MODULAR WALL PANEL SECTION, SYSTEM AND METHOD THEREOF

Abstract

A modular wall panel section configured to retain ground and structural elements is provided, the section comprising one or more pillars, at least one wall panel secured to the one or more pillars, and surrounding elements coupling the one or more pillars to the at least one wall panel. Further provided is a modular wall panel system comprising two or more modular wall panel sections and wherein the two or more modular wall panel sections are coupled to one another at one of the one or more pillars. A method of installing a modular wall panel system comprising two or more modular wall panel sections is also provided.

Description

FIELD OF THE INVENTION

The present invention generally relates to the field of landscaping and retaining wall building and construction panel namely for railroad works such as for waysides, grade crossing signals and signal bridges.

BACKGROUND OF THE INVENTION

There presently exists various industrial solutions for structural ground landscaping by means of retaining walls and panels which are set onto the ground mainly with pillars and walls attached thereafter and herein is presented an alternative and innovative approach to achieve an adaptable and integrated retaining wall method in order to build an installation and assembly of universally reversible retaining panels into a universal and standard modular multi-stage retaining wall architecture, with having various and variable staircases, steps or stages. Namely here are various means of retaining wall architecture that don't allow the full advantages herein disclosed, such as limited and limitative methods to:

• • Erect a building (U.S. Pat. No. 102,871,544)
  • Construct of a building simultaneously below and above ground level (U.S. Pat. No. 103,457,690)
  • Construct underground concrete walls and reinforcement cages (U.S. Pat. No. 104,005,582)
  • Build a basement construction (U.S. Pat. No. 104,875,807)
  • Combine a traffic barrier and a retaining wall and method of construction (U.S. Pat. No. 105,471,811)
  • Build underground structure (U.S. Pat. No. 106,332,303)

SUMMARY OF THE INVENTION

According to a standard, modular and multi-stage architecture method for a universally reversible ground retaining wall panel system, the present invention is made to be built with a partly underground or buried structure capable of utilizing part of a permanent structure with a pillar design which can be of many shapes or various standard structures such as but not limited to, rounded bars or H-section, and of which the said pillar position can be made from various existing solutions, implying namely bayonet joints, towards a universal and standard approach for a variable, modular and adaptable boundary wall to retain the ground. The system can take part in a simple installation method through repeating the same steps to constitute an easy and simpler solution than what is existing on the market. The system can take part in excavation work, landscaping, construction, and other industrial applications with providing in itself a simpler and safer solution. The concept is built around the standard coupling of pillars, which can be added altogether and receive said surrounding elements solidary to the wall panels for their rotation of angle and their solidary intertwining and interlocking with other wall panel architectural formations. The pillar system works after then as to hold many possible retaining wall designs comprised of solidary and surrounding elements to the said retaining wall panels in order to be fixed about to and/or around to the said pillars. Thereby, the innovative approach is always standard and modular and can provide various retaining wall functions and positions, at multiple locations, and constitute a multi-stage architecture method for a universally reversible ground retaining wall panel system, build on ground, with ability to be installed underground. All of the above parts of the system can be built from any materials such as, and not limited to, composite, steel, synthetic and concrete.

The shortcomings of the prior art are generally mitigated by providing a modular wall panel section, the section comprising: one or more pillars; at least one wall panel secured to the one or more pillars; and surrounding elements coupling the one or more pillars to the at least one wall panel. The surrounding elements of the one or more pillars may be offset from one another along a height of the pillar. The surrounding elements of a first pillar may be offset unsymmetrically with the surrounding elements of a second pillar. The one or more pillars may be configured to be coupled with surrounding elements of another modular wall panel section, the offset of the surrounding elements being different from the offset of the surrounding elements of the other modular wall panel section.

In another aspect of the invention, a section may further comprise intermediary surrounding elements located along a length of the at least one wall panel and configured to be coupled to a pillar of another modular wall panel section.

