Patent Application
20110146175
The present invention relates to landscaping products (e.g. retaining wall building materials, landscaping stones/boulders, pavers . . . ) and wall veneering products that provide a replica image of a natural stone, rock, brick or wood surface. Such landscaping and veneering products are easily installable due to its lightweight characteristics and engagable design. The present invention further includes methods of use for such landscaping and veneering products and also includes systems for assembling such products to provide pleasing landscaping and wall veneering arrangements. The present invention also includes methods of manufacture of these imaged stone products, which ensures the natural appearance of stone, rock, brick or wood by imaging a natural surface, such as stone or a rock, preparing a mold from that image to mass produce a replica of that particular surface and applying a coating to the surface of the replica to provide the appearance and texture of the natural stone or rock.
Even though the use of the actual natural materials (e.g. cut stone, rocks, boulders, brick or wood) is common in the construction and landscaping industries, such products have produced challenges that have caused problems related to transportation and installation. For example, the utilization of natural stone, concrete, boulders, brick or wood can be cumbersome during transportation and installation of such products due to their heavy weight and, when used as wall coverings, the difficulties in easily attaching such products to each other or to the surface of a substrate such as a wall or panel. Furthermore, stone (natural or cultured), rock, concrete and wood products often discolor, stain or degrade over time, thereby damaging their aesthetic appearance and ultimately requiring their replacement.
The landscaping/construction industry and home improvement product manufacturers have found difficulties in manufacturing products utilizing materials such as plastic, fiberglass, ceramics and the like that simulate cut stone, rock and boulders. Such products have not been able to adequately capture the desired look found in their natural counterparts and in many of these products, have been less that durable. For example, such products often do not have the proper combination of texture, relief and color that would lead an observer to believe it was the natural product rather than a poor simulation. The industry still searches for a landscaping, construction and/or resurfacing product that is lightweight, easily installable, consistently durable, provides stunning natural aesthetics and maintains its natural appearance for long periods of time.
Embodiments of the present invention relate to polymeric or composite landscaping products or wall surface veneering products and the methods of use and manufacture for such products. The landscaping and veneering products of the present invention are generally produced with one or more materials (e.g. thermoplastics, thermosets, fiberglass, ceramics . . . ) that are resistant to damage and wear caused by the environment, such as sunlight, water, pest infestation and staining from dirt or other organic materials. In various embodiments of the present invention, the utilization of polymers (e.g. high density polyethylene, polypropylene and the like), that are processed using high pressure injection molding, compression molding, structural foam and/or other foamed polymer techniques (e.g. implementation of chemical foaming agents) produce landscaping and wall veneering products that have desirable textures and relief, but still provide incredibly robust and sturdy structural characteristics. Moreover, in various embodiments, the use of structural foam and/or foamed polymer products that are coated using the processes and techniques described herein provide the desired texture and color of the natural product, such as stone, rock or boulders. The landscaping and veneering products of the present invention are generally light weight and provide a beneficial alternative to other landscaping or wall coverings, such as natural or cultured stone, brick, wood, boulders, rock and the like.
The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention. Hence, the methods and processes described in each of the embodiments disclosed below may be applicable to other embodiments. For example, the techniques described below to image, texture, paint and or coat a substrate to produce a stone, rock or boulder appearance may be utilized in any embodiment related to retaining wall block/mass confinement cell technology, pavers, boulders, wall veneering or any other landscaping or wall covering product wherein the appearance of natural stone, rock or boulders is desired.
In various embodiments of the present invention, deterioration resistant blocks or mass confinement cells may be imaged, textured and painted to provide the appearance of cut or quarried stone or rock. Examples of such blocks or mass confinement cells may be found in U.S. Pat. Nos. 6,571,154, 6,817,154 and 7,198,435, and U.S. patent application Ser. Nos. 11/463,816 and 11/463,820, the entire contents of which are incorporated by reference herein.
Similar to the embodiments depicted in the paragraphs above, the mass confinement cells 210 of this embodiment include no top panel or a partial top panel and no bottom panel or a partial bottom panel. When a plurality of confinement cells 210 are positioned in proximity to each other in a wall structure, the open top and bottom allows for the flow and/or commingling of fill material from one confinement cell to adjacent confinement cells above and/or below through the continuous flow chambers 220.
In various embodiments of the present invention, the front panel 224 of the confinement cell 210 may be flat, rounded, beveled and/or textured by molding or by a secondary fabrication process to provide the desired earthen appearance and/or design. However, in other embodiments a fascia 254, as depicted in
As depicted in
The front panel 224 may further include one or more load bearing members 204. These load bearing members 204 are configured to take pressure off the fascia 254 when a wall is assembled, thereby allowing for greater ease in removal and replacement when desired. The front panel 224 or fascia 254 may further include one or more side flaps (not shown) positioned on the outer edges of the front panel 224 or fascia 254. The side flaps may be flexible, textured and colored to hide the gaps between the various cells 210 placed in a wall and to assist in the reduction of fine fill material moving through the face of the wall.
In various embodiments of the present invention, as depicted in
The side panels 216 may further include one or more anchoring devices that may be utilized to position each cell 210 when assembling a wall and may also function to reduce or prevent overturn of the cells upon filling and compacting of fill material. One embodiment of the anchoring devices, as depict in
The frame 212 of this embodiment may also be transported and stored in a flat configuration.
