U.S. patent application number 10/769290 was filed with the patent office on 2004-11-18 for composite interlocking pavers.
Invention is credited to Lombardo, Dave.
Application Number | 20040228684 10/769290 |
Document ID | / |
Family ID | 33423042 |
Filed Date | 2004-11-18 |
United States Patent
Application |
20040228684 |
Kind Code |
A1 |
Lombardo, Dave |
November 18, 2004 |
Composite interlocking pavers
Abstract
A composite paver system comprising two distinct types of
interlocking pavers, both being formed from a mixture of sawdust
and polymers. One type of paver has a groove around the entire
periphery, and a plurality of interlocking members are provided to
fit into the grooves between adjoining pavers to secure them
together. The other type of paver comprises a plurality of tiles
all of which are notched at each corner, and at least one
interlocking member that fit into the notches at the corners of
adjoining tiles. The interlocking members are screwed to the
corners to secure the tiles together as one unitary paver. Using
both formats an economical composite patio or deck surface can be
built at one fourth the weight of conventional cement pavers, at a
lower cost (using a wood mitre saw for trimming rather than a
diamond cut saw), and yet with increased integrity. Moreover, the
reduced thickness and weight of the pavers eases installation by
reducing the excavation needed as well as the carrying weight of
the pavers thereto.
Inventors: |
Lombardo, Dave; (Baltimore,
MD) |
Correspondence
Address: |
LAW OFFICES OF ROYAL W. CRAIG
A PROFESSIONAL CORPORATION
SUITE 153
10 NORTH CALVERT STREET
BALTIMORE
MD
21202
US
|
Family ID: |
33423042 |
Appl. No.: |
10/769290 |
Filed: |
January 30, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60444071 |
Jan 30, 2003 |
|
|
|
Current U.S.
Class: |
404/41 |
Current CPC
Class: |
E01C 5/005 20130101;
E01C 5/20 20130101; E01C 5/22 20130101; E01C 2201/12 20130101 |
Class at
Publication: |
404/041 |
International
Class: |
E01C 005/00 |
Claims
I claim:
1. A composite paver system, comprising: a plurality of solid
composite members each being formed from a mixture of sawdust and
plastic and having a groove around the entire periphery; a
plurality of interlocking members that fit into the grooves between
adjoining composite members.
2. A composite paver system, comprising: a plurality of solid
composite members each being formed from a mixture of sawdust and
plastic and being notched at each corner; a plurality of
interlocking members that fit into the notches at the corners of
adjoining composite members to secure them together.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application derives priority from U.S.
Provisional Patent Application No. 60/444,071 filed Jan. 30,
2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to paver systems for decks,
patios, walk paths, and other open on grade surfaces and, more
particularly, to a composite paver system for with interlocking
feature to simplify assembly, ensure a more uniform deck
appearance, and to prevent shift and/or roll over time.
[0004] 2. Description of the Background
[0005] To improve their aesthetics, decks and patios are often
surfaced by tiles and/or pavers. Such pavers provide durability,
protection and performance despite harsh weather conditions.
Currently, there are a variety of pavers available to give a
variety of textured finishes and appearances. Moreover, pavers can
be cut and intermixed to yield striping, banding and paving
patterns having unique colors, sizes and finishes. The typical
steps for laying a paver surface are as follows:
[0006] 1. Demarcate perimeter
[0007] 2. Drive stakes in around perimeter.
[0008] 3. Excavate down to assure that there is room for base
layers upon which the pavers will lie, and create a level but
sloping surface (for drainage).
[0009] 4. Lay gravel about 4 inches thick and tamp it down.
[0010] 5. Fill the bed with about 11/2 inches of stone dust and
level it.
[0011] 6. Lay the pavers over the stone dust, tamping each
paver.
[0012] 7. Spread another layer of stone dust over the paver and
sweep into cracks between the pavers and along the edge.
[0013] 8. Spray water over the pavers to secure them in the stone
dust. The stone dust will harden.
