METHOD AND APPARATUS FOR INSTALLING MARBLE PANELS

Abstract: A system for installing individual marble panels on flat wall surfaces which eliminates the need for skilled artisans to do the installation. The marble panels are formed of a thin marble layer (114) which is attached to a backing layer or carrier (116). In one embodiment, special clips are attached to the flat wall surfaces to which the marble panels are secured, and the clips are inserted in routed out portions in the backing layer behind the layer of marble (114). In another embodiment, the backing layer or carrier (116) is formed with a tongue (118) and groove (119) assembly, whereby adjoining marble panels are interfit with each other. In order to form a continuous pattern of the marble layers (114) on the wall surface, a slab of marble is into a plurality of thin marble sheets; a backing panel is attached to opposite sides of each marble sheet; each marble sheet is then cut in half to define two marble panels, each comprised of a marble layer (114) and a backing panel; the marble panels are installed on the flat wall such that marble layers (114) which represent successive cuts from the slab of marble are adjacent to each other and such that adjacent side edges of adjacent marble layers (114) are in abutting relation and correspond to the same end of the slab of marble.

Description: METHOD AND APPARATUS FOR INSTALLING MARBLE PANELS- The present invention relates generally to a method and apparatus for installing marble walls and, more particularly, is directed to a method and apparatus for installing marble walls formed of thin marble layers. Marble panels and walls have always been a desirable architectural and interior design feature. Conventionally, such marble panels are provided by a solid marble slab which must be secured to a flat surface. A skilled artisan is required to handle the slab and to secure it to the flat surface without cracking or breaking the marble. Obviously, this is a time consuming and expensive process, and the damage to marble slabs which occurs is a very expensive problem. One attempt to eliminate the need of such an assembly procedure has been to provide materials made of plastic which are marble look-alikes and which are assembled as squares on a wall surface. Obviously, such squares do not resemble a marble panel, and the undesirability of such squares as a replacement for natural marble is quite clear. U.S. patent No. 3,963,846 entitled "Marble-Faced - Composite Surface Element" discloses a composite marble panel formed of a thin marble layer attached to a honeycomb backing structure. This composite panel is difficult to assemble and also leaves unfinished, edges . There is a further problem when using thin layers of marble. Specifically, the grains in each marble layer form a pattern on the front face thereof. hen the marble panels are installed on the wall, the patterns on adjacent marble layers do not correspond with each other, clearly indicating that separate marble layers are being used, and more importantly, imparting a less than desirous appearance. This is particularly due to discontinuities between patterns of adjacent layers at the side edges thereof. OBJECTS AND SUMMARY OF THE INVENTION Accordingly, it is an object of the present Invention to provide a a marble panel and assembly system which enables whole marble panels of the size of a natural marble slab to be installed without requiring skilled artisans. It is another object of the present invention to provide such an assembly system which is relatively foolproof, simple to use and easily adaptable to on-site installation. It is still another object of the present invention to improve the time and efficiency of installation of marble walls which materially can reduce the installation cost. It is yet another object of-the present invention to provide a system in which cracking and breaking of marble slabs is eliminated, yet in which marble walls are installed with the apparent thickness of marble slabs. It is a further object of the present invention to provide a marble panel which not only has a thin marble layer, but also has substantially finished side edges. It is a still further object of the present invention to provide a method of installing marble panels on a f1-at wall such that a substantially continuous pattern extends along the wall. It is a yet further object of the present invention to provide a method of installing marble panels on a flat wall with the patterns of adjacent panels being continuous at the side edges thereof. In accordance with an aspect of the present invention, a