REUSABLE RECYCLED POLYMER COBBLE AND PAVING SYSTEM

Abstract

 Reusable recycled polymer cobble and paving system. The cobble comprises two removable pieces: an inner block of polymeric material and a coating cover of different composition and properties that encapsulates the inner block making the assembly capable of fulfilling its function. Likewise, the paving system includes a modular grid on which the cobbles are positioned, optimizing the assembly and subsequent maintenance of the pavement.

Description

TECHNICAL SECTOR

[0001] This patent application concerns a reusable cobble made of recycled polymer and a paving system for such cobble with a modular grid for the assembly of the cobbles.

[0002] The invention is framed in the construction sector and, in particular, with cobbles used in the paving of streets, roads and paths.

BACKGROUND OF THE INVENTION

[0003] In the state of the art are known conventional cobbles made with moldable or extrudable materials, usually mortar, ceramic and concrete. These cobbles have disadvantages in terms of weight, durability, transport and are difficult to replace due to rupture or other reasons.

[0004] Currently, there is a serious problem of environmental pollution, generated mainly by the accumulation of polymeric waste in natural spaces and landfills. In order to reduce this problem, the present invention proposes to reuse this waste in the elaboration of the cobble with better properties than conventional ones, based on the philosophy of reducing, recycling and reusing. This idea aims to contribute to a sustainable construction and offer a solution in the treatment of plastics that are difficult to recycle, making it an alternative to the process of eliminating plastic waste. This invention allows to integrate in a respectful way with the environment all kinds of plastic waste in pavements of sidewalks, squares and roundabouts, parks, roads, gardens and other similar places.

EXPLANATION OF THE INVENTION

[0005] A first object of the present invention relates to a reusable recycled polymer cobble according to claim 1.

[0006] The recycled polymer cobble object of the invention comprises two removable pieces, separable from each other, which are preferably joined by a embedding system, for example, by tabs or another equivalent system. These two removable pieces are, respectively, an inner block and a coating cover that encapsulates the inner block, when it is introduced into the interior of the cover. The combination of both pieces gives the cobble the mechanical and aesthetic properties required.

[0007] The inner block is preferably a geometric body, comprising a lower base, an upper base and at least one side wall linking both bases, preferably a rectangular prism, not dismissing other geometric bodies.

[0008] The coating cover has a recess inside to receive and encapsulate this block, so that it comprises an upper surface, a lower opening. The upper base of the inner block is arranged inside the cover, facing the inside of the upper surface of the cover and the lower base of the block is exposed by the lower opening of the cover.

[0009] To facilitate the assembly of the inner block in the cover it is possible that the inner block presents slight modifications in its surface to guarantee a quick introduction into the cover, for example, incorporating chamfers in its edges as well as to ensure the correct assembly of the block inside the cover.

[0010] To ensure the position of the inner block in the cover and to prevent the two from separating while maintaining unity, it is preferable that the assembly has embedding means or an embedding system, for example, by means of existing tabs inside the hollow of the cover that will be introduced, when the coupling between both pieces is made, in holes practiced on the surface or surfaces of the inner block. There are other alternatives to the tabs as means of embedding, for example, protruding pins or inlets on the inner surface of the cover that are complementary with inlets or protruding pins at the upper base of the inner block, ensuring the press-fit coupling between both pieces. Another possibility is to fix the cover to the block or vice versa by means of, for example, screws, preferably two, arranged on the side wall or walls.

[0011] The lower base of the inner block may also have holes or stands out that will facilitate its installation in a paving system as described below.

[0012] The assembly of the cover and internal block once assembled form a solid cobble with the features required to the construction standard to which it is intended. This two-piece design allows the total or partial and simple replacement of any of the two pieces of the cobble, either due to repair, or any other reason, such as the horizontal signaling of a zebra crossing in which only the covers will be replaced by others of the corresponding color.

[0013] In accordance with the above, the main property of the cobble coating cover is to allow the assembly formed by both pieces the possibility of disassembly for replacement due to deterioration and the customization of the exposed face of the cobble in terms of texture, color and light, among others.

