Note: Descriptions are shown in the official language in which they were submitted.
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PAVER WITH INTERLOCKING SPACERS
BACKGROUND OF THE INVENTION
1. Field of the Invention.
[0004] The present invention relates to exterior hardscaping. More
specifically, the
present invention relates to a paving stone for use in roadways, sidewalks,
and other hardscaped
surfaces to construct permeable surfaces.
2. Description of the Related Art.
[0005] An interlocking paving block, or paver, is a pre-cast piece of
material¨
typically concrete or clay¨that is commonly used in exterior hardscaping
applications, such as
roads, walkways,- patios, pool decks, and driveways. Such pavers are installed
over a compacted
stone sub-base and a leveling bed of sand.
[0006] Instead of connecting the pavers by pouring grout between the joints,
as one
would do with tiles, sand particles are spread over the pavers and tamped
down. The sand
stabilizes the interlocking pavers, yet allows for some flexibility. Typical
paver hardscapes will
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absorb the stresses caused by freezes, thaws, and slight ground erosion by
shifting each paver
slightly. This minimizes cracking or buckling often associated with concrete
surfaces.
[0007] Interlocking pavers can also be used to construct permeable surfaces.
These
pavers are configured to maintain open joints or gaps between adjacent pavers.
The joints or
gaps are filled with a permeable material that allows stormwater to infiltrate
down through the
surface. The open joints traditionally compromise 5 to 15% of pavement surface
and the joints
are limited in width to ten-millimeter for compliance with the requirements of
the Americans
with Disabilities Act. Permeable pavement surfaces are a method to reduce
stormwater runoff
and water pollution, along with other benefits.
[0008] Many modern permeable pavers include spacers, but such spacers do not
allow
the paver to be arranged in multiple configurations while still providing
interlocking
functionality from the spacers. For example, U.S. Patent No. 6,015,243
discloses a paving stone
with support attachments arranged on the lateral surfaces. The paving stone
includes two
attachments on each lateral surface. As shown in Fig. 7 of the '243 patent,
movement in one
direction parallel to the lateral surface will be resisted by one of the
attachments on a lateral
surface but not the other attachment, which could cause adjacent paving stones
to rotate with
respect to each other at the point of contact depending on the strength and
direction of the
applied force. In other words, interlocking functionality is not provided by
all of the attachments
on the relevant side in both directions.
[0009] U.S. Patent No 5,902,069 teaches a paver with identical spacing
elements
formed around the lateral surfaces of the paver body. Each spacing element is
capable of being
engaged by an identical but oppositely orientated spacing element or an
adjacent paver. One
drawback to this technique, however, is that, because each spacing element is
identical, the width
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ot= the space between the bodies of adjacent stones must be relatively large
because each spacer
must be wide and deep enough to include a trough and a tooth as well as handle
the anticipated
stresses that may be applied. It is also more difficult to manufacture the
more intricate spacer
design raising manufacturing costs.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention provides an improved paving stone with
interlocking and
self-aligning spacers that, when installed with other similar paving stones,
provides a strong
structural interlock with a low profile and create relatively narrow joints
between adjacent
paving stones. The present invention can be aligned in multiple
configurations.
[0011] Specifically, the present invention comprises a paving stone in the
shape of a
rectangular solid with a top surface, a bottom surface, opposing long lateral
surfaces, and
opposing wide lateral surfaces. A spacer pair extends from a first wide
lateral surface and each
of the long lateral surfaces and a single spacer extends from the second wide
lateral surface and
each of the long lateral surfaces. The single spacers and spacer pairs are
positioned on the lateral
surfaces of the paving stone so that the single spacers interlock with the
corresponding spacer
pairs on a similar adjacent paving stone in multiple paving configurations.
More specifically, the
position of the single spacers and spacer pairs allow similar adjacent paving
stones to be
configured in a herringbone pattern, a runner bond pattern, and a basketweave
pattern.
[0012] Each spacer pair is comprised of two adjacent spacers defining a trough
therebetween. Each of the single spacers and spacer pairs are sized and
positioned such that a
single spacer is positioned within the volume defined by the trough of a
corresponding spacer
pair of an adjacent paving stone when the paving stones are aligned in a
desired pattern. The
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single spacers and spacer pairs are also sized and configured to ensure a
maximum, predetermined gap width between adjacent paving stones.