system for assembling and attaching marble panels substantially flush to a flat surface to give the appearance of marble slabs or surfaces, includes a plurality of marble panels; each marble panel including a marble sheet and a coextensive backing layer attached thereto which is routed out adjacent the marble sheet at selected portions thereof to define thin sections spaced from the marble sheet at the selected portions; independent and separate fastening strips attached to the flat surface, the fastening strips attached on the surface at preselected heights; a plurality of clips adapted to be secured to the fastening strips for laterally aligning the marble panels on the flat surface; each clip including an inner leg, an outer leg spaced-apart and parallel to the inner leg, and a transverse web interconnecting the inner and outer legs in a spaced-apart and parallel arrangement to define a guide channel, the guide channel receiving the panels in a non-load bearing manner to laterally align the marble panels; the inner leg of each lip being secured to the fastening strips at an orientation substantially parallel to the horizontal such that each guide channel laterally guides the marble panels with respect to each other so that vertical edges of adjacent panels are in abutment and substantially co-planar; wherein the spacing between respective portions of the common inner and outer legs of each clip which define the guide channel enables the legs to be freely inserted in the backing layer of the panels to eliminate bending of the outer common leg of each clip. In accordance with another aspect of the present invention, an assembly system for installing individual marble panels to a flat surface includes individual marble panels formed of a flat sheet of marble and a mounting carrier secured thereto; each mounting carrier comprising a front attaching surface and a rear mounting surface for attachment to the flat surface, one. side edge of the carrier comprising a groove and the opposite side edge comprising a tongue insertable into a groove in an adjoining marble panel, each mounting carrier comprising an extension on the opposite side edge, the extension having apertures enabling the marble panel to be attached to the flat surface, the marble sheet of each marble panel being substantially coextensive with and secured to the respective front attaching surface such that side edges of each marble sheet positioned between adjacent marble sheets on the flat surface are aligned with and abut side edges of the adjacent marble sheet, when the tongues of respective mounting carriers are inserted into the grooves of adjacent mounting carriers. In accordance with still another aspect of the present invention, a method of installing marble panels on a flat wall, includes the steps of cutting a slab of marble having a front face and opposite ends, into a plurality of thin marble layers; attaching a backing panel to each marble layer to form a plurality of marble panels; installing the marble panels on the flat wall such that marble layers which represent successive cuts from said slab of marble are adjacent to each other and such that adjacent side edges of adjacent marble layers are in abutting relation and correspond to the same end of the slab of marble, to form a continuous pattern on the flat wall. In accordance with yet another aspect of the present invention, a method of installing marble panels on a flat wall, includes the steps of cutting a slab of marble having a front face and opposite ends, into a plurality of thin marble sheets; attaching a backing panel to opposite sides of each marble sheet; cutting each marble sheet in half to define two marble panels, each comprised of a marble layer and a backing panel; installing the marble panels on the flat wall such that marble layers which represent successive cuts from said slab of marble are adjacent to each other and such that adjacent side edges of adjacent marble layers are in abutting relation and correspond to the same end of the slab of marble, to form a continuous pattern on the flat wall. The above, and other, objects, features and advantages of the present invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a front and side wall having mounting strips attached thereto; Fig. 2 is a perspective view of the front and side wall of Fig. 1 with marble panels attached thereto according to one embodiment of the present invention; Fig. 3 is a cross-sectional view, taken along line 3-3 of Fig. 2, showing the assembly of marble panels on the walls; Fig. 4 is a top plan view of an H-shaped clip forming part of the