As previously mentioned, various embodiments of the frame 212 depicted in previously described FIGS. include one or more securing mechanisms 222 that secure the side panels 216 to the front panel 224 and/or back panel (not shown) when folded into assembly position. The securing mechanisms 222, in the embodiment depicted in
The load cell fasteners 205 may be any fastening device or material that securely adjoins the load cell 204 to the frame 212. In one embodiment, as depicted in
The load cell 204 may further include one or more grid fasteners 206 for securing and positioning geogrid when it is utilized in a wall structure. The grid fastener 206 is configured to be inserted in an aperture of the geogrid and positioned over the geogrid at connection so that the grid does not move in a vertical direction once it is applied.
Additionally, in other embodiments, the load cell 204 may be split in two or more sections, wherein one section nests with the other section. The two nested sections allows for the compression of the sections together to make a smaller load cell that may be utilized when secured to a cut frame for partial confinement cells. In such embodiments, the two sections would further include a fastening device to fixedly secure the two sections together when the proper size is achieved, thereby preventing movement of the two sections of the load cell.
Various embodiments of the present invention may also include a fascia with the desired aesthetic appearance, rather than having the aesthetic appearance (e.g. texture and color) molded into the front face of the front panel 212.
In various embodiments of the mass confinement cells 210 and wall coverings of the present invention, the surface visible to the observer, such as the front panel 224 or fascia 254 of the mass confinement cell 210 will generally include a molded and/or fabricated texture and/or pattern in the deterioration resistant material. In various embodiments of the present invention the exposed surface of the landscaping product or wall covering, such as the front panel 224 or fascia 254, will have a natural earthen appearance simulating the texture and color of natural earthen surfaces. For example in some embodiments, the exposed surface of the front panel 224 or the surface of the fascia 254 may be textured and colored to have the appearance of rock, natural stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. In other embodiments, the front panel 224 or fascia 254 will have a crystalline appearance or will have another aesthetically appealing design. Additionally, in other embodiments, the exposed surface of the landscaping product, such as the front panel 224 or fascia 254, may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural earthen appearance texture and color, crystalline texture and color or other design (e.g. a company logo embedded in a stone color and texture). Also, in other embodiments of the present invention, the front panel 224 or fascia 254 may further include a design, such as the appearance of multiple bricks, stones, or rocks. This allows for the installation of larger mass confinement cells (e.g. mega-cells) in a wall that appears to include a multitude of bricks, stones, blocks, timbers and the like.
In various embodiments of the present invention the texture and/or front surface of the front panel 224, 324 or fascia 254, 354 or the wall covering is produced by imaging an actual natural surface, such as natural stone, rock, brick or wood and producing a mold that mimics that particular image. In various embodiments of the present invention the front panel or other visible surface is produced by imaging an actual natural surface, such as natural stone, rock, brick or wood. The imaging of the natural surface can be performed by processes such as cast imaging of the natural surface or by digital scanning the natural surface. When cast imaging the natural surface a mirror image of the surface can be produced by providing a casting material, such as silicone, ceramics or fine sand, and casting it over and/or around the natural surface. Once the casting material sets or has formed a mirror image of the natural surface the object casted is removed from the newly formed mold of the natural surface and an opposite image or negative of the natural surface has been produced. Next the negative image can be cast again with a solidifying material to produce the positive image of the natural surface. Such a process produces a casting that captures the texture and relief of the natural surface. Once the casted mirror images (i.e. positive and negative) are produced, a mold and/or a mold insert manufactured from a suitable mold material, such as aluminum, steel or a ceramic, can be produced for mass manufacture by administering the mold material to the positive and/or negative casting to form the production mold. In various embodiments of the present invention, a very fine sand or ceramic is used to provide a detailed negative and/or positive image thereby providing the desired detail found in the natural surface which then can be transferred to a more durable steel or aluminum production mold for mass manufacture of panels having one or more natural surface images. Cast imaging of the natural surface may be performed by a cast foundry. Foundries that may be used to prepare such castings include but are not limited to Arrow Pattern and Foundry Company, 9725 South Industrial Drive, Bridgeview Ill. and WK Industries, 6120 Millett Ave., Sterling Heights, Mich.
Alternatively, a mold may be prepared by digitally scanning the natural surface, such that the surface of a stone, rock, brick or piece of wood. Once scanned, a mold can be produced from a suitable mold material for mass manufacture of the front panels or fascias having a front surface supporting the scanned image.
The mass confinement cell embodiment depicted in
The mass confinement cell 210, 310 of the various embodiments of the present invention may further be fitted with an end cap 278 to finish the end of a wall, provide an end finish for a sharp turn (e.g. 90° turn) in the wall or to accommodate a partial confinement cell when a confinement cell must be cut for fitting. A front and back view of one embodiment of an end cap 278 is depicted in
In yet another embodiment, the end of a wall constructed of mass confinement cells of the present invention may also be completed with a corner cell.
