The present invention relates generally to the field of retaining walls, and more particularly to a retaining wall system and retaining wall panels having an arcuate or curved profile, and in particular examples having a catenary curve profile.
Various forms and manners of construction of retaining walls are used to hold back soil and other substrates on terraces or embankments, for landscaping, soil stabilization, structural support, and other purposes. For example, typical planar retaining walls utilize gravity and mass to hold back soil. Retaining walls consisting of stacked stone or block, concrete walls, wood walls, and sheet piling walls are known. Many known retaining walls may involve high labor costs and longer than desired installation times. The heavy materials of many types of retaining walls are not well-suited to do-it-yourself (DIY) type installations by homeowners or landscape professionals without heavy equipment.
Accordingly, it can be seen that needs exist for improved retaining walls, retaining wall components, and methods of retaining wall construction. It is to the provision of improved retaining walls, retaining wall components, and methods of retaining wall construction meeting these and other needs that the present invention is primarily directed.
In example embodiments, the present invention provides improved retaining walls, retaining wall components, and methods of retaining wall construction. In example embodiments, the wall system can be installed faster than a traditional stacked stone or block wall, with less labor. In example embodiments, the material costs are less than that of concrete or stacked stone/block walls. In example embodiments, the system can be a do-it-yourself (DIY) retaining wall solution suited for installation by homeowners or contractors without the need for heavy equipment.
In one aspect, the present invention relates to a wall panel preferably including a central body portion; a first side including a post attachment flange extending at an angle relative to a main directional plane of the wall panel, and configured to align with and attach to a first support post; and a second side including a post surround channel having a proximal portion, a medial portion and a distal portion, and configured to at least partially surround and engage with a second support post spaced a distance from the first support post.
In another aspect, the invention relates to a retaining wall system preferably including a plurality of support posts arranged in a spaced array; and at least one wall panel configured for engagement between a first support post of the plurality of support posts and an adjacent second support post of the plurality of support posts. A first side of the at least one wall panel includes a post attachment flange configured for attachment to the first support post, and the second side of the at least one wall panel includes a post surround channel configured for attachment to the second support post.
In yet another aspect, the invention relates to a retaining wall system preferably including a plurality of support posts arranged in a spaced array and including at least a first support post and a second support post; and at least one wall panel configured for engagement between the first support post and the second support post. The at least one wall panel preferably includes a central body portion having a catenary curved profile, a first side including a post attachment flange extending at an angle from the central body portion and configured for attachment to the first support post, and a second side including a post surround channel configured to at least partially surround and engage with the second support post.
In another aspect, the invention relates to a retaining wall system including a plurality of support posts arranged in a spaced array, and at least one wall panel configured for engagement between a first support post and a second support post. The at least one wall panel preferably has a plan profile defining a curvature, and in particular examples the curvature profile defines a catenary curve.
In another aspect, the invention relates to a panel for a retaining wall. In example forms, the panel preferably includes a front face, a back face, a top edge, a bottom edge, a first side edge and a second side edge. The panel preferably defines a plan profile from a top perspective having an arched curvature, for example following a catenary curve.
In still another aspect, the invention relates to a method of constructing a retaining wall. The method preferably includes installing a plurality of posts anchored in or to the ground in a spaced array and mounting at least one wall panel between adjacent pairs of the plurality of support posts. The at least one wall panel preferably has a plan profile defining a curvature, for example a catenary curve.
In another aspect, the invention relates to a composite polymeric post for a retaining wall system. The post preferably includes a polymeric external portion and an internal portion comprising one or more of a wood-based core, a mineral-filled core, a hollow core, a solid core, and/or one or more stiffening rods extending through at least a portion of a length of the post.
These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.
The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.
Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views,
The posts 20 may be installed in a spaced array, with their lower ends buried in, or otherwise anchored to the ground 15, which may be at a lower elevation in front of the wall than the higher elevation or backfill 16 behind the wall. In particular examples, backfill 16 elevation level may reach part way up the height of the panels 40. In other examples, the backfill grade 16 may reach the top height of the panels 40.
The posts 20 may be arrayed in linear, curved, or other fashion, generally following the path of the retaining wall to be constructed. Adjacent posts 20 may be spaced from one another at regular intervals. In some examples, the spacing between posts 20 may be between about 3′ (36″) to 8′ (96″). In other embodiments, the spacing between posts 20 may be between about 3′ (36″) to 6′ (72″), or shorter or longer spacing as determined by the particular application. In particular embodiments, the spacing between posts 20 may be about 3′ (36″), 4′ (48″), or 5′ (60″). In further examples, the spacing may be between about 42″ to 48″. In particular examples, the spacing between posts 20 may be 44″.