[0014] Unfortunately, existing pavers are relatively thick (3-4")
and require a great deal of excavation down about eight inches to
assure that there is room for base layers upon which the pavers
lie. Moreover, existing pavers are made from cement or stone and
are very heavy. This not only presents problems and undue expense
in shipping and distribution, but it also creates functional
problems. The installation of a large paver job becomes a
physically challenging affair. Moreover, the weight of the pavers
can cause them to settle over time. It would be greatly
advantageous to provide a light-weight alternative without
sacrificing functionality or aesthetics.
[0015] There are a number of lighter-weight composite materials
used in fabricating decking. One of the first composites introduced
was Trex.RTM., a combination of furniture sawdust mixed with
polymers. Trex.RTM. requires virtually no maintenance, comes with a
ten year warranty and does not need to be sealed. Newer composite
lumbers include: TimberTech.RTM., SmartDeck.TM. and Dreamworks.TM..
The low maintenance aspects of these composite wood panels has
helped them to gain widespread acceptance in recent years for
above-ground applications such as decks.
[0016] However, they have not been adapted for use as pavers
because they are one-fourth the weight of cement, lack vertical
stability, and are much more prone to wind and weather.
[0017] It would be greatly advantageous to design an economical
composite paver system with interlocking feature that provides
stability, and which automatically spaces the pavers to give an
aesthetically pleasing deck structure, at one fourth the weight of
conventional cement pavers, without compromising integrity.
SUMMARY OF THE INVENTION
[0018] It is, therefore, an object of the present invention to
provide a light weight composite paver system with interlocking
feature that provides vertical stability, and automatically spaces
the pavers to give an aesthetically pleasing deck structure.
[0019] It is another object to provide a composite paver of 1-1.5"
thickness that eases installation by reducing excavation, and by
lightening the carrying load.
[0020] It is another object to provide a composite paver which
allows the use of a wood mitre saw rater than a diamond cut saw for
trimming.
[0021] It is another object to provide a scalable composite paver
design with interlocking feature that gives the ability to fasten
the edges, and which prevents shifting or roll over time, thereby
increasing the structural integrity of the finished surface.
[0022] It is still another object to provide a scalable composite
paver design which facilitates easy replacement of damaged
pavers.
[0023] According to the present invention, the above-described and
other objects are accomplished by providing a composite paver
system comprised of two distinct types of interlocking pavers, both
being formed from a mixture of sawdust and plastic.
[0024] One type of paver has a groove around the entire periphery,
and a plurality of interlocking members are provided to fit into
the grooves between adjoining pavers.
[0025] The other type of paver comprises a plurality of tiles all
of which are notched at each corner, and at least one interlocking
member that fit into the notches at the corners of adjoining tiles.
The interlocking members are screwed to the corners to secure the
tiles together as one unitary paver.
[0026] Using both formats an economical composite patio or deck
surface can be built at one fourth the weight of conventional
cement pavers, without compromising integrity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Other objects, features, and advantages of the present
invention will become more apparent from the following detailed
description of the preferred embodiments and certain modifications
thereof when taken together with the accompanying drawings in
which:
[0028] FIG. 1 is a side perspective view of a composite paver 2
according to a first embodiment.
[0029] FIG. 2 is a front perspective view of two composite large
paver 2A & 2B with interlocking members 6.
[0030] FIG. 3 is a top perspective view of a plurality of composite
large paver 2 assembled together.
[0031] FIG. 4 is a side perspective view of a composite paver 4
according to an alternative embodiment.
[0032] FIG. 5 is a front perspective view of two composite large
paver 4A & 4B with interlocking members 8.
[0033] FIG. 6 is a top perspective view of a completed patio
surface formed from composite large paver 2, 4 in accordance with
the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] In all of the succeeding paver embodiments the pavers are
formed by combining recycled plastic and sawdust (approximately 50
percent recycled wood, like wood fiber from sawdust and used wooden
pallet, and 50 percent recycled plastic materials, from plastic
grocery bags and industrial stretch film). These materials are
mixed together, and then extruded into boards. The boards are then
cut into pavers as described. The pavers are defect free, low
maintenance products, and once installed only occasional washing is
necessary. They resist rot and decay, and under usual conditions
should last a lifetime.
