WO2010069038A1

WO2010069038A1 - Set of blocks such as pavers or wall blocks

Info

Publication number: WO2010069038A1
Application number: PCT/CA2009/000474
Authority: WO
Inventors: Marcel Thomassen
Original assignee: Transpave Inc
Current assignee: Transpave Inc
Priority date: 2008-12-18
Filing date: 2009-04-14
Publication date: 2010-06-24
Anticipated expiration: 2011-06-18
Also published as: USD639454S1

Abstract

A set of pavers for paving an area. Each paver comprises: a first side surface generally coincident with a first side of an imaginary rectangle; a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle; a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle; a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle; a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface. The pavers are installable in a pattern in which the male side surface of one of the pavers registers with the female side surface of an adjacent one of the pavers. Other sets of blocks, such as wall blocks for constructing walls, can be designed in a similar manner.

Description

SET OF BLOCKS SUCH AS PAVERS OR WALL BLOCKS

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U. S. C. 120 of U.S. Design Patent Application No. 29/329,646 filed on December 18, 2008 by Marcel Thomassen and hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to blocks such as pavers for paving walkways, driveways, patios, pool decks and various other areas to be paved, or wall blocks for constructing building walls, retaining walls and other types of walls.

BACKGROUND

Pavers used in walkways, driveways, patios, pool decks and various other paved areas often have rectangular shapes. In some cases, rectangular pavers of various sizes are arranged in a particular pattern to create a paved area with a more aesthetic look.

While they are certainly useful, rectangular pavers present some drawbacks. For example, in addition to requiring various molds to be manufactured, rectangular pavers of various sizes can often be time-consuming and complicated to install. Conversely, while possibly simpler to manufacture and install, rectangular pavers all of the same size are usually installable only in a few patterns and/or result in paved areas exhibiting a degree of linearity that can sometimes be undesirable.

Similar drawbacks are often encountered with walls (e.g., building walls, retaining walls, etc.) or other types of structures made using rectangular blocks. Accordingly, there is a need for pavers, wall blocks or other construction blocks which are relatively simple to manufacture and install, while being installable in various different patterns providing different looks and/or functions.

SUMMARY OF THE INVENTION

According to a first broad aspect, the invention provides a set of pavers for paving an area. Each paver comprises: a first side surface generally coincident with a first side of an imaginary rectangle; a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle; a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle but longer than half of the third side of the imaginary rectangle; a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle; a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface. The pavers are installable in a pattern in which the male side surface of one of the pavers registers with the female side surface of an adjacent one of the pavers.

According to a second broad aspect, the invention provides a set of pavers for paving an area. Each paver comprises: a first side surface generally coincident with a first side of an imaginary oblong rectangle; a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary oblong rectangle; a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary oblong rectangle, the first side surface being shorter than the third side of the imaginary oblong rectangle; a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary oblong rectangle, the fourth side surface being shorter than the second side of the imaginary oblong rectangle; a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary oblong rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface. The pavers are installable in a pattern in which the male side surface of one of the pavers registers with the female side surface of an adjacent one of the pavers.

According to a third broad aspect, the invention provides a set of pavers for paving an area. Each paver comprises: a first side; a second side generally perpendicular to the first side; a third side opposite and generally parallel to the first side; a fourth side opposite and generally parallel to the second side, a normal distance between the first side and the third side being longer than a normal distance between the second side and the fourth side; a fifth side generally perpendicular to the fourth side; and a sixth side generally perpendicular to the first side, the first side being shorter than the third side and the fourth side being shorter than the second side such that the fifth side and the sixth side define a rectangular recessed space. The pavers are installable in a pattern in which a portion of the second side and a portion of the third side of a given one of the pavers respectively register with the sixth side and the fifth side of an adjacent one of the pavers such that part of the given one of the pavers fits in the rectangular recessed space of the adjacent one of the pavers.

According to a fourth broad aspect, the invention provides a set of wall blocks for constructing a wall. Each wall block comprises: a front surface exposed when the wall block is in the wall; a first side surface generally coincident with a first side of an imaginary rectangle; a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle; a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle; a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle; a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface. The wall blocks are installable in a pattern in which the male side surface of one of the wall blocks registers with the female side surface of an adjacent one of the wall blocks.

According to a fifth broad aspect, the invention provides a set of construction blocks for constructing a structure. Each construction block comprises: a first side surface generally coincident with a first side of an imaginary rectangle; a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle; a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle; a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle; a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface. The construction blocks are installable in a pattern in which the male side surface of one of the construction blocks registers with the female side surface of an adjacent one of the construction blocks. These and other aspects of the invention will now become apparent to those of ordinary skill in the art upon review of the following description of embodiments of the invention in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of embodiments of the present invention is provided below, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a paved area comprising a plurality of pavers in accordance with an embodiment of the invention;

Figure 2 shows a perspective view of one paver of the pavers shown in Figure 1 ;

Figure 3 shows a top view of the paver shown in Figure 2;

Figure 4 shows a cross-sectional view of the paver shown in Figure 2;

Figures 5 to 8 show examples of other patterns in which the pavers can be installed;

Figures 9 to 14 show examples, in outline form, of various other contours of pavers in accordance with other embodiments of the invention;

Figure 15 shows a paver in accordance with another embodiment of the invention;

Figure 16 shows the top view of the paver shown in Figure 3 to illustrate an alternative way of describing a contour of the paver; and Figure 17 is a flowchart illustrating an example of a process for manufacturing pavers in accordance with an embodiment of the invention.

