The present invention is generally directed toward decorative walls such as retaining walls and freestanding walls having a decorative surface. In particular, the invention is directed to modular walls with a decorative facing and components of such walls. More specifically, the present invention is directed toward walls, which have a pair of decorative surfaces.
Retaining walls are used in landscaping around residential or commercial buildings. Retaining walls can be made of various materials, but for reasons of durability are most often either concrete structures cast in situ or walls formed of stacked courses of natural stone or masonry blocks. Concrete masonry blocks have become the most popular retaining wall components, due to their ease of manufacture, transport and handling.
Freestanding walls are often used as demarcation structures along roads, walkways or property lines. These walls can be cast in situ or modular, preferably made of stacked blocks, for added flexibility in shaping the wall.
Conventional concrete masonry blocks are generally molded in a dry cast process in which a concrete mixture is filled into a mold box and compressed to generate a pre-consolidated block. This pre-block is removed from the mold box and transported to a setting location at which the block is stored for setting of the concrete mixture. Due to the particularities of the molding process used, the pre-block can be provided with an embossed surface structure, but only on the top and bottom surfaces. Thus, this process does not allow for the molding of a dry cast concrete block with a front decorative surface. Several methods have been developed to provide hollow dry cast blocks with a textured front surface. Molding a slab including several blocks and subsequently braking the slab into individual blocks allows for the creation of an irregular, rough front surface similar to the surface of a split natural stone. Alternatively, the smooth front surface of a finished molded block can be subjected to a percussive treatment which brakes up and roughens the front surface. However, neither method allows for the manufacture of a hollow block with any decorative front surface, for example a surface having a regular surface structure, such as an embossed surface.
Thus, an economical and effective method is desired for providing a decorative finish on any building, retaining or freestanding wall, preferably on both sides of a freestanding wall.
Therefore, improvements in producing freestanding walls are desirable.
In a first aspect, the present disclosure presents a method of providing a double sided hollow wall. The method comprises providing a plurality of concrete facing panels each having a front surface and an opposite, back surface, the back surface including at least one retaining structure. The method further comprises stacking the concrete facing panels back-to-back in spaced apart parallel rows to form a pair of spaced apart parallel first and second wall components and an intermediate space. The method also comprises, in each row, connecting a first concrete facing panel in the first wall component with a second concrete facing panel in the second wall component in the back-to-back orientation, using at least one separate connector having a first connecting end for engagement in the at least one retaining structure of the first concrete facing panel and a second connecting end for engagement to the at least one retaining structure in the second concrete facing panel to form the double sided wall. In this method, the at least one separate connector is an articulated connector that has a link for forming a pivot joint between the first connecting end and the second connecting end.
In a second aspect of the present disclosure, there is provided a wall kit for a double sided hollow wall. The wall kit comprises a plurality of concrete facing panels each having a front surface and an opposite back surface, the back surface including at least one retaining structure; and a plurality of connectors for connecting the plurality of concrete facing panels in back-to-back, spaced apart parallel rows to form a pair of spaced apart parallel first and second wall components with an intermediate space. The connectors are articulated connectors each having a first connecting end, a second connecting end and a link, the link forms a pivot joint between the first connecting end and the second connecting end, the first connecting end removably engages a respective retaining structure of a concrete facing panel of the first wall, and the second connecting end removably engages a respective retaining structure of a concrete facing panel of the second wall.
In a third aspect of the present disclosure, there is provided a double sided hollow wall. The wall comprises: a plurality of concrete facing panels, each concrete facing panel having a front surface and an opposite back surface with a retaining groove; the facing panels being stacked side-by-side and in a spaced apart back to back arrangement for forming back-to-back and spaced apart parallel first and second wall components with an intermediate space. The wall further comprises a plurality of first connectors respectively connecting the retaining groove in a concrete facing panel in the first wall component to the retaining groove in at least one concrete facing panel in the second wall component to form the double sided hollow wall. The connectors are articulated connectors each having a first connecting end, a second connecting end and a link, the link forms a pivot joint between the first connecting end and the second connecting end. The first connecting end removably engages a respective retaining structure of a concrete facing panel of the first wall, and the second connecting end removably engages a respective retaining structure of a concrete facing panel of the second wall.
Preferred embodiments of the invention will now be further described by way of example only and with reference to the attached drawings, wherein
Before explaining the present invention in detail, it is to be understood that the invention is not limited to the preferred embodiments contained herein. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein are for the purpose of description and not of limitation.
Multiple facing panels 110 as shown in
As illustrated in
The keyhole slots 102 in the facing panels 110 will now be discussed in more detail with reference to
The connectors 120 can be made of any material sufficiently strong to reliably connect the facing panels 110 of the partial walls. The connectors are preferably made of any material which will be resistant to deterioration upon exposure to the elements, soil, gravel and the like. The most preferred material is plastic, although non-corroding metal alloys or metal connectors with a non-corroding surface finish can also be used.
Although all the preferred connectors 120, 140 described herein include interlocking members in the form of the cylindrical stems 122 intended for being mounted to the facing panels 110 by sliding them along the keyhole slots 102, connectors with stems of different cross-section can also be used, the only requirement being that the stems have a shape and thickness which prevents the connection being pulled out of the keyhole slot in which it is engaged. Furthermore, connector and retaining groove combinations other than those particularly exemplified can be used without deviating from the present invention. For example connectors of the snap in type can be used (not shown).
Of course, it will be readily apparent to the art skilled person that a retaining structure other than keyhole slots can be provided in the panels 110 as long as a reliable interlocking engagement between the retaining structure and the connectors respectively used is ensured. For example, the retaining structure can be in the form of a slot or bore and the connector can be a compressible/expandable connector which is insertable into the slot or bore and locks in the slot or bore when fully inserted in order to reliably retain the connector in the slot.
The facing panels 110 are preferably provided with a bevel at their lateral ends in order to allow for a closer fit of the facing panels in curved wall applications. The curvature of the wall can then be adjusted by using facing panels of different length, longer panels being used in the outer partial wall of the decorative wall. Generally, the shorter the blocks, the tighter the radius that can be created.
While the invention has been described with a certain degree of particularity, it is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claims, including the full range of equivalency to which each element thereof is entitled.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
This application is a Continuation application from U.S. patent application Ser. No. 15/267,719, filed Sep. 16, 2016, which is a Continuation application from U.S. patent application Ser. No. 14/876,871, filed Oct. 7, 2015, issued Oct. 11, 2016 as U.S. Pat. No. 9,464,431, which is a Continuation application from U.S. patent application Ser. No. 12/752,766, filed Apr. 1, 2010, issued Dec. 8, 2015 as U.S. Pat. No. 9,206,599, which is a Continuation-in-Part application from U.S. patent application Ser. No. 12/525,491, filed Jul. 31, 2009, which is a 371 of PCT/CA2007/002351, filed Dec. 21, 2007, which claims priority from U.S. Ser. No. 60/887,877, filed on Feb. 2, 2007, all of which are incorporated herein by reference.
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Number | Date | Country | |
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20180044915 A1 | Feb 2018 | US |
Number | Date | Country | |
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60887877 | Feb 2007 | US |
Number | Date | Country | |
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Parent | 15267719 | Sep 2016 | US |
Child | 15792102 | US | |
Parent | 14876871 | Oct 2015 | US |
Child | 15267719 | US | |
Parent | 12752766 | Apr 2010 | US |
Child | 14876871 | US |
Number | Date | Country | |
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Parent | 12525491 | US | |
Child | 12752766 | US |