In one embodiment of the present invention, the fascia 254 used with the corner cell 292 may generally be the same fascia that is utilized with the mass confinement cells of the present invention. Such a fascia 254 may be secured to the side panels 298 in a similar way as the fascia 254 attaches to the front panel 24 of the mass confinement cell as depicted in
The mass confinement cell embodiments depicted in previously disclosed FIGS. and the embodiments of the present invention are also especially advantageous for mega-cell products of sizes equal to or greater than one foot in height, two feet wide and one foot deep (e.g. greater than 2 feet in height, four feet wide and two feet deep) and multi-cell products (e.g. products that appear like multiple individual units that are approximately 3-36 in height, 2-4 feet wide and 9 inches to 4 feet deep) that are advantageous for the mass consumer market. Such large confinement cells and multi-unit cells allow for easy storage and transportation of such mega-cells and multi-cells by allowing them to flatten, thereby decreasing the space needed for large numbers of cells. In some embodiments of the confinement cells 210 of the present invention, a plurality of load cells 204 may be adjoined together and secured to the larger frame to reduce the flow forces of the fill materials in the larger walls. The load cells of the multi-cell embodiments may be adjoined with tabs that may be separated to curve the wall when desired. Furthermore, the multi-cell embodiments of the present invention may be utilized to install large sections of wall with few components and still provide the appearance of a multitude of individual cells.
As previously indicated the mass confinement cells 210, 310 of the present invention generally include a frame 212, 312 that has one or more side panels 216, 316 that engage and extend from the front panel 224, 324 back to engage with a back panel 214, 314. As depicted generally in a number of the FIGS., various embodiments of the present invention include side panels 216, 316 engaging the front panel 24, 224, 324 at angles to provide for a tapering of the confinement cell as it moves back in width. The angle formed between the front panel 224, 324 and side panel 216, 316 is generally less that 90° when the front panel 224, 324 is substantially straight and less than 150° when the front panel 224, 324 is rounded or beveled. In other embodiments, the angle is between about 45° and 85° for substantially straight front panels 224, 324 and between 60° and 110° for beveled and rounded front panels 224, 324. In various embodiments the side panels 16, 216, 316 may extend from the front panel 224, 324 at angles that would allow them to engage each other at the back of the confinement cell, thereby forming the back panel 214, 314 and chamber 220, 320 by their engagement (e.g. a triangle or diamond configuration). Finally, in various embodiments, the top edge of the side panels 216, 316 may slightly slope down from front to back, thereby providing a back end of the confinement cell that is slightly lower than the front of the confinement cell (e.g. 0.5-10 mm).
In various embodiments of the present invention, the mass confinement cell 210, 310 further includes a partial top panel that extends from the front panel 224, 324 or fascia 254, 354 that is exposed when a retaining wall is constructed. The partial top panel assists to close or partially close the top front portion of the confinement cell 210, 310 that may be exposed to the outer environment. In various embodiments, the mass confinement cells 210, 310 include a partial top panel that extends from the front panel 224, 324 or fascia 254, 354 back to no more than 80% of the depth of the confinement cell 210, 310. It is noted that cell depth is measured from the front panel 224, 324 or fascia 254, 354 to the back panel 214, 314 of the confinement cell 210, 310. In other embodiments of the present invention, such a partial top panel extends from the front panel 224, 324 or fascia 254, 354 no more than 50% of the depth of the confinement cell. In yet other embodiments the partial top panel extends from the front panel 224, 324 or fascia 54, 254, 354 no more than 35% of the depth of the confinement cell (e.g. 5% to 30%). Such a partial top panel provides for at least a partial sealing of the confinement cell at the top front portion, of which may be exposed when the retaining wall is constructed in a configuration wherein the wall inclines back toward the surface or slope intended to be protected. It is noted that in various embodiments the top panel may further include one or more planting apertures (not shown) that may allow plant growth from the top surface of the confinement cell 210, 310. As previously suggested, the open top and bottom of each mass confinement cell 210, 310 allows for the receiving and commingling of fill material that may flow from and through the confinement cell 210, 310 to one or more adjacent cells 210, 310 below or above.
Alternatively, in one embodiment of the present invention side by side adjacent confinement cells 210 may be adjoined with a clipping device 108. In one embodiment as depicted in
It is noted that other landscaping products, such as boulders or rocks, pavers and edgers may be imaged in a similar fashion as described above and coated with an polymer adhesion paint in a similar technique as described below.
In other embodiments of the present invention, wall covering products may be imaged, textured and painted to provide the appearance of cut or quarried stone or rock, wood or brick. Examples of such wall covering products may be found in U.S. patent application Ser. No. 11/872,812, the entire contents of which are incorporated by reference herein.
In some embodiments of the present invention the hollowed back surface may be filled with a sound deadening and/or insulating material. For example, an insulating foam (e.g. a polyurethane foam) may be sprayed or applied to the back surface of each panel to provide additional sound and/or thermal insulation.
In various embodiments of the present invention, as depicted in
The general plastic thickness of the panels of the present invention may vary depending upon the desired rigidity and also the manufacturing process (e.g. panels of structural foam will generally be thicker than panels that are high pressure injection molded). However, various embodiments of the panels of the present invention will have an average thickness of approximately 50 mils to 500 mils. In various embodiments the average thickness will be approximately 80 mils to 300 mils. In additional embodiments the average thickness of the panels will be approximately 120 mils to 250 mils. It is noted that portions of the panel, such as the attachment platforms or ribs, may be of a greater thickness, but a majority of the panel 10 will generally include the thinner wall thickness.
