Note: Descriptions are shown in the official language in which they were submitted.
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A PATIO, PORCH OR WALKWAY ASSEMBLY INCORPORATING
A PLURALITY OF BLOCKS AND INCLUDING ANY COMBINATION
OF PRE-CAST AND EXPOSED SURFACED PATTERNS, INTERIORLY
SUPPORTED HEATING PADS AND LED EFFECT LIGHTING
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional Application
61/734,044 filed
on December 6, 2012 and US Patent Application 14/095,280 filed December 3,
2013, the
contents of which are incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present application discloses a variety of kits, assemblies
incorporating pre-cast
and modular blocks of material (including any of a lightweight composite
concrete material as
well as any type of polymeric or composite materials). The blocks can be
designed so as to
exhibit a suitable configuration enabling them to be assembled into a multi-
step exterior
construction, such as associated with any of a stairway, porch, patio or
walkway surface.
Specific advantages associated with the present designs include the ability to
easily and rapidly
reconfigure the blocks, utilizing a tongue and groove arrangement, for
facilitating rapid
assembly.
[0003] Exposed surfaces of the blocks can be precast with any desired
pattern or decorative
surface/texturing during their initial manufacture, thus avoiding the
necessity of stamping on site
in a semi-cured state. Additional features include the provision of heating
pads or interior
filaments, these being installed within surface located blocks in order to
facilitate melt off of
snow or ice.
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[0004] Other variants contemplate the heating pads being integrated, this
including being
replaceable, into a planar shaped body which can in turn define a recess
defining shelf or tier
exhibiting a ledge within which the pad can be installed. Stackable support
blocks, such as
exhibiting a tongue and groove arrangement, are assembled in an initial tier
at an earthen grade
location and which are stacked in order to provide support for the tier
defining shelves.
[0005] Additional effects lighting, such as LED (light emitting diode)
elements can be
installed within the interior architecture of the blocks, and such the lights
are visible through at
least vertical extending step surfaces. Other features include the provision
of underside recesses
associated with each of the individual blocks or shelves for receiving gravel
or the like (such as
which are filled during successive stacking of the blocks into levels or
tiers), as well as drainage
or run-off channels.
[0006] Other features includes the provision of an extending walkway
surface, such as
associated with the steps and/or porch, and which can likewise integrate any
combination of
heating pads, lighting or other accessories in order to provide the desired
feature and
functionality to the assembly. Throughout the several variants disclosed, the
exterior surfaces of
the shelves or patio blocks can exhibit any precast or subsequently stamped
pattern or texturing
in order to establish a desired decorative design.
BACKGROUND OF THE INVENTION
[0007] The prior art is documented with examples of steps, patio and
walkway assemblies,
such as which can be constructed from arrangements of concrete pre-cast
blocks. Disadvantages
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of existing assemblies include both the shipping and transport weight of the
blocks, combined
with the limitations as to feature and functionality with which the blocks can
be reconfigured or
accessorized.
[0008] Reference is also made to the heating system for use on or in a
driveway, roadway,
walkway, patio, deck or stairs as disclosed in U.S. Patent No. 6,943,320 to
Bavett. Other
examples drawn from the prior art include the thermal walkway cover with
laminated layers of
carbonized rubber (USPN 5,614,292 to Saylor) and the composite building block
having
moisture barrier and insulation element disclosed in Collier (US Patent
Application Publication
2005/0005556). Other and additional retaining wall systems include each of the
modular earth
system of Rainey, USPN 6,089,793, and the interlocking block and retaining
wall system of Risi
et al., USPN 4,490,075.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a variety of kits and assemblies for
creating any of a
porch, patio, step or walkway surface, such incorporating a variety of pre-
cast components which
can be stacked or otherwise assembled as well as reconfigured in any fashion
in order to create a
visually appealing construction at reasonable cost and with high efficiency.
The individual
components can include any silicate based (e.g. concrete) or other material
which may be a
composite of a silicate with foam or other polymeric filler components, and
which are shaped or
otherwise formed in a mold in order to create a three dimensional shape.
[0010] The mold which creates the individual components, also termed step
blocks and
under supporting blocks, can exhibit any desired surface pattern or texturing
in order to provide a
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desired decorative appearance. Alternatively, the invention contemplates a
subsequent roughing,
texturing or other imprinting step performed on pre casted blocks in order to
achieve a desired
patterning or design.
[0011] The configuration of the blocks can exhibit comprising a plurality
of individual
prefabricated elements arranged in either of a side-by-side or vertically
stacked fashion in order
to create a desired structure. In one application, pluralities of blocks
define each of succeeding
layers and which are stacked via tongue and groove profiles, with a top pad
resting upon an
upper most plurality of blocks.
[0012] The blocks can each further exhibit at least one recessed cavity for
receiving a
volume of a gravel, pea stone or other ballasting or compact-able material
(these often available
in natural form on-site or otherwise easily transported), the advantage of
which being that such
natural loose fill materials provide the necessary anchoring and weighting to
the interiorly
recessed volume established by the blocks or shelves. In this fashion, the
blocks can be
produced and shipped at a lighter weight than is associated with standard
concrete blocks,
thereby saving in transport cost.
[0013] The individual blocks can each exhibit a one-piece construction with
an outer bull
nose configuration. Heat generating elements can be installed within the
individual elements and
can include any of electrical resistant generating pads or fluid conduit
conveying systems
extending through and between the prefabricated elements or sections. Other
features include
effect lighting installed within any one or more of the prefabricated
sections, these including in
one construction individual LED elements mounted within aperture locations
defined in vertical
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riser locations of each layer of blocks (or possibly in other locations
including horizontally
arrayed and as associated with any other type of porch, patio, step or walkway
surface).
[0014] A further variant of an assembleable kit includes a multi-tier
assembly in which a
heat generating shelf or insert is provided in installed fashion within any
one or more of a
plurality of blocks arranged in any stacked or tiered fashion. An electrical
or fluid heating pad is
capable of being installed within an underside ledge associated with a
recessed interior of each
shelf variant of tiered heating shelves or jackets, with the pads capable of
being daisy-chained
together to feed electricity or heated fluid from a single input location.
[0015] A plurality of three dimensional shaped and tongue and groove inter-
assembleable
support blocks are provided, an initial layer of which is assembled upon and
into the earth or
ground location in order to array a top extending surface thereof level or
flush to a grade surface.
Additional support blocks are stacked in order to provide tiered support for
the step blocks which
are installed in stepped fashion, with associated walkway surface also depicts
apertures for
receiving heating elements to facilitate the melting of snow and ice;
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Reference will now be made to the attached drawings, when read in
combination with
the following detailed description, wherein like reference numerals refer to
like parts throughout
the several views, and in which:
[0017] Fig. 1 is an environmental perspective of a multi-tier step assembly
incorporating the
pre-cast and reconfigurable block structures according to one non-limiting
embodiment of the
present invention;
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[0018] Fig. 2 depicts an initial tier of configured blocks in the assembly
of Fig. 1, such as
supported upon compactible gravel during emplacement;
[0019] Fig. 3 is a succeeding illustration of a second tier of block
supported upon the first
ground biased tier;
[0020] Fig. 4 is a side cutaway of Fig. 1 and which depicts a multi-tiered
stacking
arrangement of the assembly, this further exhibiting the tongue and groove
configuration for
establishing ease and rapidity of installation, along with such other features
as a one piece bull nose
configuration associated with each block;
[0021] Fig. 5 is an upper perspective of a top most pad depicted in Fig. 1;
[0022] Fig. 6 is a rotated underside perspective view of the top layer pad
of Fig. 5 and
illustrating a recessed interior construction;
[0023] Fig. 7 is an upper perspective view of an inter-assembleable block
construction
associated with a second upper most layer of the assembly depicted in Fig. 1;
[0024] Fig. 8 is a rotated underside perspective view of the second layer
block depicted in Fig.
