Patent Publication Number: US-8967917-B1

Title: Retaining wall system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application for a utility patent is a continuation-in-part of a previously filed utility patent, having the application Ser. No. 13/485,673, filed May 31, 2012. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to the construction of retaining walls, and more particularly to an apparatus and method constructing such walls through the use of spiralnails attached to pilasters which support a specially constructed wire truss system. 
     2. Description of Related Art 
     The following art defines the present state of this field: 
     Hilfiker et al., U.S. Pat. No. 6,874,975, teaches a soil reinforced retaining wall for an earthen embankment which is formed by driving nails into the embankment at spaced intervals. The nails have helical threads extending there-around of such proportion and pitch as to screw into the formation as the nails are driven into place with a vibratory hammer, without prior boring of the embankment to accommodate the nails, or the necessity of cementing the nails into place. The wall is constructed from the top down and face panels are progressively assembled over the embankment and secured in place by the nails. This patent is hereby incorporated by reference in full. 
     The prior art teaches an apparatus and method for constructing soil reinforced earthen retaining walls, such as is described above. However, the prior art does not teach the use of spiralnails attached to pilasters which support a specially constructed wire truss system. The present invention fulfills these needs and provides further related advantages as described in the following summary. 
     SUMMARY OF THE INVENTION 
     The present invention teaches certain benefits in construction and use which give rise to the objectives described below. 
     The present invention provides a retaining wall system for installation on an earthen embankment. The retaining wall system has a plurality of pilasters, a plurality of spiralnails, a wire truss system, and a plurality of face panels. The plurality of pilasters are horizontally spaced along the earthen embankment, and each have an elongate pilaster body that is vertically mounted on the earthen embankment. The plurality of spiralnails that have each been driven into the earthen embankment are attached to one of the plurality of pilasters to anchor the pilasters in the earthen embankment. The wire truss system is operably mounted on the plurality of pilasters for supporting the earthen embankment. 
     A primary objective of the present invention is to provide a retaining wall system having advantages not taught by the prior art. 
     Another objective is to provide a retaining wall system that is inexpensive to manufacture and easy to install. 
     A further objective is to provide a retaining wall system that is strong and durable. 
     Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings illustrate the present invention. In such drawings: 
         FIG. 1  is an exploded perspective view of a first step in the construction of one embodiment of a retaining wall system, illustrating the installation of initial truss elements and pilasters, each of the truss elements having a V-shaped portion; 
         FIG. 2  is a perspective view of the retaining wall system following installation of additional truss elements; 
         FIG. 3  is a perspective view of the retaining wall system, illustrating face panels being installed to cover the V-shaped portions of the truss elements; 
         FIG. 4  is a top plan view of one of the truss elements and one of the face panels; 
         FIG. 5  is a perspective view of a second embodiment of one of the truss elements, illustrating an extended portion of the truss element; 
         FIG. 6  is a top plan view thereof; 
         FIG. 7  is an exploded perspective view of a first step in the construction of a second embodiment of the retaining wall system, using the truss element of  FIGS. 5-6 ; 
         FIG. 8  is an exploded perspective view of the retaining wall system of  FIG. 7 , following installation of additional truss elements, illustrating the extended portion of each truss element being used to cover the V-shaped portion of the adjacent truss element; 
         FIG. 9  is a perspective view of the retaining wall system of  FIG. 8  once installed; 
         FIG. 10  is an exploded perspective view of the retaining wall system of  FIG. 8 , illustrating the installation of an end truss to complete the retaining wall system; 
         FIG. 11  is a perspective view thereof once installed; 
         FIG. 12  is an exploded perspective view of a locking mechanism used to lock the pilaster to a spiralnail; 
         FIG. 13  is a perspective view thereof; 
         FIG. 14  is a front elevational view of the pilaster and the spiralnail; 
         FIG. 15  is a front elevational view of the locking mechanism in an untorqued position; and 
         FIG. 16  is a front elevational view of the locking mechanism in a torqued position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The above-described drawing figures illustrate the invention, a retaining wall system  10  for installation on an earthen embankment  12 . 
