AU2007100581A4 - Paving block - Google Patents

Description

29/OG/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 03/15 o PAVING BLOCK Ci Field of the Invention SThe present application relates to paving blocks, and in particular, to a paving Sblock having a decorative surface for use in paths and other paved surfaces.

00 Background of the Invention Pavements made up of individual paving blocks are used for a variety of 00 applications, such as streets, driveways, walkways and open public and private spaces.

t Such paving blocks are typically made from a clay material or a concrete of cement and Saggregate and are formed so as to assume a variety of shapes, colours and textures.

In order to support a load, individual blocks may be arranged such that they Sinterlock with adjacent blocks. Such blocks may form a substantially gap-free surface 0 with runs of seams extending between blocks. Paving blocks arranged in such a manner allow for a degree of ground motion or movement between blocks without causing cracks to appear in the surface of the pavement. In many concrete surfaces, ground movement can result in the formation of cracks in the surface, which can greatly reduce the aesthetic appeal of the surface and be hazardous to users of the surface.

Paving blocks can be arranged in a pattern so as to provide both an aesthetic and functional purpose. Different coloured pavers and/or pavers of varying textures and/or shapes can be used to further increase the aesthetic and functional purpose of the surface. In this regard, pavers of different colours or shapes can be used to delineate different regions of a pavement, such as defining a driveway along a paved surface.

Typically, paving blocks are moulded to form a desired shape. In order to massproduce paving blocks having a common shape/texture/colour, the moulding process is relatively simple and requires the step of mixing the material, pouring the material and allowing the material to cure. As such, conventional paving blocks are formed as one piece units, with any colour or texture differences controlled during the mixing and pouring of the mixing material.

More recently, paving blocks incorporating synthetic materials such as plastics as well as natural and synthetic rubbers and the like have been introduced. Such blocks provide additional colour and texture options as well as provide improved wearing and greater resilience due to the properties of the introduced materials. Typically, the materials are added during the mixing of the material such that the material is poured into the moulds in the usual manner. In this regard, the placement of the material is not c:\documents and settinscadmlnistratorldesktobraakhuisdoc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 2e/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 04/15 2 readily controlled and cannot be easily regulated to provide a specific pattern or effect oon the surface of the paving block.

l As such, there is a need to provide a paving block that enables greater variation in the aesthetic design of the block.

Any discussion of documens, acts, materials, devices, articles or the like which 0, has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the 00 field relevant to the present invention as it existed before the priority date of each claim of this application.

Summary of the Invention According to a first aspect, the present in.vention is a paving block comprising: a body comprised of a first material having a base, an upper strface and at least one side wall extending from said base to said upper surface; an indentation formed in the upper surface; and an insert comprised of a second material, said insert being securable to the body within said indentation such that said insert substantially fills the indentation; wherein said first material substantially differ in composition to said second material.

In one embodiment the indentation is formed in the upper surface in a position remote from the at least one sidewall of the body. The indentation may be centrally positioned in the upper surface of the body and shaped so as to provide a decorative function.

The first material may be a settable material such as a concrete composition The body may be nne from moulding the settable material such that the indentation is formed in the upper surface thereof.

At least a portion of the insert may be poured into the indentation such that it is securable to the body upon setting.

In another embodiment, the second material may include a thermoplastic material, such as an acrylic, a fluoroplastic, and/or PVC. In another embodiment, the second material includes a phosphorescent material that illuminates the insert. In yet another embodiment, the second material includes a combination of a stone mix and a binding resin.

The second material may be poured into the indentation and allowed to cure to substantially fill the indentation. The second material may have adhesive properties e:\documents and dettinqs\administrator\deskto\braakhuis.doc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 28/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 05/15 3 O that secure the insert to the body upon curing. In an alternative form, an adhesive may be applied to the indentation to secure the second material to the body.

b According to a second aspect, there is provided a method of forming a paving ;Z block, comprising; 0k preparing a mould defining a body of the paving block, said body of the paving N block having an indention provided in an upper surface thereof; placing a first material into said mould to form the body of the paving block; removing said body from the mould; and 0 substantially filling the indentation in said body with a second material, said second material having a different composition to said first material.

