Method for assembling cobblestones into mats and device for carrying out thereof

Abstract

A cobblestone mat usable for covering roads, sidewalks, patios, outside/inside walls, etc., is disclosed, comprising a plurality of predeterminedly shaped cobblestones disposed at a certain distance to each other and a binding net internally imparted into and joining the cobblestones. A method is provided for assembling concrete cobblestones and the net, comprising the steps of providing a mold for forming the mat, predeterminedly placing the net into the mold, pouring liquid concrete into therein, hardening the concrete, forming the mat, and extracting the mat from the mold. An automated device for making the mat is proposed. There are also described preferable shapes and sizes of the cobblestones and cobblestone mats. The invention permits achieving high quality covering even by low-experienced workers, expediting the covering, minimizing dust and noise at work site since it avoids cutting the cobblestones, decorating surfaces with imitation of natural stone appearance and various colors and designs.

Description

TECHNICAL FIELD

The present invention relates to covering roads, pavements, sidewalks, driveways, walls, etc. with small paving stones, also sometimes referred to as cobbles. More particularly, the invention is dedicated to artificially made stones, herein defined as ‘cobblestones’, and bound into specific assemblies herein called ‘cobblestone mats’.

BACKGROUND OF THE INVENTION

Commonly known cobble roads, widely spread in Europe in 18-20 centuries, are difficult to construct, since the cobbles are different in size and shape, and it's hard to adjust them in relation to each other.

It is well known that some artificially made materials found wide usage for covering roads, sidewalks, driveways, etc. for public and private facilities. Some of them are covered by artificial paving stones imitating the shape of natural stones. There exist a number of technologies for production of such types of covering.

One of typical technologies is known as “interlock”, wherein paving stones are pre-manufactured in the form of bricks, and then they are embedded into the road body. Another broadly known technology is a so-called “stamp-concrete”, wherein specially shaped molds are impressed into the not-yet-hardened concrete (with a thickness of approximately 4-5 inches), making an imitation of paving stones covering.

The above named technologies however have their drawbacks. For example, the “interlock” is characterized with (a) high laboriousness, since the embedding is manually performed one-by-one for each paving stones; (b) necessity of having a highly graded sand ‘pillow’ (underlying layer), otherwise the covering will soon have an uneven surface; (c) impossibility to achieve an imitation of natural stone appearance because of the uniformity of the paving stones' shapes and sizes.

The “stamp-concrete” has the following disadvantages: (a) it is labor intensive and requires a significant physical force from the operator; (b) it's necessary to excavate substantial masses of earth to place a concrete layer of 4-5 inches; (c) large masses of concrete are required to be embedded; (d) the work is performed on-site, hence depends on weather conditions, is dirty, and more expensive; (e) the technology requires special equipment; (f) the covered concrete surface often becomes cracked during exploitation.

The process of installation of slabs and concrete blocks is usually a set of laborious operations that requires highly qualified personnel to achieve a high grade covering of roads, sidewalks, etc. Therefore, many technologies are directed to ease the process, lower the expenses, and employ less qualified workers. One of such technologies is taught in U.S. Pat. No. 3,406,618 to Bowman.

The latter in particular teaches that “the concrete . . . is poured from a cement mixer . . . , then the concrete is leveled . . . . The concrete hardens first at its bottom layer and it is softest at its top layer. The concrete is bull-floated by a wooden float . . . sufficiently to bring the finer particles of the plastic cement to the surface . . . . Then dry coloring powder . . . is hand-cast over the bull-floated surface . . . . This dry coloring powder usually contains fine sand, fine cement, and a mineral pigment . . . . This addition of powdered color topping is continued until the top surface is hardened to at least the same plasticity as the rest of the body of the concrete. Then the final texture is formed on the surface . . . at the stage when the plasticity of the concrete is sufficiently hard . . . . The general pattern of the bricks, tiles or cobblestones and the direction of the pattern is predetermined . . . . After individual bricks, tiles or cobblestones are so made over a given area, the bricks, tiles or cobblestones so formed are allowed to set to a sufficient dryness of the surface to permit the application of wax. A wax sealer is brushed on the exposed surfaces of the bricks, tiles or cobblestones in such a manner as to prevent the filling of the spaces between the bricks, tiles or cobblestones. After the wax dries then the joints or spaces between the manufactured bricks, tiles or cobblestones are grouted by suitable mortar . . . . The spurplus grout is removed from the exposed surface of the bricks, tiles or cobblestones by dragging wet sacks . . . over the surface . . . .

