This invention relates generally to patio blocks, paver blocks, landscaping blocks and block systems having side surface guidance, positioning and retaining structures. This invention also relates to patios and the like and methods of constructing patios and the like with blocks having side surface guidance, positioning and retaining structures.
Patio, paver and landscaping blocks are used in various landscaping projects and are available in a wide variety of styles. Numerous methods and materials exist for the construction of patios, walkways, driveways, roadways and the like. In recent years, segmental concrete patio, paver and landscaping units, which may be laid, positioned or dry stacked without the use of mortar or other complex securing means, have become widely accepted in the construction of patios, walkways, driveways, roadways and the like. Such patio, paver and landscaping units have gained popularity because they are mass produced and, consequently, relatively inexpensive. They are structurally sound, easy and relatively inexpensive to install, and couple the durability of concrete with the attractiveness of various architectural finishes.
In the manufacture of patio, paver and landscaping blocks and other kinds of blocks made from concrete, it is common to use a mold that forms a block module which is then split to form two or more blocks. Another method is wherein blocks are individually formed in a mold and the surfaces are textured by removal of the mold. Another known method of creating a block having an irregular, textured or patterned surface is to form the block in a mold box that has been provided with a top shoe and/or sidewall liner shaped to impart the textured or patterned surface on the top surface and/or side surfaces of the block during the block molding process.
In the construction of a patio, walkway, driveway or roadway, the aesthetic design of the individual block units and the overall visually pleasing aesthetic appearance of the constructed structure is important. Blocks that have a desirable texture or pattern create an exposed surface of a patio, walkway, driveway and roadway that is visually appealing. Additionally, in the construction of a patio, walkway, driveway or roadway, the functionality of the individual block units and the overall ease/difficulty in constructing the structure is important. Blocks that have high functionality and are user friendly allow greater ease in constructing a structure and, as such, are desirable.
It would be desirable to provide a patio, paver or landscaping block with a textured or patterned exposed surface with multiple areas separated by a false joint for use in constructing a patio, walkway, driveway or the like. It would be further desirable to provide a block with a textured pattern or textured surface with multiple areas separated by false joints that could create multiple desirable and aesthetic designs in an exposed surface of a patio, walkway, driveway or the like.
It would be desirable to provide a patio, paver or landscaping block having a side surface with guiding and retaining structures that would allow adjacent blocks positioned in the construction of a structure to be guided into a desired position and retained in the desired position.
It would further be desirable to provide a patio, paver or landscaping block with a side surface having an outward extending spacer projection and a spacer locator that is sized and shaped to accept the spacer projection such that during the construction of a structure, the spacer projections of the side surface of a first blocks are guided into and retained by the spacer locators of the side surface of an adjacent second block preventing slippage, pavement movement and shifting of the side surface of the first block relative to the side surface of the second adjacent block and provide proper and correct alignment of a block relative to adjacently positioned blocks.
It would further be desirable to provide a patio, paver or landscaping block with a side surface having an outward extending spacer projection and a spacer locator that is sized and shaped to accept the spacer projection such that during the construction of a structure, the spacer projections and spacer locators of the side surface of a first block and the spacer projections and spacer locators of the side surface of an adjacent second block are positioned on each side surface such that the top surface of the first patio block is spaced a desired and consistent distance from the top surface of the second adjacent block.
It would further be desirable to provide a patio, paver or landscaping block with an irregularly contoured or non-planar side surface having an outward extending spacer projection and a spacer locator that is sized and shaped to accept the spacer projection such that during the construction of a structure, the spacer projections and spacer locators of the side surface of a first block and the spacer projections and spacer locators of the side surface of an adjacent second block are positioned on each side surface such that the top surface of the first block has a variable or inconsistently spaced gap or distance that is predetermined and within a desired length range from the top surface of the second adjacent block, giving the patio a more natural, visually desirable aesthetic.