present invention; Fig. 5 is a top plan view of a corner U-shaped clip forming part of the present invention; Fig. 6 is a perspective view of a front and side wall to which intermediate carriers are attached, according to second embodiment of the present invention; Fig. 7 is a perspective view of intermediate and lower panel assemblies used in the embodiment of Fig. 6; Fig. 8 is a perspective view of a marble panel attached to a carrier of Fig. 6; Fig. 9 is a perspective view of the front and side walls of Fig. 6, with marble panels secured thereto; Fig. 10 is a cross-sectional view, taken along line 10-10 of Fig. 9, showing the installation of the marble panel to the intermediate panel assembly and walls; Fig. 11 is a cross-sectional view, taken along line 11-11 of Fig. 9, showing a kickplate section; Fig. 12 is a perspective view of a corner clip used in the assembly procedure of the second embodiment of the - present invention; Fig. 13 is a cross-sectional view of another embodiment of a marble panel that can be used in the second embodiment of the present invention; Fig.14 is a perspective view of a slab of marble from which a plurality of marble sheets is obtained according to a third embodiment of the present invention; Fig. 15 is an end plan view of a section of the marble slab of Fig. 14, used for illustrating the step of cutting the marble slab into a plurality of marble sheets; Fig. 16 is an end plan view of three intermediate structures, each formed of a marble sheet having a backing layer secured on opposite sides thereof; Fig. 17 is an enlarged end plan view of the three intermediate structures of Fig. 16, with the last one cut to form two marble panels; Fig. 18 is an enlarged end plan view of the three intermedi.ate structures of Fig. 17, each shown separated into two marble panels and indicating the manner of arrangement with respect to each other; Fig. 19 is a perspective view of a flat wall having the marble panels of Fig. 18 installed thereon; and Fig. 20 is a cross-sectional view of the marble panels of Fig. 19, taken along line 20-20 thereof. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings in detail, and initially to Fig. 1 thereof, there is illustrated a flat surface or wall 10 and a perpendicular flat surface or wall 12. These walls are illustrative of structures to which marble panels can be attached to assemble marble walls. These walls are generally finished with sheet rock attached to sticks in a conventional manner. In order to effectively attach the individual marble panels of the present invention to the walls, horizontal fastening strips 14 are attached to the walls by suitable screws, bolts or the like, to be level at preselected heights. Fastening strips 14 are level on the walls to enhance the assembly and installation of the marble panels, and may be made of aluminum or plastic, as desired. Referring now to Fig. 3, there is illustrated a sectional view of the panels 16 according to the present invention attached to the walls. Each panel 16 generally comprises a marble layer 18 and a co-extensive backing layer 20. Backing layer 20 is formed of a honeycomb or similar material which may be routed out as at 22, so that the clips of the present invention, which will be described in greater detail hereinafter, can be inserted into backing layer 20 thereat to secure each marble panel 16 to the respective wall. It is to be appreciated that panels 16 are to be installed inside a building. Marble layers 18 therefore have a height which extends from floor to ceiling. Thus, no marble layer 18 extends above another, but rather, marble layers 18 are only laterally adjacent each other. The system of the present invention utilizes an H- shaped clip 23, as shown in Fig. 4, which is preferably made of plastic. Clip 23 is comprised of an inner common leg 24 and a parallel outer common leg 26 between which there is located a web 28, so as to form back-to-back left and right channels 29 and 31, respectively. A pair of apertures 30 and 32 are provided through inner leg 24, on one side of web 28, while an aperture 34 is provided on the same side of outer leg 26 to align with aperture 30 of inner leg 24 and thereby permit access to aperture 30. Clips 23 can be fastened to fastening strips 14, as shown in Fig. 1, or directly to the walls. preferably, however, clips 23 are_ secured to fastening strips 14 to avoid surface irregularities which may occur on the walls. If clips 23 are fastened on a wall surface in which there are imperfections, panels 16 which are connected with clips 23, will not lay flat with respect to the wall surface. Thus, fastening