7;
[0025] Fig. 9 is an upper perspective view of a selected one of a pair of
end-most disposed
blocks associated with a third row of inter-assembleable blocks;
[0026] Fig. 10 is a rotated underside perspective view of the end disposed
blocks of Fig. 9 and
depicting each of an alternating recess profile as well as a channel
communicating with an upper
side recess located rearwardly of an upper tongue profile;
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[0027] Fig. 11 is an upper perspective of a further block configuration
associated with the
third row and of which a plurality are inter-assembled between said pair of
end-most disposed
blocks of Fig. 9;
[0028] Fig. 12 is an underside rotated perspective view of the block in
Fig. 11 and exhibiting a
similar alternating recess profile construction as referenced in the end-most
disposed blocks of Fig.
9;
[0029] Fig. 13 is an upper perspective view of a fourth level block
configuration which is
progressively larger in overall dimension than preceding layer defining blocks
and which exhibits a
similar configuration as shown in the preceding blocks depicted in each of
Figs. 7, 9 and 11;
[0030] Fig. 14 is a rotated underside perspective view of the block shown
in Fig. 13 and
exhibiting a similar alternating recess profile construction;
[0031] Fig. 15 is an upper perspective view of a selected one of a pair of
end-most disposed
blocks associated with a fifth row of inter-assembleable blocks;
[0032] Fig. 16 is a rotated underside perspective view of the block
depicted in Fig. 15;
[0033] Fig. 17 is an upper perspective of a yet further block configuration
associated with a
fifth row of which a plurality are inter-assembled between said pair of end-
most disposed blocks of
Fig. 16;
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[0034] Fig. 18 is a rotated underside perspective view of the block
depicted in Fig. 17;
[0035] Fig. 19 is an upper perspective of a base level located construction
block, such as
which is installed on a gravel bed below grade;
[0036] Fig. 20 is a rotated underside perspective view of the construction
block of Fig. 19
and which exhibits a flattened surface through extends a channel in
communication with the
channels formed through the upper succeeding levels;
[0037] Fig. 21 is an exploded perspective of a top level pad, such as
previously depicted in
Fig. 5, and which illustrates a plurality of heating pads installable within
upper surface proximate
locations to facilitate melt-off of snow or ice accumulations;
[0038] Fig. 22 is an upper perspective view of a second level block,
similar to that shown in
Fig. 7, and illustrating a sideways installed heating pad extending within a
pocket underlying an
exposed step area of the block;
[0039] Fig. 23 is a rotated underside perspective view of the block shown
in Fig. 22 and
illustrating an alternate recess configuration with horizontal channel, as
compared to that shown
in Fig. 8, and in order to accommodate the positioning of the sideways
installed heating pad;
[0040] Fig. 24 is a perspective view of an alternately configurable and
assembleable block
assembly depicting an elongated three dimensional shape as compared to Fig. 1;
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[0041] Fig. 25 is a rotated rear view of Fig 24, in partial upper
horizontal cutaway, and
better showing the interlocking tongue and groove profiles for facilitating
stack-ability of the
blocks;
[0042] Fig. 26 is a partial perspective of Fig. 25 depicting additional
vertical extending
tongue and groove profiles for further facilitating inter-locking of the
stackable layers in both
horizontal and vertical directions;
[0043] Fig. 27 is a perspective illustration of a top pad and assembled
second layer
exhibiting pre-cast decorative patterns exhibited along at least exposed
horizontal surfaces and
according to a further embodiment;
[0044] Fig. 28 is a succeeding illustration of Fig. 27, depicting the top
pad removed and
further showing a connecting network of heating pads and wiring associated
with the second
assembled layer and including a junction box and main power cord;
[0045] Fig. 29 is a rotated underside perspective view of Fig. 28;
[0046] Fig. 30 is an enlarged perspective of Fig. 28 and further depicting
the features of the
exposed stamped patterns formed in the precast blocks, along with smooth and
flat boundary
locations separating the pre-cast decorative patterns and the interlocking
tongues and for
assisting in maintaining a level surface for stacking the upper succeeding
(top pad) layer;
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[0047] Fig. 31 is a perspective view of a further variant of assembly
exhibiting vertical
(riser) surface located effect lighting along with indicia molding schemes
which are built into the
block designs;
[0048] Fig. 32 is a rotated underside perspective view of Fig. 31
illustrating a recess pocket
defined through a rear side vertical surface of the block, such as for
receiving an LED light;
[0049] Fig. 33 is a perspective view of a yet further variant of an inside
corner block
assembly defining a combined porch and step;
[0050] Fig. 34 is a succeeding view of an outside corner block assembly;
and
[0051] Fig. 35A is an illustration of a walkway path constructed of a
plurality of precast
construction blocks in the shape of interlocking patio pads and including heat
generating pads
installable within pockets defined within each block;
[0052] Fig. 35B is a top view of a selected walkway defining block
illustrating in phantom
an insertable pad in combination with a plurality of (4) corner defined
lighting elements;
[0053] Fig. 35C is an end view similar to that shown in Fig. 35C of a
selected walkway
defining block with spaced apart precast lighting element pockets;
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[0054] Fig. 35D is a partial side depiction in cutaway at 35D-35D of Fig.
35B of a selected
walkway construction block and which depicts a pre-cast pocket defined in the
underside of the
block for eventually receiving a top surface directed lighting element;
[0055] Fig. 35E is an illustration similar to that shown in Fig. 35B and
depicting a finishing
top surface drilling of an increased diameter portion facilitates top surface
seating of the LED or
other desired lighting element;
[0056] Fig. 36 is a rear perspective of a multi-tier assembly according to
a further variant
and which a shelf, such as containing any type of heat generating pad or
insert, is provided in
installed fashion within any one or more of a plurality of step blocks blocks
arranged according
to any successive stacked or tiered fashion;
100571 Fig. 37 is a further rotated and modified view of an assembly
similar to Fig. 36 and
in which a fluid heating variant of tiered heating support block is depicted
in which conduit feeds
the heated fluid through the support blocks via opposite end located inlet and
outlet ports;
[0058] Fig. 38 is a perspective of a further assembly including tiered step
section with
decorative stamped or other exteriorly configured design associated with each
block, in
combination with a walkway portion illustrating side inserting apertures for
receiving electric
heating pads;
[0059] Fig. 39 is a similar illustration to Fig. 38, with the tiered steps
removed and in order to
further illustrate the initial layer of support blocks, such as which are
assembled upon and into the
earth or ground location in order to array a top extending surface thereof
level or flush to a grade
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surface, the associated walkway surface again depicting apertures for
receiving heating elements to
facilitate the melting of snow and ice;
[0060] Fig. 40 is an illustration of a further variant of a stackable
assembly including a
plurality of tiered steps, supporting blocks and stepping stones;
[0061] Fig. 41 is a perspective view of a further variant of assembled step
construction similar
to that originally disclosed in Fig.1 and depicting a pre-cast decorated upper
platform surface;
[0062] Fig. 42 is an assembly view of a pair of support blocks forming a
portion of the
assembly shown in Fig. 36 and illustrating mating tongue and groove profiles
to facilitate tier
supporting stackability;
[0063] Fig. 43 is a further illustration of the blocks in Fig. 42 in a
rotated underside looking
view;
[0064] Fig. 44 is an illustration similar to Fig. 37 from a further rotated
and cutaway
perspective and showing a pair of step blocks with associated heating pads
which are daisy chained
together to permit a single power supply input to feed any plurality of the
pads such as which can
be arranged in chained or series communication;
[0065] Fig. 45 is a sectional perspective of a selected tier defining step
block illustrating a top
decorative surface;
[0066] Fig. 46 is a rotated underside perspective of the step block in Fig.
