Background of the Invention It is well-known to protect surfaces such as horizontal surfaces with materials that can withstand substantial wear.

Examples are surfaces around sinks and cooking areas. This protection is also important in applications such as vertical surfaces adjoining wet areas, such as showers.

The materials can include ceramic materials or quarried materials that are shaped and placed together to form a substantially impervious surface. While it is possible to make such surfaces from a single portion of a material, such applications are necessarily custom-made and, accordingly, expensive, because of the time required to make them. In many cases, it is more economical to cover surfaces with substantially identical tiles. These tiles are either abutted against one another, or placed close to one another and the gaps between filled with a grout material that renders the surface substantially impervious. Where necessary to fit the tiles, the tiles are individually cut, placed and grouted.

In construction, such surfaces are first defined by structural components, such as plywood, to support the surface. The protective surface is then formed over the structural components and glued to the structural components.

In most modern-day applications, the finish of the installed surface is all-important. Unless the surface is expensively custom-made, the facing of the surface, i. e. , the portion of the surface that faces outward, must be applied separately from the application of the major portion of the surface. For example, where the application is that of a

substantially horizontal surface, the edges of the horizontal surface must be finished properly, typically by forming a vertical face that adjoins the edges of the horizontal surface.

In currently applications, the facing of a surface is created separately, generally by adhering a face piece onto the outer edge of the major portion of the surface. This process, however, requires a seam (such as a channel of grout) to be formed in the major portion of the surface. Such a process is both unsightly and subject to allowing intrusion of undesirable substances (such as water) into the surface.

Furthermore, it is frequently desirable to give the facing a shape that is difficult to form by adherence to the major portion of the surface.

Accordingly, it is desirable to have a surface-covering system that is not subject to these faults.

Summary of the Invention According to one aspect, the invention is an integral surface-covering component for covering a surface. The component includes a substantially planar portion having a plurality of edges. The planar portion has an upper surface and an under surface. The component also includes a second portion attached to the under surface of the planar portion along a first predetermined one of the edges. This forms a first thickened edge. Each point on the first thickened edge has a first predetermined cross-section in the plane perpendicular to the first thickened edge at the point.

According to another aspect, the invention is a plurality of surface-covering components as described above. The plurality of components cover a substantially planar surface.

Each of the surface-covering components is adjacent at least one of the other surface-covering components along an edge other than a predetermined one of the edges.

According to another aspect, the invention is a method for making an integral surface-covering component for covering a surface. The method includes the step of a) forming a substantially planar portion from a material, where the

substantially planar portion has a plurality of edges, and the planar portion has an upper surface and an under surface. The method also includes the step of b) forming a second portion from the material. The method further includes the step of c) attaching the second portion to the under surface of the planar portion along a first predetermined one of the edges, thereby forming a rough thickened edge.

According to a further aspect, the invention is an integral surface-covering component made according to the method described above.

Brief Description of the Drawings Figure 1 is a perspective drawing of a bull nose component of the inventive system.

Figure 2 is a plan view of the bull nose component shown in Figure 1.

Figure 3 is an elevation view of the components of the inventive system Figure 4 is a perspective drawing of a left hand inside corner component of the inventive system.

Figure 5 is a plan view of the left hand inside corner component shown in Figure 4.

Figure 6 is a detail view of the miter edge of the left hand inside corner component of the inventive system.

Figure 7 is a perspective drawing of an outside corner component of the inventive system.

Figure 8 is a plan view of the outside corner component shown in Figure 7.

Figure 9 is a diagram of an exemplary layout of the inventive system, using the inventive components described above.

Detailed Description of the Preferred Embodiment of the Invention Figure 1 is a perspective drawing of a bull nose component of the inventive system, and Figure 2 is a plan view of the bull nose component shown in Figure 1. The bull nose component 10 includes a substantially planar portion 12 and a

second portion 14. The substantially planar portion 12 has an upper surface 16 and an under surface 18.

