CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims a benefit of priority based on patent application no. 61/746,709 filed December 28, 2012, the entire contents of which are hereby expressly incorporated by reference into the present application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates in general to the field of paving systems. More particularly, the present invention relates to a modular, permeable paving system and an end cap for the perimeter of said system. Specifically, a preferred embodiment of the present invention relates to an end cap with a non-planar side that mates with a non-planar side of a permeable paving block.

2. Discussion of the Related Art

As is known to those skilled in the art, paving systems historically create a surface impervious to water. The water that falls on the paved surface runs off the edge of the paving surface rather than being absorbed into the ground beneath the paved surface. It is recognized that an increasing number of paved surfaces and the subsequent stonnwater runoff from these paved surfaces contributes to lowered water tables and rising stream levels. Thus, it is a previously recognized problem with paving systems that stonnwater runoff needs to be managed. Historically, it was known in the prior art to manage stormwater using a curb and gutter system to guide the stonnwater into sewer systems. More recently, the stonnwater has been guided into detention basins to allow the water to be absorbed closer to the paved surface. Needless to say, it is desirable to provide a permeable pavement system allowing the stormwater to drain through the paving system and to be absorbed into the ground under the paving system, minimizing the need for any additional stormwater management system.

One solution to this problem is addressed in U.S. Patent Application No. 13/163,232, filed on June 17, 201 1, and published as U.S. Publication No. 2011/0250013, the entire contents of which are herein expressly incorporated by reference, A similar solution is also addressed in U.S. Patent Application No. 13/307,863, filed on November 30, 2011 , and published as U.S. Publication No. 2012/0143202, the entire contents of which are herein expressly incorporated by reference. Paver blocks with water channels and spacers are disclosed in these applications to create a permeable surface. A plurality of blocks may also be linked together with cables passing through channels in each block. This creates a pre-assembled paving unit of paving blocks. Once the paving unit is laid in place, it is desirable to install an expansion joint around the perimeter of the paving unit. This ''expansion joint" absorbs expansion of the blocks along the abutting surfaces. It is also desirable to conceal or remove the exposed cables on the ends of the blocks for aesthetic purposes.

SUMMARY AND OBJECTS OF THE INVENTION

Consistent with the foregoing and in accordance with the invention as embodied and broadly described herein, a paver block and a permeable pavement system are disclosed in suitable detail to enable one of ordinary skill in the art to make and use the invention.

A paving block system is herein disclosed with an expansion joint in the form of an end cap. The end cap includes a generally planar top, back, and bottom. The planar top and bottom are parallel to one another. The planar back is generally perpendicular to the planar top and bottom. A non-planar front extends parallel with the planar back and is generally perpendicular !o the planar top and bottom. The non-planar front includes a first raised edge extending along the planar top and a second raised edge extending beyond the first raised edge from the planar top to the planar bottom.

The end cap may also include a generally planar back extending perpendicular from the planar top, a generally planar bottom extending parallel with the generally planar top and perpendicular to the generally planar back, and a generally non-planar front, extending parallel with the generally planar back and perpendicular to the generally planar top and bottom, with a first-stepped extension and extending along the planar top parallel to the generally planar bottom, and a projection extending perpendicular to the first-stepped extension toward the generally planar bottom.

The end cap is designed to conform to the shape of a plurality of paving blocks, each having a generally planar top and bottom and generally non-planar front and back sides. The non-planar front of the end cap matches the profile of the non-planar front and back sides of the paving blocks, covering the respective side of the paving block. The end cap includes a first recess defined by the non-planar front side, the first raised edge, and the second raised edge and a second recess defined by the non-planar front side, the first raised edge, and the second raised edge. The second raised edge separates the first recess from the second recess. Both of the first recess and the second recess of the end cap may receive a cable when the end cap is installed against a paving block. The cables extend from the paving block and are concealed within the recess when the end cap is covering the side of the paving block.

