SYNTHETIC SURFACE ELEMENT

ELEMENT SYNTHETIQUE POUR REVETEMENT DE SURFACE

English Abstract

A synthetic surface element having a central core of filler
material, for example wood chips, saw dust, foam, or any other inert filling
material, said central core being disposed between top and bottom layers of
thermaplastic or thermaset material, the outer perimeter of the synthetic
surface element being provided with first flanges extending substantially
outwardly from the thermaplastic or thermaset material covering the top of
the central core and said flanges having substantially downwardly extending
supplementary flanges located proximate the terminus of the first flanges, the
length of the supplementary flange being greater than the distance between the
top and bottom surfaces of the layers covering the central core filler so as
to
define proximate the bottom of the synthetic surface element a continuous
channel bounded by the supplementary flange and the central core, wherein in
placing said synthetic surface element in engagement with a supporting
surface, for example a gravel or aggregate bed, the hollows will engage with
the supporting elements, for example the aggregate sand or the like, and
position the synthetic surface element, and prevent it from moving in relation
to the supporting surface.

Claims

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THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE AS FOLLOWS:
1. A synthetic surface element having an outer perimeter and comprising
a central core of inert filler material, said central core being disposed
between top
and bottom layers of thermaplastic or thermaset material, the outer perimeter
of the
synthetic surface element being provided with first flanges extending
substantially
outwardly from the thermaplastic or thermaset material covering the top of the
central core and said flanges having substantially downwardly extending
supplementary flanges located proximate a terminus of the first flanges, the
length
of the supplementary flange being greater than the distance between the top
and
bottom surfaces of the layers covering the central core so as to define
proximate a
bottom of the synthetic surface element a continuous hollow bounded by the
supplementary flange and the central core, wherein in placing said synthetic
surface
element in engagement with a supporting surface, the continuous hollow will
engage with the supporting surface, and position the synthetic surface
element, and
prevent it from moving in relation to the supporting surface.
2. The synthetic surface element of claim 1 wherein there is provided a
second hollow located directly below the central core extending towards the
bottom
of the synthetic surface element.
3. The synthetic surface element of claim 1 or 2 wherein said
thermaplastic or thermaset material is fiberglass reinforced resin.
4. The synthetic surface element of claim 1, 2 or 3 wherein said element
is a patio stone.

Description

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TITLE OF INVENTION
SYNTHETIC SURFACE ELEMENT
FIELD OF INVENTION
This invention relates to surface elements such as paving stones,
patio blocks, elements for docks or the like and finds particular application
in
the field of patio blocks.
BACKGROUND OF THE INVENTION
It is known to provide synthetic surface elements to replace the
much heavier more costly concrete or stone based structures.
An example of such a structure is found in United States Patent
No. 5,139,845 issued August 18, 1992 which teaches a light weight structure
composite having a cellular core and fiber reinforced resinous skin. However
the product does not include hollow portions proximate the bottom thereof for
engaging the surface upon which the synthetic surface element is being
fastened.
United States Patent No. 2,839,442 issued June 17, 1958 refers to
a process of making a light weight structural panel formed of a light weight
core material which may be paper, wood, foam etc. The core is faced with
sheet material such as metal, plywood etc. or fiber reinforced plastic. In
describing a new method the above mentioned patent does not teach providing
hollows within the structure to engage with the supporting surface.
Great Britain Patent specification 1,175,821 published December
23, 1969 describes a patio tile formed of clay with glass fiber reinforcement.
Again the hollows which provide the engagement with supporting surfaces are
not provided. West German Offenlegungsschrift 2,731,604 provides a
sandwiched building panel having outer layers of fiber glass plastic with a
core of foam. Again the structure does not include the hollows as described
above.
Finally French Patent Application No. 2,275,605 provides a