[0012A] In one broad aspect, the invention provides a paving stone
for interlocking with a similar adjacent paving stone, the paving stone
comprising a top surface having a first long side, a second long side
opposing the first long side, a first wide side, and a second wide side
opposing the first wide side. A first long lateral surface and an opposing
second long lateral surface, are each perpendicular to the top surface, and
a first wide lateral surface and an opposing second wide lateral surface, are
each perpendicular to the top surface and the first and second long lateral
surfaces. A first spacer pair extends from the first wide lateral surface
and has an outer surface. The first spacer pair comprises two adjacent
spacers each having a crest at the outer surface positioned a first distance
D1 from the first wide lateral surface and defining a first trough
therebetween. The first trough has a nadir at the outer surface positioned
a second distance D2 from the first wide lateral surface, and a second spacer
pair extends from the first long lateral surface and has an outer surface.
The second spacer pair comprises two adjacent spacers each having a crest at
the outer surface positioned the first distance D1 from the first long
lateral surface and defining a second trough therebetween. The second trough
has a nadir at the outer surface positioned a second distance D2 from the
first long lateral surface. A third spacer pair extends from the second long
lateral surface and has an outer surface. The third spacer pair comprises
two adjacent spacers each having a crest at the outer surface positioned the
first distance Di from the second longer lateral surface and defining a third
trough therebetween. The third trough has a nadir at the outer surface
positioned a second distance D2 from the second long lateral surface. A
first singlerspacer extends from the second wide lateral surface and has an
outer surface, with a crest positioned the distance D1 from the second wide
lateral surface. A second single spacer extends from the first long lateral
surface, the second single spacer has an outer surface with a crest
positioned the distance D1 from the first long lateral surface, a third
single spacer extends from the second long lateral surface, and the third
single spacer has an outer surface with a crest positioned said perpendicular
distance D1 from the second long lateral surface.
[0012B] The invention also pertains to a system of arranged paving
stones forming a paved surface. The stones are configured as set out above
and positioned adjacent to and interlocked with each other.
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BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is an isometric view of the preferred embodiment present
invention.
[0014] FIG. 2 is a top view of the preferred embodiment of the present
invention.
[0015] FIG. 3 is a side view from line 3-3 of FIG. 2 of the preferred
embodiment of the
present invention.
[0016] FIG. 4 is a top view of a first alternative embodiment of the present
invention.
[0017] FIG. 5 is a top view of a second alternative embodiment of the present
invention.
[0018] FIG. 6 is a top view of an exemplar running bond pattern combining
multiple
paving stones of the present invention.
[0019] FIG. 7 is a top view of an exemplar herringbone pattern combining
multiple
paving stones of the present invention.
[0020] FIG. 8 is a top view of an exemplar basketweave pattern combining
multiple
paving stones of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] FIGS. 1-3 show a preferred embodiment 20 of the present invention,
which
comprises a generally rectangular block body 22 having a generally rectangular
traversable top
surface 24 defined by opposing first and second long sides 26, 28 and first
and second wide sides
30, 32. The body 22 includes first and second long lateral surfaces 34, 36
orientated at a right
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angle relative to the top surface 24, and first and second wide lateral
surfaces 38, 40 that are
adjacent to the first and second long sides 34, 36. The first and second wide
lateral surfaces 33,
40 are also oriented at a right angle relative to both the top surface 24 and
the first and second
long lateral surfaces. A chamfer surface 33 can be positioned between the top
surface 24 and the
first and second long lateral surfaces and first and second wide lateral
surfaces. The body 22 is
symmetrical about a first reference plane P1 which is oriented perpendicular
to the top surface 24
and that bisects the first and second wide sides 30, 32 of the top surface 24
with each of the first
and second long lateral surfaces 34, 36 being a distance D3 from the first
reference plane P 1 . As
used herein, a distance D between an element of the paving stone and lateral
surface or between
a reference plane and a lateral surface means the shortest perpendicular
distance between the
lateral surface and a parallel reference plane extending through the element
or between the lateral
surface and the reference plane. The body 24 is also symmetrical about a
second reference plane
P2 that bisects the first and second long sides 34, 36 of the top surface 24
and is perpendicular to
the first reference plane Pl.
[0022] A first spacer pair 46 extends from the first wide lateral surface 38
and
comprises two adjacent convex spacers 48. Each of the convex spacers has a
crest 49 positioned
a distance D1 from the first wide lateral surface 38. The two spacers 48 are
joined to define a
concave trough 50 between them. The trough 50 has a nadir 51 positioned a
second distance D2
from the first wide lateral surface 38 and a first trough curvature. As used
herein, the nadir is the
lowest point of the trough nearest the lateral surface from which the spacer
pair extends.