Furthermore, the front surface of each panel 10 may include various degrees of relief, thereby in some embodiments, providing the appearance of natural cut stone, rock or wood. The degrees of relief generally highlight the texture of the surface and are exhibited by the peaks and valleys present. The degrees of relief may vary depending upon the desired appearance. For example, various embodiments of the present invention may include large amounts of relief (e.g. up to 10 cm from high point to low point) providing a very rough texture. In other embodiments, the relief may be of average degree (e.g. up to 5 cm). And in yet other embodiments, the relief may be somewhat mild (e.g. up to 1.5 cm).
In various embodiment of the present invention, the front surface 12 of the panel 10 may be flat, rounded or beveled. The front surface 12 of this embodiment may include a beveled front having one or more bends, slants or creases in the front surface 12. In some embodiments the beveled front surface 12 takes on a tri-panel appearance, such as a beveling or slanting down at the edges. It is noted that the front surface 12 may also be rounded, substantially flat and/or include positions of relief to provide a more natural appearance.
As previously mentioned, embodiments of the front surface may be flat, rounded, include texture and relief and/or beveled to accommodate molding or fabrication (e.g. painting) to provide the desired appearance. In various embodiments of the present invention the front surface is produced by imaging an actual natural surface, such as natural stone, rock, brick or wood. The imaging of the natural surface can be performed by processes such as cast imaging of the natural surface or by digital scanning the natural surface. When cast imaging the natural surface a mirror image of the surface can be produced by providing a casting material, such as silicone, ceramics or fine sand, and casting it over and/or around the natural surface. Once the casting material sets or has formed a mirror image of the natural surface the object casted is removed from the newly formed mold of the natural surface and an opposite image or negative of the natural surface has been produced. Next the negative image can be cast again with a solidifying material to produce the positive image of the natural surface. Such a process produces a casting that captures the texture and relief of the natural surface. Once the casted mirror images (i.e. positive and negative) are produced, a mold and/or a mold insert manufactured from a suitable mold material, such as aluminum, steel or a ceramic, can be produced for mass manufacture by administering the mold material to the positive and/or negative casting to form the production mold. In various embodiments of the present invention, a very fine sand or ceramic is used to provide a detailed negative and/or positive image thereby providing the desired detail found in the natural surface which then can be transferred to a more durable steel or aluminum production mold for mass manufacture of panels having one or more natural surface images. Cast imaging of the natural surface may be performed by a cast foundry. Foundries that may be used to prepare such castings include but are not limited to Arrow Pattern and Foundry Company, 9725 South Industrial Drive, Bridgeview Ill. and WK Industries, 6120 Millett Ave., Sterling Heights, Mich.
Alternatively, a mold may be prepared by digitally scanning the natural surface, such that the surface of a stone, brick or piece of wood. Once scanned, a mold can be produced from a suitable mold material for mass manufacture of the front panels or fascias having a front surface supporting the scanned image. It is noted that the core side of the mold may be produced by either digitally scanning or casting the natural surface. Such imaging provides a core that will substantially mirror the front surface of the mold and thereby provide a manufactured panel 10 that is relatively uniform in thickness.
As previously mentioned the panels of the present invention may take on the image of a single stone, brick or piece of wood. Alternatively, as depicted in
When covering a wall with panels that have the image of multiple items, such as stones, wood or brick, it is important to avoid the appearance of a reoccurring pattern. When utilizing such products it is not uncommon that visually unacceptable straight lines are formed when individual items, such as stones, are aligned, thereby forming long vertical or horizontal breaks in the wall wherein a series of stones or wood planks end in the same location. Such breaks are perceived as being an unacceptable pattern. Therefore, embodiments of the present invention are designed to provide imaged items, such as stones, brick or wood planks, in positions which break designated fields or planes. In such embodiments, individual stones are positioned on a majority of the panels (e.g. >50% of the panels or in other embodiment >75% of the panels) so as to break at least two or more fields/planes that extend partially along the perimeter of the panel, but also pass through the interior of the panel. In other embodiments of the present invention, individual stones are positioned on a majority of the panels (e.g. >50% of the panels or in other embodiment >75% of the panels) so as to break at least three or more fields/planes that extend partially along the perimeter of the panel, but also pass through the interior of the panel. In yet other embodiments of the present invention, individual stones are positioned on a majority of the panels (e.g. >50% of the panels or in other embodiment >75% of the panels) so as to break at least four or more fields/planes that extend partially along the perimeter of the panel, but also pass through the interior of the panel. If such fields are not broken by a strategically placed stone a reoccurring break pattern on the wall may become recognizable.
Various embodiments of the panels of the present invention may further include interlocking members that allow the panels to overlap and/or secure to each other.
During assembly of a wall using the embodiment depicted in
The panels 10 and corner panels 64 may also be of varying size. In some embodiments of the present invention the panels 10 are greater than eight square feet. In yet other embodiments of the present invention the panels 10 are approximately two to eight square feet. In still other embodiments the panels 10 are approximately ¼ to four square feet or are ½ to 3 square feet. Additionally different size panels may be utilized to provide an irregular pattern (e.g. Ashlar or ledgestone patterns).
