US20230002279A1 - Photoluminescent sand - Google Patents

Photoluminescent sand Download PDF

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Publication number
US20230002279A1
US20230002279A1 US17/803,269 US202217803269A US2023002279A1 US 20230002279 A1 US20230002279 A1 US 20230002279A1 US 202217803269 A US202217803269 A US 202217803269A US 2023002279 A1 US2023002279 A1 US 2023002279A1
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Prior art keywords
photoluminescent
sand
pigment
mix
manufacturing
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Abandoned
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US17/803,269
Inventor
Alex Ketty
John Ketty
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Glow Path Pavers LLC
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Glow Path Pavers LLC
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Priority to US17/803,269 priority Critical patent/US20230002279A1/en
Publication of US20230002279A1 publication Critical patent/US20230002279A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/06—Luminescent, e.g. electroluminescent, chemiluminescent materials containing organic luminescent materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/022—Agglomerated materials, e.g. artificial aggregates agglomerated by an organic binder
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/06—Quartz; Sand
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/22—Glass ; Devitrified glass
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic materials
    • C04B20/1029—Macromolecular compounds
    • C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1092—Coating or impregnating with pigments or dyes
    • C04B20/1096—Coating or impregnating with pigments or dyes organic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/004—Reflecting paints; Signal paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/22—Luminous paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/02—Use of particular materials as binders, particle coatings or suspension media therefor
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/08—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/08—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
    • C09K11/59—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing silicon
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C17/00—Pavement lights, i.e. translucent constructions forming part of the surface
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C5/00—Pavings made of prefabricated single units
    • E01C5/06—Pavings made of prefabricated single units made of units with cement or like binders
    • E01C5/065—Pavings made of prefabricated single units made of units with cement or like binders characterised by their structure or component materials, e.g. concrete layers of different structure, special additives
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01F—ADDITIONAL WORK, SUCH AS EQUIPPING ROADS OR THE CONSTRUCTION OF PLATFORMS, HELICOPTER LANDING STAGES, SIGNS, SNOW FENCES, OR THE LIKE
    • E01F15/00—Safety arrangements for slowing, redirecting or stopping errant vehicles, e.g. guard posts or bollards; Arrangements for reducing damage to roadside structures due to vehicular impact
    • E01F15/02—Continuous barriers extending along roads or between traffic lanes
    • E01F15/08—Continuous barriers extending along roads or between traffic lanes essentially made of walls or wall-like elements ; Cable-linked blocks
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01F—ADDITIONAL WORK, SUCH AS EQUIPPING ROADS OR THE CONSTRUCTION OF PLATFORMS, HELICOPTER LANDING STAGES, SIGNS, SNOW FENCES, OR THE LIKE
    • E01F9/00—Arrangement of road signs or traffic signals; Arrangements for enforcing caution
    • E01F9/50—Road surface markings; Kerbs or road edgings, specially adapted for alerting road users
    • E01F9/553—Low discrete bodies, e.g. marking blocks, studs or flexible vehicle-striking members
    • E01F9/559—Low discrete bodies, e.g. marking blocks, studs or flexible vehicle-striking members illuminated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/54—Pigments; Dyes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/807—Luminescent or fluorescent materials

Definitions

  • the present invention relates generally to outdoor surface construction and more specifically to mortar and block products made with photoluminescent products, which includes a mortar mix, polymeric sand, pavers, coping blocks, concrete blocks and ceramic tile that provide illumination without the need for electrical power.
  • Paving blocks are used for walkways, large public pedestrian areas, driveways, paths and the like.
  • the paving blocks allow ground action without deterioration.
  • Paving blocks, like cement blocks for pathways, can be laid in various patterns that are aesthetically pleasing.
  • Walkway lighting for pathways have been used along with paving blocks to increase safety, provide sure footing and visibility.
  • Many walkways are illuminated with low or medium voltage lighting, and must be furnished with low-or medium voltage electricity to power an illumination system. There are electrical consumption costs associated with the use of illumination systems.
  • There are also difficulties in setup of the illumination system if the walkway is a long walkway or is located at a distance from an electrical connection. A licensed contractor must be hired to install electrical supplies for the illumination system.
  • U.S. Pat. No. 6,665,986 to Kaplan discloses a phosphorescent paving block.
  • Patent publication no. 2006/0065879 to Beimel discloses a luminous cementitious composition and methods of making and using the same.
