Patent Publication Number: US-11377863-B1

Title: Aggregate panel system

Description:
RELATED APPLICATIONS 
     This application claims priority of U.S. Provisional Patent Application Ser. No. 62/934,958 filed on Nov. 13, 2019 incorporated herein by reference. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     Field of the Disclosure 
     This disclosure relates to the field of rigid panels cast in place against an existing base wall. The panel system cast against the base wall to optionally provide corrosion protection and structural support to the base wall. 
     BRIEF SUMMARY OF THE DISCLOSURE 
     Disclosed herein is an aggregate panel system comprising in one example: a rigid first panel having: a first side comprising a fluid impermeable, non-porous outer layer; a second side facing a first base wall to which the first panel is attached. Also disclosed is at least one optional panel brace fixed to the second side of the first panel and extending toward the base wall, the panel brace configured to increase rigidity of the first panel. An aggregate fill (e.g. concrete) is then poured or otherwise disposed between the first panel and the first base wall to fill the region therebetween. The aggregate fill configured to harden to a solid aggregate fill and thus structurally support both the base wall and the rigid panel. 
     When hardened, the solid aggregate fill is mechanically bonded to the first panel and also mechanically bonded to the first base wall. When a panel brace is fitted to the first panel, the solid aggregate fill is also mechanically bonded to the panel brace. 
     To ensure that the first panel is properly and securely offset from the base wall; a plurality of panel offsets may be provided. The panel offsets extending from the first panel to the base wall and attached thereto via fasteners, adhesives, welding, or combinations thereof. 
     The aggregate panel system may be arranged wherein the second side of the first panel facing the base wall comprises a rigid layer. This rigid layer may be formed of metals, natural materials (wood, bamboo etc.) fiber reinforced plastic such as fiberglass or carbon fiber infused with hardened resin or epoxy, and equivalents. 
     The aggregate panel system may be arranged wherein the panel offsets are monolithic with the first panel. The term monolithic used herein as: cast as a single piece; formed or composed of material without joints or seams; consisting of or constituting a single unit; constituting an undifferentiated and rigid whole. In one example, these panel offsets are fixed to the base wall by adhesives, welding, or fasteners passing through the panel offsets and fastened to the base wall. 
     Often it may be desired to seal the first panel at the edges thereof to the base wall, to a base (floor) or to adjacent adjoining panels. Thus, in one example may be attached the first side of the first panel comprising a weldable perimeter face edge. 
     When the first panel is not large enough to cover the desired area, the aggregate panel system may comprise a rigid second panel immediately adjacent the first panel. In one example the second panel is parallel to the first panel. In other examples the second panel is angled relative to the first panel. In one example the second panel is attached to a second base wall. The second panel comprising a weldable perimeter edge similar to the weldable perimeter edge of the first panel. To attach the first panel to the second panel, an overlap panel may be provided. The overlap panel may be welded or otherwise sealed to the perimeter edge of both the first panel and the second panel to seal the gap therebetween. 
     In locations where a pipe fixture is in the base wall, the aggregate panel system may further comprise a pipe fitting sealed to the first panel. The pipe fitting forming a void through the first panel to the base wall; and the pipe fitting forming a conduit to a plumbing fixture extending into the base wall. 
     To ensure that the base wall nor the aggregate fill nor the panel are deteriorated by nor permeated by fluids, including corrosive fluids, in one example the first panel comprises a corrosion-resistant inner surface. In one example, this corrosion resistant inner surface comprises a hardened polymer such as: polypropylene; fiber reinforced plastic, equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective environmental view of the disclosed aggregate panel system. 
         FIG. 2  is an end perspective view of the disclosed aggregate panel system. 
         FIG. 3  is a top perspective view of the disclosed aggregate panel system. 
         FIG. 4  is an end cutaway view taken along line  4 - 4  of  FIG. 3 . 
         FIG. 5  is a rear view of a panel as shown in  FIG. 1  prior to attachment to a base wall. 
         FIG. 6  is an enlarged hidden line view of the region  6  of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     In the field of base walls used in the construction of structures such as manholes, vaults, rooms, storage spaces, and other fluid conduit and holding tank structures, great advances have been made to improve efficiency, reduce problems, reduce leakage into and out of fluid systems, and to improve the longevity of fluid conveying and holding systems. 
     In this disclosure, for ease in description, the term “vault” will be used to describe all these structures and equivalents. 
     Historically, a great number of base walls of such vaults have been installed which have deteriorated, are expected to deteriorate, or are prone to leakage and failure. In many instances, these problematic base walls need to be repaired or replaced, often with the cost of replacement less than the cost of repair using previously known techniques. 
     To provide a relatively quick, easy, inexpensive, dependable repair, the aggregate panel system  20  having a corrosion resistant layer  22  is herein disclosed. Such an aggregate panel system  20  may be used to structurally reinforce and add corrosion resistance to an existing vault  24  or other fluid structure formed with a base wall  26 . In some instances, the disclosed aggregate panel system  20  may be utilized interior of an existing vault  24 . 