       FIG. 1  is an exploded perspective view of a first step in the construction of one embodiment of the retaining wall system  10 .  FIG. 2  is a perspective view of the retaining wall system  10  following installation of additional elements.  FIG. 3  is a perspective view of the retaining wall system  10 . As shown in  FIGS. 1-3 , the retaining wall system  10  includes a plurality of pilasters  20 , a plurality of spiralnails  22 , a locking mechanism  24 , a wire truss system  26 , and a plurality of face panels  28 . 
     As illustrated in  FIGS. 1-3 , the plurality of pilasters  20  may be in the form of elongate posts, as described in greater detail below. The plurality of pilasters  20  may be vertically mounted and horizontally spaced on the earthen embankment  12 . At least one spiralnail  22  may be attached to each of the pilasters  20  to anchor the pilasters  20  into the earthen embankment  12  and provide support to the wire truss system  26 . The spiralnails  22  may be locked in place by the locking mechanism  24 , which is discussed in greater detail below, or via alternative attachment devices or mechanisms, and suitable alternative attachments should be considered within the scope of the present invention. For purposes of this application, the term “earthen embankment” is defined to include any form of embankment, slope, or formation that may require a retaining wall. 
     The spiralnails  22  may be any form of elongate structure suitable for being driven into the earthen embankment  12  as discussed herein. In the present embodiment, the spiralnails  22  are elongate generally rectilinear steel tubes that are shaped into a polyhedral cross section (or other suitable shape), and then twisted about a longitudinal axis to form a spiral thread. The spiral-shaped configuration of the spiralnail  22  is of such proportions and pitch that the nail will screw itself into place in response to being hammered into the earthen embankment  12 . The structure of the spiralnail  22  is discussed in greater detail in Hilfiker et al., U.S. Pat. No. 6,874,975, which is hereby incorporated by reference in full. 
     As illustrated in  FIGS. 1-3 , the wire truss system  26  is shaped and structured for resisting the lateral pressure of soil in order to stabilize a slope and/or otherwise provide useful areas at different elevations. In the embodiment of  FIGS. 1-3  the wire truss system  26  is operably mounted on the plurality of pilasters  20 . The wire truss system  26  may include plurality of truss elements  32 . While one chain of truss elements  32  is illustrated, multiple tiers of truss elements  32  will typically be used to stabilize a typical earthen embankment  12 . 
     The plurality of truss elements  32  may include a wire lattice body  34 , a pilaster attachment portion  38 , and an interlocking portion  40 , to be discussed in detail below. While  FIGS. 1-3  illustrate one embodiment of the wire truss system  26 , one skilled in the art may design alternative embodiments that remain within the scope of the present invention. 
     The wire lattice body  34  of the truss element, illustrated in  FIGS. 1-3 , prevents soil from moving past the retaining wall system  10 . The wire lattice body  34  may be planar and formed of wire lattice. In the embodiment of  FIGS. 1-3 , the wire lattice body  34  may include a V-shaped portion  42 , such that the wire lattice body  34  may extend outwardly from a center apex  44  at an angle of between 10-80 degrees from the plane of the plurality of face panels  28 . The term “V-shaped portion” is defined to include not only a generally V-shaped structure, but also equivalent structures, such as a parabolic (or “U-shaped”) structure, that is equivalent to the present invention. Therefore, while  FIGS. 1-3  illustrate one embodiment of the wire lattice body  34  and the V-shaped portion  42 , those skilled in the art may devise alternative embodiments, and these equivalent embodiments are considered within the scope of the present invention. 
     As shown in  FIGS. 1-3 , the plurality of face panels  28  are operably attached to the wire truss system  26  for covering the V-shaped portions  42  of the truss elements  32 . The face panels  28  may be generally rectangular walls (although other shapes might be used, if desired) formed of wire lattice that are sized and shaped to cover the V-shaped portions  42 , and may further extend to form a complete wall to contain the earthen embankment  12 . Furthermore, prongs  29  may extend from each of the face panels  28 , to enable adjacent face panels  28  to be physically connected to each other, to provide greater structural integrity to the retaining wall system  10 . 