It is to be expressly understood that the description and drawings are only for the purpose of illustrating certain embodiments of the invention and are an aid for understanding. They are not intended to be a definition of the limits of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Figure 1 shows a paved area 10 comprising an arrangement of pavers 12-_t ...12_N in accordance with an embodiment of the invention. The paved area 10 may be part of a walkway, a driveway, a patio, a pool deck, or any other hardscaping structure.

A given paver 12_j (1 < j < N) will be described with additional reference to Figures 2 and 3, with this description similarly applying to other ones of the pavers 12L ..12N.

In this embodiment, the paver 12, is a dry-cast concrete block, i.e., it is made of no-slump concrete (also known as zero-slump concrete), which can be viewed as concrete with a slump of 6 mm or less. Various types of no-slump concrete may be used. In other embodiments, the paver 12, may be made of other types of concrete (e.g., measurable-slump concrete so that it can be wet-wast).

The paver 12, comprises a top surface 14, a bottom surface 15, and a plurality of side surfaces forming a contour of the paver 12,, namely a first side surface 181 , a second side surface I8₂, a third side surface 18₃, a fourth side surface 18₄, a female side surface18₅, and a male side surface 18β.

As can be seen in Figure 3, the first side surface I8-₁, the second side surface 18₂, the third side surface 18₃ and the fourth side surface 18₄ are generally coincident with respective sides of an imaginary rectangle 29 (shown in dotted line). More particularly: the first side surface 18i is generally coincident with a first side 31₁ of the imaginary rectangle 29; the second side surface 18₂ is generally perpendicular to the first side surface 18₁ and generally coincident with a second side 31₂ of the imaginary rectangle 29; the third side surface 18₃ is opposite and generally parallel to the first side surface 18i and generally coincident with a third side 31₃ of the imaginary rectangle 29; and the fourth side surface 18₄ is opposite and generally parallel to the second side surface 18₂ and generally coincident with a fourth side 31₄ of the imaginary rectangle 29.

The first side surface I8₁ is shorter than the third side 31₃ of the imaginary rectangle 29 and the fourth side surface 18₄ is shorter than the second side 31₂ of the imaginary rectangle 29 such that the female side surface 18₅, which extends from the first side surface I81 to the fourth side surface 18₄, can be viewed as delimiting a cutout 37 extending inwardly from a corner 39 of the imaginary rectangle 29.

The male side surface 18₆, which extends from the second side surface 18₂ to the third side surface 18₃, is complementary to the female side surface 18₅. That is, the male side surface 18₆ has a profile which generally matches that of the female side surface 18₅. This allows the paver 12_j to be placed relative to an adjacent paver 12, (1 < i < N) such that the male side surface 18₆ of the paver 12_j registers with the female side surface 18₅ of the adjacent paver 12,. In other words, the male side surface 18₆ can be viewed as delimiting a portion 49 of the paver 12_j configured to substantially fill the cutout 37 delimited by the female side surface 18₅ of the adjacent paver 12,.

The pavers 12-ι ...12_N can thus be installed in the paved area 10 such that the male side surface 18₆ of each of the pavers 12i ...12_N registers with the female side surface 18₅ of an adjacent one of the pavers 12i ...12_N. As shown in Figure 1 , this results in a pattern in which adjacent ones of the pavers 12-ι...12_N are diagonally offset relative to one another (i.e., the second side surface 18₂ of a given one of the pavers 12i ...12_N is offset relative to the second side surface 18₂ of an adjacent one of the pavers 12i ...12_N in a first horizontal direction Hi while the third side surface 18₃ of the given one of the pavers 12-| ...12_N is offset relative to the third side surface 18₃ of the adjacent one of the pavers 12i ...12_N in a second horizontal direction H₂ perpendicular to the first horizontal direction Hi ).

Therefore, in addition to having a generally simple contour which facilitates their manufacture and installation, the pavers 12-ι ...12_N can produce an aesthetic pattern that avoids exhibiting an unwanted degree of linearity. Furthermore, as further discussed below, the pavers 12-| ...12_N can also be installed in various other patterns to produce different looks and/or enhance permeability of the paved area 10.

More particularly, in this embodiment, the imaginary rectangle 29 is an imaginary oblong rectangle (i.e., a rectangle having two parallel sides (in this example, the sides 31₂, 31₄) that are longer than its other two parallel sides (in this example, the sides 31₁, 3I₃)). In other words, a normal distance between the first side surface 18₁ and the third side surface I 8₃ is longer than a normal distance between the second side surface 18₂ and the fourth side surface 18₄.

