Abstract:
A modular surface element that can be arranged in a running bond pattern with other such modular surface elements. The modular surface element has a configuration comprising a decorative face, an opposed base, and sides extending therebetween generally orthogonal to the base. The sides are proximal to and within a modular perimeter defined by three non-alike pairs of opposed matching segments that are oriented substantially parallel to each other. At least two of the pairs of opposed matching segments are non-linear and at least two of the pairs of opposed matching segments are point symmetric. Optionally, the modular surface element may comprise two or more mating components.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to the field of modular elements for covering a surface. More specifically, the invention relates to a novel shaped modular element for paving or facing surfaces in the form of tiles, pavers, bricks, artificial stones, etc. or for use in puzzles and other toys and games.  
       BACKGROUND OF THE INVENTION  
       [0002]     Walls, floors, ground coverings and other structures are often constructed by fitting irregularly sized and shaped natural stones. The work requires a skilled stonemason to select, cut and fit the stone. It is labor intensive, and accordingly expensive. However, custom-built natural stone surfaces are considered very attractive and desirable.  
         [0003]     Conventional manufactured pavers, bricks, tiles, and so forth, are cheaper and easier to install than natural stone due to their regular geometric shapes, typically squares, rectangles, hexagons, or combinations thereof. These surface coverings are typically laid in repeating patterns, which simplifies installation and therefore decreases labor costs. However, the repeating patterns lack the same aesthetic appeal of irregular natural stone.  
         [0004]     It is known to produce manufactured pavers and other surface elements in shapes that can be laid in repeated patterns that create an effect that somewhat resembles irregular natural stone. For instance, PCT application No. PCT/CA2005/001644 to Castonguay shows such a design. However, the pattern extends radially, an arrangement that is not very well suited for producing elongated structures such as walkways. It can also be difficult for an unskilled person to lay pavers in such a pattern, requiring careful selection and orientation of each element. Furthermore, the shapes that such manufactured surface elements may adopt are somewhat limited, which restricts manufacturing freedom as well as the choices offered to consumers.  
         [0005]     Some known paver designs intended to imitate the look of natural stone, such as the pavers disclosed in U.S. Pat. No. 4,217,740, use a combination of different shapes. However, these require multiple moulds and the stocking of different pieces. Also, such pavers are more complicated to install.  
         [0006]     In addition, some known surface elements intended to imitate irregular natural stones are not well suited for manufacture on pre-existing production boards because their shapes and dimensions do not efficiently fit within the production board, and the dimensions and angles of the surface element cannot readily be modified while still fitting together in the intended pattern.  
         [0007]     Many known designs of modular surface elements are also not suited for installation where it is desired to include internal spacing, such as for water drainage. Some of these designs cannot have open spaces in their pattern without losing necessary support of surrounding stones, while others cannot be laid at all in their intended patterns while accommodating open spaces.  
         [0008]     Certain playthings, such as puzzles, also comprise a collection of elements that can be arranged so as to cover a surface. In some cases it may be desirable to lay out such elements in a variety of arrangements. However, the pieces of common picture puzzles and similar known playthings are intended to fit together in only one arrangement.  
       SUMMARY OF THE INVENTION  
       [0009]     It is an object of the present invention to provide a modular surface element that overcomes or mitigates one or more disadvantages of known modular surface elements, or at least provides a useful alternative.  
         [0010]     In accordance with an embodiment of the present invention, there is provided a modular surface element that can be arranged in a running bond pattern with other such modular surface elements. The modular surface element has a configuration comprising a decorative face, an opposed base, and six sides extending therebetween generally orthogonal to the base. The sides are proximal to and within a modular perimeter defined by three non-alike pairs of opposed matching segments that are oriented substantially parallel to each other. At least two of the pairs of opposed matching segments are non-linear while at least two of the pairs of opposed matching segments are point symmetric. The third of the pairs of opposed matching segments may also be point symmetric. Alternatively, the third of the pairs of opposed matching segments is non-point symmetric.  
