Patent Application
20050183385
1. Field of the Invention
The present invention relates generally to thermoplastic fencing, wall and building structures.
2. Description of Prior Art and Related Information
Plastic wall structures associated with the prior art include fencing assemblies having individual components. Such assemblies require a plurality of parts which are expensive to manufacture. Furthermore, assembling so many individual components is time consuming, especially if a large overall structure is contemplated.
Vertical concrete walls are often desirable as an inexpensive alternative to expensive stone walls composed of, granite or marble, for example. Since they can be sculpted and colored to resemble expensive stone surfaces, concrete can often serve as a cheaper substitute for a wall desired in a residential or commercial setting. Conventional manufacturing of concrete walls, however, consists of producing the walls in a facility and allowing the concrete to cure in the facility. Such an approach is time consuming and inefficient since a concrete manufacturing facility is unable to operate at full capacity due to the storage of the curing concrete.
Concrete walls can also be quite heavy and difficult to transport and manage. What is needed is a more lightweight vertical concrete structure that is inexpensive to manufacture.
The present invention provides structures and methods which overcome the deficiencies in the prior art.
In one aspect, a multi-layer wall panel is provided. The panel comprises a first plastic sheet, a second plastic sheet and a filler material disposed between the first plastic sheet and the second plastic sheet. The first plastic sheet has a first outer surface and a first inner surface. The first outer surface comprises a first three-dimensional texture. The first inner surface is substantially parallel to the first outer surface. The second plastic sheet has a second outer surface and a second inner surface. The second outer surface comprises a second three-dimensional texture. The second inner surface is substantially parallel to the second outer surface. The second plastic sheet is disposed in a back-to-back relationship with the first plastic sheet such that the second inner surface faces the first inner surface. The first plastic sheet and the second plastic sheet may each be composed of vinyl.
The filler material may comprise a composite of polyurethane, a composite of polyurethane and waste materials, concrete, a foam material such as polystyrene, a composite of concrete and polystyrene, a composite of concrete and waste materials, or any other materials or composites that is lightweight and inexpensive to manufacture.
Each of the three-dimensional textures may be formed to resemble other masonry, other building materials, or any other aesthetically pleasing appearance as desired. For example, the three-dimensional textures may be formed to resemble a brick pattern, pavers, a random assortment of stones, and more.
The panel further comprises one or more side rails coupled to the first plastic sheet and second plastic sheet. Each side rail comprises a U-channel configured to receive a post. The panel may further comprise a top rail and a bottom rail configured to mate with the top rail. The panel also comprises a top decorative cap covering the top rail.
The panel may also include a first concrete layer disposed between the filler material and the first vinyl sheet as well as a second concrete layer disposed between the filler material and the second vinyl sheet. The first concrete layer may be permanently attached to, or removable from, the first inner surface of the first plastic sheet. The second concrete layer may also be permanently attached to, or removable from, the second inner surface of the second plastic sheet.
In another aspect, an outdoor wall assembly is provided. The assembly comprises a first wall panel and a second wall panel. The first wall panel includes a first plastic sheet and a second plastic sheet. The first plastic sheet has a first outer surface and a first inner surface. The first outer surface comprises a first three-dimensional texture. The first inner surface is substantially parallel to the first outer surface. The second plastic sheet has a second outer surface and a second inner surface. The second outer surface comprises a second three-dimensional texture. The second inner surface is substantially parallel to the second outer surface. The second plastic sheet is disposed in a back-to-back relationship with the first plastic sheet such that the second inner surface faces the first inner surface. A first filler material is disposed between the first plastic sheet and the second plastic sheet. The first wall panel further comprises a first bottom rail and a first top rail.
The second wall panel is disposed on top of the first wall panel. The second wall panel includes a third plastic sheet and a fourth plastic sheet. The third plastic sheet has a third outer surface and a third inner surface. The third outer surface comprises a third three-dimensional texture. The third inner surface is substantially parallel to the third outer surface. A fourth plastic sheet has a fourth outer surface and a fourth inner surface. The fourth outer surface comprises a fourth three-dimensional texture. The fourth inner surface is substantially parallel to the fourth outer surface. The fourth plastic sheet is disposed in a back-to-back relationship with the third plastic sheet such that the fourth inner surface faces the third inner surface. A second filler material is disposed between the third plastic sheet and the fourth plastic sheet. The second wall panel further comprises a second top rail, a second bottom rail configured to mate with the first top rail, and a first side rail.
The wall assembly further comprises a post coupled to the first side rail. The first side rail comprises a U-channel configured to receive the post. The assembly further comprises a top decorative cap covering the second top rail. The first top rail and the second bottom rail are configured to removably mate with each other. In particular, the first top rail comprises a longitudinal male portion while the second bottom rail comprises a longitudinal female portion. The first filler material and the second filler material may comprise polyurethane. The first plastic sheet, the second plastic sheet, the third plastic sheet and the fourth plastic sheet preferably comprise vinyl.
A first concrete layer may be disposed between the first plastic sheet and the first filler material. A second concrete layer may be disposed between second plastic sheet and the first filler material. The second wall panel may comprise a third concrete layer disposed between the third plastic sheet and the second filler material as well as a fourth concrete layer disposed between fourth plastic sheet and the second filler material. In such an assembly, the first filler material and the second filler material may be composed of a foam material, such as polystyrene.
