METHOD OF CONSTRUCTING A WALL OR FENCE WITH PANELS

Abstract

This invention relates generally to a method of constructing walls or fence systems from panels. More particularly, the invention relates to constructing such walls or fence systems wherein a back face of one panel connects to a back face of another panel and further wherein the front faces of the panels have a desirable texture and further wherein a concrete footing of the wall or fence system is poured after courses of panels have been stacked one upon the other.

Description

This application claims the benefit of U.S. Provisional Application No. 60/989,295, filed Nov. 20, 2007, entitled “Method of Constructing a Wall or Fence with Panels”, the contents of which are hereby incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates generally to a method of constructing walls or fence systems from panels. More particularly, the invention relates to constructing such walls or fence systems wherein a back face of one panel connects to a back face of another panel and further wherein the front faces of the panels have a desirable texture and further wherein a concrete footing of the wall or fence system is poured after courses of panels have been stacked one upon the other.

BACKGROUND OF THE INVENTION

Generally, free-standing block walls or fences are constructed of concrete blocks (or similar material) in running courses. A trench is usually dug and a concrete footing is prepared by the placement of batter or screed boards to define the width and thickness of the footing. Horizontal reinforcing material, such as steel, running both laterally and transversally is tied together forming a cage within the screed board framework. The reinforcing material cage generally has vertical support elements that protrude above the screed board framework and are used to connect to the vertical wall structure. Concrete is then poured into the screed board framework and is leveled off so that it is flush with the screed surface. This leveling process can be difficult to achieve when working around the vertical support elements. The concrete is generally allowed to set for a time and then later a first course of blocks is laid using mortar to level the blocks on the concrete footing. Due to the irregularity of the footing with all the vertical support elements protruding through it, the first course usually requires the use of mortar at the bed and head joints of the blocks in order to ensure that it is level. Typically each subsequent course is placed in such a manner so that the vertical joints between blocks are staggered in a running bond pattern from a previous course. Mortar is used as a binding agent between the courses and between the ends of each of the blocks. Conventional concrete blocks typically have one or more voids or cores extending through them in the vertical direction to create open vertical columns through the walls. The vertical support elements are accommodated within these vertical columns. The blocks are installed over the vertical support elements. The cores or voids are filled with masonry (concrete) grout to connect the wall to the vertical support elements of the footing to help ensure that the wall and footing perform as a structure in resisting lateral moment loads. Additional reinforcing bars may be placed in these columns for enclosure with concrete grout within the columns, in accordance with building code standards and are connected to the vertical support elements of the footing to help ensure wall stability.

In order for a wall constructed in this manner to be approved, a building inspector normally will require what is known as a “knockout”. A “knockout” is an inspection opening in a wall block at or near the base course. This requires that a portion of a block be removed in order to visibly ensure that the concrete grout has fully filled the entire vertical column.

Another widely accepted method of construction of such walls is to dry stack concrete wall units, or blocks. Mortar is not used in this method. These blocks are popular because they are mass produced and, consequently, relatively inexpensive. They are structurally sound and easy and relatively inexpensive to install. Because they comprise concrete, they are durable. They can be given a desired appearance, for example by using coloring and textures to simulate natural stone and/or adding a real or cultured stone veneer. Many block systems also use pins that are adapted to fit in corresponding pin holes in adjacent blocks or may use other mechanical means to contribute to the alignment and stability of a wall.

Typically, retaining wall blocks are manufactured to have the desired appearance on the front face (i.e., the outer face of a wall) because only the front is visible after the wall is constructed. It is highly desirable to have the front face of the wall system have a natural stone appearance, and many approaches are used in the art to treat or process concrete to evoke the appearance of natural stone, including splitting the block, tumbling the block to weather the face and edges of the face, and using processing or texturing equipment to impart a weathered look to the concrete.

Depending upon their location, the soil type, the amount of water that can flow through the wall, and the mineral content of the water, an undesirable appearance (efflorescence) can develop on the surface of a retaining wall. Efflorescence refers to the leaching of mineral salts from water and this often occurs on walls in contact with water. The resultant deposit on a surface creates an unattractive white stained appearance on a wall. In addition, due to exposure to the elements and freeze/thaw cycles, concrete retaining walls may exhibit spalling, that is, chipping and cracking of concrete, which affects their appearance and can ultimately affect their utility. Freeze-thaw effects are worsened when the wall face is exposed to salt spray, which commonly occurs on roadways where de-icing salts are used to clear the road of ice and snow.

There have been prior efforts to veneer segmental retaining walls with natural stone or concrete that is molded to closely resemble natural stone. While such veneering produces aesthetically pleasing walls, it is a laborious and highly expensive process, as it requires skilled masonry work to tie in the stone or concrete veneer to the wall using traditional mortared masonry construction methods. Such veneering can double the cost of the finished wall. In addition, segmental retaining walls are not rigid structures and applying a rigid mortared veneer may cause cracking if the non-rigid underlying segmental wall moves, unless appropriate steps are taken to provide slip joints.

High density structural poly foam can be utilized to create panel forms of accurate dimensions and shape. Poly foam panels are relatively lightweight (approximately 1 lb/sq foot area, that is 1 to 2 inches thick). The material is easy to handle due to its lightweight, can be shipped easily long distances, and is durable and long lasting. The molds to produce the high density structural poly foam panels can be made to make a wide variety of shapes and sizes thus offering a wide range of styling and geometry.

SUMMARY OF THE INVENTION

This invention relates generally to a method of constructing walls or fence systems from panels. More particularly, the invention relates to constructing such walls or fence systems wherein a back face of one panel connects to a back face of another panel and further wherein the front faces of the panels have a desirable texture and further wherein a concrete footing of the wall or fence system is poured after courses of panels have been stacked one upon the other.

