IL284366B1

IL284366B1 - Decorated paving stones

Info

Publication number: IL284366B1
Application number: IL284366A
Authority: IL
Inventors: Nahun Arie
Original assignee: Ytong Paving Ltd; Nahun Arie
Priority date: 2021-06-24
Filing date: 2021-06-24
Publication date: 2024-08-01
Also published as: IL284366A

Description

DECORATED PAVING STONES FIELD OF THE DISCLOSUREThe present disclosure relates to concrete based blocks that serve to form paving stones and more specifically to paving stones with colorful decoration within them.

BACKGROUND OF THE DISCLOSURETypically paving stones are mass produced from concrete with standard sizes and shapes, which can easily be assembled to form a path or a road. The paving stones may be manufactured in interlocking shapes so that they can completely cover an entire surface. A typical block has two layers: a lower layer that is generally rough and positioned facing the ground and an upper layer that is positioned upward and is generally manufactured with a smoother surface that is more aesthetically appealing.The paving stones are generally suitable for outdoor use and designed to endure heavy loads and durable under the influence of strong forces, for example to remain intact even when receiving strong blows and subject to frictional forces. The paving stones may be manufactured in various colors and the colors are generally applied using chemical mixtures that last for a long time without fading.

SUMMARY OF THE DISCLOSUREAn aspect of an embodiment of the disclosure, relates to paving stones and a method for manufacturing paving stones with colored plastic flakes embedded in an upper layer. The embedded plastic flakes are viewable on an upper surface of the paving stone.

There is thus provided according to an embodiment of the disclosure, a paving stone, comprising: A lower layer, configured to serve as a base for the paving stone;An upper layer coupled to the lower layer and configured to form an upper surface that serves as an aesthetic interface for the paving stone;plastic flakes that are embedded in the upper layer and are observable on the upper surface of the paving stone.

In an embodiment of the disclosure, the lower layer is 2-10 times thicker than the upper layer. Optionally, the lower layer also includes plastic flakes but less than in the upper layer. In an embodiment of the disclosure, the upper layer includes at least 10 times as many plastic flakes as in the lower layer. Alternatively, the plastic flakes are only embedded in the upper layer. In an embodiment of the disclosure, the upper layer has finer grains than the lower layer. Optionally, the weight of plastic flakes is between about 1% to about 5% of the weight of the upper layer. In an embodiment of the disclosure, the plastic flakes have a single color. Alternatively, the plastic flakes have more than one color. In an embodiment of the disclosure, the upper surface has a higher density of plastic flakes than in the rest of the upper layer.There is further provided according to an embodiment of the disclosure, a method of manufacturing a paving stone, comprising:Pouring a mixture for a lower layer of the paving stone, configured to serve as a base for the paving stone; Embedding plastic flakes in a mixture for an upper layer of the paving stone;Pouring the mixture for the upper layer coupled to the lower layer; Wherein the upper layer forms an upper surface that serves as an aesthetic interface for the paving stone and wherein the plastic flakes are observable on the upper surface of the paving stone.

BRIEF DESCRIPTION OF THE DRAWINGSThe present disclosure will be understood and better appreciated from the following detailed description taken in conjunction with the drawings. Identical structures, elements or parts, which appear in more than one figure, are generally labeled with the same or similar number in all the figures in which they appear, wherein:Fig. 1 is a schematic illustration of a perspective view of a paving stone, according to an embodiment of the disclosure;and Fig. 2 is a flow diagram of a method of manufacturing a paving stone, according to an embodiment of the disclosure.

DETAILED DESCRIPTIONFig. 1 is a schematic illustration of a perspective view of a paving stone 100, according to an embodiment of the disclosure. In an embodiment of the disclosure, paving stones 100 include a lower layer 110, which is configured to be positioned facing the ground, and an upper layer 115, which is configured to be positioned facing upward to form a path. The lower layer 110 is generally hidden from view so aesthetic appearance of the lower layer 110 is generally not important.