[0014] The inner block of the cobble is made by means of a compression molding process of post-consumed polymeric waste, that is, waste of recycled material obtained from products already used, which may be, for example, of urban, agricultural or industrial origin. In this process the homogenization of the polymer mixture used as a raw material is not required, the proportions and types of polymers that can be found in it can be extremely variable, depending on the type of post-consumed waste used. In general, the mixture resulting from this type of waste usually contains the following polymers: Polyethylene (LDPE, MOPE and HDPE), PP Polypropylene, Polyvinyl Chloride (PVC), Polystyrenes (PS, EPS, ABS, ASA), Polyamide (PA 6, PA 6.6, etc.), hard plastics, polymer plastic composite materials and other thermoplastics. The mixture may also contain other kinds of non-polymeric waste such as paper labels, metal staples, small pieces of glass, fabrics, wood and other elements. To achieve that the resulting blocks are compact, of a homogeneous or partially homogeneous compound, it is required that the base material used as a whole contains a minimum proportion of 60% polyolefins. This proportion is determined by the set of polymers contained in the base matter that forms the mixture. In case the mixture does not reach the recommended proportion, it will be necessary to add to it one or more polymers of which are listed below until the mixture reaches a minimum purity required: acrylonitrile/butadiene/styrene (ABS), polyethylene (PE) including high, medium and low density polyethylene (PE), polycarbonates (PC), polytetrafluoroethylene (PTFE), polyethylene terephthalates (PET), ethylene/vinyl acetate (EVA) polymers, polymethylene (PMMA), polyoxymethylene (PEM), styrene/acrylonitrile polymers (SAN), polystyrene (PS, EPS, ASA), polyamides (PA), polypropylene (PP), polyvinyl chlorides (PVC) and polyurethanes (PUR) and especially polyethylene (PE) and/or polypropylene (PP). This proportion of polyolefins in the mixture is sufficient to all non-polymeric materials be integrated into the resulting block, obtaining compact blocks of great resistance, fully valid for the manufacture of the cobble of this invention.

[0015] The main advantage in the use of these recycling materials is that they do not require selection by type, nor prior washing of the waste used, in most cases.

[0016] The coating cover is preferably made by a co-injection process or other similar processes from two different formulations, in order to achieve a multilayer structure with the best properties provided by each of the formulations. The formulations are applied to the structure of the cover, one for the outer lining of said cover and one for the upper surface of the cover, as can be seen, for example, in Figure 5. Co-extrusion process allows the cover to be made with two different formulations: a first formulation with better quality material, dyes and extra additives, such as glass microspheres that intertwin within the material that forms this face, so that the resistance to abrasion is increased, the non-slip properties is increased and aesthetic improvement of the product, and which is applied in the elaboration of the upper surface of the cover that is the visible face of the cobble; and a second formulation with the recycled polymer material with the essential additives for the creation of the lateral structure, or outer coating, of the cover according to use requirements. With this process a high quality coating is obtained at a competitive price, in which two formulations can be used, which combine their properties in a multilayer structure. Thus, with the additives in the formulation it can be modified the durability, improve the impact and UV light resistance, anti-slip, abrasion resistance and improvement of aesthetic properties among others.

[0017] The main mechanical features that the cover brings to the assembly are durability, higher coefficient of friction, resistance to UV rays, resistance to thermal fatigue, resistance to mechanical fatigue and resistance to abrasion. Therefore, the main functions of the cover are:

• Providing durability to the internal block, protecting it from degradation by the action of the environment by the encapsulation of the inner block.
• Reinforcing the structure of the cobble, adding and / or improving the necessary features depending on the use for which it will be intended.
• Aesthetics, determining the exterior appearance of the cobble in relation to colors, textures, reliefs and other features.

[0018] The formulation used in the elaboration of the outer lining of the cover preferably includes thermoplastic polymeric compounds, with different additives that satisfy different functions, depending on the use for which the cobble is intended, and requirements of the current regulations for the manufacture of cobbles depending on their use (for example, pedestrian, traffic, climate, construction standards or other conditions, etc.) and/or to obtain a higher degree of quality. Preferably, the polymeric material used in the formulations is recycled and/or virgin polypropylene to create the structure of the cover, although any other type of polymer can be used for achieving the required properties. The preferred material is polypropylene because it has certain advantages compared to other plastics, as it has good impact resistance among thermoplastics, has good mechanical resistance and fatigue, excellent dielectric properties, is not affected by acids or atmospheric gases, is resistant to the attack of moths, bacteria and fungi, resistant to heat and has a low coefficient of moisture absorption. In addition to having a low cost, good processability, it is easily accessible through recycling and has great durability. All these features provide significant advantages when using this polymer in the manufacture of the cobble coating cover.

