Patent Publication Number: US-2005136148-A1

Title: Concrete block configuration and method of using the same

Description:
FIELD OF THE INVENTION  
      The present invention relates to concrete walkways, and more particularly, to preformed concrete walkways.  
     BACKGROUND OF THE INVENTION  
      Walkways and patios are typically formed of concrete, brick pavers, or stone. Concrete surfaces must be formed, poured, and trowelled to a desired finish by a skilled artisan. Also, concrete surfaces can lack style, feel, and elegance. Brick paver surfaces require careful positioning of many small bricks on a compacted slag or earth surface. This construction can be very time consuming. Also, the brick pavers can be prohibitively expensive. Stone surfaces, such as flagstone or fieldstone, require careful selection and positioning of random stones. While such stone surfaces can be elegant, construction can be prohibitively time-consuming.  
     SUMMARY OF THE INVENTION  
      The present invention provides a method of assembling and constructing a hard surface covering, such as a walkway or patio. The first step is to select a pattern. The next step is to position a plurality of stone cells having distinct geometries relative to each other in accordance with a fixed configuration. The fixed configuration is defined by the distinct geometries of the stone cells. The positioned stone cells define a unit. Subsequently, another plurality of stone cells are positioned relative to each other in accordance with the same fixed configuration. This plurality of stone cells also defines a unit. This unit is positioned generally adjacent to the first unit according to the pre-selected pattern. Further pluralities of stone cells, which define further units, are positioned in accordance with the pre-selected pattern to create the desired walkway or patio.  
      In a further aspect of the present invention, the stone units each include a lateral edge having a first dimension and a longitudinal edge having a second dimension. The second dimension is approximately wholly divisible by the first dimension. In yet a further aspect of the present invention, each of the stone units include four distinct stone cells. In yet a further aspect of the present invention, each of the stone cells are molded of concrete to resemble natural stone, such as fieldstone or flagstone.  
      Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
       FIG. 1  is a perspective view of a concrete mold in accordance with the present invention;  
       FIG. 2  is an elevational view of a stone unit in accordance with the present invention;  
       FIG. 3A  is a top elevational view of a first embodiment of an assembly step in accordance with the present invention;  
       FIG. 3B  is a top elevational view of a second embodiment of an assembly step in accordance with the present invention;  
       FIG. 4A  is a top elevational view of a first embodiment of a pattern in accordance with the present invention;  
       FIG. 4B  is a top elevational view of a second embodiment of a pattern in accordance with the present invention;  
       FIG. 4C  is a top elevational view of a third embodiment of a pattern in accordance with the present invention;  
       FIG. 4D  is a top elevational view of a fourth embodiment of a pattern in accordance with the present invention; and  
       FIG. 4E  is a top elevational view of a fifth embodiment of a pattern in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the scope of the invention, its application, or its uses.  
       FIG. 1  illustrates a mold  10  for constructing a surface covering in accordance with the present invention. The mold  10  generally includes a body  12 , which has a working surface  14  and a plurality of cavities  16   a ,  16   b ,  16   c , and  16   d . The mold also has a network of walls  15  disposed between the body  12  and the working surface  14 . The walls  15  have a base portion attached to the body  12  and a top portion mating with the working surface  14 . The top portion is slightly narrower than the base portion such that the walls  15  are inclined. The walls  15  define the cavities  16   a ,  16   b ,  16   c , and  16   d  to be distinctly shaped in a plane common with the working surface  14 . In an exemplary embodiment, the cavities  16   a ,  16   b ,  16   c  and  16   d  are textured to impress a material contained therein. In an exemplary embodiment, the mold  10  has four cavities.  
      During use, the cavities  16   a ,  16   b ,  16   c , and  16   d  are filled with a moldable material. In an exemplary embodiment, the cavities  16   a ,  16   b ,  16   c , and  16   d  are filled with standard concrete. In an alternative embodiment, the moldable material may be dyed to reflect different types of stone. In yet an alternative embodiment, the cavities  16   a ,  16   b ,  16   c , and  16   d  may be sprinkled with an abrasive material, such as sand, prior to filling them with moldable material. The abrasive material would provide for enhanced traction on the walking surface of the stones. The moldable material is then allowed to harden. This creates a plurality of corresponding stone cells  18   a ,  18   b ,  18   c , and  18   d . The stone cells  18   a ,  18   b ,  18   c , and  18   d  are then removed from the cavities  16   a ,  16   b ,  16   c , and  16   d . The inclined network of walls  15  in the mold  10  help in removing the cells  18   a ,  18   b ,  18   c , and  18   d . The inclined network of walls  15  also provide the cells  18   a ,  18   b ,  18   c  and  18   d  with inclined sides. The inclined sides of the walls provide for a walkway or patio free from sharp corners or edges.  