  • U.S. Pat. No. 8,617,638 to Hill discloses a method of manufacturing photoluminescent pavers at a paver manufacturing facility.
  • U.S. Pat. No. 9,114,422 to Toma et al. discloses a paving block with embedded photoluminescent material.
  • U.S. Pat. No. 9,114,422 is hereby incorporated by reference in its entirety.
  • U.S. Pat. No. 10,519,612 to Toma discloses a paving block with improved illumination, which is hereby incorporated by reference in its entirety.
  • the present invention provides mortar and block products made with photoluminescent products, which includes a mortar mix, polymeric sand, pavers, coping block, concrete block, fascia panels and ceramic tile.
  • the mortar and block products made with photoluminescent sand replaces the need for regular sand in such products as a mortar mix, pavers, concrete blocks, coping blocks, ceramic tile, fascia panel and polymeric sand.
  • regular sand must be used.
  • the photoluminescent sand may be purchased from at least one manufacturer.
  • Photoluminescent mortar mix preferably includes the photoluminescent sand, cement and fine aggregate.
  • the photoluminescent paver preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment and regular sand if photoluminescent sand is not used.
  • the photoluminescent concrete block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; gravel; cement; water; and regular sand if photoluminescent sand is not used.
  • the photoluminescent coping block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment; and regular sand if photoluminescent sand is not used.
  • the photoluminescent ceramic tile preferably includes clay, at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; feldspar; water; and regular sand if photoluminescent sand is not used.
  • the photoluminescent fascia panel preferably includes a base portion and a fascia portion. The fascia panel is typically used on an outside surface of a retainer wall.
  • the base portion preferably includes sand, aggregate, gravel, cement; and water.
  • the fascia portion preferably includes small gravel, cement, water and at least one of photoluminescent sand, photoluminescent polymer and chips photoluminescent glass.
  • Photoluminescent polymeric sand preferably includes photoluminescent sand, polymer binder and quart silica. However, Portland cement may also be added to the photoluminescent polymeric sand. Photoluminescent polymer chips and/or glass are used to enhance the photoluminescent effect and appearance.
  • Photoluminescent sand preferably includes play sand, photoluminescent pigment, a powdered binder and a curing agent.
  • the photoluminescent pigment may be replaced with photoluminescent resin or photoluminescent glass.
  • the play sand is preferably mixed with the photoluminescent pigment to form a photo sand mix.
  • the photo sand mix is then mixed with the powered binder and the curing agent to form a photoluminescent sand mix.
  • the photoluminescent sand mix is allowed to cure for between 3-7 days form the photoluminescent sand.
  • mortar and block products made with photoluminescent products which includes mortar, polymeric sand, pavers, coping block, concrete block, fascia panels and ceramic tile that provide illumination without the need for electrical power.
  • FIG. 1 is a perspective view of a fascia panel for a retainer wall in accordance with the present invention.
  • FIG. 2 is an end view of a fascia panel retained on a base block of a retainer wall in accordance with the present invention.
  • the mortar and block products made with photoluminescent sand replaces regular sand in such products as mortar, pavers, concrete blocks, coping blocks, ceramic tile, fascia panel and polymeric sand.
  • the photoluminescent sand, photoluminescent polymer chips and photoluminescent glass may be purchased from Zhejiang Minhui luminous Technology Co., LTD of Lanxi City, Zhejiang China.
  • Photoluminescent mortar preferably includes the photoluminescent sand, cement and fine aggregate. The photoluminescent mortar mix is combined with water at the time of use to create photoluminescent mortar.
  • the photoluminescent paver preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment and regular sand if photoluminescent sand is not used.
  • the photoluminescent sand or regular sand is preferably pre-moistened before mixing with the other elements.
  • the water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the cement and the pigment to form an uncured mixture.
  • the uncured mixture is poured in a paver block mold, pressurized and vibrated. If the photoluminescent polymer chips or photoluminescent glass are used in the paver, a top of the paver is preferably ground to enhance illumination thereof.
  • the photoluminescent concrete block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; gravel; cement; water; and regular sand if photoluminescent sand is not used.
  • the water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the gravel and the cement to form an uncured mixture.
  • the uncured mixture is poured in a block mold, pressurized and vibrated.
  • the photoluminescent coping block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment; and regular sand if photoluminescent sand is not used.