strips 14 are level to the surface of the walls and cover up or compensate for wall surface irregularities. Once clips 23 are attached to fastening strips 14, a first marble panel 16 is inserted in the right hand channels 31 of clips 23. It will be appreciated that the inner and outer legs 24 and 26 of each clip 23 extend horizontally, and therefore, guide channels 29 and 31 formed thereby also extend horizontally. Thus, clips 23 only laterally guide marble panels 16 and hold the same to walls 10 and 12. In view of the weight of the ' marble panels 16, it is important that the web 28 of each clip 23 be non-load bearing to prevent cocking of the clip. Thus, the clips do not support marble panels 16, but rather, marble panels 16 are supported on the floor of the building. A second marble panel 16 is then installed after its backing layer 20 is routed out as at 22, by sliding it into the left channel 29 of the same vertically aligned clips 23, and is securely held therein. With such arrangement, the inner common leg 24 of each clip 23 bears against the respective fastening strip 14, while the outer leg 26 sits in the routed areas 22 in backing layers 20 of the first and second marble panels 16, whereby the marble panels 16 may be installed by merely inserting them into clips 23 which are attached on walls 10 and " 12. As may be understood, adjoining marble panels 16 will abut each other in the area of each web 28. The marble panels 16 are then installed from right to left, until the left corner 35 of front wall 10 is reached. At this point, the last panel 16 is cut at the site to be flush with left wall 12. As shown in Figs. 3 and 5, the present invention also uses corner clips 36. Each corner clip 36 has a generally U-shape with an inner leg 38 having apertures 40 and 42, an outer leg 43 with an aperture 44, and a base 46 connecting inner leg 38 to outer leg 43. Each clip 36 is mounted against a fastening strip 14 or directly on the wall surface 12, as appropriate. Each corner clip 36 is inserted with its base 46 bearing against the left front edge of the marble panel 16 adjacent side wall 12, and is securely fastened to wall 12 through apertures 40, 42 and 44 in a conventional fashion. A first marble panel 16 is assembled on left wall 12 by inserting the corner clips 36 in routed out portions 22 of the backing layer 20 of such marble panel 16. In this way, corner clips 36 hold the front marble panel 16 firmly against front wall 10, while beginning the corner turn for the marble panel 16 attached to side wall 12. It is important to note that the spacing between the inner and outer legs 24 and 26 of each clip 23 enables the legs to be freely inserted into panels 16 to eliminate bending of the common outer leg 26 of each clip 23. Since the system is recited as being used on inner walls with the marble panels 16 being substantially flush to the walls, it is also important to the system that the close fit between each panel 16 and wall 10, with the clip 23 in between, be such as to eliminate stress on the legs. This could result from the legs of each clip 23 being snapped onto panels 16 by their expanding to grip such panels 16 much in the way of clothes hanger clips. Prevention of that type of cocking or bending is achieved because of the spacing provided in the routed-out areas 22 of the marble panels 16 with respect to the legs 24 and 26 of clips 23. In addition to the spacing between the legs of each clip, the thickness of each U-shaped corner clip 36 or H-shaped clip 23, in conjunction with the routed out portions 22 in backing layers 20, is such that the front outer leg 26 will not bend when inserted in the routed out portions 22. This also prevents a cocking or unevenness from occurring between adjacent marble panels. Thus, with the present invention, as described above, marble walls may be assembled which appear to be constructed of full marble slabs, without requiring such full marble slabs. This not only reduces the cost of such marble walls, but also the cost of installation and eliminates the need for skilled artisans to assemble such marble slabs. Thus, the present invention provides for a relatively foolproof method of assembling marble wall panels which will have the same appearance as marble slabs. Referring now to Figs. 6-13, there will now be described another emDodiment of the present invention. Specifically, marble-panels 108 illustratively are to be installed on a front wall 110 and a perpendicular side wall 112, shown in Fig. 6. One embodiment of a marble panel " 108 is illustrated in Fig. 13. As shown, marble panel 108 comprises