WO1995009277A1

WO1995009277A1 - Method and assembly for fabrication pavers

Info

Publication number: WO1995009277A1
Application number: PCT/US1994/011055
Authority: WO
Inventors: James R. Kline
Original assignee: Kline James R
Priority date: 1993-09-30
Filing date: 1994-09-30
Publication date: 1995-04-06
Also published as: AU7846294A

Abstract

A plurality of paving assemblies (10) pave a surface (12). The paving assembly (10) includes a polygonal surface (16) having sidewalls (20, 32) extending perpendicularly downwardly therefrom. Spacers (22) extend out from the edges to align and evenly space the paving assemblies (10) from each other. Screws (14) are used to fasten the paving assemblies (10) to hard surfaces (12), i.e., wood, asphalt, concrete. If a soft surface is being paved, a spike (42) is fastened to the bottom of the paver (10), after which the spike (42) is driven into the soft surface. Support structures (36) extend between the sidewalls (20, 32) along the bottom of the polygonal surface (16) to add support to the polygonal surface (16) and help anchor the paver (10) into a soft surface.

Description

METHOD AND ASSEMBLY FOR FABRICATION PAVERS

Background Art

1. Technical Field

The subject invention relates to pavers used to pave hard and soft surfaces.

2. Description Of Related Art

In looking for alternatives to concrete and asphalt, more people are returning to the old concept of paving an area with individual stones or bricks. Paving a surface area with stones or bricks (hereinafter "bricks") is aesthetically pleasing and inexpensive to complete. In addition, aesthetically pleasing designs may be created when using uniquely shaped bricks, such as those manufactured by Unilock*, of Brighton, Michigan which consists of an octagon adjoined by a square to create a ten-sided brick. These bricks come in a multitude of colors allowing for unique designs which accent the immediately surrounding environment.

Problems associated with using bricks is the expense associated with transporting these bricks. The bricks are solid and dense resulting in high transportation costs for a high volume, heavy weighted articles. Another problems associated with the bricks is the porosity of the bricks. Bricks have a tendency to absorb water and, over time, will destroy the bricks through subsequently heating and cooling, especially when the cooling phases extend below 0° C resulting in the freezing of the water absorbed by the bricks.

Summary Of Invention A paving assembly for paving a surface and secured to the surface by at least one fastener is disclosed. The paving assembly comprises a polygonal surface defining a plurality of edges. First and second sets of side walls extend perpendicularly to the polygonal surface along the plurality of edges. The first and second sets of side walls, in combination with the polygonal surface, defines a hollow interior for receiving a surface therein. Supporting structures are fixedly secured to the polygonal surface and the first and second sets of side walls. The supporting structures extend through the hollow interior subdividing the hollow interior into a plurality of sub- interior spaces. A spacing flange extends out from each of the first set of side walls away from the hollow interior. The spacing flange is also parallel to the polygonal surface. This spacing surface spaces the paving assemblies from one another. This spacing flange includes at least one hole for receiving a fastener to secure the paving assembly to the surface. Further, each spacing flange includes at least one locking protrusion extending upwardly away from and substantially perpendicular to the spacing flanges. The second set of side walls includes a locking recess. Each of the locking recesses receives one of the locking protrusions of another of the paving assemblies. The interlocking of the recesses and protrusion aligns and locks the paving assembly adjacent thereto. A stabilizing spike is removably secured to the supporting structures for minimizing shift in location of the paving assembly. The stabilizing spike includes a base end and a sharp distal end. Further, the base end includes a plurality of detents for receiving the plurality of protrusions extending down from the support structures. The base end further includes a plurality of tabs extending out from the base end. Spike fasteners extend through tabs in the base end of the spike to fixedly secure the stabilizing spike to the support structures.

Brief Description Of The Drawings

Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

Figure 1 is a perspective view of the preferred embodiment of the subject invention; Figure 2 is a bottom view of the preferred embodiment of the subject invention;

Figure 3 is a cross-sectional side view of the preferred embodiment of the subject invention taken along line 3-3 in Figure 1; Figure 4 is a perspective view of a stabilizing spike of the preferred embodiment of the subject invention; and

Figure 5 is a cross-sectional side view of an injection molding assembly used to fabricate the subject invention.

Detailed Description of the Drawings Turning to the Figures 1-4, the subject invention is generally shown at 10. The subject invention is a paving assembly 10 for paving a surface 12 and is fabricated from a plastic material. If the surface to be pave is hard, as is shown in Figure 3, the paving assembly 10 is secured to the surface by at least one fastener 14. The paving assembly 10 comprises a polygonal surface 16 defining a plurality of edges 18. The polygonal surface 16 in the preferred embodiment is a rectangle. It is, however, well-known in the art to use other polygons and combinations of polygons as pavers.