It further states “The tool . . . has a walking and stamping surface in the form of a grid . . . , which forms a frame with one closed side . . . and one closed end . . . . On the top of the grid there are a plurality of buttons or striking enlargements . . . arranged in such a manner that the workman, by striking them in sequence, will depress the tool into the plastic cement uniformly. From the bottom of the grid . . . extend a plurality of blades . . . arranged in the desired pattern and shaped according to whether bricks, tiles or cobblestones are to be made . . . .” After the concrete has been formed the grid is removed from the concrete and can be repeatedly used. As shown above, Bowman's process is extremely laborious, involves heavy manual operations, and has essentially the same drawbacks as the aforementioned “stamp-concrete”.

Another U.S. Pat. No. 3,891,340 to Bolli teaches “A concrete paving stone unit formed of a number of individual spaced paving stones connected together by integral thin webs. The webs constitute predetermined breaking points in the unit, so that when the unit is laid in sand and vibrated, some of the webs can break to allow the individual stones to bed firmly in the sand. If the ground shifts at a later date, other webs may break to allow the stones to conform to the new ground contour.”

The mentioned webs are made as thin concrete members having a height significantly less than the height of paving stones. The group of stones (unit) is laid into the sand as a whole. When some of the webs break, the stones retain their integrity and the gaps therebetween.

Bolli's method allows quick installation of the stones (due to the use of the units), forming essentially equal gaps between them (due to the webs), making a pattern from stones of essentially identical shape and size. It however has certain shortcomings: (a) supplemental equipment is required; (b) the webs might break during transportation that may cause traumas of workers and slow down the installation; (c) since the stones are of essentially identical shapes and sizes, it does not allow changing the pattern.

Another method allowing installation of a set of stones at once is described in U.S. Pat. No. 5,588,775 , to Hagenah as follows: “1. Paving stone set and process and device for the manufacture thereof. 2.1. In the case of lawn-paving blocks formed from paving stones (10) spaced at a considerable distance apart, these are joined together, against relative displacements, by a holding grid (11) embedded in the paving stones (10) and comprising tension-resistant strands. The said holding grid allows the transfer of traction forces and hence the reciprocal safeguarding of the paving stones (10) within a paving stone set held together by the holding grid (11). 2.2. The manufacture of the paving stone sets is effected in a concrete stone mold which is conventional in its principle. A flask (19) disposed on a molding plate (28) and a drawing sheet (29) is divided in the horizontal plane (33), creating a top part-flask (34) and a bottom part-flask (35). The holding grid (11) is clamped between the two part-flasks during pouring of the concrete. Following the completion of a paving stone set, the bottom part-flask (35) is withdrawn from the concrete stone mold. Demolding can now be carried out in the usual manner.”

The tension-resistant strands allow certain deformation of the metal grid, so that the stones remain joined and spaced from each other at a certain distance during exploitation of the set of stones. After the installation, the grid functions as a holder means of the stones to keep the aforesaid distance. The grid also provides essentially even distribution of tension forces applied to the stone set during its operation. To a certain extent, the surface of stone sets may conform to the relief of the ground. According to Hagenah, the gaps between the stones are not covered by concrete, and therefore allow for the growth of grass, which provides environmental and decorative effects. Nevertheless, the molding tools for formation of the stone sets are complicated, and the set's construction is significantly expensive, particularly due to the additional cost of the grid.

SUMMARY OF THE INVENTION

As demonstrated, the aforementioned technologies provide positive features, but exhibit certain deficiencies. The proposed invention intends to keep and improve these positive features (such as quick installation, fixed distance between the cobblestones, etc.) and at the same time to avoid the mentioned deficiencies (high costs, laboriousness, heavy complicated equipment for installation, etc.). It substantially reduces the costs and the weight of the stone set (cobblestone mat) comparatively to the prior art stone sets, and, on the other hand, provides integrity and an essentially unchanged distance between the cobblestones in the mat during exploitation after its installation, and its safe transportation. The invention discloses an article called a ‘cobblestone mat’, a method of manufacturing the mat, and a specific automated device for manufacturing the mat.