In another aspect of the invention, the one or more pillars may comprise a base and a pole, the base comprising a hole for receiving an elongated section of the pole and the pole configured to be coupled to the surrounding elements.

In another aspect of the invention, the surrounding elements may be manufactured unitarily with the at least one wall panel.

In another aspect of the invention, two or more of the wall panels may be stacked on top of one another.

In another aspect of the invention, the at least one wall panel may have a curved shape.

In another aspect of the invention, the at least one wall panel may comprise reinforcing elements.

In another aspect of the invention, the section may be configured to retain ground and structural elements.

In yet another embodiment of the invention, a modular wall panel system is provided, the system comprising: two or more modular wall panel sections, the sections each comprising: one or more pillars; at least one wall panel secured to the one or more pillars; and surrounding elements coupling the one or more pillars to the at least one wall panel, wherein the two or more modular wall panel sections are coupled to one another at one of the one or more pillars. The surrounding elements of one of the two or more modular wall panel sections may be offset from one another, the offset being different from the offset of surrounding elements of another of the two or more modular wall panel sections.

In another aspect of the invention, the two or more modular wall panel sections may further comprise intermediary surrounding elements located along a length of the at least one wall panel and configured to be coupled to the pillar of another modular wall panel section.

In another aspect of the invention, a height of one of the two or more modular wall panel sections may be different from a height of another of the two or more modular wall panel sections.

In another aspect of the invention, a length of one of the two or more modular wall panel sections may be different from a length of another of the two or more modular wall panel sections.

In another aspect of the invention, the system may be configured to retain ground and structural elements.

In another embodiment of the invention, a method of installing a modular wall panel system is provided, the method comprising the steps of: securing to the ground two or more pillars; coupling to the two or more pillars at least one wall panel with surrounding elements to create a first wall section; and securing a second wall section to the first wall section by coupling surrounding elements of the second wall section to one of the two or more pillars of the first wall section. The method may further comprise offsetting the surrounding elements of the at least one wall panel of the first wall section at a predetermined distance from one another, and offsetting the surrounding elements of the second wall section unsymmetrically to the offset of the surrounding elements of the at least one wall panel of the first wall section. The method may further comprise: securing for each of the two or more pillars a base to the ground and securing to each of the bases a pole configured to be coupled to the surrounding elements.

Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:

FIG. 1 is a perspective view of a modular wall panel system in accordance with the principles of the present invention.

FIG. 2 is an exploded perspective view of a wall panel section in accordance with the principles of the present invention.

FIG. 3 is a perspective view of another wall panel section in accordance with the principles of the present invention.

FIG. 4 is a partial perspective view of a wall attachment mechanism in an unlocked position according to the principles of the present invention.

FIG. 5 is a top view of the attachment mechanism of FIG. 4 in an closed position.

FIG. 6 is a perspective view of a wall section showing an attachment mechanism as shown in FIG. 4 in an open position and another one in the closed position.

FIG. 7 is a perspective view of a wall section having a bevelled upper portion.

FIG. 8 is a perspective view of a corner wall section.

FIG. 9 is a perspective view of a corner wall section having a different configuration.

FIG. 10 is a perspective view of a post used to anchor the wall sections to the ground.

FIG. 11 is a perspective view of a wall made of a plurality of wall sections in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A novel modular wall panel section, system and method thereof are herein presented. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.

Referring to FIG. 1, an embodiment of a modular wall panel system 100 is illustrated. The modular wall panel system 100 comprises a plurality of wall section 1, 2, 3 coupled to one another at pillars 20 which may be secured in the ground. The sections further comprise one or more rows of panels 15, 16, 17 installed between two pillars 20 and used to retain external elements such as the ground surfaces 30, 31, 32, 33 and/or structural elements 34. The system 100 may be configured to be used in excavation work, landscaping, construction, and other industrial applications while providing a simpler and safer solution. For example, in FIG. 1, the ground surfaces from ground level 30, can variate into ground 33, 32, 31. Understandably, the system 100 may also be used to retain other types of materials or liquids.