As previously suggested the wall covering product of the present invention may be utilized in the construction of any type of wall or surfacing project wherein a natural appearance, such as stone, brick or wood, is desired. In application, a substrate surface may be veneered with various panel 10 embodiments of the present invention by applying one or more of the panels to a surface of a substrate. In a number of embodiments of the present invention the process begins by preparing the substrate to be resurfaced by cleaning the substrate surface. The substrate surface may be a wall, such as an existing wall that is substantially planar and made of one or more materials, such as wood, drywall, masonry, sheathing, sheet metal, insulation (e.g. foam insulation), poured concrete, cinder and concrete block, segmental retaining wall block, brick and the like. In other embodiments, the substrate may be prepared by securing a grid system or backing to the substrate surface. Upon identifying the substrate, one or more panels are administered to the surface of the substrate or an attached grid system or backing previously applied to the substrate surface.
In various embodiments of the present invention a pattern can first be placed on the substrate surface to be covered with panels of differing shapes. For example, a pattern, such as an Ashlar pattern may be applied to the wall by a rubbing or stencil, thereby leaving an image of the desired placement positions of the various shaped panels. Once the stencil pattern is administered to the wall or surface, the equivalent shaped and sized panel is applied to the pattern similar to the placement of puzzle pieces in a jigsaw puzzle. It is noted that more than one pattern may be applied to the same wall thereby giving a random final appearance.
The panels of the present invention may be administered to the surface or the grid system or backing by one for more fasteners, such as adhesives, rivets, screws, nails, two sided tapes, ball and socket attachments, snaps, hook and pile attachments, sliding brackets, clipping devices (e.g. barb clip and radius clips) sliding brackets, structural VELCRO® or other attachment means known in the art that would secure the panels of the present invention to the substrate or grid system or backing. It is noted that combinations of the fasteners may also be utilized to secure the panels of the present invention. For example, various embodiments may utilize a combination of screws, nails or rivets with one or more adhesives to secure the panels to a substrate or the grid system or backing.
In a number of embodiments of the present invention each veneering panel is adhered to the substrate and/or adjacent panel with a two sided tape that includes an adhesive that has an affinity to polymeric materials. For example various embodiments of the panels may be secured with adhesives, such as the two sided VHB and acrylic or polyurethane foam tapes produced by 3M. In such embodiments of the present invention, the two sided tape may be adhered to the attachment platforms on the back surface of each panel. The backing of the two sided tape is removed and the panel is attached to the wall or substrate in the desired location. Examples of such tapes that may be utilized with the panels 10 of the present invention include 4952, 5952, 5925 and 5962 VHB two sided adhesive tapes manufactured by 3M, 3M Center, St. Paul, Minn. 55144-1000. Another adhesive tape that may be utilized includes, but is not limited to, the 4466W Double Coated Polyethylene foam tape manufactured by 3M. Other examples of suitable two sided tapes that may be utilized with the panels of the present invention include, but are not limited to, 3M® Double Coated Polyethylene Foam Tape 4492W and 4462W, 3M® VHB® Acrylic Foam Tape 5952 and 5925 and 3M® Double Coated Urethane Foam Tape 4016. Additionally adhesive sealants, such as the 4000 and 5200 sealants produced by 3M may also be used to secure the panels 10 to a substrate, such as a wall. The sealants may be applied on the substrate surface or on the back surface of the panel prior to pressing the panel to the surface of the substrate by any means known in the art (e.g. spraying or spreading). However, it is important that the adhesive (e.g. tape or sealant) utilized be appropriate to adhere a resin based product. The examples listed above provide this feature. In general, the curing of the adhesive properly affixes the panel to the substrate. Curing times vary depending on the adhesive, but many will cure within less than 72 hours.
As previously identified, any wall may be covered with the veneering product of the present invention. For example, segmental retaining wall block may be adapted to accept and secure a veneering panel of the present invention. Such a panel would provide additional durability, deterioration resistance and aesthetic appearance to the normally problematic concrete product.
Another example of a panel 10 that may be utilized to cover concrete blocks is depicted in
In many embodiments of the present invention, the appearance of the landscaping products, such as the front panel 224, 324, partial top panel (not shown), fascia 254, 354, the boulders, pavers, edgers, veneering panels or any portion of these landscaping or wall covering products that are intended to be seen, generally include an earthen appearance or other aesthetically pleasing design and color. When referring to the manufacture, molding and coating/painting of the products of the present invention, the term “substrate” may be used to describe the front panel 224, 324, partial top panel (not shown), fascia 254, 354 or any other portion of the mass confinement cell 210, 310, the veneering panel of the wall covering, the boulders or pavers or any portion of these products that are intended to be seen.
In various embodiments of the present invention, the earthen appearance, such as a stone, rock, boulder or wood appearance may be accomplished by coating the visible surface substrate with a polymer adhesion paint. For example, in some embodiments of the present invention the texture and color of substrate (e.g. the mass confinement cell 210, 310, the molded boulders, the pavers, the edgers or the veneering panels) may be formed by thermal molding one or more resins (e.g. recycled or virgin resins) that include colors and other additives in a mold that has a desired texture.