Also, in this embodiment, the female side surface 18₅ comprises two (2) surface portions 44i, 44₂ that are generally perpendicular to one another such that the cutout 37 is generally rectangular. More specifically, in this example, the surface portions 44i, 44₂ are generally of the same length and thus the cutout 37 is generally square. Similarly, in this embodiment, the male side surface 18₆ comprises two (2) surface portions 46i, 46₂ that are generally perpendicular to one another. When the paver 12_j is placed relative to an adjacent paver 12, such that the male side surface 18₆ of the paver 12_j registers with the female side surface 18₅ of the adjacent paver 12,, the surface portions 46i , 46₂ of the paver 12_j respectively face the surface portions 44-ι, 44₂ of the adjacent paver 12,. Furthermore, in this embodiment, while it is shorter than the third side 31₃ of the imaginary rectangle 29, the first side surface 18i is longer than half of the third side 31₃ of the imaginary rectangle 29. Similarly, while it is shorter than the second side 31₂ of the imaginary rectangle 29, the fourth side surface 18₄ is longer than half of the second side 31₂ of the imaginary rectangle 29. More specifically, in this example, the first side surface I8₁ has a length which is about 2/3 that of the third side 31₃ of the imaginary rectangle 29, and the fourth side surface 18₄ has a length which is about 4/5 that of the second side 31₂ of the imaginary rectangle 29. These length ratios may take on various other values (e.g., 3/4) in other examples. Having at least one of the side surfaces I81, I 84 longer than half of the side of the imaginary rectangle 29 opposite to that side surface (i.e., the third side 31₃ for the first side surface I81 and the second side 31₂ for the fourth side surface 18₄) is particularly useful. For instance, this can allow the paver 12_j to have an overall shape which is aesthetically appealing, provides ample space to incorporate a pattern representing several paving units on the top surface 14 (as discussed below), eliminates or reduces a potential for fracturing of a salient portion of the paver 12_j adjacent to the female side surface 18₅, and/or enhances a molding efficiency of the pavers 12i ...12_N (as a relatively large quantity of paving material can be molded per unit of time).

To impart a natural look to the paved area 10, in this embodiment, the side surfaces 18_r186 of the paver 12_j are irregular so as to have a chiseled stone appearance. This can contribute to the paved area 10 appearing to be paved with chiseled stones.

In order to further enhance aesthetics of the paved area 10 and enable creation of various patterns of different looks, in this embodiment, the top surface 14 of the paver 12_j comprises a plurality of surface portions 20i-20₃ that are separated by false joints 211, 21₂ to represent a plurality of paving units. In the paved area 10, the surface portions 20_r20₃ result in a region of the paved area 10 being perceivable as including plural, in this case, three (3), paving units of different sizes and configurations. In other cases, the paver 12_j may comprise any number of surface portions representing any number of paving units. For example, in Figure 1 , some of the pavers 12i ...12_N are provided with two (2) surface portions representing two (2) paving units, while others are provided with four (4) surface portions representing four (4) paving units. Alternatively, in some cases, the top surface 14 may not comprise any false joint such that it does not comprise surface portions representing different paving units.

More particularly, in this embodiment, each of the surface portions 20_r20₃ has a texture with a natural stone appearance, i.e., an aged, worn, or weathered appearance that resembles natural stone. In this case, this texture is a cast texture that is realized during casting of the paver 12_j and that may be based on a natural stone's surface which has been used to produce a mold for casting the paver ^2_j.

A given surface portion 20_k (1 < k <3) will be described in further detail with additional reference to Figure 4, with this description similarly applying to other ones of the surface portions 20i-20₃. The surface portion 20_k includes a pattern of cast relief elements 23-_I ...23M formed during casting of the paver 12_j. This pattern of cast relief elements 23i ...23_M includes a plurality of peaks and a plurality of valleys, which are sized so as to be visually distinguishable when the paver 12_j is in the paved area 10. Various patterns of cast relief elements are possible in various embodiments.

The cast texture of the surface portion 20_k defines a "surface level difference" ΔL, which refers to the normal distance between a maximum level L_max and a minimum level L_mιn of that surface portion. As shown in Figure 4, the paver 12_j can be viewed as defining orthogonal X, Y and Z axes, where the X-Y plane is parallel to a plane that would be formed by the surface portion 20_k if that surface portion was flat. The surface level difference ΔL can be viewed as being measured along the Z axis. In some embodiments, the surface level difference

ΔL may be greater than 4 mm, for example, between 4 mm and 12 mm. This can enable the surface portion 20_k to exhibit desired natural stone appearance characteristics, while maintaining a degree of surface irregularity suitable for supporting pedestrian or other traffic. In other embodiments, the surface level difference ΔL may be greater or less.

