Patent Publication Number: US-10781606-B2

Title: Border wall

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 62/477,620, filed on Mar. 28, 2017, which is incorporated by reference. 
    
    
     BACKGROUND 
     A border wall, i.e., is a wall placed at a border and designed to discourage crossing of the border from an incursion side of the wall to a protected side of the wall. It is a challenge to quickly and efficiently build a border wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a plan view of a wall from a top. 
         FIG. 1B  is a plan view of a wall from a protected side. 
         FIG. 1C  is a plan view of a wall from an incursion side. 
         FIG. 2A  is a plan view of a base unit from the incursion side. 
         FIG. 2B  is a plan view of a base unit from the top. 
         FIG. 2C  is a plan view of a base unit from the side. 
         FIG. 3A  is a plan view of a base unit with a detachable axle and a detachable coupling coupled to a truck. 
         FIG. 3B  is a plan view of a truck transporting a plurality of detachable axles and detachable couplings. 
         FIG. 4A  shows two base units on a hill. 
         FIG. 4B  shows the overlap between the first overlapping structure and the second overlapping structure. 
         FIG. 5A  shows a below grade barrier system. 
         FIG. 5B  shows a below grade barrier system. 
         FIG. 6A  shows a base unit with a upper barrier section from the protected side. 
         FIG. 6B  shows a base unit with a upper barrier section from the incursion side. 
         FIG. 6C  shows a base unit with a upper barrier section from the side. 
         FIG. 7A  shows a base unit with a high barrier section from the protected side. 
         FIG. 7B  shows a base unit with a high barrier section from the incursion side. 
         FIG. 7C  shows a base unit with a high barrier section from the side. 
         FIG. 8  is a cross-sectional view of a partitioned base unit. 
         FIG. 9  is a perspective view of a protected side of a wall having aesthetic elements. 
         FIG. 10  is a perspective view of an incursion side of a wall having aesthetic elements. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description illustrates embodiments of the present disclosure. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice these embodiments without undue experimentation. It should be understood, however, that the embodiments and examples described herein are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and rearrangements may be made that remain potential applications of the disclosed techniques. Therefore, the description that follows is not to be taken as limiting on the scope of the appended claims. In particular, an element associated with a particular embodiment should not be limited to association with that particular embodiment but should be assumed to be capable of association with any embodiment discussed herein. 
     General: 
     A wall  100 , shown from above in  FIG. 1A , from the protected side in  FIG. 1B , and from the incursion side in  FIG. 1C , includes a base system of carbon steel fabricated base units  102   a ,  102   b ,  102   c , etc., placed in line end to end. Additional steel plate structures  104   a ,  104   b ,  104   c , etc., supported by structural supports  106   a ,  106   b ,  106   c , etc. (only one structural support per base unit is labeled) may be placed on top of the base units to result in an overall wall height of 20 feet. There are approximately 126 base units  102   a ,  102   b , etc. per mile of wall  100 . The linear weight of the 20′ tall wall  100  is approximately 750 lbs per running foot. The base units  102   a ,  102   b , etc. and steel plate structures  104   a ,  104   b , etc. may be painted a Bureau of Land Management approved color or other specified color. It will be understood that while  FIGS. 1A, 1B, and 1C  show six base units  102   a ,  102   b , etc., and six steel plate structures  104   a ,  104   b , etc., resulting in a length of approximately 258 feet, the wall  100  may include many more such structures and may run for many miles. 
     Base System: 
     A representative base unit  202 , shown from the incursion side in  FIG. 2A , from the top in  FIG. 2B  and from the side (with the incursion side to the right) in  FIG. 2C  which is representative of the base units  102   a ,  102   b , etc. illustrated in  FIGS. 1A-1C , is 42 feet long, 8 feet wide, 10 feet high, and weighs 25,300 pounds, although it will be understood that these dimensions can be varied. For example, the base unit  202  may be a re-purposed container for fracing fluids, which have substantial walls designed to withstand the stresses of the fracing environment, or the base unit  202  may have the dimensions of a standard shipping container with fortified walls. Other dimensions are possible. 
     The base unit  202  has a protected face  204 , an incursion face  206  opposite the protected face  204 , a first face  208  between the protected face  204  and the incursion face  206 , a second face  210  between the protected face  204  and the incursion face  206  and opposite the first face  208 , a top  212  coupled to the protected face  204 , the incursion face  206 , the first face  208 , and the second face  210 , a bottom  214  coupled to the protected face  204 , the incursion face  206 , the first face  208 , and the second face  210  and opposite the top  212 , 
     Each base unit  202  is mobile for transport to the construction site, for example by a truck  302  as shown in  FIG. 3A , facilitating ease of placement and reduced construction time. The base unit  202  may be loaded on a trailer (not shown) or it may have a detachable axle  304  and coupling  304 , as shown in  FIG. 3A . The transport components  304 ,  306  are removed from the base units  202  before the units  202  are placed in line in the wall  100 . The transport components  304 ,  306  may be transported to the manufacturing location, as shown in  FIG. 3B , for example by the truck  302  that delivered the base unit  202  to the construction site. 