Preferably, the nadir 51 is centered on the first wide lateral surface 38
halfway between the first
and second long lateral surfaces 34, 36 such that the first reference plane P1
intersects the nadir
51.
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=
[0023] Second and third spacer pairs 52, 54 extend from the first and second
long
lateral surfaces 34, 36, respectively. Each of the second and third spacer
pairs 52, 54 comprises
two adjacent convex spacers 56. Each of the adjacent convex spacers 56 has a
crest 55
positioned a distance D1 from the respective long lateral surfaces 34, 36 from
which the spacers
56 extend. The adjacent convex spacers 56 of each spacer pair 52, 54 define
second and third
concave troughs 58, 59, respectively, each having a nadir 51 positioned a
second distance D2
from the respective long lateral surfaces 34, 36 from which the spacer 56
extends. The second
and third troughs 58, 59 of the second and third spacer pairs 52, 54 have a
second trough
curvature and a third trough curvature, respectively. A third reference plane
P3 is oriented
perpendicular to the top surface 24 and the first reference plane P1 and
intersects each nadir 51
of the second and third spacer pairs 52, 54. The third reference plane P3 is
positioned a distance
D3 from the second wide lateral surface 40.
[0024] A first single spacer 60 having a convex surface extends from the
second wide
lateral surface 40 of the body 22 and has a crest 61. In the preferred
embodiment, the crest 61 is
positioned a distance D1 from the second wide lateral surface and is centered
on the second wide
lateral surface halfway between first and second log lateral surfaces 34, 36
such that the first
reference pane P1 intersects the crest.
[0025] Second and third single spacers 62, 64, each having a convex surface,
extend
from the first and second long lateral surfaces 34, 36, respectively. Each of
said second and third
single spacers 62, 64 have crests 63, 65 which are positioned a distance D1
from the respective
long lateral surfaces 34, 36 from which the single spacers 62. 64 extend. A
fourth reference
plane P4, which is perpendicular to the top surface 24 and the first reference
plane P 1 , intersects
each of the crests 63, 65 and is positioned a distance D3 from the first wide
lateral surface 38.
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[0026] Preferably, the first, second and third single spacers 60, 62, 64 are
symmetric on
either side of their respective crests 61, 63, 65. Similarly, the first,
second and third spacer pairs
46, 52, 54 are symmetric on either side of their respective nadirs 51.
further, although the first,
second and third single spacers 60, 62, 64 and the first, second and third
spacers pairs 46, 52, 54
are described with curved convex and concave surfaces, it is also anticipated
that these surfaces
could be planar such that the cross-sections of the single spacers 60, 62, 64
and each side of the
spacer pairs 46, 52, 54 are triangular or trapezoidal as shown in Figs. 4 and
5, respectively.
[0027] The preferred embodiment of the paving stone 20 will have the following
relative dimensions:
= (1) the length (L) of each of the first and second long lateral surfaces
34, 36 is equal to
twice the width (W) of a wide lateral surface 38, 40 plus the width of the gap
between
two adjacent, interlocked paving stones. This gap width is equal to distance
D1 plus
distance D2 plus the standard clearance C between a spacer and spacer pair of
interlocked
paving stones. As used in the specification and the claims herein, the
standard clearance
C shall mean width of the clearance between a single spacer of one paving
stone and a
spacer pair of an adjacent paving stone. The standard clearance is typically 1
mm .5
mm. The length L can be calculated by the following: L=2W+D1+D2+C;
(2) the distance D3 is equal to one-half of the width (W) of a wide lateral
surface 30, 32
and can be calculated by the following: D3=W/2;
(3) each of the single spacers 60, 62, 64 are identically sized and shaped;
(4) each of the spacer pairs 46, 52, 54 are identically sized and shaped.
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[0028] The preferred dimensions of the paving stone 20 are as follows:
(1) the length (L) of each of the first and second long lateral surfaces 34,
36 is 244
millimeters;
(2) the width (W) of each wide lateral surface 38, 40 is 117.5 millimeters;
(3) the distance D1 of each spacer crest from its respective lateral surface
is 6
millimeters;
(4) the distance D2 of the nadir 51, of each spacer pair from its respective
lateral
surface is 2.5 millimeters;
(5) the width of each single spacer 60, 62, 64 as measured along its
respective long or
wide side is 38 millimeters;
(6) the width of each spacer pair 46, 52, 54 as measured along its respective
long or wide
side is 64 millimeters;
(7) the thickness of each paving stone 20 is 80 millimeters. With these
dimensions, the
open area between adjacent paving stones 20 in a combination of multiple
paving stones
20 forming a hardscaped surface area, the open area between the pavers will be
approximately eight percent (8%) of the hardscaped area and will meet industry
standards.