As previously mentioned, the products of the present invention may be manufactured from a deterioration resistant, substantially rigid composite or polymeric material including, but not limited to, plastic (e.g. recycled or virgin), a rubber composition, fiberglass, or any other similar material or a combination thereof. Preferable materials comprise light-weight and slightly flexible polymers, such as high and low density polyethylene (HDPE or LDPE) and polypropylene (PP). It is noted that a polypropylene copolymer may be utilized with the present invention, but it is recommend that the polypropylene copolymer have a polyethylene content no greater than 30% polyethylene and in other embodiments no greater than 20% polyethylene. However, other plastics may also be used. Examples of other plastics include, but are not limited to acrylonitrile-butadiene-styrene (ABS), poly(butylene terephthalate) (PBT), poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrile copolymers (SAN), polystyrene, polycarbonate, polyvinyl chloride (PVC), polyurethane, copolymers and combinations thereof. It is also noted that the deterioration polymeric materials may also be utilized with filler materials or recycled filler materials, such as titanium, carbon fibers, talc, glass, saw dust, cellulose fibers, paper byproducts and the like. Generally, the embodiments of the present invention may comprise any type of material that would have the similar characteristics to plastic, vinyl, silicone, fiberglass, rubber or a combination of these materials.
One other material that may be utilized with the present invention may be a thermoset. For example, a bulk molding compound (BMC) or thermoset that includes one or more polyester resins, glass fibers and other additives may be utilized to manufacture one or more components of the present invention. Various embodiments of thermosets and BMC is manufactured and/or molded by Bulk Molding Compounds, Inc. 1600 Powis Court West, Chicago Ill. 60185 and Kenro Incorporated, a Carlisle Company, 200 Industrial Drive, Fredonia, Wis. 53021.
It is noted that the material utilized in the present invention should be rigid enough to hold its form upon installation, impact and/or when placed in contact with other objects. Another material may be comprised of a material similar to that utilized in the production of some types of garbage cans or the utilization of recycled rubber from objects such as tires. Such materials would be capable of holding rigidity and still offer flexibility upon impact. Also, such materials have the ability to regain its original form when the impact force has been removed or completed.
Embodiments of the present invention may also vary in appearance. Since embodiments of the present invention may be manufactured by a process such as injection molding, structural foam molding, injection molding using chemical and other foaming agents, extrusion, thermo-forming, compression molding, roto-molding and the like, the molds may include any type of design, size and shape. Furthermore, the substrates could be molded in almost any type of texture, relief and/or configuration. For example, the substrates may be designed to appear like a plurality of field stones, cut stones, bricks, wood planks, or any other natural wall construction material. In other embodiments, multiple substrates could be molded to include designs that, when positioned on a retaining wall, would complete a larger single design, such as the spelling of a company or school name in large letters or the completion of a large image. It is noted that embodiments of the present invention may also be used in conjunction with other wall products, such as vinyl siding, bricks, stones and the like.
Each of the substrates of the present invention may be textured and include color and/or other additives (e.g. U.V. inhibitor, texture enhancer, metal or glass particulates and the like) to provide protection to the substrates and other components and/or provide the desired natural appearance. Generally, the substrate surface visible to the observer will include a molded and/or fabricated texture and/or pattern in the deterioration resistant material. In various embodiments of the present invention the exposed surface of the substrate will have a natural appearance. For example, the exposed surface of the substrate may be textured and colored to have the appearance of rock, natural stone, brick, wood, or any other natural earthen appearance.
In some embodiments of the present invention, a color that is close to the final natural appearance color of stone, rock, wood and the like may be integrated into the polymers that are molded. For example, an integral color may be incorporated into recycled resin to provide a close color match to the substrate's painted surface. In many embodiments of the present invention the color of the substrate is in the same color family as the painted surface. For example, a tan painted surface would have a tan/brown colored substrate and a gray painted surface would have a gray colored substrate. In some embodiments a tan-gray substrate may be prepared to accommodate both a tan and gray color scheme. In various embodiments of the present invention, the color match of the resin color of the substrate to the painted surface is at least 50%. In other embodiments the color match is at least 70%. This can be challenging with recycled materials since many products molded from regrinds are normally black in color, mainly because of the carbon black content. To provide the desired substrate color one or more neutralizing colorants, color concentrates and/or color additives (e.g. white or light gray colorant) and/or one or more neutralizing resins (e.g. white or light gray polypropylene resin) may be added to the recycled black and/or colored resin to neutralize or reduce (e.g. lighten) the color. In various embodiments, a neutralizing resin (e.g. white polypropylene resin or light grey or tan polypropylene resin) may be added to the recycled resin to neutralize or reduce the color. In some embodiments about 1% to 25% (weight percent) neutralizing resin is added to a batch of recycled regrind and mixed thoroughly, thereby neutralizing the black or other color. Alternatively, the neutralizing or coloring of the color of the recycled resin may be performed by adding varying amounts of one or more neutralizing colorants, color concentrates, and/or color additives (e.g. white or light gray colorant) to the recycled resin. It is noted that the term colorant may be used in this disclosure to identify colorants, color concentrates and/or color additives. These colorants are typically let down as a percentage during the molding process. The amount of colorant added to a batch of recycled resin to neutralize the color may vary depending on the amount of carbon black present. However, in various embodiments 0.5 to 6% of a neutralizing colorant may be added to neutralize the color of the recycled resin. In other embodiments, 1 to 3% of a neutralizing colorant may be added to neutralize the color of the recycled resin. In yet other embodiments both a neutralizing colorant and neutralizing resin may be added to a batch. Subsequently or simultaneously, one or more other colorants, color concentrates and/or color additives (e.g. gray or tan) may be added to the recycled resin to provide the desired substrate color. The use of integral color in the substrate reduces the appearance of scratches or chips when the paint coating is abraded, scratched or chipped.