In contrast the pavement blocks 100 are generally selected for use based on the appearance of the upper layer 115, for example based on shape, color and smoothness to form an appealing path or road. Optionally, the upper layer 115 may be manufactured with aggregates having a smaller grain size so that the path formed by the paving stones will be more aesthetic (e.g. smoother). Alternatively or additionally, the upper layer can be designed to have different friction levels to match an intended use, for example to have more friction to prevent slipping in wet environments.In an embodiment of the disclosure, the upper layer 115 includes colorful plastic flakes 120 that provide an aesthetic appearance to the surface 1of paving stone100, while not hurting the strength of the paving stone 100. Optionally, the plastic flakes 120 may be of any specific color or a mixture of colors, for example two or three distinct colors or more. In an embodiment of the disclosure, the plastic flakes 120 may densely populate the upper layer 115 (e.g. populating more than 5-10% by volume) or may be non-dense (e.g. populating less than 5% by volume). In an embodiment of the disclosure, the plastic flakes 120 are essentially evenly dispersed throughout the upper layer 115.

In some embodiments of the disclosure, the lower layer 110 may have the same thickness as the upper layer 115 or the lower layer 110 may be much thicker (e.g. 2 to 10 times as thick). Optionally, the surface 125 of the upper layer 115 may be smoothed or filed down to provide the pavement with a smoother surface. Alternatively, the surface 125 of the upper layer 115 may be coated (e.g. with a transparent coating) to protect the paving stone 100.

Fig. 2 is a flow diagram of a method 200 of manufacturing a paving stone 100, according to an embodiment of the disclosure. In an embodiment of the disclosure, the manufacturer places required elements in a mixer to prepare 210 a cement mixture for the lower layer 110 of the pavement block 100. Optionally, the required elements include: 1. Water 201;2. Cement 202; 3. Sealer 203 (e.g. Silane or Silicates) to protect the resulting concrete paving stones100 from surface damage and staining, by blocking pores and reducing absorption of water and salts;4. Paint 204 to provide a specific color to the resulting concrete paving stones100; and . Aggregates 205, which may include sand, gravel, crushed stones, slag, recycled glass and other materials to add strength to the resulting concrete paving stones100.Additionally, the manufacturer prepares 220 a similar mixture to prepare the upper layer 115 of the paving stones100. Optionally, the upper layer includes similar elements as the lower layer including: water 201, cement 202, sealer 203, paint 204 and aggregates 205. In some embodiments of the disclosure, the relative percentages by weight of the elements used for the lower layer 110 may differ from the percentages used in the upper layer 115, for example to provide a finer grained upper layer 115 in contrast to a more course grained lower layer 110.

In an embodiment of the disclosure, colorful plastic flakes 120 are added to the mixture of the upper layer 115 to provide a more decorative surface 125.

Optionally, the plastic flakes 120 are made from a durable plastic, so that the color of the plastic flakes 120 won’t fade and the plastic flakes won’t deteriorate and disappear over time (e.g. by turning into a powder due to heat, rain and physical forces endured by the paving stones100). Optionally, the plastic flakes can be made from a plastic such as low density polyethylene (LDPE), which is a soft, flexible, lightweight plastic material. LDPE is noted for toughness and corrosion resistance.

Optionally, the size of the plastic flakes is between about 2 to 10 mm in length by about 1-2 mm in width and with a thickness of less than 1mm.

In some embodiments of the disclosure, the lower layer may also contain a small amount of plastic flakes 120, for example less than 10% of the amount added to the upper layer to be able to identify a specific paving stone100 also based on the lower layer 110. Alternatively, only the upper layer 115 includes plastic flakes 120, whereas the lower layer 110 is completely free from plastic flakes 120.