Throughout this specification the word "comprise", or variations such a 0 comprises" or "comprising", will be understood to imply the inclusion of a stated Selement, integer or step, or group of elements, integers or stelps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Brief Description of the Drawings By way of example only, the invention is now described with reference to the accompanying drawings: FIG. 1 is a perspective view of a paving block in accordance with one embodiment of the present invention; FIG 2 is a sectional side view of the paving block of FIG. 1; FIG. 3A and 3B show top views of alternative embodiments of a paving block according to the present invention; FIG. 4A is a perspective view of a mould arrangement in accordance with one embodiment of the present invention; FIG. 4B is a perspective view of the mould arrangement of FIG. 4A filled with settable material; FIG. 4C is a side sectional view of a body of a paving block according to an embodiment of the present invention being filled with a filler material; and FIG. 4D is a top view of a paving block made in accordance wit the steps as shown in FIGS. 4A 4C.

Detailed Description of an Exemplary Embodiment of the Invention The paving block of the present invention will be described below in relation to a standard square/rectangular paving block or stone. It will be appreciated that the c:\documents and settin.s\administrator\deskto\braakhuisdoc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 28/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 06/15 4 paving block of the present ilivetion could assume a variety of shapes and textures and still fall within the spirit of the present invention.

pe Referri.g to FIG. i, paving block 10 according to one embodiment of the ;Zpresent invention is shown. The block 10 comprises a main body 12 in the form of a substantially rigid body that defines the overall shape of the block 10, The edges 13 of ,00 the body 12 are shaped so as to allow the block 10 to be positioned in closeproximity to another block of the same or different configuration. Individual blocks 10 can then _be arranged in such a manner so as to form a paved smurface. Whilst not shown, it will 00 be appreciated that the edges 13 of the block could be formed so as to engage or o' 10 interlock with an adjacent block in the paved surface.

The body 12 is formed by moulding a concrete of Portland cement and aggregates in a predetermined proportion to form a body 12 having a desired strength Sand texture. As shown, the body 12 is formed so as to provide a substantially flat paving block of uniform thickness having an upper surface 14 which receives a load, and a lower surface 18 arranged to be placed on an underlying substrate, such as sand or soil. The materials employed to form the body 12 may vary in accordance with the proposed application of the block 10, as will be appreciated by those skilled in the art The upper surface 14 of the body 12 has an insert 16 provided therein. As shown in FIGS. I and 2, the insert 16 has a circular or ovate shape, however, as will be apparent below, the shape of the insert 16 could vary as desired. The insert 16 is substantially centrally located in the upper surface 14 of the block 10, so as to be remote from the edges 13.

As more clearly shown in FIG. 2, the insert 16 is in the form of a filler material 17 that is attached to the body 12 such that its outer surface is substantially flush with the upper surface 14 of the body 12. n order to receive the ller material, the body 12 has an indentation/recess 15 formned in thle upper surface 14 which is shaped to a desired pattern (an oval or circle in the embodiment as shown in FIGS. 1 and The indentation or recess 15 is formed in the upper surface 14 during formation of the body 12, such as during the moulding of the body 12. However, other methods of forming the indentation 15 are also envisaged. The indentation 5 may be recessed a depth X, as shown in FIG. 2, which may be between 1-10 mm In a prefesred form, the indentation 15 has a depth of 3mm below the upper surface 14.

The filler material 17 received within the indentation IS has a composition that differ3 to the composition of the material of the body 12. In a preferred form, at least a portion of the filler material 17 has an initial liquid state that enables the filler material 17 to be poured into the indentation 15 so as to fill the indentation to a level c\docurment and settint \administrator\deskto\braakhuis.doc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 28/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 07/15 0 substantially equal to the upper surface 14, Following pouring, the filler material ]7 may set/solidify to form a hard and durable surface capable of bearing a weight.