         [0011]     Each pair of the contiguous segments may form an obtuse angle. Alternatively, each of two pairs of the contiguous segments forms an angle of approximately 180° and each of the other pairs of contiguous sides forms an angle of approximately 90°. As another alternative, each of two pairs of the contiguous segments forms an angle greater than 180° and each of two other pairs of the contiguous sides forms an angle of less than 90°.  
         [0012]     All six of the segments may be non-linear. The face may include grooves resembling joints between areas of the face. The sides may have projecting regions that align more closely to the segments of the modular perimeter. Optionally, the projecting regions of the sides are adjacent to the base. The projecting regions of the sides may be near the ends of the segments. It is possible to have the sides and the decorative face define edges that are irregularly recessed from the segments of the modular perimeter. Optionally, the modular surface element is made of at least two pieces.  
         [0013]     In accordance with another embodiment of the present invention, there is provided a surface covering system comprising a multiplicity of modular surface elements as previously described where the modular surface elements are substantially congruent and arranged in aligned rows in a running bond pattern. A plurality of adjacent modular surface elements in one of the aligned rows may be positioned with respect to an adjacent row such as to create open spaces, so as for example to provide drainage. Optionally, several renditions of modular surface elements are distinguished by having different decorative faces.  
         [0014]     In accordance with yet another embodiment of the present invention, there is provided a pair of substantially identical components assemblable into a modular surface element as previously defined. The components have mating sides that are point symmetric and that pass through the geometric center of such an assembled modular surface element of said pair of components. Advantageously, each said mating side is non-linear.  
         [0015]     The invention provides the advantages of being easy to install because it requires only one type of manufactured stone that is designed to match perfectly when installed in running bond pattern. Because of the seaming irregularity of its shape, and features such as false joints and variation in the appearance of its face, the manufactured stone of the present invention may be assembled to produce a surface covering that closely resembles the look of natural stone. Using the same design principle, many different shapes of manufactured stones may be produced, which enhance customer choice and offers manufacturers great flexibility. Moreover, the manufactured stone of the present invention may easily be installed without modification so as to provide internal spacing for water drainage or other purposes. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0016]     These and other features of the present invention will become more apparent from the following description in which reference is made to the appended drawings wherein:  
         [0017]      FIG. 1  is a top view of a modular surface element in accordance with an embodiment of the present invention.  
         [0018]      FIG. 2   a  to  2   c  are top views of a portion of such a modular surface element showing the steps for creating segments of the perimeter of the modular surface element of  FIG. 1 .  
         [0019]      FIG. 3  is a top view of a modular surface element in accordance with another embodiment of the present invention;  
         [0020]      FIGS. 4   a  and  4   b  are top views of patterns created using modular surface elements similar to the modular surface element of  FIG. 1 .  
         [0021]      FIG. 5  is a top view of a pattern created using modular surface elements similar to the modular surface element of  FIG. 3 .  
         [0022]      FIG. 6   a  to  6   d  are top views of examples of patterns created using modular surface elements similar to the modular surface element of  FIG. 1 .  
         [0023]      FIG. 7   a  to  7   c  are top views of examples of patterns created using modular surface elements similar to the modular surface element of  FIG. 3 .  
         [0024]      FIG. 8  is a top view of a pattern having water drainage spaces made of modular surface elements similar to the modular surface element of  FIG. 1 .  
         [0025]      FIG. 9  is a top view of another pattern made having water drainage spaces made of modular surface elements similar to the modular surface element of  FIG. 1 .  
         [0026]      FIG. 10  is a top view of a portion of a manufactured paver superposed within the modular perimeter of a modular surface element similar to that of  FIG. 1 .  
         [0027]      FIG. 11  is a perspective view of a manufactured paver in accordance with another embodiment of the invention.  
         [0028]      FIG. 12  is a top view of a pattern made with a plurality of manufactured pavers similar to that of  FIG. 11 .  