It would further be desirable to provide a patio, paver or landscaping block having spacer projections and spacer locators on the side surfaces of adjacently positioned blocks that provide a void or space between the blocks for the permeation of water/moisture, and the like, to pass or flow from the top surface of the block to the ground below. It would be further desirable to provide a patio, paver or landscaping block having irregularly contoured side surfaces such that when the bocks are positioned adjacent to one another, the blocks would be prevented from aligning completely and abutting one another, ensuring that spaces or voids in the joints between the blocks would be maintained throughout any completed structure made with the blocks.
A patio block including a block body having at least a first side surface, a second side surface, a third side surface and a fourth side surface, and opposed and substantially parallel top and bottom surfaces, each side surface having a height extending from the bottom surface to the top surface, each of the side surfaces having at least one spacer projection extending outwardly from the side surface and at least one spacer locator. The patio block including that the at least one spacer locator of each side surface has a first and second exposed surface, the first and second exposed surface extending outward from the side surface and a retaining surface extending inwardly from the first and second exposed surface toward the block body, the retaining surface of each spacer locator being shaped to receive a spacer projection.
A patio system including a plurality of patio blocks, the patio blocks having a block body with at least a first side surface, a second side surface, a third side surface and a fourth side surface, and opposed and substantially parallel top and bottom surfaces, each side surface having a height extending from the bottom surface to the top surface, each of the side surfaces having at least one spacer projection extending outwardly from the side surface and at least one spacer locator, the at least one spacer locator of each side surface having a first and second exposed surface, the first and second exposed surface extending outwardly from the side surface and a retaining surface extending inwardly from the first and second exposed surface toward the block body, the retaining surface of each spacer locator being shaped to receive a spacer projection. The patio system further including that when a patio is made with the plurality of patio blocks, the at least one spacer locator receives a spacer projection such that when a side surface of a first patio block is laid adjacent to a side surface of a second patio block the spacer projection of the side surface of the first patio block is accepted and retained into the spacer locator of the second patio block preventing displacement of the first patio block relative to the adjacent second patio block.
A method of making a patio including providing a plurality of patio blocks, the patio blocks having a block body with at least a first side surface, a second side surface, a third side surface and a fourth side surface, and opposed and substantially parallel top and bottom surfaces, each side surface having a height extending from the bottom surface to the top surface, each of the side surfaces having at least one spacer projection extending outwardly from the side surface and at least one spacer locator, the at least one spacer locator of each side surface having a first and second exposed surface, the first and second exposed surface extending outward from the side surface and a retaining surface extending inwardly from the first and second exposed surface toward the block body, the retaining surface of each spacer locator being shaped to receive a spacer projection. The method including forming a patio by positioning the patio blocks with a side surface of a first patio block laid adjacent to a side surface of a second patio block such that the at least one spacer projection of the side surface of the first patio block is accepted and retained into the at least one spacer locator of the second adjacent patio block preventing displacement of the first patio block relative to the adjacent second patio block.
A patio block including a block body having opposed top and bottom surfaces, and at least a first side surface, a second side surface, a third side surface and a fourth side surface, each of the at least first, second, third and fourth side surfaces extending from the top surface to the bottom surface. The patio block including at least one spacer projection positioned along each one of the at least first, second, third and fourth side surfaces, the at least one spacer projection extending outwardly from the at least first, second, third and fourth side surfaces and at least one spacer locator positioned along each one of the at least first, second, third and fourth side surfaces. The patio block including that the at least one spacer locator has a first and second exposed surface and a retaining surface, the retaining surface extending from the first exposed surface to the second exposed surface and having a contour shaped to receive a spacer projection, at least a portion of at least one of the first and second exposed surfaces extends outward from the side surface and block body and at least a portion of the contour of the retaining surface extends outside/beyond the side surface and the block body.
The patio block may include that the at least one spacer projection of each side surface extends a partial height of the side surface from the bottom surface toward the top surface of the patio block. The patio block may further include that the at least one spacer locator of each side surface extends the entire height of the side surface from the bottom surface to the top surface of the patio block.
