Abstract:
Recycled tire paver blocks with hidden interconnectors are cast blocks composed at least of a binder and rubber, the rubber being shredded rubber from recycled tires. The block has a top, a bottom and at least one sidewall, and has a substantially symmetric shape from a top view. It has at least one protruding male interconnector located on and extending outwardly from the at least one sidewall, and having at least one female interconnector located under the block on its bottom, at least 90 degrees away from the male interconnector as measured in an arc from a centerpoint of the block. The at least one female interconnector is a recess adapted to receive a male interconnector of a similar block. When the paver block male interconnector is inserted into a female interconnector of a similar block, both interconnectors are significantly hidden from top view.

Description:
BACKGROUND OF INVENTION 
       [0001]    a. Field of Invention 
         [0002]    The invention relates generally to recycled tire paver blocks (also called patio blocks) that may be used for any paver application, including walkways, patios, pools and landscape treatments, as well as other applications, such as paddock pathways, and exercise and gym areas. By “pavers” is meant blocks that are designed to interfit, like bricks or patio blocks, to create a pattern or array of units to accommodate different size areas that are typically walked upon. The present invention recycled tire paver blocks have unique construction and hidden interconnectors. The pavers are composed of binder(s), optional colorant and shredded rubber. The shredded rubber, also known as crumb rubber, is made predominantly of recycled shredded rubber and is preferably entirely shredded rubber from used, recycled tires. 
         [0003]    b. Description of Related Art 
         [0004]    The following patents are representative of the field of this invention: 
         [0005]    U.S. Pat. No. 7,344,334 B2 to Thorkelson describes a paver system that comprises of a plurality of paver pieces and at least one substrate. Each of the paver pieces has a top surface and a bottom surface. The bottom surface of the paver pieces is configured for mating with the upper surface of the substrate, whereby paver pieces coupled to the substrate are prevented from moving laterally. 
         [0006]    U.S. Pat. No. 7,300,032 B2 to Williams et al. describes a crumb rubber base pad which is for supporting mechanical machines and equipment and which is configured such that it reduces the noise and vibration emanating from these machines. The pad is constructed entirely from shredded and comminuted rubber tires and is configured such that it provides for the efficient run-off and/or draining of any moisture generated from under the machine unit. 
         [0007]    U.S. Pat. No. 6,185,893 B1 to Gaston describes a paving block system and corresponding components and methods. The system finds particularly efficacious application in forming patios, walkways and driveways, and may comprise interconnecting or adjoining bottom barriers and side barriers. Each bottom barrier receives one or more paving blocks thereon, and may optionally have formed in the bottom surface thereof a recess for receiving a top rail formed into the bottom barrier. In preferred embodiments of the present invention, adjoining blocks interconnect to form a relatively continuous paving block top surface. The present invention permits the effects of undesired displacement forces acting on the blocks, such as frost heave, to be reduced or minimized, and further permits a user to install a driveway, walkway or patio relatively rapidly. 
         [0008]    U.S. Pat. No. 5,468,539 to Crivelli describes a rubber tire recycling process that comprises the steps of granulating black rubber tire side walls and treads and granulating white rubber tire side walls to form coarse rubber crumbs, mixing the coarse rubber crumbs with fine clay particles to form a closely packed mixture, thoroughly wetting the surfaces of the coarse particles with an uncured EPDM rubber to provide a fluid, casting the fluid into a sheet-like configuration, and curing the sheet-like configuration under sufficient heat and for a sufficient time to provide an environmentally compatible paver for outdoor or indoor surfaces. 
         [0009]    U.S. Pat. No. 5,258,222 to Crivelli describes a rubber tire recycling process that comprises the steps of granulating rubber tires to form coarse rubber crumbs, mixing the coarse rubber crumbs with coarse siliceous grains to form a closely packed mixture of coarse particles that are roughly commensurate in size, thoroughly wetting the surfaces of the coarse particles with a polymerizable liquid binder to provide an environmentally compatible sheet-like product, e.g. a paver or tile for driveways, or a shingle for roof tops, that is characterized by excellent weather, wear and chemical resistance. The surface characteristics of the coarse particles of vulcanized rubber and crystalline grains are critical to the present invention. 
         [0010]    U.S. Pat. No. 3,842,562 to Daigle describes precast concrete slabs that are joined together to form a walk or patio-like matrix by embedding a plurality of rods in each slab and providing cavities in the bottom faces of each slab. Each rod has a hooked end portion which projects beyond opposing end walls of the slab, the hooked end portions and the cavities being positioned such that the hooked end portions of one slab are receivable in the cavities of another slab, whereby the slabs may be interlocked end to end to form a strip of slabs. Similar cavities and rods having hooked ends may be positioned in each slab at right angles to the aforementioned rods and cavities to permit sidewise connections of the slabs along with end-to-end connection. 