  • the photoluminescent sand or regular is preferably pre-moistened before mixing with the other elements.
  • the water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the cement and the pigment to form an uncured mixture.
  • the uncured mixture is poured in a coping block mold, pressurized and vibrated. If the photoluminescent polymer chips or photoluminescent glass are used in the coping block, a top of the coping block is ground to enhance illumination thereof.
  • Photoluminescent ceramic tile preferably includes clay, at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; feldspar water; and regular sand if photoluminescent sand is not used. The mixture is fired to form at least one ceramic tile.
  • the photoluminescent fascia panel 1 preferably includes a base portion 10 and a fascia portion 12 .
  • a retainer wall 14 is made from a plurality of base blocks 16 and a plurality of fascia panels 1 .
  • At least one support projection 18 extends from a side of the base block 16 .
  • At least one support groove 20 is formed in a rear of said base portion 10 for hanging the fascia panel 1 on the at least one support projection 18 .
  • the base portion 10 preferably includes sand, aggregate, gravel, cement; and water.
  • the fascia portion 12 preferably includes small gravel, cement, water and at least one of photoluminescent sand, photoluminescent polymer and chips photoluminescent glass.
  • the components of the fascia portion 12 are mixed and poured into a fascia mold.
  • the fascia portion mix is allowed to cure.
  • the components of the base portion 10 are mixed and poured on top of the fascia panel mix and allowed to cure to form photoluminescent fascia panel 1 .
  • a bottom of the fascia mold may be textured.
  • Photoluminescent polymeric sand preferably includes photoluminescent sand, polymer binder and quart silica. Portland cement may also be added to the photoluminescent polymeric sand.
  • the photoluminescent polymeric sand is mixed with water and then poured into spaces between pavers or blocks.
  • Photoluminescent sand preferably includes play sand, photoluminescent pigment, a powdered binder and a curing agent.
  • the play sand (child's sandbox sand) may be purchased from Quikrette.
  • the play sand has a granulation of up to 2 mm. However, other sands may also be used.
  • the photoluminescent pigment has a granulation size of 0.3 mm to 0.9 mm.
  • the photoluminescent pigment may be replaced with crushed photoluminescent glass or photoluminescent resin.
  • the photoluminescent glass is manufactured with photoluminescent pigment.
  • the photoluminescent resin is made from photoluminescent pigment mixed with some type of polymer.
  • the photoluminescent glass and the photoluminescent resin have the same particle size as the photoluminescent pigment. Satisfactory results have been found when using DirtGlueDry for the powered binder, which is manufactured by Global Environmental Solutions, but other powered binders may also be used. Satisfactory results have been found when using Polycure for the curing agent, which is manufactured by SpecChem, but other curing agents may also be used.
  • Formula I includes 91.5% of play sand, 5% of photoluminescent pigment, 3% powdered binder and 0.5% of curing agent all by weight.
  • Formula II includes 89% of play sand, 5% of photoluminescent pigment, 5% of powdered binder and 1% of curing agent all by weight.
  • the play sand is preferably mixed for five minutes at 500 rpm in a V-blender.
  • the play sand is preferably mixed with the photoluminescent pigment to form a photo sand mix for five minutes at 500 rpm in the V-blender.
  • the photo sand mix is then mixed with the powered binder and curing agent to form a photoluminescent sand mix for fifteen minutes at 500 rpm.
  • Formula I is discharged into a bag and allowed to cure for 7 days.
  • Formula II is discharged into a bag and allowed to cure for 3 days.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Road Paving Structures (AREA)

Abstract

Photoluminescent sand preferably includes play sand, photoluminescent pigment, a powdered binder and a curing agent. The play sand is preferably mixed with the photoluminescent pigment to form a photo sand mix. The photo sand mix is then mixed with the powered binder and curing agent to form the photoluminescent sand mix. The photoluminescent sand mix is allowed to cure for between 3-7 days to form the photoluminescent sand.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This is a continuation-in-part patent application taking priority from patent application Ser. No. 16/811,776 filed on Mar. 6, 2020, which takes priority from patent application Ser. No. 16/782,112 filed on Feb. 5, 2020.
    • BACKGROUND OF THE INVENTION Field of the Invention
  • The present invention relates generally to outdoor surface construction and more specifically to mortar and block products made with photoluminescent products, which includes a mortar mix, polymeric sand, pavers, coping blocks, concrete blocks and ceramic tile that provide illumination without the need for electrical power.