     In many examples, a pipe fixture  28  such as a cross-pipe, inlet pipe, outlet pipe, or equivalent extends through the inner surface of the base wall  26 . This pipe fixture  28  may in some applications be a section of pipe which has been cut off to enable installation of the aggregate panel system  20 . In other applications it may be a pipe, bell housing, pipe fitting, pipe bell, pipe valve, or other equivalent apparatus. 
     The term vault used herein encompasses many different structures including structures forming a substantially enclosed chamber extending from a base  30  generally upward to a ground level. Commonly a vault  24  comprises a base  30 , one or more base walls  26  extending upward from the base  30 , and often a cover  32 . The vault may also include a cover cap  34  which is commonly removable from the vault  24  to allow access to the vault  24 . In many instances the vault  24  is large enough to fit an adult person may then enter the vault  24  to access the pipe fixture  28  and other components of the vault  24  for inspection, cleaning, or repair. Where the cover  32  in some examples is called a manhole and is the component normally seen by most people the term manhole has become synonymous with the manhole cover but the distinction is intended herein between the components forming the vault  24  and the cover cap  34 . 
     Looking to  FIG. 1  is shown one example of an aggregate panel system  20  attached to a first base wall  26 . This example of the aggregate panel system  20  comprises a first panel  42  having a first side  36 . The first side  36  comprising a corrosion resistant liner  22 . The corrosion resistant liner  22  forming a physical/chemical barrier between fluids (liquids and gasses) within the vault  24  and the first base wall  26 . Thus, the corrosion resistant liner  22  provides corrosion and fluid intrusion protection to the base wall  26 . This corrosion resistant liner  22  may comprise a hardened polymer such as: polypropylene; fiber reinforced plastic, gel coat, polyvinylchloride, copper or other metals, natural materials, glass, and equivalents. 
     The second side  38  of the first panel  42  may be formed of fiber reinforced plastic (FRP) such as fiberglass (FRP), carbon fiber, bamboo, or other fibers infused with a volume of hardened epoxy, polyurethane resin, or equivalents. In one example the second side  38  is formed by known fiberglass layup techniques on a mold and the first side  36  is molded thereon. In another example the first side  36  is molded on a mold and the second side  38  is formed by known fiberglass layup techniques on the first side  36 . 
     The second side  38  of the panel  42  may be offset from the base wall  26  by a gap, forming a space  40 . During construction a volume of aggregate material  44  is poured in fluid form into this space  40 . The fluid aggregate material  44  thus filing the space  40  as it flows therein, the ends of the panel  42  may be sealed to the base wall  26  or other structures to keep the fluid aggregate in place, and the bottom edge  58  may be sealed to an adjacent structure such as the base  30 . As the aggregate material  44  cures/hardens to a hardened or solid state, the aggregate material  44  may mechanically/physically bond to the second side  38  of the first panel  42  and may simultaneously mechanically/physically bond to the base wall  26 . The hardened aggregate material thus structurally reinforcing and sealing both the base wall  26  as well as the first panel  42 . 
     Where the second side of the first panel  42  is not smooth, such as unfinished FRP, the aggregate  44  may bond sufficiently without additional attachment needed. In other applications it may be desired to increase the structural rigidity of the panel  42  and to increase the mechanical bond to the aggregate  44 . In such applications one or more offset struts  46  may be attached to the first panel  42  or formed monolithic thereto. 
     In one example shown in the figures, each offset strut  46  comprises one or more surfaces  48  defining voids  50  therethrough. Such a permeated structure increases the structural rigidity of the strut  46 , reduces overall weight relative to a solid strut  46 , and increases the mechanical bond to the aggregate  44  as the fluid aggregate  44  fills each void  50  and hardens in this position. 
     Before continuing, an axes system  10  is defined herein for ease in description. This axes system used to assist in describing the components relative the drawings shown. It is understood that the orientation of the structures may be varied to other orientations. For example, the first panel  42  may be arranged flat to cover a floor or ceiling, or any angles shown or not shown. The axes system not intended as a limiting orientation of the claimed invention. The axes system  10  including a vertical axis  12  orthogonal to the base  30 , and a longitudinal axis  14  orthogonal to the vertical axis  12 . The longitudinal axis  14  in this example is parallel to the first base wall  26 . 
     The offset struts  46  in one example extend away from the second side  38  of the first panel  42  toward the base wall  26  and thus will engage the aggregate fill  44 . As shown in  FIG. 6 , the offset struts  46  may each comprise an end plate  52  at the distal (transverse) end of the offset strut  46 . Each end plate  52  may be formed monolithic with the web  54  of the offset strut  46  forming the voids  50 . The end plate  52  is configured to increase the structural rigidity of each offset strut  46  and increase the mechanical bond to the aggregate  44 . In one example each offset strut  46  comprises one or more transverse plates  56  extending from the second side  38  of the first panel  46  to the end plate  52 . The transverse plate  56  also increasing the structural rigidity of the offset strut  46 . 
     In the example shown the offset struts  46  are orientated vertically and extend substantially from the bottom edge  58  of the panel  42  substantially to the upper edge  60 . Thus, the aggregate should be poured into the space  40  between each adjacent pair of struts  46 , although some of the aggregate  44  may travel through the voids  50  in each strut when provided. 