The invention provides a method for constructing a wall or fence comprising: providing a plurality of connectors and a plurality of panels, each panel having a front face and an opposed back face, a set of opposed and substantially parallel upper and lower surfaces and first and second opposed and substantially parallel side surfaces; preparing a level base; forming a base layer of panels on the level base by placing opposed panels on the level base and connecting a back face of at least one first panel of the base layer to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, the at least one first panel and at least one second panel each having a knockout cavity; placing at least one course of opposed panels on the base layer of panels and connecting a back face of at least one first panel of the at least one course to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, to form a top surface of an uppermost course of panels; and pouring a flowable material from the top surface between the opposed panels to form a support footing for the wall or fence, the support footing encasing at least a portion of the base layer of panels. In an embodiment, the method further comprising: forming a trench; and adding base material to the trench, wherein the step of preparing a level base comprises leveling the base material in the trench. In an embodiment, the base material is compacted granular material or crushed stone. In one embodiment, the flowable material is concrete or cement.

In one embodiment, the method further comprises: after placing a plurality of panels and prior to pouring the flowable material, forming a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members. In an embodiment, at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing after the flowable material is poured. In an embodiment, the reinforcing framework includes horizontal reinforcement members. In one embodiment, the panels of the base layer and the panels of at least one course have the same structure. In an embodiment, the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of the adjacent course of panels. In an embodiment, the connector has at least four dovetail projections. In one embodiment, the panels are made of polyfoam.

In one embodiment, the support footing encases at least one half of a vertical height of the base layer of panels, and in another embodiment, the support footing substantially encases the base layer of panels. In an embodiment, each set of opposed panel surfaces has mating tongue and groove attachments, respectively, so that a respective tongue attachment and groove attachment of adjacent panels connect the adjacent panels. In one embodiment, the back faces of the panels have dovetail channels. In an embodiment, at least one horizontal reinforcement member rests on at least one connector. In one embodiment, at least one vertical reinforcement member passes through a vertical support ring that is part of at least one connector.

In one embodiment, the at least one first panel of the at least one course and the at least one opposed second panel of the at least one course have a pattern molded into their front faces. In embodiments of the invention, the pattern is an ashlar pattern, a boulder rock pattern, or a ledge rock pattern.

In one embodiment, the method further comprises attaching a capping block onto a top of the wall or fence. In an embodiment, the method further comprises attaching an end wall block to some of the plurality of panels before pouring the flowable material.

The invention provides a wall or fence comprising: a support footing formed from a hardened flowable material; a base layer of opposed panels, at least a portion of the base layer of panels being encased within the support footing, a back face of at least one first panel of the base layer being connected to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, and the at least one first panel and at least one second panel each having a knockout cavity, and a plurality of courses of opposed panels placed on the base layer of panels, a back face of at least one first panel of the at least one course being connected to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, a volume between the opposed panels containing the hardened flowable material. In an embodiment, the hardened flowable material is concrete or cement. In one embodiment, the wall or fence further comprises a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members. In an embodiment, at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing. In an embodiment, the reinforcing framework includes horizontal reinforcement members. In one embodiment, the panels of the base layer and the panels of the plurality of courses have the same structure. In an embodiment, the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of an adjacent course of panels. In one embodiment, the panels are made of polyfoam. In one embodiment, the thickness of the wall or fence terraces from wider to narrower as the wall heightens.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:

FIGS. 1A and 1B illustrate perspective views of a panel mold embodiment of the present invention.

FIG. 1C illustrates a perspective view of an alternate panel mold embodiment of the present invention.

FIGS. 2A to 2C illustrate back, perspective and front views of a panel of the present invention.

FIG. 2D illustrates a back view of an alternate embodiment of the panel of FIGS. 2A to 2C.

FIGS. 3A and 3B illustrate perspective views of third and fourth embodiments of the panel of the present invention.

FIGS. 4A, 4B and 4C illustrate front views of second, third and fourth embodiments of front faces of the panel of the present invention.

FIG. 5A illustrates a perspective view of a connector of the present invention.

FIGS. 5B and 5C illustrate front and top views, respectively, of a second embodiment of the connector of the present invention.

FIG. 5D illustrates a front view of a third embodiment of the connector of the present invention.

FIGS. 5E and 5F illustrate perspective and bottom views of a fourth embodiment of the connector of the present invention.

FIGS. 6A to 6C illustrate side, front and perspective views of a wall made from the panel system of the present invention.

FIGS. 6D and 6E illustrate partial cut-out perspective views of first and second embodiments of walls formed using the panels and panel system of the present invention. 6F illustrates a side view of the tongue and groove connection of the panel wall system of the present invention.

FIG. 6G illustrates a top view of the dovetail projection of a connector attaching to a dovetail channel of a panel for the panel wall system of the present invention.

FIG. 6H illustrates a side view of the tongue and groove connection of an alternate embodiment of the panel of the present invention.

FIGS. 7A and 7B illustrate top views of a corner of walls made from first and second embodiments of corner panels of the panel system of the present invention.

FIGS. 8A and 8B illustrate top views of pilasters or columns made from first and second embodiments of pilaster panels of the panel system of the present invention.

FIGS. 8C and 8D illustrate top views of pilasters or columns made from third and fourth embodiments of pilaster panels of the present invention.

FIGS. 9A and 9B illustrate top views of ends of walls made from first and second embodiments of end panels of the panel system of the present invention.

FIGS. 10A to 10H illustrate side views of various embodiments of capping panels of the panel system of the present invention.

FIG. 11A illustrates a front view of a finished wall of the present invention showing a running bond configuration.

FIG. 11B illustrates a front view of a finished wall of the present invention showing a stacked bond configuration.

FIG. 11C illustrates a front view of a wall of the present invention showing a wall terracing with the slope of the grade.