a layer 114 of marble attached to a solid mounting carrier 116, the carrier comprising a tongue 118 and groove 119 assembly to enable adjoining marble panels to fit and interlock one in the other to ensure abutting of adjoining panels. Solid mounting carrier 116 comprises a front attaching surface 117 coextensive with the marble sheet or layer 114 and a rear mounting surface 120 parallel to the front surface 117. Carrier 116 may alternatively be formed of a series of support webs 122, as shown in Fig. 8, to which a rear mounting surface 126 is attached. Marble layer 114 is attached to the feet 149 of webs 122 which form a discontinuous front attaching surface, and is coextensive therewith. The tongue 118 and groove 119 may be molded of plastic. The entire carrier assembly of Fig. 8 may be manufactured of molded plastic by providing a mold and injecting a plastic material to form the panel 108 as shown in Fig. 8. Whether the panel is an integrally molded structure or a composite structure, it will be seen that the edges 127 of the carrier panel 116 are finished and may be clad with marble strips. Once the individual marble panels are assembled, they can then be mounted directly to the wall, with mounting surface 120 or 126 bearing against the wall. A preferred and different embodiment for a mounting system for such marble assemblies is illustrated in Fig. 7. There is shown a perspective view of an individual intermediate assembly panel 128 which may be a molded structure having parallel areas 132 which alternate between parallel projecting mounting surfaces 134. The mounting surfaces 134 lie in a single plane. These molded intermediate panels 128 are attached to wall 110 by screws, bolts or the like 140 extending through apertures 136 in the recessed portions 132. The intermediate assembly panels 128 and 130 are level with respect to the floor, and once so assembled, the individual marble panels 108 can be attached to the wall. An intermediate foot panel 138 comprises a recessed area 140 between two projecting mounting co-planar surfaces 142 and 144. Recessed and projecting portions 142 and 144 are parallel and arranged in rows. A bottom support lip 146 is also provided in foot panel 138 to provide support for the individual marble panels attached to the intermediate assembly panel 128. Once the intermediate assembly panels 128 are attached to the walls, the individual marble panels are then attached to the intermediate assembly panels by utilizing apertures 160 provided in the extensions 162 on the sides of the carriers containing grooves 119. Panels 128 and 138 may be formed of unitary members of a molded plastic material. Fig. 10 illustrates use of the embodiment of Fig. 8 for an individual marble panel which includes the substantially hollow carrier 116 and mounting surface 126 adapted to be mounted against the intermediate assembly panels or the wall surface. The plurality of webs 122 extend perpendicular to surface 126 and terminate in ledges 149 onto which the marble sheet 114 may be directly secured. Mounting surface 126 and webs 122 may be molded of plastic and the tongue 118 and groove 119 may also be simultaneously molded at the opposite side edges of the carrier. To complete the assembly of the panels on the walls, corner clips 150 are provided, as shown in Figs. 10 and 12. Each corner clip 150 comprises a unitary plastic member having a rear mounting leg 152 attached to a flexible finger 156 through a base 157. The leg 152 has an aperture 154 to enable the clip to be attached to a recessed portion 132 of an intermediate panel 128. Each clip 150 is attached to the first intermediate panel attached to side wall 112, as illustrated in Fig. 10. When so installed, the flexible finger 156 is flexed outwardly so that base 157 bears against the left portion of the marble panel installed against front wall 110. Additionally, the flexible finger 156 bears inwardly against the first marble panel installed against side wall 112, as shown in Fig. 10, and the recessed area 132 accommodates the flexible finger 156 of clip 150. Referring now to Figs. 14-20, there is shown a slab 210 of marble from which a plurality of thin sheets of marble are to be cut, according to still another embodiment of the present invention. It will be noted that the front face 212 of marble slab 210 includes a particular pattern determined by the marble grains. The pattern on the top face 214 and an end face 216 are also shown. As shown in Fig. 14, marble slab 210 is divided into a plurality of sections 210a, 210b, 210c, 210d, 210e and 210f, the latter three only being partially shown, and