The end cap may be constructed out of a compressible material such as rubber, but may also be constructed out of a cast concrete materia!. When recycled rubber is used to construct the end cap, automotive tires, for example, may provide a good source of rubber. When cast concrete is used, the same casting material used to for paving blocks may be used, thus reducing manufacturing costs. The concrete may be impervious to water, but water-permeable concrete may also be used.

An added benefit of the end cap is the prevention of debris including dirt, rock, gravel, sand, etc. from entering channels and a cavity in the paving blocks. The end cap ensures that the channels and cavity do not become clogged or plugged and allow for water to freely flow through the respective passages.

The end cap, which may be compressible _. , forms an appropriate expansion joint between paving blocks and abutting surfaces including concrete, asphalt, dirt, wood, or structures. The end cap is also water permeable allowing for water to seep through the end cap and into the ground.

As mentioned, above, the end cap may be manufactured by molding an end cap from recycled rubber. The molding operation may form a non-planar side configured to conform to a non-planar side of the paving block in such a manner as for a top side of the end cap to be flush with a top side of the paving block when joining the non-planar front or back sides of the end ca and the paving block together.

Now turning to the paving blocks used with the end cap, the paving blocks may be constnicted using either a wet or dry cast technique. Preferably, the paving blocks are wet cast with a press. The design of the paving block allows for the casting to be completed with a single pressing of the press. Spacers are formed during the pressing that extend from, opposing sides of the paving blocks. A plurality of channels is also formed in the paving block during the single pressing. A tapered edge on opposing sides of the paving block, along with an arched cavity on a bottom, is similarly formed during the single pressing to allow for the paving blocks. The paving block includes a minimum compressive strength of 3,500 Ib/f (24,130kPa), maximum water absorption of 11.7 lb/ft ³ (80.67kPa) and minimum density of 125 lb/ft ^" ' (86L8kPa) per each paving block, respectively.

A paving block system, including paving blocks and end caps, may be constructed by laying a support of geogrid or geotextile on a surface. A stone bedding with a thickness of 6 inches to 10 inches may further be placed on the support. Each stone in the bedding may include 1 inch to 1.5 inch diameter stone. A plurality of paving blocks may then be placed on the stone bedding proximate to one another to form a paving unit of paving blocks, with a gap in between each paving block in one axis formed by at least one spacer in between each block in the respective axis. The paving blocks may be individually set in place, or a paving unit may be pre- assembled with a plurality of paving blocks linked to one another with cables passing through channels in each block.

An end cap may then be set in between at least one side of the paving unit and an abutting structure. The abutting structure may include concrete, asphalt, wood, stone, dirt, a structure, or a combination of many different elements. Due to the end cap being formed of a mbber materia!, it acts as an expansion joint between the paving blocks and the abutting structure. The end cap is shaped on its front side to conform to a non-planar surface on the side of the paving unit, thus providing an effective expansion joint.

When the paving blocks are set in place with a preassembled paving unit, the paving unit is held together with cables. The end cap conceals at least one cable extending from at least one side of the paving unit in a recess formed in between the non-planar surface of the side of the paving unit and the end cap. The end cap also prevents debris in the form of soil, stone, sand, dirt, etc. from entering a plurality of channels or a cavity in the paving blocks, thus ensuring the free flowage of water through the respecting channels.

These and other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings, it should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the mvention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features constituting the present invention and of the constmction and operation of typical mechanisms provided with the present invention will become more readily apparent by referring to the exemplary, and, therefore, non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which:

Fig. 1 is a perspective view of an end cap according to the present invention;

Fig. 2 is a top view of the end cap according to Fig, 1 ;

Fig, 3 is a bottom view of the end cap according to Fig. 1 ;

Fig. 4 is a perspective view of the end cap of Fig. 1 next to a paving block;

Fig. 5 is a top view of a paving block system including paving blocks and end caps according to an embodiment of the invention;

Fig. 6 is a side view of the paving block system of Fig. 4 installed in a typical environment according to the present invention;

Fig. 7 is a flow chart describing the steps to create a paving block system with an end cap according to an embodiment of the invention ;

