WATER PERMEABLE PAVER

Abstract

A paver system for paving a surface is provided. The paver system includes a plurality of cells interconnected to form a grid. The cells generally include six walls to form a hexagonal shape. The cells share at least two walls with adjacent cells, wherein the grid is arranged having parallel rows and columns of cells defining a parallelogram shaped grid. The grid defines four sides, wherein adjacent sides are not at a right angle, wherein select cells may have one or more walls which include a flexible expansion node, and wherein the cells are adapted to receive a filler.

Claims

1. A paver system for paving a surface, comprising: a plurality of cells interconnected to form a grid, the cells generally include six walls to form a hexagonal shape, the cells share at least two walls with adjacent cells, wherein the grid is arranged having parallel rows and columns of cells defining a parallelogram shaped grid, the grid defining four sides, wherein adjacent sides are not at a right angle, wherein select cells may have one or more walls which include a flexible expansion node, and wherein the cells are adapted to receive a filler.

2. The paver system of claim 1, wherein flexible expansion node extends from a flexible wall of a cell, wherein the wall is interrupted to form a first and second short wall, the first and second short wall extend from adjacent vertices of the cell and form a gap between ends of the first and second short wall, the flexible expansion node extends from the flexible wall and is surrounded by the walls of a cell.

3. The paver system of claim 2, wherein the flexible expansion node includes a curved wall forming a horse-shoe or U-shape like structure.

4. The paver system of claim 1, wherein at least a majority of the cells include a filler, the filler includes tumbled rubber chips and a binder, wherein the filler provides a tortuous path extending through the filler.

5. The paver system of claim 1, wherein the cells include at least one retention tab extending from a wall in a generally horizontal direction and from a location spaced apart from the top edge and bottom edge of the cell wall, wherein the retention tab is adapted to retain the filler within the cell.

6. The paver system of claim 1, wherein a plurality of the cells include an anchor flange, the anchor flange extends horizontally between opposing facing walls from a bottom edge of the walls, an opening is located in the anchor flange and adapted to receipt a spike or other fastener to secure the paver system.

7. The paver system of claim 1, wherein the walls of the cells have a thickness, and the majority of the walls have a first thickness, and walls along a perimeter of the grid have a second thickness, wherein the second thickness is approximately half of the first thickness.

8. The paver system of claim 1, wherein two sides of the grid include locking tabs extending from an exterior side of a wall, and the other two sides of the grid include locking slots extending through a wall, wherein the locking tabs of one grid are received by respective locking slots of another grid.

9. The paver system of claim 8, wherein a shroud extends from the interior side of the wall having a locking slot and over the locking slot, wherein the bottom of the shroud is open to allow the locking slot to receive a respective locking tab.

10. The paver system of claim 1, wherein the upper edge of cells and flexible expansion nodes include a notch, wherein notches are aligned to form two rows of aligned notches, and each of the pair of aligned rows of notches receives a divider bar, each divider bar extends down to approximately the bottom of the cell, pairs of aligned divider bars form a straight row, for receiving filler between the pair of divider bars, wherein the filler has a different characteristic from the filler on the other side of the pair of divider bars.

11. The paver system of claim 10, wherein the divider bars include a first end and a second end, each end includes a tang to be received by a notch in the upper edge of a cell, and between the first end and second end are a plurality of slots spaced apart for being received by a respective notch in the upper edge of cell walls, and wherein the area within each cell which may receive a divider bar is void of structure which would impede with receiving a divider bar.

12. The paver system of claim 1, wherein the grid is formed by an odd number of rows of cells and an odd number of columns of cells, and the center row and the center column each include a plurality of flexible expansion nodes arranged symmetrically and wherein the grid is defined into four quadrants.

13. The paver system of claim 1, wherein the grid is formed by an odd number of rows of cells and an odd number of columns of cells, and wherein the cell located in the center of the grid includes a flexible expansion node in each of the six walls in a symmetrical arrangement.

14. The paver system of claim 1, wherein two sides of the grid include a plurality of anchor tabs extending horizontally from a lower edge of a cell wall, each anchor tab includes an opening for receiving an anchor stake.

15. The paver system of claim 1, wherein the grid is formed from molded plastic.

16. A method of manufacturing a paver system, the method comprises: forming a grid having a plurality of interconnected cells, the cells include retention tabs; creating a filler by tumbling rubber chips with an adhesive; adding filler to at least a majority of the cells; and installing one or more grids over a prepared surface.