The patio block may include that the entire contour of the retaining surface of the spacer locator of each side surface extends outside of the side surface and is located outside of the block body. The patio block may include that a portion of the contour of the retaining surface of the spacer locator of each side surface extends outside of the side surface and block body and a portion of the contour of the retaining surface of the spacer locator extends through the side surface and into the block body. The patio block may further include that the entire contour of the retaining surface of the spacer locator of at least one of the first, second, third and fourth side surfaces extends outside of the side surface and is located outside of the block body and the contour of the retaining surface of the spacer locator of at least one of the other of the at least first, second, third and fourth side surfaces has a portion that extends outside of the side surface and block body and a portion that extends through the side surface and into the block body.
The patio block may include that each side surface has a vertical plane and a portion of the contour of the retaining surface of the at least one spacer locator is in the same vertical plane as the side surface. The patio block may include that the block body has a fifth and sixth side surface such that the block body has an “L” shape, wherein the patio block has at least one spacer projection positioned along the fifth and sixth side surface and at least one spacer locator positioned along the fifth and sixth side surfaces.
A patio system including a plurality of patio blocks, the patio blocks having a block body with opposed top and bottom surfaces, and at least a first side surface, a second side surface, a third side surface and a fourth side surface each extending from the top surface to the bottom surface, each of the at least first, second, third and fourth side surfaces having an irregular contour such that top and bottom edges along the top and bottom surfaces where the at least first, second, third and fourth side surfaces extend also have an irregular contour, at least one spacer projection extending outwardly from each of the at least first, second, third and fourth side surfaces and at least one spacer locator positioned along each one of the first, second, third and fourth side surfaces, the at least one spacer locator positioned along each side surface having a retaining surface shaped to receive a spacer projection, at least a portion of the retaining surface extending outwardly from the side surface. The patio system including that when a patio is made with the plurality of patio blocks, the at least one spacer locator receives a spacer projection such that when a side surface of a first patio block is laid adjacent to a side surface of a second patio block the spacer projection of the side surface of the first patio block is accepted and retained into the spacer locator of the second patio block preventing displacement of the first patio block relative to the adjacent second patio block and creating a joint between the first patio block and the second patio block, the joint having variable widths along the length of the adjacent portions of the irregularly contoured top edges of the first and second patio block.
The patio system may include that the at least one spacer locator of at least one of the at least first, second, third and fourth side surfaces is at least two spacer locators, one of the spacer locators being of a first type having an entire retaining surface located outside of the block body and one of the spacer locators being of a second type having only a portion of a retaining surface located outside of the block body.
A method of making a patio including providing a plurality of patio blocks, the patio blocks having a block body with opposed top and bottom surfaces, and at least a first side surface, a second side surface, a third side surface and a fourth side surface each extending from the top surface to the bottom surface, each of the at least first, second, third and fourth side surfaces having an irregular contour such that top and bottom edges along the top and bottom surfaces where the at least first, second, third and fourth side surfaces extend also have an irregular contour, at least one spacer projection extending outwardly from each of the at least first, second, third and fourth side surfaces and at least one spacer locator positioned along each one of the first, second, third and fourth side surfaces, the at least one spacer locator positioned along each side surface having a retaining surface shaped to receive a spacer projection, at least a portion of the retaining surface extending outwardly from the side surface. The method including forming a patio by positioning the patio blocks with a side surface of a first patio block laid adjacent to a side surface of a second patio block such that the at least one spacer projection of the side surface of the first patio block is accepted and retained into the at least one spacer locator of the second adjacent patio block preventing displacement of the first patio block relative to the adjacent second patio block and creating a joint between the first patio block and the second patio block that has a width, the width of the joint having variable dimensions along the length of the adjacent portions of the irregularly contoured top edges of the first and second patio block.