     In the embodiment of  FIGS. 1-3 , each of the plurality of face panels  28  is disposed on a plane and may be mounted on the truss elements  32 , as discussed below. In an alternative embodiment, discussed below, the face panels  28  are integrally formed with the wire lattice body  34  of the adjacent truss element  32 . Those skilled in the art may design alternative embodiments of the face panels  28 , and such alternative embodiments should be considered within the scope of the present invention. 
     Fasteners  30 , such as spiral binders, may be used to adjoin the truss elements  32  by wrapping around both of the truss elements  32 , as illustrated in  FIGS. 1-3 . In this embodiment, the spiral binders  30  also wrap around portions of the face panels  28  as well, securing the entire construction together. The spiral binders  30  may be elongate rods formed into a spiral shape that is shaped and sized to fit around portions of both the truss elements  32  and/or the portions of the face panels  28 . While the spiral binders  30  illustrate one embodiment of acceptable fasteners, alternative fasteners known in the art may also be used, including tire wires, zip ties, and/or any forms of hooks, welding, or other alternatives known to one skilled in the art. 
     As illustrated in  FIGS. 1-3 , a wire stiffening wall  36  may be further included to attach the face panel  28  to the truss element  32 . As illustrated in  FIGS. 1-3 , the wire stiffening wall  36  is perpendicular to the plane of the face panels  28  and extends between a center apex  44  of the truss element  32  and one of the face panels  28 . The wire stiffening wall  36  increases the structural integrity of the wire truss system  26 , and particularly the V-shaped portions  42 , when installed in the earthen embankment  12 . Much like the wire lattice body  34 , the wire stiffening wall  36  may be constructed out of wire lattice, although other suitable structures may be used to strengthen the wire truss system  26  as described herein. 
     The wire stiffening wall  36  may be operably attached to the wire lattice body  34  and the face panels  28  with the spiral binders  30 , or with other suitable attachment devices or mechanisms. It should be noted that one skilled in the field may design alternative forms of wire stiffening walls  36  and means of attachment while still remaining within the scope of the present invention. 
     As illustrated in  FIGS. 1-3 , the pilaster attachment portion  38  operably attaches the wire lattice body  34  to the pilasters  20 . In the embodiment of  FIGS. 1-3 , the pilaster attachment portion  38  is formed in the center apex  44  of the V-shaped portion  42 , and provides a suitable surface to which the pilaster  20  may attach. By positioning the pilaster attachment portion  38  between the pilaster  20  and the earthen embankment  12 , the pilaster attachment portion  38  serves to anchor the wire truss system  26  to the earthen embankment  12 . However, the pilaster attachment portion  38  may be formed at an alternative location along the wire lattice body  34 , as deemed suitable by one skilled in the art, and such alternative embodiments are within the scope of the present invention. 
     As illustrated in  FIGS. 1-3 , the interlocking portion  40  of the wire truss system  26  provides a means by which one of the truss elements  32  may be interconnected with an adjacent truss element  32 . In the embodiment of  FIGS. 1-3 , the interlocking portion  40  is formed by a planar wire lattice flange disposed on a plane that is generally parallel to the place of the face panel. As such, adjoining truss elements  32  may be interconnected by overlapping adjacent planar wire lattice flanges  40  and connecting them to each other with spiral binders  30  that wrap around both of the truss elements  32 . However, alternative embodiments of the interlocking portion  40  may be devised by one skilled in the art while still remaining within the scope of the present invention. 