The cast texture of the surface portion 20_k interacts with ambient light to create shadows that further contribute to its natural stone appearance. More particularly, in addition to its surface level difference ΔL, in this example, each point of the cast texture of the surface portion 20_k defines a respective "texture angle" θ, which refers to the acute angle between a plane parallel to the X-Y plane and a plane tangent to the surface portion 20_k at that point. In some cases, the texture angle θ of each of a plurality of points of the surface portion 20_k may be between 75^° and 90°. Providing a surface level difference ΔL in the above- mentioned ranges has been found to facilitate formation of such texture angles θ during casting. In other cases, the texture angles θ may take on various other values.

Each of the false joints 21_{1 s} 21₂ that separates two of the surface portions 2O₁- 2O₃ of the paver 12_j is a depression that can be viewed as having a depth, which refers to the normal distance between the maximum level L_max of either of these surface portions and that depression's deepest point. The depth of each of the false joints 21₁, 21₂ may take on various values. For example, in some embodiments, this depth may be greater than 4 mm, for example, between 4 mm and 12 mm. In other embodiments, this depth may be greater or less.

In order to facilitate proper positioning of the pavers 12i...12_N in the paver area 10 while imparting some degree of permeability to the paved area 10, in this embodiment, the side surfaces 18i-18e of the paver 12_j are provided with spacers 42_r42i₆. As shown in Figure 1 , in the paved area 10, the spacers 42_r 42-_I6 of the paver 12_j abut with corresponding ones of the spacers 42i-42₁₆ of adjacent ones of the pavers 12i...12_N. In this case, each of the spacers 42_r42i₆ extends upwardly from the bottom surface 15 of the paver 12_j, is spaced apart from an adjacent one of the spacers 42i-42₁₆, and projects from the side surface 18-₁-18₆ on which is it provided by a distance which is about half of a width of each of the false joints 21₁ , 21₂. In this way, joints between adjacent ones of the pavers 12-ι ...12_N are generally of the same width as false joints (such as the false joints 2I ₁, 21₂) on the pavers 12i ...12_N- The joints and false joints may then be filled with joint material (e.g., sand).

It will thus be appreciated that the pavers 12i ...12_N provide an aesthetic look to the paved area 10, which appears to be made of several paving units of various sizes and configurations. In this pattern in which adjacent ones of the pavers 12i ...12_N are diagonally offset relative to one another, the paved area 10 avoids exhibiting an unwanted degree of linearity, thereby further enhancing its aesthetic look. Owing to their generally simple contour, the pavers 12-ι ...12_N are relatively easy and quick to install. Also owing to their generally simple contour, the pavers 12i ...12_N can be efficiently manufactured as a relatively large quantity of paving material can be molded per unit of time. In this case, the manufacturing efficiency is further enhanced by realizing the natural stone appearance of the surface portions on the top surface 14 of the pavers 12i ...12_N during casting without requiring any subsequent mechanical artificial aging/weathering process (e.g., tumbling, object impacting, etc.). An example of a process for manufacturing pavers such as the pavers 12-| ...12_N will be presented later on.

In addition, the pavers 12-ι ...12_N may be installed in various other patterns to produce different looks and/or enhance permeability of the paved area 10. For instance, Figures 5 to 8 show examples of other patterns in which the pavers 12-| ...12_N can be installed. In these examples, adjacent ones of the pavers 12-| ...12_N form voids 50-ι-50_v, 52_r52_R in the paved area 10 that allow water to drain through the paved area 10 and into soil beneath it. The voids 50-ι-50_v, 52_r 52_R may be filled with drainage media (e.g., small, open-graded crushed stone) through which water can drain and optionally be filtered. Alternatively, one or more of the voids 50i-50_v, 52_r52_R may be covered by a drainage device positioned therein to drain and optionally filter the water. More particularly, in Figures 5 and 6, the pavers 12-| ...12N are arranged in a "herringbone" pattern. Specifically, in this case, a given paver of the pavers 12i ...12_N is surrounded by two (2) of the pavers 12i ...12_N which are in the same orientation as the given paver (i.e., the side surfaces 18₂, 18₄ of the given paver and those of these two pavers are generally parallel to the first horizontal direction H₁, and the side surfaces '\ 8<_\, I 8₃ of the given paver and those of these two pavers are generally parallel to the second horizontal direction H₂) as well as four (4) of the pavers 12i ...12_N which are in an orientation 90°-rotated relative to the given paver's orientation (i.e., the side surfaces 18₂, 18₄ of the given paver are generally parallel to the first horizontal direction Hi while those of these four pavers are generally parallel to the second horizontal direction H₂, and the side surfaces I8₁, 18₃ of the given paver are generally parallel to the second horizontal direction H₂ while those of these four pavers are generally parallel to the first horizontal direction H-i).

In the pattern of Figure 5, each of the voids 50i-50_v formed by the pavers 12-| ...12_N has a configuration that substantially corresponds to the cutout 37 delimited by the female side surface 18₅ of each paver. Thus, in this example, each of the voids 50i-50_v is generally rectangular (in this case, square). In contrast, in the pattern of Figure 6, the female side surfaces 18₅ of adjacent ones of the pavers 12-ι ...12_N are located next to one another such that each of the voids 52r52_R formed by the pavers 12-ι ...12_N has a configuration that substantially corresponds to two (2) contiguous instances of the cutout 37 delimited by the female side surface 18₅ of each paver. Thus, in this example, each of the voids 52r52_R has a generally oblong rectangular configuration that is twice as large as the voids 50_r50v in the pattern of Figure 5. The pattern of Figure 6 can therefore be more permeable than that of Figure 5.