    • Discussion of the Prior Art
  • Paving blocks are used for walkways, large public pedestrian areas, driveways, paths and the like. The paving blocks allow ground action without deterioration. Paving blocks, like cement blocks for pathways, can be laid in various patterns that are aesthetically pleasing. Walkway lighting for pathways have been used along with paving blocks to increase safety, provide sure footing and visibility. Many walkways are illuminated with low or medium voltage lighting, and must be furnished with low-or medium voltage electricity to power an illumination system. There are electrical consumption costs associated with the use of illumination systems. There are also difficulties in setup of the illumination system, if the walkway is a long walkway or is located at a distance from an electrical connection. A licensed contractor must be hired to install electrical supplies for the illumination system.
  • The use of outdoor lighting is known in the prior art. For example, U.S. Pat. No. 6,027,280 to Connors et. al (Connors) discloses an interlocking paving block with interior illumination capability. However Conners does not allow for non-electrical use of an outdoor light. Similarly, U.S. Pat. No. 5,472,737 to Anders (Anders 737) discloses a photoluminescent highway paint composition that is painted on highways to aid in driving. However, Anders 737 does not disclose the use of paving blocks. Lastly, U.S. Pat. No. 6,005,024 to Anders et al (Anders 024) discloses a photoluminescent overlay that covers existing signs and gives moisture stability to the phosphorescent materials. However, Anders 024 does not disclose the use of paving blocks.
  • While the above-described devices fulfill their respective objections and requirements, the aforementioned patents do not describe a photoluminescent paving block that allows for being used for outdoor lighting. Connors makes no provision for non-electrical use, since it includes an insect bulb and wiring. Anders 737 and 024 only disclose the use of photoluminescent material in conjunction with paving blocks.
  • Additionally, U.S. Pat. No. 6,665,986 to Kaplan discloses a phosphorescent paving block. Patent publication no. 2006/0065879 to Beimel discloses a luminous cementitious composition and methods of making and using the same. U.S. Pat. No. 8,617,638 to Hill discloses a method of manufacturing photoluminescent pavers at a paver manufacturing facility. However, U.S. Pat. No. 9,114,422 to Toma et al. discloses a paving block with embedded photoluminescent material. U.S. Pat. No. 9,114,422 is hereby incorporated by reference in its entirety. U.S. Pat. No. 10,519,612 to Toma discloses a paving block with improved illumination, which is hereby incorporated by reference in its entirety.
  • Accordingly, there is a clearly felt need in the art for mortar and block products made with photoluminescent products, which includes a mortar mix, polymeric sand, photoluminescent sand, pavers, coping blocks, concrete block, fascia panels and ceramic tile that provide illumination without the need for electrical power.
    • SUMMARY OF THE INVENTION
  • The present invention provides mortar and block products made with photoluminescent products, which includes a mortar mix, polymeric sand, pavers, coping block, concrete block, fascia panels and ceramic tile. The mortar and block products made with photoluminescent sand replaces the need for regular sand in such products as a mortar mix, pavers, concrete blocks, coping blocks, ceramic tile, fascia panel and polymeric sand. However, if photoluminescent polymer chips or photoluminescent glass is used, but not photoluminescent sand, regular sand must be used. The photoluminescent sand may be purchased from at least one manufacturer. Photoluminescent mortar mix preferably includes the photoluminescent sand, cement and fine aggregate. The photoluminescent paver preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment and regular sand if photoluminescent sand is not used. The photoluminescent concrete block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; gravel; cement; water; and regular sand if photoluminescent sand is not used. The photoluminescent coping block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment; and regular sand if photoluminescent sand is not used.
  • The photoluminescent ceramic tile preferably includes clay, at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; feldspar; water; and regular sand if photoluminescent sand is not used. The photoluminescent fascia panel preferably includes a base portion and a fascia portion. The fascia panel is typically used on an outside surface of a retainer wall. The base portion preferably includes sand, aggregate, gravel, cement; and water. The fascia portion preferably includes small gravel, cement, water and at least one of photoluminescent sand, photoluminescent polymer and chips photoluminescent glass. Photoluminescent polymeric sand preferably includes photoluminescent sand, polymer binder and quart silica. However, Portland cement may also be added to the photoluminescent polymeric sand. Photoluminescent polymer chips and/or glass are used to enhance the photoluminescent effect and appearance.