Fig. 8 is a flow chart describing the steps to install a paving block system and end cap according to an embodiment of the invention;

Fig. 9 is a top view of an end block showing an alternative embodiment of the invention;

Fig. 10 is a side view of the end block according to Fig. 9;

Fig, 1 1 is a front view of the end block according to Fig. 9;

Fig. 12 is a back view of the end block according to Fig. 9; and

Fig. 13 is a top view of a paving block system including paving blocks and end blocks according to another embodiment of the invention. in describing the preferred embodiments of the invention, which are illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word "connected", "attached", or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.

DETAILED DESCRIPTION OF EMBODIMENTS

Specific embodiments of the present invention will now be further described by the following, non-limiting examples which will serve to illustrate various features of significance. The examples are intended merely to facilitate an understanding of ways in which the present invention may be practiced and to further enable those of skill in the art to practice the present invention. Accordingly, the examples should not be construed as limiting the scope of the present invention.

Referring to Figs. 1, 2, and 3, an end cap 8 is shown. The end cap 8 may be constructed out of a multitude of materials including rubber, plastic, foam, or any other compressible material. Preferably, the end cap 8 is formed out of a recycled rubber. A particularly good source of recycled rubber may be automotive tires which have been ground into small particles. The particles of automotive tire may then be bonded together with an adhesive to form the end cap 8 in a mold. The resulting end cap 8 is therefore compressible, pliable, and slightly deformable. The end cap 8 may also be water permeable. These properties allow the end cap 8 to be an effective expansion joint for a paving block system. The end cap 8 may absorb expansion of the paving block or an abutting surface such as asphalt, concrete, stone, dirt, a structure, or any other object during climate changes.

The end cap 8 includes a top 12 that is generally parallel to the bottom 16. The generally parallel sides 18 connect the top 12 to the bottom 16, and are each generally perpendicular to the top 32 and bottom 16. The end cap 8 may also include rounded edges or be formed into a multitude of shapes such as rectangular, square, trapezoidal, or any other shape. On the front 14 of the end cap 8, a first raised edge 20 extends along a portion of the top 12. A second raised edge reforms 22 on top of the first raised edge 20 along the top 12 and includes a projection 24 that extends generally perpendicular from the top 12 and the first raised edge 20 toward the bottom 16 of the end cap 8. A first recess 26 is formed on one side of the projection 24, and a second recess 27 is. formed on the opposing side of the projection 24. The first raised edge 20, second raised edge 22, and the projection 24 form a generally "T"-shape 37, stepped formation on the front 14 of the end cap 8. The first raised edge 20 transitions to the front 14 with a rounded outside edge. The second raised edge 22 transitions from the first raised edge 20 with a rounded inside edge. Rounded edges aliow the end cap 8 to be removed from a mold during the manufacturing process with minimal effort. The front 14 of the end cap 8 is preferably positioned against at least one paving block while the back 10 of the end cap 8 rests against an abutting surface.

Turning now to Fig. 4, the end cap 8 is shown next to an exemplary paving block 28. A paving block 28 of this type includes a generally planar top 40 parallel to a generally planar bottom 50. The front 30 of the paving block 28 is non-planar and may include a series of steps. The general shape of the front 14 of the end cap 8 includes a first raised edge 20, second raised edge 22, and projection 24 that may fit against the front 30 of the paving block 28. Rounded outside edges 13 transition the first raised edge 20 from the front of the end cap 8 and rounded inside edges 1 1 transition the second raised edge 22 from the first raised edge 20. The first and second raised edges 20, 22, along with the projection 24, form a general "T"-shaped formation.

When the end cap 8 is fitted against the paving block 28, the first raised edge 20 of the end cap 8 fits against a first step 54 on the front 30 of the paving block 28, while the second raised edge 22 of the end cap 8 fits against a second step 56 in the front 40 of the paving block 28. The projection 24 of the end cap 8 also fits against the second ste 56 of the paving block 28. This produces a snug fit and allows the front 14 of the end cap 8 to effectively match the contour of the front 30 or back 58 of the paving block 28.