The cobblestone mat usable for covering roads, driveways, sidewalks, patios, outside and inside walls covering, etc., is disclosed below, comprising a plurality of predeterminedly shaped cobblestones, preferably made of concrete, disposed at a certain distance to each other and a binding net internally imparted into and joining the cobblestones. The method for assembling concrete cobblestones and the net comprises the steps of providing a mold for forming the mat, predeterminedly placing the net into the mold, pouring liquid concrete into the mold, hardening the concrete, forming the mat, and extracting the mat from the mold. The automated device for making the mat is proposed and described in detail below. There are also disclosed preferable shapes and sizes of the cobblestones and cobblestone mats. The invention permits achieving high quality covering even by low-experienced workers, expedite the covering, minimize dust and noise at work site, since avoids cutting the cobblestones, decorate surfaces with imitation of natural stone appearance and various colors and designs.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an isometric view of a device for making cobblestone mats in its initial position according to an embodiment of the present invention.

FIG. 2 illustrates an isometric view of the device shown on FIG. 1 in its catching position with a pushing frame in the lifted position.

FIG. 3 illustrates an isometric view of a portion of the device shown on FIG. 1.

FIG. 4 illustrates an isometric view of an enlarged portion of the device shown on FIG. 1.

FIG. 5 illustrates a partial isometric view of a concrete mold and the pushing frame in the lowered position of the device shown on FIG. 1.

FIG. 6 illustrates a partial detail view of the pushing frame of the device shown on FIG. 1.

FIG. 7 illustrates a partial view of a binding net and a dragging mechanism's portion of the device shown on FIG. 1.

FIG. 8 illustrates a partial isometric view of a detail portion of the device shown on FIG. 1.

FIG. 9 illustrates a general isometric view of a cobblestone according to an embodiment of the present invention.

FIG. 10 illustrates a sectional view of the cobblestone shown on FIG. 9.

FIG. 11 illustrates a general isometric view of a cobblestone mat according to an embodiment of the present invention.

FIG. 12 illustrates a general isometric view of a concrete preparation mold with the binding net situated above, according to an embodiment of the present invention.

Identical reference numerals in the drawings generally refer to the same elements in different figures. A first-time introduced numeral or letter in the description is enclosed into parentheses.

PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

While the invention may be susceptible to embodiment in different forms, there are described in detail herein, specific embodiments of the present invention, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as described herein.

As stated above, the invention discloses an article called a ‘cobblestone mat’, a method of manufacturing the mat, and a specific automated device for manufacturing the cobblestone mat.

Cobblestone Mat

FIG. 9 shows a general view of a cobblestone (1) in a preferred embodiment made of concrete. The cobblestone 1 has a squared base and squared-like lateral sides. The top of cobblestone 1 has an uneven surface 1′ imitating a natural stone. A binding net (2) is internally imparted into the cobblestone 1 as shown on FIGS. 9 and 10. FIG. 10 depicts a sectional view of the cobblestone 1 with the binding net 2 incorporated in the cobblestone.

The cobblestone mat is depicted on FIG. 11, and comprises a set of cobblestones 1. Generally the cobblestones may be performed in different design, shape, and size, joined by the binding net made of ropes, or the like. The preferable size of the cobblestones 1 ranges from 25 to 200 mm (from 1 to 8 inches). Often, the preferable height of the cobblestones is about 40 mm. The preferable distance (gap) between the cobblestones 1 in the mat ranges from 5 to 10 mm (from ⅕ to ⅖ inches). The distance generally depends on the average size of cobblestones 1 used in a given mat. The binding net 2 can be made of predeterminedly strong cotton, polyethylene, thin flexible and strong wire of a suitable metal, or can be made of another material possessing similar properties.