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building slab consisting of central core of expanded polystyrene or other foam
which is surrounded by expanded sheet metal in a fiberglass reinforced resin.
The structure includes what appears to be reinforcing ribs as seen in Figures
3
and 4. Again this building unit does not included the limitation above
mentioned.
Nowhere in the prior art is there provided a synthetic surface
element for engagement with a supporting surface, said element including
hollows provided therewith for engaging with portions of the supporting
surface to locate the synthetic surface element in place.
It is a further object of the invention to provide a light weight
synthetic patio stone which is economical to manufacture and easy to use.
Further and other objects of the invention will become apparent
to those skilled in the art when considering the following summary of the
invention and the more detailed description of the preferred embodiment
illustrated herein.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a
synthetic surface element and preferably a patio stone comprising a central
core of filler material, for example wood chips, saw dust, foam, or any other
inert filling material, said central core being disposed between top and
bottom
layers of thermaplastic or thermaset material and preferably fiberglass
reinforced resin, the outer perimeter of the synthetic surface element being
provided with first flanges extending substantially outwardly from the
thermaplastic material covering the top of the central core and said flanges
having substantially downwardly extending supplementary flanges located
proximate the terminus of the first flanges, the length of the supplementary
flange being greater than the distance between the top and bottom surfaces of
the layers covering the central core filler so as to define proximate the
bottom
of the synthetic surface element a continuous channel bounded by the

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supplementary flange and the central core, and preferably there being
provided a second hollow located directly below the central core extending
towards the bottom of the synthetic surface element, wherein in placing said
synthetic surface element in engagement with a supporting surface, for
example a gravel or aggregate bed, the hollows will engage with the
supporting elements, for example the aggregate sand or the like, and position
the synthetic surface element, and in one embodiment a patio block, and
prevent it from moving in relation to the supporting surface.
It is understood that the synthetic surface element may take any
convenient shape including rectangular, hexagonal, square, round and
triangular. However it is preferred that the shape be defined by the heavier
stone article which the synthetic surface element replaces. Of course the
colour of the element may be provided so as to match the colour of the stone
item being replaced. For example if replacing interlocking paving stones a
brick colour is preferred. If replacing concrete patio blocks then a grey
colour may be preferred. In a preferred embodiment the filler is wood
shavings, chips and/or saw dust.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be illustrated with respect to the
following drawings illustrating embodiments of the invention in which:
Figure 1 is a top schematic view of the synthetic patio stone
illustrated in a preferred embodiment of the invention.
Figure 2 is a cut away view of the patio stone of Figure 1
illustrated in a preferred embodiment of the invention.
Figure 3, Figure 4 and Figures 5 are alternative embodiments of
the invention in shape only.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE
INVENTION
Referring now to Figures 1 and 2 there is illustrated a generally

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square shaped synthetic patio stone 10 having a top and a bottom T and B
respectively. The patio stone has located between the top and the bottom a
central core made of inert filler material such as wooden chips and/or saw
dust. The central core is then cover with fiberglass reinforced resin so as to
define about the core 25 a synthetic resin covering 20 reinforced with
fiberglass having a top 24 and a bottom 26 and end portions 31 which
completely surround the central core 25. Extending from the top 24 are
provided laterally extending flange portions 35 which extend from the top
surface 24. Located proximate the terminus of the lateral extending flanges
35 are provided substantially downwardly extending flanges 30 having an
inner wall 30a. The inner wall 30a and the side wall 31 of the central core 25
providing hollows 40 extending about the perimeter of the synthetic patio
stone and providing channels 41, 42, 43 and 44 circumscribing a second
hollow 45 located proximate the bottom of the synthetic resin layer 26. The
hollow 45 thus extends from the bottom 26 to the bottom of patio stone.
Therefore when installing the synthetic patio stone 10 upon an
aggregate bed, such as sand or gravel, by providing the hollows 40 and 45
within the bottom of the patio stone structure, when installed, the aggregate
will substantially fill the hollows 40 and 45 and in doing so prevent the
motion
of the synthetic patio stone in relation to the aggregate. Therefore as
clearly
seen in Figure 2 the flange 30a extends about the entire perimeter of the
patio
stone and its end represents the very bottom of the patio stone as opposed to
the bottom of the central core item 26.
Referring to Figure 3, 4 and 5 there is illustrated identical
structures to that described to the relation to Figures 1 and 2 with exception
of
the shape. Clearly Figure 3 illustrates a hexagonal shape, Figure 4
illustrates a
triangular shape and Figure 5 illustrates a rectangular shape. Clearly the
operation of and provision of the hollows are identical to that in relation to
Figures 1 and 2. The purpose of the hollows is identical as well.

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As many changes can be made to the invention without departing
from the scope of the invention, it is intended that all material contained
herein by interpreted as illustrative of the invention and not in a limiting
sense.

Representative Drawing