Cast concrete paver block

Abstract

Precast concrete paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, the tapered joint projection on each block enters the joint recess on the other block. The taper on the projections move the blocks to align the block surfaces. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.

TECHNICAL FIELD

[0003] The invention relates to precast concrete products and more particularly to a precast concrete paver block.

BACKGROUND OF THE INVENTION

[0004] Precast concrete paver blocks are used for many applications, such as patios, driveways, sidewalks and courtyards. In the past, concrete paver blocks have generally been relative small, frequently from about the size of a brick up to about 2 feet square (about 61 cm square). In some applications, thin, decorative pavers are used as overlays on concrete foundations. Large pavers have not been available. One problem with larger paver blocks is to maintain a flat surface where the blocks abut. It is difficult to provide a flat foundation for the blocks and to prevent shifting of the blocks with ground movement, for example, due to frost or heavy rainfall.

BRIEF SUMMARY OF THE INVENTION

[0005] The invention is directed to large precast concrete paver blocks of a type suitable for constructing driveways, sidewalks, patios, courtyards, boat ramps, and the like. Optionally, the exposed surfaces of the blocks are textured and, optionally, colored, to simulate natural stone. The paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each edge joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, each tapered projection on each block enters a recess on the other block. The taper on the projections move the blocks into alignment. Preferably, there are at least two edge joints on each block edge which will abut another block edge. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.

[0006] Accordingly, it is an object of the invention to provide cast concrete paver blocks with edges which interlock for initially aligning and for maintaining alignment of abutting block edges.

[0007] Other objects and advantages of the invention will become apparent from the following detailed description of the invention and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a fragmentary perspective view showing an exemplary layout for a driveway, a sidewalk, steps and a patio constructed with cast concrete paver blocks according to the invention;

[0009] FIG. 2 is a top plan view of a rectangular paver block according to the invention;

[0010] FIG. 3 is a top plan view of a corner paver block according to the invention;

[0011] FIG. 4 is a top plan view of a square paver block according to the invention;

[0012] FIG. 5 is a top plan view of a triangular paver block according to the invention;

[0013] FIG. 6 is an enlarged fragmentary cross sectional view showing details of the connection between abutting edges of two paver blocks according to the invention;

[0014] FIG. 7 is a fragmentary side view of abutting edges of two paver blocks which have a slight angle between the blocks; and

[0015] FIG. 8 is a fragmentary cross sectional view showing details of one joint on one of the paver blocks.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to FIG. 1, an exemplary layout 10 is shown for a residential application including a driveway 11, a sidewalk 12, steps 13 and a patio 14 made from different types of cast paver blocks. The illustrated layout 10 is formed from four different shaped blocks, consisting of rectangular paver blocks 15, corner paver blocks 16, square paver blocks 17 and triangular paver blocks 18. Although the four illustrated block shapes will work for most applications, it will be appreciated that other block shapes also may be made to meet specific application requirements.

[0017] The blocks 15-18 are cast from concrete and, preferably, are reinforced with steel mesh or with rebar rods to provide the strength required for the application. For example, greater reinforcement will be needed for paver blocks used in a driveway 11 which must support the weight of heavy vehicles, than for paver blocks used in a patio 14 or in portions of a sidewalk 12 which do not cross a driveway. The blocks 15-18 are cast to a desired thickness, such as 4 inches (10.2 cm). In order to provide a pleasing appearance, the exposed top surfaces and any exposed edges of the blocks 15-18 may be textured, for example, to simulate natural stone. The block surfaces also may be stained or otherwise colored to more closely simulate stone using techniques which are well known in the art or to provide a desired appearance.

[0018] According to the invention, the sides of the blocks which abut the sides of other blocks are provided with one or more joints 19 which engage complimentary joints on the other blocks. The joints 19 are spaced on each block side for engaging the complimentary joint 19 on an abutting block side. FIG. 2 shows the rectangular block 15 as having two short sides 20 and 21, each having two joints 19, and as having two long sides 22 and 23, each having three joints 19. The rectangular block 15 may have, for example, a width of 4 feet (122 cm) and a length of 6 feet (183 cm).

[0019] FIG. 3 shows details of the corner block 16. The block 16 is substantially trapezoidal in shape having a side 24 which is either 4 feet (122 cm) or 6 feet (183 cm) long, two angled sides 25 and 26 which are 4 feet (122 cm) long and, for example, form an angle of 30° to each other, and a side 27 which is shorter than the side 24. In order to keep the width of the block at 4 feet or the width of the rectangular blocks 15, ends 28 of the side 24 are slightly angled. By arranging the sides 25 and 26 at an angle of 30°, three corner blocks 16 can be used to form a 90° bend. If the sides 25 and 26 were angled at 45°, two blocks 16 would be used to form a 90° bend. The block 16 is intended to have the sides 25 and 26 abut sides of other blocks 15-18. Thus, the sides 25 and 26 are each provided with two joints 19. The center portion of the side 24 (without the ends 28) may be of the same length as the side 27, for example, either 4 feet (122 cm) or 6 feet (183 cm). This will allow abutting a block to the center portion of the side 24.

[0020] FIG. 4 shows the square block 17, which has four sides 29-32, each of which is 4 feet (122 cm) long. Each side 29-32 has two joints 19.

[0021] FIG. 5 shows the triangular block 18, which has two adjacent 4 feet (122 cm) long sides 33 and 34 which form a 90° angle and a long side 35. Each of the sides 33 and 34 has two joints 19 for engaging joints on the other blocks.