The substantially planar portion 12 also has a plurality of edges 20,22, 24, and 26. If desired, the edges 20,22, 24 and 26 can be beveled at a 45 degree angle, providing a very thin bevel, approximately 0.03 inch across. In general, the substantially planar portion 12 can have any number of edges, as will be understood by those skilled in the art. However, for illustrative purposes, the component 10 shown in Figure 1 is rectangular, having four edges, which can be grouped into two pairs of parallel edges. One pair of parallel edges includes edges 20 and 24, while the other pair of parallel edges includes edges 22 and 26.

The second portion 14 is attached to the under surface 18 of the component 10, along the edge 20 of the substantially planar portion 12, forming a thickened edge 28. Each point of the thickened edge 28 can have a predetermined cross-section in the plane perpendicular to the thickened edge 28 at the point. As shown in Figure 1, the thickened edge 28 is an arc of a circle.

The custom of the surface tiling industry is that the tiles should be 3/8 inch thick, and most common tiles are square, with sides equal to 12 inches. Accordingly, to make the components of the inventive system compatible with the currently-existing tiles, the substantially planar portion 12 of the inventive components is preferably also 3/8 inch thick and the edges 20 and 24 are 12 inches long. The purpose of the component 10 is to provide a finished look to an installed system according to the present invention. Accordingly, the dimension of the component 10 in the direction parallel to the edges 22 and 26 is 13-1/4 inches, and the overall thickness of the thickened edge 28 is 1-1/2 inches.

The second portion 14 of the component 10 can be attached to the under surface 18 of the component 10 by means of a very thin layer of an adhesive, such as an epoxy adhesive that can be colored to blend with the color of the substantially planar portion 12 and the second portion 14. Conventional colors in the trade that are especially suitable for use with the

present invention are absolute black, midnight jade, imperial sage, venito topaz, and black empress, although no limits to the colors of the components is to be inferred by any portion of this specification.

Typically the portions 12 and 14 are made from quarry material such as field granite, although they could be made from any other suitable material, including natural and synthetic materials known to those skilled in the relevant arts. In the case where the components 10 are made from synthetic materials, the portions 12 and 14 can be attached as integral pieces, i. e. , they can be manufactured attached to one another.

Figure 3 is an elevation view of the components of the inventive system. For illustrative purposes, the relevant portions of the component shown in Figure 3 is labeled as if it were a part of the component 10, taken along the cross- section A-A of Figure 2.

Figure 4 is a perspective drawing of a left hand inside corner component of the inventive system, and Figure 5 is a plan view of the left hand inside corner component shown in Figure 4.

Where it applies, the features of the left hand inside corner component will be given the same reference numbers as were used in the description of the bull nose component 10. The component 40 includes a substantially planar portion 12 and a second portion 14. The substantially planar portion 12 has an upper surface 16 and an under surface 18.

The substantially planar portion 12 also has a plurality of edges 20,22, 24,26, and 42. The component 40 shown in Figure 4 is rectangular with one mitered edge, having five edges. Four of the edges can be grouped into two pairs of parallel edges. One pair of parallel edges includes edges 20 and 24, while the other pair of parallel edges includes edges 22 and 26. The edge 42 is the mitered edge, which is adjacent the edges 20 and 26. In the presently described preferred embodiment, the edges 20 and 26 form 135 degree angles with the edge 42, although in general the edges 20 and 26 could form any desired obtuse angles with the edge 42.

The second portion 14 is attached to the under surface 18 of the component 40, along the edge 20 of the substantially planar portion 12, forming a thickened edge 28. Each point of the thickened edge 28 can have a predetermined cross-section in the plane perpendicular to the thickened edge 28 at the point. As shown in Figure 4, the thickened edge 28 is an arc of a circle.