Posts 20 may be made from any suitable material and in any suitable shape. In example embodiments, the posts 20 may comprise wooden posts, for example 4×4, 6×6, or other nominal dimension pressure treated lumber. In alternate embodiments, for example as shown in
As seen throughout
In example embodiments, the panels 40 may comprise rigid or semi-rigid materials. In some embodiments, the panels 40 may be comprised of plastics, thermoset composite, fiber-reinforce plastic (FRP), and/or thermoplastic composite materials. In other embodiments, the panels 40 may be formed of vinyl, polyvinyl chloride (PVC), steel, aluminum or other metals, composites, or other materials of construction. In example forms, the panels 40 may be constructed of materials providing a degree of elasticity, allowing some flexure under load, and optionally having a shape-memory to bias the panels 40 against a load and back toward their unflexed state.
The panels 40 may comprise attachment flanges 50, 52 along their first side 43 and second side 44 for attachment to posts 20. The attachment flanges 50 and 52 may optionally be pre-drilled with holes for receiving fasteners 60 to attach the panels 40 to the posts 20.
In plan view (i.e., viewed from the top or bottom), as seen with reference to
where C1, C2 & C3 are constants, x is in the direction of the width W, and y is in the direction of depth D described below. In example embodiments the constants may be chosen to optimize the curve for the widths between posts 20 (nominally, 3′, 4′, 5′, etc.). In example embodiments, the catenary sheet panel 40 may be formed to have the catenary curvature in its natural unbiased equilibrium state without any load applied. In other embodiments, the panel 40 may be formed to elastically deform into the catenary curvature when a load is applied, for example the anticipated load of fill or soil backfill 16 loading behind the wall system when in use. In some embodiments, panels 40 may be preformed in the catenary shape before installation. In other embodiments, the panels 40 may be fabricated as flat sheets or panels of flexible material, and later bent into the catenary shape during installation by flexing panels having a width greater than the spacing between adjacent posts and affixing the panels in compression in the flexed state between posts 20.
The curved profile of the panels 40 may result in a curvature depth D (the front-to-back distance from a first line extending between the first side 43 and second side 44 of the panel 40 to a parallel second line tangent with the point on the panel furthest from the first line, generally at the midpoint of the panel's 40 width and at or adjacent the inflection point or apex of the panel's 40 curvature), as indicated in
The catenary or curved profile of the catenary sheet or panel 40 allows the load or pressure applied by backfill 16 behind the retaining wall system 10 to be distributed across the panels 40 and to the posts 20. By contrast, C-channel, S-channel or other previously known types or profiles of retaining wall panels may concentrate stress loads on and around the center face lying roughly perpendicular to the load, and/or at one or more discontinuities or points of curvature along the panel profiles. In contrast, the catenary sheet allows the load to be distributed over a wider area, resulting in a more even stress distribution and avoiding localized stress concentrations on the panel.
In example installations and modes of use, the backfill 16 load biases the panels 40 toward a flatter curvature profile against the shape memory of the material, whereby the internal stress within the panel's 40 material resists deformation by the backfill 16 load. Also, the biasing of the panel 40 toward a flatter curvature profile may cause the side-to-side width of the panel 40 to expand, pressing the sides edges of the panel 40 against the support posts 20, to provide support against the backfill 16 load. Support posts 20 not at the ends of the wall will typically receive a side or transverse load from a first panel 40 on a first side of the post 20, and a generally equal but opposed or oppositely-directed side or transverse load from a second panel 40 on an opposite second side of the post 20, whereby the post 20 is held in generally equilibrium or balanced compression loading from opposite sides by the adjacent panels. In this manner, the panel and post components of the wall work together to distribute and support the soil load behind the wall. Optionally, posts at the ends of a wall system may be larger and/or more deeply embedded than intermediate posts, or may be otherwise reinforced, in order to resist the unbalanced load from a panel on one side of the post.
Otherwise defined, the panels 40 may utilize the geometry of a catenary shape which translates outward forces into transverse forces allowing a “thin” panel 40 or part to do the work of a “thick”, planar, retaining wall. The catenary shape generally corresponds to the curve that an idealized hanging chain or cable assumes under its own weight when supported only at its ends. Without being bound by theory, catenary arches or structures as disclosed herein are understood to provide superior strength because they redirect the force applied on the arch of the structure into compression forces pressing along the arch's curve, and in a uniformly loaded catenary arch, the line of thrust runs through its center.
