U.S. patent application number 13/010485 was filed with the patent office on 2011-07-21 for self supporting paver system.
This patent application is currently assigned to BROCK USA, LLC. Invention is credited to Richard R. Runkles, Daniel C. Sawyer.
Application Number | 20110173901 13/010485 |
Document ID | / |
Family ID | 43759986 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110173901 |
Kind Code |
A1 |
Runkles; Richard R. ; et
al. |
July 21, 2011 |
Self Supporting Paver System
Abstract
A paver support system includes an edging rail or bracket that
engages an underlayment layer. The paver support system contains a
plurality of paving elements within a prescribed area bordered by
the edging rail and supported on the underlayment layer. The
cooperating underlayment layer and edging rail are self-supporting
to maintain the relative spatial relationship of the plurality of
paving elements supported thereon.
Inventors: |
Runkles; Richard R.;
(Windsor, CO) ; Sawyer; Daniel C.; (Boulder,
CO) |
Assignee: |
BROCK USA, LLC
Boulder
CO
|
Family ID: |
43759986 |
Appl. No.: |
13/010485 |
Filed: |
January 20, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61297236 |
Jan 21, 2010 |
|
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Current U.S.
Class: |
52/102 ;
52/169.1 |
Current CPC
Class: |
E01C 11/221
20130101 |
Class at
Publication: |
52/102 ;
52/169.1 |
International
Class: |
E02D 27/00 20060101
E02D027/00; E02D 5/80 20060101 E02D005/80 |
Claims
1. A self supporting paving system comprising an underlayment
layer; and an edging rail configured to be fixed to the
underlayment layer such that the edging rail and the underlayment
layer are adapted to cooperate to support a plurality of paver
elements atop of a support surface.
2. The self supporting paving system of claim 1 wherein the edging
rail includes a first leg and a second leg, the first leg having a
front tie that is severable such that the second leg is formable to
accommodate a contour.
3. The self supporting paving system of claim 2 wherein the front
tie includes at least one scribe configured to facilitate severing
of the front tie.
4. The self supporting paving system of claim 2 wherein the front
tie includes a frangible element.
5. The self supporting paving system of claim 1 wherein the edging
rail includes a first leg and a second leg, the first leg having a
plurality of barbs configured to pierce the underlayment layer such
that the edging and the underlayment layer are fixed together.
6. The self supporting paving system of claim 5 wherein the
plurality of barbs each include a flat face, the flat faces being
oriented at a relative angle to each other such that the flat face
resists movement of the underlayment layer relative to the first
leg.
7. The self supporting paving system of claim 5 wherein the first
leg includes at least one window formed therethrough, the at least
one window being bounded by a front tie that is spaced opposite to
the second leg, the front tie being configured to be readily
severed such that the second leg is formable to accommodate a
contour.
8. The self supporting paving system of claim 7 wherein the front
tie includes at least one scribe configured to facilitate severing
of the front tie.
9. The self supporting paving system of claim 8 wherein the at
least one scribe is bounded by spaced apart chamfers.
10. The self supporting paving system of claim 8 wherein the at
least one scribe is a pair of spaced apart scribes that define a
frangible element.
11. The self supporting paving system of claim 5 wherein the first
leg includes a plurality of windows that are each bounded by a
front tie and the plurality of barbs are a plurality of primary and
secondary barbs, the primary barbs being spaced between adjacent
windows and the secondary barbs being provided on the front
tie.
12. The self supporting paving system of claim 11 wherein each of
the plurality of windows includes a back flange.
13. The self supporting paving system of claim 1 wherein the edging
rail and the underlayment support the plurality of paving elements
in a generally lateral and vertical direction relative to the
support surface and the underlayment layer is configured to drain
water away.
14. The self supporting paving system of claim 13 wherein the
underlayment layer is formed from a closed cell foam material and
includes a plurality of channels and drain holes adapted for water
drainage.
15. The self supporting paving system of claim 13 wherein the
underlayment layer includes interstitial voids that facilitate
water drainage.
