CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application No. 62/402,103, entitled, "DECORATIVE MATERIAL VENEER," filed September 30, 2016, naming David Fieldhouse as the inventor, the disclosure of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure generally relates to decorative material product manufacturing and, in particular, systems and methods for producing a decorative material adhered to a backing plate.

BACKGROUND

[0003] In manufacturing decorative material products (especially for natural stone), some of the material can be brittle and fragile, thereby causing a low yield of products from the available raw material. For example, stone may be first retrieved from a quarry as a large block of material and subsequently cut into to thinner pieces of the material thereby weakening the pieces, such that they can break in handling and processing operations. These broken pieces may be salvaged and used in producing mosaics, or other products that can utilize the smaller pieces, but they may no longer be available for products that require the larger pieces.

[0004] Therefore, it will be readily appreciated that improvements in the arts of manufacturing decorative material products are continually needed. SUMMARY

[0005] The embodiments of the invention are summarized by the claims that follow the description.

[0006] In one embodiment, a method of producing a decorative veneer assembly 13, 16 can include operations of adhering a first backing plate 30 to a first surface 42 of a slab 20 of material, adhering a second backing plate 30 to a second surface 49 of the slab 20 of the material, the second surface 49 being opposite the first surface 42, and cutting the slab 20 along a line 80, 82, 84 that is between the first and second surfaces 42, 49, thereby dividing the slab 20 into first and second portions 22/24, 26/28, with the first portion 22/24 including the first surface 42 of the slab 20 and a third surface 45 created by the cutting of the slab 20, the second portion 26/28 including the second surface 49 of the slab 20 and a fourth surface 46 created by the cutting of the slab 20, and the third surface 45 of the first portion 22/24 being a mirrored pattern of the fourth surface 46 of the second portion 26/28.

[0007] For any of the foregoing embodiments, the method may include any one of the following elements, alone or in combination with each other.

[0008] The first backing plate 30 can be selected from a group consisting of a magnesium (also referred to as MGO) board, a metal sheet, and a laminated metal sheet.

[0009] The method can also include operations of polishing the third and fourth surfaces 45, 46 to produce first and second decorative veneer assemblies 13, 16 with mirrored patterns relative to each other. The first decorative veneer assembly 13, 16 can include the first portion 22/24 adhered to the first backing plate 30 via the first surface 42, and the second decorative veneer assembly 13, 16 can include the second portion 26/28 adhered to the second backing plate 30 via the second surface 49. A thickness L9 of either one of the first decorative veneer assembly 13, 16 or the second decorative veneer assembly 13, 16 can be selected from a group consisting of 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, and 27 millimeters.

[00010] Either one of a width L2 or a length LI of the first portion 22/24 (and/or the second portion 26/28) can be in a range from 0.25 meters (9.84 inches) to 2 meters (78.7 inches). [00011] The width L2 of the first portion 22/24 (and/or the second portion 26/28) can be selected from a group consisting of 0.25 meters (9.84 inches), 0.406 meters (16 inches), 0.457 meters (18 inches), 0.5 meters (19.7 inches), 0.610 meters (24 inches), 0.75 meters (29.5 inches), 0.762 meters (30 inches), 914 meters (36 inches), 1.0 meter (39.4 inches), 1.125 meters (44.3 inches), 1.25 meters (49.2 inches), 1.5 meters (59.1 inches), and 2.0 meter (78.8 inches).

[00012] The length LI of the first portion 22/24 (and/or the second portion 26/28) can be selected from a group consisting of 0.25 meters (9.84 inches), 0.406 meters (16 inches), 0.457 meters (18 inches), 0.5 meters (19.7 inches), 0.610 meters (24 inches), 0.75 meters (29.5 inches), 0.762 meters (30 inches), 914 meters (36 inches), 1.0 meter (39.4 inches), 1.125 meters (44.3 inches), 1.25 meters (49.2 inches), 1.5 meters (59.1 inches), and 2.0 meter (78.8 inches).

[00013] A thickness L8 of the first portion 22/24 (and/or the second portion 26/28) can be in a range of 5 millimeters to 22 millimeters (0.197 inches to 0.866 inches). The thickness L8 can be in a range selected from a group consisting of 5 millimeters to 7 millimeters (.197 inches to 0.276 inches), 7 millimeters to 11 millimeters (.276 inches to 0.433 inches), 10 millimeters to 14 millimeters (.394 inches to 0.551 inches), and 14 millimeters to 22 millimeters (.551 inches to 0.866 inches). The thickness L8 can be selected from a group consisting of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, and 22 millimeters.