As described above, the second portion 14 of the component 40 can be attached to the under surface 18 of the component 40 by means of a very thin layer of an adhesive, such as an epoxy adhesive that can be colored to blend with the color of the substantially planar portion 12 and the second portion 14.

Figure 6 is a detail view of the miter edge of the left hand inside corner component of the inventive system.

It will be understood by those skilled in the relevant arts that a right hand inside corner component could be made as described above, with the provision that the descriptions given in Figures 4-6 are mirror images of those needed to describe the right hand inside corner component. Accordingly, no further description of a right hand inside corner component is deemed needed.

The major dimensions of the bull nose, and left and right inside corner components are 13-1/4 x 12 inches.

Figure 7 is a perspective drawing of an outside corner component of the inventive system and Figure 8 is a plan view of the outside corner component shown in Figure 7. Where it applies, the features of the outside corner component will be given the same reference numbers as were used in the description of the bull nose component 10. The component 60 includes a substantially planar portion 12, a second portion 14 and another second portion 62. The substantially planar portion 12 has an upper surface 16 and an under surface 18.

The substantially planar portion 12 also has a plurality of edges 20,22, 24, and 26. The component 60 shown in Figure 6 is rectangular, having four edges. The four edges can be grouped into two pairs of parallel edges. One pair of parallel edges includes edges 20 and 24, while the other pair of

parallel edges includes edges 22 and 26.

The second portion 14 is attached to the under surface 18 of the component 60, along the edge 20 of the substantially planar portion 12, forming a thickened edge 28. Each point of the thickened edge 28 can have a predetermined cross-section in the plane perpendicular to the thickened edge 28 at the point. As shown in Figure 4, the thickened edge 28 is an arc of a circle.

The other second portion 62 is attached to the under surface 18 of the component 60, along the edge 26 of the substantially planar portion 12, forming a thickened edge 64.

Each point of the thickened edge 64 can have a predetermined cross-section in the plane perpendicular to the thickened edge 64 at the point. As shown in Figure 4, the thickened edge 64 is an arc of a circle.

As described above, the two second portions 14 and 62 of the component 60 can be attached to the under surface 18 of the component 60 by means of a very thin layer of an adhesive, such as an epoxy adhesive that can be colored to blend with the color of the substantially planar portion 12 and the two second portions 14 and 62.

An outside corner has major dimensions of 13-1/4 x 13-1/4 inches.

Figure 9 is a diagram of an exemplary layout of the inventive system, using the inventive components described above. As described above, it is conventional for individual tiles to be 12 inch squares. Typically, counters are designed to be 24 inches deep and a multiple of 12 inches in the other dimensions. Thus, in the 90 degree layout shown in Figure 9, the tiles marked with reference numbers 90 are conventional 12 by 12 inch tiles. Also, the tiles marked with reference numbers 10 are bull nose components described above, the tile marked with reference number 40 is a left hand inside corner component described above, and the tiles marked with reference numbers 60 are outside corner components described above. The tile marked with reference number 40'is a right hand inside corner component made as a mirror image of a left hand inside corner component are described above.

In addition to its application for counter tops and the like, the inventive system can be used with island counter configurations, which are conventionally 24,36 and 48 inches in their principal dimensions. The components can also be used in raised counters, custom showers and custom tubs. Further the components can be used as surrounds for fireplaces, using rolled edge bull nose and inside corners.

In manufacturing the components of the inventive system, the second portion can be attached to the substantially planar portion by a press that uniformly applies pressure to the two portions to obtain the desired very thin layer of epoxy.

Thereafter, the components can be finished to have the desired rectangular dimensions and the desired finished contour on the thickened edges. Also, the upper surface of the substantially planar portions will be polished to the desired finish.

While the foregoing is a detailed description of the preferred embodiment of the invention, there are many alternative embodiments of the invention that would occur to those skilled in the art and which are within the scope of the present invention. For example, it will be understood that the tile do not necessarily have to have rectangular shapes.

Accordingly, the present invention is to be determined by the following claims.