16. A self supporting paving system comprising: a plurality of
paving elements; an underlayment layer configured to support the
plurality of paving elements in a vertical direction relative to a
subgrade layer; and an edging rail configured to support the
plurality of paving elements in a lateral direction relative to a
subgrade layer, the edging rail being further configured to be
fixed to the underlayment layer such that the edging rail and the
underlayment layer are adapted to cooperate to support the
plurality of paver elements atop of a support surface.
17. The self supporting paving system of claim 16 wherein the
edging rail includes a first leg and a second leg, the first leg
having a plurality of windows formed therethrough, the plurality of
windows being bounded by a front tie that is spaced opposite to the
second leg, the front tie including a frangible element configured
to be severed such that the second leg is formable to accommodate a
contour.
18. The self supporting paving system of claim 17 wherein the first
leg includes a plurality of barbs formed between adjacent windows,
the plurality of barbs each including a flat face, wherein at least
two of the flat faces are oriented at a 45 degree relative angle to
each other such that the flat faces resist movement of the
underlayment layer relative to the first leg.
19. A self supporting paving system comprising: a plurality of
paving elements configured as perimeter paving elements and
interior paving elements, the interior paving elements having a
bedding material disposed therebetween; an underlayment layer
configured to support the plurality of paving elements in a
vertical direction relative to a subgrade layer, the underlayment
layer having a plurality of drainage channels and drain holes that
cooperate to direct water away from the paving elements; and an
edging rail configured to support the plurality of paving elements
in a lateral direction relative to a subgrade layer, the edging
rail having a plurality of primary and secondary barbs that are
configured to pierce the underlayment layer such that the edging
rail and the underlayment layer are fixed together and to adapted
to cooperate to fully support a plurality of paver elements atop of
a support surface.
20. The self supporting paving system of claim 19 wherein the
subgrade layer is one of a graded soil layer and a compacted sand
layer.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates, in general, to edging structures. In
particular, this invention relates to paver element supports that
are part of a self-supporting paver system. Traditional edge
restraint systems use spikes that are anchored to the ground to
hold the edge restraint relative to the individual paving elements.
One limitation of using spikes to hold the edging in place is that
the spikes need a compacted base under the bedding sand to act as
an anchoring structure. If there is no compacted base, the spikes
will not hold the edging in place very effectively. Further, the
edging material is anchored to the ground surrounding the paved
walkway, for example. Any shifts in the bedding that supports the
paver elements will cause the edging to move relative to the
pavers, thus disrupting the perimeter containment of the paver
elements. Thus, it would be desirable to provide a paving system
that is generally self supporting and does not rely on a compacted
bed to stabilize the paving elements.
SUMMARY OF THE INVENTION
[0002] This invention relates to a retaining structure that
cooperates with an underlayment material to support and contain the
relative location of paving elements. The cooperating retaining
structure is in the form of an edging rail that, together with the
underlayment layer, defines a self supporting paving system. In one
embodiment, the self supporting paving system comprises an
underlayment layer and an edging rail configured to be fixed to the
underlayment layer such that the edging rail and the underlayment
layer are adapted to cooperate to fully support a plurality of
paver elements atop of a support surface.
[0003] In another exemplary embodiment, the paving system includes
a retaining structure in the form of an edging rail or bracket that
includes piercing barbs. The piercing barbs are configured to
engage an underlayment sheet, such as a polymer foam sheet, and
form an outer perimeter frame. The edging rail and underlayment
layer are placed on soil or a prepared surface, such as for example
compacted sand. Paving elements may then be placed on and supported
by the underlayment layer and the edging rail. The paving elements
are bounded, at least along a portion of the perimeter of the paved
area, and are thus spatially contained on the surface of the
underlayment by the edging rail.
[0004] Various aspects of this invention will become apparent to
those skilled in the art from the following detailed description of
the preferred embodiment, when read in light of the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an elevational view, in partial cross section, of
a paving system having an underlayment layer and an edging rail
that support and contain a plurality of paving elements.
[0006] FIG. 2 is a perspective view of an embodiment of an edging
rail configured for use with an underlayment layer of a
self-supporting paving system.