[00014] A thickness L3 of the slab 20 can be in a range of 10 millimeters to 44 millimeters (0.394 inches to 1.73 inches).

[00015] The method can further include operations of adhering a third backing plate 30 to a third surface 45 of the first portion 22/24, and cutting the first portion 22/24 along a line 82 that is between the first and third surfaces 42, 45, thereby dividing the first portion 22/24 into third and fourth portions 22, 24, with the third portion 22 can include the first surface 42 of the slab 20 and a fifth surface 43 created by the cutting of the first portion 22/24, the fourth portion 24 can include the third surface 45 of the first portion 22/24 and a sixth surface 44 created by the cutting of the first portion 22/24, and the fifth surface 45 of the third portion 22 being a mirrored pattern of the sixth surface 44 of the fourth portion 24

[00016] The method can further include operations of adhering a fourth backing plate 30 to a fourth surface 46 of the second portion 26/28, and cutting the second portion 26/28 along a line 84 that is between the second and fourth surfaces 49, 46, thereby dividing the second portion 26/28 into fifth and sixth portions 26, 28, with the fifth portion 26 including the fourth surface 46 of the second portion 26/28 and a seventh surface 47 created by the cutting of the second portion 26/28, the sixth portion 28 including the second surface 49 of the slab 20 and an eighth surface 48 created by the cutting of the second portion 26/28, and the seventh surface 47 of the fifth portion 26 being a mirrored pattern of the eighth surface 48 of the sixth portion 28, thereby producing four of the decorative veneer assemblies 16.

[00017] The material of the slab 20 can be selected from a group consisting of one or more pieces of natural stone, one or more pieces of a man-made material, one or more pieces of glass, one or more pieces of ceramic, and combinations thereof.

[00018] In another embodiment, a system for producing a decorative veneer assembly 13, 16 that can include an assembly 10 that can include a slab 20 of material with a first backing plate 30 adhered to a first surface 42 of the slab 20 and a second backing plate 30 adhered to a second surface 49 of the slab 20, the second surface 49 being opposite to the first surface 42, a cutting tool 90 that receives the assembly 10 and cuts the slab 20 along a line 80, 82, 84 that is between the first and second surfaces 42, 49, wherein the slab 20 is divided into first and second portions 22/24, 26/28 in response to the cut, thereby yielding first and second subassemblies 13, with the first subassembly 13 comprising the first portion 22/24 adhered to the first backing plate 30 and the second subassembly 26/28 comprising the second portion 26/28 adhered to the second backing plate 30, and a polisher 92 that polishes third and fourth surfaces 45, 46 of the first and second portions 22/24, 26/28, respectively, wherein the third and fourth surfaces 45, 46 are created by the cut along the line 80, 82, 84.

[00019] A width L2 of the first portion 22/24 can be selected from a group consisting of 0.25 meters (9.84 inches), 0.406 meters (16 inches), 0.457 meters (18 inches), 0.5 meters (19.7 inches), 0.610 meters (24 inches), 0.75 meters (29.5 inches), 0.762 meters (30 inches), 914 meters (36 inches), 1.0 meter (39.4 inches), 1.125 meters (44.3 inches), 1.25 meters (49.2 inches), 1.5 meters (59.1 inches), and 2.0 meter (78.8 inches).

[00020] A length LI of the first portion can be selected from a group consisting of 0.25 meters (9.84 inches), 0.406 meters (16 inches), 0.457 meters (18 inches), 0.5 meters (19.7 inches), 0.610 meters (24 inches), 0.75 meters (29.5 inches), 0.762 meters (30 inches), 914 meters (36 inches), 1.0 meter (39.4 inches), 1.125 meters (44.3 inches), 1.25 meters (49.2 inches), 1.5 meters (59.1 inches), and 2.0 meter (78.8 inches).

[00021] A thickness L8 of the first portion 22/24 can be in a range of 5 millimeters to 22 millimeters (0.197 inches to 0.866 inches). The thickness L8 of the first portion 22/24 can be in a range selected from a group consisting of 5 millimeters to 7 millimeters (.197 inches to 0.276 inches) and 7 millimeters to 11 millimeters (.276 inches to 0.433 inches) 10 millimeters to 14 millimeters (.394 inches to 0.551 inches), and 14 millimeters to 22 millimeters (.551 inches to 0.866 inches). A thickness L8 of the first portion can be selected from a group consisting of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 and 22 millimeters.

