Patent Application
20090056270
1. Field of the Invention
This invention relates to prefabricated custom patios and methods of fabricating and installing such patios.
2. Description of the Related Art
Custom patios are well known. However, these patios are usually expensive to design and to install.
In addition, custom patios typically are poured and installed on site (e.g., at a customer's home). As a result, environmental conditions sometimes cannot be controlled during installation. Wet ground, poor weather at the time of installation, and the like can affect the quality of a patio. As a result, custom patios sometimes are of relatively poor quality despite their cost.
Furthermore, properly installed patios slope slightly away from a structure such as a house so that water drains away from the structure. The patios are therefore poured with a sloping top surface, which results in different thicknesses across the patio. As a result, an upslope part of the patio should be thicker than required for durability so that the downslope part is thick enough. If this is done, excess material (e.g., concrete) can be used, resulting in increased cost. If this is not done, the downslope part of the patio can have inadequate strength, resulting in poor durability.
The invention provides techniques for fabricating and installing custom patios that address the foregoing concerns.
In some embodiments, a custom patio is fabricated by constructing, at a first location, a patio customized for a second location, and cutting the patio into sections.
The patio preferably is customized for the second location in one or more of size, shape, color, and surface pattern.
Preferably, the patio is constructed at the first location under controlled conditions. The conditions can be controlled by constructing the patio indoors, for example for temperature, humidity, or temperature and humidity, or can be controlled by constructing the patio outdoors but only under certain weather conditions. The conditions also can include controlling a grade of a base on which the patio is constructed to be level, as well as other conditions.
The patio preferably is further fabricated by installing a level gravel base, covering the gravel base with plastic to create a flat level surface, constructing a form on the base, placing a wire mesh on the base inside the form, pouring concrete into the form, allowing the concrete to cure, and adding a sealant to the patio's surface. One or more colors, surface patterns, or colors and surface patterns can be added to the patio.
Preferably, the sections are transported to and installed at the second location. Transporting the sections to the second location can also include adding numbers to the sections, stacking the sections separated by a protective material, and transporting the stacked sections. Installing the sections can include preparing the second location for installation of the patio, and assembling the sections at the second location according to the numbers.
The invention encompasses patios fabricated as described above, as well as method of fabricating such patios.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention may be obtained by reference to the following description of the preferred embodiments thereof in connection with the attached drawings.
U.S. Provisional Application No. 60/970,053 filed Sep. 5, 2007, titled “Prefabricated Custom Patios,” in the name of the same inventor, attorney docket no. BBC-001, is hereby incorporated by reference as if fully set forth herein.
In some embodiments, the term “custom” refers to customized for a single location. In other words, a custom patio could be a “one-off” patio that has a particular size, shape, pattern, coloration, etc. for a single location. In other embodiments, the term “custom” refers to customized for a particular class or group of locations. In other words, a custom patio could be a copy of another custom patio already installed at another location, possibly with some variances. However, “custom” precludes patios mass produced without consideration for their installation location.
Briefly, one embodiment of a method of fabricating a custom patio includes step 10 of constructing, at a first location, a patio customized for a second location, and step 20 of cutting the patio into sections. Fabrication can further include step 30 of transporting the sections to the second location, and step 40 of installing the sections at the second location to form the custom patio. Possible characteristics and sub-steps for these steps are further described below.
Preferably, step 10 includes controlling conditions 11 under which construction occurs. For example, if construction occurs indoors, temperature, humidity, and/or other conditions can be controlled to help ensure good quality. As another example, if construction occurs outdoors, construction could be performed during good weather conditions. In particular, because the patio is constructed at a separate location from where it is going to be installed, the construction can occur at any time, so construction can be delayed during bad weather such as cold temperature, high wind, rain, or the like. Other types of control of construction conditions can be used.
Steps 12 to 19 are possible sub-steps for step 10 of constructing, at a first location, a patio customized for a second location.
At step 12, a level gravel base is installed. This base preferably is graded and checked with a carpenter's (or other) level to ensure that it is close to true level. Even though the patio preferably will be installed in later steps with a slight slope away from any adjacent structure such as a house, the patio preferably is constructed at the first location on a level base. This helps to ensure uniformity and quality of the resulting patio.
