flowing stone adhesive.

24. Stone surfacing as recited in Claim 18, wherein in a transverse cross section of said seams, said bonding regions have an extent along said unfinished faces of said stone tiles on opposite sides of said seam that is greater than the extent of said bonding regions along said finished faces of said stone tiles on opposite sides of said seam.

25. Stone surfacing for installation at a residential or commercial facility, said stone surfacing comprising: a. a rigid substrate having an exposed surface substantially coextensive with said stone surfacing; b. a layer of mastic on said exposed surface of said substrate; c. a tessellating array ofstone tiles disposed on said layer of mastic in edge-to-edge contact, said array being coextensive with said stone surfacing, and each of said stone tiles in said array comprising: i. an unfinished face; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and iii. a planar finished face on said stone tile opposite from said unfinished face, said finished face being adjacent to and encircled by said side surfaces, and said finished faces of said stone tiles in said array being in coplanar alignment defining said stone surfacing.

26. Stone surfacing as recited in Claim 25, wherein each said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array.

27. Stone surfacing as recited in Claim 26, wherein said grooves are filled by said layer of mastic.

28. Stone surfacing as recited in Claim 26, wherein said grooves have a V-shaped transverse cross section.

29. Stone surfacing as recited in Claim 25, wherein said side surfaces of said stone tiles in said array are bonded to said side surfaces of said adjacent of said stone tiles in said array with a stone-penetrating adhesive.

30. Stone surfacing as recited in Claim 29, wherein said stone-penetrating adhesive is applied to said side surfaces of said adjacent of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

31. Stone surfacing for installation at a residential or commercial facility, said stone surfacing comprising: a. a rigid substrate having an exposed surface substantially coextensive with said stone surfacing; b. a layer of mastic on said exposed surface of said substrate; c. a tessellating array ofstone tiles disposed on said layer of mastic in edge-to-edge contact, said array being coextensive with said stone surfacing, and each of said stone tiles in said array comprising: i. an unfinished face; ii. a plurality of side surfaces encircling said unfinished face, said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and iii. a planar finished face on said stone tile opposite from said unfinished face, said finished face being adjacent to and encircled by said side surfaces, and said finished faces of said stone tiles in said array being in coplanar alignment defining said stone surfacing; and d. a stone-penetrating adhesive bonding said side surfaces of said stone tiles in said array to said side surfaces of said adjacent of said stone tiles in said array.

32. Stone surfacing as recited in Claim 31 , wherein each said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves having a V-shaped transverse cross section between said unfinished faces of said adjacent of said stone tiles in said array.

33. Stone surfacing as recited in Claim 32, wherein said grooves are filled with an adhesive.

34. Stone surfacing as recited in Claim 31, wherein said stone-penetrating adhesive is applied to said side surfaces of said adjacent of said stone tiles in said array from the edges of said side surfaces located opposite from said finished faces of said stone tiles.

35. A stone tile for use in a tessellating array ofstone tiles in a finished stone surface at a residential or commercial facility, said stone tile comprising: a. a planar finished face; b. a plurality of side surfaces adjacent to and encircling of said finished face; and c. an unfinished face on said stone tile opposite from said finished face.

36. A tile as recited in Claim 35, further comprising a plurality of beveled edges encircling the periphery of said unfinished face of said stone tile intermediate said unfinished face and said side surfaces thereof.

37. A tile as recited in Claim 36, wherein each of said beveled edges is substantially planar and is oriented at uniform bevel angle relative to a respective individual of said plurality of said side surfaces.

38. A tile as recited in Claim 35, wherein said stone tile is comprised of granite.

39. A tile as recited in Claim 35, wherein said stone tile is comprised of marble.

40. A method for constructing a finished surface at a residential or commercial facility, said method comprising the steps of: a. assembling in edge-to-edge contact on a planar work surface a tessellating array of stone tiles, said array being coextensive with said finished surface, and each of said stone tiles comprising: i. a planar finished face, said finished faces of said stone tiles in said array being disposed against said work surface; ii. a plurality of side surfaces adjacent to and encircling of said finished face, said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and iii. an unfinished face on said stone tile opposite from said finished face; b. applying a stone-penetrating adhesive to said side surfaces of said stone tiles in said array and to said side surfaces of said adjacent of said stone tiles in said array; c. disposing a layer of mastic on said unfinished faces of said stone tiles in said array; d. adhering said unfinished face of each of said stone tiles in said array to a rigid substrate with said layer of mastic; and e. attaching said substrate to a support structure at the residential or commercial facility.