sections 210b and 210c only being shown in dot-dash lines. Each section is cut, in turn, as indicated by arrow 218 in Fig. 14, into a plurality of thin sheets of marble. Accordingly, the cutting of section 210a will first be discussed. As shown in Fig. 15, section 210a is cut into a plurality of thin sheets 220 of marble, as indicated by the vertical cut lines 222 therein. It will be appreciated that the pattern on front face 212 varies and shifts as one travels from front face 212 to the rear face 224 of section 210a. However, the amount of shift and variation in the pattern over a small distance is not great, and may not even be visually noticeable. Thus, the pattern on the front face of any thin sheet 220 of marble will be substantially identical to that on the front face of any adjacent thin sheet 220 of marble. The present invention uses this to form a continuous pattern when the marble is installed on a flat wall, as will be described in greater detail hereinafter. Three thin sheets 220a, 220b and 220c of marble are shown generally in Fig. 16, each having a backing or carrier panel 226a, 226b; 226c, 226d; and 226e, 226f, respectively, attached thereto, the intermediate structures of thin sheets 220 of marble and two backing panels 226 being referred to by numerals 228a, 228b and 228c, respectively. Each backing panel 226 can be constructed substantially identical to the carrier 116, discussed above. Thus, each backing panel 226 can be constructed as a solid structure or a hollow structure, the latter hav.ing a honeycc b or web-like construction. In addition, one edge of each backing panel 226 is formed with a groove 230 and the opposite edge of each backing panel 226 is formed with a tongue 232 for insertion into a groove 230 in an adjoining marble panel, as shown in Fig. 20. Fig. 17 shows the intermediate structures 228a, 228b and 228c of Fig. 16 in an enlarged scale, and which will be used for describing the next step according tc the method of the present invention. Specifically, each intermediate structure 228 is divided in half along a vertical line 234 shown in Fig. 17 which extends centrally through each thin sheet 220 of marble, and then the two halves are separated as shown by by the last intermediate structure 228, to form two marble panels 236. Thus, each marble panel 236 is formed from a thin layer 238 of marble (one-half of a thin sheet 220 cf marble) and a backing panel 226. Marble panels 236 constitute the end product and are installed on a flat wall, as taught above. In order to better understand the present invention, marble panels 236 and thin layers 238 of marble have been designated with the letters a, b, c, d, e and f, as shown in Figs. 17 and 18. It will be appreciated that the resultant front faces 240 of marble layers 238a and 238b cut from the same sheet 220a of marble, have an identical pattern thereon. Thus, if the corresponding marble panels 236a and 236b are installed on a flat wall adjacent to each other, as indicated in Fig. 18, there will be a continuity between the patterns at the edges thereof. The same holds true for marble layers 238c, 238d; and 238e, 238f. Further, since the pattern does not vary much for a thickness equal to a thin sheet 220 of marble, the patterns at the edges 242b and 242c, shown in Fig. 18, between front faces 240b and 240c of adjacent marble layers 238b and 238c cut from adjacent thin sheets 220a and 220b of marble, will be substantially identical. The same holds true for marble layers 238d, 238e. There will thus be continuity in the pattern cf marble throughout the entire wall on which the marble panels 236 are installed, as shown in Fig. 19. It is important, however, that any two abutting edges 242 of adjacent marble layers 238 correspond to the same end face, that is, end face 216 or the opposite end face, of section 210a, so that there is a continuity in the pattern presented on the flat wall. It will be appreciated that various modifications can be made to the present invention. For example, instead of cutting the thin sheets 220 of marble, the marble layers 238 could be cut from section 210a and then a backing panel 226 would be attached to each marble layer 238. It is only important that the edges be matched to provide a continuous pattern when the marble panels are affixed to the flat wall. Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is. not limited tc those precise embodiments and that various changes and modifications can be effected therein by one of ordinary skill in the art, without departing from the sccpe or spirit of the invention as defined in the appended claims.