Referring now to FIGS. 2 and 3 illustrating two respective modular wall panel sections 1 and 2, the sections may comprise a partly buried or underground base 23 configured to retain or support a pole 21 of a pillar 20 which may comprise various shapes or various standard structures such as, rounded bars or H-section. The pillar 20 may utilize various existing solutions for interconnecting the pole 21 to the base 25. For example, bayonet joints may be used, in which a bayonet 22 is configured to be received in a hole 24. In other embodiments, the reversible ground retaining wall may comprise any other connection means known in the art.

The modular wall panel sections 1 and 2 may comprise pillars 20 going within surrounding elements 10, 11, 12. The pillars 20 are thus configured to guide and secure the surrounding elements 10, 11, 12 further securing the rows of panel walls 15, 16, 17.

As shown in FIGS. 1-3, the pillars 20 may be vertically coupled to one another to form a continuous pillar structure. The pillars 20 may comprise a base 22, which is configured to mate with the top of another pillar 20. Alternatively, the pillars 20 may be coupled using interlocking mechanisms such as bayonet joints or other coupling methods, allowing one pillar to stack securely on top of another. This stacking feature facilitates the incremental extension of the wall's height without replacing or modifying existing components. The surrounding elements 10, 11, and 12 are designed to interlock along the length of the pillars, ensuring stability and providing attachment points for the wall panels 15, 16, and 17.

The surrounding elements 10, 11 and 12 may be made solidary to the panel walls 15, 16, 17 or may be manufactured separately. If manufactured separately, the surrounding elements 10, 11 and 12 may be secured to the rows 15, 16, 17 on-site by any fastening means know in the art or by slits adapted to secure the two parts. In some embodiments, a plurality of pillars 20 may be coupled on top of one another to increase the height of the system 100 wherein other embodiments, the height of a pillar 20 may be adapted at a predetermined length. It may be appreciated that the coupling of pillars 20 and surrounding elements 10, 11, 12 provides the ability to rotate a wall section 1 from another 2. As can be seen in FIG. 1, the wall section 1 is angled from the wall section 2 at an angle 4. Understandably, different wall sections 1, 2, 3 may be coupled to one another at an interlocking location 13. The pillar system may be configured to hold many possible retaining wall designs 1, 2, 3, comprised of solidary and surrounding elements 10, 11 and 12 to the said retaining wall panels 1, 2 and 3 in order to be fixed about and/or around the pillars 20. Therefore, the system 100 may be standard and modular and may provide various retaining wall functions and positions, at multiple locations. The system may further constitute a multi-stage architecture method for a universally reversible ground retaining wall panel system, built on ground, with the ability to be installed underground. All of the above parts of the system 100 can be built from any materials such as, but not limited to, composite, steel, synthetic materials and concrete, including reinforcement elements along and among the very wall panels 15, 16.

Referring back to FIG. 1, the modular wall panel system 100 comprises a plurality of wall sections 1, 2, 3. The wall sections 1, 2, 3 may have various and variable height and shape configured to retain the ground surfaces 30, 31, 32, 33 and 34. Accordingly, the wall sections 1, 2, 3 comprise at least one or two standard pillar structures 20 of various lengths being set out from a lowermost parts 25, 23 installed firmly from below the ground 30, 31, 32, 33 and 34. From the ground level are the elements 22 to 21 of the pillar 20. From the standpoint of the exterior part of the system 100, opposed to the wall sections 1, 2, 3 in contact with the retained soil from the ground up, at least one in-between universally reversible retaining panel 1, 2 and 3 forming the central interconnecting part among and between the said at least one to two pillars 20 along the vertical lengths of the two lateral sides 10 and 11 or the central part 12 of the retaining panel to form at least one universally modular retaining wall; at least one solidary universal surrounding element 10, 11, and 12 on each said of the two respective lateral sides of the said retaining panel 10 and 12, or at least one about the main surface 11 of the said retaining panel; at least each said surrounding element 10, 11 and 12 forming in vertical length along axis 19, in respect to vertical height of the panel 1, 2 and 3, having no more than at least half of the full vertical height of the simplest panel 1, 2 and 3 to form the shortest in vertical height said panel architecture for it to be considered universal and intertwining interlocking 13 in order to be said an adaptable and integrated of universally reversible retaining panel 1, 2 and 3 constituting a universal and standard modular multi-stage ground retaining wall architecture; at least the same said vertical length of surrounding element 10, 11 and 12 forming any given set of said retaining panels 1, 2 and 4 for a given built installation and assembly of universally reversible panels into a universal and standard modular multi-stage retaining wall architecture; at least each said part of universal surrounding elements 10, 11 and 12 being centrally piled around said at least one to two pillars' structures 23, 25, 24, 22 and 21 of pillar 20 thereby to behold the said at least one retaining panels 1, 2 and 3 which constitute thereby a retaining wall architecture.

