U.S. patent application number 11/875300 was filed with the patent office on 2008-04-24 for modular surface element.
Invention is credited to Rene Brun.
Application Number | 20080095577 11/875300 |
Document ID | / |
Family ID | 39313572 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080095577 |
Kind Code |
A1 |
Brun; Rene |
April 24, 2008 |
MODULAR SURFACE ELEMENT
Abstract
A modular surface element that can be arranged in a running bond
pattern with other such modular surface elements. The modular
surface element has a configuration comprising a decorative face,
an opposed base, and sides extending therebetween generally
orthogonal to the base. The sides are proximal to and within a
modular perimeter defined by three non-alike pairs of opposed
matching segments that are oriented substantially parallel to each
other. At least two of the pairs of opposed matching segments are
non-linear and at least two of the pairs of opposed matching
segments are point symmetric. Optionally, the modular surface
element may comprise two or more mating components.
Inventors: |
Brun; Rene;
(St-Christophe-d'Arthabaska, CA) |
Correspondence
Address: |
BERESKIN AND PARR
40 KING STREET WEST
BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Family ID: |
39313572 |
Appl. No.: |
11/875300 |
Filed: |
October 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60862120 |
Oct 19, 2006 |
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Current U.S.
Class: |
404/42 |
Current CPC
Class: |
E01C 11/225 20130101;
E01C 2201/02 20130101; B44C 3/123 20130101; E01C 5/00 20130101 |
Class at
Publication: |
404/042 |
International
Class: |
E01C 5/00 20060101
E01C005/00 |
Claims
1. A modular surface element that can be arranged in a running bond
pattern with other such modular surface elements, having a
configuration comprising a decorative face, an opposed base, and
six sides extending therebetween generally orthogonal to said base,
said sides being proximal to and within a modular perimeter defined
by three non-alike pairs of opposed matching segments that are
oriented substantially parallel to each other, at least two of said
pairs of opposed matching segments being non-linear, and at least
two of said pairs of opposed matching segments being point
symmetric.
2. The modular surface element of claim 1 wherein the third of said
pairs of opposed matching segments is point symmetric.
3. The modular surface element of claim 2 wherein each pair of said
contiguous segments forms an obtuse angle.
4. The modular surface element of claim 2 wherein each of two pairs
of said contiguous segments forms an angle of approximately
180.degree. and wherein each of said other pairs of contiguous
sides forms an angle of approximately 90.degree..
5. The modular surface element of claim 2 wherein each of two pairs
of said contiguous segments forms an angle greater than 180.degree.
and wherein each of two other pairs of said contiguous sides forms
an angle of less than 90.degree..
6. The modular surface element of claim 2 wherein all six of said
segments are non-linear.
7. The modular surface element of claim 6, wherein said face
includes grooves resembling joints between areas of said face.
8. The modular surface element of claim 6, wherein said sides have
projecting regions that align more closely to said segments of said
modular perimeter.
9. The modular surface element claim 8, wherein said projecting
regions of said sides are adjacent said base.
10. The modular surface element claim 8, wherein said projecting
regions of said sides are near the ends of said segments.
11. The modular surface element of claim 6, wherein said sides and
said decorative face define edges that are irregularly recessed
from said segments of said modular perimeter.
12. The modular surface element of claim 6 comprising at least two
mating components.
13. A surface covering system comprising a multiplicity of modular
surface elements as recited in claim 1, said modular surface
elements being substantially congruent and being arranged in
aligned rows in a running bond pattern.
14. The surface covering system of claim 13 wherein a plurality of
adjacent modular surface elements in one of said aligned rows are
positioned with respect to an adjacent row such as to create open
spaces to provide drainage.
15. The surface covering system of claim 13 wherein said
multiplicity of modular surface elements are distinguished by
having different decorative faces.
16. A pair of substantially identical components assemblable into a
modular surface element as defined by claim 1, each said component
having a mating side that is point symmetric and that passes
through the geometric center of such an assembled modular surface
element of said pair of components.
17. The pair of components of claim 16 wherein each said mating
side is non-linear.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
modular elements for covering a surface. More specifically, the
invention relates to a novel shaped modular element for paving or
facing surfaces in the form of tiles, pavers, bricks, artificial
stones, etc. or for use in puzzles and other toys and games.
BACKGROUND OF THE INVENTION
[0002] Walls, floors, ground coverings and other structures are
often constructed by fitting irregularly sized and shaped natural
stones. The work requires a skilled stonemason to select, cut and
fit the stone. It is labor intensive, and accordingly expensive.
