AU3405500A - Paving system - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): John Francis Tindale CHERIE LEANNE TINDALE Invention Title: PAVING SYSTEM .11.

9900.o 0** 0 The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 PAVING SYSTEM FIELD OF THE INVENTION The present invention relates to a paving system, in particular, to a mould for forming such a paving system.

When the terminology "paving system" and "paving element(s)" is used herein, it refers to any ground covering element that can be moulded and then laid over ground, and includes pavers, cobble stones, elongate elements etc.

BACKGROUND ART Paving systems are known in the art. Systems which comprise integrated units, having a plurality of paving elements attached together are shown in EP 4364, WO e• 93/07339, and GB 2,212,195. These systems have inflexible oo 15 links between the paving elements and thus have limited versatility in ground covering applications.

US 5,615,971 discloses a paving system having flexible links between adjacent paving elements, and also discloses automated methods for forming such systems. However, the manufacturing methods disclosed therein are moderately complex, in that press plates or push rods are required to hold the connecting flexible link in place during moulding of the paving elements. Accordingly, this requires more complex moulding apparatus and hence greater economic expense.

SUMMARY OF THE PRESENT INVENTION The present invention in a first aspect provides a mould for forming a paving system having two or more paving elements, each connected to an adjacent element by a connector, the mould including two or more respective cavities, each for forming a paving element therein, with a given cavity being separated from an adjacent cavity by a wall, and with the wall having a recess therein that connects the cavity on one wall side to an adjacent cavity 35502 3 on the other wall side, and that extends into the wall from a free end of the wall; wherein the recess includes a passage extending in from the free end to an enlarged region at a base thereof and into which region the connector is received during moulding.

In a second aspect the present invention provides a mould for forming a paving system having two or more paving elements, each connected to an adjacent element by a connector, the mould including two or more respective cavities, each for forming a paving element therein, with a given cavity being separated from an adjacent cavity by a wall, and with the wall having a recess therein that connects the cavity on one wall side to an adjacent cavity on the other wall side; S. 15 wherein the recess includes a region into which the connector is interferingly received for fastening against movement during moulding.

By providing a recess arrangement for holding the connector in the mould in this way, separate push rods or ego* eo 20 protrusions formed on a mould plate are not required, and thus the moulding operation can be substantially simplified.

Preferably in the first aspect the passage is sized and the wall material adjacent to the passage is 25 sufficiently flexible such that the connector is only passed through the passage and into the enlarged region by deforming one or both of the passage adjacent walls. In this way mouldable material is prevented from flowing from one cavity to another via the passage, and enables the connector to be easily inserted into the enlarged region.

Preferably in both the first and second aspects one or both sides of the adjacent wall deform as the connector is passed therebetween, and typically both sides deform. In this regard, preferably the entire mould is formed from a flexible (typically polymeric) material.

35502 4 Preferably the wall sides of the recess are sufficiently closed such that in use, with a connector positioned in the recess, a moulding material introduced into a given cavity to form a paving element is prevented from flowing to an adjacent cavity via the recess. In the first aspect it is preferred that the connector is received in an interference fit in the enlarged region.

Typically the mould includes a plurality of cavities formed therein in a lengthwise direction and a plurality of cavities formed therein in a breadthwise direction, to define a matrix of cavities in the mould. Typically in this regard each wall between each adjacent two cavities has a like recess formed therein. In other words, the recess configuration is typically repeated right throughout 15 the mould.

Preferably the connector is an elongate cord, string, link or the like that extends lengthwise through a plurality of recesses, typically in a line (although it may •coo be a short link extending just between two cavities). In this regard, the connector can be provided in the form of a single connector net that is aligned with and extends through all of the recesses, across all of the cavities altogether.

Preferably the recess is located such that, when a 25 given cavity is filled with a paver element moulding material, that part of the connector protruding into the cavity becomes positioned within the element. In this regard, typically the connectors are positioned to extend out from a side wall of the resulting paving element, typically near a base thereof (eg. a third of the way up the side wall from the base) although this depends specifically on the application.

Preferably, when forming the mould, the base of each cavity is textured (eg. by forming the mould in a template including a plurality of paving element templates, the upper surface of each of which is textured accordingly.

