Patent Application
20050217201
In general, the present invention relates to skirting assemblies for building structures (including modular/manufactured structures, associated stairwell structures, etc., whether used for residential or commercial/governmental purposes), and panel assemblies for use in hedging/retaining-walls/walkways and other such landscape features. The assembly is typically fabricated at a factory or warehouse then shipped to a building or landscape(d) site as kits, partial or full assemblies, for installation around the lower perimeter (ground-to-building interface) of the manufactured and mobile homes and buildings, commercial buildings, residential dwellings, and the like, or for assembly into hedging/retaining-walls/walkways and other such landscape features, for aesthetic and structural purposes.
More particularly, the invention is directed to a new lightweight skirting assembly adapted for use in providing structural support at the ground-to-building interface as an upwardly directed extension to a foundation along with having an outwardly-directed surface to which an ornamental façade is affixed. The ornamental façade can be any artificial front comprising one or more types of a wide range of raw, natural and manmade materials, made to resemble the siding of a building or some other landscape feature (e.g., hedging/retaining-wall of rock, brick, railroad ties, wood or log fencing, lighted walkway, and so on). Each of the assemblies is preferably fastened adjacent one another, side-by-side or stacked atop, and adapted for securing along a foundation within a ground, such as the footing perimeter and cross-runner(s) of a building structure, perimeter foundation around or along an area or parcel of real estate (yard, garden area, park, parking lot, etc.), foundation extending along a walk- or roadway, and so on. Several panels of the invention fastened together according to the invention produces a system that provides an amount of structural integrity and operates as an aesthetic barrier functioning as a back-fill support, a cover of ground-level imperfections and utilities (tubing, wiring/cabling, pipes, ductwork, building framing, etc.), as well as providing a level interface line beneath the wood, metal, vinyl, stucco, brick, stone, concrete, glass, etc., siding of a building, and so on.
One can readily appreciate the many fundamental distinguishing features of the instant invention from conventional skirting and traditional landscape retaining-walls/hedging. While the current decorative skirting designs provide a certain amount of stability, few of these conventional panel designs provide much, if any, structural compression-support. Furthermore, regarding the select few current designs purporting to provide structural support, each is absent any plastic support framework as well as the unique angle iron shaped vertical supports contemplated by the instant invention. Skirting used beneath modular/manufactured dwellings requires not only compression-support but also sufficient strength and structural integrity to accommodate the shear stresses experienced as a result of at least partial immersion in soil, clay, sand, etc. (the composition of which varies greatly from region to region and includes moisture and other corrosives). None of the conventional skirting or hedging/retaining-wall/walkway panel designs include built-in illumination source(s).
It is a primary object of this invention to provide a panel having an ornamental façade adapted for securing to a foundation. The panel may be assembled to produce a skirting system for building structures (including modular/manufactured structures, associated stairwell structures, etc., used for residential or commercial/governmental purposes) or in hedging/retaining-walls/walkways and other such landscape features, all within the spirit and scope of this technical disclosure.
In a first characterization, the panel has a plastic member comprising an outwardly-directed surface to which the ornamental façade is affixed, and an inwardly-directed surface to which a plastic support framework is integrally coupled. The support framework comprises a first section having a cross-section shaped in any suitable form (tubular or solid) such as that of a square, rectangle, triangle, circle, oblong, an irregular polygon, or irregular in shape (including shapes comprising any combination of straight edges and/or curvilinear sections); the support framework is located generally along the periphery of the inwardly-directed surface and further includes at least one interconnect section extending between the first section. The interconnect section of the support framework may likewise be tubular or solid and of a similar, or different, cross-sectional shape as the first section. The support framework may comprise additional interconnect sections that may also extend between the first section. For example, one or more of these interconnect sections may comprise a bend between distal ends from which the interconnect section extends from the first section. The one or more interconnect sections may form a diagonal “/” shape, an “X” shape, “H” shape, “” shape, or any other shape interconnecting the framework from one side to another side of the first section. A plurality of apertures are provided through a lower length of the first section, sized for accepting a fastener that permits the securing of the panel to the foundation (such as, for example, bolts, nails, screws, stakes/pins, rivets, pins, clamps and other latching mechanisms, etc. with or without an adhesive material for additional strength).