17. The method of claim 16, further comprising inserting pairs of divider bars into the grid to form the outline of a desired stripe; and adding a filler of a contrasting color into the cells or portion of cells located between the pair of divider bars.

18. The method of claim 16, further comprising the step of installing one or more grids which include cells without a filler; and adding soil to empty cells which extend into a green space.

19. The method of claim 16, including creating a filler on the job site by tumbling rubber chips with an adhesive; and adding filler to cells as desired.

20. The method of claim 16, further comprising trimming a grid as desired; and installing the trimmed grid over a prepared surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1A is a top view of the grid of the water permeable paver in accordance with a first embodiment of the present invention.

[0011] FIGS. 1B and 1C are side views of the grid of FIG. 1

[0012] FIG. 2 is a perspective view of the grid of FIG. 1

[0013] FIG. 3 is a partial perspective view of the grid of FIG. 1.

[0014] FIG. 4A is a top view of a cell shown in isolation having a flex node extending from opposing walls of the cell.

[0015] FIG. 4B is a partial perspective view of the cell shown in FIG. 6A.

[0016] FIG. 5A is a top perspective view of a cell shown in isolation from the grid and having a locking tab.

[0017] FIG. 5B is a bottom perspective view of a cell shown in FIG. 5A.

[0018] FIG. 5C is a bottom view of a cell shown in FIG. 5A

[0019] FIG. 6A is a top perspective view of a cell shown in isolation from the grid and having a locking pocket and slot.

[0020] FIG. 6B is a bottom perspective view of a cell shown in FIG. 6A.

[0021] FIG. 6C is a bottom view of a cell shown in FIG. 6A.

[0022] FIG. 7 shows a top view of four grids of FIG. 1 interconnected.

[0023] FIGS. 8A and 8B are top views of a portion of the grids shown in FIG. 7.

[0024] FIG. 9 is a perspective view of divider

[0025] FIG. 10 is a top view of the grid of FIG. 1 including a plurality of the dividers shown in FIG. 9.

[0026] FIG. 11A is a plan view of several cells of the grid of FIG. 1, wherein two cells are shown with a filler.

[0027] FIG. 11B is a sectional side view taken along the line 11B-11B shown in FIG. 11A.

[0028] FIG. 12 is a perspective view of a stake such as those shown in FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

[0029] FIG. 1A is a top view of the grid or frame 10 of the water permeable paver system in accordance with a first embodiment of the present invention. FIGS. 1B and 1C are side views of the grid 10 of FIG. 1. The grid is shown prior to installation and prior to a filler 12 being added. The grid is arranged having parallel rows 14 and columns 16 of cells 18 defining a parallelogram shaped grid. The grid defines four sides 20, 22, 24, 26, wherein adjacent sides are not at a right angle. The cells are adapted to receive a filler.

[0030] The top view depicts that the grid 10 includes seven columns 16 of cells with seven rows 14 of cells. The rows extend at an angle with respect to the columns. In one embodiment, the length 28 of a row of seven cells is about 19.60 inches, and the width 30 of the grid is about 17.78 inches and the length 32 about 28.00 inches. The height 34 of the cells may be about 1.75 inches. Of course, the invention is not limited to these dimensions. The grid includes a plurality of hexagonal cells 18 formed by six walls 36, 38, 40, 42, 44, 46, wherein at least two walls of each cell 18 are shared with an adjoining cell. Cells in the center generally share six walls with six surrounding and adjoining cells. Cells along the side may share four walls with four surrounding and adjoining cells. Cells at the four corners may share only two walls.

[0031] The hexagonal cells 18 provide the structural and compressive strength that is required for load bearing and durability. Merely as exemplary, in one embodiment, the width 48 of the cell across opposing walls is about 2.94 inches.

[0032] The cell 18 walls have a thickness. The majority of cells have walls with a first thickness 50. The cells along the four sides include walls that are not shared with another cell. Rather, it is anticipated that these walls will be arranged in facing engagement with similar walls of another grid 10 installed adjacent one another. These walls have a second thickness 52 which is approximately half the thickness of the first thickness.

[0033] Select cells may have one or more walls which include a flexible expansion node 54. The flexible expansion node includes a flexible wall 56 which extends from a cell wall. The cell wall is interrupted to form a first and second short wall 58, 60, the first and second short wall extend from adjacent vertices 62 of the cell and form a gap 64 between ends of the first and second short wall, the flexible expansion node 54 extends from the ends of the first and second short wall. As seen, the flexible expansion node 54 is surrounded by the walls of a cell. That is, the flexible expansion node 54s are located within the area defined by the cell walls.