     Placement of the base units  102   a ,  102   b , etc. creates an instant barrier to passage. Base units  202  are tightly abutted to each other end to end, each with mating overlapping structures, i.e., first overlapping structure  216  extending from the first face  208 , and second overlapping structure  218  extending from the second face  210  (see  FIGS. 2A-2C ) to allow for variations in level and plumb with respect to each adjacent base unit  202 . In one or more embodiments, the first overlapping structure  216  is set back from the incursion face  206  of the base unit  202  by a different amount than the second overlapping structure  218  to allow the two overlapping structures  216 ,  218  to overlap, as shown in  FIG. 4A , which shows two base units that are misaligned because of their location on a hill, and  4 B, which shows the overlapping structures  216 ,  218 . Once in place, the overlapping structures  216 ,  218  can be welded together or bolted together or otherwise secured to prevent or limit relative movement. 
     The effective base unit  202  barrier length, including the overlapping structures  216 ,  218 , is approximately 43 feet per unit. The large size and weight of the base units  202  provides a formidable barrier, with an extremely high stability foot print, without the need for additional foundation work, such as footings, posts, or pilings. The base units  202  are not readily moved by impact or other envisioned methods. As a result of the wide base of the base units  202  ease of tunneling under the base units  202  is also reduced. In one or more embodiments, base unit  202  walls are ¼″ steel plate with strengthening corrugations. In one or more embodiments, there is no access into the interior of the base unit. 
     Below Grade Barrier System 
     Before placement of a base unit system consisting of a set of base units  202 , a below grade barrier  502  can be installed by placing sheet piling (type structure) materials in a continuous path, in line with the placement of the base units  202 . In one or more embodiments, the depth of the below grade barrier  502  is 4 to 6 feet, but it will be understood that the depth can be varied. Further, while  FIG. 5B  shows the below grade barrier  502  installed directly below the center of the base unit  202 , it will be understood that the below grade barrier  502  can be installed anywhere beneath the base unit  202  and even a few inches on either side of the footprint of the base unit  202  and still perform the function of below grade barrier  502 . The installation of the below grade barrier  502  is typically accomplished by either trenching and back filling or driving the barrier plates. This would be done after all surface and grade preparation is completed to ensure the proper relation between the top of the below grade barrier  502  and the bottom of the base unit  202 . 
     Upper Wall System: 
     Subsequent to placement of the base units  202 , an additional 10 foot high upper barrier section  602 , shown in  FIG. 6A  from the protected side, in  FIG. 6B  from the incursion side, and in  FIG. 6C  from the side with the incursion side to the right on the drawing, is placed on top of the base units  202  resulting in an overall barrier height of 20 feet. The upper barrier section  602  is fabricated from ¼ inch steel plate with strengthening corrugations and structural member framing including support knee bracing  604  (corresponding to structural supports  106   a ,  106   b , etc. in  FIG. 1 ) to base unit  202  roofs. The pattern of the upper barrier sections  602  follows the pattern of the base units  202 . The upper barrier sections  602  are attached to the base sections  202  using tamper proof methods and materials. 
     An additional 10 foot high barrier section  702 , shown in  FIG. 7A  from the protected side, in  FIG. 7B  from the incursion side, and in  FIG. 7C  from the side with the incursion side to the right on the drawing, can be installed above the upper barrier section  602  resulting in a total barrier height of 30 feet. In one or more embodiments, the high barrier section  702  is constructed using horizontal wire or other approved open air flow system with vertical posts  704 . The higher barrier section  702  is attached to the upper barrier section  602  using tamper proof methods and materials. 
     Partitioned Base Unit: 
     The base unit  202  may be partitioned into two or more chambers  802 ,  804  by an internal partition  806 , as shown in  FIG. 8 . While  FIG. 8  shows a single partition  806  and two chambers  802 ,  804 , it will be understood that the base unit  202  can be further partitioned by the addition of additional partitions. Each partition  806  provides an additional barrier to penetration—e.g., partition  806  converts base unit  202  from a two-walled barrier to a three-walled barrier. 