45 illustrating its
recess construction and underside ledge for supporting an inserted heating
pad;
[0067] Fig. 47 is an end plan view of the shelf of Figs. 45 and exhibiting
the exterior
decorative pattern in phantom;
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[0068] Fig. 48 is a side plan view of the shelf of Fig. 45 and disclosing
in phantom the inner
pad supporting profile with inside forward ledge communicating with
interconnecting side ledges
shown in Figs. 46-47 in order to secure the heat generating shelf;
[0069] Fig. 49 is a perspective illustration of a heat generating shelf
according to one non-
limiting configuration;
[0070] Fig. 50 is a rotated underside perspective of the heating shelf
shown in Fig. 49;
[0071] Fig. 51 is a top plan view illustrating in phantom the undercut
angled forward
underside edge of the shelf;
[0072] Fig. 52 is a front plan view of the shelf of Fig. 49 and depicting
in phantom the rear
inserting edge of the pad; and
[0073] Fig. 53 is a side profile view of the shelf of Fig. 49.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] With reference to the following illustrations and description, the
present application
discloses a variety of kits and assemblies incorporating pre-cast and modular
blocks of material
(including any of a lightweight composite concrete material as well as any
type of polymeric or
composite materials). As will be described in further detail, the blocks
exhibit a suitable
configuration enabling them to be assembled into a multi-step exterior
construction, such as
associated with any of a stairway, porch, patio or walkway surface.
[0075] Additional advantages of the kit, assembly and methods described
herein further
include the lightweight construction of the precast blocks permitting an
individual (or pair of
individuals) to quickly and fairly effortlessly assemble the lightweight and
precast blocks into a
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desired configuration, such assisted by the use of compactible aggregate or
like material which is
often available on site and which provides the necessary weighting and
ballasting aspects which
are typical of heavier pre-cast block constructions. Unlimited variations of
the kit, assembly and
method also contemplate the ability to quickly assemble the (lightweight)
blocks, usually without
the need to mix cement or to otherwise cut or section the blocks.
[0076] As also previously noted, specific advantages associated with the
present designs
include the ability to easily and rapidly reconfigure the blocks, these
incorporating interlocking
tongue and groove arrangements extending along both horizontal and vertical
exterior surfaces,
for facilitating rapid assembly. Exposed surfaces of the blocks can be precast
with exposed
patterns during their initial manufacture, thus avoiding the necessity of
stamping on site in a
semi-cured state.
[0077] Additional features include the provision of heating pads or
interior filaments, these
being installed within surface located blocks in order to facilitate melt off
of snow or ice. As
will be also described, other options for facilitating snow/ice melt-off
include utilization of solar,
geothermal and other heat conducting properties, such as incorporated into a
water/glycol or
other heat convecting fluid which can be pumped through lines extending within
the assembled
block structure.
[0078] Additional effects lighting, such as LED (light emitting diode)
elements can be
installed within the interior architecture of the blocks, and such the lights
are visible through at
least vertical extending step surfaces. Other features include the provision
of underside recesses
for receiving gravel, pea stone or other compactible and loose fill materials
(such as which are
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filled during successive stacking of the blocks into levels or tiers), as well
as drainage or run-off
channels.
100791 With reference to the illustrations, and initially to Fig. 1, an
environmental
perspective, generally at 10, is shown of a multi-tier step assembly in a half-
round configuration
and incorporating the pre-cast and reconfigurable block structures according
to one non-limiting
embodiment of the present invention and which is depicted defining a plurality
of ascending steps
from a ground (turf) location 2 to an elevated porch 4 or other like surface
associated with a
structure. As will be further described in succeeding views Figs. 2-20, the
pre-cast blocks
associated with this initially depicted variant can be constructed of any
material not limited to a
lightweight concrete composite, and can also include any heavy duty polymer or
other suitable
material.
[0080] As will be further described in reference to the succeeding
depictions, the assembly 10
can include a number of stacked levels depicted in any arrangement or
configuration. As further
shown, this can include each of a top most located (and typically one piece)
pad 12, a second tier
or level exhibiting a plurality of formed blocks 14, a third level optionally
including a pair of
opposite end-most depicted blocks (e.g. at 16) along with an intermediate
aligning arrangement of
blocks 18, a fourth level of end-to-end aligned blocks 20, a fifth level of
blocks again including a
pair of opposite end-most blocks 22 and intermediate aligning blocks 24, as
well as a base, below
grade plurality of subterranean blocks 26. Without limitation, the steps will
be residential building
code compliant (per rise, tread and landing length before an entry door). In
particular, the landing
area length, in walking direction, of a top surface must be at a minimum
thirty six inches long
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when flush to an entry door floor height. Industry standard hand railing can
be attached when
necessary (see again Fig. 1).
[0081]
A grading or support for the assembly 10 is depicted in each of Figs. 2-4, at
6 and
includes such as without limitation a compactible gravel which provides a bed
upon which the
bottom most array of blocks, e.g. again at 26 in Fig. 2, are initially
embedded and supported.
Alternatively, the bottom most layer of blocks can be supported upon a level
cement pad (not
shown). As will be further described, each of the succeeding/upper levels of
blocks includes a
recessed underside which can be filled with additional volumes of gravel as
needed (see
additionally side cutaway of Fig. 4) and in order to provide a secure base and
interior for
maintaining the structural integrity of the assembly. It is further envisioned
that additional
configurations of the present kit and assembly can include installing upon a
solid concrete base or
compactible material at grade level, with the remaining (upper tier) support
blocks being stacked
above grade in combination with or without filling their recessed interiors
with additional volumes
of compactible aggregate material. Along these lines, it is envisioned in one
application that the
various rectangular or square shaped (inner or hidden) components of the
designated kit
configurations can exhibit a hollow interior, with the half round shaped
(outer or exposed) blocks
being filled/weighted with the compactible aggregate.
[0082]
As further shown in Fig. 4, and as will be explained in additional detail with
reference
to the succeeding views, and interlocking configuration of tongue and grooves
are provided for
assisting in providing interlocking supported between the vertically stacked
layers. In
combination, the succeeding assembled layers or levels are shown arranged in
laterally offset and
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overlapping relationship, with further disclosed variants explaining that the
mating tongue and
groove profiles can additionally extend vertically between lateral edges of
adjoining blocks.
100831 Without limitation, Figure 3 can depict either an initial layer of
blocks alternate to that
shown at 26 in Fig. 2 or, alternatively, can also depict a succeeding
illustration of a second tier of
blocks, such as previously depicted at 24, supported upon the first ground
biased tier. Figure 4
again shows a side cutaway of Fig. 1 and which depicts a multi-tiered stacking
arrangement of the
assembly, this further exhibiting the tongue and groove configuration (as will
be described in
further detail in succeeding illustrations) for establishing ease and rapidity
of installation, along
with such other features as a one piece bull nose configuration associated
with each block, and as
opposed to a two piece assembly such as is known with existing products.
[0084] Proceeding to Fig. 5, an upper perspective view is shown of the top
most pad 12
depicted in Fig. 1 and which includes a one piece body with semi-circular
shape exhibiting a
smooth top and a forward bull nose edge 28. A function of a rear bull nose
configuration formed
into the block also acts as a handle for facilitating ease of assembly. A
front bull nose is provided
for appearance and an optional second handle arranged opposite the handle
defined by the rear bull
nose. Additional block configurations are envisioned and which may not exhibit
a rear handle
(bullnose) configuration due to the design aspects desired, however the block
construction may
(alternately or additionally) include an opening to act as a handle.
[0085] As further depicted in the rotated underside perspective view of
Fig. 6, the top layer
pad 12 illustrates a recessed interior construction established by a forward
arcuate extending and
outer wall 30 combined with a straight rear interconnecting wall 32 and a
forward extending and
middle interior and intersecting wall 34, these in combination defining
pockets 36 and 38 which
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are fillable with gravel or the like during placement and settling and without
the need for mortar or
other special tools or saws. The underside view of figure 6 also best shows
notched locations 37
and 39 where opposite outer edges of the rear interconnecting wall 32 meet the
rearmost locations
of the outer arcuate wall 30.