         [0029]      FIG. 13  is a top view of a pattern made with manufactured pavers in accordance with another embodiment of the invention.  
         [0030]      FIG. 14  is a top view of manufactured pavers in accordance with another embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]     The present invention may be used in a wide variety of industries, ranging from manufactured stones, pavers, floor and wall coverings to puzzles and other games. The invention provides a way of designing an element for the applications so that once a multitude of such elements are installed in a pattern, the pattern looks random and the elements do not look similar.  
         [0032]      FIG. 1  depicts a modular surface element  1  having a modular perimeter  10  made of six contiguous segments,  12 ,  12 ′,  14 ,  14 ′,  16  and  16 ′ organized in three pairs of matching segments. The segments  12  and  12 ′ form a first pair of matching segments, the segments  14  and  14 ′ form a second pair of matching segments, and the segments  16  and  16 ′ form a third pair of matching segments. The two segments of each pair ( 12  and  12 ′;  14  and  14 ′; and  16  and  16 ′) are parallel to each other, that is an imaginary line  13  joining both extremities of a segment is parallel to a similar imaginary line  13 ′ joining both extremities of the paired segment. Moreover, both segments of a pair of matching segments are opposed to each other, that is they are located at opposed sides of the modular surface element  1  such that they cannot be contiguous. The end result is that, viewed counter-clockwise, segment  12  is contiguous to segment  14 , which is contiguous to segment  16 , which is contiguous to segment  12 ′, which is contiguous to segment  14 ′, which is contiguous to segment  16 ′, which is contiguous to segment  12  thereby closing the modular perimeter  10 . Another way of expressing it is that each segment of the first pair of matching segments  12 ,  12 ′ is connected at one end to one segment of the second pair of matching segments  14 ,  14 ′ and at its other end to one segment of the third pair of matching segments  16 ,  16 ′.  
         [0033]     The modular surface element  1  is created by defining its modular perimeter  10  according to a set of design rules. In a first embodiment of the invention, the segments  12 ,  12 ′,  14  and  14 ′ have point symmetry. Point symmetry exists when a segment is built around a single point called the central point. For every point in the segment, there is another point found at the same distance from the central point, but in the opposite direction. A segment that is point symmetric is unchanged in appearance by a 180 degree rotation. In order to achieve point symmetry, the segments are built in a specific manner. Each segment is built of two identical portions. As shown in  FIG. 1 , segments  12  and  12 ′ are each made of portions  12   a  and  12   b , and segments  14  and  14 ′ are each made of portions  14   a  and  14   b . A portion is defined as the portion of a segment extending from its central point to one of its extremities.  
         [0034]      FIGS. 2   a  to  2   c  depict the steps to create a segment having point symmetry. In  FIG. 2   a , a portion  18  of length X/2 is defined by a set of continuous lines or curves. In  FIG. 2   b , a copy of portion  18  is rotated 180° around extremity  20  of portion  18  to form portion  18 ′. The extremity  20  then becomes the central point. Portion  18  and portion  18 ′ define segment  21  of length X. This is how the segments are constructed to be point symmetric. This also defines the opposed segment of the matching pair of segments because both are substantially identical. Segments  12 , 12 ′ and  14  and  14 ′ are constructed this way.  
         [0035]     Referring again to  FIG. 1 , segment  14  is joined at an extremity to segment  12  and segments  14 ′ and  12 ′ are similarly joined such that in a plane, the pair of identical segments  12 - 12 ′ have the same orientation and are spaced apart from each other. Various angles R may be chosen. Similarly, the pair of matching segments  14 - 14 ′ must also be placed in the same orientation and spaced apart from each other. The pairs of matching segments  12 - 12 ′ and  14 - 14 ′ may be placed anywhere in a plane as long as they are oriented similarly and spaced apart from each other. Segment  16  is then created by joining the free extremity of segment  14  to the free extremity of segment  12 ′. Various paths may be given to segment  16 . Segment  16 ′ matches segment  16  and similarly joins the free extremity of segment  14 ′ to the free extremity of segment  12 . Segments  16  and  16 ′ must have the same orientation to each other. However, in this first embodiment, there is no requirement that matching segments  16  and  16 ′ have point symmetry.  