The present invention will now be described by way of example with reference to the accompanying drawings, wherein:
An embodiment of the landscaping or patio block is shown in
Two spacer projections 120 and two spacer locators 125 are positioned on each of the first, second, third and fourth side surfaces 101, 102, 103 and 104, respectively. The spacer projections 120 and spacer locators 125 alternate along the length of the side surface and are spaced a predetermined distance from one another and from the ends of the side surface such that when a first patio block is positioned adjacent a second patio block during the construction of a patio or other desired structure, the spacer projections of any side surface of a first patio block will be guided into and retained by the spacer locators of any side surface of the second patio block and the spacer projections of the side surface of the second patio block will be guided into and retained by the spacer locators of the side surface of the first patio block. Additionally, the spacer projections and spacer locators are positioned along the side surfaces such that when one side surface of a first patio block is positioned adjacent to portions of side surfaces of second and third (or more) patio blocks during the construction of a patio or other desired structure, spacer projections of the side surface of the first patio block will be guided into and retained by the one or more spacer locators of the portions of the side surfaces of the second and third (or more) patio blocks and the one or more spacer projections of the portions of the side surfaces of the second and third (or more) patio blocks will be guided into and retained by the one or more spacer locators of the side surface of the first patio block.
Spacer projections 120 extend outwardly a desired distance from each of the side surfaces and from the block body 110. Spacer projections 120 extend vertically from the bottom surface 105 towards top surface 106 any desired distance or length and may extend a partial length of the height of the side surface of the block. It should be understood that each of spacer projections 120 of patio block 100 may have the same height or may have differing heights depending upon the application. Spacer projections 120 may have any desired shape or contour and are shown in
Spacer locators 125 extend vertically from the bottom surface 105 towards top surface 106 any desired distance or length and may extend the entire height of the side surface of the block. Spacer locators 125 may have any desired shape or contour and are shown having a concave or radial contour. Further, spacer locators 125 may be shaped and sized to receive, either partially or wholly, a locator projection from an adjacently positioned block in the construction of a patio. As best seen in
Further, the top surfaces, or features of the top surfaces, of the patio blocks may have irregular contours that may differ from the contour of the side surfaces and sidewalls of the block. These irregular contours of the top surface of a first patio block could cause uneven positioning, slippage, pavement movement and/or shifting relative to the top surface of an adjacent patio block without the guidance and positioning of the spacer projections and spacer locators. Further, the joints between adjacently positioned patio blocks having irregular contoured top surfaces could have widely varying widths that fall out of an acceptable predetermined range without the guidance and positioning of the spacer projections and spacer locators, such that the joint may be too narrow to allow a binding or finishing material to be inserted or too wide as to become structurally unsound/unsafe or visually unpleasing.
Top surface 202 has a first shaped area 211, a second shaped area 212 and a third shaped area 213, all of which are the uppermost surfaces of block 200. First area 211, second area 212 and third area 213 form a total upper area 215 of block 200. Top surface 202 may also have recessed surface or false joint 216 that separates first area 211 and second area 212 and may also have recessed surface or false joint 217 that separates second area 212 from third area 213. The first, second and third areas may be formed in a mold box with a roughened texture, a texture like that of natural stone, or any other desired texture or pattern. The pattern or texture may be formed, imparted, imprinted or applied to the mold in the mold box by a liner, a stripper shoe or any other suitable process as known in the art. First area 211, second area 212 and third area 213 may have any desired size or shape as can be seen in alternate embodiments of block 200 in
As can be seen in
Additionally, the irregular contour of each side surface (and top surface) of the first patio block and the irregular contour of each side surface (and top surface) of the adjacently positioned second patio block allow the space between adjacently positioned blocks created by the spacer projection to have variable widths that narrow and widen along the length of the space between blocks. However, the positioning of the spacer projections along the length of each side surface that are retained within the positioned spacer locators in adjacent patio blocks prevents the variable width of the space between blocks from going over a maximum allowed width required by regulatory safety guidelines as outlined in the Americans with Disabilities Act (ADA). Thus the spacer projections and spacer locators keep the variable width of the space between adjacent blocks within an acceptable and predetermined range. Positioning blocks without the spacer projections and spacer locators would result in greatly varied space/distance between adjacent blocks since the irregular contoured side surfaces of adjacent patio blocks would have no natural mating/aligning mechanism. The irregular contour of the adjacently positioned patio blocks would result in at least some portions of the space between adjacently positioned blocks to exceed regulatory ADA safety guidelines. Additionally, blocks not having the spacer projections and mating spacer locators would cause the patio blocks to slip, shift, move or displace during construction, and would reduce the overall functionality, safety and appearance of the patio, while failing to provide proper and correct alignment of a block relative to adjacently positioned blocks.