[0086] Figure 7 is an upper perspective view of an inter-assembleable block
construction
associated with one of the selected second upper most layer blocks 14 of the
assembly depicted in
Fig. 1, with Fig. 8 further depicting a rotated underside perspective view of
the second layer block
depicted in Fig. 7. As shown, the block exhibits a one piece construction with
a forward bull nose
edge 40 at an arcuate upper tongue or protuberance 42 at an inner-intermediate
location separating
a smooth exposed surface of the step and an inner recess configured location
44. The protuberance
42 is configured for receiving the outer arcuate wall 30 of the upper pad 12
in an inner seated and
supported fashion, with the protuberances 42 of opposite edge most located
blocks seating within
the notched locations 37 and 39 of the upper pad 12.
[0087] The bull nose 40 extends from a front wall 45, with an underside
groove 46 is depicted
in each block 14 proximate its outer perimeter located on an inside edge of
the front wall, and
which is configured for seating upon a tongue of an underside located layer of
blocks, as again
clearly depicted in cutaway in Fig. 4. A recessed volume 48 is defined in the
outer portion of the
block 14 as shown in Fig. 8 and which alternates with the upper accessible
volume 44 shown in
Fig. 7. A rearward wall 47 of the block 14 exhibits an upper stepped ledge 49,
such that the
arcuate assembly of each layer of blocks facilitates a back fill of grave, pea
stone or other
compactible material in a fashion which provides additional ballasting support
along the horizontal
and vertical interior volume defined between the upper most pad 12 underside
and the lower most
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grade level section or tray 26. Reference is also made to the side cutaway of
Fig. 4 which depicts
in line depiction outer located blocks associated with each ascending level or
tier with the
understanding that additional volumes of gravel or pea stone or deposited into
the ascending and
restricting interior defined by the successively stacked layers in order to
create a structurally
supporting and secure assembly.
100881 An aperture 50 is shown in Fig. 8 and which communicates with any of
the upper
recessed area 44 or which can access a hidden electrical pad which can be
inserted into each of the
blocks (as will be further described in succeeding embodiments). It is also
envisioned that any
arrangement or network of apertures can be formed within the assembled levels
of blocks, such as
for accommodating a junction box with designated electrical wires, or
alternatively any other
convective fluid network for providing heat to a surface area associated with
the blocks in order to
facilitate ice and/or snow melt-off.
[0089] The arrangement and configuration of an interconnecting aperture
network can further
be such that it facilitates any needed drainage or runoff of moisture building
up within the interior
of the block assembly, into the underlying gravel or other external or grade
tile location, this in
order to maintain the structural integrity of the assembly. As further
depicted in Fig. 1, the blocks
are arranged in side-by-side plural aligning fashion (the indicated variant
depicting eight such
blocks establishing a semi-circular shape).
[0090] Figure 9 is an upper perspective view of a selected one of the pair
of end-most
disposed blocks 16 associated with a third row of inter-assembleable blocks.
As further shown in
the rotated underside perspective view of Fig. 10, each of the pair of end
positioned blocks 16
depict upper 52 and lower 54 recess profiles, as well as a vertical aperture
56, upper (arcuate width
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extending) tongue 58, and lower (arcuate width extending) groove locations 60.
A rear arcuate
edge 57 of the block 16 exhibits an upper edge extending ledge 59 which,
similar to the ledge
previously depicted at 49 in Fig. 7 for block 14, provides additional inner
locating edge support in
combination with the in-filled volumes of gravel, pea stone or other weighted
and compactible
material. The block further exhibits forward bull nose 62 is also shown
extending from a front
arcuate wall 63.
[0091] Figures 11 and 12 depict both upper and rotated underside
perspectives of the further
block configuration 18 associated with the third row, and of which a plurality
(such as eight
shown) are inter-assembled between said pair of end-most disposed blocks of
Fig. 9. As with the
previous block constructions, the block includes a forward bull nose edge 64
extending from an
upper perimeter location of a front wall 65 as well as alternating upper 66
and lower 68 recessed
configurations are defined in rearward and forward accessible locations of the
blocks 18, these in
combination with upper tongue 70 and lower groove 72 depictions. Also shown is
aperture 74 in
similar fashion as in preceding variants. Also shown is a rear wall 73 with an
upper edge
projecting ledge 75.
[0092] Figures 13 depict upper and rotated underside perspectives of a
fourth level block 20
configuration which is progressively larger in overall dimension than
preceding layer defining
blocks 14 and 18 shown in each of Figs. 7, 9 and 11. A plurality of such
blocks (nine shown)
include alternating upper 76 and lower 78 recess profiles, along with upper
tongue 80 and lower
grooves 82. A forward edge 83 is provided and from which a forward bull nose
edge is shown at
84 in upper perimeter extending fashion along with an underside accessible
aperture 86. A rear
CA 02836086 2013-12-05
wall 85 includes an upper perimeter projecting ledge 87 of similar
construction and application as
with the preceding described blocks.
100931 Figures 15 and 16 are upper and lower rotated perspective views of a
selected one of a
pair of end-most disposed blocks 22 associated with a fifth row of inter-
assembleable blocks. As
with the previous block constructions, the block 22 includes a forward wall 87
from which projects
a bull nose edge 88, as well as alternating upper 90 and lower 92 recessed
configurations are
defined in rearward and forward accessible locations of the blocks 22, these
in combination with
upper tongue 94 and lower groove 96 depictions. Also shown is aperture 98 in
similar fashion as
in preceding variants. A rear arcuate wall 97 is provided with an upper
perimeter ledge 99.
100941 Figures 17 and 18 are upper and lower rotated perspective views of
an intermediate
aligning plurality 24 of additional fifth row blocks which are inter-assembled
between the pair of
end-most disposed blocks 22 of Figs. 15 and 16. A plurality of the blocks 24
(such as eight which
are shown) are inter-assembled between the pair of end-most disposed blocks
22. As with the
previous block constructions, the block 24 includes a forward arcuate wall 99
with a projecting bull
nose edge 100, as well as alternating upper 102 and lower 104 recessed
configurations are defined
in rearward and forward accessible locations of the blocks 24, these in
combination with upper
tongue 106 and lower groove 108 depictions (these again arranged in outer side
locations of the
block underside located against and inside surface of the forward wall 99).
Also shown is aperture
110 in similar fashion as in preceding variants. A rear wall 109 also exhibits
and upper perimeter
projecting ledge 111.
21
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[0095] Figure 19 is an upper perspective of the base level block 26 which
is installed on a
gravel bed below grade and includes a recessed interior 112 with a central
positioned drainage
hole 114. Repetitive features again include an upper/outer edge exhibited and
arcuate/width
extending groove 116. Figure 20 is a rotated underside perspective view of the
base level block
26 and which exhibits a flattened bottom surface 118. Also shown is a front
end wall 115, a lip
edge location 117 separating the front wall 115 from the projecting groove
116, and a rear wall
119.
[0096] Proceeding to Figure 21, an exploded perspective is shown of a top
level pad 120
according to a further variant, similar to that previously depicted in Fig. 5,
and which illustrates a
plurality of heating pads 122, 124 and 126 (these exhibiting thin wafer-like
profiles) which are
installable within upper surface proximate locations, such as pockets 128, 130
and 132 accessible
from a rear flat edge surface of the pad 120, this in order to facilitate melt-
off of snow or ice
accumulations. As will be further described in additional detail in succeeding
views, the pads or
like thin wafer inserts 122, 124 and 126 can exhibit any type of electrical
resistance generating
elements which are embedded within surface proximate locations of the pad 120,
this in order to
communicate (such as via heat conduction) the heat emanations generated by the
inserts in order
to warm and thermally melt any ice or snow accumulations upon the top surface
of the pad 120.