The retaining wall system 10 optionally further comprises a plurality of fasteners 60 for attachment of the panels 40 to the posts 20, for example along the attachment flanges 50, 52 of the panels 40. In example forms, the fasteners 60 may comprise bolts, screws, or other threaded fasteners, nails, clips, slots, or other retainers. In particular embodiments, the fasteners 60 may comprise 2″ (or other length) stainless steel (or other material) lag bolts. In further examples, such as the example shown in
The retaining wall system 10 optionally further comprises a drainage system 70, shown in example form in
Example embodiments of the invention may also include a method of constructing a retaining wall. The method may include digging or drilling post holes in the ground 15 and installing the posts 20 in the holes. Alternatively, the posts 20 may be driven or otherwise inserted into the ground 15. In example forms, the posts 20 are embedded to a depth of roughly one third to one half the exposed height of the wall. In alternate embodiments, the wall panels 40 are not embedded or driven into the ground 15, but instead are installed above grade, and backfilled behind the wall. The posts 20 are spaced in an array along the desired path of the wall. The spacing between posts 20 generally corresponds to width W of the panels 40 to be installed (for example on 4′, 5′, or 6′ centers). The posts 20 may be anchored by filling the post holes with dirt or filling with concrete and allowing the concrete to cure.
Panels 40 having a curved profile, for example according to the catenary equations above, may be attached between the posts 20. The posts 20 are kept plumb and aligned during the attachment process, optionally with bracing or other supports. The catenary sheet panels 40 may be fastened to the posts 20 with fasteners such as bolts 60. Drainage pipe system 70 may optionally be installed behind and at bottom of wall and covered with filter cloth 74 and stone 73. Earth or gravel 72 is backfilled behind the wall. Decorative post caps 26 or other components may be installed on the posts 20 and/or panels 40, if desired.
The wall panel 140 comprises a generally curved or arcuate central body portion 142, a first side comprising a post attachment flange 144, and an opposite second side comprising a post surround channel or section 146. The central body portion 142 may comprise an arcuate, arched or generally U-shaped curvature viewed end-on or in cross-section (see
In example embodiments, the proximal portion 150 and the distal portion 154 extend at generally right angles (about 90°) from the medial portion 152, forming a generally square or rectangular cross-sectional channel configured to receive and at least partially surround and engage with a square or rectangular-sectioned post 20′. In alternate embodiments, the proximal portion 150, the medial portion 152, and the distal portion 154 may form a curved or semi-circular cross-sectional channel configured to receive and at least partially surround and engage with a round or circular-sectioned post. The spacing between the proximal portion 150 and the distal portion 154 may be configured to closely receive and engage with the post and wall panel thickness dimensions intended for use. For example, with a nominal 4×4 (3.5″×3.5″) square-sectioned post 20′ and a ¼″ (0.25″) wall panel thickness T, a spacing of about 3.75″ (or slightly greater, i.e., +0.1″-0.5″ to allow for manufacturing and installation alignment tolerances) may be provided between the proximal portion and the distal portion of the post-surround channel 146. In another example, with a nominal 6×6 post (5.5″×5.5″) and a 1/2″ (0.5″) wall panel thickness T, a spacing of about 6″ or slightly greater may be provided between the proximal portion and the distal portion of the post surround channel 146. In further example embodiments, the transverse dimension or width of the proximal portion 150 and/or the distal portion 154 may also be configured to substantially surround and engage the size and shape of the intended post 20′, for example having a width of at least about 3″-3.5″ for use with a nominal 4×4 post, or at least about 5″-5.5″ for use with a nominal 6×6 post. In example embodiments, the central body portion 142, the post attachment flange 144 and the post surround channel 146 comprise a substantially rigid, unitary or integral body, for example formed as a single piece by molding, extrusion, stamping or other manufacturing process. The panels 140 may be of substantially similar dimensions and materials of construction as described above with respect to the panels 40.
In use, one or more panels 140 are mounted to and attached between posts 20′ along a spaced post array or fence-line to form a retaining wall assembly. A first panel 140 may be mounted between first and second adjacent posts of the spaced array, with the post surround channel 146 positioned around one of the posts, and the post attachment flange 144 along or against the other post. A second panel may optionally be mounted between one of the first and second posts and a third next-adjacent post. Fasteners 160 are installed through the proximal portion 150 of the post surround channel 146 of the first panel 140 and into one side of the post 20′ along one side of the wall panel 140; and/or installed through the distal portion 154 of the post surround channel 146 of the first panel 140 and through the post attachment flange 144 of the second panel (if present), and into the opposite side of the post. Successive panels may be installed in like manner between adjacent posts along the spaced post array or fence-line to form a retaining wall assembly of the desired length and configuration. Optionally, two or more such retaining wall assemblies may be constructed to form a terraced retaining wall system.
While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.
This application is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 17/717,183 filed Apr. 11, 2022, which claims the benefit of U.S. Provisional Patent Application Ser. No. 63/173,821 filed Apr. 12, 2021, the entireties of which are hereby incorporated herein by reference for all purposes.
Number | Date | Country | |
---|---|---|---|
63173821 | Apr 2021 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 17717183 | Apr 2022 | US |
Child | 18402398 | US |