FIG. 11D illustrates a side view of a wall of the present invention showing a partial retaining wall that terraces with the height of the wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention comprises panels that are used together in the construction of a wall. The panels are configured to be compatible with each other in the construction of a partial retaining wall, a parapet wall, a free-standing wall, a sound wall or a fence system. Such walls may be straight and may have corners and 90 degree angles. Although not a requirement of this invention, each panel may have at least one face that is textured in a manner resulting in the appearance of natural stone. Preferably, there is a natural-appearing finish on all exposed sides of the wall. The wall system is designed to be structurally sound and easy to install.

It is to be emphasized that the surface of a panel may be molded to have any desired appearance. A natural appearance, such as stone, is generally most desirable. The panel may have a uniform appearance or it may have an ashlar pattern formed into it. The panels may also resemble stone that has been processed or treated as is commonly known in the natural stone industry. For example, the panel may resemble weathered stone, polished stone or flame treated stone. In addition, the mold may be configured to produce panels that resemble stone that has been hand or machine pitched or tumbled to produce an aesthetically pleasing natural quarried stone appearance.

The panels are produced in dimensions that are convenient to manufacture and handle. The panels are substantially planar. Convenient panel sizes may have a height of 12 inches (30.5 cm) and a length of 48 inches (121.9 cm), another convenient size are panels that have a height of 24 inches (61 cm) and a length of 48 inches (121.9 cm). These panels are light weight, relatively large, durable, weather resistant and easy to handle. The dimensions of the panel may vary from these stated dimensions in order to meet aesthetic or functional requirements of particular applications. The panel can be composed of fiberglass, concrete, wood, particle board, plastic, etc. but is preferably composed of a high density structural polymer foam. Some examples of suitable polymers that may be utilized to create the high density structural polymer foam are disclosed in U.S. Pat. Nos. 6,607,683 B1 and 7,235,204 B2 both to Harrington and consist of urethanes, phenolics, epoxies, alkyds, allylics, aminos, polyesters and silicones. The polymer foam is usually of a pre-selected color and injected into a mold that may additionally have a surface oxide coating to give the polyurethane foam a more visually appealing appearance as well as resistance to the natural elements of U.V. sunlight deterioration, water, ice, etc. The polymer foam preferably is durable, weather resistant, light weight and easy to handle. High density structural polyurethane foam can be used to create panels of accurate dimensions and shapes. These panels can be textured by forming in molds that have been made to simulate true stone and stone patterns. Color can be added that provides further natural appearance and resistance to U.V. degradation. The various finishes and molded textures that can be formed from the polymer foam visually enhances the panel and makes it look like real stone. The panel can be made with poly foam that is flame and ignition resistant. The density of the poly foam can be varied with filler materials to increase durability and hardness and to further resist impact damage.

A back face of the panel preferably is provided with single or multiple elevated columns which include structure for attaching a connector. For example the columns may contain dovetail channels that have been molded or routed into the elevated column. The dovetail channels of the panel can be affixed to an attachment means such as a connector as described in more detail below. The polymer foam composition of the panels allows the channel to be molded into the panel when it is formed or cut to a precise location and size (post-forming). In one embodiment the back face of one panel may be attached to the back face of one or more opposing panels with the connector. The connector may protrude vertically from the top of the panel and can engage the back faces of opposing panels in another course of a wall or fence adding to the structural integrity and support of the structure. The subsequent courses of panels may be offset from the previous course in a running bond pattern or stacked directly on top of the previous course depending on the desired look of the structure. In another embodiment, the mirror image back faces of opposing and non-offsetting first and second panels are attached to one or more connectors to form a panel block. This panel block can be assembled at the site of the construction of the structure being built and is easy to handle and work with. Alternately, panels may be attached to alternate attachment means and affixed directly to a preexisting structure such as a wall or fence without the need to form a panel block. The poly foam panel can be attached to block faces on existing retaining walls and other structures as well to give the structure a more desirable appearance. It would also be beneficial to attach the poly foam panels of the present invention to an effloresced structure that is still structurally sound in order to improve the overall aesthetic quality of the structure. Such alternate methods of attachment are described in detail in U.S. Patent Application Ser. No. 60/945,457 (Veneers for Walls, Retaining Walls, Retaining Wall Blocks, and the Like) and U.S. Patent Application Publication No. 2005/0252144 A1 (Veneers for Walls, Retaining Walls and the Like), both hereby incorporated herein by reference. A spacer may be placed between the poly foam panel and the surface it is being affixed and/or a back surface of the poly foam panel may be given a corduroyed texture that would be beneficial by allowing drainage and any efflorescence that occurs in the structure to flow down open air space cavities and channels between the back surface of the panel and the surface of the structure where it would not affect the aesthetic quality of the panel covered structure.

In a preferred embodiment, the panels are additionally provided with tongue and groove attachment means so that two adjacent panels can be connected to each other. Preferably, each panel has two adjacent sides with a groove adapted to receive a tongue from corresponding sides of adjacent panels. Preferably, the attachment means provide a joint that discourages or minimizes penetration of water from rain or roadway spray. Optionally the groove may be molded or routed with a drip edge to further discourage collection and penetration of water into the structure.

Panels of the present invention used in the production of a structure such as a wall or fence may be supported with a concrete footing. The wall or fence may be further reinforced with vertical reinforcing members that may be located in vertical cavities created by the spatial void between the opposing panels of the wall, and/or horizontal reinforcing members located in horizontal channels within the connectors attached to the back faces of the panels of the wall to form a reinforcing framework. In order to form the footing, concrete may be poured from the top of the structure into the cavities created by the opposing panels spaced apart the distance of the connector. The concrete flows down through the cavities and out through knockout cavities at the bottom surface of the structure. The concrete covers a footing framework to a pre-determined depth and encases the vertical and horizontal reinforcing members to form a support structure for the wall as described further in U.S. Patent Application Ser. No. 60/928,466 (Method of Constructing a Block Wall) hereby incorporated herein by reference.

Turning now to the Figures, the panel wall system of this invention is shown and described.