Claims: WHAT IS CLAIMED IS: 1. A system for assembling and attaching marble panels substantially flush to a flat surface to give the appearance of marble slabs or surfaces, said system comprising: a plurality of marble panels; each marble panel including a marble sheet and a coextensive backing layer attached thereto which is routed out adjacent said marble sheet at selected portions thereof to define thin sections spaced from said marble sheet at said selected portions; independent and separate fastening strips attached tc said flat surface, said fastening strips attached en said surface at preselected heights; a plurality of clips adapted to be secured to said fastening strips for laterally aligning said marble panels on said flat surface; each clip including an inner le<g, an outer leg spaced-apart and parallel to said inner leg, and a transverse web interconnecting said inner and outer legs in a spaced-apart and parallel arrangement to define a guide channel, said guide channel receiving said panels in a non- load bearing manner to laterally align said marble panels; said inner leg of each lip being secured tc said fastening strips at an orientation substantially parallel to the horizontal such that each said guide channel laterally guides the marble panels with respect to each other such that vertical edges cf adjacent panels are in abutment and substantially co-planar; wherein the spacing between respective portions of said ccir on inner and cuter legs of each clip which define said guide channel enables said legs to be freely inserted in the backing layer of said panels to eliminate bending of the outer common leg of each clip. 2. A system as claimed in Claim 1, wherein said backing layer comprises a honeycomb assembly. 3. A system as claimed in Claim 1, wherein at least one said clip comprises an H-shape unitary assembly formed of a common inner leg, a spaced-apart common, outer leg " and a common web connected therebetween to from back-to-back guide channels, a portion of the inner leg defining one cf said guide channels including at least one aperture enabling said clip to be attached to said surface, said one guide channel receiving a routed out portion cf said backing layer of a first marble panel tc laterally align and hold said marble panel, a second marble panel having its backing layer routed out and inserted in the other guide channel cf said clip, with the m.arble sheets of said first and second marble panels extending over said common cuter leg and abutting each other in the vicinity cf said common web. 4. A system as claimed in Claim 3, wherein the outer leg includes at least one aperture aligned with at least one aperture in said inner leg. 5. A system as claimed in Claim 1, wherein at least one said clip is a corner clip and comprises a unitary assembly having a U-shape to hold one marble panel to a first flat surface, a base cf said corner clip bearing against said one marble panel, the corner clip enabling installation of a second marble panel on a surface substantially perpendicular to said first flat surface. 6. A system as claimed in Claim 1, wherein said clip is made of plastic. 7. An assembly system for installing individual marble panels to a flat surface, comprising: individual marble panels formed of a flat sheet cf marble and a mounting carrier secured thereto; each said mounting carrier comprising a front attaching surface and a rear mounting surface for attachment tc said flat surface, one side edge of said carrier comprising a groove and the opposite side edge comprising a. tongue insertable into a groove in an adjoining marble panel, each said mounting carrier comprising an extension on said opposite side edge, said extension having apertures enabling said marble panel to be attached tc said flat surface, said marble sheet cf each marble panel being substantially coextensive with and secured to the respective frcnt attaching surface such that side edges of each marble sheet positioned between adjacent marble sheets on said flat surface are aligned with and abut side edges of said adjacent marble sheet, when said tongues cf respective mounting carriers are inserted into said grooves of adjacent mounting carriers. 8. An assembly system as claimed in Claim 7, wherein said mounting carrier is sclid and comprises a melded plastic member having said front attaching and said rear mounting surfaces parallel tc each ether. 9. An assembly system as claimed in Claim 7, wherein said mounting carrier is substantially hollow, including a plurality of webs perpendicular to said rear mounting surface, terminating in ledges forming said frcnt ettachirg surface, said flat sheets cf marble being attached tc said front attaching surfaces. 10. An assembly system as claimed Claim 7, further comprising intermediate assembly panels to be secured between said individual marble panels and said flat surface, said intermediate assembly panels secured to said flat surface, and said individual marble panels attached to said intermediate assembly panels, each said intermediate assembly panel comprising a rear surface mounted to said flat surface, a front mounting surface on which said rear mounting surface of a carrier is mourted and a recessed area through which securing means extend to secure said intermediate assembly panel to said flat surface, said apertures in the extension of said mounting carrier being _ _ aligned with apertures in said front mounting surface of a corresponding intermediate assembly panel. 