Referring to FIG. 3, the wall section 2 comprises three pillars 20, two at opposite ends and one in the center of the section 1. Surrounding elements 10, 11, 12 of one pillar 20 may be offset from one another along the vertical length/axis 19 of said pillar 20. Furthermore, the placement of surrounding elements 10, 11, 12 of one of the pillars 20 may also be offset from the placement of another of the pillars 20. It may be seen in the surrounding elements 11 of one of the outmost pillars 20 being offset along the axis 19 compared to the surrounding elements 10, 12 of the other two pillars 20. Understandably, any configuration of surrounding elements 10, 11, 12 placement may be used. The unsymmetrical placement of surrounding elements of two opposites pillars 20 may allow the coupling of two sections 1, 2, 3 without having surrounding elements of two sections overlapping over one another. The unsymmetrical placement of the surrounding elements 10, 11 may allows a universal and intertwining interlocking 13 of surrounding elements 10, 11 and 12 of different sections 1, 2, 3. The coupling 13 may be made at its lateral elements 10 and 11, yet it may also be made in the centered element 12 of the section 2. It may be appreciated that a wall section 1, 2, 3 may comprise less or more than three pillars 20 as shown in FIG. 3 and that the sections 1, 2, 3 may be connected to other sections 1, 2, 3 at any of the pillars 20. It may further be appreciated that surrounding elements 12 may be located at any point in the length of a wall panel 15, 16, 17 and may thus be coupled to a pillar of another modular wall panel section.

Referring back to FIG. 1, the system 100 comprises multiple sections 1, 2, 3 having unsymmetrical surrounding elements being offset 14 with a different placement than the offset 14 of the surrounding element 10. The quantity of surrounding elements 10, 11, 12 and their offset 14 differ for each height of the different sections 1, 2, 3 along the axis 19. In order to allow any additional universal surrounding elements 10, 11 and 12 and wall panels 15, 16 along any of the pillars 20, the height of the pillars 20 must be increased. The increase of the pillars' 20 length may be made by replacing said pillars 20 with longer ones or by adding another pillar 20 over the original one.

In FIG. 1, the modular wall panel system 100 is made into a wall architecture of various sections 1, 2, 3 having variable lateral orientations 4 in respect to the distance and position of each of the pillars 20. Furthermore, the length 18 and height 19 of a section 1, 2,3 and therefore of the system 100 may be varied by providing different lengths and heights of wall panels 15, 16, 17 and/or a varying quantity of pillars 20 within a section 1, 2, 3. It may further be appreciated that the shape 3 of the wall panels 15, 16, 17 may be configured to vary and thus offer differing lengths 18. In another embodiment of the invention, reinforcing elements may be used to strengthen the wall panels 15, 16, 17. As illustrated in FIG. 1, each wall section may be disposed at any selected angle in relation to the adjacent wall sections to provide varying shapes of the wall system 100.