FIGS. 1A and 1B illustrate a first embodiment of a mold used to form a panel of the present invention. Panel mold 20 has top plate 22 hinged to bottom plate 23. When in the closed position shown in FIG. 1A the top and bottom plates form a substantially enclosed mold cavity. The inner surfaces of top plate 22 and bottom plate 23 have been designed to imprint a desired surface texture onto front and back faces of the panel. Groove inserts 28 and 29 can be placed into front 25 and side 27 of the panel mold to form the groove of the panel. The tongue of the panel on adjacent sides opposite the groove sides is formed within a channel 24 defined between the top and bottom plates. Note that for purposes of illustration a portion of the panel has been removed and one side of the panel mold is shown in section. Although not shown it will be understood that the removed portion forms channel 24 between the top and bottom plates to form a tongue along the side of the panel. When forming the panel polymer foam in its liquid state is placed in a metered amount into the mold. Slideable channel inserts 21 are sprayed with a release agent, along with the groove inserts and the inner surface of the top plate and then channel inserts 21 are slid into top plate 22. The release agent functions to lubricate the surfaces so the panel can be more readily stripped from the mold after the panel has formed and set in the mold by restricting the ability of the polymer foam to bond to the surfaces of the mold. After the polymer form has sufficiently hardened, channel inserts 21 are withdrawn to enable the hardened polymer panel to be removed from the mold. Alternatively, the dovetail channels of the elevated column may be routed into the panel after the panel has been removed from the mold and after the polymer foam has set and hardened. It should be further understood that only a portion of the panel mold boxes are shown in FIGS. 1A and 1B. Additional dovetail channel forming members may be included in the removed portions. Additionally, any number of dovetail channels may be formed within each plate. FIG. 1B illustrates a silicone liner 26 which imprints the desired pattern of the front face onto the panel and functions to give the front face of the panel a more natural stone appearance as desired.

FIG. 1C illustrates an alternate embodiment of a panel mold of the present invention. Panel mold 30 has top plate 32 hinged to bottom plate 33. The inner surfaces of top plate 32 and bottom plate 33 have been designed to imprint the desired surface texture onto front and back faces of the panel. Groove inserts 38 and 39 can be placed into the front 35 and side 37 of the panel mold to form the groove of the panel. In this embodiment the dovetail channels are formed by channel inserts 31 which are slideably accommodated in grooves formed into the top surface of top plate 32. The channel inserts include wedge shaped bars which extend into the mold cavity. The width of the bars is greater along the surface closer to the center of the mold cavity. Channel inserts 31 are coated with a lubricating release agent and placed into the top plate of the mold when the polymer foam is placed into the mold. The polymer foam hardens around the channel inserts and when the foam has set the channel inserts are slid out of the mold box forming dovetail shaped channels and the panel is stripped from the mold. The release agent enables the coated channel inserts to be more readily removed from the mold by restricting the ability of the polymer foam to bond to the channel inserts.

The panel molds of FIGS. 1A to 1C can be used in a method of making a panel as follows. (1) “Clean store” area. The mold is stored clean and in a ready to use condition. (2) Color stage. Oxide colors are placed into the silicone liner of the bottom plate and are then brushed into the silicone liner beds. (3) Spray sealer stage. This locks in the oxide colors. (4) Temporary drying station for sealer. (5) Polymer application stage. A metered amount of the high density structural polyurethane foam is placed in its liquid state by a manual or robotic method into the mold. (6) The top plate and the groove inserts of the mold are sprayed with a release agent and the top plate is then closed. The top and bottom plates are then clamped together. As the polymer foam expands and hardens, the top plate does not dislodge from the bottom plate and ruin the panel as it forms in the mold. Channel inserts are sprayed with a release agent and slid into the mold. (7) Cure area. The mold is allowed to cure for approximately 20 minutes and the cure area may hold up to 60 molds. (8) The molds are pulled out of the cure area and are prepped for demolding. (9) Channel and groove inserts are removed. (10) The mold is unclamped and the top plate is opened. (11) The cured panel is demolded and the silicone liner is stripped from the panel and re-inserted into the bottom plate. (12) The mold is cleaned and checked before placing back into the “clean store” area. (13) De-buffing stage. Any excess flash is removed at panel edges. (14) Rout out stage. If channel inserts were not used to create dovetail channels, the dovetail channels can be routed into the panel. Grooves and other desired features of the panel may also be routed if not formed into the panel. (15) Color touch up as required prior to packaging. (16) Packaging station. This station provides protective wrap to panel or between panels and places panels in box. (17) Assemble shipping/distribution pallet. Boxes are placed on a pallet into a complete cube. The pallet is then stretch wrapped and plastic banded. (18) Completed pallets are then placed into inventory with clearly labeled boxes and pallet signs.

FIGS. 2A to 2C illustrate back, perspective and front views respectively of panel 100a of this invention. The panel comprises opposing and substantially parallel upper and lower surfaces 102 and 104 respectively, and opposing and substantially parallel side surfaces 110 and 112. The panel also comprises front and back faces 106a and 108a, respectively. Front face 106a and rear face 108a each extend from top surface 102 to bottom surface 104 and side wall surfaces or ends 110 and 112 each extend from top surface 102 to bottom surface 104 and from front face 106a to rear face 108a. Back face 108a has elevated vertical columns 120a, 120b, 120c, 120d, 120e, and 120f and elevated horizontal reinforcing ribs 130 forming a grid-like framework which protrudes from back face 108a and functions to add support and rigidity to the panel and the wall formed therefrom and also helps to prevent bowing. Elevated columns 120b, 120c, 120d and 120e each contain a dovetail channel or slot 122 which engage and secure to the dovetail projections of connectors 450a and 450b as described below. Elevated columns 120b, 120c, 120d, and 120e function to strengthen the attachment to the connectors of the panel wall system. The dovetail channels or slots 122 may be routed into the elevated columns or may be molded during production. Arched knockout indentations 190 may be molded into the back face of the panel. Arched knockout indentations 190 provide a indented guideline on the back face of the panel for the optional production of knockout cavity 195 described below. Tongues 132 and 134 project outwardly from top surface 102 and side surface 112, respectively and may be slightly tapered. Grooves 136 and 138, which can be molded or routed into the poly foam, project inwardly from bottom surface 104 and side surface 110, respectively. The tongue of a first panel is designed to engage and secure with the groove of a second adjacent panel thereby interlocking the panels and adding to the structural integrity and visual appeal of the wall or fence. A convenient panel height of 12 inches (31.5 cm) and a length of 48 inches (121.9 cm) is shown but these dimensions may vary due to the desired aesthetics or manufacturing and construction efficiencies.

