Paving block including improved illumination

Abstract

To provide a manufacturing method of photoluminescent paving block including improved illumination.SOLUTION: A manufacturing method for paving block including an embedded photoluminescent material comprises the steps of: (A) combining sand, aggregate, water, and cement to form uncured concrete; (B) providing polyester resin combined with photoluminescent pigment; (C) preparing randomly sized chips or particulates by crushing the polyester resin after being cured to form photoluminescent polyester resin mixture fragments; (D) combining the resin mixture fragments, cement, and water to form uncured photoluminescent mixture; (E) providing a paving block mold; (F) charging the uncured concrete formed in step (A) to the paving block mold to obtain a concrete base layer; and (G) charging the uncured photoluminescent mixture formed in step (D) to the paving block mold so as to substantially fill it to obtain a photoluminescent layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates generally to outdoor surfacing construction, and more particularly to a paving block with improved lighting, which provides lighting without the need for electrical power. [Background technology]

[0002] Paving blocks are used for walkways, large public walking areas, roadways, sidewalks, etc. Paving blocks allow for ground preparation without deterioration. Paving blocks, like cement blocks for walkways, can be laid in various patterns that are aesthetically pleasing. Walkway lighting systems for walkways have been used along with paving blocks to enhance safety and provide sure footing and visibility. Many walkways are lit with low or medium voltage lighting, and low or medium voltage electricity must be provided to power the lighting system. There is a cost of electrical consumption associated with the use of the lighting system. There is also difficulty in setting up the lighting system if the walkway is a long walkway or located far from an electrical connection. A permit contractor must be hired to install the electrical fixtures for the lighting system.

[0003] The use of outdoor lighting is known in the prior art. For example, U.S. Patent No. 6,027,280 to Connors et al. (Connors) discloses interlocking paving blocks with interior lighting capabilities. However, Connors does not allow for non-electrical use of outdoor lighting. Similarly, U.S. Patent No. 5,472,737 to Anders (Anders 737) discloses a photoluminescent highway coating composition that is applied on highways to aid in driving. However, Anders 737 does not disclose the use of paving blocks. Finally, U.S. Patent No. 6,005,024 to Anders et al. (Anders 024) discloses a photoluminescent overlay that covers existing signs and provides moisture stability to the photoluminescent material. However, Anders 024 does not disclose the use of paving blocks.

[0004] Although the above devices meet their respective challenges and requirements, the U.S. patents do not describe photoluminescent paving blocks that can be used for outdoor lighting. Because Connors includes a moth light and wiring, Connors has no provision for non-electrical uses. Anders 737 and 024 simply disclose the use of photoluminescent materials in conjunction with paving blocks.

[0005] Additionally, U.S. Patent No. 6,665,986 to Kaplan discloses glittering paving blocks. U.S. Patent Application Publication No. 2006 / 0065879 to Beimel discloses glittering cementitious compositions and methods of making and using same. U.S. Patent No. 8,617,638 to Hill discloses a method of making glittering paving slabs in a paving slab manufacturing facility. However, U.S. Patent No. 9,114,422 to Toma et al. discloses paving blocks with embedded glittering material. U.S. Patent No. 9,114,422 is incorporated herein by reference in its entirety.

[0006] Thus, there is a clear need felt in the art for improved illuminated paving blocks that provide lighting without the need for electrical power. Summary of the Invention

[0007] The present invention provides a paving block with improved lighting that provides illumination without the need for electrical power. The paving block with improved lighting (photoluminescent paving block) preferably includes a concrete base layer and a photoluminescent layer. The photoluminescent layer is formed on the concrete base layer. The concrete base layer is produced by combining sand, aggregate, water, pigment and cement to form an uncured concrete mixture. The photoluminescent layer preferably includes very fine aggregate, cement, water, pigment, photoluminescent sand, and polyester resin mixed with photoluminescent pigment or silica-based glass material mixed with photoluminescent pigment. Furthermore, a light-transmitting coating can be placed on the cured photoluminescent layer. Thus, the present invention aims to provide a photoluminescent paving block, which has all the advantages and none of the disadvantages of the prior art for outdoor lighting.