A first set of side walls 20 extend perpendicularly to the polygonal surface 16 along a portion of the plurality of edges 18. The first set of side walls 20 includes a spacing flange 22 extending out from each of the first set of side walls 20 away from the hollow interior and parallel to the polygonal surface 16. In the preferred embodiment, two adjacent sides 20 of the rectangle comprise the first set of side walls 20. The spacing flanges 22 space and align the paving assemblies 10 from one another. The spacing flanges 22 further include at least one hole 24 for receiving a fastener 14 to secure the paving assembly 10 to a surface 12. A fastener 14 used in conjunction with this hole would include a nail or screw or the like wherein the surface 12 below is a hard surface such as wood, asphalt or concrete.

The spacing flanges 22 further include at least one locking protrusion 26 extending upwardly and away from and substantially perpendicular to the spacing flanges 22. The locking protrusions 26 are substantially parallel to the first set of side walls 20. The upwardly extending sides 28 of the locking protrusions may be tapered as to enhance the locking capabilities of the locking protrusions 26 with the locking recesses 30 (discussed subsequently) . The subject invention 10 further includes a second set of side walls 32 extending perpendicularly to the polygonal surface 16 along the plurality of edges which do not have the spacing flanges 22 extending therefrom. Together the first 20 and second 32 sets of side walls and the polygonal surface 16 define a hollow interior 34.

The second set of side walls 32 includes locking recesses 30. Each of the locking recesses 30 receives one of the locking protrusions 26 of a paving assembly 10 located directly adjacent thereto. These locking recesses 30 are cut into the second set of side walls 32. Once the locking protrusions 26 are extended into the locking recesses 30, the two paving assemblies 10 are aligned and locked together.

Support structures 36 are fixedly secured to the polygonal surface 16 and to the first 20 and second 32 sets of side walls. The support structures 36 extend through the hollow interior 34 subdividing the hollow interior 34 into a plurality of sub-interior spaces 38. In the preferred embodiment, the support structures 36 intersect or criss-cross each other as well as extending from one side wall 20 to another 32 without crossing another support structure 36. The support structure 36 includes a plurality of protrusions 40 which extend out from the support structures 36 away from the polygonal surface 16. If the paver assemblies 10 are to be secured to a hard surface 12, i.e., asphalt, concrete, wood, the above-identified fasteners 14 which extend through the spacing flanges 22 are used. Conversely, if the surface which is being paved is soft, i.e., grass, sand, dirt, a stabilizing spike 42 is secured to the support structures for minimizing the shift and location of the paving assembly 10. The stabilizing spike 42 includes a base end 44 and a sharp distal end 46. The base end 44 includes a plurality of detents 48 for receiving the plurality of protrusions 40 extending down from the support structures 36. The base end 44 further includes a plurality of tabs 50 extending out of the base end 44. Fasteners such as screws secure the stabilizing spike 42 to the support structure 36 of the paving assembly 10 by being screwed into holes in the tabs at the base end of the stabilizing spike 42 and into the support structures. In the preferred embodiment, the stabilizing spike has a cross-sectional shape of a cross.

The method for paving a hard surface 12 with a plurality of paver assemblies 10 as described above, include the steps of paving a hard surface with a plurality of paver assemblies 10. The paver assemblies 10 are then locked together using the interlocks 26, 30 of the plurality of the paver assemblies 10. The paver assemblies 10 are then secured by a fastener 14 to a hard surface 12 below the plurality of pavers 10 through the spacer flanges 22 in the plurality of pavers 10. This prevents the pavers from moving once they are positioned. The final step includes filling the spaces between the plurality of paver assemblies 10. Sand or grout 54 or other similar materials may be used to fill the spaces between the plurality of paver assemblies 10. The method for paving a soft surface is identical to the method for paving a hard surface 12 with the following exceptions. First, fasteners 14 extending through the spacing flanges 22 to secure the plurality of paver assemblies 10 to the surface 12 are not used. Instead, a stabilizing spike 42 is fixedly secured to at least one of the paver assemblies 10. The paver assembly 10 with the spike 42 is then driven into the soft surface such that the stake 42 is fully embedded in the soft surface being forced into the hollow interior 34 of the paver assembly 10. This greatly reduces the lateral movement of a paver assembly 10 along a soft surface.

Turning to Figure 5, the assembly for fabricating the pavers is generally shown at 56. The pavers 10 are injection molded. The two mold halves 58 are aligned using pins 60 and guide holes 62. Once the two mold halves 58 are brought together by a hydraulic press 64, or the like, the plastic used to fabricate the pavers 10 is transported from the hopper 66 into the mold cavity 68 by use of a screw drive 70, driven by a motor 72. The plastic is injected into the mold cavity through a nozzle 74. Once the mold cavity 68 is filled, the resulting paver 10 begins to cure. The mold halves 58 are pulled apart after a substantial portion of the curing occurs and the newly fabricated pavers are removed.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.