FIG. 2D illustrates the back face of panel 100b, a further embodiment of the invention. Panel 100b has additional reinforcing ribs 130, no arched knockout indentations and a height of 24 inches (61 cm) and a length of 48 inches (121.9 cm). It is to be noted that the dimensions of the panels could vary depending on the particular application and are not limited to the two dimensions supplied above.

FIG. 3A illustrates back face 208 of panel 200 of the present invention. Panel 200 has two elevated columns 220 which protrude from back face 208. Each column contains two dovetail channels or slots 222 which engage and secure to the dovetail projections of connector 450 or 550 as described below. Elevated columns 220 add rigidity and support to vertically reinforce the panel to prevent bowing and also function to strengthen the attachment to connectors 450 or 550. Reinforcing ribs 230 are formed during the mold process and protrude horizontally from back face 208.

FIG. 3B shows back face 308 of panel 300 of the present invention. Panel 300 is similar to panel 200 except that elevated columns 320 each contain a single dovetail channel 322.

FIGS. 4A to 4C illustrate front views of alternate embodiments of the front face of the panels of the present invention. FIG. 4A illustrates an ashlar pattern molded onto front surface 106b of the panel. FIG. 4B illustrates a boulder rock pattern molded onto front surface 106c of the panel and FIG. 4C illustrates a ledge-rock pattern molded onto front surface 106d of the panel. It should be noted that the patterns shown are not limiting and that various other patterns could be imprinted onto the front surface of the panel in order to achieve a desired visual appearance.

Connector 450a as shown in perspective in FIG. 5A and connector 450b as shown in front and top views in FIGS. 5B and 5C, have dovetail projections 452 configured to engage and secure to a dovetail channel of the back face of the panels of the present invention. Dovetail projection 452 may also be formed with a gusset or web located within the dovetail of the projection for added stability. Connectors 450a and 450b also have angled truss supports 454 which add stability and rigidity to the connectors and to a wall formed from the connector and panels attached thereto. The connectors are provided with a ledge 456 to support the horizontal reinforcing members 80 as described below. Connector 450a has reinforcing tab 457 which creates two separate channels on ledge 456 which further help to separate, secure and hold the horizontal reinforcing members 80 used in the framework of the wall support. The connector can be made of an injection molded plastic, metal, wood or other convenient material. The connector may also be sized to extend the entire height of the panel or may extend the height of two or more panels in order to additionally interconnect courses of panels. FIG. 5D illustrates connecter 450c and is similar to connectors 450a and 450b but has been made to correspond to the panel height of which it is connecting, thus allowing for the remote assembly of 2 face panels and a connector to form a panel block as described previously. These blocks can then be assembled into a wall or other structure. This connector also allows for the placement of additional horizontal reinforcing members to further stabilize and strengthen the structure.

FIGS. 5E and 5F illustrate an alternate embodiment of a connector of the present invention. Connector 550 has dovetail projections 552a, 552b, 552c and 552d which extend outwardly from side walls 562 and 564. Projections 552a to 552d may contain vertical friction ribs 590 that help secure the projections into the dovetail channels of the panels. Vertical friction ribs may also be used on other variations of connectors as so desired. Side wall 566 contains horizontal reinforcing channels 556a and 556b and side wall 568 contains horizontal reinforcing channels 556c and 556d. Vertical support ring 560 which is connected to the inside corners of each side wall by bridge 570a, 570b, 570c, and 570d is used to secure, guide and support the vertical reinforcing members of the framework of the wall support as discussed in detail below. The connector can be made of an injection molded plastic. The connectors illustrated in FIGS. 5E and 5F are designed to be used with a panel having columns formed with two dovetail channels such as panel 200 with back face 208 as illustrated in FIG. 3A. Dovetail projection 552 of connectors 550 are received in dovetail channels 222 of back faces 208 of panels 200. The dovetail projections of each connector 550 engage both dovetail slots for each elevated column. There may be single or multiple connectors 550 engaged and secured to the dovetail channels of each elevated column. This connection secures the two panels to one another while leaving a predetermined distance the width of connector 550 between the two faces.

Referring now to FIGS. 6A to 6H, a method of constructing a freestanding wall or fence 600 with a wall system which includes a plurality of panels 100a and a plurality of connectors 450b will be described. FIG. 6A illustrates a side view of an excavated trench T of a pre-selected depth, which has been dug into soil S and lined with a level base B of compacted granular material such as crushed stone. Depending upon the soil conditions the trench can be dug to the exact size needed for the footing of the desired structure and wherein the walls of the trench acts like form boards for the footing. It should be noted that this is not limiting and that the trench can be dug to any specification and that form boards can be used to form the footing to desired specifications. A base layer 10 is formed by attaching the back face 108a of panel 100a to the back face of an opposing panel 100a with connector 450b whereby the dovetail projections 452 of connector 450b are received in opposing dovetail slots 122 of the back faces 108a of panels 100a as shown in FIG. 6G. This connection secures the two panels to one another while leaving a predetermined distance the width of connector 450b between the two faces. This distance is determined by the connector span between the two opposing panels and is a function of the structure's strength. The thicker the core of the structure being built, the more height or lateral load can be subjected on the structure, allowing the wall to be built taller due to the thicker wall cross-sections with wider concrete dimensions. It may also be beneficial to build a structure with varying and terracing widths from wider to narrower the higher the structure is built especially if the thicker wall cross-sections are not necessary for structural stability over the full height of the wall as illustrated in the partial retaining wall of FIG. 11D. The back face of one panel may be offset from the back face of an opposing panel thus attaching the panel to the back faces of two opposing panels. Alternatively, the back faces of opposing panels may be aligned. The base layer is leveled onto the granular material of the excavated trench. Arched knockout indentations 190, which are indentation guides for the panel assembly and construction crew, are removed from the panels used to form the base layer, forming knockout cavities 195. It should be understood that if the panel being used in the formation of the wall does not have arched knockout indentations 190 for producing knockout cavities 195, knockout cavities may be cut into the panel being used on site or the base layer could be laid with spatial gaps between adjacent panels. The panels 100a of base layer 10 are placed so that the lower surfaces of the panels lay directly on top of the granular material.