11. An assembly system, as claimed in claim 10, wherein each said intermediate assembly panel comprises a unitary assembly having at least one front mounting row defining said front mounting surface and at least one contiguous recessed row defining said recessed area. 12. An assemibly system as claimed in Claim 10, wherein said intermediate assembly panels are attached level to said flat surface, said apertures in said extension aligning with preset apertures in said intermediate assembly panels to ensure that said marble panels are • assembled level and abutting each other. 13. An assembly system as claimed in Claim 12, wherein said intermediate assembly panels are formed of plastic 14. An assembly system as claimed in Claim 11, wherein said unitary assembly includes a plurality of alternating recessed and front mounting rows. 15. An assembly system as claimed in Claim 11, further comprising at least one corner clip secured tc a recessed area cf an intermediate assembly panel, each said corner clip comprising a flexible cuter finger, each said corner cli attached at an extreme side position of said flat surface adjacent a perpendicular second flat surface, a marble panel inserted into each said clip with said flexible cuter finger holding said marble panel flat against an intermediate assembly panel which is attached to said second flat surface, each said corner clip comprising a base bearing against the marble panel secured to the first flat surface. 16. An assembly system as claimed in Claim 15, wherein each said ccrner clip and intermediate assemibly panel are made of plastic. 17. An assembly system as claimed in Claim 10, further comprising intermediate assembly foot panels for mounting on the flat surface at floor level, each said foot panel including a support ledge for supporting the lower edge of a marble panel secured thereto. 18. A method of installing marble panels on a flat wall, comprising the steps of: cutting a slab of marble having a front face and opposite ends, into a plurality of thin marble layers; attaching a backing panel to each marble layer to form a plurality of marble panels; - installing said marble panels on said flat wall such that marble layers which represent successive cuts from. ' said slab of m.arble are adjacent to each ether and such that adjacent side edges cf adjacent marble layers are in abutting relation and correspond to the same end cf said slab of marble, to form e continuous pattern en said flat wall. 19. A method as claimed in Claim 18, wherein each backing panel includes a groove along a side edge thereof and a tongue alcng an epposite side edge thereof for insertion into a grccve cf an adjacent backing panel when εaid marble panels are installed on said flat wall, and wherein said step of installing further includes the step of inserting the tongue of each backing panel into a groove cf an adjacent backing panel when said marble panels are installed on said flat wall. 20. A method as claimed in Claim 18, further comprising the step cf initially aligning said marble panels with respect to each other prior to installing the same such that adjacent side edges of adjacent marble layers correspond to the same end cf said slab of marble. 21. A method of installing marble panels on a flat wall, comprising the steps cf: cutting a slab of marble having a front face and opposite ends,, into a plurality of thin marble sheets; attaching a backing panel to opposite sides cf each marble sheet; cutting each marble sheet in half to define two marble panels, each comprised of a marble layer and a backing panel; installing said marble panels on said flat wall such that marble layers which represent successive cuts from said slab of marble are adjacent to each ether and such that adjacent side edges of adjacent m.arble layers are in abutting relation and correspond to the same end of said slab of marble, tc form a continuous pattern on said flat wall. 22. A method as claimed in Claim 21, wherein each backing panel includes a groove along a side edge thereof and a tongue along an opposite side edge thereof for insertion into a groove of an adjacent backing panel when said marble panels are installed on said flat wall, and wherein said step of installing further includes the step of inserting the tongue cf each backing panel into a groove of an adjacent backing panel when said m.arble panels are installed on said flat wall. 23. A method as claimed in Claim 21, further comprising the step of initially aligning said marble panels with respect to each other pricr to installing the same such that adjacent side edges of adjacent marble layers correspond to the same end of said slab of marble.

Inventors: MIGLIORE NEIL, MIGLIORE, NEIL
Applicants: MIGLIORE NEIL, MIGLIORE, NEIL
Application year: 1986
Main classification: E04F13
IPC codes: B28D1, E04F13