Method for Making Cobblestone Mat

The invention proposes a method for making the cobblestone mats. The inventive method comprises a step of providing a pattern for the mat. Generally, in order to make the pattern, a plurality of stones or stone-like articles can be disposed on a flat surface and can be covered by a liquid material capable to harden, for example, polyurethane. In this way a mold for pouring concrete could be produced, which mold then would be used for forming the cobblestones.

In a preferred embodiment shown on FIG. 12, a concrete mold (10) includes a number of rows; each row consists of a number of cells (11). The number of cells in the mold equals to the desirable number of cobblestones in the mat. Each cell 11 has a squared base, having four preferably vertical walls (two longitudinal walls and two transversal walls) and a bottom. Each bottom may have a different configuration of its concave surface (11′), defining the top surface 1′ of the cobblestone 1.

Essentially at the middle of each wall a substantially vertical slit (12) is cut from the top approximately at ⅓-½ of the wall's height, as shown on FIG. 12. Thusly, the mold 10 includes longitudinal and transversal slits 12. The preferable thickness of the peripheral walls of the mold is about 20 mm, the thickness of the inter-cell walls between adjacent cells is preferably 5-7 mm.

The method's next step is a placing of the net 2 into the mold 10 so that its ropes are inserted into the slits 12 of each cell 11 in the longitudinal and transversal directions. The slits 11 therefore retain the net substantially at a certain level of the mold 10.

The following step constitutes pouring liquid concrete into the mold 10. When the concrete in the mold has been hardened, the so formed concrete cobblestones 1 are extracted from the mold 10, which cobblestones are jointed by the binding net 2, and thereby assembled into cobblestone mats. The method can be performed by known tools. However, the present description further discloses an automated device for production of the mats.

The preferable size of the mat is 16 by 36 inches. A typical pattern can encompass 4 or 5 rows including from 7 to 9 cobblestones each. The mats are bedded into a padded base layer of sand or gravel (23) shown on FIG. 11. Such mats are not heavy, and can be bedded by only one workman. FIG. 11 also shows portions of the neighboring mats (11″).

The mats may be easily adapted to a particular surface to be covered by the cobblestones and can be installed around an obstacle on the surface without the necessity to cut the cobblestones. Mats with different gaps and cobblestones' sizes can be chosen for a given portion of the surface. If necessary, a section of a mat can be cut off to fill in a spot of the surface, or a portion of a first size (pattern) cobblestones mat can be substituted with a portion of a second size (pattern) cobblestones mat. For a small extension of the covered area, the ropes can be cut in one direction (for example, longitudinally) and the cobblestones can be bedded arbitrarily on the surface. The technology does not require cutting the cobblestones at all.

The mats can cover small or big areas, while providing an effect of uniqueness of all cobblestones and a natural stone look of the cobblestones, since their upper surface can have various types of curviness. Having mats of different colors and identical sizes, even low-qualification workers can create a multitude of distinct patterns and even pictures. Two- or one-row mats (that can be obtained by cutting a multi-row mat, or by special manufacturing thereof) have shown good results for the creation of patterns. They allow surrounding trees, forming stairs, circles, ovals, arcs, and zigzags of practically any sizes. Color striped mats can be utilized to form patterns of any shapes and color sets necessary for a road or wall design.

Thusly, the invention permits to: (a) provide bedding of high quality road or wall covering even by low-experienced workers; (b) substantially save time for the bedding, since the cobblestones are bedded 30-40 items at once, depending on the size; (c) the bedding can be performed with minimal amount of dust and noise, since there's no necessity to cut the cobblestones. The invention can be employed for covering roads, shopping malls, sidewalks, swimming pools (especially their steps), patios, outside and inside walls, etc. to decorate them with imitation of natural stone appearance, as well as making each item covered with an individual design.

Description of Automated Device for Making the Mats

The invention envisages a device for automation of the alluded technology for making the cobblestone mats. As depicted on FIGS. 1 and 2, the device comprises a known stationary mounted vibration stand (9), and a mold 10 for preparation of concrete cobblestones mounted on the vibration stand 9. The mold 10 includes a predetermined number of rows each having a predetermined number of essentially squared cells 11 as disclosed above. Some embodiments may include cells with a cross-section of a rectangular or another shape. The cells comprise substantially vertical walls and bottoms with predeterminedly curved surfaces 11′, shown on FIG. 12. Each cell 11 therefore has four such walls, and each wall includes a slit 12 cut from the top of the wall essentially at the middle of the wall, which slit 12 having a predetermined height. The upper portions of the slits 12 are preferably made slightly wider at their tops tapering downwards (as shown on FIG. 7).