N n one form, the Filler mate one form, the filer material 17 may be selected from the group of Sthermoplastics, including acrylics, fluoroplastics, PVCs and other such materials that OO 5 are able to be poured in a fluid state and solidify to provide a durable weight-bearing C surface. In such an arrangement, the filler material 17 may be coloured or otherwise textured to visually enhance the insert 16, In another form, the filler material 17 may be a phosphorescent material that 0 mit a light that illuminates the insert 16. Such a material may be a made of a polyester resin with a phosphorescent pigment that can be poured into the indentation and cured accordiengly Other types of luminescent pigments could also be employed, such as fluorescent pigments, to create a desired luminescent effect-

FIG.

S3A shows one such example of a block 20 employing an insert 16 with such C' luminescent properties. In this regard, the indentation 15 is siaed to represent a number, such as a house number. Such an arrangement can be particularly useful to assist emergency vehicles and the like to identify house numbers in the dark.

In another form, the filler material 17 may be a combination of a settable resin and a stone or glass mix, as is show in PIG. 3B. In this regard, following formation of the body 12, the block 10 can be further decorated by filling the indentation 15 with a suitable stone mix and applying a resin based binder to bind the stone/glass mix together within the indentation 15 This enables a user of the paver block 10 to personally decorate individual pavers 10 to their own tastes and styles, using natural materials that can be readily purchased or otherwise obtained.

In another form, the filler material 17 may be a combination ofa settable resin and one or more electric light sources embedded within the resin. The electric light SOurces may be in the form of light emitting diodes (LEDs) which may be externally powered from remote power source to emit a light The resin may be selected such that it permits light to be transmitted therethrough thereby creating a visually pleasing paving block that can be used for a variety of purposes.

It will be appreciated that in each of the above-described forms, the insert 16 is fixed to the block 10 due to the adhesive properties of the filler material 17. In some instances it may be necessary to apply additional adhesives agents, such as glues and the like, to ensure bonding of the filler material 17 to the body 12.

It will also be appreciated that, the composition of he filler material 17 is such that, following curing of the filler material 17, it is able to support a load as would be umens and settn intrarktupport a load as would be c:\documnts and settinpsadministratorskolbrakhui.doc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 2B/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 08/15 6 0 :expected during use of the block 10, withoutcuin the ins- t 16 to rema O break-up and/or deteriorate. premature C] t The various steps of forming a block 40 in accordance with one embodiment of the present invention, isshown in FIGS. 4A 4D.embodiet f 00 5 In FIG. 4A a mouId 42 is provided for forming the body 12 of the block 10 as sA"hown in FIGS. I and 2. The mould 42 has an interior portion 41 shaped to form the upper surface 14 and side edges 13 of the block 40, and has an open top portion.

A

mould insert 44 is positioned on the base of the mould 42 to fo theop poon. A V indentation 15 and the subsequent insert 16. The specific shape form the shape of the mould insert 44 b sp e sl ap e a nd configuration of the mould i nsert 44 may vary between moulds 42 to provide a degree of variation in itblock desi v The mould insert 44 is secured to te base of the mould 42 by way of a Sste ad e to ensure that the mould insert 44 does not move during pouring of Sthe mould 42. Once the mould insert 44 has been positioned the mould 42 way be Streated to ensure that the mould 42 can. be readily sepaated fiom the settable material of the block 10 following pouring. the ma Refer p ng to FIG. 4, a settable material 45, such as a volume of concrete, is then poured into the mould 42 to a desired level. The settable material 45 may be omprised ofly well-known concrete composition such as cement, sand d water.

The settable material 45 may also be comprised of a sand and lime composition and may include a variety of other aggregates as is ow in the concrete industy.