       FIG. 2  illustrates a first plurality of stone cells  18   a ,  18   b ,  18   c , and  18   d  in accordance with the present invention. The stone cells  18   a ,  18   b ,  18   c , and  18   d  are assembled according to a fixed configuration. The fixed configuration is a product of the distinct geometries of the cells  18   a ,  18   b ,  18   c , and  18   d . The first cell  18   a  includes a lateral edge  60 , a longitudinal edge  61 , a first concave edge  62 , and a second concave edge  64  having a first leg  65  and a second leg  66 .  
      The second cell  18   b  includes a longitudinal edge  68 , a first convex edge  70 , a second convex edge  72 , and a concave edge  74 . The first convex edge  70  of the second cell  18   b  is interpositioned with and received by the concave edge  62  of the first cell  18   a.    
      The third cell  18   c  includes a first longitudinal edge  76 , a lateral edge  78 , a second longitudinal edge  80 , and a concave edge  82  having a first leg  77  and a second leg  79 . The first leg  77  of the concave edge  82  of the third cell  18   c  is interpositioned with the concave edge  74  of the second cell  18   b.    
      The fourth cell  18   d  includes a longitudinal edge  84 , a first convex edge  86 , a concave edge  88 , and a second convex edge  90 . The first convex edge  86  of the fourth cell  18   d  is interpositioned with and received by the first leg  65  of the second concave edge  64  of the first cell  18   a . The concave edge  88  of the fourth cell  18   d  is interpositioned with and in receipt of the second convex edge  72  of the second cell  18   b  and the second leg  66  of the concave edge  64  of the first cell  18   a . The second convex edge  90  of the fourth cell  18   d  is interpositioned with and received by the second leg  79  of the concave edge  82  of the third cell  18   c.    
      The assembled stone cells  18   a ,  18   b ,  18   c , and  18   d  define a first stone unit  20 . The first stone unit  20  is generally rectangular in shape and has first and second lateral edges  22 ,  24  of a first dimension and first and second longitudinal edges  32 ,  34  of a second dimension. The first lateral edge  22  is generally defined by lateral edge  60  of the first cell  18   a . The second lateral edge  24  is generally defined by the lateral edge  78  of the third cell  18   c . The first longitudinal edge is generally defined by the longitudinal edge  68  of the second cell  18   b  and the first longitudinal edge  76  of the third cell. The second longitudinal edge  34  is generally defined by the second longitudinal edge  80  of the third cell  18   c , the longitudinal edge  84  of the fourth cell  18   d , and the longitudinal edge  61  of the first cell  18   a . The second dimension of the stone unit  20  is approximately wholly divisible by the first dimension. In an exemplary embodiment, the second dimension is approximately twice the first dimension.  
       FIGS. 3A and 3B  illustrate further assembly of the surface covering in accordance with the present invention. Subsequent to the first stone unit  20  being assembled, further stone units are assembled. A second plurality of stone cells  28   a ,  28   b ,  28   c , and  28   d  are generally identical to the first plurality of stone cells  18   a ,  18   b ,  18   c , and  18   d  because they are constructed from the same mold  10 . Also, the second plurality of stone cells  28   a ,  28   b ,  28   c , and  28   d  are assembled in accordance with the same fixed configuration as the first plurality of stone cells  18   a ,  18   b ,  18   c , and  18   d . The assembled second plurality of stone cells  28   a ,  28   b ,  28   c , and  28   d  define a second stone unit  40 . The second stone unit  40  is generally identical to the first stone unit  20 . The second stone unit  40  is generally rectangular in shape and has lateral edges  42 ,  44  of a first dimension and longitudinal edges  52 ,  54  of a second dimension. The second stone unit  40  is assembled generally adjacent to the first stone unit  20  in accordance with a pre-selected pattern.  
      In an exemplary embodiment, a longitudinal edge  52  of the second stone unit  40  is positioned generally adjacent to a longitudinal edge  34  of the first stone unit  20 , as shown in  FIG. 3A . In an alternative exemplary embodiment, a lateral edge  42  of the second stone unit  40  is positioned generally adjacent to a longitudinal edge  34  of the first stone unit  20 , as shown in  FIG. 3B . It should be appreciated that alternative positions for the second stone unit  40  are intended to be within the scope of the present invention.  
       FIGS. 4A-4E  illustrate a plurality of alternative patterns attainable with the surface covering of the present invention.  FIG. 4A  illustrates a double crosshatch pattern.  FIG. 4B  illustrates a double running pattern.  FIG. 4C  illustrates a herringbone pattern.  FIG. 4D  illustrates a single running pattern.  FIG. 4E  illustrates an alternating single/double crosshatch pattern. It should be appreciated that the patterns illustrated herein are merely exemplary. Alternative patterns are intended to be within the scope of the present invention. The pre-selected pattern is assembled with a plurality of stone units  20 ,  40 , as described above, to construct a walkway or patio.  
      The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within its scope. Such variations are not to be regarded as a departure from the spirit and scope of the invention.