As one will appreciate, additional distinguishing features are many: The first section may further comprise a right-side section, left-side section, and upper section—each of these sections may include a plurality of apertures therethrough. By way of example, only, the panels may be arranged such that the left-side section of one is secured to the right-side section of an adjacent side-by-side panel, and/or the upper section of a ground-level panel may be secured to the lower length of a panel adjacent and atop the ground-level panel. Fasteners can be utilized in connection with the apertures of the left-side section, right-side section, upper section and lower length, respectively. For example, the apertures through the upper section may be sized for accepting another fastener permitting the securing of the panel to a lower support of a manufactured/modular type building structure or to an adjacent (atop or side-by-side) panel. Suitable fasteners include, for example, bolts, nails, screws, rivets, clamps and other latching mechanism, pins/dowels, specialty fasteners such as those used for securing wall hangings to drywall, and so on, with or without an adhesive material for additional strength. Other securing mechanisms are contemplated hereby for the securing of panel(s) to a building structure or to adjacent panels—suitable securing mechanisms include: adhesives compatible with the materials being joined; weld spots, soldering, or other thermally-produced joints using a material selected for compatibility with the material(s) out of which the framework section(s) and/or the support joist of the building structure; interlocking surfaces (such as mating tongue-and-groove type edges along the top of the upper section and building structure support joists) that may be interlocked in a snap-fit or in sliding-fit fashion coupled with suitable adhesive; and so on.
The outwardly-directed surface may be generally planar, or have any suitably-shaped surface that accommodates the type of ornamental façade selected. For example, to accommodate larger stones or rock, logs or wood siding, and so on, the outwardly-directed surface may include indented or curved regions sized for accepting the rock, logs, etc. to fit therewithin; alternatively to match house siding, the outwardly-directed surface may be tiered, and so on. The ornamental façade may comprise any one or more types of a wide variety of items having been affixed to the outwardly-directed surface using any suitable adhesive; by way of example, such items include pebbles, glass block, artificial stone, log sections, wood siding, metal siding, vinyl siding, brick, tiles, sand, stucco, clay, and rock. While the outwardly-directed surface may be rectangular, square, or triangular in shape, the outwardly-directed surface may take on a myriad of other regular and irregular polygon shapes, or be irregular in shape (including shapes comprising any combination of straight edges and/or curvilinear sections). Associated features of the panel will be accordingly sized and fabricated of material(s) having sufficient strength to provide support, for example, where the panel is intended to serve a weigh-bearing function (whether to aid in support of a building structure or used in a column of panels atop one another).
The support framework and the plastic member may be integrally fabricated by any suitable process, such as: injection molding (such as reaction injection molding, i.e., RIM), structural foam molding, blow molding, transfer molding, compression molding, thermoforming, and adhesion of the framework and plastic member (having been separately extruded earlier), all according to well known plastic production techniques.
Further unique to the invention is an ornamental façade that also includes an illumination source. The illumination source may comprise an incandescent light source or an arc light along with a fixture and/or a photo-voltaic cell and battery for more-efficient outdoor use. Incandescent light sources include those that use a filament; arc lights use an electrical arc running through a gas plasma. The outwardly-directed surface may further comprise a port-hole for use in connection with the illumination source; for example, the fixture may be arranged with an electrical cabling passing through the port-hole to ‘hide’ other electrical components such as connectors and outlet(s), if needed, to connect the illumination source to a power/voltage source. The port-hole may be conveniently sized to provide ventilation from one side of the panel through to the other, with or without a grating cover depending on aesthetic preference.
The panels are arranged as skirting or hedging/retaining-wall/walkway structures and other such landscape features (for example, circumscribing a ground-area), atop a foundation comprised of a compressive-support material poured and set, stacked, filled, or otherwise constructed within a ground employing known techniques in a manner that will accommodate anticipated compressive and shear stresses. Suitable compressive-support materials include cement, masonry, brick, slate, rock, structural soil fill, clay, sand, etc.