         [0011]    Notwithstanding the prior art, the present invention is neither taught nor rendered obvious thereby. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention relates to recycled tire paver blocks with hidden interconnectors. The present invention is a cast block being composed at least of a binder and rubber, the rubber being shredded rubber from recycled tires. The present invention is a cast block, and preferably a heat fused, cast paver block, that has a top, a bottom and at least one sidewall, the block having a substantially symmetric shape from a top view (at least symmetric as to one axis), and having at least one protruding male interconnector located on and extending outwardly from the at least one sidewall, and having at least one female interconnector located under the block on its bottom, at least 90 degrees away from the male interconnector as measured in an arc from a centerpoint of the block. The at least one female interconnector is a recess adapted to receive a male interconnector of a similar block. When the paver block male interconnector is inserted into a female interconnector of a similar block, both interconnectors are significantly hidden (at least 90% hidden) from top view. 
         [0013]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, there are at least two male interconnectors and at least two female interconnectors. 
         [0014]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, each male interconnector has a symmetrically opposite female interconnector. 
         [0015]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, the cast block has a top view shape selected from the group consisting of circle, oval, square, rectangle, polygon and combinations thereof. 
         [0016]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, each of the at least one female interconnector includes and open bottom horizontal slot and an upward recess. 
         [0017]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, each of the at least one male interconnector includes an outwardly extending portion and an upcrop extending upwardly. 
         [0018]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, at least one side includes at least two male interconnectors and at least one side includes two female interconnectors. 
         [0019]    In some preferred embodiments of the present invention recycled tire paver block with hidden interconnectors, the block includes at least one embossed design on the top. 
         [0020]    Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings: 
           [0022]      FIG. 1  illustrates a top view of present invention recycled tire paver block having a square configuration with two male interconnectors and two female interconnectors, and  FIGS. 2 and 3  show side and bottom views thereof, respectively.  FIGS. 1 ,  2  and  3  are top, side and bottom views, respectively, of one embodiment of a present invention paver block; 
           [0023]      FIG. 4  shows a partially cut side view of a plurality of present invention recycled tire paver blocks of the type shown in  FIGS. 1 ,  2  and  3  above with adjacent blocks having male and female interconnectors connected to one another; 
           [0024]      FIGS. 5  illustrates a top view of present invention recycled tire paver block having an octagonal configuration with two male interconnectors and two female interconnectors; 
           [0025]      FIG. 6  shows a top view of a paver block insert that may be used with interconnected blocks of the type shown in  FIG. 5 ; 
           [0026]      FIG. 7  shows a partially top view of a plurality of present invention recycled tire paver blocks and inserts of the types shown in  FIGS. 5 and 6  above with adjacent blocks having male and female interconnectors connected to one another; 
           [0027]      FIGS. 8 and 9  show a top view and a side view of a present invention paver block with embossed designs thereon; 
           [0028]      FIG. 10  shows a top view of a plurality of present invention recycled tire paver blocks of the type shown in  FIGS. 8 and 9  above with adjacent blocks having male and female interconnectors connected to one another to create a linear pattern of blocks; 
           [0029]      FIG. 11  shows a top view of one embodiment of a present invention recycled tire paver block having a square configuration with sets of dual interconnectors on each side to allow for either adjacent or half offset adjacent connections; 
           [0030]      FIGS. 12  shows a top view of a plurality of present invention recycled tire paver blocks of the type shown in  FIG. 11  above with adjacent blocks having male and female interconnectors connected to one another to create a staggered pattern of blocks; 
           [0031]      FIG. 13  shows a top view of a plurality of present invention recycled tire paver blocks of circular shape; 
           [0032]      FIGS. 14   a  and  14   b  illustrate identical shifted double rectangle blocks of the present invention; and, 
           [0033]      FIG. 15  shows a plurality of the present invention  FIG. 14   a  and l 4   b  blocks interconnected. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0034]    Used tires are recycled by being macerated mechanically through a series of cutters with increasingly smaller pieces being produced, from full tires, to tires with sidewall beads removed, to 9″ to 12″ pieces, to 3′ to 5″ pieces, down to an inch or less and then to smaller sizes that are tenths of an inch or less. Centrifuges or other processes remove fiber from rubber and magnets remove metal fines. The resulting crumb rubber is utilized as the major constituent in forming the products of the present invention. The crumb rubber is mixed with a binder and the mixture may include other additives, such as colorants and flame retardants. Binders may be thermoset plastics, polyvinyl chloride, urethane or other material, or combinations thereof. 
         [0035]    The crumb rubber and binder (and other constituents, where applicable) are cold blended or hot blended and then molded into the shape of the finished paver blocks of the present invention. The molding process may be hot melt molding and hot pressure molding is preferred. The mixture is poured into an open mold and pressed into the mold with predetermined heat and pressure. The heat is typically below the melting point of the crumb rubber in terms of temperature and exposure time, but in some preferred embodiments, sufficient heating is applied to fuse the binder and crumb rubber particles together. The molded products are ejected or removed from the molds manually or automatically using ejector systems. 