[0007] FIG. 3 is a plan view of the edging rail of FIG. 2 showing
an underlayment attachment structure.
[0008] FIG. 4 is an elevational view of the edging rail of FIG.
2.
[0009] FIG. 5 is an end view of the edging rail of FIG. 2.
[0010] FIG. 6 is an enlarged plan view of an alternative embodiment
of an edging rail having an underlayment attachment structure.
[0011] FIG. 7 is yet another alternative embodiment of an edging
rail having an underlayment attachment structure.
[0012] FIG. 8 is a perspective view of another embodiment of an
edging rail configured for use with an underlayment layer of a
self-supporting paving system.
[0013] FIG. 9 is a plan view of the edging rail of FIG. 6 showing
an underlayment attachment structure and further having frangible
elements.
[0014] FIG. 10 is an embodiment of an edging rail having an
underlayment attachment structure and frangible elements.
[0015] FIG. 11 is a perspective view of an edging rail having
severable linking elements that are selectively removable to form a
contoured configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring now to the drawings, there is illustrated in FIG.
1 a paving system, shown generally at 10, having an edging rail or
bracket 12 and an underlayment support layer 14 that supports a
plurality of paving elements 16. The paving elements are shown as
perimeter paving elements 16a and interior paving elements 16b. The
paving system 10 is a self-supporting structure that confines the
paving elements 16 within a defined area. The containment area of
the paving elements 16 is defined generally as a perimeter of the
underlayment layer 14 that is bounded by the edging rail 12 and
also the supporting surface of the underlayment layer 14 positioned
below the pavers. The self supporting characteristic of the paving
system 10 confines the paving elements 16 together such that
disruptions of a supporting base foundation have a minimized impact
on the arranged pavers. This minimizing effect reduces or prevents
heaving or separation of the arranged paving elements 16. The
edging rail 12 and the underlayment layer 14 of the self supporting
paving system 10 are connected to function as a unitary body that
supports and contains the paving elements 16 in both a lateral and
a vertical direction relative to a supporting base foundation. The
paving system 10 may be placed over a layer of sand 18, that may be
compacted over a layer of subgrade soil 20. Alternatively, the sand
layer 18 may be raked, washed in, or otherwise topically applied.
The sand layer 18 may be used to facilitate water drainage and/or
to provide a consistent, graded surface formed to the desired
elevation. The sand layer 18 may be omitted, if desired. The
subgrade soil layer may be undisturbed, virgin soil; graded soil;
or compacted material that may include stone, sand, asphalt,
concrete, and the like.
[0017] The underlayment support layer 14 may be formed from a
polymer foam, such as a polyethylene foam, a polypropylene foam, a
polystyrene foam, and the like. The underlayment layer 14 may be a
closed cell foam that is water-impervious. Alternatively, the
underlayment layer 14 may provide for water drainage. Such water
drainage may include one or more drain holes formed through the
underlayment. The one or more drain holes may cooperate with one or
more drainage channels. The drainage channels may be on the top
support surface and/or the bottom surface of the underlayment layer
14. Alternatively, the underlayment layer 14 may have foam beads
having interstitial voids formed therebetween to allow for water
flow through the layer.
[0018] The edging rail 12 is illustrated, in cross-section, as a
generally "L" shaped bracket having two legs 22 and 24. The bracket
legs 22 and 24 are shown as having equal lengths, though legs of
unequal lengths may be provided. The first leg 22 of the edging
rail includes a surface 26 configured to support the underlayment
layer 14. This underlayment support leg 22 includes one or more
piercing barbs 28 formed into the leg that extend toward the
underlayment layer 14. The barbs 28 are shown as triangular barbs
having a point 30 configured to pierce through and retain the
relative position of the edging rail 12 to the underlayment 14. The
barbs 28 may alternatively be rectangular, star shaped,
semi-circular cylindrical projections, and the like. Alternatively,
the barbs 28 may be separate structures similar to nails that are
secured to the first leg by any means, such as welding, bonding, or
frictional engagement.