In a second characterization, the panel has a member comprising an outwardly-directed surface to which the ornamental façade is affixed, and an inwardly-directed surface to which a plastic support framework and right and left vertical supports are coupled. The support framework comprises a first section at least located generally along a top periphery of the inwardly-directed surface. Once again, the framework may have a cross-sectional shape (tubular or solid) in any suitable form such as that of an oval, circle, regular or irregular polygon, or irregular in shape. Each of the right and left vertical supports comprises an angle iron shaped extension, a top-end and lower-end of which has a respective ledge permanently affixed. While “angle iron” is often used in connection with a length of metal, alloy, or any substantially rigid plastic having an “L” shaped cross-section, as used herein, the cross-section of the angle iron shaped extension preferably has at least one angle—not necessarily 90 degrees—interposed between a first and second leg; the first and second leg may be generally equal in length or of different lengths, as is the case of an “L”. When at least two panels are adjacently arranged such that the left vertical support of one panel is secured with a respective right vertical support of the adjacent panel, the two adjacent angle iron shaped extensions may be secured to one another with suitable fasteners and/or adhesives with opposing back-faces in contact. By way of example, where the angle iron shaped extensions each have an “L” shaped cross-section with the shorter leg of the “L” having been coupled to the inwardly-directed surface of the panel member, the back-faces of the longer leg of the “L” may be arranged in contact and secured such that a “T” shaped combined extension is created and interposed between adjacent panel members (for example, see
Additional distinguishing features are many: Each of the lower-end ledges may include an aperture for accepting a fastener permitting the securing of the panel to the foundation. An aperture through the top-end ledge may be used in connection with a fastener to secure the top-end ledge to a lower support, such as a floor joist, of a manufactured/modular building or to another panel arranged atop. The first section of the support framework may be equipped with a plurality of apertures for accepting fastener(s) permitting securing of the panel's framework to the building lower support or an adjacent (atop) panel. The angle iron shaped extension may also be equipped with a plurality of apertures for accepting second fasteners permitting the securing of a left vertical support with a respective of right vertical support of an adjacent (side-by-side) panel.
The first section may also be comprised right-side and left-side sections coupled to the inwardly-directed surface a distance from a respective right and left periphery of the inwardly-directed surface. This distance provides spacing for coupling the right and left vertical supports to the inwardly-directed surface: For example, the right vertical support may be coupled to the inwardly-directed surface within the distance from the respective right periphery, and the left vertical support may be coupled to the inwardly-directed surface within the distance from the respective left periphery. This coupling may be by way of employing fasteners, welding or other thermally-produced joints, and/or an adhesive—such that it provides a sufficiently secure coupling of the vertical supports and inwardly-directed surface, and will depend upon materials out of which they are made. Once again, the support framework and the member, if made from a plastic, may be integrally fabricated by any suitable process, such as: injection molding (such as reaction injection molding, i.e., RIM), structural foam molding, blow molding, transfer molding, compression molding, thermoforming, and adhesion of the framework and plastic member (having been separately extruded earlier), all according to well known plastic production techniques.
In another characterization, the invention includes a method of producing a panel having an ornamental façade adapted for securing to a foundation. The method includes the step of integrally fabricating a plastic support framework comprising a first section located generally along the periphery of an inwardly-directed surface of a plastic member and at least one interconnect section extending between the first section; this fabrication may be performed by a process such as: injection molding, structural foam molding, blow molding, transfer molding, compression molding, thermoforming, and adhesion of the framework and plastic member having been separately extruded. The ornamental façade is then affixed to an outwardly-directed surface of the plastic member. A plurality of apertures can be provided through a lower length of the first section, each aperture sized for accepting a fastener permitting the securing of the panel to the foundation. Where the first section further includes right-side and left-side sections, apertures can also be provided therethrough; the panels may then be arranged with a left-side section of one panel secured to a right-side section of an adjacent panel by using fasteners through these apertures. The step of integrally fabricating a plastic support framework generally along the periphery of an inwardly-directed surface can further comprise fabricating the right-side and left-side sections of the first section to have a cross-section that is tubular or solid, in the form of a variety of shapes as mentioned above. Prior to or after affixing the ornamental façade, an illumination source within the ornamental façade may be added; this may include arranging and securing a fixture and a visual light source on the plastic member.
As one will appreciate, certain of the several unique features of the invention, as well as unique combinations of features, all supported and contemplated hereby may provide a variety of advantages including versatility of use/application, portability, flexibility in design, and so on. The basic panel structure is adaptable for supporting a wide variety of shapes and sizes, ornamental façades, lighting types, ventilation configurations, etc. Portions of the panels may be preassembled for portability and handy arrangement into a building skirting, hedging/retaining-wall/walkway and other landscape feature(s), on-site. The new panel is preferably sized for manipulation and set-up on-site by individual(s). Different configurations and material(s) of the support framework coupled to the inwardly-directed surface make the panel(s) adaptable to handle different or uneven loads within a variety of ground/landscape environments. These and other advantages of providing the new panel design, and associated method of producing a panel having an ornamental façade adapted for securing to a foundation, will be appreciated by perusing the instant technical discussion, including the drawings, claims, and abstract, in light of drawbacks to existing modular skirting structures that have been identified, or may be uncovered.
For purposes of illustrating the innovative nature plus the flexibility of design and versatility of preferred and alternative structures and method of producing panels, supported and disclosed hereby, the invention will be better appreciated by reviewing the accompanying drawings (in which like numerals, as included, designate like parts). One can appreciate the many features that distinguish the instant invention from traditional, known modular skirting. The drawings have been included to communicate the unique features of the innovative structures of the invention by way of example, only, and are in no way intended to unduly limit the disclosure hereof.