[00022] A thickness L3 of the slab 20 can be in a range of 10 millimeters to 44 millimeters (0.394 inches to 1.73 inches).

[00023] The material of the slab 20 can be selected from a group consisting of one or more pieces of natural stone, one or more pieces of a man-made material, one or more pieces of glass, one or more pieces of ceramic, and combinations thereof.

[00024] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[00025] Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the disclosure. In the drawings, like reference numbers may indicate identical or functionally similar elements. Embodiments are described in detail hereinafter with reference to the accompanying figures, in which:

[00026] Figure 1 is a representative view of a quarry from which large blocks of natural stone are produced;

[00027] Figure 2 is a representative large block of natural stone produced from a quarry; [00028] Figure 3 is a representative perspective view of a large block of natural stone being cut into smaller slabs;

[00029] Figure 4 illustrates a representative perspective view of an embodiment of an assembly of the present disclosure.

[00030] Figure 5 illustrates a representative cross-sectional view of the embodiment of the assembly of the present disclosure.

[00031] Figure 6 illustrates a representative cross-sectional view of an embodiment of an assembly of the present disclosure cut along a middle line.

[00032] Figure 7 illustrates a representative cross-sectional view of two assemblies of the present disclosure that resulted from cutting along the middle line.

[00033] Figure 8 illustrates a representative cross-sectional view of four assemblies of the present disclosure that resulted from cutting along the middle lines of the two assemblies of Figure 7.

[00034] Figure 9 illustrates a top view of a possible embodiment of an assembly of the present disclosure.

[00035] Figure 10 illustrates a top view of another possible embodiment of an assembly of the present disclosure.

[00036] Figure 11 illustrates a representative perspective view of an example of a cutting tool for cutting the blocks and slab of material used for producing the decorative veneer assemblies.

[00037] Figure 12 illustrates a representative perspective view of an example of a polisher for polishing the surfaces of the decorative veneer assemblies.

DETAILED DESCRIPTION OF THE DISCLOSURE

[00038] The disclosure may repeat reference numerals and/or letters in the various examples or Figures. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as beneath, below, lower, above, upper, uphole, downhole, upstream, downstream, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. Unless otherwise stated, the spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the Figures. For example, if an apparatus in the Figures is turned over, elements described as being "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[00039] As used herein, the words "comprise," "have," "include," and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods also can "consist essentially of or "consist of the various components and steps. It should also be understood that, as used herein, "first," "second," and "third," are assigned arbitrarily and are merely intended to differentiate between two or more objects, etc., as the case may be, and does not indicate any sequence. Furthermore, it is to be understood that the mere use of the word "first" does not require that there be any "second," and the mere use of the word "second" does not require that there be any "first" or "third," etc.

[00040] The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[00041] Dimensions given in this disclosure are to be given an implied tolerance of +/- 5% of the value of the stated dimension. Therefore, if a thickness of 6 millimeters is given, then this dimension shall be seen as including a tolerance of 6 millimeters +/- 10% of 6 millimeters. [00042] Generally, this disclosure provides a method and system to produce decorative veneer assembly products. The system can include a decorative material being adhered to a backing plate (such as magnesium board, metal sheet (e.g. aluminum, titanium), laminated metal sheets, etc.) to improve a structural integrity of the decorative material (such as natural stone, pieces of natural stone, manmade stone/glass, etc.) as it is processed through production operations. For example, if the decorative material is a fragile natural stone (such as a stone called "Blue Ice," "Ice Blue," "Blue Jeans Marble," etc.), then processing this fragile stone in normal production operations can cause significant waste from breakage of the stone. With a backing plate adhered to the fragile natural stone prior to the production operations, the utilization of the fragile stone can be increased. Additionally, already broken pieces can be adhered to the backing plate to then processed through production operations to produce decorative material products/assemblies.

[00043] It should be understood, that any material that can be adhered to the backing plate and compatible with the production operations can be used to produce decorative veneer assembly products. Therefore, multiple pieces of decorative material (such as natural stone as well as pieces of natural stone, manmade stone and/or manmade glass, ceramics, etc.) can be adhered to a backing material, a large piece of decorative material can be adhered to backing plate, a mixture of large and small pieces can be adhered to backing plate, a single large piece can be adhered to backing plate, etc.