A first course 20 of panels is then stacked upon the base layer 10 panels. Panels 100a of first course 20 are placed end to end upon base layer 10. Connector 450b protrudes vertically from the base layer and engages opposing back faces 108a of the first course interlocking the two courses together as shown in FIG. 6D. It should be noted that the panels may be stacked or offset from the previous course. The side wall tongue or grooves of each block secure into the tongue or groove of the next adjacent panel when placed end to end and also engage the tongue or groove of the panel of each previous course adding additional support and interconnecting of the panels as shown in FIG. 6F. FIG. 6H illustrates a tongue and groove of a panel wall system whereby the panel has been molded with a drip edge 197 to further discourage collection and penetration of water into the structure. Subsequent courses of panels are laid the same way as the base layer and first course except that the arched knockout indentations are not removed above any elevation where foundation/footing elements will be formed. Two rows of horizontal reinforcement members 80 are placed parallel onto ledge 456 of connector 450b. Horizontal reinforcement members 80 can be placed onto the first course of panel wall 600 and then added at other locations as desired or in accordance with the requirements of the wall being built. For example, subsequent horizontal reinforcement members may be placed on every course, every other course, or any combination thereof. Additional courses of panels are stacked one upon another and attached to opposing panels by connector 450b until the desired height is reached. If the desired height of the wall is reached and the connector vertically protrudes from the last course of panels, the connector may be cut to the desired height. It should be noted that in courses where the panel wall structure retains earth on one side, or the wall structure requires being built to code specified frost depth, then a non-textured (generally smooth), and/or non-colored, and/or non surface-oxide panel can be used below grade or where aesthetics are not critical in order to reduce the cost of the overall structure. An alternate material, such as wood, metal, plastic, fiberglass concrete etc., may optionally be used in these circumstances as well to reduce overall cost, as desired.

Vertical reinforcement members 90 are attached or tied to connector 450b (or if connector 550 were being used with panel 200, the vertical reinforcement member would be threaded through the vertical support ring of connector 550; or if connector 450a were being used in combination with panel 200, the vertical reinforcement member would be placed into the cavity created by the side to side placement of connectors 450a into the double slot dovetail channels of each elevated column of panel 200). The vertical reinforcement members are preferably L-shaped, having a perpendicular leg portion and a vertical portion. The perpendicular leg of vertical reinforcement member 90 is placed through the desired opening and protrudes outwardly through knockout cavity 195 in the panels of base layer 10 and is perpendicular to the first course as shown in FIG. 6B. The vertical reinforcement members can be inserted through the cavities during the laying of the first course or can be inserted during a later course, however they must be inserted before the perpendicular leg of the vertical reinforcement member can no longer be placed or threaded through the knockout cavity of the panels of the base layer. The desired height of the structure may be taller than the vertical reinforcing members themselves. In this case an additional straight vertical reinforcement member can be spliced onto or overlapped with the initial or first stage vertical reinforcement member. The horizontal reinforcement members (two per course where required) are used to position and align the vertical reinforcement member in the open core space or vertical column when placing the vertical steel into the wall after the wall has been assembled but before grouting. Thus there can be much variation with the height of the structure. The 1 foot by 4 foot dimension of one embodiment size of the panel of the present invention is ideal for creating a pattern of step down terracing in the length of the structure to follow changing grade lines as shown in FIG. 11C. Typically a change of 1 foot over 8 feet is average in a reasonable slope.

FIG. 6C is a perspective view of a wall and support footing framework for the panel wall system of the present invention. The support footing framework includes horizontal footing reinforcing members 96 and transverse footing reinforcing members 95. The perpendicular leg of the vertical reinforcement member is secured to the transverse footing reinforcing members 95. The transverse footing reinforcing members protrude outward on both sides of the knockout cavity in the panels of base layer 10 and are perpendicular to the first course of block. Horizontal footing reinforcing members 96 are secured to the transverse footing members and run parallel the length of the freestanding wall. The horizontal footing members and transverse footing members create a footing support framework that has been elevated above the granular material by the height of rebar blocks 85 which are attached at various positions to the footing framework. The size of the rebar block can be selected to achieve a desired height in order to ensure proper placement of reinforcing members and footing specifications for support requirements and functions to help prevent the framework from corroding. The footing framework can be completed at anytime during the laying of the wall block courses. It may sometimes be beneficial to wait until all course layers have been laid so that block installers will not trip over the framework during construction of the wall. It may also be beneficial to lay three or four initial courses and then complete the footing and support framework. Concrete could then be poured to encase the footing and support framework and then be allowed to set. This method would also leave unencumbered access along the wall as the construction workers are building the remaining structure to the desired specifications.

The horizontal and transverse footing reinforcing members and the vertical and horizontal reinforcing members are selected of suitable diameter for structural support and integrity and can be made from suitable materials including but not limited to steel reinforcing bars (also referred to as “rebar”, which may be deformed, natural and/or galvanized), threaded steel (galvanized) post-tension rods, fiberglass rods, and other reinforcing members that are suited for reinforcement in concrete/masonry.