In connection with discussing the unique features depicted in
One can appreciate that the number of panel subassemblies arranged adjacent side-by-side or atop, depends on use and perimeter or length of the foundation to which the panels are secured. Panel assemblies of different façades may be adjacently arranged and connected side-by-side such as is shown in
The support framework sections (e.g., those labeled 16-17-18, 26-27-28, 36-37-38) are shown with rectangular cross-sections; however, the cross-section may be shaped in any suitable form (tubular or solid) such as that of a square, rectangle, triangle, circle, oblong, an irregular polygon, or irregular in shape (including shapes comprising any combination of straight edges and/or curvilinear sections). The support framework is located generally along the periphery of the inwardly-directed surface (better viewed from the back in FIGS. 4A, 5-7) and can further include an interconnect section (e.g., ” shape, or any other shape interconnecting the framework from one side to another side. Apertures may be drilled, molded, cut, or otherwise formed through the framework sections and sized for accepting fastener(s) that permit the securing of the panel (in direction of arrows 41a-c,
Ornamental façade 14 and 34 are shown in
The outwardly-directed surface may further comprise a port-hole (e.g., at 94 in
The framework, while appearing to have separately constructed right-side, left-side, upper, and/or lower, plus interconnect, etc., sections—one or more of which may include a plurality of apertures—it may be machined, extruded, molded or otherwise formed as a single framework (e.g., see
Apertures (not shown for simplicity) through the upper sections 17, 27, 37 of each panel may be sized for accepting fasteners permitting the securing of panels 10, 20, 30 to a lower support 50 of a manufactured/modular type building structure or to an adjacent (atop or side-by-side) panel. In
The outwardly-directed surface may be generally planar (as depicted in
The partially exploded assembly back view of panel 80 in
Illustrated, also, in
In
As discussed above,
As mentioned, the tubular or solid sections of the framework are preferably made of a lightweight material having sufficient strength for supporting anticipated weights to which it will be exposed. For example, if a panel is intended for use as skirting for a modular/manufactured building that, the panel framework and any vertical supports used will have to provide sufficient compressive-support and accommodate anticipated ground-soil sheer stresses. If the panel is intended for use in hedging assembly, less compressive-support will be required, however, the panel framework preferably is selected to withstand sheer stresses associated with ground-soil composition, as well as wind gusts, snow, rain, etc., associated with inclement weather. A multitude of plastic and metal materials are contemplated for use according to the invention in connection with fabricating the panel member, its framework, and vertical supports—and components thereof—including resins, generally rigid plastics (both thermoplastic and thermosetting structures), alloys, and metals.
By way of background: The thermoplastics include those plastics having polymer chains more-easily broken with heat, such as polystyrene, polycarbonate, polyarylate, polybutylene, medium- to high-density polyethylene(s), and acrylic, in particular, thermoplastic structural foams are useful according to the invention. The polymer chains in thermosetting plastics typically do not separate completely with heat. After being fully cured, thermosets cannot be resoftened by heat; thermosets include polyester, silicone, urethane, urea-formaldehyde. The term ‘alloy’ refers to any combination of elements typically having metallic properties. Resins are any of a class of solid or semisolid organic products of natural or synthetic origin with no definite melting point, generally of high molecular weight—typically composed of a polymer. In any case and as one can appreciate, many well known manufacturing techniques exist (such as extruding/extrusion, casting, pulling, many types of molding, machining, cutting, and so on) that are suitable for use in fabricating the framework sections, vertical supports, and panel members. Structural foam molding is a process of molding thermoplastic articles with a cellular core and integral solid skins in, generally, a single operation. Material weight-to-strength ratio is targeted to be on the lower side for components of panels where portability is key. By way of example only, a panel may be made using a structural foam RIM process; fasteners may be selected from off-the-shelf standard or special-order (including those that are plated): bolts, nails, screws, and pins, clamps, plastic welding, adhesion, ultrasonic fusion.
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, those skilled in the art will readily appreciate that various modifications, whether specifically or expressly identified herein, may be made to any of the representative embodiments without departing from the novel teachings or scope of this technical disclosure. Accordingly, all such modifications are contemplated and intended to be included within the scope of the claims. Although the commonly employed preamble phrase “comprising the steps of” may be used herein in a method claim, applicants do not intend to invoke 35 U.S.C. §112 ¶6. Furthermore, in any claim that is filed herewith or hereafter, any means-plus-function clauses used, or later found to be present, are intended to cover at least all structure(s) described herein as performing the recited function and not only structural equivalents but also equivalent structures.