  • Photoluminescent sand preferably includes play sand, photoluminescent pigment, a powdered binder and a curing agent. The photoluminescent pigment may be replaced with photoluminescent resin or photoluminescent glass. The play sand is preferably mixed with the photoluminescent pigment to form a photo sand mix. The photo sand mix is then mixed with the powered binder and the curing agent to form a photoluminescent sand mix. The photoluminescent sand mix is allowed to cure for between 3-7 days form the photoluminescent sand.
  • Accordingly, it is an object of the present invention to provide mortar and block products made with photoluminescent products, which includes mortar, polymeric sand, pavers, coping block, concrete block, fascia panels and ceramic tile that provide illumination without the need for electrical power.
  • These and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a perspective view of a fascia panel for a retainer wall in accordance with the present invention.
  • FIG. 2 is an end view of a fascia panel retained on a base block of a retainer wall in accordance with the present invention.
    •  DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • The mortar and block products made with photoluminescent sand replaces regular sand in such products as mortar, pavers, concrete blocks, coping blocks, ceramic tile, fascia panel and polymeric sand. The photoluminescent sand, photoluminescent polymer chips and photoluminescent glass may be purchased from Zhejiang Minhui luminous Technology Co., LTD of Lanxi City, Zhejiang China. Photoluminescent mortar preferably includes the photoluminescent sand, cement and fine aggregate. The photoluminescent mortar mix is combined with water at the time of use to create photoluminescent mortar. The photoluminescent paver preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment and regular sand if photoluminescent sand is not used. The photoluminescent sand or regular sand is preferably pre-moistened before mixing with the other elements. The water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the cement and the pigment to form an uncured mixture. The uncured mixture is poured in a paver block mold, pressurized and vibrated. If the photoluminescent polymer chips or photoluminescent glass are used in the paver, a top of the paver is preferably ground to enhance illumination thereof.
  • The photoluminescent concrete block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; gravel; cement; water; and regular sand if photoluminescent sand is not used. The water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the gravel and the cement to form an uncured mixture. The uncured mixture is poured in a block mold, pressurized and vibrated.
  • The photoluminescent coping block preferably includes at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; aggregate; cement; water; pigment; and regular sand if photoluminescent sand is not used. The photoluminescent sand or regular is preferably pre-moistened before mixing with the other elements. The water is mixed with the at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass, the aggregate, the cement and the pigment to form an uncured mixture. The uncured mixture is poured in a coping block mold, pressurized and vibrated. If the photoluminescent polymer chips or photoluminescent glass are used in the coping block, a top of the coping block is ground to enhance illumination thereof.
  • Photoluminescent ceramic tile preferably includes clay, at least one of photoluminescent sand, photoluminescent polymer chips and photoluminescent glass; feldspar water; and regular sand if photoluminescent sand is not used. The mixture is fired to form at least one ceramic tile. With reference to FIGS. 1-2 , the photoluminescent fascia panel 1 preferably includes a base portion 10 and a fascia portion 12. A retainer wall 14 is made from a plurality of base blocks 16 and a plurality of fascia panels 1. At least one support projection 18 extends from a side of the base block 16. At least one support groove 20 is formed in a rear of said base portion 10 for hanging the fascia panel 1 on the at least one support projection 18. The base portion 10 preferably includes sand, aggregate, gravel, cement; and water. The fascia portion 12 preferably includes small gravel, cement, water and at least one of photoluminescent sand, photoluminescent polymer and chips photoluminescent glass. The components of the fascia portion 12 are mixed and poured into a fascia mold. The fascia portion mix is allowed to cure. The components of the base portion 10 are mixed and poured on top of the fascia panel mix and allowed to cure to form photoluminescent fascia panel 1. A bottom of the fascia mold may be textured. Photoluminescent polymeric sand preferably includes photoluminescent sand, polymer binder and quart silica. Portland cement may also be added to the photoluminescent polymeric sand. The photoluminescent polymeric sand is mixed with water and then poured into spaces between pavers or blocks.