However, custom-built natural stone surfaces are considered very
attractive and desirable.
[0003] Conventional manufactured pavers, bricks, tiles, and so
forth, are cheaper and easier to install than natural stone due to
their regular geometric shapes, typically squares, rectangles,
hexagons, or combinations thereof. These surface coverings are
typically laid in repeating patterns, which simplifies installation
and therefore decreases labor costs. However, the repeating
patterns lack the same aesthetic appeal of irregular natural
stone.
[0004] It is known to produce manufactured pavers and other surface
elements in shapes that can be laid in repeated patterns that
create an effect that somewhat resembles irregular natural stone.
For instance, PCT application No. PCT/CA2005/001644 to Castonguay
shows such a design. However, the pattern extends radially, an
arrangement that is not very well suited for producing elongated
structures such as walkways. It can also be difficult for an
unskilled person to lay pavers in such a pattern, requiring careful
selection and orientation of each element. Furthermore, the shapes
that such manufactured surface elements may adopt are somewhat
limited, which restricts manufacturing freedom as well as the
choices offered to consumers.
[0005] Some known paver designs intended to imitate the look of
natural stone, such as the pavers disclosed in U.S. Pat. No.
4,217,740, use a combination of different shapes. However, these
require multiple moulds and the stocking of different pieces. Also,
such pavers are more complicated to install.
[0006] In addition, some known surface elements intended to imitate
irregular natural stones are not well suited for manufacture on
pre-existing production boards because their shapes and dimensions
do not efficiently fit within the production board, and the
dimensions and angles of the surface element cannot readily be
modified while still fitting together in the intended pattern.
[0007] Many known designs of modular surface elements are also not
suited for installation where it is desired to include internal
spacing, such as for water drainage. Some of these designs cannot
have open spaces in their pattern without losing necessary support
of surrounding stones, while others cannot be laid at all in their
intended patterns while accommodating open spaces.
[0008] Certain playthings, such as puzzles, also comprise a
collection of elements that can be arranged so as to cover a
surface. In some cases it may be desirable to lay out such elements
in a variety of arrangements. However, the pieces of common picture
puzzles and similar known playthings are intended to fit together
in only one arrangement.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
modular surface element that overcomes or mitigates one or more
disadvantages of known modular surface elements, or at least
provides a useful alternative.
[0010] In accordance with an embodiment of the present invention,
there is provided a modular surface element that can be arranged in
a running bond pattern with other such modular surface elements.
The modular surface element has a configuration comprising a
decorative face, an opposed base, and six sides extending
therebetween generally orthogonal to the base. The sides are
proximal to and within a modular perimeter defined by three
non-alike pairs of opposed matching segments that are oriented
substantially parallel to each other. At least two of the pairs of
opposed matching segments are non-linear while at least two of the
pairs of opposed matching segments are point symmetric. The third
of the pairs of opposed matching segments may also be point
symmetric. Alternatively, the third of the pairs of opposed
matching segments is non-point symmetric.
[0011] Each pair of the contiguous segments may form an obtuse
angle. Alternatively, each of two pairs of the contiguous segments
forms an angle of approximately 180.degree. and each of the other
pairs of contiguous sides forms an angle of approximately
90.degree.. As another alternative, each of two pairs of the
contiguous segments forms an angle greater than 180.degree. and
each of two other pairs of the contiguous sides forms an angle of
less than 90.degree..
[0012] All six of the segments may be non-linear. The face may
include grooves resembling joints between areas of the face. The
sides may have projecting regions that align more closely to the
segments of the modular perimeter. Optionally, the projecting
regions of the sides are adjacent to the base. The projecting
regions of the sides may be near the ends of the segments. It is
possible to have the sides and the decorative face define edges
that are irregularly recessed from the segments of the modular
perimeter. Optionally, the modular surface element is made of at
least two pieces.
[0013] In accordance with another embodiment of the present
invention, there is provided a surface covering system comprising a
multiplicity of modular surface elements as previously described
where the modular surface elements are substantially congruent and
arranged in aligned rows in a running bond pattern. A plurality of
adjacent modular surface elements in one of the aligned rows may be
positioned with respect to an adjacent row such as to create open
spaces, so as for example to provide drainage. Optionally, several
renditions of modular surface elements are distinguished by having
different decorative faces.
[0014] In accordance with yet another embodiment of the present
invention, there is provided a pair of substantially identical
components assemblable into a modular surface element as previously
defined. The components have mating sides that are point symmetric
and that pass through the geometric center of such an assembled
modular surface element of said pair of components. Advantageously,
each said mating side is non-linear.