41. A method as recited in Claim 40, further comprising the step of removing from said work surface said substrate with said stone tiles in said array adhered thereto, and wherein said step of removing occurs prior to said step of attaching said substrate to said support structure.

42. A method as recited in Claim 40, further comprising the step of shifting from said work surface said stone tiles in said array with said stone-penetrating adhesive applied thereto, and wherein said step of shifting occurs prior to said step of disposing said layer of mastic.

43. A method as recited in Claim 42, further comprising the step of spreading said layer of mastic on said substrate prior to said step of adhering said unfinished faces of said stone tiles to said substrate.

44. A method as recited in Claim 43, wherein said step of attaching said substrate to said support structure occurs prior to said step of spreading said layer of mastic.

45. A method as recited in Claim 40, wherein each of said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array.

46. A method as recited in Claim 45, further comprises the step of filling said grooves with an adhesive.

47. A method as recited in Claim 40, wherein said step of applying is effected from the edges of said side surfaces of said adjacent of said stone tiles in said array opposite from said finished faces of each of said stone tiles.

48. A method as recited in Claim 47, wherein said step of applying occurs after said step of assembling.

49. A method for manufacturing stone surfacing for installation at a residential or commercial facility, said method comprising the steps of: a. providing a plurality of stone tiles, each of said stone tiles comprising: i. a planar finished face; ii. a plurality of side surfaces adjacent to and encircling of said finished face; and iii. an unfinished face on said stone tile opposite from said finished face; b. assembling said plurality of stone tiles on a planar work surface in edge-to-edge contact in a tessellating array, said finished faces of said stone tiles in said array being disposed against said work surface in coplanar alignment defining said stone surfacing, and said side surfaces of each of said stone tiles in said array abutting said side surfaces of adjacent of said stone tiles in said array; and c. applying a stone-penetrating adhesive to said side surfaces of said adjacent of said stone tiles in said array.

50. A method as recited in Claim 49, further comprising the steps: a. disposing a layer of mastic on said unfinished faces of said stone tiles in said array; and b. adhering said unfinished faces of said stone tiles of said array to a rigid substrate with said layer of mastic.

51. A method as recited in Claim 50, further comprising the step of shifting from said work surface said stone tiles in said array with said stone-penetrating adhesive applied thereto, and wherein said step of shifting occurs prior to said step of disposing said layer of mastic.

52. A method as recited in Claim 51 , further comprising the step of spreading said layer of mastic on said substrate prior to said step of adhering said unfinished faces of said stone tiles to said substrate.

53. A method as recited in Claim 52, further comprises the step of attaching said substrate to a support structure at the residential or commercial facility after said step of spreading said layer of mastic.

54. A method as recited in Claim 49, wherein each of said stone tiles further comprises a plurality of beveled edges encircling the periphery of said unfinished face intermediate said unfinished face and said side surfaces of said stone tile, whereby opposed pairs of said beveled edges on said adjacent of said stone tiles in said array cooperate to form grooves between said unfinished faces of said adjacent of said stone tiles in said array.

55. A method as recited in Claim 54, further comprises the step of filling said grooves with an adhesive.

56. A method as recited in Claim 49, wherein said step of applying is effected from the edges of side surfaces of adjacent of said stone tiles in said array opposite from said finished faces of each of said stone tiles.

57. A method as recited in Claim 49, wherein abutting of said side surfaces of adjacent of said stone tiles define seams between said stone tiles, and wherein said step of applying produces bonding regions of stone-penetrating adhesive traversing said seams and being enmeshed in the matrix of said stone tiles on opposite sides of said seams.

58. A method as recited in Claim 56, wherein in a transverse cross section of said seams, said bonding regions have an extent along said unfinished faces of said stone tiles on opposite sides of said seams that is greater than the extent of said bonding region along said finished faces of said stone tiles on opposite sides of said seams.

59. A method as recited in Claim 56, wherein said step of applying occurs after said step of assembling.