[00044] Turning to Figure 1, this figure shows a representative quarry from which decorative material, such as natural stone, can be harvested from an earthen formation. The quarry operations generally produce large blocks 12 of decorative material from the earthen formation (see Figure 2, as well). Figure 3 shows how smaller slabs 20 of the decorative material can be cut from an end of the block 12 (however, it is not required that the smaller slab be cut from the end of the block 12). The slab 20 can have a length LI, a width L2, and a thickness L3. It should be understood that FIGS. 5-8 are representative side views of intermediate and finalized versions of the material, and that length LI, and width L2 (which can also be referred to as length L2) apply to these figures similarly as they are shown in FIGS. 3 and 4. The next slab 20 to be cut can be cut along the dashed line producing a slab 20 of thickness L4, which can equal thickness L3 or can be different than thickness L3. Again, this is only one of many ways that decorative material can be acquired to support the processes and systems of this disclosure. Other ways can be where scrapped material, such as leftover (or cast off) material after natural stone material is cut via a cutting tool, can be adhered to a backing plate 30. Either one of lengths LI and L2 can be up to, but not restricted to, 2 meters (78.7 inches). In particular, either one of lengths LI and L2 can be 0.25 meters (9.84 inches), 0.406 meters (16 inches), 0.457 meters (18 inches), 0.5 meters (19.7 inches), 0.610 meters (24 inches), 0.75 meters (29.5 inches), 0.762 meters (30 inches), 914 meters (36 inches), 1.0 meter (39.4 inches), 1.125 meters (44.3 inches), 1.25 meters (49.2 inches), 1.5 meters (59.1 inches), and 2.0 meter (78.8 inches).

[00045] Figure 4 shows an exploded view of an assembly 10 that can include two backing plates 30, each with surfaces 31, 32, and each with a thickness L5. The thickness L5 can be 4 millimeters +/- 0.5 millimeters. However, it should be understood that thicker backing plates 30 (such as 5 millimeters, 6 millimeters, 7 millimeters, 8 millimeters, 9 millimeters, 10 millimeters, 20 millimeters, 39.3 millimeters, etc.) can be used in producing a decorative veneer assembly product with a relatively thin layer of material adhered to a backing plate 30. This slab 20 can be a single piece or multiple pieces as mentioned above. If the slab 20 comprises multiple pieces, then the pieces can be adhered to the surface 32 of one of the backing plates to generally form a layer of material that can be referred to as the slab 20. Additionally, the slab 20 can be a single piece at a beginning of the process and be broken, fractured, or otherwise separated into multiple pieces during the process, and still support the process of producing decorative veneer products/assemblies.

[00046] An adhesive 40 (see Figure 5) can be applied with resulting thickness L7 between surface 32 of the top backing plate 30 and surface 42 of the slab 20, thereby adhering the surface 32 of the top backing plate 30 to the surface 42 of the slab 20, as well as between the surface 32 of the bottom backing plate 30 and surface 49 of the slab 20, thereby adhering the surface 32 of the bottom backing plate 30 to the surface 49 of the slab 20. This can "sandwich" the slab 20 between two backing plates 30 to produce the assembly 10. The adhesive can be any suitable adhesive (such as an epoxy resin, a polymer based slurry that cures to a hardened state, a glue, etc.) for adhering the slab 20 (or slab pieces) to one or more backing plates 30 that are compatible with stone processing operations used to produce the decorative veneer products/assemblies. The thickness L7 can be in a range from 0.01 millimeters to 2 millimeter. The thickness L7 can be 0.01 millimeters, 0.1 millimeters, 0.5 millimeters, 1.0 millimeters, 1.25 millimeters, 1.5 millimeters as well as other values within the stated range for the thickness L7.

[00047] Figure 5 shows an assembly 10 with a surface 32 of each backing plate 30 adhered by an adhesive 40 to the top and bottom surfaces, 42, 49, respectively. Once the adhesive 40 (such as epoxy resin, etc.) is cured, the assembly 10 can be sent through a machine that can cut the assembly along any one of lines 80, 82, and 84. Lines 80, 82, and 84 indicate possible cut lines through the decorative material slab 20 to produce portions of the decorative material 22, 24, 26, 28. However, it should be understood, that these cut lines are only possible paths the machine can take to separate the slab 20 into multiple portions 22, 24, 26, 28. Many other cut lines through the slab 20 are possible and anticipated by this disclosure. Also, the cut lines are shown as being straight lines through the slab 20. However, the actual cut lines can be non-linear due to tolerances of the manufacturing equipment used to produce the decorative material products/assemblies. The resulting surface of the slab 20 when cut along one or more of these lines can include small peaks and/or valleys, as well as possibly an undulating pattern.