       FIG. 4  is a top plan view of one of the truss elements  32  and one of the face panels. As illustrated in  FIG. 4 , the wire lattice body  34  is disposed on a first plane P1 and the face panel is disposed on a second plane P2. Angle A is formed by the intersection of the first and second planes P1 and P2. The pilaster  20  may operably attach to the pilaster attachment portion  38 , to receive the spiralnail  22  therethrough. Additionally, the wire stiffening wall  36  may be adjoined to the center apex  44  of the wire lattice body  34 , adjacent the pilaster  20 . Although previously described as ranging between 10 and 80 degrees, the angle A may alternatively range from 15 to 50 degrees. Thus, alternative embodiments may be employed as deemed suitable by one skilled in the art. 
       FIG. 5  is a perspective view of a second embodiment of one of the truss elements  48 .  FIG. 6  is a top plan view thereof. As shown in  FIGS. 5 and 6 , the second embodiment of one of the truss elements  48  includes an extended portion  50  of the truss element  48 . The extended portion  50  of the truss element  48  may function as the face panel  28  to cover the V-shaped portion  42  of an adjacent truss element  48 . In the embodiment of  FIGS. 5 and 6 , the extended portion  50  extends outwardly from the V-shaped portion  42  of the wire lattice body  34 , such that the V-shaped portion  42  is not at the center of the truss element  48 , as in previous embodiments discussed above. While  FIGS. 5 and 6  illustrate one embodiment of the extended portion  50  of the truss element  48 , those skilled in the art may devise alternative embodiments, and these alternative or equivalent structures are considered within the scope of the present invention. 
       FIG. 7  is an exploded perspective view of a first step in the construction of the second embodiment of the retaining wall system  10 , using the truss element  48  of  FIGS. 5-6 .  FIG. 8  is an exploded perspective view of the retaining wall system  10  of  FIG. 7 , following installation of additional truss elements  48 , illustrating the extended portion  50  of each truss element  48  being used to cover the V-shaped portion  42  of the adjacent truss element  48 .  FIG. 9  is a perspective view of the retaining wall system  10  of  FIG. 8 .  FIG. 10  is an exploded perspective view of the retaining wall system  10  of  FIG. 8 .  FIG. 11  is a perspective view thereof. 
     As illustrated in  FIGS. 7-11 , the construction process of the second embodiment of the retaining wall system  10  includes several steps.  FIG. 7  illustrates the plurality of pilasters  20  attached to the pilaster attachment portion  38  of the wire lattice body  34  and inserted into the earthen embankment  12 . The truss elements  48  may be adjoined to one another via spiral binders  30 , with the extended portions  50  of the truss elements  48  covering the V-shaped portion  42  of the wire lattice body  34 , as shown in  FIG. 8 . The wire stiffening wall  36  of  FIG. 9  may be operably mounted to the extended portion, to further attach the extended portion  50  to the truss element  48 . 
     Additionally, in the embodiment of  FIGS. 7-11 , the present invention includes an end truss  54  used to complete the retaining wall system  10 . The end truss  54  is a generally L-shaped structure formed out of wire lattice. It may be operably attached to the end of the truss element  48  once the desired length of the retaining wall system  10  has been reached. However, while one embodiment of the construction process and end truss  54  are illustrated in  FIGS. 7-11 , alternative embodiments devised by one skilled in the art are considered within the scope of the present discussion. 
     The present invention also includes a method of constructing a retaining wall system  10 , as described above, for installation on an earthen embankment  12 . In this method, the plurality of pilasters  20  are positioned in vertically mounted and horizontally spaced positions along the earthen embankment  12 . Spiralnails  22  may then be driven into the earthen embankment  12 , before being attached to one of the plurality of pilasters  20  as a means to anchor the pilasters  20  to the earthen embankment  12 . The wire truss system  26  may be mounted on the plurality of pilasters  20  such that each of the pilasters  20  is attached to the pilaster attachment portion  38  of one of the truss elements. 
     Finally, the face panels  28  may be attached to the wire truss system  26 , as discussed above, such that the face panels  28  cover the V-shaped portions  42  of the truss elements  32 . Or, in the alternative, extended portions  50  of the second embodiment of the truss elements  48  may be positioned to cover the V-shaped portion  42 , also as described above. 