[0035] FIG. 1 is a side perspective view of a composite paver 2
according to a first embodiment. Here, the paver 2 is formed as a
rectangular brick-like form of 4".times.8" dimensions with a 1/2"
groove extending around its entire periphery (approximately 1/3 of
the way from the bottom of the paver 2). Each paver 2 is
approximately 1-1.5" thick. The combination of reduced mass and
thickness greatly reduces weight and eases installation. Moreover,
the reduced thickness reduces the necessary excavation. The pavers
3 may be compression-molded in this configuration or extruded and
machined.
[0036] FIG. 2 is a front perspective view of two composite large
paver 2A & 2B as in FIG. 1 with interlocking members 6. Each
interlocking member 6 is a flat member having a thickness that
conforms to the grooves 21 in pavers 2 (for a friction fit). The
interlocking members are approximately 1.0" wide and 4" long, such
that when inserted sidelong between two pavers 2A & 2B they
automatically space the pavers approximately 0.125" apart from each
other. Generally, two interlocking members 6 will be used alongside
of each paver 2, and one along each end. The interlocking members 6
provide vertical and lateral stability, and the automatic spacing
gives an aesthetically pleasing appearance. It is envisioned that
the foregoing paver 2 design (with interlocking members 6) will be
provided in 4" to 12" square and rectangular sizes, although larger
sizes are possible.
[0037] FIG. 3 is a top perspective view of a plurality of composite
large pavers 2 assembled together. The interlocking feature gives
the ability to fasten the edges around the patio, and this prevents
shifting or roll over time. If a paver 6 is ever damaged the
composite design facilitates easy replacement.
[0038] In addition to the discrete pavers of FIGS. 1-3, larger
pavers may be constructed either by integral molding or from
component parts.
[0039] FIG. 4 is a side perspective view of a composite paver 4
according to an alternative embodiment. The composite paver 4
comprises four (or any other number) of discrete tiles 42 secured
together with corner locks 44 that are screwed to the corners of
adjoining tiles 42 via screws 46. Each discrete tile 42 is notched
at all four corners to seat the corner locks 44, and corner locks
44 are screwed onto the corners of adjoining tiles 40 via stainless
steel screws 46 to collectively form a larger paver 4.
[0040] FIG. 5 is a close-up perspective view of two composite tiles
42 with seated corner locks 44 screwed onto the corners via
stainless steel screws 46. These pavers 4 are provided in square
and rectangular sizes ranging from 12".times.12" to
24".times.24".
[0041] Given an array of pavers 2, 4 of differing dimensions, it
becomes a simple task to compile an entire patio surface.
[0042] FIG. 6 is a top perspective view of a completed patio
surface formed from an array of composite large paver 2, 4 in
accordance with the present invention. It is readily apparent that
the composite paver system uniformly spaces individual pavers to
give an aesthetically pleasing deck structure. In addition, the
interlocking feature provides vertical stability and greatly
increases the structural integrity of the finished deck or patio
surface, especially around the edges where it prevents shifting or
roll over. In addition, the interlocking feature allows easy
replacement if a paver is ever damaged. Moreover, the reduced
1-1.5" thickness eases installation by reducing excavation and
carrying weight, and a wood mitre saw can be used for trimming
rather than a diamond cut saw.
[0043] Having now fully set forth the preferred embodiments and
certain modifications of the concept underlying the present
invention, various other embodiments as well as certain variations
and modifications of the embodiments herein shown and described
will obviously occur to those skilled in the art upon becoming
familiar with said underlying concept. It is to be understood,
therefore, that the invention may be practiced otherwise than as
specifically set forth in the appended claims.
* * * * *