Claims

I claim:

1. A paving assembly (10) for paving a surface (12) and secured to the surface (12) by at least one fastener (14) , said paving assembly (10) comprising: a polygonal surface (16) defining a plurality of edges (18) ; first (20) and second (32) sets of side walls extending perpendicularly to said polygonal surface (16) along said plurality of edges (18), said first (20) and second (32) sets of side walls and said polygonal surface defining a hollow interior (34) ; supporting structures (36) fixedly secured to said polygonal surface (16) and said first (20) and second (32) sets of side walls extending through said hollow interior (34) subdividing said hollow interior (34); a spacing flange (22) extending out from each of said first set of side walls (20) away from said hollow interior (34) and parallel to said polygonal surface (16) for aligning and spacing said paving assembly (10) from another of said paving assemblies (10) , said spacing flange (22) including at least one hole (24) for receiving a fastener (14) to secure said paving assembly (10) to the surface (12) , each of said spacing flanges (22) further including at least one locking protrusion (26) extending upwardly away from and substantially perpendicular to said spacing flanges (22) ; and said second set of side walls (32) including locking recesses (30) , each of said locking recesses (30) receiving one of said locking protrusions (26) of another of said paving assemblies (10) adjacent thereto.

2. A paving assembly (10) for paving a surface and secured to the surface, said paving assembly (10) comprising: a polygonal surface (16) defining a plurality of edges (18) ; first (20) and second (32) sets of side walls extending perpendicularly to said polygonal surface (16) along said plurality of edges (18) , said first (20) and second (32) sets of side walls and said polygonal surface (16) defining a hollow interior (34) ; supporting structures (36) fixedly secured to said, polygonal surface (16) and said first (20) and second (32) sets of side walls extending through said hollow interior (34) subdividing said hollow interior (34) , said support structures including a plurality of protrusions (40) extending out therefrom; a spacing flange (22) extending out from each of said first set of side walls (20) away from said hollow interior (34) and parallel to said polygonal surface (16) for aligning and spacing said paving assembly (10) from another of said paving assemblies (10) , each of said spacing flanges (20) including at least one locking protrusion (26) extending upwardly away from and substantially perpendicular to said spacing flanges (22) ; said second set of side walls (32) including at least one locking recess (30) , said locking recess (30) receiving one of said locking protrusions (26) of another of said paving assemblies (10) adjacent thereto; a stabilizing spike (42) removably securable to said support structures (36) for minimizing shift and location of said paving assembly (10) , said stabilizing spike (42) including a base end (44) , a sharp distal end (46) , said base end (44) including a plurality of detents (48) for receiving said plurality of protrusions (40) extending down from said support structures (36) , said base end further including a plurality of tabs (50) extending out from said base end (50) ; and spike fasteners (52) extending through said tabs (50) and said base end (44) fixedly securing said stabilizing spike (42) to said support structures (36.

3. A method for paving hard surface with a plurality of paver assemblies wherein each of the plurality of paver assemblies includes a polygonal surface with interlocks along the edges thereof and a spacer extending out from at least one of the edges for receiving at least one fastener therein, the method comprising the steps of: paving a hard surface with a plurality of paver assemblies; locking together the interlocks of a plurality of paver assemblies; securing a fastener to a hard surface below the plurality of pavers through a spacer and the plurality of pavers to secure the plurality of pavers to prevent the plurality of pavers from moving; and filling the spaces between each of the plurality of paving assemblies.

4. A method for paving a soft surface with a plurality of paver assemblies wherein each of the plurality of paver assemblies includes a polygonal surface with interlocks along the edges thereof and a spacer extending out from at least one of the edges for uniformly spacing each of the plurality of paver assemblies from each other, and a spike fixedly securable to the bottom of one of the plurality of paving assemblies, the method comprising the steps of: fixedly securing a spike to at least one of the plurality of paver assemblies; driving the stake into a soft surface until the paver assembly is fully contacting the soft surface; paving the soft surface with the remainder of the plurality of paver assemblies; locking together the interlocks of the plurality of paver assemblies; and filling the spaces between each of the plurality of paver assemblies.

5. A method for fabricating a plastic paver using an injection molder having two mold halves, a materials drive, the method comprising the steps of: aligning two mold halves together to form a mold cavity; sealing the mold cavity; injecting molten plastic into the mold cavity to fill the mold cavity; curing the molten plastic injected into the mold cavity; separating the two mold halves; and removing the plastic from the mold halves.