       FIG. 12  is an exploded perspective view of the locking mechanism  24  according to one embodiment of the present invention, illustrating the spiralnail  22 , the pilaster  20 , and the locking mechanism  24 .  FIG. 13  is a perspective view of the locking mechanism  24  applied to two spiralnails  22  threaded through the pilaster.  FIG. 14  is a front elevational view of the spiralnail  22  and the pilaster  20 . 
     As illustrated in  FIGS. 12-14 , the pilaster  20  is shaped to receive the spiralnail  22  and provide support for the retaining wall system  10 . In the embodiment of  FIGS. 12-14 , the pilaster  20  is a vertically extending column that is generally rectangular in shape. The pilaster  20  includes an elongate pilaster body  56 , a front surface  58 , and edge walls  60 . The elongate pilaster body  56  may include a nail hole  62  which is shaped to receive the spiralnail  22  therethrough, as well as a bolt slot  64  adjacent the nail hole  62 . In the present embodiment of  FIGS. 12-14 , the nail hole  62  has a curved perimeter  66  and the bolt slot  64  is also curved in order to match the curved perimeter  66  of the nail hole  62 . 
     In this embodiment, the edge walls  60  of the elongate pilaster body  56  extend outwardly from the front surface  58  to form a right side  68  and a left side  70  of the pilaster  20 . The pilaster  20  of  FIGS. 12-14  may be constructed out of a sturdy material, such as steel, so as to prevent buckling, bending, or other structural damage to the retaining wall system  10 . While  FIGS. 12-14  illustrate an embodiment of the pilaster  20 , those skilled in the art may devise alternative embodiments, and these alternative or equivalent designs are considered within the scope of this present invention. 
     As shown in  FIGS. 12-14 , the locking mechanism  24  includes a locking ring  72 , a cam plate  74 , a bolt  76 , and a nut  78 . The locking ring  72  of  FIGS. 12 and 13  fits onto and interlocks with the spiralnail  22 . The locking ring  72  may include opposed surfaces  80  that extend to a perimeter  82 , and provide a nail engaging aperture  84  and a first bolt hole  86 . The opposed surfaces  80  of the locking ring  72  terminate at the perimeter  82 , or edge, and may form a disc-like shape. As illustrated in  FIGS. 12 and 13 , the nail engaging aperture  84  is located adjacent the first bolt hole  86  and has a perimeter  82  shaped to receive the spiralnail  22  therethrough in order to lockingly engage the spiralnail  22 . The first bolt hole  86  may be an elongate shape (e.g., an oval or an ellipse) as a means to facilitate the installation of the locking mechanism  24 , as described below. The locking ring  72  may be formed out of any strong and durable material, such as steel, that is suitable to lock the spiralnail  22  in place. Although  FIGS. 12 and 13  illustrate one embodiment of the locking ring  72 , alternative embodiments may be designed by one skilled in the art and are therefore considered within the scope of the present discussion. 
     As illustrated in  FIGS. 12 and 13 , the cam plate  74  of the locking mechanism  24  is used to rotate the locking ring  72 , to lock and maintain a torque against the spiralnail  22 . In the embodiment of  FIGS. 12 and 13 , the cam plate  74  includes opposed surfaces  80  that extend to a cam-shaped outer perimeter  92 , a second bolt hole  94 , and a torque application element  96 . The second bolt hole  94  of the cam plate  74  is formed through the opposed surfaces  80  that extend to the cam-shaped outer perimeter  92 . The torque application element  96  of  FIGS. 12 and 13  may be a drive aperture through which a driver (not shown) may be inserted to increase torque and rotate the cam plate  74 . In doing so, the cam-shaped outer perimeter  92  may contact one of the edge walls  60  of the pilaster  20  and acts as a lever to rotate the locking ring  72  and apply torque to the spiralnail  22 . However, while  FIGS. 12 and 13  illustrate one embodiment of the cam plate  74 , alternative embodiments deemed suitable by those skilled in the art are considered to be within the scope of the present invention. 