[0022] FIGS. 6-8 show details of a construction for the joints 19. Each joint 19 extends along an edge 38 of the block parallel to a top surface 39 of the block. Each joint 19 consists of a projecting rib 40 and of a groove 41 sized and shaped to receive a projecting rib 40 from a joint 19 on an abutting block. Preferably, the rib 40 is triangular or wedge shaped in cross section with sides 42 and ends 43 which taper to an apex 44. Thus, the sides 42 are trapezoidal shaped and the ends 43 are triangular shaped. The groove 41 has complementary tapered sides and ends which are sized to receive the rib 40. Consequently, when two joints 19 are moved into position where the adjacent sides 38 abut, as shown in FIG. 6, the top surfaces 39 of the adjacent blocks are moved into alignment when the rib 40 is moved into the groove 41. Tapering the ribs 40 in two directions facilitates alignment of the blocks when they are positioned to form a desired layout. In the drawings, the rib 40 and the groove 41 for each joint 19 are shown as being aligned and adjacent each other. It will be appreciated that the rig 40 and the groove 41 may be spaced from each other, so long as they have the same spacing from the top surface 39.

[0023] A lower portion 45 of the edge 38 on each block may be angled slightly inwardly from the joint 19 to a bottom 46 of the block to form an angle between the lower portion 45 and the bottom 46 greater than 90°. Optionally, a chamfer may be provided between the lower portion 45 and the bottom 46 to eliminate sharp edges which may be subject to impact damage when installing the paver block. The angled lower portion 45 serves two functions. First, it allows a relief area for any dirt or other foundation material which may be trapped between the abutting edges. Second, it allows two adjacent blocks to be slightly angled relative to each other when the ground on which the blocks are placed is not level, while maintaining a tighter fit at the top of the paver block.

[0024] The joints 19 are formed to have the same configuration on each side of the block which will abut a side of another block. Thus, when looking at an elevational view of any block side having a joint 19, the rib 40 will be on the left side of the joint 19 and the recess 41 will be to the right of the rib 40. As a consequence, when any two sides are moved into an abutting arrangement, the two joints are complementary and each rib 40 will align with a recess 41. Alternately, all of the joints 19 can be made with the ribs 40 on the right and the recesses 41 on the left.

[0025] The joints 19 may be omitted from edges of the cast paver blocks which will not abut an adjacent paver block, especially any of these sides which may be visible after the blocks are installed. These edges may be textured with a pattern and colored similar to the exposed top surface of the block.

[0026] It will be appreciated that various modifications and changes may be made to the above described preferred embodiment of a cast concrete paver block without departing from the scope of the following claims. Although a preferred construction for the joints 19 has been described, it will be appreciated that other configurations also may be used to achieve the same results. For example, the ribs 40 can be replaced with round or oval knobs and the recesses 41 can be configured to receive the knobs. Also, the number of joints 19 on each side of the paver blocks may be changed to meet the needs for any particular application.

[0027] The block dimensions provided herein are intended to be exemplary. It will be appreciated that the block dimensions can be modified to meet local building codes and conventional sized in the community in which the blocks are used. However, the invention is particularly useful for paver blocks having a minimum dimension of at least 3 feet (91 cm) for providing larger hard surfaces.

Claims

1. A cast concrete paver block having a top surface, a bottom, and at least three side edges, and at least two joints on at least one of said side edges, wherein each of said joints is adapted to engage a complementary joint on an edge of another paver block, and wherein each joint includes a portion projecting form said at least one side edge and a recess in said at least one side edge, and wherein said projection is tapered to facilitate alignment with a complementary joint on an edge of another paver block when said block edges are moved together.

2. A cast concrete paver block, as set forth in claim 1, and wherein said joints on said at least one edge are spaced a predetermined distance below the top surface, and wherein said at least one side edge below said joints is angled towards said bottom at an angle greater than 90°.

3. A cast concrete paver block, as set forth in claim 2, and further including a chamfer between said at least one side edge and said bottom.

4. A cast concrete paver block, as set forth in claim 2, and wherein for each joint, said projection is elongated extending along a line substantially parallel to said top surface, and wherein said recess is at least as long as said projection and extends along said line substantially parallel to said top surface.

5. A cast concrete paver block, as set forth in claim 4, and wherein for each joint, said projection has an upper surface and a lower surface angled towards an apex, and opposing ends angled towards said apex, whereby said upper and lower surfaces are trapezoidal shaped and said opposing ends are triangular.

6. A cast concrete paver block, as set forth in claim 1, and wherein for each joint, said projection is elongated extending along a line substantially parallel to said top surface, and wherein said recess is at least as long as said projection and extends along said line substantially parallel to said top surface.

7. A cast concrete paver block, as set forth in claim 6, and wherein for each joint, said projection has an upper surface and a lower surface angled towards an apex, and opposing ends angled towards said apex, whereby said upper and lower surfaces are trapezoidal shaped and said opposing ends are triangular.

8. A cast concrete paver block, as set forth in claim 6, and wherein said block has a predetermined uniform spacing between each two adjacent joints on said at least one side edge.

9. A cast concrete paver block, as set forth in claim 1, and wherein at least said top surface is textured to simulate natural stone.

10. A cast concrete paver block, as set forth in claim 9, and wherein side edges of said block which do not include joints are textured to simulate natural stone.

11. A cast concrete paver block having a top surface, a bottom, and six side edges, first and second of said side edges extending parallel to each other, third and fourth of said side edges joining opposite ends of said first side edge and each extending at angles of at least 15° to said first side edge, and fifth and sixth of said side edges connecting between opposite ends of said second side edge and ends of said third and forth side edges.

12. A cast concrete paver block, as set forth in claim 11, and wherein said first and second side edges are of the same length and at least as long as said third and forth side edges.