[0019] Likewise, the upper surface of the cover, or visible face of the cover and the cobble, is preferably made with an improved formulation, because it is the most exposed part, both in mechanical terms (pressure, abrasion, impacts, others) and environmental (temperature, climatology, UV rays, others), in addition to the fact that to a large extent it determines the final features of the cobble and its aesthetics. For these reasons, the polymer formulation used in the manufacture of this piece is additive with compounds that improve its mechanical, thermal and aesthetic properties, depending on the final quality required. The use of these additional additives increases the cost of production, so it is restricted to the parts of the cover that require it through the aforementioned co-injection process or other similar processes. The thickness of the upper surface of the cobble will be defined according to the required quality of the surface to be paved, as well as, for example, the density of traffic that will circulate above the cobble and the nature of it.

[0020] Below, as an example, some of the additives that can be used in the formulations of the cover are detailed:

• UVA stabilizers: Cobbles are used in outdoor pavements so they can be exposed to hard weather conditions. Cobbles require a weather-resistant polymeric material, capable of withstanding the negative effects that ultraviolet radiation can have on appearance and mechanical properties.
• Plasticizers, to increase the flexibility and resistance to impact / ductility of the polymer. In order to enhance the impact resistance of the visible face of the cobble cover, ethylene can be added in the polymerization, obtaining with this a copolymer of great resistance to impact.
• Thermal stabilizers: They prevent the degradation of polymers during their treatment in high/low temperatures. For example, adding ethylene to polypropylene solves the problem of polypropylene fragility below 40°C, thus expanding the resistance to thermal fatigue of the final product, as well as its operating range.
• Loads: Loads are substances that are incorporated into the base formulation with various objectives, among others the modification of mechanical properties. For example, the addition of premixed glass microspheres during the manufacturing process of the upper face or visible face of the cobble cover, to enhance the coefficient of friction and achieve non-slip properties. These techniques make it possible to create a suitable coating at a competitive price, using an environmentally friendly process. Likewise, other loads can be used with the aim of improving the result of the product, such as polycarbonate, chopped glass fiber, textile fibers, calcium carbonate, silica or mineral powder.
• Flame retardants: Flame retardants reduce the flammability of plastics, for example, coating the polymer to remove/reduce oxygen negatively influences combustion.
• Color pigments: Color can be included in the upper surface of the cover or in the entire cobble, during processing with a color concentrate, to give the cover or upper surface a certain color. For example, titanium dioxide (TiO2), which provides white color, or graphite, which provides black color.

[0021] Likewise, it is possible to incorporate in the cobble covers other technological elements such as, electrical and electronic elements to provide lighting to the cobble, active signaling with LED on the coating cover, generation of electricity by photoelectric cells or by pressure by quartz crystals, as well as the conversion of the floor into a matrix of LED diodes for the projection of images.

[0022] A second object of the invention is, according to claim 14, a paving system comprising a series of cobbles such as the one described above and a modular grid for the assembly on it of cobbles. The modular grid comprises a framework of elements with means of coupling by pressure to attach to the cobbles. Likewise, the elements of the framework will present at their free ends coupling means for their union with other grids providing modularity to the system. In addition, and as can be seen in Figure 9, the grid can incorporate wiring guides, clamping media and through holes for the connectors in the luminaire mode.

[0023] The assembly of the cobbles on a pavement can be carried out in the same way as traditional cobbles or by means of the paving system object of the invention. In all cases the pavements built with the cobbles of the present invention (with or without modular grid) provide a removable paving, being able to lift and place again as many times as necessary in a simple and fast way.