  • Photoluminescent sand preferably includes play sand, photoluminescent pigment, a powdered binder and a curing agent. The play sand (child's sandbox sand) may be purchased from Quikrette. The play sand has a granulation of up to 2 mm. However, other sands may also be used. The photoluminescent pigment has a granulation size of 0.3 mm to 0.9 mm. The photoluminescent pigment may be replaced with crushed photoluminescent glass or photoluminescent resin. The photoluminescent glass is manufactured with photoluminescent pigment. The photoluminescent resin is made from photoluminescent pigment mixed with some type of polymer. The photoluminescent glass and the photoluminescent resin have the same particle size as the photoluminescent pigment. Satisfactory results have been found when using DirtGlueDry for the powered binder, which is manufactured by Global Environmental Solutions, but other powered binders may also be used. Satisfactory results have been found when using Polycure for the curing agent, which is manufactured by SpecChem, but other curing agents may also be used.
  • The following parameters are given by way of example and not by way of limitation. Satisfactory results have been found with the following two formulas. Formula I includes 91.5% of play sand, 5% of photoluminescent pigment, 3% powdered binder and 0.5% of curing agent all by weight. Formula II includes 89% of play sand, 5% of photoluminescent pigment, 5% of powdered binder and 1% of curing agent all by weight. The play sand is preferably mixed for five minutes at 500 rpm in a V-blender. The play sand is preferably mixed with the photoluminescent pigment to form a photo sand mix for five minutes at 500 rpm in the V-blender. The photo sand mix is then mixed with the powered binder and curing agent to form a photoluminescent sand mix for fifteen minutes at 500 rpm. Formula I is discharged into a bag and allowed to cure for 7 days. Formula II is discharged into a bag and allowed to cure for 3 days.
  • While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.

Claims (12)

I claim:
1. A method of manufacturing a photoluminescent sand comprising the steps of:
providing sand;
providing a powdered binder;
providing a curing agent;
mixing photoluminescent pigment, a photoluminescent resin, or photoluminescent glass with said sand to form a photo sand mix; and
mixing said powdered binder and said curing agent with said photo sand mix to form photoluminescent sand.
2. The method of manufacturing a photoluminescent sand of claim 1 comprising the step of:
allowing said photoluminescent sand to cure.
3. The method of manufacturing a photoluminescent sand of claim 1 wherein:
said sand has a granulation of up to 2 mm.
4. The method of manufacturing a photoluminescent sand of claim 1 wherein:
said photoluminescent pigment, said photoluminescent resin, or said photoluminescent glass has a granulation of between 0.3 mm to 0.9 mm.
5. A method of manufacturing a photoluminescent sand comprising the steps of:
providing sand in a percentage of between 89-91.5 by weight;
providing a powdered binder in a percentage of 3-5 by weight;
providing a curing agent in a percentage of 0.5-1 by weight;
mixing photoluminescent pigment in an amount of 5 percent by weight with said sand to form a photo sand mix; and
mixing said powdered binder and said curing agent with said photo sand mix to form photoluminescent sand.
6. The method of manufacturing a photoluminescent sand of claim 5 comprising the step of:
allowing said photoluminescent sand to cure.
7. The method of manufacturing a photoluminescent sand of claim 5 wherein:
said sand has a granulation of up to 2 mm.
8. The method of manufacturing a photoluminescent sand of claim 5 wherein:
said photoluminescent pigment has a granulation of between 0.3 mm to 0.9 mm.
9. A method of manufacturing a photoluminescent sand comprising the steps of:
providing sand;
providing a powdered binder;
providing a curing agent;
mixing photoluminescent pigment, photoluminescent resin, or photoluminescent glass with said sand to form a photo sand mix for a period of 5 minutes; and
mixing said powdered binder and said curing agent with said photo sand mix to form photoluminescent sand for a period of 15 minutes.
10. The method of manufacturing a photoluminescent sand of claim 9 comprising the step of:
allowing said photoluminescent sand to cure.
11. The method of manufacturing a photoluminescent sand of claim 9 wherein:
said sand has a granulation of up to 2 mm.
12. The method of manufacturing a photoluminescent sand of claim 9 wherein:
said photoluminescent pigment, said photoluminescent resin, or said photoluminescent glass has a granulation of between 0.3 mm to 0.9 mm.
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US11279654B2 (en) * 2019-08-07 2022-03-22 Alliance Designer Products Inc. Photoluminescent premixed compositions, related methods and uses
US11299423B1 (en) * 2020-02-05 2022-04-12 Glow Path Pavers, Llc Photoluminescent sand

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