35502 5 Preferably in the formation of the mould, the template is arranged within a frame box, and the mould material is then poured into that frame box to cover all of the paving element templates. Additionally, a lid may be placed thereon before or after filling up the frame box with mould material, to provide an essentially flat baseto the resultant mould.

Optionally, each paving element template is formed as a composite structure, having a natural stone material or the like at an upper surface thereof, and a base (to which the upper surface is affixed) formed from a curable material, such as a clay, plaster, plasticine or polymeric resin.

~Typically the mould is formed from a curable polymeric 15 resin, such as polyurethane, acrylonitrile-butadienestyrene or the like.

In a third aspect the present invention provides a method for forming a paving system employing a mould as oooo defined for the first and second aspects, including the oo o oo 20 steps of: arranging the connector in each recess such that protrudes into each cavity on opposing sides of the wall; introducing a mouldable and curable material into 25 each cavity up to a level such that each connector is at least partially submerged within the material; and allowing the material to cure sufficiently such that the elements can be removed from the mould.

BRIEF DESCRIPTION OF THE DRAWINGS Notwithstanding any other forms which may fall within the scope of the present invention, preferred formsof the invention will now be described, by way of example only, with reference to the accompanying drawings in which: 35502 6 Figures 1 to 5 illustrate, in side elevation, the sequential steps in producing a preferred mould for forming a paving system in accordance with the present invention; Figures 6, 7 and 7A show, respectively, an inset partial perspective view and two partial cross-sectional views (taken on the line 7-7 of Figure of preferred moulds in accordance with the present invention; Figure 8 shows a partial detail of the moulds of Figures 7, 7A in side elevation with a connector cord arranged therein; Figures 9 and 10 show, in side elevation, the mould of Figure 8 after having received the mouldable paving elements therein; Figure 11 shows, in side elevation, the formed paving 15 system removed from the mould; and Figures 12 and 13 show, respectively, side perspective and plan views of a resultant paving system produced in accordance with the present invention.

~MODES FOR CARRYING OUT THE INVENTION Preferred methods for producing a mould in accordance with the present invention will firstly be described with specific reference to Figures 1 to 5, and then the use of that mould in forming a paving system will be described with specific reference to Figures 8 to 11.

Reference will also be made to the key at the end of the drawings, which explains the different shadings employed for different material components in the mould production and paving system production processes respectively.

Mould Forming Referring firstly to Figure 1, a paving element template 10 for use in producing a preferred mould is depicted in side elevation. The template is typically square or rectangular shaped in plan view (not shown), although any suitable shape, including circular, hexagonal 35502 7 or a rough shape etc can be employed. The template includes an original stone layer 12 (typically formed from a natural stone such as sandstone, bauxite, bluestone etc, and which is employed to impart a natural textured effect to the resultant mould (and thus the resultant paving elements of the paving system). A thin stone layer can be employed to keep costs to a minimum. The stone layer is mounted (typically adhesively affixed) to a base layer 14, which is typically formed from a curable or fireable material such as clay, plaster, plasticine or polymeric resin. Typically the base layer comprises the bulk of the template 10, as it can be formed form far cheaper material '-than the natural stone. In addition, it is typically mouldable so that interesting textured effects on the side S' 15 of the paving elements can also be achieved.

The base layer can also ensure that a consistent :oooos thickness is provided for each stone (eg. 40mm thickness) Therefore, an even surface height on laying of the product can be achieved. Typically, slight irregularity exists in oeoo the natural stone upper surface, but the paver overall is made safer for pedestrians etc by the regular thickness of go* each stone, providing a generally regular surface.

Typically a plurality of paving elements are produced and are then arranged in a sealable box frame 16 (Figure The templates can be arranged in any desired pattern within the box frame, and typically rectangular, square and circular template matrices are employed. The box frame is also effectively sealed to contain moulding material poured therein.

Referring to Figure 3, it will be seen that the box frame has now been filled up with a mould material 18, which is typically poured or injected therein. The mould material is usually a thermosetting yet flexible polymeric resin, such as a polyurethane, acrylonitrile-butadienestyrene or other similar flexible polymeric material.

35502 8 Alternatively, the mould material can be injected into the box frame under heat and/or pressure.

Optionally a mould lid 20 can be positioned over the frame 16, with its side walls extending down around the frame to provide closure. This arrangement can also provide an enclosed cavity space into which mould material can be injected.