The inventive device, presented on FIGS. 1, 2 and 3, comprises a drum (20) with a plurality of dents (20′) whereon the binding net 2 is wound. The drum 20 is used for orderly keeping and supplying the binding net 2 for further imparting it into a cobblestone mat.

The binding net includes a predetermined number of longitudinal and transversal ropes attached to each other via knots. The device comprises a pushing frame (7) for placing the binding net 2 into the mold 10. The pushing frame 7 is capable to move to an upper position (shown on FIGS. 1 and 2) and a lower position (shown on FIG. 5), for example, by means of hydraulic, pneumatic, electric, or other conventional driving mechanisms.

FIGS. 1, 2 and 4 show the pushing frame 7 that includes a predetermined number of springed clamps (8), preferably having a fork-like shape (shown on FIGS. 5 and 6), attached to the body of the pushing frame 7, and disposed peripherally. As mentioned, the pushing frame 7 is movable upward and downward. While moving from the upper position to the lower position, the pushing frame 7 substantially pushes the ropes of the net 2 into the slits 12, which ropes are then secured in the slits 12 essentially at a certain level due to elasticity of the net's ropes or/and of the material the mold 10 is made of. The springed clamps 8 are so configured that capable to hold the corresponding edge squares of the binding net 2 while the net is lowered into the slits 12 (FIG. 6).

The device comprises an upper roll (3) and a lower roll (4) (illustrated on FIGS. 1, 2, and 3) disposed in parallel to the transversal ropes of the binding net 2 above and under the net respectively. The rolls have an elastic outer surface, and rotatably mounted at a predetermined distance from the top of the drum 20. The rolls 3 and 4 are driven by a known motor (not illustrated), preferably a step-motor. The beginning portion of the binding net 2 is depressed by the rolls 3 and 4, and when the rolls rotate, they pull the net 2 out from the drum 20.

The device comprises a guiding slot (5) (illustrated on FIGS. 1, 2, and 3) disposed at the other side of the rolls 3 and 4 (opposite to the drum), from which rolls the guiding slot 5 receives the net 2 pulled from the drum 20.

The device comprises a pair of blades that includes an upper blade (6a) having a skewed edge, and a lower blade (6b) with a straight edge (illustrated on FIGS. 1, 2, 3, 5, and 7) disposed substantially vertically above and below the binding net respectively and located at a predetermined distance from the guiding slot 5. The blades 6a and 6b are installed to cut the binding net 2 into a predeterminedly sized piece of net to be imparted into a cobblestone mat.

The device comprises a dragging mechanism (18) (shown on FIGS. 1 and 2, and partially on FIGS. 7 and 8) including stationary guiding rails (13), a turnable frame (14) pivotally mounted on a carriage (15), which carriage is driven by a known mechanism. The carriage 15 is capable to roll upon the guiding rails 13 to and from the mold 10. The turnable frame 14 can be driven by a known hydro-cylinder, a pneumo-cylinder, or another mechanism (not shown) and can be set in an upper position (shown on FIG. 1) and in a lower position (shown on FIG. 2).

The device's dragging mechanism 18 includes a springed holder (illustrated on FIGS. 1, 2, 7, and 8) made in a fork-like shape consisting of two lateral springed arms (16) longitudinally extended at a predetermined angle to each other, and coupled with their first ends to the turnable frame 14 as shown on FIGS. 1 and 2. The springed arms 16 each at its second end has a hole.

The dragging mechanism 18 includes a substantially horizontal shaft (17) (illustrated on FIGS. 7 and 8) having two male screw-threaded ends, each of them is inserted into the holes of the arms 16. The shaft 17 has a threading-free middle portion. In the longitudinal direction from one end to the other, the shaft 17 has two parallel flat faces.