[0008] It is a further object of the present invention to provide glittering paving blocks that can be easily and efficiently manufactured and commercially available.

[0009] It is yet a further object of the present invention to provide glittering paving blocks which are low cost to manufacture, both in terms of materials and labor.

[0010] It is yet a further object of the present invention to provide a photoluminescent paving block that does not require wiring, power consumption, or installation by an electrical contractor.

[0011] Finally, it is another object of the present invention to provide a photoluminescent paving for outdoor lighting that is aesthetically pleasing.

[0012] These and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a light-reflecting, glittering paving block according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Referring now to the drawings, and in particular to FIG. 1, a perspective view of a glittering paving block (1) is shown. The glittering paving block (1) includes a concrete base layer (10) and a glittering layer (12). The glittering layer (12) is formed on the concrete base layer (10). The concrete base layer (10) is preferably produced by combining sand, aggregate, water-based pigment, and cement to form an unhardened concrete mixture. The glittering layer (12) preferably includes very fine aggregate, cement, water, pigment, glittering sand, and a polyester resin mixed with glittering pigment or a silica-based glass material mixed with glittering pigment. Additionally, a light-transmitting sealant may be placed on the glittering layer (12).

[0015] The photoluminescent pigment preferably comprises strontium aluminate doped with europium. A 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 a uniformly distributed suspension and poured into shallow molds to cure. Once the polyester resin mixture is sufficiently cured, the hardened polyester resin mixture is crushed in a hammer mill or other suitable device to produce a mixture of randomly sized chips or particulate matter to form polyester resin mixture fragments.

[0016] A silica-based glass material is mixed with strontium aluminate pigment to form a silica-based glass mixture. The silica-based glass is mixed with the strontium aluminate pigment to form a uniformly distributed suspension and poured into shallow molds in preparation for firing in a glass kiln. After the silica-based glass mixture is sufficiently fired, the glass is cured and hardened. The silica-based glass mixture, once sufficiently cooled and hardened, is then crushed in a hammer mill or other suitable device to produce a mixture of randomly sized chips or particulate material to form silica-based glass fragments.

[0017] The following dimensions are given by way of example and not by way of limitation. Where the glittering paving blocks have a thickness of approximately 2·(3 / 8) inches, the concrete base layer (10) preferably has a thickness between 1·(7 / 8) inches and 2·(1 / 8) inches. The glittering layer 12 preferably has a thickness of no more than .5 inches. The concrete base layer (10) is produced by combining sand, aggregate, water, pigments, and cement to form an unhardened concrete mix. The unhardened concrete mix is ​​poured into a paver block mold (not shown) to a desired height. The concrete base layer (10) is then compressed with a hydraulic press to further eliminate any gaps or voids and enhance the durability of the concrete base layer (10) to withstand rated loads and environmental forces. The glittering layer (12) is produced by combining very fine aggregate, sand, cement, water, pigments, glittering sand, and a polyester resin mixed with glittering pigments or a silica-based glass material mixed with glittering pigments to form an unhardened glittering mix. The green glitter mix is ​​poured onto the green concrete mix. The glitter layer (12) is then compressed in a hydraulic press to eliminate any gaps or voids and to enhance the durability of the glitter layer (12) to enhance its ability to withstand rated loads and environmental forces. The paver block mold is then vibrated on a shaker table. A shaker table is a device well known in the art that is designed to agitate the green concrete mix and eliminate any gaps, spaces or voids.

[0018] The cast concrete blocks (10) are then cured in a controlled environment for up to 28 days. Finally, once sufficiently dry and cured, the paving blocks (1) are subjected to light surface grinding to remove excess concrete material and polyester resin mixture fragments or silica-based glass fragments from the top surface and the glittering sand on the surface of the glittering blocks (1). After the paving blocks (1) are ground, a light-transmitting sealant containing methyl methacrylate or polyurethane material may be applied in the form of a spray. The light-transmitting sealant is allowed to dry for 24 hours before the glittering paving blocks (1) are stocked and ready to be shipped.

[0019] 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 can be made without departing from the invention in its broader aspects, and therefore, it is the object of the appended claims to cover all such changes and modifications as are within the spirit and scope of the invention.

