Patent Publication Number: US-2007113501-A1

Title: Wall system and method

Description:
BACKGROUND OF THE INVENTION  
      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.  
     SUMMARY OF THE INVENTION  
      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.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is an exploded, perspective view of a first preferred embodiment of a wall panel according to the invention;  
       FIG. 2  is a top to bottom cross-sectional view of the first preferred wall panels;  
       FIG. 3  is a top view of the first preferred wall panel;  
       FIG. 4  is an exploded, perspective view of a first preferred embodiment a wall assembly;  
       FIG. 5  is a cross-sectional view of a second preferred embodiment of a wall panel;  
       FIG. 6  is a cross-sectional view of a second preferred embodiment of a wall assembly comprising the wall panel shown in  FIG. 5 ;  
       FIG. 7  is a top view of an alternate post;  
       FIG. 8  is a cross-sectional view of a stack of molds each carrying cement poured therein;  
       FIG. 9  illustrates a method of manufacturing vertical concrete walls;  
       FIG. 10  is a front elevation view of a vertical concrete wall comprising a three-dimensional texture resembling a random stone pattern; and  
       FIG. 11  is a front elevation view of a vertical concrete wall comprising a three-dimensional texture resembling rectangular tiles in a diagonal pattern.  
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      The invention add 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  FIGS. 1-3 , a first preferred embodiment of a wall panel  10  is illustrated in exploded view. The wall panel  10  comprises a first outer sheet  20  and a second outer sheet  22  disposed in a back-to-back relationship. The sheets  20 ,  22  are preferably composed of plastic, such as vinyl. In particular, the first sheet  20  comprises a front, outer surface  24  with a three-dimensional texture which can be made to resemble natural masonry or stone work. In the illustrated embodiment shown in  FIG. 1 , the three-dimensional texture resembles a brick pattern  26 . The sheet  20  preferably comprises a thin layer of the plastic material such that an inner, the rear surface  28 , shown in  FIG. 2 , is substantially parallel to the outer surface  24 . Accordingly, rear surface  28  comprises an inverted brick pattern.  
      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  FIG. 1  as a brick pattern. The sheet  22  further comprises a rear, inner surface  33  that is substantially parallel to the outer surface  31  and, therefore, configured with an inverted pattern of the three dimensional texture of the outer surface  31 . When assembled in the back-to-back configuration, the inner surfaces  28 ,  33  of the sheets  20 ,  22 , respectively, face each other.  
      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  FIGS. 1-2 , a filler material  42  is disposed between the outer sheets  20 ,  22 . The filler material  42  may comprise any lightweight yet sturdy material that is inexpensive to manufacture. As examples, the filler material  42  may comprise polyurethane, waste materials, polystyrene foam, concrete, and/or a composite of two or more of any of the foregoing.  
      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  FIG. 4 . Accordingly, the panel  10  comprises a top rail  44  and a bottom rail  46  configured to removably mate with each other. In the illustrated embodiment, the top rail  44  comprises a longitudinal male section  48  while the bottom rail  46  comprises a female section  51  although it should be expressly understood that the female and male sections can be interchanged with the top and bottom rails. The top rail  44  and bottom rail  46  cover the filler material  42  while the top horizontal flange  35  and bottom horizontal flange  37  cover and secure portions of the top rail  44  and bottom rail  46 , respectively.  
      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  FIG. 4 , a preferred embodiment of a wall assembly  60  comprises a plurality of the first preferred wall panels  10   a ,  10   b . In the illustrated embodiment shown in  FIG. 4 , a top wall panel  10   a  is stacked on top of a bottom wall panel  10   b . It will be appreciated that the top rail  44  of the bottom panel  10   b  removably mates with a female section  51  of the top panel  10   a , as shown more clearly in  FIG. 3 . The side rails  53  and side hooks  39  collectively form a recess to receive posts  62 . A top decorative cap  64  is disposed on top of the top wall panel  10   a  to cover the top rail  44  and form an aesthetically pleasing appearance.  
      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  FIGS. 2 and 3 . Thus, whether the panels  10  are being joined side-by-side or on top-of one another, the panels  10  are configured to be easily joined to form a wall assembly.  