[0015] The invention provides the advantages of being easy to
install because it requires only one type of manufactured stone
that is designed to match perfectly when installed in running bond
pattern. Because of the seaming irregularity of its shape, and
features such as false joints and variation in the appearance of
its face, the manufactured stone of the present invention may be
assembled to produce a surface covering that closely resembles the
look of natural stone. Using the same design principle, many
different shapes of manufactured stones may be produced, which
enhance customer choice and offers manufacturers great flexibility.
Moreover, the manufactured stone of the present invention may
easily be installed without modification so as to provide internal
spacing for water drainage or other purposes.
BRIEF DESCRIPTION OF DRAWINGS
[0016] These and other features of the present invention will
become more apparent from the following description in which
reference is made to the appended drawings wherein:
[0017] FIG. 1 is a top view of a modular surface element in
accordance with an embodiment of the present invention.
[0018] FIG. 2a to 2c are top views of a portion of such a modular
surface element showing the steps for creating segments of the
perimeter of the modular surface element of FIG. 1.
[0019] FIG. 3 is a top view of a modular surface element in
accordance with another embodiment of the present invention;
[0020] FIGS. 4a and 4b are top views of patterns created using
modular surface elements similar to the modular surface element of
FIG. 1.
[0021] FIG. 5 is a top view of a pattern created using modular
surface elements similar to the modular surface element of FIG.
3.
[0022] FIG. 6a to 6d are top views of examples of patterns created
using modular surface elements similar to the modular surface
element of FIG. 1.
[0023] FIG. 7a to 7c are top views of examples of patterns created
using modular surface elements similar to the modular surface
element of FIG. 3.
[0024] FIG. 8 is a top view of a pattern having water drainage
spaces made of modular surface elements similar to the modular
surface element of FIG. 1.
[0025] FIG. 9 is a top view of another pattern made having water
drainage spaces made of modular surface elements similar to the
modular surface element of FIG. 1.
[0026] FIG. 10 is a top view of a portion of a manufactured paver
superposed within the modular perimeter of a modular surface
element similar to that of FIG. 1.
[0027] FIG. 11 is a perspective view of a manufactured paver in
accordance with another embodiment of the invention.
[0028] FIG. 12 is a top view of a pattern made with a plurality of
manufactured pavers similar to that of FIG. 11.
[0029] FIG. 13 is a top view of a pattern made with manufactured
pavers in accordance with another embodiment of the invention.
[0030] FIG. 14 is a top view of manufactured pavers in accordance
with another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention may be used in a wide variety of
industries, ranging from manufactured stones, pavers, floor and
wall coverings to puzzles and other games. The invention provides a
way of designing an element for the applications so that once a
multitude of such elements are installed in a pattern, the pattern
looks random and the elements do not look similar.
[0032] FIG. 1 depicts a modular surface element 1 having a modular
perimeter 10 made of six contiguous segments, 12, 12', 14, 14', 16
and 16' organized in three pairs of matching segments. The segments
12 and 12' form a first pair of matching segments, the segments 14
and 14' form a second pair of matching segments, and the segments
16 and 16' form a third pair of matching segments. The two segments
of each pair (12 and 12'; 14 and 14'; and 16 and 16') are parallel
to each other, that is an imaginary line 13 joining both
extremities of a segment is parallel to a similar imaginary line
13' joining both extremities of the paired segment. Moreover, both
segments of a pair of matching segments are opposed to each other,
that is they are located at opposed sides of the modular surface
element 1 such that they cannot be contiguous. The end result is
that, viewed counter-clockwise, segment 12 is contiguous to segment
14, which is contiguous to segment 16, which is contiguous to
segment 12', which is contiguous to segment 14', which is
contiguous to segment 16', which is contiguous to segment 12
thereby closing the modular perimeter 10. Another way of expressing
it is that each segment of the first pair of matching segments 12,
12' is connected at one end to one segment of the second pair of
matching segments 14, 14' and at its other end to one segment of
the third pair of matching segments 16, 16'.
[0033] The modular surface element 1 is created by defining its
modular perimeter 10 according to a set of design rules. In a first
embodiment of the invention, the segments 12, 12', 14 and 14' have
point symmetry. Point symmetry exists when a segment is built
around a single point called the central point. For every point in
the segment, there is another point found at the same distance from
the central point, but in the opposite direction. A segment that is
point symmetric is unchanged in appearance by a 180 degree
rotation. In order to achieve point symmetry, the segments are
built in a specific manner. Each segment is built of two identical
portions. As shown in FIG. 1, segments 12 and 12' are each made of
portions 12a and 12b, and segments 14 and 14' are each made of
portions 14a and 14b. A portion is defined as the portion of a
segment extending from its central point to one of its
extremities.