Following pouring of the setlel ae 4 s known in th e concrete industry, Following pouring of the settable material 45 it may be pressed and/or vibration compacted into the mould 42 and allowed may bepe se d a nd or viraio compacted into the mould 42 and allowed to cure to form the body 12 of the block Following curing, the body 12 is separated from the mould 42. This results in the body 12 having an indentation 15 provided in the upper surface 14 of the body 12, having a shape and configuration consistent with the shape and configurat of the mould insert 44, as shown in FTG. 4C. Filler material 17 is then poured or placed into the indentation 15 such that it substantially fills the indntation 15 and is substantially level with the upper surface 14 of the body 12. During pouring of the filer material 17, the amount of filler material 17 poured may exceed the volume of the indentation This may be required to ensure that troughshollows are not formed in the upper surface 14 of the block 40 that may collect surface water on the blocks 40 during use. In such an arrangeent, following curing of the filler material 17, the excess material 17 may be scraped or otherwise removed from the surface te block 40 to esure that the upper surface 14 is substantially level.

In the event that the filler material 17 is a combination of binder resin and decorative tones/glass (as shown in FIG. 2A) an initial volume ofresin may be poured c:\docurnents and settin.sadministratordesktop\braakhuidoc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 2e/06/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 09/15 7 0 into the indentation 15 prior to adding the stones, The remainder of the resin may then 0be added over the stones to ensure that the stones are at least partially embedded within NA the resin upon curing.

;Z As shown in FIG. 4D, following curing of the filler material 17 and removal of any excess filler material 17, the block 40 is completed. The block 40 has an integral insert 16 that is formed from a material that has a of a predetermined shape and texture and a different composition to that of the body 12 of the block 40. This provides a striking aesthetic appeal to the block 40 that enables te paving block 40 to be utilised 1 0 aesthetically pleaing paved area, such as a street, walkway or open space.

0o The incorporation of blocks 40 having decorative inserts 16 within a paved area "allows for a variety of decorative choices in the design of a paved area. Individual blocks 40 can be readily made in a variety of styles and textures, having a standard body 12 to onform to standard paving blocks being used Individual blocks can also be arranged in the pavement to provide illumination of a driveway or house number, or to provide an individual aesthetic appeal to a space.

It will be appreciated that whilst the insert 16 has been described in relation to an at least partially pourable filler material capable of beingpoured into the indentation the insert 16 could also be in the form of a solid material fixed within the indentation 15 by way of adhesives or the like. In such an arrangement, the insert 16 may be shaped to conform to the indentation 15 and fixed in place by way of an adhesive or the like.

It will be appreciated by persons skilled in the art that ntunerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

e:\documents and settinos\admnir;trator\desktoDo\bakhuicdoc COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28

Claims (6)

1. 2. A paving block according to claim i, wherein said indntation formed remote from the at east one side wall of the body. 3 A paving block according to claim I or claim 2, wherein at least a portion of the insert is poured into the indentation and is securable to the body upon setting.
2. 4. A paving block according to claim 3, wherein said second material includes a thermoplastic material. A paving block according to claim 3, wherein the econd material includes a phosphorsent material.
3. 6. A paving block according to claim 3, wherein the second material includes a combination of a stonce/glass mix and a binding resin.
4. 7. A paving block according to claim 1 or claim 2, wherein fle insert is securable to the body within the indentation by a suitable adhesive.
5. 8. A paving block according to any one of the previous claims, wherein the first material is a concrete.
6. 9. A method of forming a paving block, comprising; preparing a mould defining a body of the paving block, said body of the paving block having an indention provided in an upper surface tbereof; placing a first material into said mould to form the body of the paving block; c:\documents and settinOsladministratordesktoobraakhuisdo COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28 28/05/2007 13:53 61-3-98901337 PATENT ATTORNEY SERV PAGE 11/15 removing said body from the mould; and substantially filling the indentation in said body with a second material, said second material having a substantially different composition to said first material. c:documents and settins\administratordesktobbraakhuis.doe COMS ID No: SBMI-07947334 Received by IP Australia: Time 13:57 Date 2007-06-28