[0097] Each of the pads 122, 124, 126 can exhibit a pair of electrical
leads or wires, these
including input 123 and output 125 for selected pad 122, the leads or wires
providing power in
communication with any suitable electrical resistor element or the like
contained within the body
22
CA 02836086 2013-12-05
of the pad which generates a desired amount of thermal energy (i.e. heat)
which is communicated
via conduction to the exterior of the block to facilitate melt off of snow and
ice). The pair of
wires or leads associated with each of the pads can be daisy chained or
otherwise connected
together in order to communicate a single power source to all of the heat
generating pads, such
connection further including wiring the pads in series of parallel for
individual tiers or levels. As
will be described in further detail with reference to the succeeding
embodiments of Figs. 36 et
seq., the assembly can be constructed such that the heating pads are
replaceable without
destroying or otherwise adversely affecting the precast block construction.
[0098] Figure 22 is an upper perspective view of a variation 134 of a
second level block,
similar to that shown in Fig. 7, and illustrating a sideways installed heating
pad or insert 136
extending within a like configured and sideways accessible pocket 138
underlying an exposed
step area of the block. Reference is also made to the rotated underside
perspective view of Fig.
23 of the block shown in Fig. 22 and additionally illustrating an alternate
recess configuration
with horizontal define and underside channel 140 leading to an underside in-
fill receiving cavity
141. Without limitation, each block configuration can include a suitably
recessed thin pocket
(again at 138) for receiving a closely tolerance pad, such as which can be
easily added following
installation (such as including disassembling each block and installing the
heating filament or
pad with the use of an industrial sealant).
[0099] Figure 24 is a perspective view, generally at 142, of an alternately
configurable and
assembleable block assembly consistent with the preceding description and
depicting an
23
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elongated three dimensional shape as compared to Fig. 1 and which includes a
modified top pad
144, aside which are aligned a plurality (such as four shown) of additional
elongated top surface
rectangular blocks 146. Additional second tier blocks include end-most
position block 148,
additional arcuate blocks 150, and elongated and straightened blocks 152 and
154. A third or
bottom most level of aligning blocks are further shown by arcuate plurality of
blocks 156 and
further straight elongating blocks 158. Also shown is a shelf attachment 157
which can be
secured or otherwise supported to a side ledge location of a given layer or
tier, or adjoining
layers, such as with any type of tongue and groove or other interconnecting
structure and thereby
providing by non-limiting example a flower pot or other accessory for
integrating into the overall
assembly.
1001001
Figure 25 is a rotated rear view of Fig 24, in partial upper horizontal
cutaway, and
better showing the interlocking tongue and groove profiles of additional
support blocks 162, 166
and 174 which facilitating stack-ability of the second 150 and third 156 tier
blocks. These are
further shown in the partial perspective of Fig. 26 and which depicts
additional vertical
extending tongue and groove profiles, such as shown by tongue 160 shown by
inner tier block
162, this inter-locking with aligning and vertical extending grooves 164
established within
further located block 166. As further shown, horizontal extending tongues (see
at 168, 170 and
172) can be defined along either of top or bottom projecting edges of each
stackable layer (see
additional level or tier defining block 174) such that the interlocking of the
blocks extends in
each of horizontal and vertical directions in order to interlock with rearward
locations of the
24
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outer arrayed and stacked blocks and to provide structural support along the
interior volume
established by the tiered blocks 156, 150 and 142-146 depicted in Fig. 24.
1001011 The blocks 162 and 174 can be similar in shape and construction and
which are
referred to as support blocks for the upper most blocks to sit upon. The
blocks are further
reconfigurable within any of a number of differing configurations, such as
which can be
associated with a standard kit. The blocks may further jointly form a pocket
or hollow
compartment for containing volumes of the compactible gravel, such as when no
suitable back
support wall is available to contain the gravel in the application of each
kit.
[00102] Referring now to Fig. 27, a perspective illustration is generally
shown at 176 of a top
pad 178 and assembled second layer defining blocks 180 (see also each of
succeeding Figs. 28-
30), each exhibiting pre-cast decorative patterns exhibited along at least
exposed horizontal
surfaces and according to a further embodiment. The decorative patterns shown
represent but
one possible arrangement or pattern and can include any type of recessed or
embossed pattern
which can extend across the horizontal and/or vertical riser surfaces of the
top pad and
underneath positioned and assembled blocks such that, and upon assembly, a
separate stamping
or imprinting of a curing cement material is unnecessary. As further shown,
the decorative
patterns (see outlines 182 in top pad 178 and additional outlines 184 in
selected underneath
assembled block 180 in Fig. 27) can exhibit any style or arrangement and, by
benefit of being a
part of the initial manufacture of the pad and individual blocks, provides
significant ease of use
and reduction in install time.
CA 02836086 2013-12-05
[00103] Figures 28 and 29 are succeeding illustrations to Fig. 27 and
depict both upper and
lower rotated views of the top pad removed, this in order to further show one
non-limiting
example of a connecting network of heating pads or inserts (see as shown by
example at 186)
and wiring (see further plural wiring 188, 190, 192, et. seq.) associated with
the second
assembled layer and including a junction box 194 to which extends a main power
cord 196 from
a remote power supply, with the individual wiring 188, 190, 192 extending
therefrom to the
individual installed pads 186. The pads 186 or filaments install within
recessed pockets defined
in sideways receiving locations of each block (see further at 198 in enlarged
view of Fig. 30).
Although not clearly shown, any desired network or configuration of wiring can
be employed in
providing resistive heating to the various pads, such further including
additional wiring to
ground.
[00104] As further previously described, substitute heating mediums can be
employed and
which are not limited to geothermal (i.e. the feeding of a water based fluid
medium via a pump
or other circulating system within a closed loop and in order to transfer heat
from an
underground location for thermal conduction through the blocks or assembled
tiles to their upper
surfaces to facilitate snow or ice melt off). Alternate to geothermal heat
transfer, a solar
collector shield can be used in conjunction with a readily reconfigurable pipe
or conduit network
in an easily adaptable variant. The enlarged perspective of Fig. 30 further
depicts the features of
the exposed stamped patterns 184 formed in the precast blocks, along with
smooth and flat
boundary locations 200 separating the pre-cast decorative patterns and
interlocking tongues 202
26
CA 02836086 2013-12-05
and underside grooves 203 and for assisting in maintaining a level surface for
stacking the upper
succeeding (top pad) layer 178.
1001051 Referring now to Fig. 31, a perspective view is shown at 204 of a
further variant of
assembly exhibiting vertical (riser) surface located effect lighting (see
pairs of LED or like
illuminating elements 206 and 208) which are mounted within vertical riser
locations of a pair of
pre-fabricated and stacked blocks or steps shown at 210 and 212, respectively.
Without
limitation, the LED lighting elements can include such as those sold under the
commercial name
"Aurora Phoenix Recessed LED Light Kits" and which may be applied to vertical
riser locations
of any one or more selected step blocks. Other light kits can further be
installed into the
horizontal surfaces of the blocks, these including without limitation "DEKOR
LED Dek Dot
Kits". As also shown, the steps 210 and 212 can exhibit a similar tongue 214
and groove 216
inter-seating profile.
1001061 The LED elements 206 and 208 are further depicted as installed
within seating
recesses, see further at 218 which is defined in a reverse interior wall
location of a selected
forward riser for lower positioned step or block 210. Heating or other
electrical resistant pads
are further shown at 220 in relation to a sideways inserting edge of the lower
block 210, and
which are individually inserted into pockets (see further as best shown at 222
for upper stacked
block 212).
1001071 The lighting elements can include any type of low voltage light and
which can
include a portable/solar power generated capacity as well as optionally being
electrically
27
CA 02836086 2013-12-05
communicated by wiring in a similar nature as depicted by the heat resistant
generating pads. As
further shown in the rotated underside perspective view of Fig. 32, the recess
apertures 218
enable installation of the lights at any time and which are installed from an
interior/rear side
location, such as further assisted by a reverse side slot 224 accessible
through an underside edge
225 of the step block 210. On this point, the slot 224 is not needed in the
instance of a
horizontally mounted LED element and as is further shown in reference to Figs.
35B-35E.