         [0036]      FIG. 1  illustrates a top view of present invention paver block  1 , and  FIGS. 2 and 3  show side and bottom views thereof, respectively. In the  FIGS. 1 ,  2  and  3 , identical elements are identically numbered and these Figures are now discussed collectively. 
         [0037]    Block  1  has a top  3 , a bottom  5 , and sides  7 ,  9 ,  11  and  13 . Top  3  is shown as a smooth flat surface, not could be embossed, painted or otherwise embellished. Two adjacent sides  7  and  9  have male interconnectors  15  and  19 , respectively. These male interconnectors have a tongue portion and a locking upcrop, shown as upcrop  17  and  21  on male interconnectors  15  and  19 , respectively ( FIG. 2  shows the side profile of male interconnector  19 ). 
         [0038]    At about 90° from male interconnector  19  on side  11  is female interconnector  27 . Female interconnector  27  is a slot with a deeper upward recess  29 , adapted to receive a male upcrop, similar or identical to upcrop  21  of male interconnector  19 . Similarly, on side  13  is a second female interconnector  23  with upward recess  25 , likewise adapted to receive a corresponding male interconnector.  FIG. 2  shows an entry view and a side profile of female interconnectors  27  and  23 , and bottom view  FIG. 3  shows the bottom views of these female interconnectors. 
         [0039]    Referring now to  FIG. 4 , there is shown a side view of present invention paver block  1 , in a partial cut view, with identical present invention paver block  10  connected thereto. This Figure shows how the present invention paver blocks interconnect. Block  1  has identical elements identically numbered as above. Block  10  has female interconnectors  12  and  14  and two male interconnectors (are not shown). Male interconnector  16  of block  10  fits into female interconnector  23  of block  1 . In this manner, the two blocks are interlocked and fixed as to relative positions, spacing, angle and cannot easily be separated from one another by sliding or incidental pushing when walked upon. Further, these blocks are available for additional connections on each of their three open (unconnected) sides. End blocks of an array or arrangement may have male interconnectors such as male interconnector  19  or  FIG. 4 , exposed. It may be buried or it may be cut off using a saw, such as sheetrock or gypsum board saw or keyhole saw or using a serrated knife. However, burying exposed male interconnectors could add more stability to end pieces. 
         [0040]      FIG. 5  shows a top view of another present invention paver block  40  made from recycled tire crumb rubber in the process described above. Block  40  has a top  43  with “cut” corners to create an octagon. Thus, block  40  has eight sides, that include major sides  47 ,  49 ,  51 ,  53 , and corner sides  71 ,  73 ,  75  and  77 . Two adjacent major sides  47  and  49  have male interconnectors  55  and  59 , respectively. These male interconnectors have a tongue portion and a locking upcrop, shown as upcrops  57  and  61  on male interconnectors  55  and  59 , respectively ( FIG. 2  shows the side profile of the type of male interconnector used here). At about 90° from male interconnector  59  on major side  59  is female interconnector  67 . Female interconnector  67  is a slot with a deeper upward recess  69 , adapted to receive a male upcrop, similar or identical to upcrop  61  of male interconnector  59 . Similarly, on major side  53  is a second female interconnector  63  with upward recess  65 , likewise adapted to receive a corresponding male interconnector. 
         [0041]      FIG. 6  shows a top view of a paver block insert  50  that would fill in the spaces created when a plurality of blocks of the octagon type of  FIG. 5  are assembled together. Thus, paver insert  50  has four equal sides  83 ,  85 ,  87  and  89  that would be contiguous to four different connected blocks (block  40  of  FIG. 5 ), with top  81  having the same of different characteristics (color, hue, topography, grain size, embossment, print) as the tops of the contiguous present invention paver blocks. 
         [0042]      FIG. 7  shows a top view of a plurality of present invention pavers with the  FIG. 6  type interconnectors, installed. Thus, present invention paver blocks  101 ,  103 ,  105 ,  107  and  109  are similar to block  40  of  FIG. 5  and are all interconnected in a manner similar to that shown in  FIG. 4 . On the outer top and right peripheries of these present invention paper blocks would be unused, extended male interconnectors. However, as indicated above, they could easily be cut or sawed off. Alternatively, they could be left in place and buried such as under earth and grass  100  of  FIG. 7 . 