     One or more of the chambers  802 ,  804  can be filled with concrete, gravel, sand, general debris, or other material to provide additional barriers to penetration. In  FIG. 8 , partition  802  is shown filled with such a material. The partition  802 ,  804  can be filled before or after installation at the construction site. 
     Better Aesthetic Presentation: 
     In one or more embodiments, the structural supports  106   a ,  106   b , etc.,  604  are replaced by corrugated sheets of metal, as shown in  FIGS. 9 and 10 , which provides a more pleasing appearance. In one or more embodiments, the corrugated sheets of metal are made from R-panel metal roofing material. 
     Construction/Installation Scope: 
     The design of the wall  100  is suitable for installation with semi improved road access and the following site conditions. The installation surface is reasonably gradable using industry standard medium sized surface preparation equipment, a gradable sloping elevational change of 10% in 500 feet or less (with no fill material needed). Gradable and stair stepped elevational changes up to 20% in 500 feet can be accommodated using sectional steel infill panels between base units to accommodate stair stepping of base units. 
     In one aspect, an apparatus includes a base unit. The base unite has a protected face, an incursion face opposite the protected face, a first face between the protected face and the incursion face, a second face between the protected face and the incursion face and opposite the first face, a top coupled to the protected face, the incursion face, the first face, and the second face, a bottom coupled to the protected face, the incursion face, the first face, and the second face and opposite the top, a first overlapping structure extending from the first face and adjacent to and set back from the incursion face by a first amount, and a second overlapping structure extending from the second face and adjacent to and set back from the incursion face by a second amount. The first amount is different from the second amount and the dimensions of the first overlapping structure and the second overlapping structure are such that placing two base units next to each other so that the first face of a first of the two base units faces the second face of a second of the two base units causes the first overlapping structure from the first of the two base units to overlap and be securable to the second overlapping structure from the second of the two base units, so that a gap between the first base unit and the second base unit is closed even if a bottom of the first base unit is not aligned with a bottom of the second base unit. 
     Implementations may include one or more of the following. The apparatus may include an upper barrier section extending upward from and parallel to the incursion face of the base unit. The apparatus may include a high barrier section extending upward from and parallel to the upper barrier section. The apparatus may include a below grade section extending into the earth below the base unit. The apparatus may include a partition between the protected face and the incursion face, extending from the first face to the second face, and dividing an interior of the base unit into a plurality of chambers. One of the plurality of chambers may be filled with a material. The base unit may include fittings whereby the base unit can be lifted by a crane and placed by the crane into a desired location at a construction site. The apparatus may include an axle system couplable to the base unit and a coupling system couplable to the base unit. The base unit with the axle system and the coupling system may be couplable to a truck for road transportation. 
     In one aspect, a method includes loading a plurality of base units onto a plurality of trailers, coupling the plurality of trailers to a plurality of trucks, transporting the plurality of trucks to a construction site, and unloading the plurality of base units from the plurality of trailers and placing them at the construction site to form a wall. 
     In one aspect, a method includes attaching detachable axles and detachable couplings to a plurality of base units at a manufacturing site, coupling the plurality of base units to a plurality of trucks using the detachable couplings, transporting the plurality of trucks to a construction site, detaching the detachable axles and the detachable couplings, placing the plurality of base units at the construction site to form a wall, and transporting the detached detachable axles and detachable couplings to the manufacturing site. 
     Implementations may include one or more of the following. Each base unit may have a protected face, an incursion face opposite the protected face, a first face between the protected face and the incursion face, a second face between the protected face and the incursion face and opposite the first face, a top coupled to the protected face, the incursion face, the first face, and the second face, a bottom coupled to the protected face, the incursion face, the first face, and the second face and opposite the top, a first overlapping structure extending from the first face and adjacent to and set back from the incursion face by a first amount, and a second overlapping structure extending from the second face and adjacent to and set back from the incursion face by a second amount. Placing the base units at the construction site to form a wall may include coupling the first overlapping structure extending from the first face of a first of the plurality of base units to the second overlapping structure extending from the second face of a second base unit adjacent to the first base unit so that a gap between the first base unit and the second base unit is closed even if a bottom of the first base unit is not aligned with a bottom of the second base unit. 
     The operations of the flow diagrams are described with references to the systems/apparatus shown in the block diagrams. However, it should be understood that the operations of the flow diagrams could be performed by embodiments of systems and apparatus other than those discussed with reference to the block diagrams, and embodiments discussed with reference to the systems/apparatus could perform operations different than those discussed with reference to the flow diagrams. 
     The word “coupled” herein means a direct connection or an indirect connection. 
     The text above describes one or more specific embodiments of a broader invention. The invention also is carried out in a variety of alternate embodiments and thus is not limited to those described here. The foregoing description of an embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.