Referring to FIGS. 4-11, another embodiment of the invention is shown. In this embodiment, the wall system 100 comprises another attachment system 99 that functions with a lock and hinge mechanism. The attachment system 99 includes a lock bar 101, a hinge closure cover 102, and a receiving slot or hinge 103 integrated into the panel 104. The lock bar 101 is a vertical element designed to slide or fit securely into the receiving slot or hinge 103, forming the primary structural connection between the panels 104 and pillars 109. Once the closure cover 102 is in place, the lock bar 101 is engaged, enclosing the locking mechanism and securing the connection to the pillar 109.

Referring to FIGS. 6-9, a rectangular panel 104 is shown. This panel is designed for use in the modular wall system 100 and features the lock and hinge attachment mechanism 99 at both ends. The lock bar 101 is secured along the vertical sides of the panel 104, after the hinge closure cover 102 is closed to enclose and protect the locking components. The attachment mechanism 99 is firmly affixed to the panel 104, ensuring a reliable connection with adjacent panels 104 or pillars 109. These rectangular panel 104 together with its attachment mechanisms 99 serve as a core element of the modular wall system 100.

Referring to FIG. 7, a panel 106 with a different shape from the rectangular design is shown. This demonstrates that flat panels in the modular wall system are not limited to a rectangular geometry. The panel 106 incorporates the same lock bar 101 and hinge closure cover 102 attachment mechanism 99, allowing it to integrate seamlessly with the rest of the system. The inclusion of various panel configurations enables greater design flexibility, accommodating different structural or aesthetic requirements while maintaining compatibility with the modular locking system. It is to be understood that the panels 104 and 106 may have type of configuration provided that the attachment mechanisms 99 are attachable thereto.

Referring to FIGS. 8-10, a corner panel 107 is shown, designed specifically to create angled connections within the modular wall system. These panels 107 feature a predefined angular geometry that allows them to seamlessly join two adjacent wall sections at a desired angle 110, such as 90 degrees as illustrated in FIG. 8 or an angle 111 of 45 degrees as illustrated in FIG. 9. The corner panels 107 use the same lock bar 101 and hinge closure cover 102 attachment mechanism 99 as other panels in the system 100, ensuring consistent compatibility and ease of assembly. Additionally, the corner panels 107 may include a a safety corner edge 108, as illustrated, which provides an attachment point for securing additional components, such as a an additional pillar 109 (FIG. 10). This feature enhances the stability of the corner connections and allows for a more robust assembly in high-stress or safety-critical applications. The lock bar 101 and hinge closure cover 102 are positioned at both ends of the panels 107, facilitating secure connections to the adjoining panels 104 or pillars 109 while maintaining structural stability. It is to be understood that the corner panels 107 may have any angle.

Further provided is a method of installing the modular wall panel system 100, the method comprising the steps of securing to the ground two or more pillars, coupling to the two or more pillars at least one wall panel with surrounding elements to create a first wall section and securing a second wall section to the first wall section by coupling surrounding elements of the second wall section to one of the two or more pillars of the first wall section. The method may further comprise offsetting the surrounding elements of the at least one wall panel of the first wall section at a predetermined distance from one another and offsetting the surrounding elements of the second wall section unsymmetrically to the offset of the surrounding elements of the at least one wall panel of the first wall section. The method may further comprise securing for each of the two or more pillars a base to the ground and securing to each of the bases a pole configured to be coupled to the surrounding elements.

In another embodiment of the invention, a method of installing a modular wall panel system is provided. The method begins by positioning the first rectangular panel 104 horizontally and sliding it into alignment with the adjacent pillar 109. Unlike other systems that require heavy panels to be lifted over and lowered onto the adjacent pillars, the hinge mechanism 99 allows the panel to be moved horizontally into position. The panel may be simply slid horizontally into place. Each hinge closure cover 102 is then engaged and locked in place by the corresponding lock bar 101, securing the connection between the panel 104 and the pillar 109. This horizontal assembly process is particularly advantageous for handling heavy panels, reducing the physical strain and mechanical equipment typically required for lifting and vertically aligning. Additional panels, including non-rectangular panels 106 or corner panels 107, can be installed in the same manner. The corner panels 107, designed for angled connections such as 90 or 45 degrees, are also slid horizontally into alignment with the pillars 105 before securing with the hinge mechanism 99.