     The bolt  76  and the nut  78 , illustrated in  FIGS. 12 and 13 , are used to mount the locking ring  72  and the cam plate  74  on the pilaster  20 . The bolt  76  is positioned through the bolt slot  64  of the pilaster  20 , through the first bolt hole  86  of the locking ring  72 , and then through the second bolt hole  94  of the cam plate  74 . The nut  78  operably engages with the bolt  76  to tighten the cam plate  74  and the locking ring  72  against the pilaster  20 . In the embodiment of  FIGS. 12 and 13 , the bolt  76  and nut  78  are of standard construction well known in the art; however, those skilled in the art may devise alternative embodiments which are still considered within the scope of the present invention. 
       FIG. 15  is a front elevational view of the locking mechanism  24  in an untorqued position. As shown in  FIG. 15 , when the locking mechanism  24  is assembled and the nut  78  is initially tightened, the bolt  76  and the nut  78  initially rotate counter-clockwise (in this embodiment) until a smaller-diameter portion  100  of the cam-shaped outer perimeter  92  abuts the edge wall of the pilaster  20 . 
       FIG. 16  is a front elevational view of the locking mechanism  24  in a torqued position. As illustrated in  FIG. 16 , once a driver (not shown) has been attached to the torque application element  96 , it may be used to turn the cam plate  74  to the torqued position, wherein a larger-diameter portion  102  of the cam-shaped outer perimeter  92  abuts the edge wall of the pilaster  20 . This rotation turns the locking ring  72  and imparts a torque to the spiralnail  22 . As a result, the spiralnail  22  is locked into position within the nail hole  62  of the pilaster  20 , thus providing support and stability to the retaining wall system  10 . Although  FIG. 16  illustrates one embodiment of the torqued position of the locking mechanism  24 , those skilled in the art may devise alternative embodiments while still remaining within the scope of the present invention. 
     The invention also includes a method of using the locking mechanism  24 , described above, for locking the spiralnail  22  in the retaining wall system  10 . In this method, the spiralnail  22  may be inserted through the nail hole  62  in the pilaster  20 , before being inserted through the nail engaging aperture  84  of the locking ring  72 . The bolt  76  may then be inserted behind the pilaster  20  into the curved bolt slot  64  and through the first bolt hole  86  in the locking ring  72 . The bolt  76  may then be threaded through the second bolt hole  94  of the cam plate  74 . These elements may then be tightened by the nut  78  and pressed against the front surface  58  of the pilaster  20 . One may finger tighten the nut  78  and rotate the cam plate  74  counter-clockwise to lock against the right side  68  of the pilaster  20 . Torque may then be applied to the drive aperture in the cam plate  74  in order to rotate to the right side  68  of the pilaster  20 . In doing so, the cam-shaped outer perimeter  92  may contact one of the edge walls  60  of the pilaster  20  and acts as a lever to rotate the locking ring  72  and apply torque to the spiralnail  22 . Once in the torqued position, the spiralnail  22  is locked into place within the pilaster  20 , to provide support to the entire retaining wall system  10 . 
     While  FIGS. 12-16  illustrate one embodiment of how the spiralnails  22  may be attached to the pilasters  20 , alternative or equivalent devices or mechanisms may also be used (e.g., bolts, welding, etc.). Any alternative or equivalent devices or mechanisms that may be devised by one skilled in the art should be considered within the scope of the present invention. 
     As used in this application, the words “a,” “an,” and “one” are defined to include one or more of the referenced item unless specifically stated otherwise. Also, the terms “have,” “include,” “contain,” and similar terms are defined to mean “comprising” unless specifically stated otherwise. Furthermore, the terminology used in the specification provided above is hereby defined to include similar and/or equivalent terms, and/or alternative embodiments that would be considered obvious to one skilled in the art given the teachings of the present patent application.