[0034] FIG. 2 is a perspective view of the grid 10 of FIG. 1. FIG. 3 is a partial perspective view of the grid of FIG. 1. FIG. 4A is a partial top view of a cell shown in isolation having a flexible expansion node 54 extending from opposing walls of the cell. FIG. 4B is a partial perspective view of the cell shown in FIG. 6A. The flexible expansion node 54 is formed by the flexible wall 56, wherein the flexible wall may form a horse-shoe shape, a U-shape, or other configuration which allow the flexing of the expansion node 54 as well as the surrounding cell and portions of the grid. Such flexing will allow the grid to remain durable when subjected to stress and movement, including extreme temperature changes and associated freezing and thawing. The expansion nodes and arrangement of the cells allow expansion and contraction and load bearing, preventing distortion of the grid and maintaining the alignment of the grid.

[0035] FIGS. 1-3 show that not all cells include a flexible expansion node. In the embodiment shown in FIG. 1, only the cells located in the center row and column include flexible expansion nodes. This arrangement divides the grid 10 into four quadrants 66, 68, 70, 72. At the center of the grid is a flex cell 74 having a flexible expansion node 54 extending from each of the six walls and into the cell area of adjacent cells. The arrangement provides a symmetry which enhances the stability of the grid while also providing a pleasing esthetic appearance.

[0036] FIG. 1 shows that some of the cells include an anchor flange 76. The anchor flange extends horizontally between opposing facing walls and vertices from a bottom edge 78 of the walls. An opening 80 is located in the anchor flange and adapted to receive a fastener 82 to secure the paver system. FIGS. 3 and 12 show that the fastener may be an anchor spike or stake. The spike 82 is inserted into the opening of the anchor flange and assists in preventing shifting of the grid.

[0037] FIG. 1-3 show that the grid may include anchor tabs 84 extending from two sides of the grid. The anchor tabs include an opening 86 adapted to receive a fastener such as an anchor spike. The anchor spike is shown in FIG. 3 to be inserted at an angle to prevent lifting of the grid. The angle of the spike may be at about a 60-degree angle. In one embodiment, the spike may may have a length of about 10.5 inches.

[0038] FIGS. 1 and 2 show that two sides of the grid 10 include locking tabs 88 extending from an exterior side of a cell wall. The other two sides of the grid include locking slots 90 extending through a cell wall, wherein the locking tabs of one grid are received by respective locking slots of another grid. FIG. 5A shows a top perspective view of a cell in isolation from the grid. The cell includes a locking tab 88. The locking tab 88 includes a flat tab 92 extending from a neck 94. The flat tab defines a receiver space 96 on either side of the neck. FIG. 5B shows a bottom perspective view of the cell of FIG. 5A. The locking tab 88 is show to extend down to the bottom edge 78 of the cell wall. FIG. 5C is a bottom view of the cell of FIG. 5A.

[0039] FIG. 6A shows a top perspective view of a cell in isolation from the grid 10. The cell includes a shroud 98 located on an interior wall of the cell. FIG. 6B is a bottom view of the cell of FIG. 6A and includes a locking slot 90. FIG. 6C is a bottom view of the cell of FIG. 6A. It can be seen that the locking slot 90 is protected from the shroud 98 so that filler 12 and other material to not block the locking slot 90 and prevent engagement with a locking tab.

[0040] FIG. 7 shows a top view of four grids 10 of FIG. 1 interconnected via the locking slots and locking tabs.

[0041] FIGS. 1 and 3 show that at least a majority of the cells include retention tabs 100. The retention tabs extend from the inner wall toward the center of the cell area. The retention tab 100 is spaced apart from the lower and upper edges 78, 102 of the cell walls and is located about mid center of the cell wall. The retention tabs allow for the securing of the filler 12 which will be formed around the retention tabs and lock the filler into the cell, not allowing it to migrate with expansion and contraction cycles.

[0042] FIG. 11A shows a top view of several cells in isolation from the grid. Two cells are shown with a filler 12. The upper portion of the filler in the top cell has been omitted to show the retention tabs. FIG. 11B is a sectional side view of the cells shown in FIG. 11A.