In Figures 7 and 8, the pavers 12-| ...12_N are arranged in a "running bond" (also known as "stretcher bond") pattern. Specifically, in this case, the side surfaces 18₂, 18₄ of all of the pavers 12i ...12_N are generally parallel to the first horizontal direction H-i, and the side surfaces 18i, 18₃ of all of the pavers 12-i...12_N are generally parallel to the second horizontal direction H₂. In the pattern of Figure 8, some of the pavers 12-ι ...12_N are in an orientation 180^c-rotated relative to other ones of the pavers 12i ...12_N such that some of the voids 50_r50v formed by the pavers 12i ...12_N are closer to one another than those in the pattern of Figure 7. Here again, each of the voids 50i-50_v formed by the pavers 12-| ...12N has a configuration that substantially corresponds to the cutout 37 delimited by the female side surface 18₅ of each paver. Thus, in this example, each of the voids 50i-50v is generally rectangular (in this case, square).

It will thus be appreciated that, with their generally simple contour, the pavers 12-_I ...12_N can easily and quickly be installed in various patterns providing different looks to the paved area 10. The pavers 12i ...12_N also allow the permeability of the paved area 10 to be enhanced in a controllable manner by selecting a distribution and size of the voids 50r50_v, 52_r52_R.

While in this embodiment the pavers 12-| ...12_N are configured in a particular manner, the pavers 12-ι ...12_N may be configured in various other manners in other embodiments.

For example, in other embodiments, instead of being an imaginary oblong rectangle, the imaginary rectangle 29 with which coincide the side surfaces 18₁- 18₄ of the paver 12_j may be a square (i.e., a rectangle having all sides equally long), in which case a normal distance between the first side surface 181 and the third side surface 18₃ of the paver 12_j is substantially equal to a normal distance between the second side surface I82 and the fourth side surface 18₄ of the paver 12_j.

As another example, in other embodiments, the female side surface I8₅ of the paver 12_j may be configured in any other desired way (e.g., curved, jagged, etc.) such that the cutout 37 may have any other desired configuration. In such embodiments, the male side surface 18₆ is configured accordingly so as to complement the female side surface I8₅. For instance, Figures 9 to 14 show examples, in outline form, of various other configurations that the contour of the paver 12_j may have in other embodiments. A myriad of other configurations are possible in other embodiments.

As yet another example, in other embodiments, instead of being slightly irregular, the side surfaces 18-i-18₆ of the paver 12_j may be straight. Also, in these and other embodiments, the top surface 14 of the paver 12_j may comprise two or more surface portions that represent different paving units (such as the surface portions 20r20₃) but that are relatively flat instead of having a texture with a natural stone appearance as shown in Figures 1 to 4. For instance, Figure 15 shows an embodiment in which the side surfaces I 8₁-I8₆ of the paver12_j are straight and in which the surface portions 20i-20₃ that represent different paving units are relatively flat.

As yet another example, in other embodiments, the side surfaces 18-₁-I 8β of the paver 12_j may be provided with more spacers, less spacers, and/or differently- shaped spacers than the spacers 42r42-i₆. For instance, in some embodiments, the paver 12, may be provided with a single continuous spacer that follows the contour defined by the side surfaces 18_r18₆. Alternatively, in some embodiments, the paver 12_j may not comprise any spacers.

While in the embodiments considered above the contour of the paver 12_j is described with respect to its side surfaces 18i-18β, the contour of the paver 12_j may also be described in terms of sides of the paver 12_j. More specifically, as shown in Figure 16, in this example, the contour of the paver 12_j can be viewed as having a first side 70i (which generally corresponds to the first side surface I81), a second side 7O₂ (which is generally constituted by the second side surface I8₂ and the surface portion 46i of the male side surface 18₆), a third side 7O₃ (which is generally constituted by the surface portion AQ₂ of the male side surface 18ε and the third side surface 18₃), a fourth side 7O₄ (which generally corresponds to the fourth side surface 18₄), a fifth side 7O₅ (which generally corresponds to the surface portion 44₂ of the female side surfacei δs), and a sixth side 7O₆ (which generally corresponds to the surface portion 44i of the female side surface18₅). The second side 7O₂ is generally perpendicular to the first side 7O₁, the third side 7O₃ is opposite and generally parallel to the first side 70i , and the fourth side 7O₄ is opposite and generally parallel to the second side 7O₂. The sides 70_r70₄ are respectively coincident with the sides 31 _r31₄ of the imaginary oblong rectangle 29 discussed previously, and so a normal distance between the first side 70i and the third side 7O₃ is longer than a normal distance between the second side 7O₂ and the fourth side 7O₄. The first side 70i is shorter than the third side 7O₃ and the fourth side 7O₄ is shorter than the second side 7O₂ such that the fifth side 70s and the sixth side 7O₆ define a rectangular recessed space 80. When the pavers 12_r12_N are installed as shown in Figure 1 , a portion of the second side 7O₂ and a portion of the third side 7O₃ of the paver 12_j respectively register with the sixth side 7O₆ and the fifth side 7O₅ of an adjacent paver 12, such that part of the paver 12_j fits in the rectangular recessed space 80 of the adjacent paver 12,.