[0029] The relative dimensions set forth supra allow a plurality of the paving
stones 20
described with reference to FIG. 1-3 to be combined to form a hardscape
surface of varying
patterns. As shown in FIG. 6, multiple paving stones 20 may be combined into a
running bond
pattern. Except for those single spacers (not shown) that may be located
around the perimeter of
hardscape, each single spacer 60, 62, 64 is interlocked with a trough defined
by a corresponding
spacer pair 46, 52, 54 to inhibit movement of one paving stone 20 with respect
to another and
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insure the preferred spacing between the paving stones 20. As used in the
specification and
claims herein, "interlocking" or "interlocked" means that a single spacer of
one paving stone is
positioned within the volume defined by the trough of the corresponding spacer
pair similar of an
adjacent paving stone with a standard clearance C between the single spacer
and corresponding
spacer pair.
[0030] In the runner bond configuration shown in FIG. 6, the first single
spacer 60 of
each paving stone 20 is interlocked with the first spacer pair 46 of an
adjacent paver. The second
single spacer 62 of each paving stone 20 is interlocked with the third spacer
pair 54 of an
adjacent paving stone 20; and the third single spacer 64 of each paving stone
20 is interlocked
with the second spacer pair 52 of an adjacent paving stone 20.
[0031] As shown in FIG. 7, multiple paving stones 20, 20' may be combined into
a
herringbone pattern. In this configuration, the paving stones 20 are all
aligned in a first direction
in a series of stepped patterns such that the second single spacer 62 of each
paving stone 20 is
interlocked with the third spacer pair 54 of an adjacent paving stone 20. The
paving stones 20'
are all aligned in a second direction which is perpendicular to the first
direction and are also
aligned in a series of stepped patterns such that the third single spacer 64'
of each paving stone
20' is interlocked with the second spacer pair 52' of an adjacent paving stone
20'.
[0032] Also, in this configuration, each of the paving stones 20 interlock
with adjacent
paving stones 20' as follows: (1) the first single spacer 60' of each paving
stone 20' interlocks
with the second spacer pair 52 of a paving stone 20; (2) the second single
spacer 62' of each
paving stone 20' interlocks with the first spacer pair 46 of a paving stone
20; (3) the first spacer
pair 46' of each paving stone 20' interlocks with the third single spacer 64
of a paving stone 20;
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and (4) the third spacer pair 54' of each paving stone 20' interlocks with the
first single spacer 60
of a paving stone 20.
[0033] As shown in FIG. 8, multiple paving stones 20, 20' may also be combined
into a
basketweave pattern. In this configuration, two paving stones 20 oriented in a
first direction are
arranged with their long sides 28 being adjacent such that the third single
spacer 64 of each
paving stone 20 interlocks with the third spacer pair 54 of the adjacent
paving stone 20. In this
manner, a set of paving stones 20 oriented in a first direction is formed.
[0034] Also in this configuration, two paving stones 20', oriented in a second
direction,
are also arranged with their long sides 28' being adjacent such that the third
single spacer 64' of
each paving stone 20' interlocks with the third spacer pair 54' of the
adjacent paving stone 20'.
In this manner, another set of paving stones 20' is formed oriented in a
second direction which is
perpendicular to the first direction. To complete the basketweave pattern,
additional sets of
paving stones 20 and sets of paving stones 20' are arranged in an alternating
checkerboard
pattern as shown in FIG. 8.
[0035] In this basketweave configuration, each of the paving stones 20
interlock with
adjacent paving stones 20' as follows: (1) the first single spacer 60 of each
paving stone 20
interlocks with second spacer pair 52' of a paving stone 20'; (2) the second
single spacer 62 of
each paving stone 20 interlocks with the first spacer pair 46' of a paving
stone 20'; (3) the first
spacer pair 46 of each paving stone 20 interlocks with the second single
spacer 62' of a paving
stone 20'; and (4) the second spacer pair 52 of each paving stone 20
interlocks with the first
single spacer 60' of a paving stone 20'.
[0036] The present invention is described above in term of a preferred
illustrative
embodiment of a specifically-described paving stone. Those skilled in the art
will recognize that
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alternative constructions of such an apparatus can be used in carrying out the
present invention.
Other aspects, features, and advantages of the present invention may be
obtained from a study of
this disclosure and the drawings, along with the appended claims.
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