         [0036]     As seen in  FIG. 3 , in a second embodiment, segments  12 ,  12 ′,  14 , and  14 ′, are similar to those of the first embodiment but whereas the segments  16  and  16 ′ did not have point symmetry, segments  316  and  316 ′ do have point symmetry. This yields different attributes to the modular surface elements  1  defined by the first and second embodiments.  
         [0037]     In both embodiments, the segments  12 ,  12 ′,  14 ,  14 ′,  16 ,  16 ′,  316  and  316 ′ may either be linear (a straight line) or non-linear. As will be discussed later on, for the intended purpose, it is sufficient that the segments of a pair of segments be matching. Indeed, for the intended purposes, each pair of matching segments may be slightly different and still match when two adjacent modular surface elements are placed together.  
         [0038]      FIGS. 1, 4  and  6   a - 6   d  depict the type of modular surface element of the first embodiment of the invention where segments  16  and  16 ′ do not have point symmetry, while  FIGS. 3, 5  and  7   a - 7   c  depict the type of modular surface element of the second embodiment where the segments  316  and  316 ′ have point symmetry.  
         [0039]      FIGS. 4   a  and  4   b  show examples of patterns made with the type of modular surface element  1  of the first embodiment. The modular surface elements  1  are assembled in running bond, meaning offset contiguous courses or rows, as opposed to the complex radial patterns of some of the modular surface elements of the prior art. It will be appreciated, by comparing  FIGS. 4   a  and  4   b , that in the first embodiment, the modular surface elements  1  of a complete row may be turned 180°. Reference points  22  indicate the orientation of the modular surface elements. It is to be noted that the modular surface elements  1  may not be rotated 180° individually, but only on a row by row basis.  
         [0040]     Similarly,  FIG. 5  depicts an example of a pattern made with the type of modular surface elements  1  of the second embodiment. The modular surface elements  1  of this second embodiment, with all of their 6 segments having point symmetry, may be rotated 180° on an individual basis. Again, reference points  22  demonstrate how the surface elements may be placed in different orientations.  
         [0041]      FIGS. 6   a  to  6   d  show examples of patterns created with modular surface elements  1  according to the first embodiment (in pairs of matching segments does not have point symmetry) while  FIGS. 7   a  to  7   c  show which one of the three examples of patterns created with the type of modular surface elements  1  of the second embodiment where all three of the pairs of matching segments have point symmetry.  
         [0042]     Some installations of modular surface elements  1  may require that adequate water drainage be provided. In the prior art, this is mostly provided by either removing a modular surface element, or part of it, from a pattern or by spacing two adjacent modular surface elements. Very often, the drawback of doing so is that as a result the modular surface element does not have the complete support from surrounding modular surface elements and is prone to stability problems when subjected to a vertical load that is offset from the modular surface element&#39;s center. This is especially the case when the modular surface element is a manufactured stone for a driveway, for instance. When no gap is present, the surrounding modular surface elements provide support to the modular surface element under load, but if a space is left, for instance with a rectangular modular surface element, the loaded modular surface element loses its support on one side and becomes unstable under load.  
         [0043]     Shown in  FIG. 8  is a pattern made of the modular surface element  1  of the present invention. The modular surface elements  1  of the third row  103  have been shifted left with respect to the modular surface elements  1  of the first and second rows  101  and  102 . This has created open spaces  106  and  108 , adequate for water drainage. Similarly, the fourth and fifth rows  104  and  105  have been shifted right with respect to the third row  103 . This creates open spaces  110  and  112 , which do not have to be exactly the same as open spaces  106  and  108 , further adding to the natural aspect of the pattern.  FIG. 9  shows that even with open spaces on each side of a row, the modular surface element  1  is still supported by surrounding modular surface elements  116 , as evidenced by arrows  118 .  