[00108] In this manner, the light recesses can be drilled out at any time,
including prior to or
subsequent initial assembly, in the latter instance following partial
disassembly of a pre-
assembled construction and in order to permit the fabricator to drill out the
desired apertures
from the back side prior to installation of the lighting elements.
Additionally, it is noted that the
light emitting diode (LED) elements 206 and 208 can be substituted by other
suitable
illuminating elements not limited by the present description, and such as
which can adequately
function in external environments and which, along with the LED style
elements, can be
electrically connected or otherwise wired in order to provide seasonal or
daily lighting patterns,
such including communicating a timer or light sensor for activating the LED's
or other lighting
patterns at given times (such as evening darkness hours).
[00109] Additional features include the ability to incorporate any type of
design indicia into
the block design, such as depicted at 211 (depicted in exemplary and non-
limiting fashion as
either a professional or college sports logo applied to top surface of
selected walkway step 212)
and at 213 and 215 (further depicted as name and street address indicia
applied to vertical riser
28
CA 02836086 2013-12-05
locations of blocks 212 and 210, respectively). The design indicia schemes can
be molded into
one or more blocks during their original casting, this further including the
possibility of inserting
a temporary and customized template or pattern (not shown) into a receiving
inside location of
the corresponding block producing die, with the particular customer
name/address and any
additional desired indicia patterns exhibited in the template, pattern or form
for placement into a
pocket or other receiving location associated with one or more of the step or
walkway surface
defining molds or dies used for creating the blocks (thus avoiding having to
reconfigure the die
of the block to exhibit a given desired design indicia). This can further
include the inside of the
die exhibiting one or more removable blocks which can be substituted by the
three dimensional
and insertable template, pattern or form exhibiting the desired indicia
pattern on its inside face.
Without limitation, it is also understood that the mold or die itself can be
modified for creating
any significant number of the blocks with a given standard design indicia, and
can also be
reconfigured or modified to any other extent desired in order to provide any
customizable pattern
or scheme.
1001101
Figure 33 is a perspective view of a yet further variant, generally at 226, of
an inside
corner block assembly defining a combined porch and step. This includes
arcuate and inner
corner stacked components 228 and 230, with additional upper elongate defining
components
232-244. Corresponding lower components include an intermediate left hand
located block 246
and end most located block 248 (located in a stacking arrangement underneath
upper tier left
hand block 234. Additional located blocks associated with the lower-most row
include
intermediate right side located blocks 250, 250' and 250", as well as a right
hand located end
29
CA 02836086 2013-12-05
block 251 (located in stacking arrangement underneath right hand upper tier
end block 244) and
defining one possible stacking arrangement. Without limitation, one possible
arrangement can
include the blocks each weighing from about forty to one hundred and twenty
pounds and
exhibiting front dimensions of 12" x 30" in size, excluding the top level cap
blocks.
1001111 Figure 34 is a succeeding view of an outside corner block assembly,
generally at 252
and including outer corner arcuate extending and stacked levels 254 & 256
(bottom-most), 258
(intermediate) and 260 (upper). Additional elongate defining pluralities of
blocks include those
shown at 262-266 extending from outer edge corner block 254 and further at 268-
276 extending
from outer edge of corner block 256. Corresponding intermediate level blocks
are arranged in
similar and elongate extending fashion from opposite sides of the corner block
258 and are
shown at 278-284 and 286-294. Upper level blocks likewise extending in
elongate defining
fashion from uppermost corner block 260 are further depicted at 296-302 and
304-312 in one
non-limiting arrangement.
[00112] Figure 35A is an illustration is generally shown at 314 of a
walkway path
constructed of a plurality of precast construction blocks, at 316, 318, 320 et
seq., in the shape of
interlocking patio pads and including heat generating pads (for example
depicting a thin wafer
like shape at 322 with extending wiring, see pair of leads 324 which can again
be arranged in a
daisy chain or like desired arrangement in order to provide series connection
of a plurality of
heating pads). As in previous embodiments, the pads are installed within
pockets, at 326, 328,
330, et seq., defined within side accessible locations of each block 316, 318,
320 et seq.
CA 02836086 2013-12-05
100113] By this construction, a sidewalk or pathway component can be
created which
matches the construction and features of the vertical step assembly (see
further blocks 332 and
334). The stepping stone configured elements 316, 318, 320 et seq. can be
likewise individually
pre-cast and can also incorporate additional lighting or other effects without
limitation, with the
heating pads 322 (such as which are again constructed in order to be
accessible and replaceable
on an as-needed basis without adversely affecting the pre-cast construction of
the various blocks)
seating within the depicted pocket recesses associated with any number of
stepping or walkway
locations as depicted and in order to assist with melting of snow and ice. As
with the LED
elements, a thermostat controller can control the activation and deactivation
of the heating pads,
such in one non-limiting example in a cycling (on/off) fashion over a given
time interval to
maintain a clear walkway or step location and without unnecessary expenditure
of power.
[00114] Figure 35B is a top view of selected walkway defining block 316'
and illustrating in
phantom an insertable pad (such as previously shown at 322) in combination
with a plurality of
(4) corner defined lighting elements, further shown representatively at 317.
Figure 35C is an end
view similar to that shown in Fig. 35B of selected walkway defining block 316'
with spaced
apart precast lighting element pockets (see further Fig. 35D) within which the
LED or other
lighting elements can be installed.
[00115] Figure 35D is a partial side depiction of a selected walkway
construction block 316'
previously referenced in Figs. 358 and 35C, which depicts (at cutaway 35B-35B
of Fig. 35B) a
pre-cast pocket associated with a selected lighting element 317, the pocket
being defined in the
31
CA 02836086 2013-12-05
underside of the block and depicted in exemplary outline by annular side wall
319 and underside
recessed end wall 321. Figure 35C is an illustration similar to that shown in
Fig. 35B (such as of
a further selected lighting element 317 and depicting a finishing top surface
drilling (or drill out)
of an increased diameter portion (see at 323) which facilitates top surface
seating of the LED or
other desired lighting element 317, again depicted in general and non-limiting
fashion for seating
within the horizontal top surface of the walkway or other defining block. In
this manner, the step
or walkway blocks can be casted to exhibit any configuration of underside
recesses or pockets,
and which are easily customizable by drilling out surface accessing portions
to facilitate quick
install of suitable lighting elements and any needed wiring so as to quickly
customize the block
to depict any lighting scheme. As is also clear from the depictions of Figs.
35B-35#, the lateral
dimensions of the pockets (as exemplary shown at 326' and compared to at 326
in Fig. 35A) can
be reduced to provide adequate material along the sides and edges of the
horizontal surface of the
block in order to facilitate mounting of the LED elements in the manner shown.
[00116]
Referring now to Fig. 36, a rear (back side) perspective is generally shown at
336 of
a multi-tier assembly according to a further variant which incorporates a
combination walkway
and stepped assembly with horizontally tiered steps, see at 338, 340, 342,
this in combination
with ground located and extending walkway portions or stones, at 344, 346, et
seq. Also
depicted are pluralities of support blocks 348, 350, 352, et seq., each of
which illustrate a
generally rectangular three dimensional shape and exhibit tongue and groove
profiles on upper
and lower surfaces, and which are assembled in supporting fashion underneath
the tiered steps
338, 340, 342 in the manner depicted.
32
CA 02836086 2013-12-05
[00117] With further reference to the succeeding illustrations, both the
steps and support
blocks provide a desired tongue and groove interlocking relationship (see by
example tongue 341
in support block 348 which seats within underside groove 343 of lowermost
positioned step 338)
in order to facilitate assembly according to any of a number of modifiable
configurations. As
further previously described, volumes of a weighted and compactible in-fill
material, such as
gravel, pea stone or the like, can be employed in order to establish a secure
grade support for the
top surface of the lower most tier of support blocks and walkway stones, with
additional volumes
of compactible material providing weighted support to the interior volumes of
each stacked step
or support block, as well as in-filling the interior volume defined between
and underneath the
shelves and supporting blocks.