A method for manufacturing vertical concrete walls is also provided. The method comprises providing a portable mold having an inner surface contoured with a texture desired for an outer surface of a concrete wall, pouring concrete into the portable mold, curing the concrete in the portable mold, and removing the portable mold from the concrete. The method further comprises transporting the portable mold with the poured concrete to a destination while the concrete is curing in the portable mold.
Removing the portable mold from the concrete comprises removing the portable mold from the concrete at the destination. Pouring concrete into the portable mold comprises pouring concrete into the portable mold at a facility. Curing the concrete in the portable mold comprises curing the concrete in the portable mold away from the facility. A layer of foam may be attached to the concrete in the portable mold. The method further comprising re-using the portable mold.
In summary, a multi-layer wall panel includes a core filler material surrounded by two plastic sheets. Each sheet includes three-dimensional texture formed to resemble masonry or other desired aesthetics. A layer of concrete may be disposed between each sheet and the filler material. The sheet may be removed from the concrete layers to expose the concrete surfaces. Multiple wall panels may be stacked on top of one another and joined side-by-side with posts and connectors to form a wall assembly. A method for manufacturing vertical concrete wall structures is also provided.
The invention, now having been briefly summarized, may be better appreciated by the following detailed description.
The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims.
In
The second sheet 22 may be configured to be substantially similar to the structure of the first sheet 22. Thus, the second sheet 22 comprises a front, outer surface 31 also having a three-dimensional texture, which is shown in
Each sheet 20, 22 preferably comprises a top horizontal flange 35, a bottom horizontal flange 37 and side hooks 39 which shall be discussed in more detail below.
In the first preferred embodiment shown in
The wall panel 10 is preferably configured to be modular so that the panel 10 may be joined with other panels to form a wall assembly as discussed below in connection with
Side rails 53 are preferably formed as U-channels and received within the side hooks 39 of the sheets 20, 22. In combination with the sheets 20, 22, the top rail 44 and bottom rail 46, the side rails 53 cover the filler material 42 such that the filler material 42 is entirely encapsulated.
In
It will be appreciated that the modular components described above collectively form a wall assembly 60 that may be easily configured to provide an outdoor barrier that is aesthetically pleasing. The outer surfaces of the sheets may be varied at the manufacturing stage so as to provide an endless variety of three-dimensional textures that may be desired by the user. As an example and not by way of limitation, the three-dimensional texture may be configured as a stone pattern. In all the embodiments, it is contemplated that the surfaces may be colored, e.g. by painting, in order to provide as natural and/or aesthetically pleasing appearance as desired.
The ease of interconnectability of the modular panels 10 is illustrated in
A second preferred embodiment of a wall panel 100 is illustrated in
The second sheet 122 may be configured to be substantially similar to the structure of the first sheet 122. Thus, the second sheet 122 comprises a front, outer surface 131 also having a three-dimensional texture. The sheet 122 further comprises a rear, inner surface 133 that is substantially parallel to the outer surface 131 and, therefore, configured with an inverted pattern of the three dimensional texture of the outer surface 131. When assembled in the back-to-back configuration, the inner surfaces 128, 133 of the sheets 120, 122, respectively, face each other.
In the second preferred embodiment shown in
In this embodiment, a first layer 173 is disposed between the filler material 142 and the first sheet 120 while a second layer 175 is disposed between the filler material 142 and the second sheet 122. Thus, the panel 100 comprises a pair of layers 173, 175 disposed on opposing sides of the filler material 142. In the preferred embodiment, the layers 173, 175 preferably comprise concrete, or a composite including concrete and other materials. Alternatively, the layers 173, 175 may be composed of any other substantially rigid material which will provide the panel 110 with overall strength and durability to withstand outdoor conditions. The layers 173, 175 may be either detachable from, or permanently attached to, the filler material 142.
The layers 173, 175 may be permanently attached to the sheets 120, 122, respectively, by bonding, for example. Alternatively, the sheets 120, 122 may be removable from layers 173, 175 so as to expose the layers 173, 175. For example, the layers 173, 175 may be composed of concrete with a certain three-dimensional texture resembling stone or any kind of decorative pattern. In such a case, it may be desirable to expose the concrete layers 173, 175 which can be colored and/or painted so as to form an aesthetically pleasing structure. A side connector 182 shown in exploded view from the panel 100 has an a “I” profile and comprises two opposing U-channels 184 configured to receive side portions 186 of the panels 100.
In an alternative embodiment shown in
It will be appreciated that a vertical wall structure 100 is provided having a lightweight and inexpensive core, and sturdy concrete outer walls which may or may not be covered by sheets of plastic material. If the plastic sheets remain on the concrete walls, the sheets may be colored and/or decorated so to provide an aesthetically pleasing appearance. If not, the exposed concrete walls may be chiseled, colored and/or otherwise configured so as to form any desired appearance such as that resembling a stone pattern.
A preferred method of manufacturing concrete walls is illustrated in
As shown in
It will be appreciated that unlike conventional techniques for manufacturing vertical concrete structures which generally occur inside a manufacturing facility, the curing process for the vertical concrete structures, such as walls, can now take place entirely outside the facility, thereby enabling a radical increase in production capacity. According to the invention, facilities no longer need to reserve space and time to allow for the curing process.
Furthermore, the vertical concrete walls may be formed with an appropriate mold such that the end product comprises a three-dimensional texture having an appearance other than concrete. For example, in
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention.
