Paving Block with Improved Illumination

Abstract

A paving block with improved illumination (luminescent paving block) preferably includes a concrete base layer and a photoluminescent layer. The photoluminescent layer is formed on top of the concrete base layer. The concrete base layer is preferably created by combining sand, aggregate, water, pigment and cement to form an uncured concrete mixture. The photoluminescent layer preferably includes very fine aggreagate, cement, water, pigment, sand and a polyester resin infused with a photoluminescent pigment or a silica-based glass material infused with photoluminescent pigment. Further, a light transmitting sealant may be placed over the photoluminescent material.

Claims

1. A method of manufacturing a paving block with embedded photoluminescent material. comprising the steps of: mixing sand, aggregate, water and cement to form an uncured concrete mixture; providing at least one of the following: a photoluminescent mixture of a polyester resin infused with a photoluminescent pigment; or a photoluminescent mixture of a silica-based glass material infused with a photoluminescent pigment; curing said photoluminescent mixture, breaking said photoluminescent mixture into randomly sized chips or particles to form photoluminescent fragments; mixing said photoluminescent fragments, sand, cement and water to form an uncured luminescent mixture; providing a paving block mold; pouring said uncured concrete mixture into the paving block mold; and pouring said uncured luminescent mixture to substantially fill said paving block mold.

2. The method of manufacturing a paving block with embedded photoluminescent material of claim 1, further comprising the step of: allowing said contents in said paving block mold to cure for a set period of time in a controlled environment to form a paving block.

3. The method of manufacturing a paving block with embedded photoluminescent material of claim 2, further comprising the step of: grinding a top surface of said paving block to remove excess concrete material and expose a photoluminescent layer.

4. The method of manufacturing a paving block with embedded photoluminescent material of claim 3, further comprising the step of: applying a transmissive sealant to cover said photoluminescent layer.

5. The method of manufacturing a paving block with embedded photoluminescent material of claim 1, further comprising the step of: pouring said photoluminescent mixture into a shallow form to allow it to cure and harden.

6. The method of manufacturing a paving block with embedded photoluminescent material of claim 1, further comprising the step of: firing said silica based glass material infused with said photoluminescent pigment in a kiln.

7. The method of manufacturing a paving block with embedded photoluminescent material of claim 1, further comprising the step of: vibrating said paving block mold on a shaker table.

8. A method of manufacturing a paving block with embedded photoluminescent material, comprising the steps of: mixing sand, aggregate, water and cement to form an uncured concrete mixture; providing a photoluminescent mixture of a polyester resin infused with a photoluminescent pigment; curing said photoluminescent mixture, and breaking said photoluminescent mixture into randomly sized chips or particles to form photoluminescent fragments; mixing said photoluminescent fragments, sand, cement and water to form an uncured luminescent mixture; providing a paving block mold pouring said uncured concrete mixture into the paving block mold; and pouring said uncured luminescent mixture to substantially fill said paving block mold.

9. The method of manufacturing a paving block with embedded photoluminescent material of claim 8, further comprising the step of: allowing said contents in said paving block mold to cure for a set period of time in a controlled environment to form a paving block.

10. The method of manufacturing a paving block with embedded photoluminescent material of claim 9, further comprising the step of: grinding a top surface of said paving block to remove excess concrete material and expose a photoluminescent layer.

11. The method of manufacturing a paving block with embedded photoluminescent material of claim 10, further comprising the step of: applying a transmissive sealant to cover said photoluminescent layer.

12. The method of manufacturing a paving block with embedded photoluminescent material of claim 8, further comprising the step of: pouring said photoluminescent mixture into a shallow form to allow thereof to cure and harden.

13. The method of manufacturing a paving block with embedded photoluminescent material of claim 8, further comprising the step of: firing said silica-based glass material infused with said photoluminescent pigment in a kiln.

14. The method of manufacturing a paving block with embedded photoluminescent material of claim 8 further comprising the step of: vibrating said paving block mold on a shaker table.

15. A method of manufacturing a paving block with embedded photoluminescent material, comprising the steps of: mixing sand, aggregate, water and cement to form an uncured concrete mixture; providing a silica-based glass material infused with said photoluminescent pigment; curing said photoluminescent mixture, and breaking said photoluminescent mixture into randomly sized chips or particles to form photoluminescent fragments; mixing said photoluminescent fragments, sand, cement and water to form an uncured luminescent mixture; providing a paving block mold; pouring said uncured concrete mixture into the paving block mold; and pouring said uncured luminescent mixture to substantially till said paving block mold.

16. The method of manufacturing a paving block with embedded photoluminescent material of claim 15, further comprising the step of: allowing said contents in said paving block mold to cure for a set period of time in a controlled environment to form a paving block.