Additionally, in other embodiments, the exposed substrate surface of the landscaping or veneering products, may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural appearance texture and color (e.g. a company logo embedded in a stone color and texture). Also, in other embodiments of the present invention, the substrate may further include a design, such as the appearance of multiple bricks, stones, timbers or blocks. This allows for the installation of larger panels in a wall that appear to include a multitude of bricks, stones, blocks, timbers and the like.
In various embodiments, the texture may also be imprinted on substrate in a secondary process after formation of one or more components of the landscaping products (e.g. mass confinement cell, boulder, paver, edgers . . . ) or wall covering product by rolling a die that imprints the texture on the surface of the substrate, such as the polymeric front panel 224, fascia 254, 354 or other visible portion of the cell 210, 310 or the veneering panel, boulder, paver, edger or any other visible portion of these products.
Once the products are molded, the exposed substrates of the landscaping products, (e.g. front panel, fascia, end cap, cell cap, boulder, paver, edger . . . ) and veneering panels, may be colored and further textured utilizing a painting process. One such painting process that may be used with various embodiments of the present invention is a polymer adhesion painting process wherein a polymeric paint is adhered to the surface of the landscaping product or wall covering product. In some embodiments the polymer adhesion paint requires no pretreatment of the substrate surface. In other embodiments the polymer adhesion paint is administered to the substrate surface after the surface of the visible portion substrate, such as the front panel 224, 324, the fascia 264, 364, the end cap 364 or the cell cap 114, boulder, paver, edger, or veneering panel, has been flame treated or plasma or corona treated. Alternatively, adhesion promoters may be utilized in other embodiments of the present invention to promote adhesion of the polymer paints rather than flaming, plasma or corona treatment. However, it is noted that paint may not require and adhesion promoter or the adhesion promoter may be included in the base coat or may be the base coat applied to the substrate.
In various embodiments of the present invention the polymer adhering paint may be a solvent or water based paint. Examples of such paints are identified below. However, many of the embodiments of the present invention utilize a polymer adhering paint that has a very low gloss. For example, in embodiments of the present invention the gloss rating of the paint utilizing a 60° gloss meter is less than 5 and may be between 0 and 4. In various embodiments the gloss is between 1 and 3.
In one polymer adhesion painting method, the substrate is manufactured utilizing a process, such as injection molding, structural foam molding (e.g. low pressure multi-nozzle structural foam), injection molding using chemical and other foaming agents, rotomolding, thermoforming, extrusion or any other process. Next, all surfaces of the substrate intended to be painted may, if necessary, be flame treated, plasma or corona treated or treated with adhesion promoter prior to applying paint. The flame treating may be performed with any gas torch system, such as propane, acetylene and the like. Plasma treatment may also be performed by any device that forms a gas plasma that can be directed to the polymeric surface. The flame or plasma treated surface should be painted within 24 hours, optionally within 8 hours and further optionally within 5 hours. Once the surface has been flame, plasma, corona, or adhesion promoter treated, a polymer adhering paint, such as a polyurethane based paint mixed with a crosslinker or a waterbase paint is applied to the surface or surfaces of the panel 10. It is noted that the polymer adhering paint mixture should be applied shortly after mixing; in some embodiments almost immediately. It is also noted that a number of the paints identified below do not require the pretreatment of the substrate surface with flame, plasma or an adhesion promoter.
One example of the types of polymer paints that may be utilized with embodiments of the present invention is a two-component polyurethane that generally includes a mix ratio of three to five parts colored paint with one to two parts crosslinker (e.g. XL-003 crosslinker or an isocynate). Two examples of two such polyurethane based paints are as follows:
Alternative polymer adhesion paints that may be utilized with the present invention include solvent based paints and waterborne paints produced for low surface energy polymers, such as polypropylene and polyethylene. Examples of such solvent and water based paints that may be utilized with the cells of the present invention include, but are not limited to the polyurethane based paints (e.g. 2K High Solids Urethane Base Coat products) produced by Redspot Paint & Varnish Company, Inc. of Evansville, Ind. or the polyurethane, waterborne or powder based paints, such as Polane® Polyurethane Systems, Polane® or Kem® AquaWaterborne Systems, Powdura® Powder Coating Systems, all produced by Sherwin Williams. Two examples of waterborne paints that do not require flame, plasma or corona treatment of the panel surface prior to application are as follows:
The polymer adhering paints may further include one or more additives to provide additional beneficial characteristics. For example, additional texture may be applied to the surface of a substrate by including additives to the paint in fine, medium or course particulate form. Such particulate additives may be selected from any suitable texture additives such as mica, sand, perlite, pumice, silica, metal, acrylic or glass beads and fibers, or any other paint texture additive. The paint additives may be included in the paint or applied in the painting process. For example, paint textures such as mica, sand, pumice and the like may be dropped, propelled (e.g. propelled toward the surface using a device, such as a sandblaster) or sifted (e.g. sprinkled onto the surface by gravity or using a sieve) onto the surface of the substrate while simultaneously applying the base coat and/or secondary coat(s) of paint. Such a process disperses and entraps the texture in the coating, thereby giving a fine, medium or course textured surface. Alternatively, the texture may be applied after the base coat and/or secondary coat is applied, thereby providing a more gritty appearance, texture and feel. This may be done while the paint is still wet or partially wet thereby adhering the texture to the surface during drying.