The paving block 28 preferably includes a cavity 36 extending along the bottom 50 of the paving block 25 to assist in the flow of water under the paving block 28. The cavity 36 is particularly useful when the paving block is placed on an inclined surface, such as a hill, and allows water to easily flow downhill under the paving block 28. At least one spacer 32 may be included on the sides 60 of the paving block 28 to ensure a gap is always present between each paving block 28 to allow water to seep to the ground. A channel 34 may also be included along the front 30 of the paving block 28 extending through the core of the paving block 28 and generally parallel to the top 40 and bottom 50. Preferably, the paving block 28 includes two channels 34 on the first step 54 of the paving block 28 with the second step 56 in between each channel 34. The channels 34 extend through the paving block 28 and produce passages for a cable 38 to pass through the paving block 28. The cable 38 may therefore protrude from each channel 34. The front 1.4 of the end cap 8 may be placed against the front 30 o the paving block 28 allowing the cables 38 to fit snugly within the first recesses 26 and the second recess 27 on the end cap 8, This configuration allows for the cables to be obscured from view when, the paving block 28 is installed as shown i Figs. 4 and 5.

Additionally, the cables 38 coming out of each channel 34 may not be individual cables that are crimped as shown in Fig 4. Alternatively, a cable 38 may come out of one channel 34 and enter the other channel 34 in the paving block 28, thus forming a loop. Such an arrangement would create one single cable 38 exiting on channel 34 and entering another channel 34. In. this example, when fitting an end cap 38 against the front 30 of the paving block 28, the loop of the cable 38 may be tucked under the paving block 28 into the cavity 36. Tucking the cable 38 into the cavity 36 underneath the paving block 28 would also al low the front 14 of the end ca 8 to sit flush against the front 30 of the paving block 28 as shown in Fig. 5.

In another embodiment the cable 38 passing through channels 34 may be replaced with a heating system. The heating system may include hollow tubing for heated water to circulate through the paving block 28. Preferably, an electric wire may be wrapped in a sheath and passed through the channels. In yet another embodiment, the same cable 38 maybe insulated with a sheath and used for electric heating by using the cable 38 as an electrical resistor heater. In such a configuration the cable 38 is not necessarily required to pass through every channel 34, but may pass through every other channel 34, to conserve energy. Solar panels and battery packs may also be used to further conserve energy and provide a sustainable power source for the heating system.

Turning now to Fig. 5, multiple paving blocks 45 and end caps 8 are shown, A plurality of paving blocks 45 may be preassembled by running the cable 38 shown in Fig. 3 through the channels 34 in each paving block 28. This system of assembling multiple paving blocks 45 together is described in U.S. Patent Publication 2012/0141202, which is commonly owned, and particularly in Fig. 16 of that publication. The spacers 32 ensure a gap is always present between each paving block 28. The multiple paving blocks 45 that are interconnected with the cable 38 form a paving system 42. The entire paving system 42 may be laid into place by lifting it and lowering it with the attached cable 38. Once the paving system 42 is in place, the end cap 8 may be positioned into place to form an expansion joint and also to conceal the cable 38 as described above and shown in Fig, 3. While the paving block 28 may be formed of a water permeable concrete mixture, the spacers 32 ensure that a sufficient amount of water may permeate through the paving system 42 to the ground below. Preferably, the end cap is sized such that one end cap fits against a single paving block 28. The end caps 8 may, however, be longer to allow a single end cap to fit against a plurality of paving blocks 28. The end cap also functions as an expansion joint 43 as the multiple paving blocks 45 expand and contract during climate changes. Fig. 5 also shows the multiple paving blocks 45 forming a non planar edge 49 along the end caps 8. Due to the profile shape of the end caps 8 matching the profile of the paving blocks 28, the end caps 8 form a planar edge 47 that makes it easier to pour an abutting surface, such as asphalt or concrete.