However, in the most simple method, mould material is simply poured into the box frame and allowed to at least partially cure. The lid is thus optional.

Paving System Formation Once the mould has at least partially cured, the lid *is removed and the mould is then released from the box frame (eg. by inverting the frame and lowering the lid, or 15 by lowering the frame whilst providing suction at the lid etc). The resulting mould 18 (Figure 4) has a number of cavities 26 defined therein, and optionally each cavity can have a textured base 28 defined therewithin (as imparted by eee, the stone layer 12). A number of partition walls 30 are oeoe e 20 defined in the mould 18, surrounded by a mould external wall 32. Each of the partition walls has a link recess 34 ***(shown in greater detail in Figures 6, 7 and 7A) defined therein. The link recess can be defined by arranging an :appropriate template element between each paving element 25 template 10 during the moulding process, but typically and more expediently is subsequently formed in the mould once it has been removed from the frame. Thus, the link recess can be moulded into the mould whilst it is still partially curing, or it can be cut, punched or drilled out of the mould etc. after at least partial curing (Figure 7A) A hole can also be formed in the wall during moulding (eg. using a "loss wax" type of forming method) Typically the link recess is a hole 35 (or the like) as shown in Figure 7A. The link recess of Figures 6 and 7 can also include a formed passageway 36 extending 35502 9 downwardly from the end of the wall 37 and opening onto hole 35 or an enlarged bulb region 38.

Typically the passageway 36 is formed sufficiently narrowly such that, during the subsequent moulding formation of a paving element, liquid paving element material poured into the cavity does not flow through the passage. Again, the passageway can be moulded into the wall 30, but more typically is cut or formed into wall after at least partial curing of the removed mould. Most preferably the passageway is a narrow slit cut into the wall 30 and extending down to previously formed hole The hole 35 or bulb region 38 are both typically sized to receive a link or connector therethrough, preferably in a friction or interference fit to stop the link from sliding 15 therewithin (eg. in the moulding operation). Preferably both are circular to prevent mould tearing in use.

Figure 8 shows a link in the form of an elongate cord or tie element 40 fitted in each hole or bulb region (or in o o holes 35 absent passageway 36). The friction fit enables a ee oo 20 taught (straight) orientation of the cord to be adopted, so that the cord can be accurately positioned within a moulded paving element that is subsequently formed therearound.

Thus, the cord can either be press fitted down through each passage 36 and into the hole or enlarged bulb region, 25 or can be threaded through each hole 35, typically by hand, in either case representing a substantial simplification of the manufacturing process. However, if desired the process can be automated, although again relatively simple assembling machinery can be employed because of the simple nature of the arrangement.

When push fitting cord into the link recess, typically the passageway deforms at its side walls (ie. the mould is typically entirely formed from a flexible material).

Alternatively, either one or both side walls of the passageway 36 can be deformable (with the remainder of the 35502 10 mould being non-deformable) to enable pressing in of the cord into the hole or bulb region.

Once the cord has been appropriately arranged, formation of the paving system is now commenced. In this regard, concrete or other curable hard wearing material 44 is poured into each of the cavities, and fills each cavity (as shown in Figure 9) so that the cord extending through each cavity is submerged within the concrete structure.

Once the concrete has at least partially set, the mould is inverted (Figure 10) and then each concrete formation is pressed out of its respective cavity so that a plurality of paving elements 50 are released from the mould. During the *.:.:pressing out of the paving elements, the cord 40 easily "passes through the passageway 36. In the case of the hole S* 15 without a passage arrangement, a cut must be subsequently formed in each partition wall to then enable the cord to pass therethrough. Thus, it is most preferable to employ the link recess arrangement wherein a cut or passageway 36 A0 is first provided, prior to paving system moulding.

S 20 Figures 12 and 13 show perspective and plan views of a light coloured and dark coloured paving system respectively, wherein each paving element is interconnected to adjacent paving elements via the cords The paving elements need not be formed from concrete 25 material, and polymer or rubber paving blocks and elements can also be formed in this way. The concrete may be a mortar having a polymeric binder, or the elements may have stone or other natural material dispersed within a polymeric matrix etc.

As stated above, the bulk of the mould need not be flexible (although it is typically entirely flexible).