Other applications may include, and not be limited to, ice-skating panels to surround the ice-skating area, fences for various purposes, and as well for other permanent to temporary installations, such as, and not limited to, construction works to secure waterway passages or construction casing for cement structures while they solidify, for instance.

While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.

Claims

1. A modular wall panel section, the section comprising: two or more pillars;at least one wall panel comprising at least a first surrounding element and a second surrounding element wherein the first surrounding element is configured to be secured to the one of the two or more pillars and the second surrounding element is configured to be secured to the another of the two or more pillars; andwherein the first surrounding element is secured at a first height and the second surrounding element is secured at a second height to allow the staggered interlocking of the one wall panel to another wall panel along one of the two or more pillars.

2. The modular wall panel section of claim 1, wherein the pillars are configured to be stackable vertically.

3. The modular wall panel section of claim 1, wherein the interlocking panels are configured to be stackable vertically and horizontally.

4. The modular wall panel section of claim 1, wherein the at least one wall panel may be stacked horizontally at any angle between 0 and 360 degrees with other wall panel.

5. The modular wall panel section of claim 1, wherein each surrounding element comprises: an opening configured as a channel to receive one of said two or more pillars,a cover configured to close the channel once the one of said two or more pillars is in place in the channel, anda lock bar configured to maintain the cover in place thereby securing the connection between the at least one wall panel and the one of said two or more pillars.

6. The modular wall panel system of claim 2, wherein the surrounding elements of a first panel are offset vertically with the surrounding elements of a second adjacent panel.

7. The modular wall panel section of claim 1, wherein the section further comprising an intermediary surrounding element located along a length of the at least one wall panel and configured to be coupled to a pillar of another modular wall panel section.

8. The modular wall panel section of claim 1, wherein the pillars comprise a base and a pole, the base comprising a hole for receiving an elongated section of the pole and the pole configured to be coupled to the surrounding elements.

9. The modular wall panel section of claim 1, the surrounding elements being unitarily with the at least one wall panel.

10. The modular wall panel section of claim 1, wherein two or more of the wall panels are stacked on top of one another.

11. The modular wall panel section of claim 1, wherein the at least one wall panel has a curved shape.

12. The modular wall panel section of claim 1, wherein the at least one wall panel comprises reinforcing elements.

13. The modular wall panel section of claim 1, wherein the section is configured to be part of a structural retaining wall.

14. A modular wall panel system, the system comprising: two or more modular wall panel sections, each section comprising:one or more pillars;at least two wall panels, each wall panel comprising at least a first surrounding element and a second surrounding element wherein the first surrounding element is configured to be secured to the one of the one or more pillars of one of the wall panel sections and the second surrounding element is configured to be secured to a pillar of another wall panel section; andwherein each of the first surrounding elements is secured at a first height and each of the second surrounding elements is secured at a second height to allow the staggered interlocking of the one of the wall panel sections to the other wall panel section along one of the two or more pillars.

15. The modular wall panel system of claim 14, wherein each surrounding element comprises: an opening configured as a channel to receive one of said two or more pillars,a cover configured to close the channel once the one of said two or more pillars is in place in the channel, anda lock bar configured to maintain the cover in place thereby securing the connection between the at least one wall panel and the one of said two or more pillars.

16. The modular wall panel system of claim 14, wherein one of the two or more modular wall panel sections further comprises an intermediary surrounding element located along a length of the one of the two or more modular wall panel sections and configured to be coupled to the pillar of another modular wall panel section.

17. A method of installing a modular wall panel system as claimed in claim 1, the method comprising the steps of: securing to the ground two or more pillars;coupling the first surrounding element of the first panel to one of the two or more pillars;coupling the second surrounding element of the first panel to another of the two or more pillars.