Fig. 6 shows a side view of an installed paving system 42 with a cross-sectional side view of the ground. In order to ensure that each paving block 28 stays in place and that they are even wit one another, the undisturbed ground 52 is excavated for a proper foundation to be set in place. The foundation consists of a geogrid 46 or a geote tiie 46. A geogrid is a geosynthetic material used to reinforce soils and similar materials. Geogrids 46 are commonly used to reinforce retaining walls, as well as subbases or subsoils below roads, structures, or paving systems 42. Soils pull apart under tension. Compared to soil, geogrids 46 are strong in tension. This fact allows them to transfer forces to a larger area of soil than would otherwise be the case. Geogrids 46 are commonly made with polymer materials such as polyester, polyethylene, or polyproylcnc. They may be woven or knitted from yams, heat-welded from strips of material or produced by punching a regular pattern of holes in sheets of material, then stretched into a grid, Geotexiiles 46 are permeable fabrics which, when used in association with soil, have the ability to separate, filter, reinforce, protect, or drain. Typically made from polypropylene or polyester, geotextiie 46 fabrics come in three basic forms: woven like burlap, needle punched like felt, or heat-bonded like ironed felt. On top of the geogrid/geotextile 46, a stone bedding 48 may be placed. The stone bedding 48 may be approximately 6 to 10 inches deep and consist of a 1 to 1.5 inch diameter clean or recycled stone, Each paving block 28 may then be manually laid on top of the stone bedding 28 or the paving system 42 may be set into place. The end cap 8 acts as an expansion joint 43 between the paving blocks 45 and an abutting surface 44. The abutting surface 44 may include asphalt, concrete, wood, dirt, stone, or any structures such as a house. As climate changes and over time, the paving blocks 45, as well as the abutting surface 44, may expand and contract. The end cap 8 functions as an expansion joint 43 and absorbs the expansion and contraction, conceals the cable 38 as shown in Fig. 3, and is an attractive transition from the paving blocks 28 to the abutting surface 44.

Turning now to Fig. 7, the steps of manufacturing a paving block system are described. First, the paving block is cas ted 100, preferably, wet casted using a press. Due to the design of the paving block 28, the casting may be completed with a single pressing of the press. The casting includes forming spacers 102 on the sides 60 of the paving block 28, as seen in Fig. 5. The casting also includes forming channels 104 which are shown as channels 34 in Fig. 4. Similarly, the casting includes forming steps 106 which are seen as the first step 54 and second step 56 in Fig. 5. As described with reference to Fig. 5, a cavity 36 allows water to flow under the paving block 28. Forming a cavity 108 is also included in the casting operation. Lastly, molding an end cap 1 10 produces the end cap 8 as shown in Figs. 1-5.

Fig. 8 discloses the steps of assembling a paving block system as seen in Figs. 5 and 6. While excavation is commonly done, it is not mandatory. The first step typically includes laying support 1 12 in the form of a geogrid and/or geotextile. Laying stone bedding 114 follows to add a strong support for the paving blocks 28 and any load on top of the paving blocks 28. Laying paving blocks 1 16 follows, and may be done manually with individual paving blocks 28 or as a complete paving block system 42. Inserting an end cap 118 provides an effective expansion joint 43, concealing cable 120, if a paving block system 42 with cables 38 was used. Lastly, preventing debris 122 with the end cap 8 allows water to flow through the cavity 36 and channel 34 of the paving block 28.

Turning now to Figs. 9-13, an alternative embodiment of the invention is disclosed. In this embodiment, the paving blocks 28 are the same as discussed above with respect to Figs. 4-6, but the end cap 8 is replaced with an alternative end cap that is referred to as an end block 78. The end cap 8 and end block 78 may be used interchangeable, and as a result, the term "end cap" and "end block" may also be used interchangeably. The end block 78 performs all the same functions as the end cap 8, but has a different shape and is made of a different material, as discussed below.