Turning now to Figure 17, there is shown a flowchart illustrating an example of a process for manufacturing pavers such as the pavers 12-| ...12_N.

At step 200, no-slump concrete is placed into a mold. To facilitate mass- production, in some embodiments, the mold has a plurality of cavities for molding respective pavers. The mold may be located such that pavers are placed on a production board when removed therefrom. Due to their generally simple contour with some of its side surfaces being generally coincident with sides of an imaginary rectangle, the pavers can be molded in an efficient manner as a relatively large quantity of paving material can be molded per unit of time.

Each cavity of the mold is configured to form a respective paver comprising side surfaces 18-₁-18₆ and, in this case, a top surface 14 with one or more surface portions (e.g., the surface portions 20_r20₃) representing different paving units.

To that end, in this embodiment, each cavity has a mold surface that includes one or more portions with a texture corresponding to the desired appearance of the corresponding surface portion of the paver to be molded. Each such portion of the mold surface thus defines a surface level difference AL' and texture angles θ'that correspond to the desired surface level difference ΔL and texture angles θ (Figure 4) of the corresponding surface portion of the paver to be molded.

In order to closely simulate natural stone, in some embodiments, each such portion of the mold surface, and thus the corresponding surface portion of pavers to be molded by the mold, may be based on a natural stone's surface. For example, data representative of the natural stone's surface may be obtained, for instance, via three-dimensional scanning of the natural stone's surface. The obtained data may then be computer-processed using software in order to generate data representative of the mold surface. In some cases, this processing may include modifying the obtained data representative of the natural stone's surface to set the desired surface level difference ΔL' and texture angles θ'.

As another possible consideration, in embodiments where individual ones of the cavities of the mold are intended to form pavers with different patterns of surface portions on their top surface 14, these individual cavities may be designed to each have a common volume in order to facilitate production. This may facilitate provision of substantially the same quantity of concrete into each cavity of the mold, which in turn facilitates efficient casting of pavers in the mold and subsequent removal of the pavers from the mold.

The mold may be manufactured via computer-aided manufacturing based on the data representative of the mold surface. Since no-slump concrete can be used, the mold may be made of metal or other rigid material. There is no requirement for one or more portions of the mold to be made of elastomeric material (e.g., rubber), which is typically used in molds for casting wet-cast products. Thus, during step 200, each cavity of the mold is filled with no-slump concrete in order to form a paver comprising side surfaces 18-ι-18₆ and, in this case, a top surface 14 with one or more surface portions representing different paving units.

At step 202, the no-slump concrete in the mold is consolidated. Consolidation may include inducing vibration of the no-slump concrete in the mold so as to cause it to compact itself and closely conform to each cavity of the mold. A pre- vibration phase may be effected during step 200 to facilitate filling of the no- slump concrete in the mold and its eventual consolidation. Consolidation may also include application of pressure on the concrete in combination with its vibration. Various other techniques may be used for consolidation in other embodiments.

Upon completion of step 202, the no-slump concrete in each cavity of the mold has formed into a paver comprising side surfaces 18r18₆ and, in this case, a top surface 14 with one or more surface portions representing different paving units.

At step 204, the paver in each cavity of the mold is removed therefrom and continues on the production board. The pavers may be directly stored for curing purposes. Since provision of a natural stone appearance may be effected during casting, the pavers do not require a subsequent mechanical artificial aging/weathering process (e.g., tumbling, object impacting, etc.) to impart them with such an appearance. Since the pavers can be made of no-slump concrete, curing times are relatively short such that they can be available for use within a short period of time (e.g., one day).

At step 206, each cavity of the mold is cleaned such that casting of new pavers may be effected. In some embodiments, a cleaning unit uses a fluid to clean each cavity of the mold. The fluid may be a gas (e.g., compressed air) or a liquid whose flow relative to each cavity of the mold removes therefrom substantially any remaining no-slump concrete. Such a fluid-based cleaning action enables rapid cleaning of each cavity of the mold, thereby increasing production efficiency. In some cases, the cleaning unit may also use, in addition to the fluid, one or more brushes to clean each cavity of the mold, whereby the fluid-based cleaning action is combined with a brushing cleaning action.

In this example, the process returns to step 200 where a new production cycle begins. In some embodiments, utilization of no-slump concrete in combination with rapid cleaning of the mold and other elements of the process may enable a production cycle to take a relatively short period of time (e.g., 15 to 20 seconds per square meter of finished products in some cases).

While this example illustrates one process that can be used to produce pavers such as the pavers 12-| ...12_N, various other processes may be used to manufacture such pavers in other embodiments.