         [0044]      FIG. 10  depicts a portion of a manufactured paver  111  whose sides  115  closely follow a modular perimeter  10  similar to that of the previously described surface element  1  in accordance with the present invention. However, the sides  115  of the paver  111  deviate somewhat within the envelope defined by the modular perimeter  10 . Moreover, although the sides  115  of the paver  111  are generally orthogonal to its base, they have irregularly beveled edges at their top. In manufactured stones, for example, such irregular beveled edges are often used to add to the rugged, natural appearance of the manufactured stone. Consequently, the spaces created between two manufactured paver  111  can vary in width, further adding to the natural aspect of the pattern. It will be understood that as long as the sides  115  remain inside the modular perimeter  10 , there is no risk of interference with similar adjacent manufactured pavers  111  when laid out in a running board pattern.  
         [0045]     Reference is now made both to  FIG. 10  and  FIG. 11 . To facilitate even spacing during installation of the manufactured pavers  111  and other surface elements  119  having a modular perimeter  10  as per the present invention, it is possible to add spacers  120  molded in the manufactured pavers  111  having the shape of the modular surface element  1 . Spacers  120  are positioned on the vertices  124  joining two contiguous segments. Preferably, the spacers  120  should substantially locally follow the modular perimeter  10 , as highlighted in  FIG. 10 . This facilitates alignment and support between adjacent manufactured pavers  111 .  
         [0046]     Adding to the natural appearance of the modular surface element  1 , it is also possible to include false joints  122  as shown in  FIGS. 11 and 12 . A modular surface element system may even include modular surface elements  1  having different shapes of false joints to create an even more natural-looking array.  
         [0047]     It is also possible to completely divide a modular surface element  400  made in accordance with the present invention into two (or more) pieces such as components  401  and  403 , shown in  FIG. 13 . Components  401  and  403  may be reassembled so as to form the shape of the modular surface element  400 . Spacers may be added to each of the components  401  and  403  in corresponding areas of the division  402 . The division  402  may be linear so as to facilitate the installation of the modular surface elements  1  along a linear border by the use of individual components  401  or  403  as needed.  
         [0048]      FIG. 14  depicts a variation where the division  402  is point symmetric, either being linear or non-linear, and passes through the geometric center  404  of the modular surface element  400 . Because the division  402  passes through the geometric center  404 , it divides each opposite segment of one pair of matching segments at the same corresponding place. For example, in the present case, matching segments  406  are divided in partial segments  406   a  and  406   b.    
         [0049]     It follows that the modular surface element  400  can be divided into a pair of substantially identical components  410 ,  412  that can be assembled to produce the modular surface element  400  by bringing them together along their point symmetric mating sides  414 ,  416  defined by a point symmetric division  402  that passes through the geometric center  404  of the modular surface element  400 . Splitting the modular surface element  400  this way is advantageous as it creates two identical components  410 ,  412  each having half the size and half the weight of the modular surface element  400 . They can therefore be more easily manipulated than the modular surface element  400  while still retaining the advantage of requiring only one overall shape for all of the pavers.  
         [0050]     It will be readily apparent that the modular surface element  1  of the present invention may be molded so as to provide a decorative top surface that closely resembles, in form, texture and color, the appearance of natural stone. Adding different geometries of false joints further enhance the natural aspect of the modular surface element  1 .  
         [0051]     Moreover, the same modular surface element system may be used to create puzzles or other games and playthings, which have a particular level of difficulty since some parts may fit upside-down.  
         [0052]     The present invention has been described with regard to preferred embodiments. The description as much as the drawings were intended to help the understanding of the invention, rather than to limit its scope. It will be apparent to one skilled in the art that various modifications may be made to the invention without departing from the scope of the invention as described herein, and such modifications are intended to be covered by the present description.