[0019] The second leg 24 of the edging rail 12 is illustrated
extending in a generally perpendicular orientation to the first
rail 22. It should be understood that the second rail 24 may extend
at any desired relative angle or multiple relative angles to the
first rail 22. Thus, the second leg 24 may be straight or have a
contoured shape. An outer perimeter edge 32 of the underlayment 14
may locate against the second leg 24. The plurality of paving
elements 16 may be placed on the underlayment layer 14 in any
desired pattern or arrangement. The outermost edge paving elements,
or perimeter paving elements 16a, abut a portion of the second leg
24. The interior paving elements 16b, adjacent to the edge paving
elements 16a (and other interior paving elements) may directly abut
the edge paving elements 16a or may have a layer of bedding
material (not shown), such as sand, infill, expansion material, and
the like disposed therebetween.
[0020] Referring now to FIGS. 2-5, there is illustrated an
embodiment of an edging rail 112 having first and second legs 122
and 124. The first leg 122 includes a plurality of barbs 128
disposed between windows 140 formed into the first leg 122. The
windows 140 may be omitted if so desired. The barbs 128 and the
windows 140 may be stamped, cut or otherwise formed into the first
leg 122. The barbs 128 are generally shown having a triangular
shape that extends upwardly toward the underlayment 14 and having a
piercing point 130 and generally flat sides or faces 130a and 130b.
The generally flat faces 130a and 130b are all positioned in
parallel planar orientations, as shown in FIG. 5. Alternatively,
the barbs 128 may be positioned in a perpendicular arrangement or
any other angular orientation relative to each other. In addition
to the barbs 128, nail holes 142 may be provided to permit external
anchoring of the edge rail 112 to the surrounding soil or other
support structure.
[0021] Referring now to FIGS. 6 and 7, there are illustrated
alternative arrangements of barbs, positioned at relative angles to
each other. As shown in FIG. 6, primary barbs 228a are formed into
a first leg 222, that is shown perpendicularly oriented relative to
a second leg 224, where flat faces 230a and 230b are oriented along
generally parallel planes. The primary barbs 228a are staggered
relative to one another so that they are spread over most of the
width of the first leg 222. The first leg 222 is shown having
optionally formed windows 240 that are partially bounded by a front
tie 244 and, optionally, a back flange 246 between the window 240
and the second leg 224.
[0022] The front tie 244 is configured to be readily severable by
way of light hand tools, such as pliers, tin snips, and the like.
Thus, as will be explained below, the edging rail 212, as well as
other embodiments described herein, may be contoured to follow the
perimeter of the underlayment. In order to be cut and bent, the
edging is preferably formed from a relatively thin material. The
edging rail 12 may be formed from metal, including sheet metal, or
plastic, including thermoplastics, fiberglass/resin composites, and
the like. Sheet metal materials may be on the order of a Gauge 3 or
greater, and may be more specifically provided between a Gauge 10
and Gauge 15 thickness. Plastic and non-metallic materials may be
thicker, if so desired.
[0023] Secondary barbs 228b are shown formed into the front tie 244
and having flat sides that are oriented in a generally
perpendicular orientation relative to the primary barbs 228a. The
barbs 228a and 228b have their broad surfaces oriented in two
perpendicular planes to restrain the underlayment 14 in two
directions. This barb orientation further prevents substantial
cutting or elongation of the pierced holes in the underlayment 14
by the thin edge of the barbs 228a and 228b in one plane by virtue
of the broad surface in the other plane. Alternatively, the
secondary barbs 228b may also be positioned adjacent to the primary
barbs 228a between the windows 240 or in lieu of the windows 240.
As shown in FIG. 7, the primary barbs 228a may be positioned in a
row closer toward the center of the first leg 222. The back flange
246 is preferably narrow to permit the second leg 224 to be bent or
formed to follow the contour of the intended pathway or shape of
the paved area, as will be described below. The embodiments of
FIGS. 6 and 7 show optional nail holes 242 formed into the first
leg 222 to provide for nails, spikes, or staples to anchor the
edging rail to the base layer, if so desired.