The polymer adhesion paints may be applied in any manner known in the art including, but not limited to, spraying, dipping, brushing, sponging and any other paint application method. In various embodiments polymer adhesion paint is applied by spraying. Generally, less than 10 mils of paint are applied to the surface intended to be painted. In other embodiments less than 5 mils of paint is applied and in other embodiments less than 3 mils of paint is applied to the surface intended to be painted. In various examples, approximately 0.2 to 3 mils or 0.5 to 2 mils dry film thickness of base color was applied to the entire surface of panels. Once the base paint has been applied, one or more secondary colors may optionally be applied to the wet or dry base coat as desired. Such secondary colors may be applied in similar ways as the base paint, such as spraying, dipping, brushing, sponging and any other spray technique known in the art. It is also noted that a primer layer may be applied to the substrate surface prior to applying the paints described herein. For example, a coating of binel, parylene or another primer coat may be applied to the surface prior to applying the paint to promote optimum adhesion.
Once the paint has been applied to the desired surface of the substrate or other visible portion of the product, the product is then cured. In various embodiments of the present invention, the product is oven cured following painting at a temperature of 225° F. and less (e.g. 175° F. to 220° F.); in other embodiments 205° F. and less (e.g. 160° F. to 200° F.); and in still other embodiments 180° F. and less (e.g. 100° F. to 150° F.). In various embodiments the paint, is cured at the above mentioned temperatures for a period of 2 minutes to 4 hours; in other embodiments 5 minutes to 2 hours and in still other embodiments 10 minutes to 30 minutes. The product is then allowed to air dry. Once air dried, the landscaping or wall covering products are ready for installation. It is noted that the curing process may be performed at room temperatures, but the curing time usually will be lengthened accordingly.
An example of one method for coating the substrates or other visible portions of the landscaping or wall covering products of the present invention is by utilizing a line manufacturing system. For example a series of substrate fixtures that adequately hold and position the substrates can be adjoined to a paint line to transport the substrates through a coating system. The paint line may be any system known in the art, including a chain on edge system or an overhead conveyor line system.
Next, the substrates exit the first paint booth 414 and are optionally exposed to a drying mechanism 418, such as a IR heater, UV heater or forced dry/heated air, for a short period of time to partially dry the paint before application of one or more secondary coatings.
Upon completion of the partial drying of the substrates 410, the substrates 410 are transported by the chain on edge system or conveyor system through one or more second paint booths 420 wherein one or more secondary coatings/paints are applied with paint guns 416 to the substrate surface to provide multiple colors to the surface of the substrate. While still wet, the base and/or secondary coatings or paints are next moved or manipulated with a paint movement device to provide the desired highlighting, streaking, shadowing, and blotching found in natural stone, rock, brick or wood. In various embodiments, the manipulation of the secondary coatings are done with compressed air or sprayed solvent (e.g. water, paint thinner . . . ) that is randomly directed toward the surface of the substrate with spray guns, hoses, air knives or flexible tubing.
In various embodiments, once the secondary coating has been manipulated, the base coat and secondary coating are allowed to partially dry by transportation of the substrates through a short flash tunnel. In various embodiments, the flash tunnel is no more than 25-100 ft (e.g. 50-80 ft). Vacuum may optionally used in the flash tunnel if desired.
In some embodiments of the present invention, once the substrates 410 have received the secondary coating, finished the coating or paint manipulation step, or have exited the flash tunnel, a texture material (e.g. sand, mica . . . ) may be added to the partially dried surface by a texture applicator. As depicted in
While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
This application claims priority to and is a continuation-in-part application of U.S. patent application Ser. No. 11/872,812, filed on Oct. 16, 2007, which claims priority to U.S. Provisional Application Ser. No. 60/829,925, filed on Oct. 18, 2006, and U.S. Provisional Application No. 60/953,040 filed on Jul. 31, 2007 and is a continuation-in-part of U.S. patent application Ser. No. 11/463,816, filed on Aug. 10, 2006. This application also claims priority to U.S. Provisional Application Ser. No. 61/091,579, filed on Aug. 25, 2008. The contents of all previously mentioned applications are incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 60829925 | Oct 2006 | US | |
| 60953040 | Jul 2007 | US | |
| 61091579 | Aug 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11872812 | Oct 2007 | US |
| Child | 12547300 | US | |
| Parent | 11463816 | Aug 2006 | US |
| Child | 11872812 | US |