The end block 78 may be manufactured with the same manufacturing equipment as the paving blocks 28. As shown in Fig. 9, the top view of the end block 78 has the same profile as half of a paving block 28 shown i Fig. 5. The end block 78 does not include cavity 36 or channel 34, however the same equipment may be used to cast the end block 78 by simply removing inserts and adjusting the mold. This aliows for manufacturing of the end block 78 in the same location as the paving block 28, thus reducing transportation costs and lead time.

As the end cap 8 is constructed out of a flexible material such as recycled rubber it often requires an adhesive to keep it in place, against the paving block 28, as shown in Fig. 5. The end cap 8 may also be nailed to the paving block for added security. The end block 79 eliminates the requirement of nailing or using an adhesi ve to keep it in place as the end block 79 is casted out of concrete and stays in place due to its large mass.

Referring specifically to Figs. 9-12, the end block 79 includes sides 70, a front 84, and a back 80, On the front 84, a first step 74 and a second step 76 form a stepped profile that matches the front 30 of the paving blocks 28. The matching steps on the paving blocks 28 and the end block 78 allow for the paving block system 42 to be formed with straight edges around the perimeter, as shown in Fig. 13. Furthermore, the end block 78 may be cut in half to provide a square edge at the comers of the paving block system 42.

As shown in Figs. 10 and 1 1, the end block 78 includes a tapered front. While the taper 82 may be formed out of any degree of slope, preferably, the taper 82 is approximately 3 degrees of slope. The taper 82 may continue along the entire front 84 of the end block 78 but, preferably, ends at the midway point 86 of the front 84 of the end block 78 as shown in Fig. 11. The taper 82 forms a path for water to flow through when the end blocks 78 are assembled in a paving block system 42 as shown in Fig. 13. The end blocks 78 also include a spacer 72 on the sides 70 to allow a drainage space to be formed when assembling the end blocks with a paving block system 42 as also shown in Fig. 13.

The end block 78 performs a similar function as the end cap 8 shown in Figs. 1-6, but is made out of the same material as the paving block 28 which provides a more uniform appeai'ance vvhile also reducing manufacturing costs. The end block 78 is also installed in a similar fashion as discussed with respect to Fig. 6. The cable 38 may also be tucked into the cavity 36 of the paving block 28 as shown in Fig. 4 when the end block 78 is abutted against the paving blocks 28. The end block 78 may also include a notch to help the cable 38 tuch into the cavity 36 of the paving block 28. Furthermore, the end block 7S may be used in any manner described herein referring to the end cap 8, thus providing for interchangeability between the end cap 8 and the end block 78,

Fig. 13 shows the end block 78 forming a straight edge along the back 80 of the end blocks 78. The straight edge may provide a iraiformly-shaped surface along the sides of the paving block system 42 which allows for asphalt or concrete to be laid with less labor than if the first step 54 and the second step 56 of the paving blocks 28 were left exposed. The end blocks 78 also conceal the cable 38 as well as the channels 34, which are shown in phantom view, within the paving blocks 28. Similar to the description above with respect to Fig. 5, Fig. 13 also shows the paving blocks 28 forming a non planar edge 49 along the end caps 8. Due to the profile shape of the end blocks 78 matching the profile of the paving blocks 28, the end blocks 78 form a planar edge 47 that makes it easier to pour an abutting surface, such as asphalt or concrete.

Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest that various additions, modifications, and rearrangements of the features of the present invention may be made without deviating from the spirit and scope of the underlying inventive concept.

For example, individual components of the disclosed paving block 28 and end cap 8 need not be formed in the disclosed shapes or assembled in the disclosed configuration, but could be provided in virtually any shape, so as to provide an end cap, a paving block 28, and/or paving unit 42 with the novel features, e.g., a cavity capable of storing fluid. Furthermore, ali the disclosed features of each disclosed embodiment can be combined with, or substituted for, the disclosed features of every other disclosed embodiment except where such features are mutually exclusive.

It is intended that the appended claims cover ali such additions, modifications, and rearrangements. Expedient embodiments of the present invention are differentiated by the appended claims.