         [0043]      FIG. 8  shows a top view and  FIG. 9  shows a side view of another present invention paver block  130  made from recycled tire crumb rubber in the process described above.  FIGS. 8 and 9  are now described collectively. Block  130  has a top  131  with a central circular raised embossment design  133  and quarter circle raised corner embossments, such as embossments  135  and  137 . Present invention paver block  130  has four equal sides  139 ,  141 ,  143  and  145 , but these could be unequal in the form, for example, of a rectangle instead of a square. Two adjacent sides  143  and  145  have male interconnectors  151  and  147 , respectively. These male interconnectors have a tongue portion and a locking upcrop, shown as upcrops  153  and  149  on male interconnectors  151  and  147 , respectively ( FIG. 2  shows the side profile of the type of male interconnector used here). At about  900  from male interconnector  147  on side  139  is female interconnector  161  with upward recess  163 . Female interconnector  161  is thus a horizontal slot with a deeper upward recess  163 , adapted to receive a male upcrop, similar or identical to upcrop  153  of male interconnector  151 . Similarly, on side  141  is a second female interconnector  155  with upward recess  157 , likewise adapted to receive a corresponding male interconnector. 
         [0044]      FIG. 10  shows a top view of a plurality of present invention pavers with the  FIGS. 8 and 9  type interconnectors, installed. Thus, present invention paver blocks  130 ,  140 ,  150 ,  160 ,  170  and  180  are the same as block  130  of  FIGS. 8 and 9  and are all interconnected in a manner similar to that shown in  FIG. 4 . On the outer top and left peripheries of these present invention paper blocks would be unused, extended male interconnectors. However, as indicated above, they could easily be cut or sawed off. Alternatively, they could be left in place and buried such as under earth and grass  132  of  FIG. 10 . 
         [0045]      FIG. 11  shows of another present invention paver block  190  similar to the one shown in  FIG. 8  above, except for the interconnector arrangements. This block  190  is made from recycled tire crumb rubber in the process described above. Block  190  has a top  191  with a central circular raised embossment design  193  and quarter circle raised corner embossments, such as embossments  195  and  197 . Any design could be used and the embossment could be raised, recessed or a combination thereof. Present invention paver block  190  has four equal sides  199 ,  201 ,  203  and  205 , but these could be unequal in the form, for example, of a rectangle instead of a square. Each of two adjacent sides  143  and  145  have two male interconnectors  207  and  211 , and  215  and  219 , respectively. These male interconnectors have a tongue portion and a locking upcrop, shown as upcrops  209 ,  211 ,  217  and  223  on male interconnectors  207 ,  213 ,  215  and  219 , respectively ( FIG. 2  shows the side profile of the type of male interconnector used here). 
         [0046]    As can be seen in this  FIG. 11 , the pairs of male interconnectors on a given side are located at about ¼ and ¾ of the length of the side. This positioning allows for staggered (shifted) interconnection, as shown in  FIG. 12  below. At about 90° from male interconnectors  215  and  219  on side  203  are female interconnectors  225  and  229  with upward recesses  227  and  231 . A similar set of female interconnectors (unnumbered) are located on side  199 . All of the female interconnectors are adapted to receive the corresponding male interconnectors of adjacent identical or similar blocks. 
         [0047]      FIG. 12  shows a top view of a plurality of staggered present invention pavers with the  FIG. 11  type dual sets of interconnectors, installed. Thus, present invention paver blocks  190 ,  200 ,  210 ,  220  and  230  are the same as block  190  of  FIG. 11  and are all interconnected, offset by half a length, in a manner similar to that shown in  FIG. 4 . On some of the peripheries of these present invention paper blocks would be unused, extended male interconnectors. However, as indicated above, they could easily be cut or sawed off. Alternatively, they could be left in place and buried such as under earth and grass or any other ground or ground coverings. 
         [0048]      FIG. 13  shows a top view of a plurality of present invention recycled tire paver blocks of circular shape. Each of these blocks has two male and two female interconnectors. Block  240  illustrates the arrangement. It has male interconnectors  243  and  245  and female interconnectors  247  and  249 . These correspond and lock into each other. Thus, blocks  240 ,  250 ,  260  and  270  are connected to one another with the interconnectors, as shown. 
         [0049]      FIGS. 14   a  and  14   b  illustrate identical shifted double rectangle blocks  310  and  320  of the present invention. The blocks are shown in adjacent Figures even though they are identical so that there potential interconnection can be more easily seen. Block  310  in  FIG. 14   a  and block  320  of  FIG. 14   b  each has a top view footprint that is equivalent to two identical rectangles being next to and touching and then staggering one a half length upwardly and away from the other, and hence, is referred to as a shifted double rectangle. Block  310  incluxxx 
         [0050]      FIG. 15  shows a plurality of the present invention  FIG. 14   a  and  14   b  blocks interconnected. 
         [0051]    Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. For example, in some preferred embodiments, before being melted and fused, the shredded rubber from used tires may be intermixed with an appropriate binding material, such as those used in the insides of a baseball, or any other available binder that works with rubber used in tires.