[00118] Further shown are either of electrical or fluid based heating
units, referenced in this
series of illustrations as a shelf depicted at 356 in Fig. 36. The shelves 356
each exhibit a thin
planar and rectangular profile which, in one non-limiting application, creates
a pocket for
accepting a suitable heating element (such as again shown by the thin and
planar heat generating
pads previously depicted in Figs. 21-23 in the preceding described
embodiments). As will be
further described in additional detail, the heating pad or element containing
shelves are adapted
to being installed through a rear open profile of each indicated step block,
e. g. at 342, which in
turn exhibits an interior and upper inside ledge for supporting the shelf 356
(this in contrast to
the thin insertion slot depicted in the side profile of the selected walkway
casted stepping blocks
shown in Figs. 21-23 and 35).
33
CA 02836086 2013-12-05
[00119] As further shown in Figs. 36 et seq., the interior defined ledges
in the open rear of
the step blocks (see as further described in Figs. 45-48) are in proximity to
the upper horizontal
surface of the step blocks (such as with or without the use of an adhesive)
and to permit the heat
generated from the shelf 356 to be conducted through the material of the step
and to emanate
from the upper surface to facilitate ice/snow melt-off. As previously
described, the heat (or cool)
generating shelves and associated steps (or step blocks) are constructed so
that the shelves can be
easily retrieved and replaced (such as upon them burning out or otherwise
failing to properly
operate), this again capable of being accomplished without damaging the pre-
cast block
construction defined by the shelves and other interlocking components.
[00120] As with the previous variants, each step block or support block can
be constructed of
any silicate based or other material, such as including a composite material
incorporating any
one or more of a silicate ingredient, an expandable foam, an entrained
aggregate and/or any
additional polymeric, ceramic or metallic ingredient. Although not shown, the
steps and blocks
are each produced in a suitable mold process using a desired application of
heat and pressure and
within which the desired recipe mixture of ingredients can be pre-deposited or
applied in an
injection molding process.
[00121] Also depicted on an upper surface of each step block and walkway
portion or stone is
a decorative pattern which again can be formed into the component during
molding (such as
being integrated into the upper horizontal and vertical interior surfaces of
the cavity). Also not
also shown is the ability to employ variations of color or pigmentation into
the production of the
34
CA 02836086 2013-12-05
shelves and walkway stones, this including modifying the recipe mixture and/or
the manner of
delivering to the mold, such as in a localized manner in relation to the
exposed surfaces and in
order to provide the finished article with a desired visual appearance without
unnecessary waste
of materials.
[00122] Figure 37 is a further rotated and modified view of an assembly,
generally at 358,
which is similar to Fig. 36 with support blocks as previously depicted at 348,
350, 352, et seq.
The electrical version of the heating shelves (see again at 356 in Fig. 36 and
which can again
include either an integrally formed inner pad element or an insertable pad
such as depicted in the
preceding embodiments), is in this variant substituted by coolant circulating
jackets
representatively shown at 362 and 364, with the associated step blocks not
being shown for
purposes of clarity of illustration.
[00123] The fluid communicating jackets are similarly configured in a daisy-
chain series
arrangement, with an upper most jacket 364 exhibiting an inlet 366 (to which
is connected a fluid
conduit not shown). The coolant (also not shown) is communicated through a
piping network
integrated throughout the interior of the planar shaped jacket 362, prior to
being outputted
through an outlet 368. A conduit (see angled sections 370 and 372) redirects
the fluid from the
first jacket outlet to a further inlet location, at 374, of the lower tier
succeeding shelf 364, with
the conduit transferring heated fluid through any number of successive
shelves, following which
a return line can be installed for returning the fluid to a source location
for reheating (such as
within a solar powered collector, a geothermal fuel pump or other conventional
gas fired
equipment not shown) and prior to being recirculated.
CA 02836086 2013-12-05
[00124] Not further shown is any suitable pump or other Venturi effect
closed loop fluid
system for ensuring constant fluid flow through any number of interconnected
fluid jackets. It is
also envisioned and understood that such a geo-heating system could also be
reconfigured in
order to cool the shelves/steps and stepping stones, such being desirable in
very hot climates in
which melting of snow and ice is not a concern however in which providing for
a temperate
walkway surface is very desirable. Such an application would envision liberal
use of solar panel
technology with appropriate heat transfer condenser/chiller equipment in order
to provide a
cooled glycol or other like water based solution (and as opposed to heated) in
order to cool the
steps and pathway.
[00125] Figure 38 is an illustration generally at 376 is a perspective of a
further assembly
including tiered step sections or step blocks 378, 380 and 382, along with
decorative stamped or
other exteriorly configured design associated with each shelf or block, and in
combination with a
walkway portion provided by additional ground located stones or other cast or
molded portions
384, 386, et seq. The ground located portions defining the walkway surface
further illustrate side
inserting apertures, see at 388 and 390 for selected portions 384 and 386
respectively, these being
configured for receiving in width inserting fashion such as electric heating
pads (not shown) of a
type previously described.
[00126] Also depicted are examples of support blocks 348, 350, 352, et seq.
which are
assembled in tongue and groove fashion along with the tiered step blocks 378,
380 and 382 to
create a durable construction. A surfacing pattern is again exhibited for each
of the steps or step
blocks and stepping stones/walkway portions in a manner consistent with that
previously described
36
CA 02836086 2013-12-05
and which can include the provision of any desired coloring/pigmentation which
can provide a
desired visual effect to the completed assembly.
[00127] Figure 39 is a similar illustration to Fig. 38, with the tiered
steps/step blocks 378, 380
and 382 removed, and in order to further illustrate the initial layer of
support blocks 348, 350, 352,
et seq., such as which are assembled upon and into the earth or ground
location in order to array a
top extending surface thereof level or flush to a grade surface, the
associated walkway surface
again depicting apertures for receiving heating elements to facilitate the
melting of snow and ice.
Also better shown is the arrangement of tongue and groove portions associated
with each of upper
and lower surfaces of each supporting block, and as exemplary shown in
reference to selected
support block 350 with upper tongue 392 and lower groove (recess) 394 for
engaging a
corresponding tongue associated with an underneath located block 352.
[00128] Figure 40 is an illustration of a further variant of a stackable
assembly, generally at
396, and which largely repeats that previously described including a plurality
of tiered steps 378,
380, 382, supporting blocks (again at 348, 350 and 52) and stepping stones
384, 386, et seq. The
illustration of Fig. 40 is meant to demonstrate the variability of the
assembly in terms of scalability
and which can include a second scaled combination of steps 378', 380' and
382', with
corresponding support blocks 348', 350', 352' et seq., such as which are
assembled alongside the
first stepped arrangement and which further demonstrate the reconfigure-
ability of the present
invention. Although not shown, additional variants can contemplate the
stepping stones being
reconfigured as ramps or the like to accommodate such as wheelchairs and the
like.
[00129] Figure 41 is a perspective view of a further variant of assembled
step construction,
generally at 398, and similar to that originally disclosed in Fig.1 and
depicting a pre-cast decorated
37
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upper platform surface 400 (such as exhibiting a desired exterior pattern
consistent with previously
described variants). For purposes of ease of description, the lower tier
blocks associated with the
assembly 398 and include such as those previously disclosed in the initial
variant of Fig. 1 with
grade level blocks 26, second tier blocks 24 and third tier blocks 20 only in
combination with the
upper tier pad 400 (as compared to at 12 in Fig. 1). Otherwise, the present
invention contemplates
any assembly which can be assembled or reconfigured, redesigned or reassembled
in any fashion
desired to create an attractive porch, stairway or walkway location.
[00130] Figures 42 and 43 provide a pair rotated perspective views of
support blocks, again at
350 and 352, and forming a portion of the assembly shown in Fig. 36. These
again illustrate
mating tongue and groove profiles (see at 392 and 394 as previously described
for selected block
350 as well as at 353 and 355 for selected block 352) to facilitate tier
supporting stackability.