[0024] The previous preparation of the paving for the placement of the cobbles object of the present invention is similar to that of conventional concrete cobbles consisting of a compacted base of sand. On this sand base are placed either the cobbles directly or the modular grids according to the paving system object of the invention. In the latter case, on this sand base the modular grids are placed joined together by corresponding couplings arranged at the ends of the grids to cover the entire area to be paved. The assembly of modular grids forms a compact mesh on which the cobbles are arranged by pressure by introducing, preferably, protruding pins from the grids into holes existing at the lower base of the inner block of the cobble. Alternatively, the protruding pins could be placed at the lower base of the inner block and the holes in the modular grid, but this option is less preferred as the protruding pins in the inner block make it difficult to store and transport. Other mechanical pressure coupling systems between the inner block and the grids are possible. Finally, the pavement is completed by filling the joints between the cobbles with sand.

[0025] The cobbles can also be mounted directly on the compacted sand base, or similar, in the same way as with conventional cobbles, although the advantages obtained with the use of the modular assembly grid are lost.

[0026] The use of the modular grid in the paving system object of the invention offers the following advantages: ease of assembly, reduction of paving times, increases the overall bearing capacity and the compaction of the resulting pavement since the grid unifies the constructive assembly as if it were a single piece, improving the distribution of pressures exerted on the pavement.

[0027] Likewise, the combined use of the modular grid and the cobble of the present invention, facilitates the replacement of deteriorated or broken cobbles. In this way, the cobbles can be removed from the pavement, opting for the replacement of the cobble coating cover and preserving the same interior block or for the replacement of the cobble with a new one.

[0028] The modular mounting grid has a configuration design and variable dimensions depending on the chosen arrangement of the cobbles on the pavement. Mainly, it consists of a mesh, preferably with pins, or protrusions, although they could also be holes or inlets, which allow the anchoring of the cobbles to it preferably by pressure. The grid is preferably manufactured with recycled materials that provide the same with flexibility and strength. The modular grids are designed to be joined together by means of fastening elements arranged at its free ends, thus being able to be sized to cover up the entire surface to be paved. As a result of the joining of grids, a compact piece is obtained that behaves as if it were a single piece and will constitute the support base of the pavement.

[0029] For all the above, the present invention is added to the previous alternatives with notable advantages that exceed those that are known because they result in a simple process that improves the features of conventional cobbles such as lower weight, greater durability, ease of replacement and repair. The additional extra features are determined by the elements that are incorporated into the upper surface or visible face of the cobble coating cover. The elements of the invention here exposed can be manufactured in any shape, color and size. It is worth emphasizing, once the nature and advantages of the invention has been described, the non-limiting nature of the invention, since changes in the shape, material or dimensions of its constituent parts will not alter in any way its essentiality, as long as they do not imply a substantial variation in the assembly.

BRIEF DESCRIPTION OF THE FIGURES

[0030] To complement the description that is being made and in order to help a better understanding of the characteristics and advantages of the invention, the following figures are accompanied by illustrative and not limiting a preferred, but not exclusive, embodiment.

Figure 1 shows a perspective top view of the main cobble block of the invention.

Figure 2 shows a lower perspective view of the main cobble block of the invention.

Figure 3 shows a top perspective view of the cobble cover of the invention.

Figure 4 shows a lower perspective view of the cobble cover of the invention.

Figure 5 shows two cross sections of the cobble cover of the invention.

Figure 6 shows a perspective top view of the cobble, coincident with the perspective top view of the cover containing the main cobble block inside.

Figure 7 shows a lower perspective view of the cobble with its two components, with the main cobble block being seen inside the cover.

Figure 8 shows a perspective view of the modular assembly grid or modular mounting grid.

Figure 9 shows a lower perspective view of the modular assembly grid or modular mounting grid.

Figure 10 shows a perspective view of the system formed by the cobbles object of the invention on the modular assembly grid forming the pavement.

PREFERRED EMBODIMENT OF THE INVENTION

[0031] Below is described an example of a preferred embodiment of a cobble and a paving system according to the present invention. The example embodiment refers to a cobble (1) shaped like a prism with a rectangular base, although it could be a prism with a triangular, square or even cylindrical base. This cobble (1) comprises two separable pieces, a first piece or inner block (10) and a second piece or coating cover (20) that can receive and house the inner block (10).