[0024] Referring now to FIGS. 8 and 9, there is illustrated another
embodiment of an edging rail, shown generally at 312, that includes
first and second legs 322 and 324, respectively, and barbs 328 that
may be similar in geometry and relative orientation to the barbs
28, 128, and 228a,b described above. The first leg 322 includes
frangible elements 350 positioned on a front tie 344 along a window
340 between spaced-apart underlayment anchoring sections having the
extending barbs 328. The barbs 328 may be oriented in any desired
relative position. Additionally, the frangible elements 350 may
also include barbs (not shown), similar to secondary barbs 228b
described above. The frangible elements 350 are defined by scribes
352 configured as thinner section score marks formed onto the front
tie 344. The scribes 352 may be formed on one side of the first leg
322 or both upper and lower sides. The scribes 352 may be bounded
by chamfers 354 on either end or both ends to facilitate removal of
the frangible elements 350. When selected frangible elements 350
are removed, the second leg 324 and a back flange 346 may be formed
to correspond to the contour of the paved area perimeter. The
frangible elements 350 may be left connected to provide for
straight sections of pavement. In order to bend or contour the
edging 312 according the shape of the desired pathway, the
frangible elements 350 may be removed by breaking or cutting. The
frangible elements 350 may be broken using light hand tools, such
as pliers, where the element 350 is bent back and forth to fatigue
the front tie 344 at the scribes 352. Alternatively, the frangible
elements 350 may be more easily cut by light hand tools, such as
tin snips, at the scribes 352. Once the frangible elements 350 are
removed, the second leg 324 may be more easily bent, contoured, or
otherwise formed to conform to the edge of the paved area and
provide better attachment to the underlayment layer 14.
[0025] Referring now to FIG. 10, there is illustrated an embodiment
of an edging rail 412 having a first leg 422 and a second leg 424.
The first leg 422 includes an alternative arrangement of barbs 428,
shown having one barb 428a arranged generally parallel to the
second leg 424 and two barbs 428b and 428c oriented generally at 45
degree angles to the second leg 424 and perpendicular to each
other. The first leg includes a window 440 having a front tie 444
and a reduced or minimal-width back flange 446. In other
embodiments, the back flange 446 may be removed. The front tie 444
includes a single scribe 452 that may be optionally bounded by
chamfers 454. The single scribe 452 is positioned generally in the
center of the front tie 444 and, when broken, forms two halves of
the front tie 444. Alternatively, the scribe 452 may be located
anywhere along the front tie 444 and may form one extra tie leg.
The two halves of the front tie 444 may be bent up to provide
additional securement with the underlayment 14 or may be bent down
into the subgrade to prevent shifting of the paver system relative
to the ground.
[0026] Referring now to FIG. 11, there is illustrated another
embodiment of an edging rail, shown generally at 512. The edging
rail 512 includes first and second legs 522 and 524, respectively.
The first leg 522 is illustrated having windows 540 bordered by a
front tie 544 that is positioned opposite the second leg 524. The
front tie 544 may be severed in order to bend the second leg to
form a contour, such as a curve with a radius, R. Alternatively,
the front tie 544 may include one or more scribes or a frangible
element (not shown) to facilitate the severing and bending
operations. The bends in the second leg 524 may be formed in any
desired direction, for example, such as is illustrated in FIG. 11
or in an opposite direction of curvature. The first leg 522 is
illustrated having a plurality of attachment holes 542 that are
each configured to accept an anchor 528. The anchor holes 542 may
be omitted such that the anchors 528 are pierced through the first
leg 522. The edging rail 512 is illustrated as a multiple component
assembly where the plurality of anchors 528 are inserted through
the first leg 522 and extend upwardly to engage the underlayment
14. The anchors 528 may be frictionally engaged within the holes
542 or may be bonded, glued, welded, or otherwise attached to the
first leg 522.
[0027] The principle and mode of operation of this invention have
been explained and illustrated in its preferred embodiment.
However, it must be understood that this invention may be practiced
otherwise than as specifically explained and illustrated without
departing from its spirit or scope. Furthermore, each of the
elements illustrated and described with respect to each embodiment
may be incorporated into any other embodiment or substituted for
another element in another embodiment.
* * * * *