However, at the passage 36, flexibility of at least one of the side wall portions of the passage is required for inserting and retracting the cord 40 therein.

The cords can be any suitable linking element, including metal, synthetic and natural fibrous string and 35502 11 rope, plastic, plastic-coated metal wire, plastic linking elements etc.

As stated above, any shaped paving system can be produced, including square, circular and rectangular matrices, random paving matrices etc. Any shaped paving element, having varying heights, depths, breadths etc. can also be produced.

Whilst the invention has been described with reference to a number of preferred embodiments, it should be appreciated that the invention can be embodied in many other forms.

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Claims (9)

1. A mould for forming a paving system having two or more paving elements, each connected to an adjacent element by a connector, the mould including two or more respective cavities, each for forming a paving element therein, with a given cavity being separated from an adjacent cavity by a wall, and with the wall having a recess therein that connects the cavity on one wall side to an adjacent cavity on the other wall side; wherein the recess includes a region into which the connector is interferingly received for fastening against movement during moulding; or wherein the recess extends into the wall from a free end of 15 the wall and includes a passage extending in from the free end to an enlarged region at a base thereof and into which *9 S"region the connector is received during moulding.

2. A mould as claimed in Claim 1 wherein one or both sides of the wall adjacent to the recess deform as the connector is passed therebetween.

3. A mould as claimed in claim 1 or claim 2 wherein the wall sides of the recess are sufficiently close such that in use, with a connector positioned in the recess, a moulding material introduced into a given cavity to form a 25 paving element is prevented from flowing to an adjacent cavity via the recess.

4. A mould as claimed in any one of the preceding claims that includes a plurality of cavities formed therein in a lengthwise direction and a plurality of cavities formed therein in a breadthwise direction, to define a matrix of cavities in the mould. A mould as claimed in claim 4 wherein each wall between each adjacent two cavities has a like recess formed therein, such that the recess configuration is repeated right throughout the mould. 35502 13 9 oooo 99 9

9. 9 O o 0 •0 1 e oo 6. A mould as claimed in any one of the preceding claims wherein the connector is an elongate cord, string, link or the like that extends lengthwise through a plurality of recesses, in a line, or is a short link extending just between two cavities. 7. A mould as claimed in claim 6 wherein the connector is a single connector net that is aligned with and extends through all of the recesses, across all of the cavities altogether. 8. A mould as claimed in any one of the preceding claims wherein the recess is located such that, when a given cavity is filled with a paver element moulding material, that part of the connector protruding into the cavity becomes positioned within the element. 15 9. A mould as claimed in claim 8 wherein the connectors are positioned to extend out from a side wall of the resulting paving element, typically near a base thereof, optionally a third of the way up the side wall from the base.

10. A mould as claimed in any one of the preceding claims wherein, when forming the mould, the base of each cavity is textured by forming the mould in a template including a plurality of paving element templates, the upper surface of each of which is textured accordingly. 25 11. A mould as claimed in claim 10 wherein in the formation of the mould, the template is arranged within a frame box, and the mould material is then poured into that frame box to cover all of the paving element templates, and a lid is optionally placed thereon before or after filling up the frame box with mould material, to provide an essentially flat base to the resultant mould.

12. A mould as claimed in claim 10 wherein each paving element template is formed as a composite structure, having a natural stone material or the like at an upper surface thereof, and a base (to which the upper surface is 35502 i 14 affixed) is formed from a curable material, such as a clay, plaster, plasticine or polymeric resin.

13. A mould as claimed in any one of the preceding claims wherein the mould is formed from a curable polymeric resin, such as polyurethane, acrylonitrile-butadiene-styrene or the like.

14. A mould for a paving system substantially as herein described with reference to the accompanying drawings. A method for forming a paving system employing a mould as defined in any one of the preceding claims, including the steps of: arranging the connector in each recess such that it protrudes into each cavity on opposing sides of the wall; 15 introducing a mouldable and curable material into each cavity up to a level such that each connector is at least partially submerged within the material; and allowing the material to cure sufficiently such that the elements can be removed from the mould. 20 16. A paving system produced using the mould of any one of claim 1 to 14 or the method of claim Dated this 12 day of May 2000 JOHN FRANCIS TINDALE AND CHERIE LEANNE TINDALE 25 By their Patent Attorneys GRIFFITH HACK 35502