[0034] FIGS. 2a to 2c depict the steps to create a segment having
point symmetry. In FIG. 2a, a portion 18 of length X/2 is defined
by a set of continuous lines or curves. In FIG. 2b, a copy of
portion 18 is rotated 180.degree. around extremity 20 of portion 18
to form portion 18'. The extremity 20 then becomes the central
point. Portion 18 and portion 18' define segment 21 of length X.
This is how the segments are constructed to be point symmetric.
This also defines the opposed segment of the matching pair of
segments because both are substantially identical. Segments 12,12'
and 14 and 14' are constructed this way.
[0035] Referring again to FIG. 1, segment 14 is joined at an
extremity to segment 12 and segments 14' and 12' are similarly
joined such that in a plane, the pair of identical segments 12-12'
have the same orientation and are spaced apart from each other.
Various angles R may be chosen. Similarly, the pair of matching
segments 14-14' must also be placed in the same orientation and
spaced apart from each other. The pairs of matching segments 12-12'
and 14-14' may be placed anywhere in a plane as long as they are
oriented similarly and spaced apart from each other. Segment 16 is
then created by joining the free extremity of segment 14 to the
free extremity of segment 12'. Various paths may be given to
segment 16. Segment 16' matches segment 16 and similarly joins the
free extremity of segment 14' to the free extremity of segment 12.
Segments 16 and 16' must have the same orientation to each other.
However, in this first embodiment, there is no requirement that
matching segments 16 and 16' have point symmetry.
[0036] As seen in FIG. 3, in a second embodiment, segments 12, 12',
14, and 14', are similar to those of the first embodiment but
whereas the segments 16 and 16' did not have point symmetry,
segments 316 and 316' do have point symmetry. This yields different
attributes to the modular surface elements 1 defined by the first
and second embodiments.
[0037] In both embodiments, the segments 12, 12', 14, 14', 16, 16',
316 and 316' may either be linear (a straight line) or non-linear.
As will be discussed later on, for the intended purpose, it is
sufficient that the segments of a pair of segments be matching.
Indeed, for the intended purposes, each pair of matching segments
may be slightly different and still match when two adjacent modular
surface elements are placed together.
[0038] FIGS. 1, 4 and 6a-6d depict the type of modular surface
element of the first embodiment of the invention where segments 16
and 16' do not have point symmetry, while FIGS. 3, 5 and 7a-7c
depict the type of modular surface element of the second embodiment
where the segments 316 and 316' have point symmetry.
[0039] FIGS. 4a and 4b show examples of patterns made with the type
of modular surface element 1 of the first embodiment. The modular
surface elements 1 are assembled in running bond, meaning offset
contiguous courses or rows, as opposed to the complex radial
patterns of some of the modular surface elements of the prior art.
It will be appreciated, by comparing FIGS. 4a and 4b, that in the
first embodiment, the modular surface elements 1 of a complete row
may be turned 180.degree.. Reference points 22 indicate the
orientation of the modular surface elements. It is to be noted that
the modular surface elements 1 may not be rotated 180.degree.
individually, but only on a row by row basis.
[0040] Similarly, FIG. 5 depicts an example of a pattern made with
the type of modular surface elements 1 of the second embodiment.
The modular surface elements 1 of this second embodiment, with all
of their 6 segments having point symmetry, may be rotated
180.degree. on an individual basis. Again, reference points 22
demonstrate how the surface elements may be placed in different
orientations.
[0041] FIGS. 6a to 6d show examples of patterns created with
modular surface elements 1 according to the first embodiment (in
pairs of matching segments does not have point symmetry) while
FIGS. 7a to 7c show which one of the three examples of patterns
created with the type of modular surface elements 1 of the second
embodiment where all three of the pairs of matching segments have
point symmetry.
[0042] Some installations of modular surface elements 1 may require
that adequate water drainage be provided. In the prior art, this is
mostly provided by either removing a modular surface element, or
part of it, from a pattern or by spacing two adjacent modular
surface elements. Very often, the drawback of doing so is that as a
result the modular surface element does not have the complete
support from surrounding modular surface elements and is prone to
stability problems when subjected to a vertical load that is offset
from the modular surface element's center. This is especially the
case when the modular surface element is a manufactured stone for a
driveway, for instance. When no gap is present, the surrounding
modular surface elements provide support to the modular surface
element under load, but if a space is left, for instance with a
rectangular modular surface element, the loaded modular surface
element loses its support on one side and becomes unstable under
load.