[00048] It should be understood that both linear cuts and non-linear cuts are in keeping with the current disclosure. The following description details a possible sequential order of cutting along these lines to produce decorative veneer assembly product assemblies 16 (see Figure 8). However, other sequential orders can be used that will also produce assemblies 16. As the slab 20 can be cut into progressively thinner and thinner portions, the backing plates 30 can help maintain structural integrity for the decorative material portions 22, 24, 26, 28, thereby substantially preventing breakage of the decorative material, and/or providing structural integrity for multiple portions 22, 24, 26, 28 of decorative material from a slab 20 with a thickness L3. The backing plates 30 can also provide structural integrity for the slab 20 even if it is made of multiple pieces (such as a broken slab 20, multiple pieces that form the slab 20, a prearranged mosaic that forms the slab 20, etc.)

[00049] For one example, the assembly 10 can be ran through the machine and cut along the line 80, which can generally be along a center line of the slab 20. Various lengths L5-L13 provide indications of various distances and thicknesses of the assembly 10, such as thickness L7 of the adhesive 40, thickness L5 of the backing plate 30, etc. Assuming the first cut of the assembly 10 is performed along line 80, then the slab 20 could be cut into two substantially equal decorative material portions 22/24 and 26/28 as shown in Figure 6 with each portion having a thickness L8.

[00050] Figure 7 shows two assemblies 14 with additional backing plates 30 adhered to surfaces 45, 46 which can be created as a result of the cut along line 80. These assemblies 14 can have an overall thickness L14 that includes two backing plates 30, two thicknesses L7 of the adhesive 40, and a decorative material portion 22/24, or 26/28. These two assemblies 14 can then individually, or at the same time, be cut along lines 82 and 84 to produce four assemblies 16 with thicknesses L15 as shown in Figure 8. It should be understood that the thicknesses of the assemblies 16 can vary and are not required to be the same thickness between each assembly 16. However, it is desirable that the resulting assemblies 16 are within an acceptable thickness tolerance for end user operations and processes, such as an assembly of multiple assemblies 16 at a construction site. However, multiple thicknesses of assemblies 16 may be desirable in the installation of multiple assemblies 16 at the construction site for esthetic purposes.

[00051] The thickness L15 of an assembly 16 can be from 9 millimeters (0.35 inches) up to 16 millimeters (0.63 inches) thick. This thickness L15 includes the thickness L5 of the backing plate 30, the thickness L7 of the adhesive layer 40, and the thickness L6 of the portion 22, 24, 26, or 28. The thickness L5 can be 4 millimeters +/- 0.5 millimeters (0.16 inches +/- 0.02 inches), as stated above. The thickness L7 can be in a range from .01 millimeters to 1 millimeters (.00039 inches to 0.039 inches) as mentioned above. The thickness L6 (which can be referred to as the thickness of the slab portion of the assembly 16) can be in a range from 5 millimeters to 11 millimeters (0.197 inches to 0.433 inches). The thickness L6 for tile applications can be in a range from 5 millimeters to 7 millimeters (.197 inches to 0.276 inches). The thickness L6 for mosaic applications can be in a range from 7 millimeters to 11 millimeters (.276 inches to 0.433 inches). Therefore, the thickness LI 5 can be from 8.51 millimeters to 16.5 millimeters (0.335 inches to 0.650 inches), with nominal thicknesses of 10 millimeters (0.394 inches) for assemblies 16 used in tile installations, and with nominal thicknesses of 14 millimeters (0.551 inches) for assemblies 16 used in mosaic installations. The assemblies 16 can be are polished to finalize the process of producing the assemblies 16. The polishing of the surface of the assembly 16 that is opposite the surface attached to the backing plate can remove up to 2 millimeters of material to create the desired polished surface. This reduction is thickness should be accounted for when selecting the intermediate thicknesses L3, L8, for example. Of course, if larger slabs 20 are used, then additional cuttings may be needed to reduce the slab portions to the desired thicknesses of the final assemblies 16.