The predetermined and desired width of the joint created by the spacer projections and spacer locators on the side surfaces of adjacently positioned blocks provide a void or space between blocks for the permeation of water/moisture, and the like, to pass or flow from the top surface of the block to the ground below the patio constructed. Further, the irregularity of the contours of the side surfaces of the block (and as such the perimeter or border of the block) prevent the side surfaces of adjacently positioned patio blocks from aligning completely and abutting one another, further ensuring that spaces or voids in the joints between patio blocks will be maintained throughout the patio constructed. The permeability created by adjacently positioned patio blocks prevents water/moisture from collecting, pooling and/or sitting on the top surface of the patio, providing for a safer, longer lasting and easier to maintain structure. The top surface of the block (along with any false joints in the top surface of the block) may be molded with a slight curve/radius to help direct the water/moisture from the center of the block to the sides of the block and thus into the spaces/voids between adjacently positioned blocks, further enhancing the permeability of the block.
Top surface 302 has a first area 311, a second area 312 and a third area 313, all of which are the uppermost surfaces of block 300. First area 311, second area 312 and third area 313 may be on the same horizontal plane and form a total upper area 315 of block 300. Top surface 302 may also have recessed surface or false joint 316 that separates first area 311 from second area 312 and may also have recessed surface or false joint 317 that separates third area 313 from first area 311 and second area 312. The first, second and third areas may be formed in a mold box with a rough texture, a texture like that of natural stone, a pattern or any other desired texture. The pattern or texture may be formed, imparted, imprinted or applied to the mold in the mold box by a liner, a stripper shoe or any other suitable process as known in the art.
First area 311, second area 312 and third area 313 may have any desired size or shape as can be seen in alternate embodiments of block 300 in
As can be seen in
Spacer locators 325 have a first outward extending portion 326 and a second outward extending portion 328. Locator surface 327 extends from first portion 326 to second portion 328. First and second portions 326 and 328 may each extend outwardly from the side surface and block body of the patio block at any desired dimension. Locator surface 327 extends inwardly a partial distance toward the side surface from first outward extending portion 326 and second outward extending portion 328 such that the most inwardly extending portion of locator surface 327 is in a different vertical plane than the side surface of the block. Locator surface 327 may or may not extend all the way to the side surface of the block or into the block body from first and second outward extending portions 326 and 328 such that the most inwardly extending portion of locator surface 327 may be in a vertical plane outside or inside of the block body 318 or may be in a the same vertical plane as the side wall. Spacer locators 325 have a lower portion 330 and an upper portion 331. Upper portion may taper from the lower portion toward the top surface of the block. Additionally, upper portion 331 may have an uppermost edge 332 that abuts the side surface. Uppermost edge 332 may have any desired contour and may, for example, have an irregular contour.
During construction of a patio with block 300, a first patio block is positioned adjacent one or more additional patio blocks with one or more side surfaces of the first patio block being placed adjacent to at least a portion of one or more side surfaces of the one or more additional patio blocks. Spacer projections 320 of the first patio block are guided, aligned and retained into the spacer locators 325 of the adjacently positioned one or more additional patio blocks and the spacer projections 320 of the one or more additional patio blocks are guided, aligned and maintained into the spacer locators 325 of the adjacent first block.
Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the appended claims, which follow. In particular, it is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choice of materials or variations in the shape or angles at which some of the surfaces intersect are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein.
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