Without limitation, the support blocks can be reconfigured or redesigned,
along with the tongue
and groove configurations of the associated shelves such as previously
depicted at 338, 340 and
342, and in order to ensure alignment of the steps or step blocks.
1001311 In one non-limiting application, the initial or support blocks 350,
352 can be
constructed to fit any desired step size of 7" rise with 12" tread, with other
potential sizes produced
as desired. As further previously described, the rectangular shaped apertures
associated with the
interior of each support block (for example best shown in Fig. 43 by inner
perimeter bound
apertures 402 in block 352 and aperture 404 in block 350) provide the blocks
with a desired weight
savings during shipping and which can be in-filled on site and during
construction with volumes of
loose gravel, pea stone or other weighted and/or other compactible material in
order to achieve the
desired durability.
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[00132] Figure 44 is an illustration of a further assembly, generally at
406, which is similar to
the previous variant shown in Fig. 37, with Fig. 44 representing from a
further rotated and cutaway
perspective and showing a selected step block 408 (bottom tier) with
representative underside
supported block 348. The step block 408 is depicted in a manner consistent
with that previously
described and can include a decorative molded, casted, stamped or otherwise
configured upper (at
410) and/or front exposed surface. Also depicted is an upper projection (or
tongue) 412 which
extends a width of the step block and which, in combination with a lower
positioned groove 414, is
capable of interlocking with the tongue and groove configuration of one or
more succeeding step
blocks and underside supporting blocks, as further again depicted by upper
tongue 349 of selected
block 348 along with lower groove 351.
[00133] A pair of heating step blocks with shelves are depicted at 416 and
418 and, in contrast
to the fluid jacket constructed heating elements 362 and 364 in the preceding
variant of Fig. 37,
can include separate or integrally formed heating pads which are electrically
communicated in a
similar daisy chain arrangement so as to permit a single power supply input,
at 420, to feed any
plurality of shelve embedded pads arranged in chained or series communication,
shown as
additional wiring 422 leading to second shelf 418 and consecutive wire 424
leading to a third
embedded shelf (not shown) associated with the step block 410 depicted.
Without limitation, one
example of a heating pad construction for facilitating conducted heat transfer
to melt off snow and
ice can include such an assembly as is sold under the commercial name "Snow
Melting Mats" and
produced by Heattrak .
[00134] Proceeding to Fig. 45, a sectional perspective is shown of a
selected step block 338 as
previously described in Fig. 36 and which defines a selected tier defining
block or shelf illustrating
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a top decorative surface. Additional features consistent with the previous
description include a top
extending tongue 345, lower extending groove 343, (see also rotated underside
of Fig. 46). An
interior ledge for receiving the electric or fluid communicating shelf is
depicted by a three sided
construction defined inside the open interior of the shelf 338 and which
includes side supported
edge profiles 426 and 428 and interconnecting front interior edge 430 (also
Fig. 48), these
collectively defining a three sided interior support in proximity to the
inside top surface of the step
block 383 (at 432 in Fig. 46). Figure 48 is a side plan view of the shelf of
Fig. 45 and disclosing in
phantom the inner shelf supporting profile with inside forward ledge
communicating with
interconnecting side ledges shown in Figs. 46-47, this in order to secure the
inserted heat
generating shelf according to any configuration previously described.
1001351 Figure 49 is a perspective illustration of a heat generating shelf
and as generally
depicted at 434, according to one non-limiting configuration and which is
installed in a rearward
inserting fashion within the three sided ledge support as defmed in Figs. 46-
48. In combination
with the rotated underside of Fig. 50, the top plan view of Fig. 51, front
plan view of Fig. 52 and,
finally, side profile view of Fig. 53, the shelf 434 includes a generally
planar construction with a
top surface 436, a bottom surface 438, rearward inserting edge 440 and forward
inserting edge 442.
A pair of notched corner locations 444 and 446 separate the rear inserting
edge 440 from opposite
side edges 448 and 450 and, in construction, facilitate installation of the
shelf 434 in a manner
consistent with the similarly shaped pad or shelf shown at 356 in previous
Fig. 36 installed within a
similarly defined inner ledge profile associated with the selected ledge 342
in Fig. 36.
1001361 The heating element employed can further, depending upon the
attendant limitations of
manufacturing, exhibit either the planar thin pad configuration such as
previously shown in Figs.
CA 02836086 2013-12-05
21-23, assuming the step block, walkway stone or the like can be produced with
a suitably thin
accessible pocket for receiving the thin profile pad. In other manufacturing
assemblies, the
feasibility of molding the concrete or mixed silaceous blocks (such as
limiting the length of a long
and thin cross sectional shaped tooling which can be retrieved from the
forming concrete or mixed
component block) may require the configuration of the inner ledge for
receiving the shelf
construction such as further shown in Figs. 49-53.
1001371
In any non-limiting application, the blocks are capable of being pre-
manufactured with
or without the heating shelf or pad included. In the latter instance, any
number of heating pads or
shelves can be post installed during on site construction of the kit and based
upon the configuration
of the final assembly.
1001381
Having described my invention, other and additional preferred embodiments will
become apparent to those skilled in the art to which it pertains. This can
include incorporating
an automated system with a controller (not dissimilar to that associated with
a conventional
sprinkler system) for operating either or both of the heating pad elements
(such as in conjunction
with a thermostat control with precipitation sensor) and/or the use of a
separate light sensor for
activating the effect lighting elements. Manual on/off controls would also be
contemplated to be
part of such as an assembly.
1001391
Additional aspects associated with the initial manufacture process include
introduction of a control process for monitoring part to part variation
(color, pattern, texture, and
application of outer concrete sealer for environmental protection) this in
addition to determining
part shape or profile of each block. Additional kit assemblies can be
integrated into the program
for enabling the construction of a given assembly according to substantially
pre-set length, width
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and height dimensions and in order to minimize the requirement for individual
cutting or resizing
of the blocks.
[00140] As previously described, the heating elements and/or effect
lighting can be original
installed with the assembly or can be subsequently retrofit installed with a
minimum of
disassembly and repeat application of any required sealant. The mold
technology associated
with the production of the varying blocks is further understood to be modified
in order to pre-
form the desired pockets for receiving the heating filaments or pads.
[00141] Other and additional features include the incorporation of a
suitable process for
creating, installing and ballasting the individual bodies in order to create a
desired functional and
decorative structure. This can include, at a minimum, the steps of producing a
plurality of
individual bodies in a suitable mold or other casting process, such including
tongue and groove
profiles on at least opposite upper and lower surfaces, providing a decorative
pattern (such as
during molding or casting) on at least one exterior surface of any body, and
assembling the
bodies according to at least one of a multi-tier or walkway extending
construction.
[00142] Additional steps can include assembling an under-structure for
supporting a plurality
of tier defining and width extending shelves, the understructure provided by
additional pluralities
of rectangular blocks with additional tongue and groove profiles for
stackability, as well as
recessed profiles for facilitating in-fill of compactible or other aggregate
material (gravel, pea
stone, etc.). Other steps include configuring a three sided inner ledge within
a rear accessible
open interior of the shelf in order to support an insertable thermal
conducting pad. At least one
vertical riser or horizontal surface of a shelf or walkway body can further
integrate receiving
locations for installing effect lighting such as L.E.D. elements or the like.
Other steps include
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providing the thermal generating pads with either of electrical or thermal
fluid input, with
plurality pads capable of being daisy-chain connected in plural fashion from a
common input
source.
[00143] Yet additional variants contemplate the kit construction creating a
free standing unit
or assembly and such as which may not be attached to a house or other
structure. One benefit of
this type of construction is that it permits creation of such a structure
often without the need for
building permits (in many jurisdictions).
[00144] Beyond that disclosed, other features will become apparent to those
skilled in the art
to which it pertains, and without deviating from the scope of the appended
claims.
I claim:
43
