Polymer-Molded Paving Stone Bumpers for Consistent Joint Gaps
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Solution Overview
Problem
Paving stones with flat sides face issues with preformed spacers falling off due to storage and transportation, leading to inconsistent gaps and uneven application, especially when using group laying machines.
Innovation Solution
Molded bumpers made of polymeric material are integrated onto the sides of paving stones to provide consistent spacing, adhering firmly even through seasonal changes and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preformed spacers are adhered to the flat sides of paving stones, then the desired gap separation can be provided, but the spacers tend to fall off during storage and transportation
Solution Approach 1:
The spacer and paving stone are merged into a single integral structure, where the spacer is formed as an extension of the paving stone body during the same manufacturing process. This eliminates the attachment interface that causes spacers to fall off, while maintaining the gap separation function.
Solution Approach 2:
The spacer structure is pre-formed as an integral part of the paving stone during manufacturing, before storage and transportation. This preliminary formation ensures the spacer remains attached throughout subsequent handling and installation processes.
2Productivity
If integral spacers are formed on concrete paving stones, then a large number of pavers can be applied efficiently using group laying machines, but the paving stones cannot be made from natural or synthetic stone materials
Solution Approach 1:
The spacer is segmented from the main paving stone body but formed as an integral extension. This segmentation allows the spacer to perform its gap-defining function while remaining attached to various types of paving stones including natural and synthetic materials.
Solution Approach 2:
The integral spacer design creates a universal solution that works with different paving stone materials (concrete, natural stone, synthetic stone) and installation methods (individual placement, group laying machines), making the system adaptable to multiple applications.
3Manufacturing precision
If preformed spacers are used between adjacent paving stones, then the desired gap can be maintained, but additional components and installation steps are required
Solution Approach 1:
The spacer function is merged with the paving stone body, creating a single component that performs both structural and spacing functions. This eliminates the need for separate spacer components and simplifies the installation process.
Solution Approach 2:
The paving stone with its integral spacer is self-sufficient and does not require additional spacer components or complex installation procedures. The spacer is already attached and ready to provide gap separation upon installation.
Data Source
AI summary
A paving stone includes: (a) a paving stone having a top surface, a bottom surface, and at least one side surface extending from the top surface to the bottom surface; and (b) a bumper pattern comprising at least one bumper formed on the at least one side surface of the paving stone by molding a polymeric material onto the at least one side surface of the paving stone. A group of paving stones arranged together includes: (a) a plurality of paving stones, each paving stone having a top surface, a bottom surface, and a plurality of side surfaces extending from the top surface to the bottom surface; (b) a bumper pattern formed on the plurality of side surfaces of each of the plurality of paving stones by molding a polymeric material; and (c) the plurality of paving stones being arranged together so that the bumper pattern is located between adjacent ones of the plurality of paving stones to provide a gap therebetween. Methods of preparing a plurality of paving stones and installing a plurality of paving stones are provided.