17. The method of manufacturing a paving block with embedded photoluminescent material of claim 16, further comprising the step of: grinding a top surface of said paving block to remove excess concrete material and expose a photoluminescent layer.

18. The method of manufacturing a paving block with embedded photoluminescent material of claim 17, further comprising the step of: applying a transmissive sealant to cover said photoluminescent layer.

19. The method of manufacturing a paving block with embedded photoluminescent material of claim 15, further comprising the step of: pouring said photoluminescent mixture into a shallow form to allow thereof to cure and harden.

20. The method of manufacturing a paving block with embedded photoluminescent material of claim 15, further comprising the step of: firing said silica-based glass material infused with said photoluminescent pigment in a kiln.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0016] FIG. 1 is a perspective view of a luminescent paving block reflecting light in accordance with the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

[0017] With reference now to the drawing, and particularly to FIG. 1, there is shown a perspective view of a luminescent paving block 1. The luminescent paving block 1 includes a concrete base layer 10 and a photoluminescent layer 12. The photoluminescent layer 12 is formed on top of the concrete base layer 10. The concrete base layer 10 is preferably created by combining sand, aggregate, water pigment and cement to form an uncured concrete mixture. The photoluminescent layer 12 preferably includes very fine aggregate, cement, water, pigment, sand and a polyester resin infused with a photoluminescent pigment or a silica-based glass material infused with photoluminescent pigment. Further, a light transmitting sealant may be placed over the photoluminescent layer 12. In some embodiments of the present invention, the sand in the photoluminescent layer 12 includes at least some photoluminescent sand.

[0018] The photoluminescent pigment preferably includes strontium aluminate doped with europium. The polyester resin is mixed with the strontium aluminate pigment to form a polyester resin mixture. The polyester resin is mixed with the strontium aluminate pigment to form an evenly distributed suspension, and is poured into shallow forms to cure and harden. When the polyester resin mixture is fully cured, the hardened polyester resin mixture is crushed in a hammer-mill or with any other suitable device to create a mixture of randomly sized chips or particles to form polyester resin mixture fragments.

[0019] The silica-based glass material is mixed with the strontium aluminate pigment to form a silica-based glass mixture. The silica-based glass is mixed with the strontium aluminate pigment to form an evenly distributed suspension, and is poured into shallow forms in preparation of firing in a glass kiln. After the silica-based glass mixture is fully fired, the glass is allowed to cure and harden. The fully cooled and cured silica-based glass mixture is then crushed with a hammer-mill or with any other suitable device to create a mixture of randomly sized chips or particles to form silica-based glass fragments.

[0020] The following dimensions are given by way of example and not by way of limitation. When the luminescent paving block has a thickness of about 2⅜ inches. The concrete base layer 10 preferably has a thickness of between 1⅞ to 2⅛ inches. The photoluminescent layer 12 preferably has a thickness of no greater than 0.5 inches. The concrete base layer 10 is created by combining the sand, the aggregate, water, pigment and the cement to form an uncured concrete mixture. The uncured concrete mixture is poured into a paving block mold (not shown) to the preferred height. The concrete base layer 10 is then compressed with a hydraulic press to further drive out any gaps or voids, and to enhance durability of the concrete base layer 10 to enhance its ability to withstand rated loads and environmental forces. The photoluminescent layer 12 is created by combining the very fine aggregate, the sand (which may include photoluminescent sand), the cement, water, pigment, and a polyester resin infused with a photoluminescent pigment or a silica-based glass material infused with photoluminescent pigment to form an uncured photoluminescent mixture. The uncured photoluminescent mixture is poured over the uncured concrete mixture. The photoluminescent layer 12 is then compressed with a hydraulic press to further drive out any gaps or voids, and to enhance durability of the photoluminescent layer 12 to enhance its ability to withstand rated loads and environmental forces. The paving block mold is then vibrated on a shaker table. The shaker table is a device well known in the art, which is designed to agitate the uncured concrete mixture to drive out any gaps, voids or air spaces. Additionally, the cast concrete block 10 is allowed to cure for up to 28 days in a controlled environment. Finally, when fully dry and cured, the paving block 1 is subjected to a light surface grinding, which removes excess concrete material from a top surface and the sand and the polyester resin mixture fragments or the silica-based glass fragments on the surface of the luminescent paving block 1. A light transmissive sealant including a methyl methacrylate or polyurethane material may be applied in the form of spray, after the paving block 1 is ground. The light transmissive sealant is allowed to dry for 24 hours, before the luminescent paving block 1 is ready to be inventoried and shipped.

[0021] While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.