The dragging mechanism 18 includes a predetermined number of springed claws (19) (illustrated on FIGS. 7 and 8) to capture the bounding net 2 coming out from the guiding slot 5 and drag it until it will be stretched above the entire mold 10. The springed claws 19, each has two legs situated at a predetermined angle to each other so that shaping two lateral sides of a trapezium. At the greater base of the trapezium, the end of each leg is furnished with a bushing (21) having an internal through hole with a profile matching the shaft's cross-section, so that the shaft 17 can easily fit into the hole and extends throughout the interiors of all bushings 19. Normally, the bushings 21 are set in contact with each other, and the ending bushings are depressed against the arms 16.

At the smaller base of the trapezium, the ends of the legs are connected with a V-like shaped tongue predeterminedly curved and predeterminedly bent relatively to the plane of the trapezium as illustrated on FIGS. 7 and 8. The legs and the tongue of claw 19 are made as a whole preferably of a metal wire having suitable spring property or a similar appropriate material. At each end of the shaft 17, a wing-nut (22) (illustrated on FIGS. 7 and 8), having a female screw-threading, is screwed onto the shaft's threading.

The closer the wing-nuts 22 are moved to each other, the more the arms 16 are depressed. This causes contraction of the claws 19 in the transversal direction along the shaft 17. Therefore the positions of the wing-nuts 22 determine the total width of the shaft's portion embracing the claws. Thusly, when the binding net 2 is chosen of a different width (the width of the binding net is changed while the number of its rows remains the same, i.e. the size of its squares called a ‘net step’ is different), the wing-nuts 22 allow adjusting the width of the dragging mechanism 18.

The automated device has a conventional control unit (not illustrated) capable to issue preferably pre-programmed commands at predetermined moments of time to executing means, such as electric motors, hydraulic or pneumatic mechanisms, etc. The executing means further actuate the rolls 3 and 4, the frame 7 and the blades 6a, the dragging mechanism 18, the vibration stand 9, concrete supplying means, and so on.

Operation of Automated Device

At its initial position, depicted on FIG. 1, members of the automated device are situated as follows: the carriage 15 is located at its right end position maximally distanced from the mold 10; the turnable frame 14 is situated at its upper position lifting the arms 16 with the shaft 17 and the claws 19 (shown on FIGS. 7 and 8).

The pushing frame 7 with the blade 6a attached thereto are situated at the upper position. The rolls 3 and 4 have pulled a portion of the binding net 2 out from the dents 20′ of the drum 20 into the guiding slot 5, so that at least a part of the front row of the net's squares has come out from the slot 5.

A corresponding command of the control unit commences a cycle, and causes the carriage 15 to roll to its left end position, maximally close to the mold 10, carrying the arms 16, the shaft 17, and the claws 19 (shown on FIGS. 7 and 8). The next command causes the turnable frame 14, the arms 16, the shaft 17, and the claws 19 to turn into the lower position. At this moment (shown on FIG. 2) the claws 19 capture the mentioned part of the front row of the net 2 outstanding from the slot 5, so that each claw 19 engages with one square of the binding net 2.

A subsequent command causes the carriage 15 to roll into its right end position, while the dragging mechanism develops a predetermined force pulling the binding net 2. The main force pushing the net 2 from the drum 20 is still caused by the rolls 3 and 4, which is significantly greater than the predetermined pulling force exerted by the claws 19 onto the net 2. During the rolling, the binding net 2 is situated substantially parallel to the mold 10. At this right end position, the piece of net 2, pulled out by the dragging mechanism 18, is disposed above the entire mold 10, so that each longitudinal and transversal rope of net 2 is positioned just above the corresponding slit 12.

Thereafter, the control unit issues the next command causing the pushing frame 7 to descent into the lower position, wherein the clamps 8 meet the corresponding peripheral squares of the net 2, and push them into the slits 12.

The clamps 8 (shown on FIGS. 2 and 5) of the most right row (most distanced from the drum 20) enter the squares row of the net, following the peripheral squares row of the binding net 2 wherein the claws 19 have been inserted.