Principles discussed above in connection with the pavers 12i ...12_N can also be applied to other types of blocks for constructing other types of structures. In particular, wall blocks for constructing walls (e.g., building walls, retaining walls, free-standing walls, etc.) may be designed according to principles discussed in connection with the pavers 12-ι ...12_N. For example, in some embodiments, each wall block may be configured generally like the paver 12_j with a front surface generally like the top surface 14 of the paver 12_j (e.g., with two or more wall- erecting units analogous to the paving units 2O_r2θ3 of the paver 12_j) and a contour formed by side surfaces generally like the side surfaces 18i-18₆ of the paver 12_V The wall blocks may then be installed into a pattern generally like that in which the pavers 12-ι ...12_N are installed in the paved area 10 shown in any of Figures 1 and 5 to 8, for example, to erect a wall. For instance, a portion of the wall may look like the paved area 10 shown in Figure 1 (with the wall being vertical whereas the paved area 10 is horizontal). Mortar or some other joint material may be used when erecting the wall to fill joints and false joints defined by the wall blocks. Although various embodiments and examples have been presented, this was for the purpose of describing, but not limiting, the invention. Various modifications and enhancements will become apparent to those of ordinary skill in the art and are within the scope of the invention, which is defined by the appended claims.

Claims

1. A set of pavers for paving an area, each paver comprising:

- a first side surface generally coincident with a first side of an imaginary rectangle;

- a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle;

- a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle but longer than half of the third side of the imaginary rectangle;

- a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle;

- a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and

- a male side surface complementary to the female side surface and extending from the second side surface to the third side surface; wherein the pavers are installable in a pattern in which the male side surface of one of the pavers registers with the female side surface of an adjacent one of the pavers.

2. A set of pavers as claimed in claim 1 , each paver comprising a top surface comprising a plurality of portions that are separated by at least one false joint to represent a plurality of paving units.

3. A set of pavers as claimed in claim 2, for each of at least one of the pavers: the plurality of portions including at least three portions, the at least one false joint including at least two false joints, and the plurality of paving units including at least three paving units.

4. A set of pavers as claimed in claim 1 , the first side surface having a length which is at least 2/3 that of the third side of the imaginary rectangle.

5. A set of pavers as claimed in claim 4, the length of the first side surface being at least 3/4 that of the third side of the imaginary rectangle.

6. A set of pavers as claimed in claim 1 , the fourth side surface being longer than half of the second side of the imaginary rectangle.

7. A set of pavers as claimed in claim 6, the first side surface having a length which is at least 2/3 that of the third side of the imaginary rectangle and the fourth side surface having a length which is at least 2/3 that of the second side of the imaginary rectangle.

8. A set of pavers as claimed in claim 1 , the female side surface comprising two portions that are generally perpendicular to one another such that the cutout is generally rectangular.

9. A set of pavers as claimed in claim 8, the two portions of the female side surface being generally of the same length such that the cutout is generally square.

10. A set of pavers as claimed in claim 1 , the female side surface being curved or jagged.

11. A set of pavers as claimed in claim 1 , the imaginary rectangle being an imaginary oblong rectangle.

12. A set of pavers as claimed in claim 1 , the first, second, third, fourth, female and male side surfaces being irregular so as to have a chiseled stone appearance.

13. A set of pavers as claimed in claim 1 , the first, second, third, fourth, female and male side surfaces being generally flat.

14. A set of pavers as claimed in claim 1 , each paver comprising at least one spacer projecting outward Iy from at least one of the first, second, third, fourth, female and male side surfaces.

15. A set of pavers as claimed in claim 2, each of the portions of the top surface that represents one of the paving units having a texture with a natural stone appearance.

16. A set of pavers as claimed in claim 15, the texture comprising cast relief elements formed during casting of the paver.

17. A set of pavers as claimed in claim 1 , wherein the pattern is a first pattern and wherein the pavers are installable in a second pattern in which adjacent ones of the pavers form a plurality of voids in the area that allow water to drain into soil beneath the pavers, each of the voids being delimited by the female side surface of at least one of the pavers.

18. A set of pavers for paving an area, each paver comprising:

- a first side surface generally coincident with a first side of an imaginary oblong rectangle; - a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary oblong rectangle;

- a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary oblong rectangle, the first side surface being shorter than the third side of the imaginary oblong rectangle;

- a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary oblong rectangle, the fourth side surface being shorter than the second side of the imaginary oblong rectangle;

- a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary oblong rectangle; and

19. A set of pavers as claimed in claim 18, each paver comprising a top surface comprising a plurality of portions that are separated by at least one false joint to represent a plurality of paving units.

20. A set of pavers as claimed in claim 19, for each of at least one of the pavers: the plurality of portions including at least three portions, the at least one false joint including at least two false joints, and the plurality of paving units including at least three paving units.

21. A set of pavers as claimed in claim 18, the first side surface being longer than half of the third side of the imaginary oblong rectangle.

22. A set of pavers as claimed in claim 21 , the first side surface having a length which is at least 2/3 that of the third side of the imaginary oblong rectangle.