Claims

1. 1. A method of making paving blocks with embedded glittering material, the method comprising: mixing sand, aggregate, water and cement to form an unhardened concrete mix; Providing at least one of a photoluminescent mixture which is a polyester resin mixed with a photoluminescent pigment and a photoluminescent mixture which is a silica-based glass material mixed with a photoluminescent pigment; curing the photoluminescent mixture to break the photoluminescent mixture into random sized chips or particles to form photoluminescent fragments; mixing the glitter fragments, glitter sand, cement and water to form an uncured glitter mixture; providing a paving block mold; pouring the unhardened concrete mixture into a paver block mold; and injecting the uncured glitter mixture into the paving block mold to substantially fill it; The method comprising:

2. 10. The method of claim 1, further comprising the step of curing the contents within the paving block mold for a predetermined interval of time in a controlled environment to form a paving block.

3. 3. The method of claim 2 further comprising the step of grinding the top surface of the paver block to remove excess concrete material and expose a polished layer.

4. The method of claim 3 further comprising applying a permeable sealant to cover the photoluminescent layer.

5. The method of claim 1 further comprising pouring the glitter mixture into a shallow mold and allowing it to cure.

6. The method of claim 1 , further comprising the step of firing the silica-based glass material mixed with the photoluminescent pigment in a kiln.

7. The method of claim 1 further comprising the step of vibrating the paver block mold on a shaker table.

8. 1. A method of making paving blocks with embedded glittering material, the method comprising: mixing sand, aggregate, water and cement to form an unhardened concrete mix; providing at least one of a photoluminescent mixture which is a polyester resin mixed with a photoluminescent pigment and a photoluminescent mixture which is a silica-based glass material mixed with a photoluminescent pigment, the photoluminescent pigment comprising strontium aluminate doped with europium; curing the photoluminescent mixture to break the photoluminescent mixture into random sized chips or particles to form photoluminescent fragments; mixing the glitter fragments, glitter sand, cement and water to form an uncured glitter mixture; providing a paving block mold; pouring the unhardened concrete mixture into a paver block mold; and injecting the uncured glitter mixture into the paving block mold to substantially fill it; The method comprising:

9. 10. The method of claim 8, further comprising the step of curing the contents within the paving block mold for a predetermined interval of time in a controlled environment to form a paving block.

10. 10. The method of claim 9, further comprising the step of grinding the top surface of the paving block to remove excess concrete material and expose a polished layer.

11. The method of claim 10 further comprising applying a permeable sealant to cover the photoluminescent layer.

12. 9. The method of claim 8, further comprising pouring the glitter mixture into a shallow mold and allowing it to cure.

13. The method of claim 8, further comprising firing the silica-based glass material mixed with the photoluminescent pigment in a kiln.

14. The method of claim 8 further comprising the step of vibrating the paver block mold on a shaker table.

15. 1. A method of making paving blocks with embedded glittering material, the method comprising: mixing sand, aggregate, water and cement to form an unhardened concrete mix; Providing at least one of a photoluminescent mixture which is a polyester resin mixed with a photoluminescent pigment and a photoluminescent mixture which is a silica-based glass material mixed with a photoluminescent pigment; curing the photoluminescent mixture to break the photoluminescent mixture into random sized chips or particles to form photoluminescent fragments; mixing the glitter fragments, glitter sand, cement and water to form an uncured glitter mixture; providing a paving block mold; pouring the unhardened concrete mixture into a paving block mold; injecting the uncured glitter mixture into the paving block mold to substantially fill it; and compressing the contents in the paving block mould; The method comprising:

16. 16. The method of claim 15, further comprising the step of curing the contents within the paving block mold for a predetermined interval of time in a controlled environment to form a paving block.

17. 17. The method of claim 16, further comprising the step of grinding the top surface of the paver block to remove excess concrete material and expose a polished layer.

18. 20. The method of claim 17, further comprising applying a permeable sealant to cover the photoluminescent layer.

19. 16. The method of claim 15, further comprising pouring the glitter mixture into a shallow mold and allowing it to cure.

20. 16. The method of claim 15, further comprising firing the silica-based glass material mixed with the photoluminescent pigment in a kiln.

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