[0032] The inner block (10) comprises an upper base (11) and a lower base (15) with sidewalls (12) between them. Between the walls (12), as well as between the upper base (11) and the walls (12) the edges are chamfered (13) to facilitate the introduction and assembly of the inner block (10) in the cover (20).

[0033] On the other hand, the coating cover (20) comprises an upper surface (21) and side walls (22) that determine a hollow (25) with a lower opening to allow the introduction into said hollow (25) of the inner block (10). The edges between the upper surface (21) and the outer walls (22) may be chamfered (23). Likewise, this coating cover (20) will comprise two materials for its manufacture. The first (27), preferably of a generic nature and recycled origin, for the outer coating or side walls of the cover (20), and the second (28) one, enriched with different additives that improve its properties, for the upper surface of said cover (20).

[0034] To ensure the coupling between the inner block (10) and the cover (20), to prevent the undesired detachment of the block (10) from the cover (20), coupling means are provided between both pieces. Preferably, these coupling and fastening means are tabs (24) existing inside the walls (22) of the cover (20) that are embedded in indentations or holes (14) existing in the inner block (10).

[0035] In a preferred construction, the lower base (15) of the lower block (10) comprises coupling means for its coupling to a modular grid (30) of assembly and forming, both elements, the cobble (1) and the grid (30), a paving system. These coupling means in the inner block (10) are preferably at least one hole (16) to be inserted into protruding pins (32) arranged in the modular grid (30).

[0036] This grid (30) comprises a framework of elements (33) forming a mesh. Said elements present the coupling means in the form of protruding pins (32) on their surface. In addition, the free ends (34, 35) of a modular grid (30) comprise joining or coupling means with other modular grids (30). Preferably, these joining means are pins (32) arranged at some free ends (34) and holes (31) arranged at other free ends (35), so that the pins (32) of a free end (34) of a first modular grid will be introduced into the holes (31) of the free ends (35) of a second modular grid (30). The pins (32) will also help to be introduced in the holes (16) of the inner block (10) of the cobble (1).

[0037] Optionally, the cobble will be able to comprise lighting properties. For this, a connector must be inserted into a hole (26), made in the cover (26), that will reach said hole (26) through holes or orifices (36) made in the positioning grid (30). To guide the required wiring, the grid (30) comprises specific guides (37) for this purpose with its corresponding fixing tabs (38).

[0038] Figure 10 shows a portion of pavement made of some cobbles (1) assembled on four modular grids (30) coupled together.

Claims

1. Reusable cobble characterized in that it comprises at least two separable pieces, a first piece, inner block, of recycled polymer and a second piece, coating cover, with a hollow in which the inner block is introduced.

2. Cobble, according to claim 1, characterized in that the inner block is a geometric body with a lower base, an upper base and at least one side wall linking both surfaces.

3. Cobble, according to claim 2, characterized in that the coating cover comprises an opening that gives access to the hollow with the shape of the inner block to allow the housing of said block in the cover, and an upper surface representing the visible face of the cobble

4. Cobble, according to claim 2, characterized in that the lower base comprises pressure coupling means.

5. Cobble, according to claim 1, characterized in that it comprises embedding means between the inner block and the coating cover to ensure the position of the inner block inside the coating cover.

6. Cobble, according to claim 1, characterized in that the coating cover is of a different material from that of the inner block.

7. Cobble, according to any of the above claims, characterized in that the inner block comprises at least 60% polyolefins in the recycled polymer that composes it.

8. Cobble, according to any of the above claims, characterized in that the coating cover and its inner block comprise at least one thermoplastic polymer in its formulation.

9. Cobble, according to claim 8, characterized in that the coating cover comprises at least one additive.

10. Cobble, according to any of the above claims, characterized in that the coating cover comprises electrical and electronic elements.

11. Paving system, characterized in that it comprises a cobble according to claim 1 and any of its dependent claims, and a modular assembly grid.

12. Paving system, according to claim 11, wherein the grid comprises a framework of intertwined elements with embedding means by pressure to receive the cobbles through its coupling interface.

13. Paving system, according to claim 12, wherein the framework elements that make up the grid have at their ends free coupling means to be coupled to at least one other grid.

Drawing