In an embodiment of the disclosure, the mixture for the lower layer 1is poured 230 into a mold to form the lower layer 110. The mold may be vibrated and pressure may be applied 240 to stabilize the lower layer 110. Then the upper layer 115 is poured 250 on top of the lower layer 110. The entire mold may continue to be vibrated and pressure may be applied 260 to stabilize the upper layer 115 and the entire paving stone100. Optionally, the plastic flakes 120 may remain evenly dispersed within the upper layer 115 or the plastic flakes 120 may rise in response to the vibrations and have an increased density on the upper surface 125.In an embodiment of the disclosure, the mold is placed in a finishing room 270 to solidify the pavement block 100 in an environment with high humidity and with an optionally controlled temperature. Optionally, water may be poured on the paving stones100 as they solidify to enhance the strength of the paving stones 100.In an embodiment of the disclosure, at a certain stage the paving stones 100 are de-molded 280. The paving stones 100 may then be smoothed or polished to reach their final form. Then the paving stones 100 may be packed 285, for example stacked on a platform or placed in cardboard boxes. Optionally, the packed paving stones100 are stored 290 in a warehouse and may be shipped 295 out to a client upon receiving an order.In an embodiment of the disclosure, the weight of plastic flakes 1 added to a mixture is between about 1% to about 5% of the weight of the upper layer 115. For example for a mixture of 600 Kg a quantity of 10-30 Kg of plastic flakes 120 may be added, to provide the required aesthetic appearance but not detrimentally affect the strength of the paving stones100.

It should be appreciated that the above described methods and apparatus may be varied in many ways, including omitting or adding steps, changing the order of steps and the type of devices used. It should be appreciated that different features may be combined in different ways. In particular, not all the features shown above in a particular embodiment are necessary in every embodiment of the disclosure.

Further combinations of the above features are also considered to be within the scope of some embodiments of the disclosure.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims, which follow.

Claims

284366/ -9- CLAIMS I/We claim:

1. A paving stone, comprising: a lower layer manufactured from a mixture for the lower layer that was poured into a mold to serve as a base for the paving stone; an upper layer manufactured from a mixture for the upper layer that is poured into the mold and coupled onto the lower layer; wherein the mixture of the lower layer and the mixture of the upper layer are cured and the upper layer forms an upper surface that serves as an aesthetic interface for the paving stone; plastic flakes that were embedded in the mixture of the upper layer and wherein plastic flakes are observable on the upper surface of the paving stone; wherein the lower layer also includes plastic flakes but less than in the upper layer; wherein the upper layer includes at least 10 times as many plastic flakes as in the lower layer; and wherein the plastic flakes in the lower layer are of a sufficient quantity to be discernable from a lower surface of the lower layer.

2. The paving stone according to claim 1, wherein the lower layer is 2-10 times thicker than the upper layer.

3. The paving stone according to claim 1, wherein the upper layer has finer grains than the lower layer.

4. The paving stone according to claim 1, wherein the weight of plastic flakes is between about 1% to about 5% of the weight of the upper layer. 284366/ -10-

5. The paving stone according to claim 1, wherein the plastic flakes have a single color.

6. The paving stone according to claim 1, wherein the plastic flakes have more than one color.

7. The paving stone according to claim 1, wherein the upper surface has a higher density of plastic flakes than in the rest of the upper layer.

8. A method of manufacturing a paving stone, comprising: pouring a mixture for a lower layer of the paving stone into a mold, configured to serve as a base for the paving stone; embedding plastic flakes in a mixture for an upper layer of the paving stone; pouring the mixture for the upper layer into the mold coupled onto the lower layer; curing the mixture of the lower layer and the mixture of the upper layer; and wherein the upper layer forms an upper surface that serves as an aesthetic interface for the paving stone and wherein plastic flakes are observable on the upper surface of the paving stone; wherein the lower layer also includes plastic flakes but less than in the upper layer; wherein the upper layer includes at least 10 times as many plastic flakes as in the lower layer; and wherein the plastic flakes in the lower layer are of a sufficient quantity to be discernable from a lower surface of the lower layer.

9. The method according to claim 8, wherein the lower layer is 2-10 times thicker than the upper layer. 284366/ -11-

10. The method according to claim 8, wherein the upper layer has finer grains than the lower layer.

11. The method according to claim 8, wherein the weight of plastic flakes is between about 1% to about 5% of the weight of the upper layer.

12. The method according to claim 8, wherein the plastic flakes have a single color.

13. The method according to claim 8, wherein the plastic flakes have more than one color.

14. The method according to claim 8, wherein the upper surface has a higher density of plastic flakes than in the rest of the upper layer.