When a first desired height of the wall has been reached, typically 3 to 4 panel courses, and the support footing framework is in place, and the ends of the wall have been fitted with end wall blocks or end wall panels as described below, concrete is poured into the top opening of the cavity created by the width of connector 450b opposing the back faces of panel 100a. The concrete is poured from the top of the wall and will fill the vertical cavity created by the vertical alignment of the side wall panels of the panel blocks. Weights, weighted spacer or connector boards 70 may be placed on top of fittings 71 that are placed on the top surface of the wall as the concrete is poured into the cavity to ensure that the concrete does not cause the wall to float or rise. Additionally or alternatively the wall panels may be tied down to help prevent any floating and to keep the panels from bowing under the weight of the wet concrete. The weight 70 may be any suitable material heavy enough to hold down the wall and the fitting 71 is designed to protect the top surface and tongue of the last course of panels from the weight 70. The concrete will flow down through the wall cavities or voids and out through knockout cavities 195 of base layer 10 until it fills the trench and covers the footing framework to a predetermined depth and encases base layer 10 into a footing support structure as shown in FIG. 6A. After the concrete has been poured and allowed to set for a predetermined time, more panel courses fitted with desired end panels or blocks of the structure may be laid, typically 3 to 4 panel courses, and more support framework may be placed. Concrete is then poured to fill the vertical cavity as described above. Again the same weight, fitting and tie downs may be employed to prevent the wall from floating or bowing. Additional courses can then be laid and the same steps repeated until the desired height of the wall has been reached. After the concrete has been poured, any extra vertical reinforcing members that extend above the last course of panels may be cut off (this could be done before the concrete is poured into the columnar cavities) and capping or coping block 40 (as described below) may be placed and secured to the top surface of the last course. It should be understood that the three to four courses before each concrete pour is not limiting and in fact the whole structure may be built, or any number of courses may be laid before the concrete is poured depending upon the specifications of the structure being built.

FIG. 6E shows an alternate embodiment of the panel wall system. In this embodiment the wall panels and connectors are assembled to form a plurality of panel blocks. The panel blocks are laid in courses to form a wall in accordance with the previous discussion. For example, panel wall block 500 has been formed from opposing and non-offsetting panels 100b whereby the dovetail projections 452 of connector 450b are received in mirror-image dovetail slots 122 of the back faces 108b of panels 100b. This connection secures the two panels to one another while leaving a predetermined distance the width of connector 450 between the two faces. This panel block can be used to form a wall by placing the panel blocks end to end in a course of the wall. The panel block of an additional course may be offset from the previous course or may be stacked directly vertical from the previous course. The panel block system of building the wall can use the same vertical and horizontal reinforcing framework and footing framework technique with concrete pour as described herein.

FIGS. 7A and 7B illustrate top views of alternate embodiments of panels for the formation of corners for the present invention. FIG. 7A shows outer corner panel 701 and inner corner panel 702. Both corner panels have elevated columns with dovetail channels to receive the connectors of the present invention and tongue and grooves designed to engage other panels of the present system and may have horizontal ribbing. It should be noted that both right handed and left handed inner and outer corner panels may be built from the same panels. FIG. 7B illustrates an alternate embodiment of a corner whereby the outer corner is formed from a first panel 710 having tongue or projection 711 which engages a groove 722 on the back face 721 of a second panel 720 and further whereby the inner corner is formed from a first panel 730 having tongue or projection 731 which engages a groove 742 on the front face 741 of a second panel 740. Panels 710, 720, 730, and 740 have elevated columns with dovetail channels to receive the connectors of the present invention. It should be noted that both right handed and left handed inner and outer corner panels may be built from this kit of parts.

FIGS. 8A to 8D illustrate top views of alternate embodiments of panels for the formation of pilasters and columns for the present invention. FIG. 8A shows an embodiment of a pilaster or column with a wall projecting from both sides. Panel 810 has groove 812 on front face 811 and engages the tongue from panel 100a of wall 600. Panel 820 has groove 822 on back face 823 and engages tongue 814 from panel 810. Panel 830 has groove 832 on back face 833 and engages tongue 824 from panel 820. Panel 830 has tongue 834 which engages the groove from panel 100a of wall 600. Panels 810, 820 and 830 have elevated columns with dovetail channels to receive connectors of the present invention. FIG. 8B shows a second embodiment of a column or pilaster with panel 840 having groove 842 and tongue 844 and is located on each side of the wall. FIG. 8C shows a third embodiment wherein panel 100a of wall 600 connects to panel 810, which connects to a first panel 820, which connects to a second panel 820 and then to a third panel 820. Third panel 820 connects to panel 830 which connects to panel 100a of wall 600. Panels 810, 820 and 830 have elevated columns with dovetail channels to receive connectors of the present invention. The connectors can be further wired together to add additional support to the pilaster or column and to prevent the structure from bowing out when filled with concrete. FIG. 8D shows a fourth embodiment wherein column or pilaster panel block 850 having groove 852 and tongue 852 connects to panels 100a of a wall.

FIGS. 9A and 9B illustrate top views of alternate embodiments of wall ends for the present invention. FIG. 9A illustrates end wall block 901 having tongue 902 and groove 903 and is designed to give the end of the wall a more finished appearance and to keep the concrete from seeping out the sides of the wall when it is poured. The end wall block is preferably textured on all exposed sides. FIG. 9B illustrates an end of a wall finished with panels. Panel 910 has groove 912 on side 911 and engages the tongue from panel 100a of wall 600. Panel 920 has groove 922 on back face 923 and engages tongue 914 from panel 910. Panel 930 has groove 932 on back face 933 and engages tongue 924 from panel 920. Panel 930 has tongue 934 which engages the groove from panel 100a of wall 600. Panels 910 and 930 have elevated columns with dovetail channels to receive connectors of the present invention.