[0043] Shown in FIG. 8 is a pattern made of the modular surface
element 1 of the present invention. The modular surface elements 1
of the third row 103 have been shifted left with respect to the
modular surface elements 1 of the first and second rows 101 and
102. This has created open spaces 106 and 108, adequate for water
drainage. Similarly, the fourth and fifth rows 104 and 105 have
been shifted right with respect to the third row 103. This creates
open spaces 110 and 112, which do not have to be exactly the same
as open spaces 106 and 108, further adding to the natural aspect of
the pattern. FIG. 9 shows that even with open spaces on each side
of a row, the modular surface element 1 is still supported by
surrounding modular surface elements 116, as evidenced by arrows
118.
[0044] FIG. 10 depicts a portion of a manufactured paver 111 whose
sides 115 closely follow a modular perimeter 10 similar to that of
the previously described surface element 1 in accordance with the
present invention. However, the sides 115 of the paver 111 deviate
somewhat within the envelope defined by the modular perimeter 10.
Moreover, although the sides 115 of the paver 111 are generally
orthogonal to its base, they have irregularly beveled edges at
their top. In manufactured stones, for example, such irregular
beveled edges are often used to add to the rugged, natural
appearance of the manufactured stone. Consequently, the spaces
created between two manufactured paver 111 can vary in width,
further adding to the natural aspect of the pattern. It will be
understood that as long as the sides 115 remain inside the modular
perimeter 10, there is no risk of interference with similar
adjacent manufactured pavers 111 when laid out in a running board
pattern.
[0045] Reference is now made both to FIG. 10 and FIG. 11. To
facilitate even spacing during installation of the manufactured
pavers 111 and other surface elements 119 having a modular
perimeter 10 as per the present invention, it is possible to add
spacers 120 molded in the manufactured pavers 111 having the shape
of the modular surface element 1. Spacers 120 are positioned on the
vertices 124 joining two contiguous segments. Preferably, the
spacers 120 should substantially locally follow the modular
perimeter 10, as highlighted in FIG. 10. This facilitates alignment
and support between adjacent manufactured pavers 111.
[0046] Adding to the natural appearance of the modular surface
element 1, it is also possible to include false joints 122 as shown
in FIGS. 11 and 12. A modular surface element system may even
include modular surface elements 1 having different shapes of false
joints to create an even more natural-looking array.
[0047] It is also possible to completely divide a modular surface
element 400 made in accordance with the present invention into two
(or more) pieces such as components 401 and 403, shown in FIG. 13.
Components 401 and 403 may be reassembled so as to form the shape
of the modular surface element 400. Spacers may be added to each of
the components 401 and 403 in corresponding areas of the division
402. The division 402 may be linear so as to facilitate the
installation of the modular surface elements 1 along a linear
border by the use of individual components 401 or 403 as
needed.
[0048] FIG. 14 depicts a variation where the division 402 is point
symmetric, either being linear or non-linear, and passes through
the geometric center 404 of the modular surface element 400.
Because the division 402 passes through the geometric center 404,
it divides each opposite segment of one pair of matching segments
at the same corresponding place. For example, in the present case,
matching segments 406 are divided in partial segments 406a and
406b.
[0049] It follows that the modular surface element 400 can be
divided into a pair of substantially identical components 410, 412
that can be assembled to produce the modular surface element 400 by
bringing them together along their point symmetric mating sides
414, 416 defined by a point symmetric division 402 that passes
through the geometric center 404 of the modular surface element
400. Splitting the modular surface element 400 this way is
advantageous as it creates two identical components 410, 412 each
having half the size and half the weight of the modular surface
element 400. They can therefore be more easily manipulated than the
modular surface element 400 while still retaining the advantage of
requiring only one overall shape for all of the pavers.
[0050] It will be readily apparent that the modular surface element
1 of the present invention may be molded so as to provide a
decorative top surface that closely resembles, in form, texture and
color, the appearance of natural stone. Adding different geometries
of false joints further enhance the natural aspect of the modular
surface element 1.
[0051] Moreover, the same modular surface element system may be
used to create puzzles or other games and playthings, which have a
particular level of difficulty since some parts may fit
upside-down.
[0052] The present invention has been described with regard to
preferred embodiments. The description as much as the drawings were
intended to help the understanding of the invention, rather than to
limit its scope. It will be apparent to one skilled in the art that
various modifications may be made to the invention without
departing from the scope of the invention as described herein, and
such modifications are intended to be covered by the present
description.
* * * * *