     In one example each of the offset struts  46  may be cast prior to casting/forming the planar portion of the first panel  42 . They may then be cast or formed to the planar portion of the first panel  42  or adhered thereto during construction. Once constructed, the struts  46  may form a monolithic structure of the first panel  42 . 
     The offset struts  46  in one example do not extend transversely  16  to contact the first base wall  26 . This allowing the aggregate  44  to flow longitudinally  14  between adjacent spaces  40  separated by an offset strut  46 . In addition, this gap  62  helps to maintain a planar first side  36  of the panel  42  where the base wall  26  may not be perfectly flat. The gap  62  keeping the offset struts  46  from transmitting the defect to the front or first side  36 . 
     Wherein the first panel  42  by itself may not be sufficient to cover the first base wall  26 , or where it may be desired to seal the first panel  42  to a second panel  64 , to the base  30 , to a second base wall  66 , or to other components, the first panel  42  may comprise a weldable perimeter edge  68 . In one example the second panel  64  is similar, or identical in structure to the first panel  42  and thus all components of the first panel  42  may be provided on the second panel  64  and other panels. This weldable perimeter edge  68  may be on one side or more than one side as needed. The term weldable based on the term weld which as used herein means to unite or fuse (as pieces of metal) by hammering, compressing, heating, chemical bonding, or the like, especially after rendering soft or pasty by heat, or chemicals, and sometimes with the addition of fusible material like or unlike the pieces to be united. 
     In this example, the weldable edges  68  of adjacent components, such as the panel  42  and the base  30  or the adjacent second panel  64  (also having a weldable edge) may be attached and sealed to prevent corrosion and fluid seepage therebetween the components. 
     In the example shown in  FIG. 1 , adjacent weldable edges  68  of the first panel  42  and a second panel  64  are connected and sealed to each other. In one example this is accomplished via a weldable panel or corner  70 . This weldable panel  70  having a surface which is configured to be heat welded, chemically welded, or otherwise sealed to each of the weldable edges  68 . Such a weldable panel  70  may extend across one seam as shown or may extend across multiple seams if desired. In one example the weldable panel  70  is pliable, to seal against a non-planar seam. The weldable panel  70  may comprise the same material as the first side  36  of the panel  42 . 
     In some examples, it may be needed or desired for the first panel  42  to be substantially smaller than the base wall (base walls  26 / 66  for example). For example, in the vault  24  shown in  FIG. 3  it may not be possible to fit a panel  42 / 64  through the relatively small opening  72  in the cover  32 . Thus, each base wall  26 / 66  etc. may require several panels  44 / 64  for proper coverage. By providing smaller panels  42 / 66  on each base wall, installation and pouring of aggregate  44  is easily accomplished in smaller steps. 
     To ensure proper spacing between the second side  38  of the first panel  42  and the base wall  26 , one or more panel offsets  74  may be attached to the panel  42  or formed as monolithic structure(s) of the panel  42 . These panel offsets  74  may be slightly longer in the transverse direction than the offset struts  46  as previously described. 
     In one example, the panel offsets  74  have a first end  76  coupled to the second side  38  of the panel  42  and extending therefrom to a second end  78  in contact with, attached to, or formed with the base wall  26 . The second end  78  may be attached to the base wall  26  via adhesives, welding, or mechanical fasteners including screws, bolts, nails, etc. 
     The panel offsets  74  in one example having a surface defining a transverse conduit  80  there though for use by a fastener. This conduit  80  allowing passage of a fastener  82  therethrough. The fastener  82  such as a screw, rivet, bolt, or combination thereof is coupled to the base wall  26  and holds the base wall  26  in place at least until the aggregate  44  hardens, thus mechanically boding the first panel  42  to the base wall  26 . In one example, the head  94  of the fastener is recessed into a recess  96  in the panel  42  and/or in the conduit  80 . In one example the conduit  80  is tapered or stepped to allow partial passage of the head of the fastener. 
     As previously mentioned, the base wall  26  may include a pipe fixture  28  or similar fluid structure forming a fluid conduit through the inner surface  84  of the base wall  26 . To ensure a secure fluid connection and sealed conduit through the first panel  42 . Thus, a surface defining a void  86  may be established though the first panel  42 , this void  86  is substantially aligned with the pipe fixture  28 . In one example, this void  86  is formed in the panel  42  prior to attachment of the panel  42  to the base wall  26 . 
     During assembly, the pipe fitting  88  is sealed to the first panel  42  and also sealed to the pipe fixture  28  such that the inner surface  90  of the pipe fitting and inner surface  92  of the pipe fixture form a fluid conduit through which fluid may flow without leaking out of the fluid conduit into the base wall  26 , aggregate  44 , panel  42 , or into the vault  24 . The pipe fitting  88  may be a bell housing, bell, spigot, valve, pipe section, or other fitting securely connectable to the pipe fixture  28  and to another conduit or pipe fixture not shown. The pipe fitting may be sealed as a butt joint or may be sealed around the exterior of the pipe fixture  28  or interior of the pipe fixture  28 . 
     While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants&#39; general concept. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.