FIGS. 10A to 10H show various embodiments of capping blocks or coping pieces for the present invention. FIGS. 10A to 10E show capping blocks 40a to 40e respectively which have grooves 42 designed to engage the tongue from the panels of the present invention. These capping blocks can be further anchored to the wall or additionally attached with use of an adhesive compound. FIGS. 10F to 10H show capping blocks 40f to 40h respectively which have cavity 44 designed to fit over the tongues of the opposing sides of the wall. These capping blocks can be further anchored to the wall or additionally attached with use of an adhesive compound.

FIG. 11A shows a finished section of the wall 1000a of the present invention with a running bond pattern. The base layer of panels and footer is shown in dash and is below grade. It should be noted that a single course (the base layer) or more may be positioned below grade depending upon the application. FIG. 11B shows a finished section of the wall 1000b of the present invention with a stacked bond pattern. FIG. 11C illustrates a front view of a wall 1000c of the present invention showing a wall terracing with the slope of the grade. FIG. 11D illustrates a side view of a wall 1000d of the present invention showing a partial retaining wall terracing from wider to narrower as the wall heightens.

Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the claims. In particular, it is contemplated that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choice of materials or variations in the shape or angles at which some of the surfaces intersect are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein.

Claims

1. A method for constructing a wall or fence comprising:

providing a plurality of connectors and a plurality of panels, each panel having a front face and an opposed back face, a set of opposed and substantially parallel upper and lower surfaces and first and second opposed and substantially parallel side surfaces;

preparing a level base;

forming a base layer of panels on the level base by placing opposed panels on the level base and connecting a back face of at least one first panel of the base layer to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, the at least one first panel and at least one second panel each having a knockout cavity;

placing at least one course of opposed panels on the base layer of panels and connecting a back face of at least one first panel of the at least one course to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, to form a top surface of an uppermost course of panels; and

pouring a flowable material from the top surface between the opposed panels to form a support footing for the wall or fence, the support footing encasing at least a portion of the base layer of panels.

2. The method of claim 1, further comprising:

forming a trench; and

adding base material to the trench, wherein the step of preparing a level base comprises leveling the base material in the trench.

3. The method of claim 2, wherein the base material is compacted granular material or crushed stone.

4. The method of claim 1, wherein the flowable material is concrete or cement.

5. The method of claim 1, further comprising:

after placing a plurality of panels and prior to pouring the flowable material, forming a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members.

6. The method of claim 5, wherein at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing after the flowable material is poured.

7. The method of claim 6, wherein the reinforcing framework includes horizontal reinforcement members.

8. The method of claim 1, wherein the panels of the base layer and the panels of at least one course have the same structure.

9. The method of claim 1, wherein the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of the adjacent course of panels.

10. The method of claim 1, wherein the panels are made of polyfoam.

11. The method of claim 1, wherein the support footing encases at least one half of a vertical height of the base layer of panels.

12. The method of claim 1, wherein the support footing substantially encases the base layer of panels.

13. The method of claim 9, wherein the connector has at least four dovetail projections.

14. The method of claim 1, wherein each set of opposed panel surfaces has mating tongue and groove attachments, respectively, so that a respective tongue attachment and groove attachment of adjacent panels connect the adjacent panels.

15. The method of claim 1, wherein the back faces of the panels have dovetail channels.

16. The method of claim 1, wherein at least one horizontal reinforcement member rests on at least one connector.

17. The method of claim 1, wherein at least one vertical reinforcement member passes through a vertical support ring that is part of at least one connector.

18. The method of claim 1, wherein the at least one first panel of the at least one course and the at least one opposed second panel of the at least one course have a pattern molded into their front faces.

19. The method of claim 1, wherein the pattern is an ashlar pattern.

20. The method of claim 1, wherein the pattern is a boulder rock pattern.

21. The method of claim 1, wherein the pattern is a ledge rock pattern.

22. The method of claim 1, further comprising attaching a capping block onto a top of the wall or fence.

23. The method of claim 1, further comprising attaching an end wall block to some of the plurality of panels before pouring the flowable material.

24. A wall or fence comprising:

a support footing formed from a hardened flowable material;

a base layer of opposed panels, at least a portion of the base layer of panels being encased within the support footing, a back face of at least one first panel of the base layer being connected to a back face of at least one opposed second panel of the base layer with at least one connector, the front faces of the at least one first panel and the at least one second panel facing outward, and the at least one first panel and at least one second panel each having a knockout cavity, and

a plurality of courses of opposed panels placed on the base layer of panels, a back face of at least one first panel of the at least one course being connected to a back face of at least one opposed second panel of the at least one course with at least one connector, the front faces of the at least one first panel and the at least one second panel of the at least one course facing outward, a volume between the opposed panels containing the hardened flowable material.

25. The wall or fence of claim 24, wherein the hardened flowable material is concrete or cement.

26. The wall or fence of claim 24, wherein the wall or fence further comprises a reinforcing framework between opposed panels, the reinforcing framework including vertical reinforcement members.

27. The wall or fence of claim 26, wherein at least one vertical reinforcement member is L-shaped and has a vertical portion and a perpendicular leg portion, the perpendicular leg portion protruding outwardly through a knockout cavity, the perpendicular leg portion being encased in the support footing.

28. The wall or fence of claim 27, wherein the reinforcing framework includes horizontal reinforcement members.

29. The wall or fence of claim 24, wherein the panels of the base layer and the panels of the plurality of courses have the same structure.

30. The wall or fence of claim 24, wherein the at least one connector that connects the at least one first panel and the at least one second panel of the base layer also connects the at least one first panel and the at least one second panel of an adjacent course of panels.

31. The wall or fence of claim 24, wherein the panels are made of polyfoam.

32. The wall or fence of claim 24, wherein the thickness of the wall or fence terraces from wider to narrower as the wall heightens.