[00052] However, the tile and mosaic installations are mere examples of the types of installations for which these assemblies 16 can be used. These assemblies are not restricted to use in these installations examples. They can be used in either installation as well as other desired installations. Another example of an installation that can utilize the assemblies 16 is a wall covering installation. The wall covering installation can install an assembly 16 directly to a wall frame. Therefore, an assembly 16 that is 16 (to 18) inches wide by 36 inches long can be purchased and installed directly to a wall without additional wall prep other than providing the framed structure to which the assembly 16 can be attached. Additionally, the assemblies 16 can be mounted directly over an existing finished wall structure as an overlay that covers the existing wall covering by various attachment means such as an adhesive, fasteners, etc..

[00053] The assemblies 16 can then be sent through a polishing and/or sealing operation to complete the production of the assemblies 16. It should be understood that several other production operations may also be performed in addition to, and/or alternatively to, the processes mentioned in this disclosure.

[00054] Some (yet not all) of the unique benefits of this method of producing assemblies 16 are that when the slab 20 is cut along the example cut lines 80, 82, 84, the portions can produce pairs of the assemblies 16 as mirrored patterns or images (sometimes known as "bookmatching" images) of each other. For example, the portions 22 and 24 would be mirrored patterns of each other once the portion 22/24 in Figure 7 was cut along line 82. Similarly, the portions 26 and 28 would be mirrored patterns of each other once the portion 26/28 in Figure 7 was cut along line 84. If the slab was a collection of smaller pieces, such as a mosaic, the "bookmatching" pairs would be mirrored patterns of the smaller pieces. The mirrored pattern can include patterns of the natural stone, as well as patterns formed by arranging small pieces together to form the slab 20 with material between the pieces such as the adhesive 40. [00055] A mosaic pattern (which can be any collection of smaller pieces to form a slab 20) can be built from any of the potential types of decorative material (such as natural stone, pieces of natural stone, manmade stone and/or manmade glass, cement, cement pieces, pebbles, pieces of decorative material cut by other processes such as water jetting, combinations thereof, etc.). The pieces of the mosaic can be secured together (such as with a webbing or mesh material) in a pattern prior to being adhered to the backing plate 30, and/or the pieces of the mosaic can be secured together by each being individually adhered to the backing plate 30. Therefore, it should be understood that the material of the slab 20 as seen in Figures 4 and 5 can comprise a single slab, pieces of a slab, pieces of various materials, etc. When a webbing (or mesh material) is used to maintain an arrangement of smaller pieces, the webbing (or mesh material) can become the surface 42 or 49 of the slab 20 prior to adherence of the backing plates 30 to the slab 20.

[00056] Figures 9 and 10 show completed assemblies 16, where the decorative material consists of multiple pieces 18. As stated above, the decorative material can be any suitable material (whether whole or in pieces) that can be adhered to the backing plates 30 and processed by the production operations, such as cutting and polishing.

[00057] FIG. 11 shows a representative industrial cutting tool 90 that can be used to cut the blocks 12 as well as the slab 20 and portions of the slab 20. It should be understood that various other types of cutting tools 90 can be utilized to cut the slabs 20, and the cutting tool 90 is not limited to the example shown in FIG. 11.

[00058] FIG. 12 shows a representative industrial polishing tool 92 that can be utilized to polish the decorative veneer assemblies 13, 16 to complete the process of producing decorative veneer assemblies 13, 16. It should be understood that various other types of polishers 92 can be utilized to polish the surface of the decorative veneer assemblies 13, 16, and the polisher 92 is not limited to the example shown in FIG. 12.

[00059] These assemblies 16 can be attached directly to a framing structure (such as wall studs, concrete, blocks, etc.) without additional wall covering. For example, a 1 meter wide by 1 meter long assembly 16 can be attached directly to wall studs which form the framing structure for a wall in a building (or outside, and/or any other desired place for such a wall) without requiring a separate wall covering (such as sheetrock, paneling, plywood, OSB panels, etc.). They can be attached with fasteners, adhesive, clips, hangers, or any other suitable attachment methods to cover the desired space with the decorative assemblies 16. The backing plate 30 can provide structural stability and integrity to maintain flatness tolerances while the assembly 16 is mounted to a structure that requires the assembly to span an unsupported space between attachment points in the framing structure. The flatness tolerances merely refer to variations in a flatness of the assembly 16 after it's installed onto (i.e. attached to) a framed structure to prevent undulations in the surface of the assembly. It should also be noted that the assembly 16 can be installed on a curved surface, and the flatness tolerances here would refer to the overall ability of the assembly 16 to maintain a substantially constant curvature surface without multiple undulations in the surface, thereby maintaining a pleasing esthetic.

[00060] Although various embodiments have been shown and described, the disclosure is not limited to such embodiments and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed; rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.