23.A set of pavers as claimed in claim 22, the length of the first side surface being at least 3/4 that of the third side of the imaginary oblong rectangle.

24.A set of pavers as claimed in claim 18, the fourth side surface being longer than half of the second side of the imaginary oblong rectangle.

25.A set of pavers as claimed in claim 24, the first side surface having a length which is at least 2/3 that of the third side of the imaginary oblong rectangle and the fourth side surface having a length which is at least 2/3 that of the second side of the imaginary oblong rectangle.

26.A set of pavers as claimed in claim 18, the female side surface comprising two portions that are generally perpendicular to one another such that the cutout is generally rectangular.

27. A set of pavers as claimed in claim 26, the two portions of the female side surface being generally of the same length such that the cutout is generally square.

28. A set of pavers as claimed in claim 18, the female side surface being curved or jagged.

29. A set of pavers as claimed in claim 18, the first, second, third, fourth, female and male side surfaces being irregular so as to have a chiseled stone appearance.

30. A set of pavers as claimed in claim 18, the first, second, third, fourth, female and male side surfaces being generally flat.

31.A set of pavers as claimed in claim 18, each paver comprising at least one spacer projecting outwardly from at least one of the first, second, third, fourth, female and male side surfaces.

32. A set of pavers as claimed in claim 19, each of the portions of the top surface that represents one of the paving units having a texture with a natural stone appearance.

33.A set of pavers as claimed in claim 32, the texture comprising cast relief elements formed during casting of the paver.

34.A set of pavers as claimed in claim 18, wherein the pattern is a first pattern and wherein the pavers are installable in a second pattern in which adjacent ones of the pavers form a plurality of voids in the area that allow water to drain into soil beneath the pavers, each of the voids being delimited by the female side surface of at least one of the pavers.

35. A set of pavers for paving an area, each paver comprising: - a first side;

- a second side generally perpendicular to the first side;

- a third side opposite and generally parallel to the first side;

- a fourth side opposite and generally parallel to the second side, a normal distance between the first side and the third side being longer than a normal distance between the second side and the fourth side; a fifth side generally perpendicular to the fourth side; and

- a sixth side generally perpendicular to the first side, the first side being shorter than the third side and the fourth side being shorter than the second side such that the fifth side and the sixth side define a rectangular recessed space; wherein the pavers are installable in a pattern in which a portion of the second side and a portion of the third side of a given one of the pavers respectively register with the sixth side and the fifth side of an adjacent one of the pavers such that part of the given one of the pavers fits in the rectangular recessed space of the adjacent one of the pavers.

36.A set of pavers as claimed in claim 35, each paver comprising a top surface comprising a plurality of portions that are separated by at least one false joint to represent a plurality of paving units.

37. A set of pavers as claimed in claim 36, for each of at least one of the pavers: the plurality of portions including at least three portions, the at least one false joint including at least two false joints, and the plurality of paving units including at least three paving units.

38. A set of pavers as claimed in claim 35, the first side being longer than half of the third side.

39. A set of pavers as claimed in claim 35, the fourth side being longer than half of the second side.

40. A set of pavers as claimed in claim 35, wherein the pattern is a first pattern and wherein the pavers are installable in a second pattern in which adjacent ones of the pavers form a plurality of voids in the area that allow water to drain into soil beneath the pavers, each of the voids being delimited by the fifth side and the sixth side of at least one of the pavers.

41.A set of wall blocks for constructing a wall, each wall block comprising:

- a front surface exposed when the wall block is in the wall; a first side surface generally coincident with a first side of an imaginary rectangle; - a second side surface generally perpendicular to the first side surface and generally coincident with a second side of the imaginary rectangle;

- a third side surface opposite and generally parallel to the first side surface and generally coincident with a third side of the imaginary rectangle, the first side surface being shorter than the third side of the imaginary rectangle;

- a fourth side surface opposite and generally parallel to the second side surface and generally coincident with a fourth side of the imaginary rectangle, the fourth side surface being shorter than the second side of the imaginary rectangle; - a female side surface extending from the first side surface to the fourth side surface and delimiting a cutout extending inwardly from a corner of the imaginary rectangle; and a male side surface complementary to the female side surface and extending from the second side surface to the third side surface; wherein the wall blocks are installable in a pattern in which the male side surface of one of the wall blocks registers with the female side surface of an adjacent one of the wall blocks.

42.A set of wall blocks as claimed in claim 41 , the front surface comprising a plurality of portions that are separated by at least one false joint to represent a plurality of wall-erecting units.

43. A set of wall blocks as claimed in claim 42, for each of at least one of the wall blocks: the plurality of portions including at least three portions, the at least one false joint including at least two false joints, and the plurality of wall- erecting units including at least three wall-erecting units.

44. A set of wall blocks as claimed in claim 41 , the first side surface being longer than half of the third side of the imaginary rectangle.

45.A set of wall blocks as claimed in claim 44, the fourth side surface being longer than half of the second side of the imaginary rectangle.