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  Method of surfacing a substrateUSPTO Application #: 20070209748Title: Method of surfacing a substrate Abstract: A method is provided of resurfacing a substrate with a natural stone the substrate having a top surface and an edge, the method including placing a plurality of templating strips on the top surface to form a template defining an outside dimension, cutting out a top piece for resurfacing the top surface based on the outside dimension of the template, cutting out an edge band for resurfacing the edge of the substrate, bonding the edge band and the top piece together to form a replacement top and adhesively joining the replacement top to the substrate. A plurality of templating jigs may be used for forming a template. Pieces of natural stone may have respective bevel cuts made in their respective edges for adjoining with other pieces to form a replacement top of natural stone. Inside edges may be reinforced with a fiberglass cloth coated with a polyester resin. A plurality of natural stone pieces may be adjoined to form a segmented radius of curvature for covering a corresponding radius of curvature of an edge of the existing substrate. (end of abstract) Agent: Norman A. Nixon Beusse Brownlee Wolter Mora & Maire, P.A. - Orlando, FL, US Inventor: Paul Lane USPTO Applicaton #: 20070209748 - Class: 156071000 (USPTO) Related Patent Categories: Adhesive Bonding And Miscellaneous Chemical Manufacture, Methods, Surface Bonding And/or Assembly Therefor, Of Lamina To Building Or Installed Structure The Patent Description & Claims data below is from USPTO Patent Application 20070209748. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATION [0001] This application is a continuation of prior application Ser. No. 10/977,056, filed Oct. 29, 2004, which claims the benefit of U.S. Provisional Application No. 60/540,455 filed Jan. 30, 2004, both of which are specifically incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] This invention relates in general to fabricating material used for utilitarian and decorative surfaces and in particular to a method of fabricating slabs of natural stone for resurfacing existing structures or surfacing new construction. [0003] Granite is used in many different applications such as fireplace surrounds, shower walls, columns, flooring and countertops. Natural stone granite and marble are typically cut in slabs that are approximately two to three centimeters thick. Such slabs have traditionally been fabricated by cutting and shaping into appropriate sizes at this thickness to form new or replacement countertops. [0004] Three areas of concern with respect to using traditional granite for countertop replacement are: 1) inconvenience to the customer, 2) turn around time to complete the job and 3) countertop removal. Replacing countertops is difficult, time consuming and potentially stressful for the customer. It typically requires more than one skilled trade to complete installation and quite often causes collateral damage to surrounding surfaces that have to be repaired at the customer's expense. It frequently takes upwards of eight to ten weeks or longer for countertops to be replaced using traditional processes and materials. SUMMARY OF THE INVENTION [0005] Technology has been developed to cut natural stone slabs thinner than the traditional two to three centimeter thick slabs. This was done to increase the yield of the blocks from which the slabs are cut. The new thickness varies from about five millimeters to about two centimeters. Processing or fabricating natural stone this thin has proved to be difficult due to full slabs breaking or developing unacceptable cracking. [0006] The inventor of the present invention has determined that using existing countertops for resurfacing instead of newly constructed wooded substrates allows for improved efficiencies in templating, fabricating, preparing and installing the countertops. This may result in cost and time savings to the customer while providing the lustrous appearance of a solid granite countertop of traditional thickness. [0007] Certain fabrication techniques may use a wooden build up or frame to support stone surfaces that are thinner than traditional stone thicknesses. Such methods typically replace existing countertops using thinner slabs in the same manner as if slabs of conventional thickness were being used. The existing countertops are removed, which risks damage to the underlying frame and ancillary structure, and the new countertops having an underlying frame are installed. In this respect, the processes using thinner natural stone product are really no different nor do they offer any measurable advantages over traditional thicknesses of the natural stone product. [0008] One aspect of the present invention allows for resurfacing existing countertops or other suitable surfaces with a resurfacing material such as a natural stone, including granite and marble, for example. An exemplary embodiment allows for using granite slabs of less than approximately two centimeters in thickness with or without a reinforced backing. It will be appreciated that natural stone of granite and marble, for example, having other dimensions may be used for resurfacing applications in accordance with aspects of the invention. DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a cross-sectional view of an exemplary templating fixture or jig used in accordance with aspects of the invention. [0010] FIG. 2 is a plan view of exemplary templating strips laid out on a material for surfacing a substrate. [0011] FIG. 3 is a plan view of exemplary templates laid out on a material for surfacing a substrate. [0012] FIG. 4 is an end view of an edge formed in accordance with aspects of the invention. [0013] FIG. 4A illustrates a relationship between an edge band and a countertop for sizing the edge band. [0014] FIG. 5 is a broken view of two exemplary pieces of material to be adjoined in accordance with aspects of the invention. [0015] FIG. 6 is an end view of the pieces of FIG. 5 assembled to form an edge. [0016] FIG. 7 is an end view of the assembly of FIG. 6. [0017] FIG. 8 is an end view of the assembly of FIG. 6. [0018] FIG. 9 is a perspective view of an edge band prepared with a radius of curvature in accordance with aspects of the invention. [0019] FIG. 10 is a partial cross-sectional view of an exemplary replacement top installed in a typical countertop arrangement. DETAILED DESCRIPTION OF THE INVENTION Continue reading... Full patent description for Method of surfacing a substrate Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Method of surfacing a substrate patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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