The pushing frame 7 substantially pushes the ropes of the binding net 2 down into the corresponding slits 12 of mold 10. The ropes are partially fixed with the slits 12, due to elasticity of the mold material and/or the rope, at a level slightly above the lowest points of the slits. Therefore, the net 2 is fixedly positioned at a predetermined level of the mold 10. The clamps 8 then push the net down disengaging it with the claws 19. Subsequently, the upper blade 6a comes into contact with the stationary lower blade 6b and cuts out the aforesaid piece of net 2. At the next moment, the net reaches the lowest point of the slits 12, and is finally fixed within the mold 10. Thereafter, the pushing frame 7 is lifted into its upper position. The turnable frame 14 is then moved into its upper position lifting the arms 16 with the shaft 17 and the claws 19.

Next, the control unit issues a command for a device supplying concrete (not shown) to start pouring liquid concrete into the mold 10 with the simultaneous activating the vibration stand 9. When the concrete cobblestones have been hardened, they are extracted from the mold 10.

In some embodiments, when the mold 10 is filled up with concrete, it can be removed and put into a respective location for hardening. Then another mold 10 can be placed on the stand 9, and the next cycle can start. A transversal conveyer can be arranged moving the molds to accelerate the process.

When the hardened cobblestones coupled with the binding net 2 and assembled into a cobblestone mat are removed from the mold 10, it then can be employed as described above.

It will be understood that each of the steps or elements described above, or two or more together, may also find a useful application in other types of constructions and methods differing from the types described above.

Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.

Claims

1. An article of manufacture called a cobblestone mat usable for covering roads, driveways, sidewalks, outside and inside walls, etc., comprising:

a plurality of cobblestones of predetermined shapes disposed at a predetermined distance to each other; and

a binding net composed of predeterminedly strong ropes having a number of rows and a number of columns, said ropes made of cotton or polyethylene, said binding net internally imparted into and joining said cobblestones.

2. The article according to claim 1, wherein said cobblestones made of concrete.

3. The article according to claim 2, wherein said cobblestones having a base of a squared shape.

4. The article according to claim 2, wherein said cobblestones having top uneven surfaces imitating a natural stone look.

5. The article according to claim 2, wherein said cobblestones having a size in the range from 25 to 200 mm.

6. The article according to claim 2, wherein the predetermined distance ranging from 5 to 10 mm.

7. The article according to claim 2, wherein the height of said cobblestones is 40 mm.

8. (canceled)

9. A device for assembly of concrete cobblestones and a binding net into a cobblestone mat, said device comprising:

a mold means for forming said cobblestone mat;

a means for orderly keeping and supplying the binding net to the mold means, said means for orderly keeping and supplying disposed at a predetermined distance from the mold means;

a driving means for moving the binding net to the mold means, said driving means disposed at a predetermined distance from the means for orderly keeping and supplying;

a guiding means receiving the binding net from the driving means, said guiding means disposed at a predetermined distance from the driving means;

a cutting means for cutting a predetermined piece of said binding net disposed at a predetermined distance from the guiding means;

a pushing means for pushing the binding net into the mold means, said pushing means disposed above the mold means, said pushing means partially coupled to said cutting means;

a dragging means for capture the binding net and predeterminedly positioning it above the mold means, said dragging means disposed at the opposite side in relation to said guiding means;

executing means for actuation of said driving means, said pushing and cutting means, and said dragging means, predeterminedly disposed in relation to said driving means, said pushing and cutting means, and said dragging means; and

a control means for controlling said executing means, predeterminedly connected to said executing means.

10. The device according to claim 9, further comprising a regulative means capable to adjust said dragging means to a changing width of the binding net for proper engagement.

11. A method for assembly of concrete cobblestones and a binding net into a cobblestone mat, comprising the steps of:

providing a mold means for forming said cobblestone mat;

providing a driving means for moving said binding net to the mold means;

providing a pushing means for pushing said binding net into the mold means;

providing a dragging means for capture of said binding net and positioning it;

actuating said driving means and moving said binding net to the mold means;

engaging said binding net at predetermined points by said dragging means and predeterminedly positioning said binding net in relation to the mold means;

engaging said pushing means with said binding net at the predetermined points;

disengaging said dragging means from said binding net;

cutting a predetermined piece of said binding net;

fixing said binding net within said mold means;

filling said mold means with concrete;

hardening the concrete; and

extracting the resultant hardened concrete cobblestone mat from the mold means.