In alternative embodiments, a different type of base such as a concrete floor or indoor workspace floor can be used. Other options for the base exist.
At step 13, the base is covered with plastic, thereby providing a flat level surface for constructing the patio. Alternatively, some other material could be used. Other options exist to provide a flat level surface.
At step 14, a form for the patio is constructed on top of the plastic. The form can be made of any suitable material, for example wood, metal, plastic, or the like. This form preferably is customized in terms of size, shape, or the like for installation at the second location.
At step 15, an optional wire mesh is placed inside the form. This mesh adds strength to the resulting patio.
At steps 16 and 17, concrete or some other suitable patio material is poured into the form and allowed to cure (if necessary). Sealant preferably is added in step 18.
Further customization can occur in step 19, for example addition of color(s), engraved or surface pattern(s), and the like.
As mentioned above, the patio is cut into section in step 20.
Preferably, square or rectangular sections are cut because of the ease of cutting a patio into these shapes. However, the sections do not have to be of any particular shape and do not have to be all of the same shape. For example, sometimes the selected pattern of sections could result in a small section that could be easily lost, harder to place, or otherwise inconvenient. In some embodiments, such sections might not be cut out completely, resulting in one or more irregularly shaped sections such as section 56 in
The sections preferably are numbered in step 21. This numbering can be used to help facilitate assembly, as discussed below.
The sections also could be modified in other ways to assist with assembly or to enhance aesthetics. For example, holes, dowels, biscuits, shaped edges, or the like can be added to help secure the sections to each other during assembly. The sections also could be shaped with edges that lock together. For another example, the sections could be cut along lines of an engraved or surface pattern that is present on the patio, thereby hiding the cuts and resulting seams when the sections are later assembled.
At this point, that patio can be considered to be fabricated. Alternatively, the patio could be considered to be fabricated after installation, which preferably involves step 30 of transporting the sections to the second location and step 40 of installing the sections at the second location.
Step 30 preferably includes steps 31 of stacking the sections and step 32 of transporting the sections to the second location. The stacked sections preferably are separated by protective materials such as foam, Styrofoam, blankets, plastic, or any other material that protects the sections from each other during transportation.
Step 40 preferably includes step 41 of preparing the second location for installation of the patio. Preparation preferably is performed as with standard patios, for example leveling, grading with a slope away from a structure, installation of plastic to inhibit growth of weeds through the patio, and the like.
Step 40 also preferably includes step 42 of assembling the section according to their numbering. Use of the numbers (if present) during assembly helps prevent having to piece the sections together like a puzzle. In some embodiments, sections of a patio can include holes, dowels, biscuits, shaped edges, or the like to secure them to each other. The sections also could be shaped with edges that lock together. Adhesives, brackets, and/or any other suitable joining materials and techniques also can be used to join the sections. Alternatively, the sections could simply be placed next to each other during assembly.
In the foregoing description, a custom patio is constructed at a first location, cut into sections, transported to a second location, and then installed. These locations could be separated from each other by significant distance, for example requiring transportation of the sections from a factory to a house or other structure. Alternatively, the locations could be on a single property, with transportation occurring by simple walking and carrying. In this later example, benefits can still accrue from being able to construct the patio on a level base and not having a structure in the way of constructing the patio. In such a circumstance, the various steps shown in
The invention is in no way limited to the specifics of any particular embodiments and examples disclosed herein. For example, the terms “preferably,” “preferred embodiment,” “one embodiment,” “some embodiments,” “alternative embodiment,” “alternatively,” “for example,” “can,” and the like denote features that are preferable but not necessarily essential to include in embodiments of the invention. The terms “comprising” or “including” mean that other elements and/or steps can be added without departing from the invention. Many other variations are possible which remain within the content, scope and spirit of the invention, and these variations would become clear to those skilled in the art after perusal of this application.
This application claims the benefit of U.S. Provisional Application No. 60/970,053 filed Sep. 5, 2007, titled “Prefabricated Custom Patios,” in the name of the same inventor, attorney docket no. BBC-001.
| Number | Date | Country | |
|---|---|---|---|
| 60970053 | Sep 2007 | US |