      A second preferred embodiment of a wall panel  100  is illustrated in  FIG. 5 . In this embodiment, the wall panel  100  comprises a first outer sheet  120  and a second outer sheet  122 , disposed in a back-to-back relationship. Each panel  120 ,  122  is preferably composed of a plastic material such as vinyl. The first sheet  120  comprises a front, outer surface  124  with a three-dimensional texture which can be made to resemble natural masonry or stone work. The sheet  120  preferably comprises a thin layer of the plastic material such that an inner, rear surface  128  is substantially parallel to the outer surface  124 . Accordingly, the rear surface  128  comprises an inverted brick pattern.  
      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  FIG. 5 , a core filler material  142  is disposed between the outer sheets  120 ,  122 . The core filler material  142  may comprise any lightweight yet sturdy material that is inexpensive to manufacture. As examples, the filler material  142  may comprise polyurethane, waste materials, polystyrene foam, concrete, and/or a composite of two or more of any of the foregoing. In the illustrated embodiment, the filler material  142  preferably comprises foam.  
      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 .  
       FIG. 6  is a cross-sectional view of a second preferred embodiment of a wall assembly  180 . Instead of employing rectangular posts  71  as shown in  FIG. 2 , the assembly  180  employs the side connectors  182 . The U-channels  184  serve not only to couple one wall panel  100  to another in a side-by-side arrangement, they also serve to hold the layers  173 ,  175 , filler material  142  and, optionally, the outer sheets  120 ,  122  together to securely form the panel  100 .  
      In an alternative embodiment shown in  FIG. 7 , a side connector  188  may comprise a single U-channel  191  with a back surface  193  that abuts the side portion  186  of the panel  100 . The connector  188  may be fastened to the concrete layers  173 ,  175  and/or filler material  142 , shown in  FIG. 5 , so as to hold the panel  100  together especially if the layers  173 ,  175  are not bonded or otherwise attached to the filler material  142 . The U-channel  191  which faces away from the panel  100  now provides a recess to receive a post such as the rectangular post shown in  FIG. 2 . In addition, the panel  100  may comprise mating top and bottom rails substantially similar to those associated with the first preferred wall panel  10  described above and illustrated in  FIGS. 1-4 .  
      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  FIGS. 8 and 9 . In  FIG. 8 , stackable molds  210  have an inner contour configured to provide the desired outer three-dimensional texture of the concrete wall. Concrete  212  is poured into the re-usable molds  210  which are then stacked on top of another. The stack  220  is then capable of being stored and/or transported away from a manufacturing facility so as to increase production capacity thereof. The concrete  212  is allowed to cure in the molds  210 , for example, while the molds  210  are being transported to a destination site. Once the concrete  212  cures, the mold  210  may then be removed from the now formed concrete wall  212  and be reused. The concrete wall  212  may then be painted or however decorated for aesthetics and then be put to use.  
      As shown in  FIG. 9 , a preferred method  300  of manufacturing vertical concrete structures is provided. The method  300  comprises the step  310  of providing a portable mold having an inner surface contoured with a texture desired for an outer surface of a concrete wall. In step  320 , concrete is poured into the portable mold, which preferably comprises plastic, such as vinyl. The concrete may be poured into the portable mold at a facility, such as a manufacturing plant. The concrete is cured in the portable mold in step  330 . In this step, the concrete may be cured in the portable mold away from the facility, e.g., while in transport to a destination. Step  340  comprises removing the portable mold from the concrete. This step may include removing the portable mold from the concrete at the destination. The method  300  may further comprise the step  350  of transporting the portable mold with the poured concrete to a destination while the concrete is curing in the portable mold, step  360  of attaching a layer of foam to the concrete in the portable mold and step  370  of re-using the portable mold.  
      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  FIG. 10 , the concrete wall  410  may be formed to include a three-dimensional texture resembling a random assortment of stones to create a flagstone or cobblestone effect. In  FIG. 11 , the concrete wall  420  may be formed to include a three-dimensional texture resembling rectangular or square tiles in a diagonal pattern so as to resemble, for example, marble, granite, or stone tiles. The walls in  FIGS. 10 and 11  may be further refined by chiseling and/or coloring so that the end result resembles a high end, expensive product.  
      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.