[0043] In one embodiment, the filler 12 is comprised of rubber chips 104 which are mixed with a poly binder or glue 106. The cells will be filled with this combination rubber and adhesive, and allowed to dry. Preferably, the rubber chips are made from recycled materials, such as ground up tires. The rubber chips may be added to a paddle mixer, such as a concrete mixer, and tumbled with the glue. This process coats parts of the rubber chips. When dried, it is still porous. However, the process creates a filler having a tortuous path extending through the filler 12. The filler 12 allows water to flow through the filler and accommodate the required drainage. However, the tortuous path does not accommodate growth of vegetation through the filler. The filler inherently provides an additional feature of weed control. In one embodiment, the filler 12 may be about 1 gallon of binder to about 44 pounds of rubber. In one embodiment, the rubber chips 104 may be about of an inch in size.

[0044] The invention also accommodates the use of parking lot striping and other markings. FIG. 9 is a perspective view of divider bar 108. Pairs of parallel extending divider bars are used to define a stipe within the grid. A filler of a contrasting characteristic, such as the color yellow, for example, is filled within the grid between the pairs of divider bars. The divider bar 108 shown in FIG. 9 includes a first end 110 and a second end 112, each end includes a tang 114 to be received by a notch 116 in the upper edge of a cell, and between the first end and second end are a plurality of slots 118 spaced apart for being received by a respective notch 116 in the upper edge of cell walls, and wherein the area within each cell which may receive a divider bar 108 is void of structure which would impede with receiving a divider bar 108.

[0045] The grid 10 includes a plurality of notches 116 in the upper edge of a cell wall, as well as the flexible expansion nodes. The notches are aligned to provide parallel rows to receive a pair of divider bars. The divider bars extend down to the bottom of the cell area and divide the cell area into two halves, creating a longitudinally extending row 120 between the pair of divider bars. The filler added to the cell areas between the divider bars provide the contrasting characteristic. In one embodiment, the rubber bits used to form the filler are solid yellow.

[0046] The divider bars 116 have two functions. The first is to form the stripes 120 as described above. The second function relates to applications where the area to be improved abuts a green space. Rather than trimming a grid at the demarcation of the improved area and green space, the grid extends into the green space. A single row of dividers 116 is used to provide the demarcation between the improved area and the green space. The area of cells extending into the green space are filled with soil so that grass or vegetation may grow. Alternatively, the area of cells may be filled with other materials as desired and consistent with the green space environment. The benefit of this approach is that a vehicle which may inadvertently run off the improved area and into the green space, will continue to be supported by the grid 10, and avoid ruts and other damage to the green space.

[0047] FIG. 10 is a top view of the grid 10 of FIG. 1 including a plurality of the dividers shown in FIG. 9. As can be seen, the retention tabs 100 are located in engagement with the divider bars and help to stabilize the divider bars. In addition, it can be seen that the retention tabs, flexible expansion nodes, shrouds and other features, are designed so as to not extend within the center of the cell area so as to not block the area should a divider bar 108 be desired to extend through the cell.

[0048] FIGS. 8A and 8B are top views of a portion of the grids shown in FIG. 7. As can be seen, the grids may be trimmed as desired.

[0049] The manufacturing process for the grid 10 may be injection molding for higher load bearing applications such as parking lots. Other lighter load bearing applications such as sidewalks could be accomplished through other manufacturing techniques.

[0050] For many applications, customers will desire that the majority of the cells 18 are prefilled with a filler 12 during manufacturing process. This will eliminate the majority of the field work as only perimeter cells, where one grid connects to another grid, will need to be done in the field.

[0051] Another scenario where field filling may be desired is when grid dividers are used.

[0052] When striping a parking lot, prefilled grids will be used up to the grid closest to where the stripe will be located. An empty grid should be inserted and then back to a prefilled grid until the next grid where a stripe will be present. After the empty grids are installed in place, dividers should be inserted to make the straight line through hexagonal grid pattern. The parking line can then be created through the use of a different color rubber such as yellow. The remainder of that grid tile can then be filled with the same color as the rest of the parking lot, such as black. This will then form a parking lot stripe that is permanent as it is as deep as the surrounding lot material.

[0053] In the case of a paving abutting green space, one option would be to cut prefilled tiles that abut green space in order to form a straight edge along the green space. However, a superior option would be to use dividers as noted above.

[0054] On the outer most tile, the installer could place an empty tile, insert a divider where the customer desires the edge of the paved surface to be, then fill the part that protrudes into the green space with dirt, and grow in it as you would in any green space. This has the advantage of stabilizing the ground around the parking area while eliminating cutting time and it will not sacrifice any aesthetics in the process. The rest of the tile would then be filled with the parking lot material.

[0055] In some application, customers may purchase just the empty grid itself, in order to stabilize wet areas, control erosion, and do many custom projects.